description stringlengths 2.98k 3.35M | abstract stringlengths 94 10.6k | cpc int64 0 8 |
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] [0001] Patent No. Inventor Dates 2,815,132 Stone Dec. 3, 1957 2,939,590 Henry Jun. 7, 1960 3,058,602 Kilman Oct. 16, 1962 3,331,900 Love Dec. 7, 1965 3,314,553 Vircks Apr. 18, 1967 3,382,988 O'Rielly May 14, 1968 3,394,778 Brinton Jul. 30, 1968 3,828,924 Young Aug. 13, 1974 3,871,477 Kuest Mar. 18, 1975 4,369,014 Jolivet Jan. 18, 1983 4,508,316 Millard Apr. 2, 1985 4,630,383 Stockton Dec. 23, 1986 4,682,926 Chambers et al. Jul. 28, 1987 4,810,151 Shern Mar. 7, 1989 4,876,789 Burell Oct. 31, 1989 4,944,366 Pryor et al. Jul. 31, 1990 5,259,721 Sato et al. Nov. 9, 1993 5,368,429 Young Nov. 29, 1994 5,586,619 Young Dec. 24, 1996 5,700,123 Rokosh et al. Dec. 23, 1997 5,839,876 McCarthy et al. Nov. 24, 1998 5,918,861 Parker Jul. 6, 1999 6,050,548 Leger Apr. 18, 2000
[0002] [0002] Foreign Patent No. Country & Dates 0 115 370 A2 Europe, August 1984 DE 36 24 309 A1 Germany, January 1988 1-192955 Japan, August 1989 5-178429 Japan, July 1993
BACKGROUNG OF INVENTION
[0003] The devise as a lift can be used in the building industry during new or remolding construction. The platform can be used as a dolly anytime.
BRIEF SUMMARY OF INVENTION
[0004] The invention described is related generally to material handling devises. More specifically, the invention is a lift to assist a person who is installing drywall or paneling to a wall or ceiling. The device is configured to fit through a 24″ door with drywall or paneling on it. It has a platform for holding material. The device can hold up to 150 LBS of material, and the telecopic column can extend 10 feet. By adding the extension to the inside column will allow the material to go higher than 10 feet. The device is also equipped with extensible legs, a winch or motor, pulleys, guides, rollers, spacers, hinges, stop bars, braces, locking mechanisms, a swivel point, and a rack. The device is easily broken down within a very short period of time allowing it to be moved from floor to floor. The platform can be used separately as a dolly. The devise allows one man to take a piece of material from the floor to the ceiling by himself and hold it in place while he fastens it to the ceiling.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] [0005] Side View of Unit Side View of Inside Column Bottom View of Inside Column Bottom View of Outside Column Front View of Outside Column Top View of Outside Column Side View of Outside Column Back View of Outside Column w/ relationship to Inside Column Extension for the Inside Column Top View of Unit Back View of Unit View of Slide Bar Side View of Slide Bar Bottom View of Unit Back View of Material Rack Stationary Bracket Side View of Latching Bracket & Top of Unit Unit Disassembled into Three Sections Top View of Inside Column Cable Rigging
DETAILED DESCRIPTION
[0006] [0006]FIG. 1, 1 —Dolly Wheels
[0007] [0007] 2 —Extendable Legs—These will swing into position to go through a 2 foot door or swing outwards to allow the unit to elevate to a higher position.
[0008] [0008] 7 —Platform—Base of unit can also be used as a dolly to haul material with or without the lift.
[0009] [0009] 8 —Latching Bar—allows you to Lock the material rack into different degree of angles.
[0010] [0010] 13 —Shows the position of the material rack at floor level
[0011] [0011] 19 —Outside column when unit is at lower level.
[0012] [0012] 20 —Inside column with relation to the outside column.
[0013] [0013] 21 —Bracket for reinforcement bars FIG. 9 is being used.
[0014] [0014] 22 —Bracket for reforcement bars without extension.
[0015] [0015] 23 —Reforcement bars.
[0016] [0016] 25 —Mounting bridge for winch.
[0017] [0017] 26 —Winch which can be replaced with motor.
[0018] [0018] 41 —Sliding bar which travels up and down outside column.
[0019] [0019] 45 —Feet for holding building boards which is mounted on Item # 13 .
[0020] [0020] 50 —Bold hole for attaching reinforcement bars.
[0021] [0021]FIG. 2, 20 —Side view of inside column with relationship to sheave.
[0022] [0022] 21 —Bracket for reinforcement bars FIG. 9 is being used.
[0023] [0023] 22 —Brachet for reforcement bars without extension.
[0024] [0024] 27 —Bold stud for reinforcement brackets.
[0025] [0025] 28 —Top sheave on inside column.
[0026] [0026] 29 —Pin hole to hold inside columb to Item # 20 .
[0027] [0027]FIG. 3, Bottom view of Item # 20 .
[0028] [0028]FIG. 4, 19 —Top view of the unit in relation to item # 20 .
[0029] [0029] 20 —Inside column with relation to the outside column.
[0030] [0030] 34 —Top sheave on the outside column mounted on item # 35 .
[0031] [0031] 35 —Bridge tying the two angles together which makes up item # 19 .
[0032] [0032] 37 —Rollers for the outside column.
[0033] [0033]FIG. 5, Item # 19 front view of the outside column which will travel up and down inside column after the slide bar item # 41 reaches the stop on top of outside column.
[0034] [0034] 33 —Sheave mounted on the top bridging which serves as a stop for the slide bar.
[0035] [0035] 34 —Sheave mounted on the bottom bridging of the outside column which is item # 19 .
[0036] [0036]FIG. 6, Top View of the outside column showing the sheave # 33 and the stop bridging item # 36
[0037] [0037]FIG. 7, Side view of outside column showing the top stop bridging and item # 36 sheave and also showes the bottom bridging and item # 34 sheave.
[0038] [0038]FIG. 8, Back view of the outside column which will travel up and down inside column after the slide bar item # 41 reaches the stop on top of the outside column.
[0039] [0039]FIG. 9, Shows the inside extension column, which is an optional attachment for higher elevation and item # 30 is the male connection for inside column item # 20 and item # 29 are the pinholes to hold it together.
[0040] [0040]FIG. 10, Is a top view of the unit and item # 2 Extendable legs. Item # 5 is the pin hole to hold the legs in place which allow you to put the legs into different positions for narrower places. Item # 46 is a flexible cable which one end is secured to the slide bar item # 41 . The cable goes through the sheaves and to the drum of the winch. In FIG. 20 shows the rigging of the cable. Item # 26 is the winch which is bolted to bracket item # 25 which is fastened to the reforcement bars. The bracket will swivel on one side with a removable pin on the other side to make it easy to disasemble. Item # 52 is the swival point of the bracket item # 25 . Item # 53 is the removable pin point for bracket item # 25 . Item # 23 are the reforcement bars. Item # 54 is the bolt for secureing the reforcement bars item # 23 to the base. Item # 55 are the wing nuts holding reinforcement bars to item # 54 for easy disasemble. Item # 4 are the swival points for the legs item # 2 . item # 36 is the bridging stop bar on top of of the outside column item # 19 . Item # 28 is the sheave that is mounted to item # 36 .
[0041] [0041]FIG. 11, Back view of the unit item # 2 the extendable legs and Item # 1 are the dolly wheels. Item # 7 which is the base which can be used as a dolly with or without the lift. Item # 13 is the material rack which is hinged to the slide bar item # 41 . Item # 25 is the bracket holding the winch. Item # 26 is the wench which operates the system and can be replaced with a motor if desired. Item # 41 is the slide bar that travels up and down the outside column. Item # 43 is the bracket which holds the slide bar in place. Item # 27 and Item # 38 are the stud bolts holding the reinforcement bars Item # 38 are the wing nuts that hold the reinforcement bars in place. Item # 32 are the bolts holding the slide bar assembly together ( 4 ).
[0042] [0042]FIG. 12, Is the detail of the slide bar assembly. Item # 44 is the spacer that also serves as the stop bar when the slide bar, item # 41 reaches the top of the unit. Item # 45 are the tie holes for the cable to the slide bar, item # 41 . Item # 43 holds the slide bar in place.
[0043] [0043]FIG. 13, Is the detailed side view of the slide bar assembly, Item # 41 . Item # 47 is the bottom spacer. Item # 42 are the rollers that make it easy to slide up and down the column. Item # 44 is the spacer that also serves as the stop bar when the slide bar, item # 41 reaches the top of the unit. Item # 43 holds the slide bar in place.
[0044] [0044]FIG. 14, Bottom view of the unit, item # 7 is the platform, item # 6 are the holes to bolting down item # 17 which is the latching brachet. Item # 65 is the reinforcement bars mounted on the bottom of the platform for extra strength. Item # 1 are the dolly wheels mounted on the bottom of the platfrom Item # 7 . Item # 2 are the extendable legs with swing in or out depending upon the amount of space available or the height of the column. item # 3 is the pin hole which hold the legs, item # 2 in place. Item # 5 are the pin holes for the legs, item # 2 .
[0045] [0045]FIG. 15, Item # 13 is the material rack. Item # 11 are the hinges which holds the material rack to the slide bar. Item # 9 is the bracket holding the latching bar item # 8 which allows you to lock the material rack into different degree of angles. Item # 10 is the pin which holds Item # 8 & Item # 9 together. Item # 12 is the steel plate which helps make up the material rack.
[0046] [0046]FIG. 16, Item # 17 is the male connection tying the platform and the column together. Item # 7 is the platform. Item # 18 is the pin holes which are used to secure column item # 20 to the male connection item # 17 .
[0047] [0047]FIG. 17, Side view of the latching bar holding the material rack, item # 13 in a flat ceiling position. Item # 8 is the latching bar which shows several notched positions for different ceiling slopes. Item # 9 is the bracket holding the latching bar item # 8 which allows you to lock the material rack into different degree of angles. Item # 10 is the pin which holds Item # 8 & Item # 9 together. Item # 41 is the slide bar which shows the relation to the latching bar. Item # 23 are the reforcement bars. Item # 38 are the wing nuts that hold the reinforcement bars on the stud bolts, item # 27 . Which make is easy to disasemble.
[0048] [0048]FIG. 18, Shows the Unit disasembled into three sections. The unit can be broken down in a very short time by removing two wing nuts and loosing two other wing nuts and removing two pins.
[0049] [0049]FIG. 19, Is the top view of the inside column which is item # 20 . Item # 28 is the top sheave on the top inside column. Item # 40 is the bolt holding the sheave in place and item # 39 is the nut holding the bolt in place. Stud bolt holding reinforcement bars item # 27 and item # 38 are the wing nuts that hold the reinforcement bars in place. Which make is easy to disasemble.
[0050] [0050]FIG. 20, Shows the rigging of the flexable cable, item # 46 goes from the winch, item # 26 then thread through the top of sheave, item # 28 down through the the lower sheave item # 34 then to the top sheave item # 33 and then down to the slide bar, item # 41 . | It is a light weight device that can be disasembled in a very short time to allow a person to move it from one floor to another. The platform can be used as a dolly when not being use as a lift or a work bench to hold screw gun and supplies when using as a lift. It saves the overhead of extra manpower by enabeling one man to raise the material all the way from the floor to the ceiling and hold it in place. Anyone can use it, no technical skills required. If desired the winch can be replaced with a motorized winch. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a divisional, filed under 35 U.S.C. 120, of U.S. patent application Ser. No. 11/260,605, filed on Oct. 27, 2005. The invention described and claimed herein below is also described in the aforesaid U.S. patent application, the entire content of which is hereby expressly incorporated by reference thereto.
[0002] The invention described and claimed herein below is also described in German Patent Application No. 10 2004 052 568.4, which was filed on Oct. 29, 2004 in Germany, the entire content of which is hereby expressly incorporated by reference. The aforesaid German Patent Application provides the basis for a claim of priority of invention for the invention described and claimed herein below under 35 U.S.C. 119 (a) to (d).
BACKGROUND OF THE INVENTION
[0003] 1. The Field of the Invention
[0004] The present invention relates to thin flat glass substrates with a thickness of less than 1.5 mm and, more particularly to thin flat glass substrates for display engineering with reduced thickness variations, and to a method of manufacturing these thin flat glass substrates.
[0005] 2. The Description of the Related Art
[0006] Thin flat glass substrates are, among other things, used to make flat display screens, e.g. plasma display panels (PDP), field emission displays (FED), TFT liquid crystal display screens (TFT=thin film transistor), STN-liquid crystal display screens (STN=Super twisted nematic), PALC display screens (PALC=Plasma assisted liquid crystal), EL displays (EL=electroluminescent) and the like.
[0007] In flat display screens either a thin layer of liquid crystal compound is placed between two glass panels or respective dielectric layers are applied to the front and rear side of the rear and/or front glass panels, from which cells are formed, in which a phosphor is placed, according to the type of display.
[0008] It is important that the layer thickness of the liquid crystal layer and/or the thickness of the dielectric layer is maintained exactly so that especially in the case of display screens with comparatively large dimensions no disturbing color adulteration or brightness variations (shadows) occur. Since layer thickness (currently about 30 microns) is always becoming smaller and display screens are always becoming larger, these requirements have attained increasing importance.
[0009] Although float glass is excellently suited for display applications because of its fire polished surface, it has not been possible to make display glass with thickness variations of less than according to the float process with the currently required large substrate format with edge lengths of above 1800 mm.
[0010] The presence of flows in the float bath, which usually comprise melted tin, explains the presence of thickness variations in float glass. These very complex flows are the result of opposing mechanical and thermally induced flows, i.e. the flow dynamics and thermal effects overlap or are superimposed on each other.
[0011] A flow in the motion direction of the glass sheet, i.e. a flow of the hot section of the tin bath in the direction of the cold section arises directly under the glass sheet due to the motion of the glass sheet. In the free surface of the tin bath beside the glass sheet a return flow, i.e. a flow in the opposite direction, arises so that the colder tin flows in the direction of the hotter front section of the tin bath. Temperature non-uniformities, which are transferred to the hot forming glass sheet and lead to viscosity non-uniformities, arise because of the mixing of these flows. These viscosity changes can then lead to undesired thickness fluctuations and waviness in the glass sheet. These fluctuations are the more noticeable, the more strongly the glass sheet is drawn out, i.e. the thinner the glass sheet becomes during manufacture.
[0012] Attempts have already previously been made to prevent and/or suppress these lateral return flows by building flow barriers, so-called flags, e.g. as described in DE-PS 1771 762 or DE-PS 2146 063. According to DE-PS the return flow is channeled by means of barriers or dam. The return flow formed between the lateral walls of the float tank and the barriers is suppressed or prevented by means of resistance bodies adjustable in their height and immersed in the return flow. DE-PS 2146 063 describes a special bottom structure for a float bath for guiding the underflow of bath liquid at the bottom of the flow bath, which prevents the lateral return flow by means of lateral baffle plates immersed in the flow bath (FIG. 8 of this reference). EP 031 772 B1 describes the arrangement and action of flags in great detail. In this reference it is also shown that these flags can be arranged not only transversely to the feed direction of the glass sheet, but also can be at an angle to it. In JP 2000-313628 a flag is shown, which is arranged substantially under the bath surface. The angle, at which this flag is immersed in the molten metal, can be adjusted as well as the distance between the flag and the glass sheet.
[0013] In spite of the improvements in the flat glass manufacturing process up to now it has not been possible to make large-area thin flat glass substrates with a thickness of less than 1.5 mm, which met high quality specifications.
SUMMARY OF THE INVENTION
[0014] It is an object of the present invention to provide a large surface or large area thin flat glass substrate, especially for display engineering, with a thickness of less than 1.5 mm, which meets high quality requirements, especially regarding permitted thickness variations.
[0015] It is also an object of the present invention to provide a process for making large area thin flat glass substrates, especially for display engineering, with a thickness of less than 1.5 mm and which have high quality, especially regarding thickness variations.
[0016] According to the invention the flat glass substrate has a thickness of less than 1.5 mm, a length of at least 1800 mm, a width of at least 1800 mm and a difference between a smallest and largest thickness of less than 50 μm.
[0017] According to the invention the float glass process for making this flat glass substrate includes the steps of:
[0018] a) pouring a hot glass melt on a molten metal bath so that melted glass spreads out on the molten metal bath because of the action of gravity to form a hot spread region;
[0019] b) arranging flags, which do not contact a glass sheet forming from the melted glass, in the molten metal bath in the hot spread region on both sides of the flowing melted glass; and
[0020] c) imparting a final outlet speed to the glass sheet by accelerating the glass sheet.
[0021] The thin flat glass substrate according to the invention fulfills the required high quality requirements as it comes from the float plant, i.e. without subsequent polishing. If a polishing is still required for any reason, it can be performed especially economically and/or efficiently, since the polishing work is kept very small because of the high surface quality of the product coming from the float plant.
[0022] It was found that a flat glass substrate with a thickness of less than 1.5 mm, respective edge lengths of more than 1800 mm and with a difference between the smallest and largest thickness of less than 50 μm met the highest requirements of display engineering applications. Because of weight saving considerations the glass substrates with very large surface area should be made as thin as possible. These substrates have a preferred thickness of from 0.4 to 1.1 mm. If the thickness is less than 0.4 mm, the glass substrates is of course always still suitable for making a display however the handling of this sort of very thin substrate, especially with large dimensions, requires a clearly greater effort and/or expense. The thin flat glass substrates have a width of over 1800 mm; in practice from handling reasons alone they may only infrequently exceed a width of from 3.5 to 4 m. Also when even larger formats are made, they are produced in practice by long divisions of the given width format. Widths up to about 2.5 m are especially easily manipulated or handled and thus are preferred. The length of the thin glass substrate is in the same size range as the dimensions given for the width for the same reasons, namely to provide easy handling. Theoretically the length of the substrate has no limits because the manufacturing process is continuous. However since very thin glass bends very easily, the substrate can be marketed in a rolled-up form, i.e. as a roll, with a suitable bending radius. Furthermore it is advantageous when the difference between the smallest and the largest thickness is less than 30 μm, especially less than 15 μm, since the increasing requirements of the processing industries are taken into consideration. On account of the good surface quality of float glass, which has the quality of fire-polished glass, a float glass is preferred with the above-stated parameters. The glass according to the invention is especially suitable for use in TFT displays. For these applications a sodium-free glass except for unavoidable trace sodium ion impurities is used. Sodium ion content may not exceed 1000 ppm in these glasses.
[0023] In the known float glass process for making flat glass a melt is poured onto a molten metal bath and the liquid glass spreads on the metal melt, thus forming a hot spread region. The spreading of the glass is subsequently assisted by so-called top rollers, which engage at the edge of the glass sheet and draw the glass sheet out further. A final outlet speed is imparted to the glass sheet by acceleration in the flow direction of the glass sheet behind the top rollers, which takes the molten metal downstream under the glass sheet and leads to a colder return flow in the upstream direction. The part of the return flow formed beside the glass sheet in the drawing region in the free surface (an additional part of the return flow occurs in the deeper layers of the bath) is prevented or hindered by placing barriers (flags) in the side surfaces of the tin bath in this region.
[0024] It was surprisingly found that the placement of flags in a region of the float bath, in which no return flow exists at the surface and in which the flags should have scarcely any effect according to the conventional understanding, still clearly reduce the thickness variations in the product float glass. This region of the float bath is the hot spread region, also the region, in which the glass freely spreads further under the influence of gravity. It is located upstream of the top rollers in the flow direction of the glass sheet. The glass has a viscosity of less than 10 6 dPas, especially a viscosity of 10 4 to 10 6 dPas, in this region.
BRIEF DESCRIPTION OF THE DRAWING
[0025] The objects, features and advantages of the invention will now be illustrated in more detail with the aid of the following description of the preferred embodiments, with reference to the accompanying figures in which:
[0026] FIG. 1 is a schematic top plan view of a longitudinally extending float glass tank according to the prior art;
[0027] FIG. 2 is a schematic top plan view of a longitudinally extending float glass tank according to the present invention;
[0028] FIGS. 3 a to 3 c are respective cross-sectional views through the float glass tank according to the invention showing a flag;
[0029] FIG. 4 is a graphical illustration showing the variation of thickness versus time for a flat glass substrate made with the float glass process of the prior art; and
[0030] FIG. 5 is a graphical illustration showing the variation of thickness versus time for a flat glass substrate with the float glass process of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0031] FIG. 1 shows a longitudinally extended float glass tank according to the prior art. The prior art float tank has sidewalls 1 and contains a bath 2 of melted tin. The glass sheet 3 , which moves in the direction of the arrow, floats on the tin bath. The float tank has plural different sections or regions Ito IV, which may differ from each other as follows.
[0032] In section I the fluid glass is poured on the tin bath and spreads out on it (Hot spread region).
[0033] In section II longitudinal forces and forces directed toward the outside are exerted under the influence of the top rollers and the outlet rollers; the glass is already drawn out and is thinner.
[0034] In section III the glass sheet attains its final form by action of the outlet rollers. Section II and III together form the drawing zone, i.e. the region, in which the glass is drawn out and attains its final form.
[0035] In section IV the glass solidifies and its cooling takes place. The liquid glass 4 is poured on the tin bath 2 at the beginning of zone or section I and already spreads out there to its equilibrium thickness of about 6 to 7 mm. Subsequently it forms the finished glass sheet 3 ′, which is drawn by the outlet rollers 5 from the float chamber. The desired thickness of the glass sheet is attained by the joint action of the top rollers 6 and the outlet rollers 5 . The top rollers are driven with speeds adjusted to the increasing speed of the glass sheet from the outside of the tank. The top rollers are slightly inclined to the feed direction of the glass sheet, are driven by means of the shafts 8 and unshown drive motors and exert a pulling force from the outside on the glass, so that a preliminary tapering of the glass sheet occurs. The motion of the glass sheet in the drawing zone causes a flow of metal directly under the glass sheet in the same direction. This flow induces a corresponding reverse flow at the bottom and sides of the bath. This lateral flow is prevented and/or suppressed by means of lateral flags 7 projecting into the float bath.
[0036] The float tank according to the invention shown in FIG. 2 differs from the prior art float tank shown in FIG. 1 because flags 9 are introduced in the melted tin beside the melted glass spreading out on the melted tin under the influence of gravitation in the hot spread region, i.e. in the region upstream or in front of the top rollers. The number of flags 9 depends on the size of the float chamber and/or the hot spread region. For optimum results one uses 1 to 3 flags on each side of the tank per meter of tank length in the hot spread region. However a definite improvement is already achieved with a respective flag 9 on each side of the tank. The glass quality may be improved with the flags according to the invention in the hot spread region in any float bath, even when no flags are present in the drawing region (sections II and III in FIGS. 1 and 2 ). All models conventionally used in float baths can be used as flags 9 . The flags are plates, which are immersed in the bath between the walls of the float tank and the edge of the glass sheet and which are arranged substantially transverse to the feed direction of the glass sheet.
[0037] FIGS. 3 a and 3 c show respective cutaway side cross-sectional views of a float bath with sidewall 1 and bottom 11 , tin bath 2 and glass sheet 3 floating on the tin bath. A flag 9 is introduced between the lateral edge of the glass sheet 3 and the tank wall 1 , which extends from above into the tin bath 2 . The flag 9 preferably extends to the bottom 11 of the float bath, however it can, as shown in FIG. 3 b , be arranged with some spacing from the bottom. The spacing between the flag 9 and the sidewall 1 is kept as small as possible in order to maximize the effect of the flag. A small spacing of the flag from the container wall does not impair the action of the flag. However that spacing should not be too large, since otherwise the acting surface of the flag is reduced. The lateral spacing of the flag to the edge of the glass sheet 3 should similarly be as small as possible, however direct contact of the flag with the glass is undesirable. Distances of about 10 to 50 cm are preferred for reasons of easy handling and adjustment. The flag 9 can, as shown in FIGS. 3 b and 3 c , extend under the edge of the glass sheet 3 . In FIG. 3 b that is caused by a step or shoulder in the flag, while in FIG. 3 c the flag has an inclined upper edge. The flag 9 is attached to a handle 15 , which is guided through the container wall 1 and is attached there in a conventional not illustrated manner. The flag 9 is usually arranged at an angle of 90° to the feed direction of the glass sheet 3 . However it can be oriented at an angle to the feed direction for an especially exact adjustment of the action of the flag. The angle can be up to 30°, however should usually not be less than 45°.
[0038] It is especially beneficial when the flag is equipped with an adjusting device by which its height, angle and spacing from the side wall 1 , the glass sheet 3 and the spacing to the container bottom 11 can be adjusted. This adjusting means is especially not shown, since it can be set up with current engineering knowledge without difficulty. The upper edge of the flag 9 should be above the level of the bath in the side region. The use of completely immersed flags, e.g. known from JP 2003313628, leads to a poor action.
[0039] The material, from which the flag 9 is made, must be inert to metal and the protective gas over the float bath and can resist the high temperatures present in the gas chamber. For example, graphite, mullite, sillimanite, fused quartz and composition materials have proven suitable for the flag. The holder can be made of materials like e.g. tempered steel.
[0040] Clearly reduced thickness variations of the thin glass produced can be attained by the arrangement of the flags in the hot spread region. Furthermore the stability of the glass sheet in regard to its width and its positioning on the float bath could be clearly improved.
Example
[0041] A thin flat glass sheet with a thickness of about 0.7 mm was drawn in a conventional float plant according to the prior art. The thickness of the glass sheet leaving the float plant of the prior art was measured. This thickness is shown graphically in FIG. 4 . The measurement occurred by a double reflection method, in which a laser contour line is projected on the glass sheet and the thickness is calculated from the spacing of the received reflections from the front side and the rear side of the glass sheet respectively. The thickness variation is shown in FIG. 4 . Then a flag was inserted in the molten metal on both sides of the forming glass sheet with a spacing of about 3.5 m from the front side of the float bath (bath inlet) in each case. The angle of the flag to the lateral wall amounted to 90°, the spacing to the sidewall 0 cm and the spacing to the glass flow 20 cm. The flag had a height of 70 cm and rests on the float tank bottom. The thickness fluctuation attained according to this structure is shown in FIG. 5 . The thickness variation of the prior art thin flat glass sheet or substrate determined from FIG. 4 is about 57 μm, while the corresponding thickness variation for the thin flat glass sheet or substrate according to the invention is about 18 μm.
[0042] While the invention has been illustrated and described as embodied in a float glass process for making thin flat glass and thin flat glass substrate made with same, it is not intended to be limited to the details shown, since various modifications and changes may be made without departing in any way from the spirit of the present invention.
[0043] Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention.
[0044] What is claimed is new and is set forth in the following appended claims. | The thin flat glass substrate, especially for display engineering, has a thickness of less than 1.5 mm, a length of at least 1800 mm, a width of at least 1800 mm and a difference between a smallest thickness and largest thickness of less than 50 μm. The float glass process for making the improved flat glass substrate provides flags ( 9 ) in the molten metal bath in the hot-spread region on both sides of the forming glass sheet to minimize the variation in thickness of the thin flat glass substrate formed by the process. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to apparatus for covering rain gutters, directing rain water from a sloping building roof into the gutter while protecting the gutter from accumulation of leaves and debris.
2. Description of the Prior Art.
Rain gutters are customarily provided adjacent to a sloping roof of a building. Typically they are comprised of a trough shaped horizontal section running along the edge of the roof and a vertical downpipe. Common problems associated with rain gutters are that leaves and debris pile up and clog them, and that water travelling down a sloping roof might gather enough momentum to overcome surface adhesion force and flow over the outer edge of the gutter and down the building wall instead of into the gutter.
Presently, the debris accumulation problem has been attempted to be solved by a variety of means. A number of patents, such as U.S. Pat. Nos. 2,219,953, 4,553,356, 4,644,704, and 4,907,381, attempt to solve this problem by covering the gutter with a screen or a mesh guard. These devices are in wide-spread use today, due in no small part to their relatively low price and ease in installation. Unfortunately this approach has proven to be less than acceptable since leaves and debris continues to pile up on the screen surface thus blocking access of water to the gutter.
Another approach to attempt to separate debris from water is addressed in a number of patents which employ the surface tension of the water along a solid arcuate member to direct only water into the gutter. Devices of this nature are disclosed in U.S. Pat. Nos. 4,404,775, 4,607,465 and 4,866,890. One of the primary problems created by deflector-type gutter guards are that they are usually bulky and are often difficult to install. Generally, these devices require the gutter to be replaced, or repositioned or modified to accommodate the curve of the arcuate member. These devices are also deficient in that their water carrying capacity is limited, depending in large part on the radius of the arcuate member, which often results in overflow in heavy rain storms. Finally, leaves continue to be a problem by sticking to the solid deflector surfaces, lessening surface adhesion force and again leading to the gutter overflow problems, and by being inadequately screened from the gutter, especially as the arc of the gutter is increased to increase the water carrying capacity.
Accordingly, it is a primary object of the present invention to provide a gutter guard which effectively separates leaves and other debris from rainwater entering a gutter, while requiring minimum maintenance.
It is a further object of the present invention to provide such a gutter guard which is relatively inexpensive to manufacturer and which may be readily installed on existing gutters without modification.
It is an additional object of the present invention to provide such a gutter guard which employs an arcuate surface to separate debris, but includes means to assure that water is always directed into the gutter even in heavy rain storms.
These and other objects of the present invention will become evident upon review of the following description of the present invention.
SUMMARY OF THE INVENTION
The present invention provides an apparatus for covering rain gutters. It comprises a shield attached to a pitched roof, providing a surface of a lesser incline than that of the roof, and an arcuate screen attached to the lower edge of the shield. The radius of the screen is great enough to cause the separation of debris from water, but not so great that the screen extends beyond the front wall of the gutter. The lower edge of the screen forms a trough shaped lip that attaches to the front wall of the gutter.
In operation, rain water flows off the roof onto the shield, and then into the gutter through the arcuate screen. Leaves and debris are prevented from accumulating on the screen by its arcuate shape and are blown off the roof either immediately upon separating from the water, or after accumulating in the trough shaped lip and being dried. Overflow in excessively heavy rains is avoided by the extra water carrying and straining capacity of the trough in the lower portion of the screen.
The angle formed between the shield and the roof permits the apparatus to be installed on a conventionally mounted gutter without the need of reinstalling the gutter lower down the building wall. Employing both roof and gutter anchoring means, the present invention may be readily installed on any commercially available gutter.
DESCRIPTION OF THE DRAWINGS
The operation of the present invention should become apparent from the following description when considered in conjunction with the accompanying drawings, in which:
FIG. 1 is a perspective view of an embodiment of the present invention;
FIG. 2 is a cross-sectional view of an embodiment of the present invention; and
FIG. 3 is an enlarged perspective view of a spring clip and lanyard shown in FIG. 2.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, the apparatus 10 of the present invention is shown in an assembly with a conventional gutter 11 installed directly below an edge 10b of a sloping roof 12. As is known, the gutter 11 comprises a back wall 11a, a bottom surface 11b, front wall 11c, and a top edge 11d.
The present invention comprises a shield portion 14, attached to the roof 12, and an arcuate screen 16, terminating in trough 18 attached to the gutter 11. The shield 14 provides a surface of lesser incline than that of the roof 12, thus decreasing the velocity of water coming from the roof and preventing it from flowing over the edge of the gutter 11 instead of into it. In the illustrated preferred embodiment of the present invention, the velocity of water may be decreased even further by flow control means 20, such as texturing of the surface of the shield 14, to provide further braking friction for the water exiting the roof. The flow control means illustrated comprise speed bumps 20, molded or welded into the surface of the shield 14.
In order to decrease the speed of the water exiting the gutter to the greatest degree possible, it is desirable that the slope of the shield 14 be as close to horizonal as possible. However, it should be appreciated that standing water should be avoided and that the shield and the flow control means 20 thereon should be oriented so that water will readily drained therefrom. This may be accomplished by any convenient manner, such as providing a slight slope to the shield 14, providing regular channels through the speed bumps 20, and/or providing periodic drain holes in the shield which will permit standing water to flow through to the roof 12 underneath the shield and into the gutter 11.
As can be seen in FIGS. 1 and 2, the arcuate screen 16 is attached at its upper most edge to the lower edge of the shield 14. The arc of the screen 16 is such that the trough 18 of the screen is positioned behind the front wall 11c of the gutter 11. When debris 22, such as a leaf or seed, is swept down the shield 14, the screen 16 segregates rain water from the debris 22 through the known surface tension of the water which will cause it to adhere to the arc of the screen 16 and enter the gutter 11 through the screen 16 either in the arc or in the trough 18. As is known, debris 22 will tend not to adhere to an arcuate surface and will either continue travelling tangentially to the arc over the front wall 11c of the gutter 11 or, to a much lesser degree, to accumulate in the trough 18 at the lowermost edge of the screen 16 and adjacent to the front wall of the gutter 11.
The trough 18 should be constructed with a narrow enough width that any leaves collected therein will be forced into a vertical position, which will permit them to be dried and subsequently blown off the roof or easily removed from the trough 18. In this regard, it is believed that the trough 18 should be of a width of approximately 1 to 5 cms. It should be understood that a wider trough 18 has greater water carrying capacity, but also provides a larger area to trap debris 22 and is less effective at drying debris 22 trapped therein.
The water collection capacity of the present invention may be further enhanced by providing an arcuate lip 24 at the lower end of the shield 14. This lip 24 serves to further direct the water downward into the screen 16 and to provide a further arc which assists in the separation of the debris 22 from the water.
As is shown in FIGS. 2 and 3, the apparatus 10 may be fastened to the gutter 11 by attaching one or more lanyards 26 to conventional studs 28 used to anchor the gutter 11 in place. In the preferred embodiment shown in FIG. 2, the lanyard 26 is attached to the stud 28 by a hook 30, which engages the stud 28. The lanyard 26 then is passed up through an opening 32 in the shield 14. The lanyard 26 may then be held in place through any conventional means, including a spring clip 34 or a lock ring (not shown). In this manner, the lanyard 26 may be pulled up tight and then held in place to provide a snug fit between the apparatus 10 and the gutter 11.
Another embodiment of the fastening means is shown in FIG. 1. The lanyard 26a in that embodiment has a threaded end 36 which may be held in place with a nut 38. The nut 38 may be tightened to hold the lanyard snugly in place. Other means of fastening the apparatus 10 to the gutter 11 include attaching the shield 14 to the roof 12 with nails, screws, staples or other known means, and/or attaching the screen 16 to the front wall 11c of the gutter 11 by clips or threaded attachments.
It should be appreciated that the apparatus 10 of the present invention may be constructed from any suitable material. In the preferred embodiment, the screen 16 and the shield 14 are fabricated from a rust-proof metal alloy or weather-resistant plastic. For ease in manufacture, it is preferred that the shield 14 and screen 16 be constructed from a single unit, such as through the use of plastic or aluminum on galvanized steel. Since the shape of the arc of the screen 16 must be maintained for best operation of the present invention, it is particularly desirable that a material be employed which will resist any serious distortion of the curve. This may be accomplished through a rigid screen material and/or the use of rigid braces affixed to the screen to maintain its shape. The screen 16 should have a mesh density of at least 4 holes per square inch, and preferably a density of 6 to 12 holes per square inch.
The advantages of the present invention are manifold. First, the use of an arcuate surface which also permits water to enter the gutter 11 throughout the length of the arc provides the separation advantages of previous arc-deflectors without the space requirement of a full semi-circular arc. As is shown, this permits the present invention to be employed with conventional gutters without the need to move or modify the gutters. Another advantage over other available arc-deflectors is that the existence of a trough 18 at the base of the screen 16 provides means to assure that water will not simply overflow the gutter when the quantity and/or velocity of the water exceeds the capacity of the arc to redirect the water.
Although particular embodiments of the present invention are disclosed herein, it is not intended to limit the invention to such a disclosure and changes and modifications may be incorporated and embodied within the scope of the following claims. | The present invention is an apparatus for covering traditionally mounted rain gutters. It is comprised of a roof attached shield and an arcuate screen attached to the gutter. In the preferred embodiment, a narrow trough is provided at the lower edge of the screen to accumulate excess water. The apparatus acts to separate water from debris, directing water from the roof into the gutter while encouraging the debris either to be immediately shed from the roof or to be collected and readily dried and removed from the trough. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. provisional patent application No. 62/037,474, filed on Aug. 14, 2014, and entitled “Multifunctional Microvalves.” Such application is incorporated herein by reference in its entirety.
BACKGROUND
[0002] The field of the invention is valves for microfluidic applications, and in particular to the use of such microvalves for safe and controlled delivery of fluids from a reservoir.
[0003] Fluidic microvalves can be constructed from shape-memory alloys. For example, U.S. Pat. No. 7,260,932 teaches a fluid control pinch valve using shape memory alloy that receives a current to open or close the pinch valve. Similarly, U.S. Pat. No. 6,843,465 teaches a shape-memory wire actuated control valve, in which the shape-memory wire is connected to an electrical platform and mechanically coupled to a transfer mechanism. The actuator is actuated by conducting electrical current through the shape-memory wire causing the wire to contract and thereby actuating the transfer mechanism, which is operably coupled to the fluid control valve such that actuating and de-actuating the transfer mechanism opens and closes the valve. U.S. Pat. No. 6,742,761 teaches a poppet valve that is used for opening and closing a miniature latching valve by means of an actuator mechanism that includes a shape-memory alloy wire. The change in shape of the shape-memory alloy wire causes the poppet to either move toward or away from the valve seat, thereby either closing or opening the valve. U.S. Pat. No. 6,840,257 teaches a proportional valve using a shape-memory alloy actuator, with a shutter axially movable from and towards a valve seat under the control of a shape-memory alloy actuating member.
[0004] Valves are a critical component of microfluidic systems. Miniaturized valves can be used in combination with miniaturized pumps to deliver pulsed and/or constant flow of microliter or nanoliter volumes of solution (or less). The valves themselves must be small and use little power to activate. Additional power can be saved by using a latching valve that does not require power to remain in any one state. Latching valves are not designed in a normally open or normally closed state; rather they can rest in either state. In drug delivery and other applications, latching valves are an important safety feature when properly configured as they prevent a direct flow path from a large reservoir to a patient in the case of a system failure.
BRIEF SUMMARY
[0005] The present invention relates generally to a valve and systems for using valves for controlled delivery of fluid and to provide a failsafe whereby the state of the valve is maintained despite a loss of power or other failure. This provides, in certain embodiments, certain advantages in applications such as the precise delivery of medicines to a patient over time. In certain embodiments, the valve may be used in connection with multiple tubes delivering drugs, and may be used with a pump, such as an electrochemical pump, to move the fluids containing drugs for delivery. In certain applications, more than one medicine may be delivered and metered independently using a single pump with multiple reservoirs and valves.
[0006] These and other features, objects and advantages of the disclosed subject matter will become better understood from a consideration of the following detailed description, drawings, and claims directed to the invention. This brief summary and the following detailed description and drawings are exemplary only, and are intended to provide further explanation of various implementations without limiting the scope of the invention as set forth in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a schematic diagram of a single sliding latching nitinol valve in the open (a) and closed (b) position (based on prior art U.S. Pat. No. 7,260,932 B1).
[0008] FIG. 2 is a graph showing fluid flow through a fluid sensor as the single sliding latching nitinol valve of FIG. 1 opens and closes.
[0009] FIG. 3 is a schematic diagram of a dual sliding latching nitinol valve in the inlet open/outlet closed (a) and outlet open/inlet closed (b) position.
[0010] FIG. 4 is a schematic diagram of a dual pivot latching nitinol valve.
[0011] FIG. 5 is a graph showing fluid flow through the dual pivot latching valve of FIG. 4 .
[0012] FIG. 6 is a graph showing results of a syringe pump coupled with the dual pivot latching valve of FIG. 4 and delivering it to a pressurized reservoir at 2 psi.
[0013] FIG. 7 shows one dual latching valve used to control fluid flow from a reciprocating pump.
[0014] FIG. 8 shows two dual latching valves with a two-sided reciprocating electrochemical pump, showing the two steps in drug delivery.
[0015] FIG. 9 shows two dual latching valves with two-sided reciprocating electrochemical pump to deliver controlled amounts of two different drugs to a patient.
DETAILED DESCRIPTION
[0016] Referring now to FIG. 1 (based on prior art U.S. Pat. No. 7,260,932 B1), a single sliding latching nitinol valve is shown in the open ( FIG. 1( a ) ) and closed ( FIG. 1( b ) ) positions. Tube 115 is located in an open receiving area between valve arm 109 and valve seat 121 which is in a fixed position. To close the valve, nitinol wire 101 attached to valve arm 109 is activated by associated circuit 103 to pull valve arm 109 , which thereby pinches tube 115 closed, as shown in FIG. 1( b ) . A resilient member such as spring 106 on latch arm 112 pushes the latch arm 112 so that it interferes with the return of valve arm 109 , causing tube 115 to remain pinched and closed without any additional power requirement. To open the valve, current is applied to circuit 104 , which activates nitinol wire 102 attached to latch arm 112 . Spring 105 forces valve arm 109 to its open position, where it interferes with the return path of latch arm 112 so that the valve remains open without any additional power. In this way, a single sliding valve may be employed using shape-memory alloy wire that stays in a desired position for an indefinite period of time without the addition of external power, until the valve is moved from the closed to open position, or the open to closed position. The valve is not dependent upon the presence of electrical power once set in either position. In a drug delivery device comprising a reciprocating pump, two of these valves may be used, one as an inlet valve and one as an outlet valve. In this case, there are no restrictions on whether either valve is open or closed so that at any point in time both valves could be open, both valves could be closed or one could be open while the other was closed. If both valves are open due to a system failure then there would be an open path from the reservoir to the delivery site, which could have devastating consequences in drug delivery applications.
[0017] The graph of FIG. 2 shows experimental results from the opening and closing of the valve shown in FIG. 1 . As can be seen from FIG. 2 , flow through tube 115 is quickly and effectively opened and closed by the operation of the valve.
[0018] FIG. 3 shows the inventive step beyond the valve of FIG. 1 in which two sections of a single fluid path (or two separate fluid paths), 305 and 307 , cannot both be in an open position at the same time. In the configuration of FIG. 3( a ) , tube 305 is open while tube 307 is pinched closed. In the configuration of FIG. 3( b ) , tube 305 is pinched closed while tube 307 is open. The dual sliding latching nitinol valve of FIG. 3 is designed so that both valves close during switching states and it is mechanically impossible for both tubes 305 and 307 to be open at the same time, thereby always preventing an unintended flow of fluid through the system in the case of a failure.
[0019] To move from the configuration of FIG. 3( a ) to the configuration of FIG. 3( b ) , nitinol wire 101 attached to inlet valve arm 301 is activated by running current through associated circuit 103 . This causes valve arm 301 to move up, pinching inlet tube 305 and allowing spring 106 to force outlet valve arm 302 to a position where outlet tube 307 is open and inlet valve arm 301 is prevented from returning to its original position. To return to the configuration of FIG. 3( a ) , nitinol wire 102 attached to outlet valve arm 302 is activated by running a current through associated circuit 104 . This causes outlet valve arm 302 to move to the right as shown in the figure, thereby pinching outlet tube 307 closed and allowing spring 105 to force inlet valve arm 301 to a position where inlet tube 305 is open and outlet valve arm 302 is prevented from returning to its open position. It may be seen that during each transition, there is a brief period during which both inlet tube 305 and outlet tube 307 are both closed; however, there is no time when both inlet tube 305 and outlet tube 307 are open, as this operation is mechanically prevented. This arrangement prevents flow in the case of a failure, such as is vitally important when the valve is used for the delivery of medication from a reservoir to a patient.
[0020] FIG. 4 depicts a variation on this design using a dual pivot latching nitinol valve. The figure shows the position of outlet tube 409 pinched closed by outlet valve arm 404 . To change the valve position, nitinol wire 101 attached to inlet arm 401 is activated to move inlet arm 401 to pinch inlet tube 405 . During this time, spring 407 forces outlet arm 404 to move so that outlet tube 409 is open (inlet tube 405 is closed) and outlet arm 404 prevents inlet arm 401 from returning to its normal position. Later activation of nitinol wire 102 attached to outlet arm 404 returns the valve to the open position (inlet tube 405 is open and outlet tube 409 is closed) as shown in FIG. 4 . As with the arrangement depicted in FIG. 3 , it may be seen that at no time in the process are both tubes 405 and 409 open. Such operation is mechanically prevented by the design of the valve, thereby providing a safety mechanism in the case of valve failure. The use of a pivot arm allows for a mechanical advantage to be used to reduce the length of nitinol wires 101 and 102 required to switch valve positions. The result is thus a smaller and more energy efficient valve.
[0021] Although various embodiments of the invention have been described herein with reference to particular applications related to the delivery of fluids and in particular drugs, it will be apparent that the invention is not so limited. In addition, the dual valve safety mechanism can be realized with a ratcheting action, or an appropriately shaped cam, for example. Furthermore, any actuation mechanism can be used to switch valve states of coupled valves including solenoid, magnetic, pneumatic or hydraulic controls, stepping motor, or manual operation. In addition, the preceding description has focused on two-dimensional layouts of the sliding or pivoting members, however, it can be extended to acting members which are arranged in a non-planar manner. Larger or smaller embodiments of a dual latching valve could be used for safety-enhanced flow control at any scale.
[0022] The graph of FIG. 5 shows normalized results from the opening and closing of the dual pivot latching nitinol valve of FIG. 4 . As can be seen from FIG. 5 , like in FIG. 2 , flow through each of outlet tube 409 and inlet tube 405 is efficiently switched by the valve. However, FIG. 5 also shows that the opening of either one of the valves always directly corresponds with the closing of the other. In this graph the y-axis shows no flow at 0 and flow at 1. The x-axis shows the cycles of alternately switching the two valve arms between open and closed. There is no time when fluid is flowing through both of the valves because at no time are both outlet tube 409 and inlet tube 405 open, thereby preventing flow through both simultaneously.
[0023] The graph of FIG. 6 shows experimental results of using a syringe pump as a fluid displacement source with the dual pivot latching valve of FIG. 4 . Fluid is removed from a balance to provide a weight reading and delivered to a reservoir held at a pressure of 2 psi. As can be seen from FIG. 6 , fluid is delivered from the balance in a stair-step fashion, with fluid removal from the balance alternating with a period when the valve is closed and fluid is being delivered to an off-balance reservoir, in a relatively even delivery over time. This data also shows that there is no backflow onto the balance from the pressurized reservoir, illustrating that there is never a time when both valves arms are open.
[0024] FIG. 7 shows an application of a dual latching valve as described herein with an electrochemical pump or “ePump” 725 . Electrochemical pumps suitable for use with the invention are taught, for example, in U.S. Pat. Nos. 7,718,047, 8,343,324, and 8,187,441, which are incorporated by reference herein. In this embodiment a dual latching valve is used for controlled dosing of a fluid, such as a drug to patient 821 . In the first step, the inlet valve arm is open (the outlet valve is closed) and the ePump is used to draw a dose of fluid along flow path 705 into chamber 706 . In the second step, the outlet valve is open (the inlet valve is closed) and the ePump is used to push fluid from chamber 706 into the patient 821 . Please note that at no time is there an open path from the reservoir to the patient, an important safety feature in drug delivery.
[0025] FIG. 8 shows an application of a two-sided ePump 825 used in combination with two dual-latching valves to generate near-continuous controlled dosing of a fluid, such as a drug, to a patient 821 . The two-sided ePump 825 has two chambers 806 and 816 . As the pump action draws fluid into the top chamber 806 , it expels fluid from the bottom chamber 816 . Conversely, as fluid is drawn into bottom chamber 816 , it is expelled from top chamber 806 . As can be seen in FIG. 8 , there are two distinct fluid paths that run from the reservoir 801 to patient 821 : 805 - 806 - 807 and 815 - 816 - 817 . Flow through each path is controlled by a dual latching valve. The upper dual latching valve has inlet valve arm 401 and outlet valve arm 404 which control flow through path 805 - 806 - 807 . Just as described in FIG. 4 , when inlet valve 401 is open, then outlet valve 404 must be closed. And, when outlet valve 404 is open, then inlet valve 401 must be closed. This important control and safety feature allows only the delivery of a metered dose (the volume of chamber 806 ) of fluid to be delivered and prevents the possibility of an open channel running from reservoir 801 to the patient. The same organization of inlet valve 411 and outlet valve 414 controls fluid movement along path 815 - 816 - 817 .
[0026] Alternatively, by arranging the inlet line 805 and outlet line 817 to both run through valve arm 401 and the outlet line 807 and inlet line 815 to both run through valve arm 404 , then only one dual latching valve is needed to provide flow from reservoir 801 to the patient 821 . In this arrangement as well, at no time is there an open fluid flow path from the reservoir to the patient.
[0027] The following steps describe how a metered dose of fluid is delivered in a near continuous fashion from reservoir 801 to the patient. In this case, the system has already been primed so that both fluid paths are full of fluid. In step ( 1 ), inlet valve 401 and outlet valve 414 are open and outlet valve 404 and inlet valve 411 are closed. When the ePump 825 is activated, it first pulls fluid from the drug reservoir 801 through flow path 805 and into chamber 806 where it is stored. Simultaneously, ePump 825 expels fluid stored in chamber 816 through path 817 and into the patient. In step ( 2 ), the valves are reversed such that output valve 404 and input valve 411 are open and input valve 401 and output valve 414 are closed. In this case, the pump draws fluid from the reservoir 801 through flow path 815 and into chamber 816 where it is stored. Simultaneously, the metered volume of fluid stored in chamber 806 (from step 1 ) is expelled through flow path 807 into the patient. Repeating of Steps 1 and 2 will result in near continuous (or intermittent) and safe delivery of controlled doses of fluid (in this case, a drug) to the patient.
[0028] FIG. 9 shows a variation of the arrangement in FIG. 8 wherein two different drugs may be dispensed to a patient 821 from two different reservoirs 901 and 902 . Using the steps described in FIG. 8 , drug A in reservoir 901 would be delivered in alternation with drug B in reservoir 902 . However, it may be desirable to deliver more doses of drug A and fewer doses of drug B. For example, insulin and glucagon as may be used in conjunction for treatment of diabetes, but insulin may need to be dispensed in more volume and or more frequently (or alternatively less) than glucagon. The following steps would allow differential and controlled delivery of two drugs using only one dual-sided ePump and two dual-latching valves. For example, nine doses of drug A in reservoir 901 are needed before a single dose of drug B in reservoir 902 is delivered to the patient. Starting with a fully primed system with both fluid paths 805 - 806 - 807 and 815 - 816 - 817 filled with the respective fluids: drug A and drug B. In Step 1 , inlet valves 401 and 411 are both open and outlet valves 404 and 414 are both closed. The first action of ePump 825 draws a metered amount of fluid from reservoir A into chamber 806 where it is stored. Simultaneously, fluid is expelled from chamber 816 through the only open path: back into reservoir 902 . In Step 2 , the top dual-latching valve switches positions such that inlet valve 401 is closed and outlet valve 404 is open. This means that the second action of ePump 825 expels the fluid stored in reservoir 806 out through path 807 and into the patient 821 . Repeating Steps 1 and 2 results in only fluid from reservoir 901 (drug A) being delivered to the patient, while the fluid from reservoir 902 (drug B) is cycled back and forth between reservoir 902 and chamber 816 , this cycling back and forth potentially having a mixing or stirring effect on the contents of the reservoir. Once it is desired to deliver fluid from reservoir 902 to the patient 821 then the bottom dual-latching valve will switch positions such that inlet valve 411 is closed and outlet valve 414 is open so that the fluid stored in chamber 816 is expelled to the patient 821 . Opposite protocol to the above would cause repeated delivery of fluid from reservoir B to be delivered to the patient and for fluid from reservoir A to be cycled back and forth between reservoir 901 and chamber 806 . By selectively operating the two dual-latching valves, each drug can be selectively pumped back into its originating reservoir or to the patient as needed.
[0029] Although various embodiments of the invention has been described herein with reference to particular applications related to the delivery of fluids and in particular drugs, it will be apparent that the invention is not so limited, and instead will find application in other fields where the precise delivery of fluids is desired in a fail-safe manner. Furthermore, although certain embodiments of the invention have been described for use in connection with an ePump, it will be apparent that the invention is not so limited, and that other types of pumps could be used in connection with the valves of the invention as described herein. In addition, although nitinol has been used as the shape-memory alloy in certain embodiments described herein, it will be understood that other shape-memory alloys or materials or actuation methods could be substituted therefor within the scope of the invention.
[0030] Unless otherwise stated, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although any systems and materials similar or equivalent to those described herein can also be used in the practice or testing of the present invention, a limited number of the exemplary systems and materials are described herein. It will be apparent to those skilled in the art that many more modifications are possible without departing from the invent concepts herein. All terms used herein should be interpreted in the broadest possible manner consistent with the context. Any ranges expressed herein are intended to include all particular values within the stated range, as well as all sub-ranges that fall within the stated range.
[0031] The present invention has been described with reference to the foregoing specific implementations. These implementations are intended to be exemplary only, and not limiting to the full scope of the present invention. Many variations and modifications are possible in view of the above teachings. The invention is intended to be limited only as set forth in the appended claims. | A valve for use in connection with microfluidic devices includes a safety feature such that flow is controlled even in the case of a loss of power, thus having applications in critical applications such as the precise delivery of drugs overtime. The valve may be used in connection with multiple tubes delivering drugs, and may be used with a pump, such as an electrochemical pump, to provide the force to move the fluids containing drugs for delivery. In certain applications, more than one medicine may be delivered and metered independently using a single pump with multiple reservoirs and valves. | 5 |
BACKGROUND OF THE INVENTION
The present invention relates to the automatic handling of workpieces, particularly in the course of a manufacturing process, when the workpieces which come from one treatment station in given direction and position must be offered to a second treatment station in predetermined direction and position which differ from the ones that they present in the first station. The invention deals more particularly with the manufacture of textile articles during which the textile workpieces, which are unitary parts of the article, pass from one station to another in order to undergo all the operations of hemming, folding, assembly, stitching . . . leading to the finished article.
French patent application No. 79 13658, corresponding to U.S. Pat. No. 4,371,159, discloses a process and an installation for taking to a second station, in predetermined fixed position and orientation, a workpiece, particularly a supple workpiece in sheet form such as a fabric, which is located in a first station in an approximate position. The fact that the workpiece is located at the first station in an approximate position requires the use of means for locating the position of the workpiece with respect to the fixed mark, with the result that the transfer means are placed on the workpiece as a function of the data transmitted by the locating means, and transfer said workpiece to the second station in the predetermined fixed position and orientation.
The major drawback of the known techniques, such as that described in the Application mentioned above, resides in the succession of independent operations which increases the time necessary for accomplishing a complete cycle.
SUMMARY OF THE INVENTION
The object of the invention is an apparatus and a process for transfer and for positioning which requires virtually no stoppage of the workpiece from the first station from which said workpiece is supplied by sliding over a flat surface by first transfer means in a given direction and a given position up to the second station where the workpiece is taken by sliding over a flat surface in predetermined direction and position which differ from those that it presents at the first station. The process according to the invention is characterized by the following steps:
a. when the workpiece reaches a first given location, it is released from the first transfer means and almost simultaneously taken over by a transfer and positioning means, these two virtually simultaneous actions being rendered possible by the sliding surface being lowered.
b. it is then transferred towards the second station by the transfes and positioning means which ensures both transfer and change of position thereof,
c. when the workpiece reaches a second given location where it has predetermined position, it is released from the transfer and positioning means and simultaneously taken over by a second transfer means which transfers it to the second station in the predetermined direction and position, by the sliding surface being raised.
The course of all the steps of the process is thus virtually uninterrupted, without waste of time. The direction given at the first station is advantageously perpendicular to the predetermined direction at the second station.
This process may be carried out in a transfer and positioning installation which, according to the invention, is characterized in that it comprises:
a. a flat table over which the workpiece slides, which is mobile in height or vertically adjustable and on which two given locations are represented,
b. a transfer and positioning means adapted to take over the workpiece as soon as the latter reaches the first given location, to transfer the workpiece from the first to the second given location, while modifying its position so that it has the predetermined position when it reaches said second location.
c. a second transfer means for transferring the workpiece to the second station in the predetermined direction and position, adapted to take over the workpiece as soon as the latter reaches the second given location,
d. means for lowering the mobile table when the workpiece reaches the first given location,
e. means for raising the mobile table when the workpiece reaches the second given location.
The workpiece is supplied from the first station by sliding over a flat surface by the displacement of the first transfer means which may be a belt; when the workpiece reaches the first given location, the mobile table whose sliding surface is in high position in line with the sliding surface of the first station, lowers, thus releasing the workpiece from contact with the first transfer means. Simultaneously to the lowering of the mobile table, the workpiece is taken over by the transfer and positioning means which transfers it by sliding over the mobile table, from the first to the second given location while giving it the determined position when it reaches said second location. Simultaneously, when the workpiece reaches the second given location, the mobile table rises and the workpiece, released from the transfer-positioning means, is taken over by the second transfer means which transfers the workpiece, by sliding over a surface which is in line with the sliding surface of the mobile table in high position, to the second station in the predetermined direction and position.
The means for lowering the mobile table when the workpiece reaches the first given location comprise a position sensor element which materializes the first given location and a bearing element which exerts on the table a pressure sufficient for the latter to pass from the high position to the low position. The high position corresponds to the one in which the workpiece is both in contact with the first transfer means of the first station and with the surface of the table; the low position corresponds to the one in which the workpiece is solely in contact with the surface of the table, and is therefor no longer driven by the first transfer means. The position sensor element controls the vertical displacement of the bearing element so that, taking into account the mechanical inertia, the workiece reaches the first given location when the bearing element has caused the table to pass from the high position to the low position.
The transfer and positioning means comprises a displacement member, which, on moving, may rotate on itself about an axis perpendicular to the plane of displacement. The displacement element is advantageously the bearing element which displaces the table in height. In this way, when the position sensor element detects the presence of the workpiece, the bearing and displacement element is applied on the workpiece as soon as the latter has reached the first given location, the pressure exerted on the workpiece places the table in low position, which releases the workpiece from the first transfer means, and simultaneously the bearing and displacement element displaces the workpiece over the table towards the second given location. During the displacement of the bearing and displacement element from the given first to the given second location, it rotates on itself about an axis perpendicular to the plane of displacement, so that the workpiece has the predetermined position when it reaches the second given location.
The means for raising the mobile table when the workpiece reaches the second given location comprise a second position sensor element which corresponds to the second given location and a counter-bearing element which causes the mobile table to return from the low position, where the bearing element held it, to the high position. The second position sensor element advantageously controls the raising of the bearing element, so that, taking into account the mechanical inertia, the workpiece reaches the second given location when, the bearing element no longer exerting its pressure on the table, the latter passes into high position. At that instant, the workpiece is then taken over by the second transfer means, which may be one or more belts having the predetermined direction; in that case the belt drives the workpiece by sliding towards the second station in the predetermined position and direction. It is generally preferable, in order to facilitate adjustments, if the belts which ensure the transfers to the first and the second station have perpendicular positions.
The invention will be more readily understood on reading the following description with reference to the accompanying drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view in perspective, and partially schematic, of a transfer and positioning installation.
FIGS. 2a, 2b, 2c and 2d schematically show the diferrent stages of operation of the installation.
FIG. 3 shows an example of the application of the process to the closure of sleeves.
FIGS. 4-7 schematically show four stages of the cycle of operation of the installation of FIG. 1, viewed from the side.
FIG. 8 schematically shows a plan view of these consecutive positions of the bearing and displacement element of the installation shown in FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, the transfer and positioning installation comprises a table 1 vertically adjustable in height. The table as shown in FIGS. 1 and 2a-2d, may pivot about an axis 2 parallel to the direction of supply of the workpiece, or may move vertically. The surface of the table 1, when the latter is in high position, is in the same plane with, on the one hand, the sliding surface corresponding to the first station from which the workpiece comes and on the other hand to the plane corresponding to the second station towards which it is directed. Furthermore, these three surfaces are approximately contiguous, with the result that a workpiece may pass by sliding from one to the other without folds or other faults being formed. The belt 3, which conveys the workpiece from the first station, extends both over the sliding surface of said first station and over a part of the table 1. In the immediate vicinity of the location of belt 3, a window 4 made in table 1 and a lamp (not shown) are place opposite a photoelectric cell 5.
A bearing and displacement or repositioning assembly is mounted on a carriage 6, displaceable from front to rear by a rod-crank system 7. This bearing and displaceable assembly consists of a comb element 8 which comprises two fingers 9 and 10 of which one, 9, is fixedly mounted on the carriage 6 while the other, 10, may pivot about the vertical axis constituted by the finger 9. The comb element 8 moves downwardly upon the opening of a retention element or follower 11 as shall be explained subsequently, such opening being controlled by the photoelectric cell 5 when it detects the presence of the workpiece on the table 1 level with window 4. The comb element 8 moves laterally in response to the displacement of the carriage itself. During the lateral displacement of the comb element 8, the finger 10 pivots through a certain angle about finger 9 as noted in FIG. 8, such pivoting is obtained by the combined action of the compression spring 12 which tends to repel the finger 10, and of the roller 13 which limits this pivoting, the roller 13 being fast with the comb element 8 and abutting on a ramp 14. The angle of this ramp 14 with respect to the predetermined direction of movement of carriage 6 is adjustable by means of screw 15, the ramp 14 being returned against this screw by a spring (not shown). At the end of stroke of the carriage 6, a stop 16 causes the comb 8 to rise by abutting on the lever 17, fast with the comb element 8. The complete cycle of displacement of the comb element 8, noting FIGS. 4-7, therefore comprises four continuous phases: lowering, lateral displacement, for example from left to right in FIG. 1, raising, displacement from right to left. Correct functioning of this cycle is effected by a guide assembly of which one part, constituted by a caster 18, is mounted on the lower lever 17 and therefore the carriage 6 and of which the other part, constituted by two bars 19 and 20, is fixed with respect to carriage 6. Bar 19 parallel to bar 20 is mounted above the latter. One of its ends is located opposite the follower 11, while the other end overhangs the corresponding end of the bar 20. The belts 21 and 22, which have the predetermined direction, perpendicular to that of the belt 3, and which ensure the transfer of the workpiece towards the second station, extend both over the sliding surface of said second station and over a part of table 1.
The transfer and positioning installation operates as follows. The workpiece 23 is conveyed by belt 3 by sliding over the horizontal sliding surface to the first station then partially over the table 1 (FIG. 2a). When it passes level with window 4, the interruption of the illumination of the lamp located beneath this window is detected by the photoelectric cell 5 which controls opening of the follower 11. The caster 18 which was maintained between the follower 11 and the bar 19 is released, and allows the comb element 8 to be lowered until the caster 18 encounters the bar 20. The comb element 8, on lowering, abuts on the workpiece 23 with the aid of fingers 9 and 10, and exerts a pressure on table 1 which pivots about axis 2 (FIG. 2b). During the displacement of carriage 6 from left to right under the effect of the rod-crank system 7, the comb element 8 takes along the workpiece 23 which slides over the inclined surface of table 1 (FIG. 2c). The inclination of table 1 is identical to that of bars 19 and 20 with respect to the horizontal, since it is the displacement of caster 18 along the rod 20 which guides the displacement of the comb element 8. During the saem displacement of the carriage 6, noting FIG. 8, the roller 13 fast with the comb element 8 follows the direction of the ramp 14 against which it abuts under the effect of the compression spring 12. In this way, during this lateral displacement, the finger 10, which follows the movement of the roller 13, pivots about the vertical axis formed by finger 9. This relative movement of the two fingers 9 and 10 one with respect to the other makes it possible to give the workpiece 23 the desired position. As a function of the workpiece to be treated on the installation, the angle through which the workpiece will pivot about the fixed finger 9, during the left to right lateral displacement, may be adjusted by modifying the angle formed by the ramp 14 with respect to the direction of transfer of the carriage, by acting on the adjusting screw 15. At the end of this lateral displacement, the stop 16 abuts on the lever 17 fast with carriage 6. On pivoting, the lever 17 raises both the caster 18 and the comb element 8. Once raised, the comb element 8 no longer exerts any pressure on the table 1, and the latter returns to its high position under the effect of the counterweight 24. The workpiece 23 comes into contact with the belts 21 and 22 which have the determined direction, and is taken along thereby in the determined position and direction by sliding firstly over a part of table 1 then over the sliding surface of the second station (FIG. 2d). During this time, the rod-crank system continues to drive the carriage 6. The caster 18, raised under the action of lever 17, is passed over rod 19 and guides the comb element 8 in its right to left displacement towards the initial position. A fresh workpiece 23 is supplied from the first station, and the cycle resumes.
The process and installation according to the invention are particularly adapted to the closure of short sleeves such as tee-shirt sleeves, as shown in FIG. 3. In that case, the workpiece 23 is a sleeve coming from a finishing station having effected for example hemming or cording of the sleeve bottom 25, then folding 26 of the sleeve along an axis of symmetry 27 so that there is exact overlapping of the two parts of the sleeve on the other. Once folded, the workpiece 23 must be closed; this closure is effected by stitching the two edges 28, matched and superposed. Taking into account the shape of the sleeve 23, it is then necessary to guide the line of stitching 28 under the sewing machine 29 in a direction and position which are different from those that it had on leaving folding 26. As shown in FIG. 3, it is necessary to both transfer the sleeve 23 from the folding station to the stitching station 30 and to subject it to a partial rotation on itself, so as to place the line of stitching 28 exactly in position and in direction under the sewing machine.
Of course, the installation according to the invention comprises all the adjustments necessary for changing workpieces and position, particularly adjustment of the ramp 14 by the screw 15 but also adjustment of the or each finger 9, 10 as a function of the size of the workpieces, adjustment of the control time of the opto-electronic sensor as a function of the choice of the first location, and adjustment of the stop 16 and of the stroke of the rod-crank 7 as a function of the desired length of lateral displacement. | Transfer and positioning apparatus including a vertically adjustable table, a workpiece introducing belt adapted to slidably move an underlying workpiece into a first location on the table. At the first location, the workpiece is engaged by fingers which depress the table to disengage the workpiece from the belt and subsequently move the workpiece across the table to a second location while changing the direction and orientation of the workpiece. At the second station, the fingers are elevated, allowing an elevation of the table and an engagement of the workpiece with a second belt which in turn slides the workpiece from the table to a second station. | 3 |
FIELD OF THE INVENTION
This invention relates to a novel use of an urushiol compound isolated from Resina Toxicodendri , and in particular, to a use of an urushiol compound in preparation of pharmaceutical compositions for inhibiting Smad3 phosphorylation.
BACKGROUND OF THE INVENTION
Natural pharmaceuticals play an important role in the research of the field of medical care and pharmaceutical research. It is shown that 80% of antimicrobial drugs and 60% anticancer drugs originate directly or indirectly from natural products ( J Nat Prod, 2003, 66: 1022-1237).
Resina Toxicodendri is the dried resin secreted by Toxicodendron vernicifluum and has been used as an anti-inflammatory and anti-scarring agent in traditional Chinese medicine for centuries.
Chinese patent application no. 201010149042.3, titled “Urushiol compound and medicinal composition thereof, preparation method and application” thereof, filed on Apr. 16, 2010, published on Aug. 18, 2010 with publication no. CN101805246A, granted on Jun. 5, 2013, disclosed that the researchers of Kunming Institute of Botany, Chinese Academy of Sciences (Kunming, China) isolated and purified an urushiol compound with the following structural formula:
The above urushiol compound is marked with a code GQ-5. GQ-5 is a small molecular urushiol compound with a molecular formula, C 21 H 34 O 2 . The compound preparation formed by the urushiol compound has obvious effects of inhibiting tumor cytotoxin activity and tumor angiogenesis.
Inventors of the present invention, from Southern Medical University (Guangzhou, China) continue the research of the phenolic component GQ-5 has effective of inhibiting fibrosis of liver tissue and kidney tissue. They filed the following two Chinese patent applications: CN 201010149042.3, titled “Use of an urushiol compound in preparation of drug for inhibiting fibrosis of liver tissue”, filed on Apr. 17, 2012, published on Oct. 30, 2013 with publication no. CN103371986A; CN 201210111642.X, titled “Use of an urushiol compound in preparation of drug for inhibiting fibrosis of kidney tissue”, filed on Apr. 17, 2012, published on Oct. 30, 2013 with publication no. CN103371987A.
All patents, patent publications, and non-patent publications cited are incorporated by reference herein.
TGF-β1 signals are transduced by transmembrane serinethreonine kinase receptors type I (TβRI) and type II (TβRII) and intracellular mediators known as Smads. Upon TGF-β1 stimulation, Smad2 and Smad3 are phosphorylated by TβRI. Phosphorylated Smadsheteroligomerize with the common partner Smad4 and then translocate into the nucleus, where they control the transcription of TGF-β-responsive genes through interaction with specific cis-acting elements in the regulatory regions. Although both Smad2 and Smad3 are strongly activated in various experimental and human fibrotic kidney diseases, it is now well recognized that Smad3 is the key mediator of TGF-β1-induced ECM production and tissue fibrosis. Deletion of Smad3 suppresses fibrogenesis in a number of rodent models, including diabetic nephropathy, obstructive nephropathy, and drug toxicity-related nephropathy. On the other hand, conditional knocking out of Smad2 from kidney tubular cells significantly enhanced renal fibrosis via up-regulation of Smad3 signaling. These findings indicate that Smad3 expression and/or phosphorylation might be a potential target for the intervention of renal fibrosis.
SUMMARY OF THE INVENTION
The object of the present invention is to provide a novel use of an urushiol compound, coded as GQ-5, isolated from Resina Toxicodendri.
The present invention provides a use of an urushiol compound GQ-5 in preparation of pharmaceutical compositions for inhibiting Smad3 phosphorylation.
In the present invention, inventors continue the research of the component of Resina Toxicodendri GQ-5, and demonstrate that treatment with GQ-5 significantly inhibited the progression of interstitial fibrosis in the unilateral ureteral obstruction (UUO) model. We further demonstrate that the anti-fibrotic effect of GQ-5 might be mediated by selective inhibition of TGF-β1-induced Smad3 phosphorylation.
In accordance with the present invention, the urushiol compound is isolated from Resina Toxicodendri.
In accordance with the present invention, the structural formula of the phenolic compound is:
The results of experiments of the present invention verify that the urushiol compound GQ-5 inhibited the interaction of Smad3 with TβRI, inhibited subsequent phosphorylation of Smad3, reduced nuclear translocation of Smads complex, and suppressed the transcription of major fibrotic genes such as α-smooth muscle actin (α-SMA), collagen I and fibronectin. Therefore, GQ-5 could be a potent and selective inhibitor of TGF-β1-induced Smad3 phosphorylation, and be used to prepare pharmaceutical compositions for inhibiting Smad3 phosphorylation.
BRIEF DESCRIPTION OF THE DRAWINGS
For a fuller understanding of the nature and advantages of the invention, as well as a preferred mode of use, reference should be made to the following detailed description read in conjunction with the accompanying drawings, in which:
FIG. 1 illustrates the NMR data of GQ-5.
FIG. 2 illustrates the MTT tests of GQ-5 in NRK 52E cells.
FIGS. 3A-3B illustrate GQ-5 dose-dependently inhibits TGF-β1-induced Smad3 phosphorylation in vitro.
FIG. 3A illustrates Western blot analysis of p-Smad3 and p-Smad2 in NRK 52E cells.
FIG. 3B illustrates Western blot analysis of p-Smad3 and p-Smad2 in NRK 49F cells. Data were expressed as mean±SD of three independent experiments. ANOVA, p<0.05 in p-Smad3 expression in GQ-5 treated cells.
FIG. 4 illustrates GQ-5 time-dependently inhibits TGF-β1-induced Smad3 phosphorylation in vitro. Cell lysates were immunoblotted with antibodies against p-Smad3, p-Smad2, total Smad3 and total Smad2. Data were expressed as mean±SD of three independent experiments. * p<0.05, vs GQ-5 untreated cells with TGF-β1 stimulation.
FIG. 5A-5B illustrate GQ-5 does not affect TGF-β1-induced Smad4, Smad7 expression or p38, PI3K, ERK phosphorylation in vitro.
FIG. 5A illustrates Western blot analysis of Smad4 and Smad7.
FIG. 5B illustrates Western blot analysis of p-p38, p38, p-PI3K, PI3K, p-ERK, and ERK. Data were expressed as mean±SD of three independent experiments.
FIG. 6A-6B illustrate GQ-5 selectively inhibits Smad3 phosphorylation in UUO rats.
FIG. 6A illustrates immunohistochemical staining for p-Smad3 and p-Smad2.
FIG. 6B illustrates Western blots analysis of p-Smad3 and p-Smad2 in UUO rats. Data were shown as mean±SD of 6 rats. *p<0.05 vs UUO+vehicle group.
FIG. 7A-7B illustrate GQ-5 does not affect Smad4, Smad7 expression or p38, PI3K, ERK phosphorylation in UUO rats.
FIG. 7A illustrates Western blot analysis of Smad4 and Smad7 in UUO rats.
FIG. 7B illustrates Western blot analysis of p-p38, p38, p-PI3K, PI3K, p-ERK, and ERK in UUO rats. Data were shown as mean±SD of 6 rats.
FIG. 8 illustrates GQ-5 reduces the TGF-β1-induced Smad3 nuclear translocation Immunofluorescence staining revealed that GQ-5 treatment inhibited TGFβ1-induced nuclei translocation of Smad3, Smad2, and Smad4 (800×).
FIG. 9 illustrates GQ-5 reduces the TGF-β1-induced Smad3-dependent collagen I promoter activity. NRK 52E cells were co-transfected with p(CACA)-luc plasmid and PGL3, followed by TGF-β1 (10 ng/ml) stimulation for 24 h in the absence or presence of indicated doses of GQ-5. Relative luciferase activity was presented. Data were expressed as mean±SD of three independent experiments. ANOVA, p<0.05 in GQ-5 treated cells.
FIG. 10A-10B illustrate GQ-5 inhibits the TGF-β1-induced α-SMA, collagen I and fibronectin mRNA expression.
FIG. 10A illustrates real-time PCR of α-SMA, collagen I and fibronectin in NRK 52E cells.
FIG. 10B illustrates real-time PCR of α-SMA, collagen I and fibronectin in NRK 49F cells. Data were expressed as mean±SD of three independent experiments. ANOVA, p<0.05 in GQ-5 treated cells in A&B; *p<0.05 vs untreated cells.
FIGS. 11A-11B illustrate GQ-5 inhibits the TGF-β1-induced α-SMA, collagen I and fibronectin protein expression.
FIG. 11A illustrates Western blot was performed to examine the protein expression of α-SMA, collagen I and fibronectin in NRK 52E cells.
FIG. 11B illustrates Western blot was performed to examine the protein expression of α-SMA, collagen I and fibronectin in NRK 49F cells. Data were expressed as mean±SD of three independent experiments. ANOVA, p<0.05 in GQ-5 treated cells in A&B; *p<0.05 vs untreated cells.
FIGS. 12A-12D illustrate GQ-5 ameliorates renal interstitial fibrosis initiating GQ-5 both right after (GQ-5 d1) and 7 days (GQ-5 d7) after operation.
FIG. 12A illustrates HE and mason staining of UUO kidneys.
FIG. 12B illustrates real-time PCR analysis of α-SMA, collagen I and fibronectin of UUO kidneys.
FIG. 12C illustrates immunohistochemical staining for α-SMA, collagen I and fibronectin of UUO kidneys.
FIG. 12D illustrates Western blot analysis of α-SMA, collagen I and fibronectin of UUO kidneys. Data were shown as mean±SD of 6 rats. * p<0.05 vs sham groups; # p<0.05 vs UUO+vehicle groups.
FIGS. 13A-13C illustrate GQ-5 selectively blocks the interaction of Smad3 with TβRI in vitro.
FIG. 13A illustrates that cell lysates were immunoprecipitated with α-TβRI, followed by immunoblotting using antibodies against Smad3, Smad2, TβRII and TβRI.
FIG. 13B illustrates that cell lysates were immunoprecipitated with a-Smad3, followed by immunoblotting using antibodies against Smad3, TβRII and TβRI.
FIG. 13C illustrates that cell lysates were immunoprecipitated with a-Smad2, followed by immunoblotting using antibodies against Smad2, TβRII and TβRI. Data were expressed as mean±SD of three independent experiments. *p<0.05 vs GQ-5 untreated cells under TGF-β1 stimulation.
FIGS. 14A-14C illustrate GQ-5 selectively blocks the interaction of Smad3 with TβRI in UUO rats.
FIG. 14A illustrates that kidney homogenates were immunoprecipitated with anti-TβRI, followed by immunoblotting using antibodies against Smad3, Smad2, TβRII and TβRI.
FIG. 14B illustrates that kidney homogenates were immunoprecipitated with α-Smad3, followed by immunoblotting using antibodies against Smad3, TβRII and TβRI.
FIG. 14C illustrates that kidney homogenates were immunoprecipitated with α-Smad2, followed by immunoblotting using antibodies against Smad2, TβRII and TβRI. Data were expressed as mean±SD of three independent experiments *p<0.05 vs vehicle treated UUO.
DETAILED DESCRIPTION OF THE INVENTION
A further illustration of the invention may be described with reference to the following examples.
Example 1
Preparation of the Urushiol Compound GQ-5
To isolate GQ-5, the dried resins of Toxicodendron vernicifluum (17 kg) (Yunnan Corporation of MateriaMedica, Kunming, P. R. China) were extracted with 80% ethanol (3×20 L) at room temperature. The extracts were concentrated under reduced pressure, and suspended in water followed by partition with ethyl acetate (3×5 L). The extract (220 g) from ethyl acetate was submitted to a silica gel column (200-300 mesh, 12×150 cm, 2.5 kg, Qingdao Marine Chemical Inc., Qingdao, P.R. China), eluted with a gradient of CHCl 3 MeOH (100:0-80:20) to yield 10 fractions. The fraction 4 (15 g) was subjected to a MCI gel CHP 20P column (75-150 μm, Mitsubishi Chemical Industries, Tokyo, Japan), eluted with gradient aqueous acetone (80:20-100:0) to yield fractions 4.1 and 4.2. Among them, the fraction 4.2 (11.3 g) was filtrated on Sephadex LH-20 (CHCl 3 MeOH, 6:4, Amersham Pharmacia, Uppsala, Sweden) to yield GQ-5 (10 g).
Example 2
Identification of the Urushiol Compound GQ-5
The spectroscopic and chemical methods were used to identify the structure of GQ-5. The 1 H NMR spectrum using Bruker DRX-500 NMR spectrometer (Bruker Daltonics, Germany) indicated the diagnostic signals of one 1,2,4-trisubstituted benzene group, one methyl, and one aliphatic chain. The 13 C NMR and DEPT spectra revealed one methyl, five methine, and three quaternary carbons (two of them are oxygenated). Mass spectra (ESI-MS) (API QSTAR Pulsar 1 spectrometer, AB SCIEX, USA) and high resolution ELMS (AutospecPrimier P776 instrument, Waters, USA) analyses indicated that the molecular formula of GQ-5 was C 21 H 34 O 2 . The NMR data of GQ-5 were in agreement with those of 3-[(Z)-pentadec-8-enyl]catechol. In addition, the position and geometry of the double bond in the side chain was confirmed by total chemical synthesis.
Example 3
The Purity Determination of the Urushiol Compound GQ-5
The purity of GQ-5 was determined by analytic HPLC using RP-18 column under 280, 254, 230, 225 and 210 nm, and then eluted by gradient aqueous MeOH (85%400%, 0-20 min) Only one symmetric peak was found in all the chromatograms in different detection conditions, indicating that GQ-5 is a HPLC grade pure compound ( FIG. 1 ). Consistently, there was no impurity present in the 1 H NMR spectrum.
Example 4
Toxicological Experiment of the Urushiol Compound GQ-5 in Mice
To test the toxicity of GQ-5, 20 C57BL/6J little male mice which are 7-8 months old, healthy and clean, their weights are between 20 and 22 gram. Antisepsis the feed and water, before and in the layoff period of the test, all the mice should be feed under the normal feeding condition.
Dissolve GQ-5 in 0.5% propylene glycol, this liquor is given to little mice by intraperitoneal injection. The dosage of GQ-5 was 10, 40, 200, and 800 mg/kg body weight of mice. After administration, they are observed for 7 days. Mice intra-peritoneal injected with single dose of GQ-5 up to 800 mg/kg did not die or developed any adverse event during 7-day observation.
Example 5
Toxicological Experiment of the Urushiol Compound GQ-5
To test the toxicity of GQ-5, rat proximal tubular cells (NRK52E) were seeded into 96-well plates in a volume of 200 μl per well (1×10 5 cell/ml) and incubated for 24 hours to allow cells to attach. The cells were then incubated with indicated amount of GQ-5 for 1 h. Cell viability was determined by addition of 20 μl of 3-(4,5-dimethylthiazol-2-yl)-2, 5-diphenyltetrazolium bromide (MTT) at a concentration of 5 mg/ml. After incubation for 4 hours, the medium was removed and 150 μl of DMSO was added to dissolve the formazan crystals. The absorbance was read at 540 nm by using iMark™Microplate Reader (Bio-Rad). As shown in FIG. 2 , GQ-5, over a complete pharmacologically relevant dose (0.25-4 μM), did not affect the viability and proliferation of the cells.
Example 6
GQ-5 Dose-Dependently Inhibits TGF-β1-Induced Smad3 Phosphorylation In Vitro
1. Cells.
NRK52E and NRK49F cells were cultured in DMEM-Ham's medium supplemented with 10% fetal bovine serum. The cells reached at approximately 50% confluence were used for in vitro experiments. Cells were serum-starved for 12 h, and randomized into 6 groups: (1) Controls; (2) GQ-5 only; (3) TGF-β1 only; (4) TGF-β1+GQ-5 0.1 μM; (5) TGF-β1+GQ-5 0.5 μM; (6) TGF-β1+GQ-5 2.5 μM.
2. Sample Source and Preparation
(1) Controls: incubated with DMEM for 2 h;
(2) GQ-5 only: pre-treated with GQ-5 (2.5 μM) for 1 h, followed with DMEM for 1 h
(3) TGF-β1 only: pre-treated with DMSO (0.1%) for 1 h, followed with TGF-β1 (10 ng/ml) for 1 h
(4) TGF-β1+GQ-5 0.1 μM: pre-treated with GQ-5 (0.1 μM) for 1 h, followed with TGF-β1 (10 ng/ml) for 1 h
(5) TGF-β1+GQ-5 0.5 μM: pre-treated with GQ-5 (0.5 μM) for 1 h, followed with TGF-β1 (10 ng/ml) for 1 h
(6) TGF-β1+GQ-5 2.5 μM: pre-treated with GQ-5 (2.5 μM) for 1 h, followed with TGF-β1 (10 ng/ml) for 1 h.
3. Experimental Methods
GQ-5 was dissolved in DMSO. Cells were treated as described. Cell lysates were immunoblotted with antibodies against phospho-Smad3, Smad3, phospho-Smad2, Smad2.
4. Results
As shown in FIGS. 5A-5B , incubation with TGF-β1 significantly induced phosphorylation of Smad2 and Smad3 in both NRK52E ( FIG. 3A ) and NRK49F cells ( FIG. 3B ). GQ-5 treatment attenuated TGF-β1-induced Smad3 phosphorylation in a dose-dependent manner, but did not affect TGF-β1-induced Smad2 phosphorylation. The inhibitory effect of GQ-5 was almost undetectable in NRK52E and NRK49F cells in the absence of TGF-β1 stimulation.
Example 7
GQ-5 Time-Dependently Inhibits TGF-β1-Induced Smad3 Phosphorylation In Vitro
1. Cells.
NRK52E cells were cultured in DMEM-Ham's medium supplemented with 10% fetal bovine serum. The cells reached at approximately 50% confluence were used for in vitro experiments. Cells were serum-starved for 12 h, and randomized into 8 groups: (1) Controls; (2) GQ-5 only; (3) TGF-β1 0.5 h; (4) TGF-β1 0.5 h+GQ-5; (5) TGF-β1 1.0 h; (6) TGF-β1 1.0 h+GQ-5; (7) TGF-β1 3.0 h; (8) TGF-β1 3.0 h+GQ-5;
2. Sample Source and Preparation
(1) Controls: incubated with DMEM for 2 h;
(2) GQ-5 only: pre-treated with GQ-5 (2.5 μM) for 1 h, followed with DMEM for 1 h
(3) TGF-β1 0.5 h: pre-treated with DMSO (0.1%) for 1 h, followed with TGF-β1 (10 ng/ml) for 0.5 h
(4) TGF-β1 0.5 h+GQ-5: pre-treated with GQ-5 (2.5 μM) for 1 h, followed with TGF-β1 (10 ng/ml) for 0.5 h
(5) TGF-β1 1.0 h: pre-treated with DMSO (0.1%) for 1 h, followed with TGF-β1 (10 ng/ml) for 1.0 h
(6) TGF-β1 1.0 h+GQ-5: pre-treated with GQ-5 (2.5 μM) for 1 h, followed with TGF-β1 (10 ng/ml) for 1.0 h
(7) TGF-β1 3.0 h: pre-treated with DMSO (0.1%) for 1 h, followed with TGF-β1 (10 ng/ml) for 3.0 h
(8) TGF-β1 3.0 h+GQ-5: pre-treated with GQ-5 (2.5 μM) for 1 h, followed with TGF-β1 (10 ng/ml) for 3.0 h
3. Experimental Methods
GQ-5 was dissolved in DMSO. Cells were treated as described. Cell lysates were immunoblotted with antibodies against phospho-Smad3, Smad3, phospho-Smad2, and Smad2.
4. Results
As shown in FIG. 4 , incubation with TGF-β1 significantly induced phosphorylation of Smad2 and Smad3 in NRK52E cells. GQ-5 treatment attenuated TGF-β1-induced Smad3 phosphorylation in a time-dependent manner, but did not affect TGF-β1-induced Smad2 phosphorylation.
Example 8
GQ-5 does not Inhibit TGF-β1-Induced Smad4 or Smad7 Expression, Nor p38, PI3K, ERK Phosphorylation In Vitro
1. Cells.
NRK52E and NRK49F cells were cultured in DMEM-Ham's medium (Gibco, Life Techologies, NY, USA) supplemented with 10% fetal bovine serum (Gibco, Life Techologies, NY, USA). The cells reached at approximately 50% confluence were used for in vitro experiments. Cells were serum-starved for 12 h, and randomized into 4 groups: (1) Controls; (2) GQ-5 only; (3) TGF-β1 only; (4) TGF-β1+GQ-5
2. Sample Source and Preparation
(1) Controls: incubated with DMEM for 2 h;
(2) GQ-5 only: pre-treated with GQ-5 (2.5 μM) for 1 h, followed with DMEM for 1 h
(3) TGF-β1 only: pre-treated with DMSO (0.1%) for 1 h, followed with TGF-β1 (10 ng/ml) for 1 h
(4) TGF-β1+GQ-5: pre-treated with GQ-5 (2.5 nM) for 1 h, followed with TGF-β1 (10 ng/ml) for 1 h
3. Experimental Methods
GQ-5 was dissolved in DMSO. Cells were treated as described. cell lysates were immunoblotted with antibodies against Smad4, Smad7, phospho-p38, p38, phospho-PI3K, PI3K, phosphor-ERK, and ERK.
4. Results
As shown in FIGS. 5A-5B , GQ-5 did not affect the protein expression of Smad4 or Smad7, nor the TGF-β1-induced phosphorylation of p38, ERK and PI3K.
Example 9
GQ-5 Selectively Inhibits the Phosphorylation of Smad3 and Smad2 In Vivo
1. Animal Model
Male Sprague-Dawley rats with body weight 200 to 250 g were randomized into 4 groups (n=6 in each group): (1) sham operated rats; (2) UUO rats; (3) UUO+GQ-5 d1 rats; (4) UUO+GQ-5 d7 rats.
2. Sample Source and Preparation
GQ-5 was dissolved in 5% propylene glycol.
(1) Sham operated rats: daily intraperitoneal injection of 5% propylene glycol;
(2) UUO rats: daily intraperitoneal injection of 5% propylene glycol;
(3) UUO+GQ-5 d1 rats: daily intraperitoneal injection of GQ-5 (40 mg/kg body weight) right after UUO;
(4) UUO+GQ-5 d7 rats: daily intraperitoneal injection of GQ-5 (40 mg/kg body weight) 7 days after UUO.
3. Experimental Methods
UUO was performed using an established protocol as described. GQ-5 was dissolved in 5% propylene glycol. Rats were administrated with GQ-5 as described before. All the rats were sacrificed 14 days after UUO. Immunohistochemical staining and Western blot analyses were performed to examine the Smad3 and Smad2 phosphorylation in kidney tissue.
4. Results
As shown in FIG. 6 , the phosphorylation of both Smad3 and Smad2 in renal tissue was significantly increased in UUO rats compared to sham controls. Treatment of GQ-5 significantly inhibited Smad3 but not Smad2 phosphorylation.
Example 10
GQ-5 does not Affect Smad4, Smad7 Expression or p38, PI3K, ERK Phosphorylation in UUO Kidneys
1. Animal Model
Male Sprague-Dawley rats with body weight 200 to 250 g were randomized into 3 groups (n=6 in each group): (1) sham operated rats; (2) UUO rats; (3) UUO+GQ-5 rats.
2. Sample Source and Preparation
GQ-5 was dissolved in 5% propylene glycol.
(1) Sham operated rats: daily intraperitoneal injection of 5% propylene glycol;
(2) UUO rats: daily intraperitoneal injection of 5% propylene glycol;
(3) UUO+GQ-5 rats: daily intraperitoneal injection of GQ-5 (40 mg/kg body weight) right after UUO;
3. Experimental Methods
UUO was performed using an established protocol as described. GQ-5 was dissolved in 5% propylene glycol. Rats were administrated with GQ-5 as described before. All the rats were sacrificed 14 days after UUO. Western blot analyses were performed to examine the Smad4, Smad7 expression and p38, PI3K, ERK phosphorylation.
4. Results
As shown in FIGS. 7A-7B , GQ-5 did not affect the expression of Smad4 and Smad7, or the phosphorylation of p38, PI3K or ERK in UUO rats.
Example 11
GQ-5 Reduced the TGF-β1-Induced Smad3 Nuclear Translocation
1. Cells.
NRK52E cells were cultured in DMEM-Ham's medium supplemented with 10% fetal bovine serum. The cells reached at approximately 50% confluence were used for in vitro experiments. Cells were serum-starved for 12 h, and randomized into 3 groups: (1) Controls; (2) TGF-β1 only; (3) TGF-β1+GQ-5.
2. Sample Source and Preparation
(1) Controls: incubated with DMEM for 2 h;
(2) TGF-β1 only: pre-treated with DMSO for 1 h, followed with TGF-β1 (10 ng/ml) for 2 h
(3) TGF-β1+GQ-5: pre-treated with GQ-5 (2.5 μM) for 1 h, followed with TGF-β1 (10 ng/ml) for 2 h
3. Experimental Methods
GQ-5 was dissolved in DMSO. Cells were treated as described Immunofluorescence staining was performed to examine the nuclear translocation of Smad2, Smad3, and Smad4.
4. Results
As shown in FIG. 8 , immunofluorescence staining reveled that pre-incubating NRK52E cells with GQ-5 significantly reduced the TGF-β1-induced Smad3 nuclear translocation. Treatment with GQ-5 also reduced nuclear translocation of Smad2 and Smad4.
Example 12
GQ-5 Reduced the TGF-β1-Induced Smad3-Dependent Collagen I Promoter Activity
1. Cells.
NRK52E cells were cultured in DMEM-Ham's medium supplemented with 10% fetal bovine serum. The cells reached at approximately 50% confluence were used for in vitro experiments. Cells were transiently transfected with a Smad3 responsive promoter p(GAGA)12-luc plasmid. PGL3 basic plasmid was co-transfected into the cells as control. Cells were serum-starved for 12 h, and randomized into 6 groups: (1) Controls; (2) GQ-5 only; (3) TGF-β1 only; (4) TGF-β1+GQ-5 0.1 μM; (5) TGF-β1+GQ-5 0.5 μM; (6) TGF-β1+GQ-5 2.5 μM
2. Sample Source and Preparation
(1) Controls: transfected with PGL3 basic plasmid and incubated with DMEM for 24 h;
(2) GQ-5 only: transfected with p(GAGA)12-luc plasmid, pre-treated with GQ-5 (2.5 μM) for 1 h, followed with DMEM for 24 h
(3) TGF-β1 only: transfected with p(GAGA)12-luc plasmid, pre-treated with DMSO for 1 h, followed with TGF-β1 (10 ng/ml) for 24 h
(4) TGF-β1+GQ-5 0.1 μM: transfected with p(GAGA)12-luc plasmid, pre-treated with GQ-5 (0.1 mM) for 1 h, followed with TGF-β1 (10 ng/ml) for 24 h
(5) TGF-β1+GQ-5 0.5 μM: transfected with p(GAGA)12-luc plasmid, pre-treated with GQ-5 (0.5 mM) for 1 h, followed with TGF-β1 (10 ng/ml) for 24 h
(6) TGF-β1+GQ-5 2.5 μM: transfected with p(GAGA)12-luc plasmid, pre-treated with GQ-5 (2.5 mM) for 1 h, followed with TGF-β1 (10 ng/ml) for 24 h
3. Experimental Methods
GQ-5 was dissolved in DMSO. Cells were treated as described. Promoter assays using a luciferase reporter system were performed to examine the Smad3-dependent collagen I promoter activity.
4. Results
As shown in FIG. 9 , treatment with GQ-5 significantly inhibited TGF-β1-induced Smad3-dependent collagen I promoter activity in a dose-dependent manner.
Example 13
GQ-5 Reduced the TGF-β1-Induced α-SMA, Collagen I and Fibronectin mRNA Expression
1. Cells.
NRK52E and NRK49F cells were cultured in DMEM-Ham's medium supplemented with 10% fetal bovine serum. The cells reached at approximately 50% confluence were used for in vitro experiments. Cells were serum-starved for 12 h, and randomized into 6 groups: (1) Controls; (2) GQ-5 only; (3) TGF-β1 only; (4) TGF-β1+GQ-5 0.1 μM; (5) TGF-β1+GQ-5 0.5 μM; (6) TGF-β1+GQ-5 2.5 μM
2. Sample Source and Preparation
(1) Controls: incubated with DMEM for 36 h;
(2) GQ-5 only: pre-treated with GQ-5 (2.5 μM) for 1 h, followed with DMEM for 36 h
(3) TGF-β1 only: pre-treated with DMSO for 1 h, followed with TGF-β1 (10 ng/ml) for 36 h
(4) TGF-β1+GQ-5 0.1 μM: pre-treated with GQ-5 (0.1 μM) for 1 h, followed with TGF-β1 (10 ng/ml) for 36 h
(5) TGF-β1+GQ-5 0.5 μM: pre-treated with GQ-5 (0.5 μM) for 1 h, followed with TGF-β1 (10 ng/ml) for 36 h
(6) TGF-β1+GQ-5 2.5 μM: pre-treated with GQ-5 (2.5 μM) for 1 h, followed with TGF-β1 (10 ng/ml) for 36 h
3. Experimental Methods
GQ-5 was dissolved in DMSO. Cells were treated as described. Cells were collected for mRNA extraction. Real-rime PCR was performed to examine the mRNA expression of α-SMA, collagen I and fibronectin.
4. Results
As shown in FIGS. 10A-10B , in compare with the control, treatment with GQ-5 significantly inhibited TGF-β1-induced mRNA expression of α-SMA, collagen I and fibronectin in NRK 52E ( FIG. 12A ) and NRK 49F cells ( FIG. 12B ).
Example 14
GQ-5 Reduced the TGF-β1-Induced α-SMA, Collagen I and Fibronectin Protein Expression
1. Cells.
NRK52E and NRK49F cells were cultured in DMEM-Ham's medium supplemented with 10% fetal bovine serum. The cells reached at approximately 50% confluence were used for in vitro experiments. Cells were serum-starved for 12 h, and randomized into 6 groups: (1) Controls; (2) GQ-5 only; (3) TGF-β1 only; (4) TGF-β1+GQ-5 0.1 μM; (5) TGF-β1+GQ-5 0.5 μM; (6) TGF-β1+GQ-5 2.5 μM
2. Sample Source and Preparation
(1) Controls: incubated with DMEM for 48 h;
(2) GQ-5 only: pre-treated with GQ-5 (2.5 μM) for 1 h, followed with DMEM for 48 h
(3) TGF-β1 only: pre-treated with DMSO for 1 h, followed with TGF-β1 (10 ng/ml) for 48 h
(4) TGF-β1+GQ-5 0.1 μM: pre-treated with GQ-5 (0.1 μM) for 1 h, followed with TGF-β1 (10 ng/ml) for 48 h
(5) TGF-β1+GQ-5 0.5 μM: pre-treated with GQ-5 (0.5 μM) for 1 h, followed with TGF-β1 (10 ng/ml) for 48 h
(6) TGF-β1+GQ-5 2.5 μM: pre-treated with GQ-5 (2.5 μM) for 1 h, followed with TGF-β1 (10 ng/ml) for 48 h
3. Experimental Methods
GQ-5 was dissolved in DMSO. Cells were treated as described. Cells lysates were immunebloted with antibodies against α-SMA, collagen I and fibronectin.
4. Results
As shown in FIGS. 11A-11B , treatment with GQ-5 significantly inhibited TGF-β1-induced protein expression of α-SMA, collagen I and fibronectinin NRK 52E ( FIG. 13A ) and NRK 49F cells ( FIG. 13B ).
Example 15
GQ-5 Ameliorates Renal Interstitial Fibrosis after UUO
1. Animal Model
Male Sprague-Dawley rats were randomized into 4 groups (n=6 in each group): (1) sham operated rats; (2) UUO rats; (3) UUO+GQ-5 d1 rats; (4) UUO+GQ-5 d7 rats.
2. Sample Source and Preparation
GQ-5 was dissolved in 5% propylene glycol.
(1) Sham operated rats: daily intraperitoneal injection of 5% propylene glycol;
(2) UUO rats: daily intraperitoneal injection of 5% propylene glycol;
(3) UUO+GQ-5 d1 rats: daily intraperitoneal injection of GQ-5 (40 mg/kg body weight) right after UUO;
(4) UUO+GQ-5 d7 rats: daily intraperitoneal injection of GQ-5 (40 mg/kg body weight) 7 days after UUO.
3. Experimental Methods
UUO was performed using an established protocol as described. GQ-5 was dissolved in 5% propylene glycol. Rats were administrated with GQ-5 as described before. All the rats were sacrificed 14 days after UUO. HE staining, Masson trichrome staining were performed to examine the renal tissue injury, and Real-time PCR analyses, immunohistochemical staining, and Western blot analyses were performed to examine α-SMA, collagen I and fibronectin expression in kidney tissue
4. Results
As shown in FIGS. 12A-12D , UUO rats exhibited marked interstitial inflammation and fibrosis in renal tissue stained with hematoxylin-eosin and Masson-trichrome. Treatment with GQ-5, either initiating right after or 7 days after operation, significantly reduced inflammatory cell infiltration and interstitial fibrosis score. Intervention with GQ-5 also significantly inhibited the up-regulation of α-SMA, collagen I and fibronectin in UUO rats at both mRNA and protein level, suggesting that treatment of GQ-5 not only prevented renal fibrosis, but also ameliorated established renal fibrosis.
Example 16
GQ-5 Selectively Blocks the Interaction of Smad3 with TβRI In Vitro
1. Cells.
NRK52E cells were cultured in DMEM-Ham's medium supplemented with 10% fetal bovine serum. The cells reached at approximately 50% confluence were used for in vitro experiments. Cells were serum-starved for 12 h, and randomized into 4 groups: (1) Controls; (2) GQ-5 only; (3) TGF-β1 only; (4) TGF-β1+GQ-5
2. Sample Source and Preparation
(1) Controls: incubated with DMEM for 2 h;
(2) GQ-5 only: pre-treated with GQ-5 (2.5 nM) for 1 h, followed with DMEM for 1 h
(3) TGF-β1 only: pre-treated with DMSO for 1 h, followed with TGF-β1 (10 ng/ml) for 1 h
(4) TGF-β1+GQ-5: pre-treated with GQ-5 (2.5 nM) for 1 h, followed with TGF-β1 (10 ng/ml) for 1 h
3. Experimental Methods
GQ-5 was dissolved in DMSO. Cells were treated as described. Cell lysates were collected for immunoprecipitation to examine the interaction among TGFβ type I receptor (TβRI), TβRII, Smad3 and Smad2.
4. Results
As shown in FIGS. 13A-13C , TβRI bound with TβRII, Smad2 and Smad3 upon TGF-β1 stimulation. Treatment with GQ-5 significantly blocked the interaction of Smad3 with TβRI, but did not affect the interaction of Smad2 with TβRI.
Example 17
GQ-5 Selectively Blocks the Interaction of Smad3 with T3RI In Vivo
1. Animal Model
Male Sprague-Dawley rats with body weight 200 to 250 g were randomized into 3 groups (n=6 in each group): (1) sham operated rats; (2) UUO rats; (3) UUO+GQ-5 rats.
2. Sample Source and Preparation
GQ-5 was dissolved in 5% propylene glycol.
(1) Sham operated rats: daily intraperitoneal injection of 5% propylene glycol;
(2) UUO rats: daily intraperitoneal injection of 5% propylene glycol;
(3) UUO+GQ-5 rats: daily intraperitoneal injection of GQ-5 (40 mg/kg body weight) right after UUO;
3. Experimental Methods
UUO was performed using an established protocol as described. GQ-5 was dissolved in 5% propylene glycol. Rats were administrated with GQ-5 as described before. All the rats were sacrificed 14 days after UUO. Immunoprecipitation analyses were performed to examine the interaction among TβRI, TβRII, Smad3 and Smad2.
4. Results
As shown in FIGS. 14A-14C , TβRI bound with TβRII, Smad2 and Smad3 in UUO kidneys. Treatment with GQ-5 significantly blocked the interaction of Smad3 with TβRI, but did not affect the interaction of Smad2 with TβRI.
In the description above, numerous specific details are set forth. However, it is understood that embodiments of the invention may be practiced without these specific details. For example, well-known equivalent components and elements may be substituted in place of those described herein, and similarly, well-known equivalent techniques may be substituted in place of the particular techniques disclosed. In other instances, well-known structures and techniques have not been shown in detail to avoid obscuring the understanding of this description.
The flowchart and block diagrams in the Figures illustrate the architecture, functionality, and operation of possible implementations of systems and methods according to various embodiments of the present invention. In this regard, each block in the flowchart or block diagrams may represent one or more modules, segments, steps, procedures, etc. It should also be noted that, in some alternative implementations, the functions noted in the block may occur out of the order noted in the figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved. It will also be noted that each block of the block diagrams and/or flowchart illustration, and combinations of blocks in the block diagrams and/or flowchart illustration, can be implemented by special purpose hardware-based systems that perform the specified functions or acts, or combinations of special purpose hardware.
The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the present invention has been presented for purposes of illustration and description, but 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 without departing from the scope and spirit of the invention. The embodiment was chosen and described in order to best explain the principles of the invention and 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.
Reference in the specification to “an embodiment,” “one embodiment,” “some embodiments,” or “other embodiments” means that a particular feature, structure, or characteristic described in connection with the embodiments is included in at least some embodiments, but not necessarily all embodiments. The various appearances of “an embodiment,” “one embodiment,” or “some embodiments” are not necessarily all referring to the same embodiments. If the specification states a component, feature, structure, or characteristic “may,” “might,” or “could” be included, that particular component, feature, structure, or characteristic is not required to be included. If the specification or claim refers to “a” or “an” element, that does not mean there is only one of the element. If the specification or claims refer to “an additional” element, that does not preclude there being more than one of the additional element. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof
While certain exemplary embodiments have been described and shown in the accompanying drawings, it is to be understood that such embodiments are merely illustrative of and not restrictive on the broad invention, and that this invention not be limited to the specific constructions and arrangements shown and described, since various other modifications may occur to those ordinarily skilled in the art. | The invention relates to a use of an urushiol compound (code named GQ-5) in preparation of pharmaceutical compositions for inhibiting Smad3 phosphorylation. We verify that GQ-5 inhibited the interaction of Smad3 with TGF-β type I receptor (TβRI), inhibited subsequent phosphorylation of Smad3, reduced nuclear translocation of Smads complex, and suppressed the transcription of major fibrotic genes such as α-smooth muscle actin (α-SMA), collagen I and fibronectin. Therefore, GQ-5 could be a potent and selective inhibitor of TGF-β1-induced Smad3 phosphorylation, and be used to prepare pharmaceutical compositions for inhibiting Smad3 phosphorylation. | 2 |
CLAIM OF PRIORITY
[0001] This application makes reference to, incorporates the same herein, and claims all benefits accruing under 35 U.S.C. §119 from an application for METHOD FOR RE-TRANSMITTING PACKET OF WIRELESS LAN SYSTEM BASED POLLING earlier filed in the Korean Intellectual Property Office on 23 Nov. 2004 and there duly assigned Serial No. 2004-0096596.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to re-transmitting a packet of a polling-based Wireless Local Area Network (WLAN) and, more particularly, to re-transmitting a packet between an Access Point (AP) and stations to reduce a packet loss rate in a LAN system employing a polling-based QoS (Quality of Service) guaranteed algorithm.
[0004] 2. Description of the Related Art
[0005] A WLAN is a communication network capable of transmitting and receiving data without any cable or wire, which has increased in the number of users from year to year due to various advantages such as mobility, simplicity of installation, etc. Textual information, information for using Internet, etc. include information capable of being transmitted and received by a WLAN.
[0006] However, currently, a study is being actively made in order to accommodate various services demanding real-time characteristics, such as voice communication services, multilateral video conference services, real-time image transmission services and so forth. WLAN telephones are currently being commercialized, which enable anyone to provide access to the WLAN to dial and receive a call.
[0007] The LAN must be capable of guaranteeing QoS to stations or users using such services to smoothly provide various application services requiring real-time characteristics. Since each of the stations connected to the WLAN makes a request for a different level of service, the WLAN must also provide optimal services to the respective stations.
[0008] Standards for the WLAN used widely nowadays function to guarantee QoS or Class of Service (CoS), or to compensate related functions. The WLAN standard of the Institute of Electrical and Electronics Engineers (IEEE), which is widely applied in North America and Korea, supports a Point Coordination Function (PCF) as an option in order to transmit real-time information, wherein the PCF refers to a Medium Access Control (MAC) function according to a polling mechanism.
[0009] The WLAN IEEE standard follows “Standard for Information technology-Telecommunications and information exchange between systems-Local and metropolitan area networks-Specific requirements-Part 11: Wireless LAN Medium Access Control (MAC) and Physical Layer (PHY) Specifications,” 1999 Edition.
[0010] Hereinafter, the IEEE WLAN standard will be referred to as the IEEE 802.11 standard. This standard defines the Medium Access Control (MAC) and Physical (PHY) layers for the WLAN.
[0011] The MAC layer defines orders and rules that a station or apparatus using the shared medium must observe in the use/access of the shared media, thereby making it possible to efficiently use the capacity of the medium.
[0012] IEEE 802.11 defines two types of access control mechanisms: a Distributed Coordination Function (DCF) and a Point Coordination Function (PCF).
[0013] The DCF is an access control mechanism defined as a fundamental specification in the IEEE 802.11 standard, which uses a contention based algorithm known as Carrier Sense Multiple Access/Collision Avoidance (CSMA/CA).
[0014] In the CSMA/CA based WLAN system, a station determines if a medium is busy. If so, the station waits for a predetermined time. After the predetermined time, if the medium is not busy, i.e. idle, the station decreases a backoff time. As such, the predetermined time for which each STA waits in order to initiate traffic is called an InterFrame Space (IFS). There are three IFSs for MAC protocol traffic. Among them, DIFS refers to a DCF InterFrame Space, PIFS refers to a PCF InterFrame Space, and SIFS refers to a Short InterFrame Space.
[0015] The station employing the DCF mechanism determines whether or not the medium is busy before transmitting a frame. If the medium is idle for a time greater than or equal to the DIFS, the station transmits the frame.
[0016] In contrast, if the medium is busy, the station initiates the back-off procedure. The station does not occupy the medium to transmit the frame until a value of a back-off timer becomes equal to zero(0).
[0017] In the back-off procedure, a random back-off time is assigned to the back-off timer. The random back-off time is dependent on the following relationship.
Back-off Time=random( )*slot-time
[0018] wherein, random( )=the random integer having a uniform probability distribution in the interval of [0, CW], and
CW=Contention Window, CWmin≦CW≦CWmax.
[0019] The back-off timer is reduced as much as the slot time whenever the medium maintains the idle state for the slot-time, but is no longer reduced when the medium is changed into the busy state.
[0020] After the medium is changed into the idle state during the DIFS, the back-off timer can be reduced as much as the slot time again. The back-off time is set to a value selected randomly within a preset range thereof rather than a generated value.
[0021] In addition, the back-off time set for an arbitrary station is reduced as much as a time slot while the medium is in the idle state. When re-transmission contention should be performed due to a failure in transmission contention, the back-off time is reduced as much as the time slot from the value reduced in the previous transmission contention. As such, the station does not initiate a transmission until the back-off timer becomes zero(0).
[0022] Whenever a plurality of stations attempt transmission at the same time to invite collision, the CWs are increased exponentially. At the same time, the back-off timer has a new back-off time.
[0023] After succeeding in transmission, the CW returns to CWmin (minimum CW). This exponential increase serves to lower a probability of a collision taking place again, thus enhancing safety of the network.
[0024] The DCF of IEEE 802.11 is a medium access mechanism capable of giving a fair chance to all of the stations when these stations have access to the medium, but it is not useful to establish the WLAN system supporting the QoS.
[0025] As the access control mechanism devised to guarantee the QoS in the WLAN, there are two: a contention-free method and a contention-based method. The polling-based mechanism is a representative contention-free method. The PCF makes use of this method.
[0026] The PCF is a centralized, polling-based access control algorithm, which requires an apparatus called a Point Coordinator (PC) in an AP. The PC gives a transmission chance to a specified station by transmitting a frame called a Contention-Free Poll (CF-Poll). When the PCF is used, a Contention-Free Period (CFP) in which only the station receiving a poll has the transmission chance without contention, and a Contention Period (CP) in which any station is capable of having access to the medium through contention are alternately repeated.
[0027] In order to use the PCF, the PC requires a function as a scheduler therein. This is because the PC predicts information on transmission time periods of all of the stations intended to transmit real time data, a size of the frame etc., and appropriately performs scheduling per cycle to give the transmission chance to the stations. If the appropriate scheduling is not performed, the station having an access delay in excess of a time limit can come into being, and the transmission efficiency of the medium can be deteriorated.
[0028] Among methods endowing a priority to each of the stations when the stations enter into transmission contention in the contention-based WLAN system, one is to differently apply the CWs determining the DIFS and the back-off time according to the priority in putting the CSMA/CA algorithm to use.
[0029] As the DIFS becomes smaller and as a value of the CW gets smaller, each data traffic or station has a higher priority.
[0030] Technology on a multi-polling DCF mechanism of overcoming disadvantages of the PCF using basic functions of the DCF is disclosed in Korean Patent Registration Publication No. 10-0442821 (issued on Jul. 23, 2004 and titled “Data Communication Method Based Back-off Number Control”).
[0031] As to the multi-polling DCF mechanism disclosed in the prior patent, when a multi-polling message, which includes information on IDentifiers (IDs) of stations intended for polling and on arbitrary back-off numbers allocated to the respective stations, is transmitted from an AP, the corresponding station receives the multi-polling message to set a back-off timer thereof to the back-off number allocated thereto, and subsequently performs a back-off procedure to attempt to get access to a medium.
[0032] In this manner, the multi-polling DCF mechanism transmits one polling message to a plurality of stations requiring the QoS (hereinafter, referred to as “MP-DCF stations”), wherein the polling message is defined by the back-off numbers of the corresponding stations using a multi-poll or a beacon, thereby making it possible for an equal transmission chance to be given to each of the MP-DCF stations.
[0033] However, for the PCF or MP-DCF, the polling-based MAC mechanism, for guaranteeing the QoS as set forth above, there is a problem to be settled with regard to packet processing.
[0034] In other words, the polling-based scheduling mechanism, such as the PCF or MP-DCF, aims at maximizing the number of times that each of the stations gets access in order to equally give the transmission chance to each of the stations with regard to the services requiring guaranteeing the QoS such as voice services. For this reason, only the method for maximizing usage of MAC resources between the AP and the stations is referred. However, no reference is made to a new measure to cope with a loss rate of wireless data having influence on a quality of the voice service.
[0035] The re-transmission algorithm for reducing the loss rate of data in the DCF that is generally used in the 802.11 WLAN MAC makes use of ACK and binary back-off mechanisms. However, the polling-based scheduling mechanism is operated on the basis of a back-off slot. Hence, using the re-transmission mechanism in the DCF causes a polling-based schedule to be broken, so that the polling-based scheduling mechanism is not operated normally.
SUMMARY OF THE INVENTION
[0036] It is, therefore, an object of the present invention to provide a method of re-transmitting a packet of a polling-based WLAN system, capable of reducing a packet loss rate in a LAN system employing a polling-based QoS guaranteed algorithm.
[0037] In order to accomplish this object, according to one aspect of the present invention, a method is provided comprising: scheduling a super frame to form a first period of providing a polling message to arbitrary stations at an Access Point (AP) and allowing only stations receiving the polling message to get access to a medium without contention, and to form a second period of allowing the stations to get access to the medium through contention; transmitting packets stored in a first transmission queue to the corresponding stations during the first period of the super frame; and enqueuing a packet whose transmission results in failure during a first portion of a second transmission queue to re-transmit the packet whose transmission has resulted in failure during the second period upon a determination that at least one of the packets transmitted to the stations has resulted in a failure to be transmitted.
[0038] The method preferably further comprises re-transmitting the packet for re-transmission stored in the first portion of the second transmission queue to the station upon the second period of the super frame being initiated.
[0039] The method preferably further comprises: determining whether or not the packet for re-transmission stored in the first portion of the second transmission queue is within a transmittable time limit upon the second period of the super frame being initiated; and re-transmitting the packet for re-transmission stored in the second transmission queue to the corresponding station upon the determination that the packet is within the transmittable time limit.
[0040] The method preferably further comprises discarding the packet for re-transmission stored in the second transmission queue upon the determination that the packet is beyond the transmittable time limit.
[0041] A determination that at least one of the packets transmitted to the stations has failed to be transmitted preferably comprises determining that an acknowledgment signal of the transmitted packet has not been received from the corresponding station.
[0042] In order to accomplish this object, according to another aspect of the present invention, a method is provided comprising: scheduling a super frame to form a first period of providing a polling message to arbitrary stations at an Access Point (AP) and allowing only stations receiving the polling message to get access to a medium without contention, and to form a second period of allowing the stations to get access to the medium through contention; transmitting packets stored in a first transmission queue to the AP during the first period of the super frame; and enqueuing a packet whose transmission results in failure during a first portion of a second transmission queue to re-transmit the packet whose transmission has resulted in failure during the second period upon a determination that at least one of the packets transmitted to the AP has resulted in a failure to be transmitted.
[0043] The method preferably further comprises re-transmitting the packet for re-transmission stored in the first portion of the second transmission queue to the AP upon the second period of the super frame being initiated.
[0044] The method preferably further comprises: determining whether or not the packet for re-transmission stored in the first portion of the second transmission queue is within a transmittable time limit upon the second period of the super frame being initiated; and re-transmitting the packet for re-transmission stored in the second transmission queue to the AP upon the determination that the packet is within the transmittable time limit.
[0045] The method preferably further comprises discarding the packet for re-transmission stored in the second transmission queue upon the determination that the packet is beyond the transmittable time limit.
[0046] A determination that at least one of the packets transmitted to the AP has failed to be transmitted preferably comprises determining that an acknowledgment signal of the transmitted packet has not been received from the AP.
BRIEF DESCRIPTION OF THE DRAWINGS
[0047] A more complete appreciation of the present invention, and many of the attendant advantages thereof, will be readily apparent as the present invention becomes better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings in which like reference symbols indicate the same or similar components, wherein:
[0048] FIG. 1 is a view of a configuration of a super frame to explain a re-transmission in a polling-based WLAN system in accordance with an embodiment of the present invention;
[0049] FIG. 2 is a view of a super frame of a re-transmission procedure in a station in accordance with an embodiment of the present invention;
[0050] FIG. 3 is a flowchart of a re-transmitting procedure in each station in accordance with an embodiment of the present invention;
[0051] FIG. 4 is a view of a super frame of are transmission procedure in an AP in accordance with an embodiment of the present invention; and
[0052] FIG. 5 is a flowchart of a re-transmitting procedure in an AP in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0053] The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which exemplary embodiments of the present invention are shown. The present invention can, however, be embodied in different forms and should not be construed as being limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the present invention to those skilled in the art. Like numbers refer to like elements throughout the specification.
[0054] FIG. 1 is a view of a configuration of a super frame for explaining a concept of re-transmission in a polling-based WLAN system according to an embodiment of the present invention.
[0055] Referring to FIG. 1 , the super frame for performing re-transmission according to one embodiment of the present invention includes a first period to provide a polling message, a poll, to arbitrary stations at an AP and to allow only the stations receiving the poll to get access to a medium without contention, and a second period to allow the stations to get access to the medium through contention.
[0056] In the first period of the super frame, scheduling is performed to allow the stations to perform a mode of transmitting packets stored in their own queues to the AP, and to allow the AP to perform a mode of transmitting packets stored in its own queue to the arbitrary stations. The super frame provides a frame period between the beacon of a certain period and the beacon of the next period.
[0057] Hereinafter, for the sake of convenience, a period of the stations performing the mode of transmitting packets stored in their own queues to the AP is referred to as a “VoUp period,” and a period of the AP performing the mode of transmitting packets stored in its own queue to the arbitrary stations is referred to as a “VoDn period.”
[0058] Furthermore, the first period is a Contention-Free Period (CFP) and the second period is a Contention Period (CP).
[0059] Thus, the CFP is a period between a point of time when a beacon signal is generated and a point of time when a contention-free end signal is generated, and the CP is period between a point of time when a contention-free (CF) end signal is generated and a point of time when the next beacon signal is generated.
[0060] The CFP consists of the VoUp period and the VoDn period, wherein the VoUp period refers to a period for transmitting packets stored in its own queue to the AP without contention by the station receiving the polling message from the AP, and the VoDn period refers to a period for for transmitting packets stored in its own queue to the corresponding station without contention by the AP.
[0061] For the VoUp period of the CFP, each station receiving the polling message from the AP transmits the packets stored in its own queue to the AP, and whenever the packets are received from the stations, the AP transmits acknowledgment signals of the packets to the corresponding stations.
[0062] For the VoDn period of the CFP, the AP transmits packets stored in its own queue to arbitrary stations, and whenever the packets are received from the AP, the stations transmit acknowledgment signals of the packets to the AP.
[0063] For the VoUp period of the CFP, whenever the packets are received from the stations, the AP transmits the acknowledgment signals to the corresponding stations. To this end, the stations occupy the medium in order to transmit the corresponding packets to the AP and give back a right to occupy the medium after terminating the transmission of the packets.
[0064] Each station occupies the medium to transmit the acknowledgment signal of the packets received from the stations to the AP. To this end, each station occupies the corresponding medium to transmit the acknowledgment signal to the AP using a Short InterFrame Space (SIFS) of InterFrame Spaces (IFSs).
[0065] Therefore, for the VoUp period of the CFP, each station transmits the packets to the AP, and then, when no acknowledgment signal has been received from the AP in the time that the SIFS has lapsed, recognizes that the AP has failed to receive the transmitted packets.
[0066] Hence, the stations transmit the corresponding packets to the AP for the CP with respect to the packets whose transmission results in failure after the CFP has been terminated.
[0067] To this end, the stations have a queue (hereinafter, referred to as a “CF transmission queue”) for transmitting the packets to the AP by polling for the CFP, and a queue (hereinafter, referred to as a “CP transmission queue”) for transmitting the packets to the AP after occupying the medium through contention for the CP.
[0068] Therefore, the stations transmit the packets stored in the CF transmission queue to the AP for the CFP, as well as transmitting the packets stored in the CP transmission queue to the AP for the CP.
[0069] The stations perform a re-transmission procedure for the packets which have been transmitted to the AP and whose acknowledgment signals have not been received from the AP, and transmit the corresponding packets to the AP.
[0070] In order to transmit the packets that the stations attempt to transmit for the CFP and have not yet transmitted to the AP, the stations transmit the packets and determine whether or not the transmission of the corresponding packets has resulted in failure. Then, when the transmission results in failure, the stations pick out the packets whose transmission has resulted in failure and transmit the picked packets to the AP for the CP following the CFP.
[0071] When the CP is initiated after the CFP has been terminated and when the stations occupy the medium, the stations re-transmit the packets whose transmission has resulted in failure for the CFP, to the AP with a first priority.
[0072] In order to transmit the packets whose transmission has resulted in failure for the CFP with a first priority, the stations enqueue the packets into a first portion of the CP transmission queue to transmit the corresponding packets for the CP, when no acknowledgment signal has been received from the AP for the CFP until the set SIFS has lapsed after the arbitrary packets have been transmitted to the AP.
[0073] When the CP is initiated after the CFP has been terminated, the stations transmit the corresponding packets stored in the first portion of the CP transmission queue to the AP, thereby re-transmitting the packets that the stations have attempted to transmit, but have failed to transmit.
[0074] As the packets whose transmission has resulted in failure for the CFP are enqueued in the first portion of the CP transmission queue, the packets can be transmitted to the AP with a first priority for the CP when the CP is initiated after the CFP has been terminated.
[0075] Similarly, for the VoDn period of the CFP, whenever the packets have been received from the AP, the stations transmit acknowledgment signals of the packets to the AP. To this end, the AP occupies the medium in order to transmit the corresponding packets to the stations and gives back a right to occupy the medium after completing the transmission of the packets.
[0076] The AP occupies the medium to transmit the acknowledgment signals of the packets received from the stations to the corresponding stations. To this end, the AP occupies the corresponding medium to transmit the acknowledgment signal to the corresponding station using an SIFS of IFSs.
[0077] Therefore, for the VoDn period of the CFP, the AP transmits the packets to each station, and then, when no acknowledgment signal has been received from the corresponding stations by the time that the SIFS has lapsed, recognizes that the packets that the AP has transmitted to the corresponding stations have not been received by the corresponding stations.
[0078] Hence, the AP transmits the corresponding packets to the corresponding stations for the CP with respect to the packets whose transmission has resulted in failure after the CFP has been terminated.
[0079] To this end, the AP has a queue (hereinafter, referred to as a “CF transmission queue” for transmitting the packets to the stations by means of polling for the CFP, and a queue (hereinafter, referred to as a “CP transmission queue”) for transmitting the packets to the corresponding stations after occupying the medium through contention for the CP.
[0080] Therefore, the AP performs operations of transmitting the packets stored in the CF transmission queue to the corresponding stations for the CFP, as well as of transmitting the packets stored in the CP transmission queue to the corresponding stations for the CP.
[0081] At this time, the AP performs re-transmission procedure to the packets which are transmitted to the corresponding stations and whose acknowledgment signals are not received from the corresponding stations, and transmits the corresponding packets to the AP.
[0082] In order to transmit the packets that the AP attempts to transmit for the CFP and does not yet transmit to the corresponding stations, the AP transmits the packets and determines whether the transmission of the corresponding packets results in failure or not. Then, when the transmission results in failure, the AP picks out the packets whose transmission results in failure and transmits the picked packets to the corresponding stations for the CP following the CFP.
[0083] When the CP is initiated after the CFP is terminated and when the AP occupies the medium, the AP performs operation of re-transmitting the corresponding packets whose transmission results in failure for the CFP, to the corresponding stations with first priority.
[0084] In order to transmit the packets whose transmission results in failure for the CFP with first priority, the AP enqueues the packets into a first portion of the CP transmission queue provided to transmit the corresponding packets for the CP, when no acknowledgment signal is received from the corresponding stations for the CFP until the set SIFS has lapsed after the arbitrary packets are transmitted to the corresponding stations.
[0085] When the CP is initiated after the CFP has been terminated, the AP transmits the corresponding packets stored in the first portion of the CP transmission queue to the corresponding stations, thereby re-transmitting the packets that the AP has attempted to transmit, but has failed to transmit.
[0086] As the packets whose transmission has resulted in failure for the CFP are enqueued in the first portion of the CP transmission queue, the packets are transmitted to the stations with a first priority for the CP when the CP is initiated after the CFP has been terminated.
[0087] FIG. 2 is a view of a super frame performing a re-transmission procedure in a station in accordance with an embodiment of the present invention.
[0088] As shown in FIG. 2 , one super frame includes a CFP that has a period from a point in time when one beacon signal has been generated to a piont in time when a CF end signal has been generated, and a CP that has a period from a point in time when a CF end signal has been generated to a point in time when the next beacon signal has been generated. The CFP consists of a VoUp period and a VoDn period.
[0089] For the VoUp period of the CFP, the stations receiving a polling message from an AP transmit packets VoUp 1 , VoUp 2 and VoUp 3 stored in their own CF transmission queues to the AP without contention, and the AP transmits an acknowledgment (ACK) signal of each packet to the corresponding station.
[0090] Furthermore, for the VoDn period of the CFP, the AP occupies a medium without contention to transmit packets VoDn 1 and VoDn 2 stored in its own CF transmission queue to the corresponding stations, and the corresponding stations transmit an acknowledgment (ACK) signal of each packet to the AP.
[0091] In this normal case, for the VoUp period of the CFP, when an arbitrary station transmits at least one packet stored in its own CF transmission queue, the AP receives the corresponding packet and transmits an acknowledgment signal of the packet to the corresponding station whenever the corresponding packet has been received.
[0092] Furthermore, in the normal case, for the VoDn period of the CFP, when the AP transmits the packets stored in its own CF transmission queue, each station receives at least one corresponding packet and transmits the acknowledgment signal of the packet to the AP whenever the corresponding packet has been received from the AP.
[0093] For the VoUp period of the CFP, whenever the packets are received from the stations, the AP transmits the acknowledgment signals of the packets to the corresponding stations. To this end, the stations occupy the medium in order to transmit the corresponding packets to the stations and give back a right to occupy the medium after completing the transmission of the packets.
[0094] The AP must occupy the medium to transmit the acknowledgment signals of the packets received from the stations to the corresponding stations. To this end, the AP occupies the corresponding medium to transmit the acknowledgment signal to the corresponding station using an SIFS of IFSs.
[0095] However, it can be seen that, as shown, for the VoUp period of the CFP, each of the stations receiving the polling message from the AP occupies the medium without contention to transmit the packets of VoUp 1 , VoUp 2 and VoUp 3 , which are stored in the queues of the corresponding stations, to the AP, while the AP does not transmit the acknowledgment signal with respect to all the packets.
[0096] In other words, it can be seen that the AP normally receives the packets of VoUp 1 and VoUp 3 that arbitrary stations transmit from their own CF transmission queues and transmits each acknowledgment signal of the reception to the corresponding stations, but the AP fails to normally receive the packet of VoUp 2 that the arbitrary station transmits from its own CF transmission queue and does not transmit the acknowledgment signal of the reception to the corresponding station. The AP does not transmit the acknowledgment signal means that the AP does not receive the corresponding packet(s) from the corresponding station(s).
[0097] If, for the VoUp period of the CFP, each station transmits the packet to the AP and fails to receive any acknowledgment signal from the AP by the time that the SIFS has lapsed, the corresponding station determines that the packet transmitted to the AP has not been received by the AP.
[0098] Therefore, since the station transmitting the packet of VoUp 2 to the AP does not receive the acknowledgment signal from the AP, the station determines that the transmitted packet has not been received by the AP. Accordingly, the station transmits the VoUp packet whose transmission has resulted in failure to the AP for the CP after the CFP has been terminated.
[0099] In other words, as set forth with reference to FIG. 1 , each station includes the CF transmission queue for transmitting the packets to the AP by polling for the CFP, and the CP transmission queue for transmitting the packets to the AP after occupying the medium through contention for the CP.
[0100] Therefore, the station transmitting the packet of VoUp 2 to the AP has transmitted the packet of VoUp 2 stored in the CF transmission queue for the CFP, but has failed to transmit, and as such, to transmit the corresponding packet with a first priority, the station enqueues the corresponding packet in a first portion of the CP transmission queue to transmit the corresponding packet for the CP.
[0101] When the CP is initiated after the CFP has been terminated, the station transmits the corresponding packet stored in the first portion of the CP transmission queue to the AP, thereby re-transmitting the packet of VoUp 2 that the station has attempted to transmit, but has failed to transmit.
[0102] Since the packet VoUp 2 whose transmission has resulted in failure for the CFP is enqueued in the first portion of the CP transmission queue provided to the corresponding station, the packet is re-transmitted to the AP with a first priority for the CP when the CP is initiated after the CFP has been terminated. The AP transmits the acknowledgment (ACK) signal indicating that the packet VoUp 2 has been normally received from the corresponding station to the corresponding station.
[0103] FIG. 3 is a flowchart of a re-transmitting operation in each station in accordance with an embodiment of the present invention.
[0104] Referring to FIG. 3 , when a CFP is initiated, each station performs a backoff procedure to receive a multi-polling message from an AP, setting a back-off time allocated from the polling message to itself, and occupying a medium (S 1 ). When performing the back-off procedure to occupy the medium, the station determines whether or not a packet to be transmitted to the AP is stored in its own CF transmission queue (S 2 ). As a result of the determination, when the packet to be transmitted to the AP is stored in the CF transmission queue, the corresponding packet is transmitted to the AP (S 3 ). After transmitting the packet to the AP, the station determines whether or not an acknowledgment (ACK) signal for the corresponding packet has been received from the AP (S 4 ). As a result of the determination, when no acknowledgment signal is received from the AP until an SIFS passes after the packet is transmitted, the station determines that it has failed to transmit the packet. Thus, the corresponding packet is enqueued in a first portion of a CP transmission queue to be transmitted for the CP (S 5 ).
[0105] When the station has transmitted the packet stored in the CF transmission queue to receive the acknowledgment signal for the CFP, it determines whether or not a CF end signal indicating an end of the CFP has been received, and waits for the CFP to lapse and thus for the CP to be initiated (S 6 ).
[0106] In addition, even after the station enqueues the packet whose transmission has resulted in failure in the CP transmission queue for the CFP, it determines whether or not the CF end signal indicating the end of the CFP has been received, and waits for the CFP to lapse and thus for the CP to be initiated.
[0107] As a result of the determination, when the CF end frame has been received, the station calculates a time between a point in time when the CF end frame has been received and the next 8 beacon frame (a point in time when the next beacon frame has been received) in order to prevent the CFP of the next super frame from being invaded due to the re-transmission and thereby determining whether or not a time for re-transmission is within an allowable limit (S 7 ).
[0108] As a result of the determination, when a time is long enough not to invade the CFP of the next super frame after the CF end frame has been received, the station transmits the packet for re-transmission which is stored in the first portion of the CF transmission queue (S 8 ), and occupies the medium through contention to transmit the other packets stored in the CF transmission queue (S 9 ).
[0109] As a result of the determination, when a time is not long enough not to invade the CFP of the next super frame after the CF end frame has been received, the station discards the packet for re-transmission which is stored in the first portion of the CF transmission queue (S 10 ), and occupies the medium through contention to transmit the other packets stored in the CF transmission queue (S 9 ).
[0110] FIG. 4 is a view of a super frame performing a retransmission procedure in an AP in accordance with an embodiment of the present invention.
[0111] As shown in FIG. 4 , one super frame includes a CFP that has a period from a point in time when one beacon signal has been generated to a point in time when a CF end signal has been generated, and a CP that has a period from a point in time when a CF end signal has generated to a point in time when the next beacon signal has been generated. The CFP consists of a VoUp period and a VoDn period.
[0112] For the VoUp period of the CFP, the stations receiving a polling message from an AP transmit packets VoUp 1 and VoUp 2 stored in their own CF transmission queues to the AP without contention, and the AP transmits an acknowledgment (ACK) signal of each packet to the corresponding station.
[0113] Furthermore, for the VoDn period of the CFP, the AP occupies a medium without contention to transmit packets VoDn 1 , VoDn 2 and VoDn 3 stored in its own CF transmission queue to the corresponding stations, and the corresponding stations transmit an acknowledgment (ACK) signal of each packet to the AP.
[0114] In this normal case, for the VoUp period of the CFP, when an arbitrary station transmits at least one packet stored in its own CF transmission queue, the AP receives the corresponding packet and transmits an acknowledgment signal of the packet to the corresponding station whenever the corresponding packet has been received.
[0115] Furthermore, in the normal case, for the VoDn period of the CFP, when the AP transmits the packets stored in its own CF transmission queue, each station receives at least one corresponding packet and transmits the acknowledgment signal of the packet to the AP whenever the corresponding packet has been received from the AP.
[0116] For the VoDn period of the CFP, the AP occupies the medium in order to transmit the corresponding packets to the corresponding stations, and gives back a right to occupy the medium after completing the transmission of the packets. The stations must occupy the medium to transmit the acknowledgment signals of the packets received from the AP to the AP. To this end, the stations occupy the medium using an SIFS of IFSs to transmit the acknowledgment signals to the AP.
[0117] However, for the VoDn period of the CFP, the AP occupies the medium without contention to transmit the packets VoDn 1 , VoDn 2 and VoDn 3 , which are stored in its own CF transmission queue, to the corresponding stations, while each of the stations does not transmit the acknowledgment signal with respect to all of the packets.
[0118] In other words, the packets of VoDn 1 and VoDn 3 which transmitted from its own CF transmission queue of the AP are normally received by the corresponding stations, and the acknowledgment signal of each packet is received by the AP, but the packet VoUp 2 transmitted to the arbitrary station is not normally received by the corresponding station, and the acknowledgment signal of the corresponding packet is not received from the corresponding station.
[0119] If, for the VoDn period of the CFP, the AP transmits the packets to the stations and fails to receive any acknowledgment signal from the corresponding stations by the time that the SIFS has lapsed, the AP determines that the packets that the AP has transmitted to the corresponding stations have not been normally transmitted to the corresponding stations.
[0120] Therefore, since the AP transmits the packet VoDn 2 to the arbitrary station and then does not receive the acknowledgment signal from the corresponding station, the AP determines that the packet that the AP has transmitted to the corresponding station has not been normally transmitted to the corresponding station. Accordingly, the AP transmits the packet VoDn 2 whose transmission has resulted in failure to the corresponding station for the CP after the CFP has been terminated.
[0121] In other words, as set forth with reference to FIG. 1 , each station includes the CF transmission queue for transmitting the packets to the AP by polling for the CFP, and the CP transmission queue for transmitting the packets to the AP through contention for the CP after occupying the medium.
[0122] Therefore, the AP transmitting the packet VoDn 2 to the arbitrary station has transmitted the packet VoDn 2 stored in the CF transmission queue for the CFP, but it has failed in transmission, and as such, for the purpose of transmitting the corresponding packet with a first priority, the AP enqueues the corresponding packet in a first portion of the CP transmission queue in order to transmit the corresponding packet for the CP.
[0123] When the CP is initiated after the CFP has been terminated, the AP transmits the corresponding packet stored in the first portion of the CP transmission queue to the corresponding station, thereby re-transmitting the packet VoDn 2 that the AP has attempted but has failed in transmitting.
[0124] Since the packet VoDn 2 whose transmission has resulted in failure for the CFP is enqueued in the first portion of the CP transmission queue provided to the AP, the packet is re-transmitted to the corresponding station with a first priority for the CP when the CP is initiated after the CFP has been terminated. The corresponding station transmits the acknowledgment (ACK) signal indicating that the packet VoDn 2 has been normally received from the AP to the AP.
[0125] FIG. 5 is a flowchart of a re-transmitting operation in an AP in accordance with an embodiment of the present.
[0126] Referring to FIG. 5 , when a CFP is initiated, an AP performs a back-off procedure for receiving a multi-polling message from any station, setting a back-off time allocated from the polling message to itself, and occupying a medium (S 11 ). When performing the back-off procedure to occupy the medium, the AP determines whether or not a packet to be transmitted to each station is stored in its own CF transmission queue (S 12 ). As a result of the determination, when the packet to be transmitted to each station is stored in the CF transmission queue, the corresponding packet is transmitted to the corresponding station (S 13 ). After transmitting the packet to the corresponding station, the AP determines whether or not an acknowledgment (ACK) signal for the corresponding packet has been received from the corresponding station (S 14 ). As a result of the determination, when no acknowledgment signal has been received from the corresponding station during a time period that an SIFS has passed after the packet has been transmitted, the AP determines that it has failed to transmit the packet. Thus, the corresponding packet is enqueued in a first portion of a CP transmission queue which is allocated to the corresponding station in order to be transmitted for the CP, and the packet stored in the CF transmission queue is transmitted to the next station (S 15 ).
[0127] As a result of transmitting the packet stored in the CF transmission queue to each station to thereby determine whether or not the packet to be transmitted to each station exists in the CF transmission queue for the CFP, when the packet to be transmitted does not exist in the CF transmission queue, the AP determines whether a CF end signal indicating an end of the CFP has been generated and transmitted to each station, and waits for the CFP to lapse and thus for the CP to be initiated (S 16 ).
[0128] As a result of the determination, when the CF end frame has been transmitted, the AP calculates a time between a point in time when the CF end frame is transmitted and a point in time when the next beacon frame has been transmitted in order to prevent the CFP of the next super frame from being invaded due to the re-transmission and thereby determining whether or not a time for re-transmission is within an allowable limit (S 17 ).
[0129] As a result of the determination, when a time for re-transmission is long enough not to invade the CFP of the next super frame after the CF end frame has been transmitted, the AP transmits the packet for re-transmission stored in the first portion of the CF transmission queue (S 18 ), and occupies the medium to transmit the other packets stored in the CF transmission queue through contention (S 19 ).
[0130] As a result of the determination, when a time for re-transmission is not long enough not to invade the CFP of the next super frame after the CF end frame is transmitted, the AP discards the packet for re-transmission stored in the first portion of the CF transmission queue (S 20 ), and occupies the medium through contention to transmit the other packets stored in the CF transmission queue (S 19 ).
[0131] According to the present invention, when the re-transmission between the AP and the station for reducing the packet loss rate is performed in the WLAN system employing the polling-based QoS guaranteed algorithm, the re-transmission is performed for the CP which is initiated after the CFP has lapsed rather than for the CFP. Thus, the re-transmitting operation can be effectively performed without having an influence on transmission of the packet for the CFP which is operated on the basis of polling.
[0132] Although a exemplary embodiments of the present invention have been described for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the present invention as recited in the accompanying claims. | A method of re-transmitting a packet of an access point (AP) in a polling-based Wireless Local Area Network (WLAN) includes: scheduling a super frame to form a first period of providing a polling message to arbitrary stations at the AP and allowing only stations receiving the polling message to get access to a medium without contention, and to form a second period of allowing the stations to get access to the medium through contention; transmitting packets stored in a first transmission queue to the corresponding stations during the first period of the super frame; and enqueuing a packet whose transmission results in failure during a first portion of a second transmission queue to re-transmit the packet whose transmission has resulted in failure during the second period upon a determination that at least one of the packets transmitted to the stations has resulted in a failure to be transmitted. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to wire connector clips that have two outer legs spaced apart in a plane for insertion of their ends into holes in a support structure to which the legs are to be rigidly attached, part of each leg being curved toward the other leg to join to a reverse-bent portion with two contact regions spaced apart to receive the edge of the conductive structure, such as the edge-connector portion of a printed circuit board, and another part of each leg, located between the curved part and the end of that leg, being formed, as by coining, into a flexure portion of reduced thickness of the wire. Each flexure portion is located between the curved part of the leg and the end, and the direction of the force that produces the thickness reduction is in the plane common to the legs to allow the curved portions, especially the contact regions, of the clip to be moved laterally in the plane relative to the rigidly held ends. In particular, this invention relates to an improvement in clips of the type described in my U.S. Pat. No. 3,340,440 to permit a row of such clips to be soldered to one printed circuit board, but not necessarily in exact alignment with each other, yet with enough flexibility to shift the contact regions so that the straight edge-connector portion of a second printed circuit board can be easily inserted between the contact portions of all of the clips in the row.
2. The Prior Art
Connector clips of the type described in U.S. Pat. No. 3,340,440 are typically mounted individually in printed circuit boards of the type frequently referred to as "mother boards". These are electrically non-conducting boards with conductive interconnections formed thereon to a number of circuits and particularly to connector clips spaced to grasp and make contact with edge-connector pads on other printed circuit boards, known as "daughter boards". In order to accommodate the daughter boards, the individual connector clips must be properly aligned with respect to each other.
While these clips may be made in different configurations, the most common type is M-shaped, with two outer supporting legs and a U-shaped central bight. Physical and electrical contact between each clip and one of the edge connector pads are formed by two small, juxtaposed regions on opposite sides of the U-shaped bight portion. When assembled on a mother board, the outer legs of each clip are rigidly soldered into plated holes in a printed circuit mother board, and the daughter board can later be removably inserted into the central bight portion. The clips may be individually inserted, but there are usually many edge-connector pads on the edge of each daughter board, and the printed circuit boards are normally designed so that there is at least one clip, and sometimes two, to make contact with each edge-connector pad. Since printed circuit boards are usually flat to a high degree of precision, it is essential that all of the contact portions of all of the clips expected to engage the edge-connector pads of a given daughter board will be precisely aligned with each other. The holes into which the outer legs of each clip are inserted are slightly larger in diameter than the legs themselves so that the legs can be inserted easily. However, this makes it possible for the clips that are supposed to be aligned with each other to be slightly out of line when they are soldered into place, thus making an imprecise row into with the daughter board must be fitted. To attempt to fit a daughter board into such improperly located connector clips would require such great pressure to be placed on the daughter board that it would be likely to break either the mother board or the daughter board or, more likely, to be impossible to accomplish. For this reason, it has been the practice heretofore to align a group of connector clips before they are soldered into place and to hold them in such alignment during the soldering operation. They may be aligned by placing a bar or jig of precise thickness in the bight portions of the row of clips and leaving the bar or jig engaged with the clips during the soldering operation.
Such an alignment procedure is unnecessary in the attachment of other components to a printed circuit board and adds an additional step of complexity to the formation of a completed board.
Manufacturers who either make or buy basic printed circuit boards and then insert components, such as integrated circuits, capacitors, resistors, transistors, and other devices into holes formed in specific locations to receive the conductive leads of such components frequently have automatic insertion devices to insert the leads into the proper holes. After all of the components have been put into their proper positions, their conductive leads are simultaneously soldered into position in a wave-soldering device. Since no further mechanical connections are normally expected to be made between such components and any other devices, it is not necessary that the components be located with great precision. However, that is not the case for conductor clips which, as previously described, must be soldered into exact locations to receive the edge-connector pads of another printed circuit board.
The resistors, capacitors, and other devices to be fed into the automatic insertion devices just mentioned are frequently attached to strips of adhesive material would on reels, each of which may contain dozens or hundreds of a specific component. As each printed circuit board passes through the automatic insertion device, the board is brought into a specific position relative to the inserting mechanism, and the leads of the component to be inserted into specific holes in the board in that operation are clipped from the adhesive strip, bent if necessary, and guided into the holes. Then the board is indexed to another position relative to the inserting mechanism and another component is similarly placed in holes formed to receive it.
It would be desirable to use the same sort of mechanism to insert connector clips, but the requirement for high precision in locating the clips has heretofore made it impossible, or at least difficult, to do so.
Various forms of jigs of the type shown in my U.S. Pat. No. 4,061,405 can be used to hold a number of the clips to allow them to be inserted as a group into a printed circuit board and to be held in proper location during the time they are being soldered rigidly into place. However such jigs are not suitable for the type of automatic feeding devices used for insertion of resistors and other such components, and they require either hand assembly or the development of a different type of automatic feeding device.
OBJECTS AND SUMMARY OF THE INVENTION
It is one of the objects of the present invention to provide an improved form of connector clips that simplifies insertion and alignment in a printed circuit board.
Another object is to provide a clip suitable for packaging with hundreds of other similar clips on a strip of adhesive material to be fed into an automatic insertion device similar to those used for insertion of other components into a printed circuit board.
Still another object is to provide a method of forming improved connector clips suitable for use with automatic insertion devices.
A further object is to provide an improved multi-clip connector in which slightly misaligned clips are rigidly held but are provided with flexure portions that allow them to be moved relatively easily and with minimum force into proper alignment to receive a printed circuit board or a similar connecting member.
A still further object is to provide an improved method of handling connector clips and assembling them onto a printed circuit board.
In accordance with the present invention, wire clips are made with two J-shaped outer legs, each of which has a flexure portion between its two ends. One of the ends is straight and of generally circular cross section to be inserted into a slightly larger hole in a printed circuit board, and the other end is bent toward the other part of the clip. The flexure portions are formed by flattening, or coining, a portion of the wire so that the flattened portion has greater flexibility in a direction perpendicular to its planar surface than does any part of the wire prior to the flattening. The location of the flattened flexure portion along the respective outer legs is such that, upon insertion of the ends into holes in a printed circuit board, the flattened portions are adjacent, and preferably slightly inside, the holes in the printed circuit board in which the respective clip is mounted. The holes in the printed circuit board are slightly larger in diameter than the rounded part of the wire, which facilitates entry of the wire, but the flattened flexure portions extend laterally outward to a maximum distance greater than the diameter of the holes, and it is this increase in dimension in one direction that causes the edges of the flattened portions to engage the walls of the holes. This not only helps make good contact with the plating on the walls but also helps hold the clips in place prior to the soldering operation.
Preferably the flattening is accomplished by feeding the round wire between pressure members that apply force from opposite sides of the wire. Thereafter the portion of the wire between each pair of such flattened portions is bent into the desired convoluted shape of the clip, with the portions of the wire that include the two flattened portions being substantially parallel to each other and constituting the outer legs of the clip. These legs are cut long enough the engage a strip of adhesive material that extends perpendicularly to the legs and is located between the flattened portions and the outermost ends thereof.
The direction of flattening of the wire at the flexure portions is such that the largest transverse dimension of these portions is perpendicular to the plane of the clip. This provides the greatest resilient flexibility of the flexure portions in this plane and allows the clip to be pressed transversely in that plane with minimal force to align the bight of each clip with the bight of the other clips in the group that is to make contact with the edge-connector pads of one daughter board.
By making the outer legs longer than is necessary to be soldered in place in a printed circuit board, a large number of clips can be attached to a strip of adhesive material placed perpendicularly to the legs and adjacent the extremities thereof. This is same arrangement used for attaching other electrical components to an adhesive strip, in particular, those components that have two wire connectors extending in the same direction, such as disc-type capacitors. The adhesive strip, or preferably two such strips attached face-to-face on opposite sides of the legs with the adhesive surface on each adherently joined to the adhesive surface of the other, can be wound on a reel with the attached connector clips and then fed into the same type of insertion apparatus as used to isert other electrical components into printed circuit boards. In so doing, it is common for the insertion apparatus to grasp each component, which would be a clip in this instance, sheer off the connecting wires at some predetermined point between the adhesive strip and the main part of the component, position the wire connecting portions properly with respect to holes in a printed circuit board, and insert the cut-off wire ends of the component into the appropriate holes.
By arranging the flexure portions on the wire outer legs of the connector clips so that they extend at least slightly into the printed circuit board material before the bight portion butts against the surface of the printed circuit board, the outwardly extending edges of the flexure portions can hold the clips in place well enough to prevent them from being easily jiggled loose by movement of the printed circuit board between the time the clips are inserted and the time the board is placed on a wave-soldering machine to affix the clips permanently to the board.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a cross-section of a printed circuit board with one embodiment of the connector clip constructed according to the present invention and shown in plan view.
FIG. 2 is a side view of the connector clip in FIG. 1.
FIG. 3 is a side view of a modified embodiment of the connector clip according to the invention.
FIG. 4 is a partial plan view of a fragment of the connector clip in FIG. 3.
FIG. 5 is a cross-sectional view of a printed circuit board with a row of connector clips soldered therein and viewed from one end of the row.
FIG. 6 shows the same cross-sectional view of the printed circuit board in FIG. 5 with all of the connector clips in the row aligned by insertion of a second printed circuit board.
FIG. 7 is a cross-sectional view taken on the sectional line 7bii--bii in FIG. 6.
FIG. 8 shows a fragment of tape with connector clips attached to it and in the process of being severed from it in accordance with the technique facilitated by the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a connector clip 11 constructed according to the general configuration of the M-shaped connector clips in my U.S. Pat. No. 3,340,440 but with flexure portions 12 and 13 at intermediate regions along the outer legs 14 and 16 of the clip. In the position in which the clip is illustrated in FIG. 1, the portion of the outer legs 14 and 16 below the flexure portions 12 and 13 is straight and is severed perpendicularly at the respective end 17 and 18 thereof. Above the respective flexure portions 12 and 13, the legs 14 and 16 are bend toward each other at curved portions 19 and 20, which gives the legs 14 and 16 a generally J-shaped configuration.
The inwardly curved upper end of the legs 14 and 16 merges continuously with a U-shaped portion 22 that defines a central bight between the outer legs 14 and 16. Since the entire clip 11 is formed of one piece of wire, generally of round configuration shown, and modified to form the flexure portions 12 and 13, the curved portions 19 and 20 extend intergrally to side members 23 and 24 of the U-shaped bight 22. As may be seen, and as is described in considerable detail in my prior U.S. Pat. No. 3,340,440, the sides 23 and 24 of the U-shaped bight 12 are not precisely parallel with each other but are farther apart toward the bottom thereof than they are at the contact areas 26 and 27. These contact areas are the regions at which the connector clip makes electrical and physical contact with a printed circuit board inserted into the U-shaped bight 22, and it is an important advantage of the round wire connector clip 11 that the contact areas 26 and 27 not only make concentrated contact with edge connector pads of the printed circuit board inserted therebetween but, by virture of their shape, which is rounded in all directions in a shape generally similar to the central part of a prolate spheroid, the plating material that forms the edge connector pads is wiped clean in the contact area as it is inserted between the connector regions 26 and 27 yet there are no sharp corners to abrade the plating material that forms the pads.
At the lowest part of the sides 23 and 24, the same wire that forms those sides also includes a central bottom portion 28. A particularly satisfactory type of wire is beryllium-copper having a diameter of 0.0201". The flexure portions 12 and 13 are regions of the wire reduced to a thickness of about one-fourth the diameter of the wire by spreading the metal laterally without allowing it to lengthen greatly. The maximum lateral dimension of the flexure portions would then be approximately three times the diameter of the wire.
The connector clip 11 in FIG. 1 is shown partially inserted into a printed circuit board 29 that has two holes 31 and 32 into which the ends 17 and 18 have been inserted. For receiving clips made of 0.0201" thick wire, these holes are preferably drilled by means of a #72 drill and therefore have a diameter of about 0.025", which is slightly larger than the diameter of the wire but substantially less than the maximum lateral dimension of the flexure portions 12 and 13. This allows the ends 17 and 18 to be easily inserted, even though the holes have metal-plated walls 33 and 34, respectively, which reduce their diameter slightly. The plating material that forms the wall 33 of the hole 31 extends between a pad 36 on the surface 37 and a pad 36a on the surface 39, and the metal that forms the wall 34 extends between similar pads 38 and 38a on the printed circuit board.
The central portion 28 of the U-shaped bight 22 of the connector clip 11 forms an abutment member that limits the extent to which the legs 14 and 16 can be forced into the holes 31 and 32.
FIG. 2 shows only the leg 16 of the clip 11 from a position 90° removed from the plan view in FIG. 1. In the side view in FIG. 2, the lateral extension of the flexure portion 13 may be easily seen. This flexure portion, like the other flexure portion 12, is formed by exerting high pressure on opposite sides of the wire of which the connector clip 11 is made. Such a technique is also referred to as coining. The pressure is preferably applied before the bends are formed in the wire, and as may be seen, the direction of flattening requires that the pressure be applied in directions that will correspond, eventually, to the plane of the connector clip 11. More specifically, it is the plane that passes through the centers of both the legs 14 and 16 and all portions of the central U-shaped bight 22.
It is also desirable that the ends of the flexure portion 13 in FIG. 2 not constitute a sharp modification of the round cross section of the wire of which the connector clip 11 is formed. It is desirable for the coining pressure to be applied in such a way that the cross-section of the wire at each end of the flexure portion 13 have a relatively smooth transition from the round configuration to the flat configuration. This prevents any concentrated stress area from being created, and in order to make the flexure portions are flexible as possible, and to maintain the strength and integrity of the connector clip 11, it is desirable to perform a suitable annealing treatment on the clip 11 after it has been formed.
FIGS. 3 and 4 show part of a modified connector clip 41, and specifically one leg 42 thereof. The difference between this leg and the leg 16 in FIG. 2 is that the leg 42 has a flexure portion in which the coining pressure is applied in such a way that the upper end 44 of the flexure portion 43 is thinner than the lower end 46 thereof. Thus, in the side view in FIG. 3, the outer edges 47 and 48 of the flexure portion 43 flare outwardly toward the top 44 of the flexure portion. In FIG. 4, the sides 49 and 51 of the flexure portion 43 slant inwardly toward the top 44 thereof. This leaves the upper part of the flexure portion 43 flexible, but allows the lower part toward to lower end 52 of the leg 41 to be forcibly inserted more easily into a hole, such as the hole 32 in FIG. 1.
FIGS. 5 and 6 are particularly illustrative of one of the main advantages of the present invention. In FIG. 5 a fragment of a printed circuit board 53 is shown in cross section. Two of the holes 54 and 56 in this board are also shown in the cross-sectional plane, and each of them is a plated-through hole with metallic plating 57 and 58 defining the walls of the respective holes 54 and 56, although plated through holes are not essential to the invention. The same M-shped connector clip 11 of FIG. 1 is shown permanently attached to the printed circuit board 53 by means of solder connections 59 and 61 between the respective ends 17 and 18 of the legs 14 and 16 of the clip 11 and two printed circuit connector pad 62 and 63 formed integrally with the plating material defining the walls 57 and 58 of the holes 54 and 56.
Directly behind the holes 54 and 56 are respective rows of holes, such as are typically formed in a mother board to receive a plurality of connectors like the connector 11 in position to make connection with a plurality of connector pads on the edges of a daughter board 64. In FIG. 5 only the end of the daughter board 64 is visible and only the two connector pads 66 and 67 to make contact with the contact regions 26 and 27 of the first connector clip 11 are visible. Connector pads similar to the pads 66 and 67 are located on the lower part of the opposite sides of the board 64 directly behind the pads 66 and 67.
A plurality of connectors 68-70 identical with the connector 11 are shown off-set to varying degrees from the desired position of perfect alignment directly behind the connector 11. Connector 68 is the one directly behind the connector 11, and as may be seen, it is off-set to the right from the position of correct alignment directly behind the connector 11. Another connector 69 is off-set to the left, and the third connector 70 is off-set even farther to the left. One of the reasons that the connectors can be off-set in either direction and by varying amounts is that the wire forming each of the connectors has a slightly smaller diameter than the hole in which that connector is inserted in the row of holes directly behind the holes 54 and 56. Unless the connectors are each held in position of specific alignment with the connector 11, some of them can tilt or shift to the left and others to the right. As a result, the combined effect of the bights of the connectors is to produce an opening that is apparently narrower than the opening of any one connector, alone. As is shown in FIG. 5, the thickness of the daughter board 64, including the thickness of the pads 66 and 67, is much greater than the distance between the contact region 71 of the connector 68 and the contact region 72 of the connector 70. In the absence of the flexure portions, such as the flexure portions 12 and 13 of the clip 11 and corresponding flexure portions of all of the other clips, it would be extremely difficult, and in some cases impossible, to insert the printed circuit board 64 into the combined bight regions of the slightly misaligned connectors.
However, the flexure portions of the outer legs of each of the connectors allows them to be shifted laterally in their respective planes so that they can be directly aligned with each other, as shown in FIG. 6 in which each of the connector clips is directly behind the first clip 11 and thus invisible from the end view of FIG. 6. The printed circuit board 64 has been inserted into the U-shaped bight regions of all of the connector clips by easily shifting the clips laterally to the extent necessary, and the lowermost edge of the board 64 has been brought into abutment against the region where the side members 23 and 24 bend inwardly to form the lowermost part 28 of the clip 11 and of corresponding portions of the other clips directly aligned behind that one.
As a result of the added flexibility in the lateral direction, it is unnecessary to take special precautions or to use special alignment jigs or holding means to hold the connector clips in proper alignment before they are soldered in place. This materially reduces the time and the manipulative effort required to assemble the group of connector clips, and thus reduces the cost of using them while still retaining the advantage of their extreme light weight, as compared with connectors that require relatively heavy plastic forms to hold the individual conductive parts.
FIG. 7 shows the way that the flexure member 13 is forced into the conductive wall plating 58 in the printed circuit board 53. The fact that the edges of the flexure portion 13 score into the conductive plating 58 improves the electrical contact between these conductive members and, as previously mentioned, helps hold the clip 11 rather firmly in place even before it is soldered rigidly to the conductive wall 58.
In order for the edge of the flexure portion to extend into the hole sufficiently for the edges of the flexure portion to engage the plating around the hole, as shown in FIG. 7, it is necessary for the lowermost part of the flexure portion to be below the central portion 28 of the bight of the connector clip 11, as shown in FIG. 6, for example. However, the entire part of the flexure portion cannot be located within the hole or the flexibility will be lost. Thus it is important that a substantial part of the flexure portions 12 and 13 in FIG. 6 extend above the lowermost part 28 of the bight.
FIG. 8 shows an adhesive strip 74 attached to extended portions of the legs 14 and 16 of the clip 11 and to corresponding extended portions of the legs 14a and 16a of the clip 11a. Although only two clips 11 and 11a are shown, it is to be understood that the adhesive strip 74 would be long enough to have a large number of other such clips attached to it. In order to prevent the adhesive material on the strip 74 from becoming attached to other clips or to other parts of itself when wound upon a reel, it is customary that the strip be formed with a backing strip 76, which may also have an adhesive surface to adhere firmly to the adhesive surface on the strip 74. In that case, as is customary when such adhesive strips are used to hold capacitors and other electronic components, the extensions of the wire forming the legs 14 and 16 and 14a and 16a are clamped between the two adhesive strips 74 and 76.
In order to insert each of the clips, in turn, into proper holes in the printed circuit board, the combined adhesive strips 74 and 76 are moved along to the left in the representation in FIG. 8, and at a certain position, the nibs of a gripping member 77 grip the upper portion of the respective clip, which is the clip 11a in FIG. 8, while sheering means (not shown) sheer off the extended portions 14' and 16' of the legs 14a and 16a to leave the severed ends 17 and 18. The gripping member 77 is controlled in a well known manner to position the ends 17 and 18 in direct alignment with suitable holes, such as the holes 31 and 32 in FIG. 1 to allow the clip to be held within those holes as has been described previously in this specification.
As the next connector clip 11 is indexed into position to be grasped by the gripping member 77, the extensions of the legs 14 and 16 are likewise severed and the clip 11 is inserted by the gripping member into another set of holes in the printed circuit board that has been indexed into position to receive the legs 14 and 16.
While the invention has been described in terms of specific embodiments it will be understood to those skilled in the art that modifications may be made therein without departing from the true scope of the invention. | A wire connector to be soldered to a printed circuit mother board has two J-shaped outer legs and a central bight integrally formed with the legs and comprising juxtaposed contact portions to receive the edge connector of another such board. The outer legs and the central bight are in a common plane and the outer legs have flexure portions of reduced thickness. The thickness is reduced in the plane so that the flexibility of the wire is increased in that direction, making it easier to flex the legs to shift the location of the contact portions. Thus, a line of such contact portions on a row of clips can easily be brought into exact alignment to receive the other board without the necessity of using a jig to align all of the clips when they are attached to the mother board. | 7 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] One or more embodiments of the invention are related to the field of image analysis and image enhancement and computer graphics processing of two-dimensional images into three-dimensional images. More particularly, but not by way of limitation, one or more embodiments of the invention enable an automated and semi-automated director-style based 2D to 3D movie conversion system and method that allows for rapid conversion of a sequence of two-dimensional images into three-dimensional images.
[0003] 2. Description of the Related Art
[0004] Generally, movies are shot by a director using a style that is characteristic of that director, and which does not change much over time. For example, nearly all directors use a master shot, which gives context to the viewing audience, a medium shot, that focuses on the performers, close-ups and cutaways that respectively show the actors up close or items related to the actors, such as an item that an actor is using or referring to. A scene may then end with a master shot. This basic formula has not changed over a long period of movie making
[0005] Cameras were eventually placed on trucks for side-to-side or simulated zoom, since movie cameras originally did not have zoom lenses. Later, vertically moving platforms were introduced to allow for up and down motion of a camera, followed by jibs that allowed the camera to remain pointed at an actor while being moved up and down. Directors generally utilize these techniques and equipment to film movies in the same director-specific manner over time. Directors generally do not change their specific style of shooting a movie. For example, some famous directors utilize only a few camera moves only in a particular movie.
[0006] The vast majority of movies ever filmed have been filmed with a single lens system as opposed to a stereoscopic camera with a pair of lenses. Recent movies shot in 3D or converted into 3D from a 2D movie have generally grossed approximately 40% more than the 2D version of a movie in a given theater complex. Hence, there is a large demand for the conversion of movies from 2D to 3D. Converting movies from 2D to 3D has traditionally been time consuming, expensive and limited in the amount of movies that can be converted. The advent of home-based 3D television sets adds to the demand for 3D content. Camera systems for shooting a movie in 3D are highly technical and have many problems including un-matched CCD chips, slightly rotated lenses, slightly different lens characteristics, etc., that make for viewing a stereoscopic pair of images from the two cameras difficult for the human brain. In addition, many of the 3D camera systems have limitations with respect to the effective depth that can be captured. For example, some 3D camera systems do not allow for capturing depth within about 6 feet. This requires directors to shoot certain shots in a completely different manner in which they would normally shoot a scene. The cost and weight of these types of cameras is very high as well. Most directors simply prefer to shoot their movies with standard single lens cameras and convert the film to 3D later.
[0007] Once a movie has been converted to 3D, there are many different technologies that are utilized to view 3D images. The different viewing technologies include shutter glasses that rapidly turn one lens on and off in alteration with the second lens of a set of glasses worn by a viewer. Another technology utilizes polarized lenses, where one lens of a pair of glasses is polarized vertically and the other lens is polarized horizontally. Yet another technology utilized Red and Blue lenses and an anaglyph image that has Red and Blue images for the right and left eyes superimposed. Regardless of the type of viewing technology, the viewer is able to perceive 3D images from a flat viewing surface.
[0008] Generally, directors shooting movies with a single lens camera have struggled over time to give a sense of depth to a two-dimensional movie. For example, some directors simply utilize a bluish or teal lighting scheme in the background and an orange or reddish lighting scheme in the foreground to give a sense of depth. Other directors may frame close up objects on the left or right side of the frame to give a sense of depth to the actors in the mid-ground or background of the image. In addition, a viewer may derive a sense of depth based on the motion of objects from frame to frame. For example, objects that appear to move fast in a scene may give a sense of near-depth as these are generally objects in the foreground. In addition, far away objects may be less saturated in color due to atmospheric interference, while objects that are near may be fully saturated with color. In addition, many directors frame using the “rule of thirds”, so that visually important items, or objects of significance, such as actors, horizons and framing objects are shot at about one-third of the way from the top of the image and/or one-third of the way from the bottom of the image. In addition, another generally observed principle is that objects that are nearer are in the bottom one-third of the frame, while actors and mid-ground objects are in the middle-third, and background objects are in the upper-third of the frame.
[0009] Existing systems that are utilized to convert two-dimensional images or sequence of images that make up movies, to three-dimensional images are of one of two types. One type of conversion system is a manual conversion type. Regardless of the type of conversion, depths are assigned to human-perceived objects in a frame and these depths determine the amount of horizontal shift that is required to move objects in the frame left or right based on their assigned depth. By shifting portions of the image associated with a human-perceived object to the left, a right viewpoint image is created, by shifting portions of the image to the right, a left viewpoint image is created. Shifting objects can occur in each horizontal direction as well to effectively place objects nearer or further away from the distance implied by the captured image, i.e., the objects can be moved to or from a desired distance from an initial distance implied by the 2D image. Generally, the more shifting that occurs, the nearer the object. When the left viewpoint image is viewed by a viewer's left eye and a right viewpoint image is viewed by a viewer's right eye, stereoscopic vision occurs and the original 2D image appears as a 3D image with depth.
[0010] The manual conversion type process makes use of masks which historically have been laboriously created and manually reshaped from frame to frame to keep the mask situated on a desired area, with the correct shape and depth. This type of conversion produces very good results if diligence is observed in masking, however, the amount of labor required is extremely large. In addition, masking errors may be found late in the process and require rework by a set of workers that are geographically distant from the stereographers that utilize the masks, generally in a different time zone and/or country. This adds delays to the conversion process.
[0011] The second type of conversion system is an automated conversion type. The automated conversion type makes use of general characteristics of scenes in order to apply depth automatically in a crude fashion. For example, one type of automated conversion process applies a depth ramp to the bottom portion of a picture under the assumption that the bottom third of a picture is a floor in which mid-ground actors are standing. This type of conversion can occur in real-time, for example in a television that is programmed to show 3D images from a 2D video stream, however, the results are generally poor and may not be agreeably viewed based on what is actually in the scene. Another type of automated conversion process utilizes blue in the upper third of the image to set that part of the background to a deep distance, under the assumption that anything blue in the upper third of the image is sky. Another type of automated conversion applies closer depths to objects that are moving from frame to frame in a scene as being closer to objects that are further away. Many of these conversion techniques fail when utilized on images that do not conform to the assumed properties. For example, attempting to convert a scene of the ocean with a Blue/Red analysis does not work. Converting a panoramic scene with no floor by applying a ramp process to the bottom-third of the image also fails.
[0012] There are hundreds of types of automated processes for automatic conversion of 2D to 3D movies, but only certain types work for certain types of images. The main problem is that there is no known system that determines what processes to apply to which images, and specifically there is no known system that takes into account repeating patterns used by a particular director that can give clues as the best process or combination of processes to use to determine the depth of objects in the images that make up a movie. However, if the particular characteristics of a director were taken into account, the decision of which processes or combination of processes to use could be determined or at least narrowed down. Hence, it would be beneficial if there was a process for determining which conversion process or processes or combination thereof, to use for each frame, based on characteristics of lighting, lenses, color schemes or camera moves that a particular director uses time and time again. Hence there is a need for a director-style based 2D to 3D movie conversion system and method.
BRIEF SUMMARY OF THE INVENTION
[0013] Embodiments of the invention enable a director-style based 2D to 3D movie conversion system and method that allows for the automated or semi-automated conversion of 2D movies into 3D movies. Embodiments of the invention utilize director-style characteristics or statistics specific to the director to apply one or more 2D to 3D conversion process or combination thereof to a region of a frame or an entire frame, without requiring the creation, moving or reshaping of masks. By refining the processes or combination of processes utilized to convert a movie from 2D to 3D for a particular director, the system learns what works best for each director's style of movie shooting.
[0014] One or more embodiments of the invention can be utilized to ignore areas of an image that have been masked and add depth to areas of an image that have not been masked for example. This allows for a hybrid approach that enables specific elements of an image, for example computer-generated objects or user-defined masked areas to be ignored and/or depth enhanced independently. This approach enables areas that require highly refined depth precision to be separately processed. This approach also allows for automatically adding depth to areas that are difficult to mask, such as fog or haze for example. Embodiments of the invention thus enable an intelligent approach to the automated or semi-automated conversion of a movie from 2D to 3D.
[0015] Embodiments of the invention analyze one or more movies from a director to create a table of director-style characteristics or statistical information, which are also known generally as director-style parameters. One or more embodiments break a movie down into scenes and shots and identifying lighting, lens, camera moves and color schemes utilized by a director. The characteristics or statistical information is stored in a database accessible by a computer, or any number of computers over a network for example. Any method of storing the director-style parameters is in keeping with the spirit of the invention, so long as information related to a director's style is capable of being utilized to convert a movie from 2D to 3D.
[0016] Once a director's style has been analyzed, one or more embodiments of the invention utilize the director-style characteristics in one or more movies filmed by the director to determine the specific process or combination of processes to utilize to convert the movie from 2D to 3D. For a given scene with characteristic lighting as used by the director in other scenes and/or movies having teal colors in the background and orange colors in the foreground, the process for determining depth of the objects in the foreground, mid-ground and background based on these colors can be utilized to convert the frames of a scene. If the director utilizes fog or haze in scenes, then the process that determines depth by saturation values of the background and foreground can be utilized to automatically assign depth to portions of the frame. If the director uses these types of lighting and effects in other frames, then statistically, the two processes can be combined in a director specific amount to assign depths to regions of the frame without manually generating, moving or reshaping masks. Since the determination of which processes to utilize can be based on the success of a previous conversion of a similar shot, great effort can be saved. In addition, some movies have so many objects or move so fast or use so many effects that they cannot be realistically be masked and converted manually. Hence, for some projects, embodiments of the system are the only cost effective technique for conversion from 2D to 3D.
[0017] Since directors are creatures of habit, and utilize the same type of camera shots and same types of lighting over and over, embodiments of the invention allow for a great reduction in labor by analyzing a shot and determining which particular director-specific technique is being utilized. After determining the particular director-specific technique that is being utilized, the specific process or combination of processes that have been utilized in the past, even for a different movie by the same director, or optionally for a different director with the same type of shooting style, can be applied to the conversion of the shot from 2D to 3D without requiring a stereographer to start from scratch.
[0018] Embodiments of the invention are implemented with one or more computers. The computer(s) contain computer software specifically programmed to determine which processes or combination of processes to apply in the 2D to 3D conversion process, based on director-style characteristics. Embodiments may utilize a library of processes that convert any specific type of 2D image to a 3D image. For example, some directors utilized 2 kicker lights and 1 key light consistently. Other directors may utilize 1 key light and 1 fill light. Based on the type of lighting utilized, different processes or combinations of processes may be employed to automatically assign depths to various lighted elements in the frame. For example, some directors utilize lights such as a light that is 30 degrees off to the right of a stage that points down and which is bright, another light that is 30 degrees up to the left that is dimmer, and a rim light pointing towards the camera (and which defines the mid-ground objects via silhouettes easily). Using a particular process that looks for silhouettes in the mid-ground allows for very good automatic assignment of depths to objects in this region. Thus, knowing that the director utilizes these types of lights repeatedly when filming a movie allows for automated assignment of depths to these objects.
[0019] If the director also is known for applying the rule of thirds to the scene, then one or more process can be utilized at around one-third of distance from the bottom of each frame, or in the bottom-third of the screen in order to intelligently apply depths automatically to that region of the frame. If the director is known for shooting scenes with a foreground floor, then for example a ramp function of depth can be applied in that area, if that shot has a foreground floor after analyzing the shot. The bottom third of each image provides an area where processing can be flexibly applied since in many instances, objects are found in that region that the viewer's eyes do not snap to, but rather gravitate towards.
[0020] In addition, skin identification software can be utilized to find faces of actors and automatically bulge depth for the face in the center and add appropriate depths for the eyes and teeth so that the do not appear sunken in the face. Any level of sophistication can be utilized for face recognition processes including processes that identify the center of the mouth, nose point and/or eye point, so that depth can be automatically applied, translated, rotated and warped to match the orientation of an actor's head for example.
[0021] After the automatic conversion process is complete for a movie, the movie is viewed using 3D glasses for example, and if there are any quality assurance issues, those portions of the frames can have different processes or varying degrees of a combination of processes applied to those specific areas. One embodiment of the invention has been utilized to convert a movie from 2D to 3D with 200 shots, wherein only 7 of the shots were re-converted to utilize one or more different depths. By training the system as to which scenes need to be re-converted or converted in a more viewer acceptable manner, the system improves its modeling of the style of the director over time. This training process yields a huge savings in labor.
[0022] Television programs generally utilize very simple lighting that is consistent through a show based on a director's style and for example lighting setup. Frames from television shows may thus be automatically depth assigned in a consistent manner based on the characteristics associated with a director.
[0023] Embodiments of the invention generally utilize one or more processes that automatically determine which area of a frame to operate on. Based on the region or segment of the frame that a process is assigned to, the process analyzes the area, based on a director's typical movie making characteristics and automatically assigns depth to a portion of the region. Embodiments of the invention then gap fill any necessary areas where underlying image data is not available (for example from a different frame) when shifting nearer objects more horizontally to create a left and right viewpoint of an image.
[0024] In one or more embodiments of the invention, each image is converted into the frequency domain, generally through use of a fast Fourier Transform (FFT). Regions of the image to apply various processes to are determined in the frequency domain. Since the frequency domain is utilized for determining regions, an inverse FFT is utilized to get the image data back into the spatial domain, wherein cross-dissolves are automatically built into the frequency domain. As such, there are no gaps since filters are utilized. In addition, one or more embodiments of the invention allow for varying degrees of the different processes to utilize in a region. This may be implemented for example via a graphical user interface element such as “sliders” or other controls that allow for a varying amount of each process to be utilized in the automated depth conversion process.
[0025] Processes that are applied in a region based on director-style characteristics may be ordered to occur before or after other processes, since one process may yield different results if the process were to execute in a different order. For example, some directors do not properly white-balance a movie or shot/scene in a movie. Thus, by properly white balancing a scene first, a process that determines depth by looking for teal or blue tones in the upper-third of a frame can execute correctly. In addition, since orange or red tones may be utilized for foreground objects by some directors, normalizing the white balance first allows for this type of automated depth processing to work properly. For regions that are difficult to convert, processes may be applied specifically to that region without masking objects in the region, so that the desired results are achieved. Processes may be globally applied to a shot as well. Furthermore, as a scene or shot in a scene changes, the percentages of the different processes to utilize may vary in time. Embodiments of the invention store the timing history for settings of the selected processes, so that the percentage of each process utilized in a scene varies. An example of a scene that may utilize a different set of processes or different values for each of the processes employed over time includes a scene that starts indoors and moves outdoors. Embodiments of the invention can automatically identify when the transition occurs and automatically perform a cross-fade of the processes through the scene. In other words, the processes that are utilized on a given shot can be “tweened” throughout the scene so that different techniques or processes are utilized as the characteristics of the shot change.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] FIG. 1 shows a hardware architecture diagram of one or more embodiments of the invention.
[0027] FIG. 2A shows a software architecture diagram for software modules configured to execute on the hardware architecture of FIG. 1 .
[0028] FIG. 2B shows a detailed embodiment of the director-style parameters data structure shown in block form in the hardware architecture of FIG. 1 .
[0029] FIG. 3 shows a process flow diagram for the Director-style Manager of FIG. 2A .
[0030] FIG. 4 shows an embodiment of the user interface of the system shown on the Display of FIG. 1 wherein the system is operating on a test pattern to show basic operation of a processing component.
[0031] FIG. 5 shows an embodiment of the user interface of the system showing workflow graphical user interface components zoomed on the upper left and frame navigation, keyed values including cell, frame and layer and a timeline of processing component invocations along the bottom of the user interface zoomed on the bottom left along with a 2D image in the center of the screen to be converted to 3D.
[0032] FIG. 6 shows an embodiment of the invention with a processing component for “bright” invoked.
[0033] FIG. 7 shows an embodiment of the invention with the “bright” processing component invoked with a low threshold so that only very bright areas of the image are “pulled forward” which means that their depth is set to be nearer the viewer.
[0034] FIG. 8 shows an embodiment of the invention with the “bright” processing component invoked with a low threshold, but with a depth blur processing component also invoked.
[0035] FIG. 9 shows an embodiment of the invention with no processing components set to deviate from their default operation, but wherein the frame is “tweened” between the image shown in FIG. 8 and the image shown in FIG. 10 .
[0036] FIG. 10 shows an embodiment of the invention with the Depth Map Blur Radius set to a higher value, to show how the image in FIG. 9 is “tweened” regardless of the number of processing components set for individual frames.
[0037] FIG. 11 shows the particular processing components that are invoked in each frame, wherein each of the processing components are “tweened” individually if their settings change in any subsequent frame.
[0038] FIG. 12 shows the next level of general depth settings provided by the system executable including allowing particular processing components to work in “depth boxes” or designated areas, or to invoke “depth lines” for cylinder based depth additions, or to set a “depth range” to set the overall max and min ranges for the conversion, or to show the “frequency space” which shows the Fast Fourier Transform of the image, “Color Range Selection” to set the color range of the image and in addition, to show particular work flow “Thumbnails” to allow shots to be graded for workflow purposes.
[0039] FIG. 13 shows a perspective view of the image of FIG. 12 with particular depth range set via the user interface on the left side of the interface.
[0040] FIG. 14 shows altered settings for “depth range” compared to FIG. 13 .
[0041] FIG. 15 shows another level of depth settings related to texture based classification of images and the associated depth settings associated with objects that have the same type of texture.
[0042] FIG. 16 shows the acceptable viewing planes from nearest and farthest from the viewer, which allows for a stereographer to determine whether too much or too little depth has been added based on the minimum and maximum acceptable amounts of depth for the project.
[0043] FIG. 17 shows the Layer interface for adding layers for any projects that also include masks that embodiments of the invention may process around for example.
[0044] FIG. 18 shows an interface that the system utilizes to obtain the desired file output type for the converted 3D image(s).
[0045] FIG. 19 shows the interface that the system utilizes to obtain the desired file output format for the converted 3D image(s).
[0046] FIG. 20 shows the interface that the system utilizes for gap fill for the converted 3D image(s), wherein embodiments of the invention may also utilize a layer with generated image data for any missing data from a frame so that realistic image data may be obtained from the layer instead of synthesized.
[0047] FIG. 21 shows the reviewing status user interface that displays and obtains Status of the shot, including Approved, “CBB” which stands for Could Be Better, Hero, meaning that the shot is flagged for promotional use, Needs Rework, etc.
[0048] FIG. 22 shows the user interface that allows for the desired viewing mode to be selected for review of the shots.
[0049] FIG. 23 shows the workflow interface that shows which shots have been completed or need rework, etc.
DETAILED DESCRIPTION OF THE INVENTION
[0050] A director-style based 2D to 3D movie conversion system and method will now be described. In the following exemplary description numerous specific details are set forth to provide a more thorough understanding of the ideas described throughout this specification. It will be apparent, however, to an artisan of ordinary skill that embodiments of ideas described herein may be practiced without incorporating all aspects of the specific details described herein. In other instances, specific aspects well known to those of ordinary skill in the art have not been described in detail so as not to obscure the disclosure. Readers should note that although examples of the innovative concepts are set forth throughout this disclosure, the claims, and the full scope of any equivalents, are what define the invention.
[0051] FIG. 1 shows a hardware architecture diagram of one or more embodiments of the invention. Embodiments of the invention may be implemented with general-purpose computer 100 , along with other computers 100 b - 100 n that may be configured to implement the software architecture and process flow shown in FIGS. 2A , 2 B and 3 respectively. Also shown in FIG. 1 are peripherals which, when programmed as described herein, may operate as a programmed computer or programmed computer system capable of implementing one or more methods directed to the embodiments described throughout this disclosure. Processor 107 may couple with a bi-directional communication infrastructure such as communication infrastructure 102 . Communication infrastructure 102 may be implemented as a system bus that provides an interface to the other components in the general-purpose computer system such as main memory 106 , display interface 108 , secondary memory 112 , communication interface 124 and human interface devices 130 , such as a keyboard and/or mouse for example. The invention may also operate on a set of networked computers 100 b - 110 n, performing various steps herein in parallel. Since movies may contain over 100,000 images to be converted, a large number of computing elements greatly speeds the conversion process. Alternatively, a computer system with a large number of internal processors may also be utilized. Any other architecture capable of determining at least one process to utilize in the conversion of a particular director's movie based on that director's specific style of shooting movies may be utilized.
[0052] Main memory 106 may provide a computer readable medium for accessing and executing stored data and applications specific to determining a director-style characteristic for a shot. Director-style characteristics for example may be stored in director-style parameters 199 in database 150 . These characteristics and corresponding processing component settings are utilized to determine the combination of methods used to convert a movie from 2D to 3D. Main memory 106 may be implemented to store 2D image 190 for example as obtained from database 150 , wherein main memory 106 may also be utilized to hold converted 3D image pair 191 (or single 3D anaglyph image). The converted image(s) 191 may then be stored in database 150 for example, or locally in secondary memory 112 , such as in hard disk drive 114 for example. Any other combination of storage elements may be utilized to obtain and store images 190 , 191 . Display interface 108 may communicate with display unit 110 that may be a 2D or 3D display and that may be utilized to display outputs to the user of the programmed computer system, such as a stereographer responsible for converting the movie, or to a viewer wearing 3D glasses for example. Display unit 110 may comprise one or more monitors that may visually depict aspects of the computer program to the user. Main memory 106 and display interface 108 may be coupled to communication infrastructure 102 , which may serve as the interface point to secondary memory 112 and communication interface 124 . Secondary memory 112 may provide additional memory resources beyond main memory 106 , and may generally function as a storage location for computer programs to be executed by processor 107 as well. Either fixed or removable computer-readable media may serve as secondary memory 112 . Secondary memory 112 may comprise, for example, hard disk 114 and removable storage drive 116 that may have an associated removable storage unit 118 and/or 122 . Since each frame or 2D image 190 may require 200 megabytes of data storage, a large array of disks, for example a RAID 5 self-healing array of several terabytes may be employed for example. There may be multiple sources of secondary memory 112 and systems described in this disclosure may be configured as needed to support the data storage requirements of the user and the methods described herein. Secondary memory 112 may also comprise interface 120 that serves as an interface point to additional storage such as removable storage unit 122 . Numerous types of data storage devices may serve as repositories for data utilized by the programmed computer system detailed in FIG. 1 . For example, magnetic, optical or magnetic-optical storage systems, or any other available mass storage technology that provides a repository for digital information may be used.
[0053] Communication interface 124 may be coupled to communication infrastructure 102 and may serve as a conduit for data destined for or received from communication path 126 . A Network Interface Card (NIC) is an example of the type of device that once coupled to communication infrastructure 102 may provide a mechanism for transporting data to and from communication path 126 . Network 140 may be implemented with any type of Local Area Network (LAN), Wide Area Network (WAN), wireless network, optical network, distributed network, telecommunications network or any combination thereof. Since the amount of data transferred is so large, the faster the network, generally the faster the conversion process.
[0054] To facilitate user interaction with the programmed computer system, one or more Human Interface Devices (HID) 130 may be provided. Some examples of HID's that enable users to input commands or data to the specially programmed computer may comprise a keyboard, mouse, drawing pad, touch screen devices, microphones or other audio interface devices, motion sensors or the like, as well as any other device able to accept any kind of human input and in turn communicate that input to processor 107 to trigger one or more responses from the specially programmed computer are within the scope of the systems and methods described throughout the disclosure.
[0055] Computers 100 b - 100 n may act as a “swarm” to convert portions of a movie, so as to speed the process of conversion from 2D to 3D. Any number of computers may be utilized to convert a movie from 2D to 3D. Generally movies have more than 100,000 frames, so a large number of computers can greatly reduce the time required to convert a movie. The computers may be programmed to operate in batch mode at night as well, or on computers within a network that are not being fully utilized for example.
[0056] FIG. 2A shows a software architecture diagram for software modules configured to execute on the hardware architecture of FIG. 1 . Software modules 200 , 200 b - 200 n, 210 and 211 , execute on computer 100 and/or 100 b - 100 n (see FIG. 1 ) to convert 2D image 190 to 3D images 191 (or single anaglyph left/right image depending on the desired output format). The system utilizes graphical user interface “GUI” 250 to obtain director-style settings for processing components 200 b - 200 n and to display 2D image 190 and/or 3D images 191 . Each processing component may have an associated GUI component ( 403 in FIG. 4 ) on GUI 250 as shown by lines between GUI 250 and processing components 200 b - 200 n. The software modules include any positive integer number of processing components 200 , 200 b - 200 n, each of which is also called a “conversion widget”. Processing component 200 may include executable processor instructions specific to processor 107 or any other interpretable instructions such as macros, scripts or any other type of instructions specifically implemented to enable a particular type of 2D to 3D conversion. Each processing component 200 may be implemented with a common input interface 201 and may provide processing instructions 202 specific to a type of 2D to 3D conversion, along with common output interface 203 . By utilizing a common input and output interface, processing components 200 b - 200 n may be utilized in an object oriented “strategy pattern” for example to operate interchangeably on images 190 to create images 191 . An example input interface may include a reference to an image to process, an area to work within and director specific settings for example. An example output interface may include a reference to an output image pair (or anaglyph image for example). Any other input and output interface that allows for the conversion of 2D to 3D images is in keeping with the spirit of the invention.
[0057] Many different types of processing components 200 b - 200 n may be loaded into or otherwise utilized by executable 210 . For example one type of processing component may be specifically configured to set depth for blue oriented pixels to a deeper depth than red oriented pixels. Another type of processing component may be specifically configured to set areas with low saturation to a deeper depth than highly saturated areas. Another type of processing component may be utilized to look for outlines in the middle-third of the 2D image 190 and set depths of the areas with outlines from backlighting to a mid-range depth. The processing components may be utilized in combination, so that mid-ground object areas as determined by the backlighting processing component, that are brighter, as determined by a brightness processing element, may be set to a depth that is nearer to the viewer for example.
[0058] Over time, director-style manager 211 obtains settings for each of the processing components 200 b - 200 n from a stereographer responsible for the conversion via executable 210 and saves the director-style settings for the processing components within the system, for example in director-style parameters 199 in database 150 for example. These settings are shown in the bottom line of the data structure of FIG. 2B , and can take the form of a list, array, set, or any other known data structure that can associate a group of director-style parameters associated with a scene and/or shot(s) and the settings for processing components 200 b - 200 n that can successfully be utilized to convert the desired image frames from 2D to 3D. The nearer a given shot is to an existing set of director-style parameters, i.e., principal style, scene/shot length, camera angle, camera motion, shot intimacy, actor positions, lighting, priority of processing, then the more likely a known setting or settings for one or more processing components is likely to acceptably convert one or more images from 2D to 3D. By checking for existing shots that are similar in director-style parameters 199 , for example by correlation techniques or any other method of determining how close one set of characteristics are to another, processing component settings can be utilized instead of requiring a stereographer to create the settings manually.
[0059] FIG. 2B shows a detailed embodiment of the director-style parameters data structure shown in simple block form in the hardware architecture of FIG. 1 . The director-style parameters can be determined programmatically, or by accepting input by the system from a user or any combination thereof for example. Regardless of the manner in which the director-style parameters are obtained, the system compares these characteristics with previously analyzed scenes/shots from a director and determines which shots for example are closest to the current shot. The processing component settings that were previously used to acceptably convert the shot from 2D to 3D can then be applied to the processing components 200 b - 200 n in the graphical user interface and automated conversion may then be performed by the system.
[0060] As shown in FIG. 2B , the director-style parameters include the principle style that a director shoots in along with metadata and/or source frames for each scene and shot in a movie that is to be converted from 2D to 3D. In addition, each shot in each scene includes a camera angle, camera motion, shot intimacy, actor positions and lighting for example. In one or more embodiments the operator is queried for a “principle style” that the director shoots in. The principal style can be first person, i.e., where the camera is in first person view. A more common principal style is that of third person. The difference between first person and third person can be somewhat subjective, but in either case, the camera may still have a good deal of motion. In first person, it is expected that there will be a lot of camera shake, a lot of handheld work or stabilized camera work. In third person, it is expected to observe only those kinds of camera motions when there is some particular action that is occurring or some dramatic effect. The rest of the time in third person there is usually a smooth camera or a locked down camera. The third type of principal style a director can have is omniscient. This is a fully objective style. This style is typically utilized in shooting documentaries with a voiceover. The camera itself is not utilized to convey drama, and is not utilized to tell part of the story, the camera is in fact just ever present. Whereas third person is more like a “fly on the wall” and first person is as if the viewer is the victim or the principal involved. Again, any manner of determining the difference between these principal styles, including motion analysis images from frame to frame for example is in keeping with the spirit of the invention.
[0061] To some degree all films will have a variety of these principal styles, but each director has a tendency to shoot in a particular principal style. Once the principal style is determined, either programmatically or by obtaining input from a subjective viewer, that knowledge can be utilized to help decompose the film.
[0062] The film is basically broken into scenes and shots. A scene uses the same environments and lighting so the computer can identify a scene break primarily by a global change in lighting conditions. This allows the system to accurately break down scenes in an automated fashion. In order to break the scenes down though, one or more embodiments of the invention samples the edges of the frame and makes sure that the camera is not in motion. If the camera is in motion and the system observes the same relative speed along the edges of the frame, then the system has to be careful because there could be dramatic changes in lighting due to running through the woods for example. The system also has to be careful to detect a tracking shot where the camera is travelling from indoors to outdoors even though the lighting changes are actually in the same scene and probably the same shot. In one or more embodiments of the invention, the user can be queried to determine if lighting changes are indicative of a scene change or shot change for example. Any other method for determining scene and shot changes may be utilized in one or more embodiments of the invention, including programmatically observing lighting changes or image changes through any known image analysis technique or in any other manner for example.
[0063] After the system has broken down the scenes, i.e., similar environments for example based on lighting changes, then the system breaks each scene into shots. Shots are the atomic element of film production and shot length typically ranges 3 to 5 seconds. Very fast cuts may go down to a second or a half a second and usually these are action sequences or music videos. On the other extreme an entire film may use a single shot or very few shots. In those cases, the film is typically associated with a “ride film”, a video of a roller coaster ride. In a ride film the principal style is first person and the shot is of a continuous ride. One or more embodiments of the system store not only the images of each scene/shot to be converted, but also metadata associated with each scene/shot, i.e., how long each scene/shot is for differentiating types of scenes and shots with a current scene/shot to be converted.
[0064] Once the system has broken the movie or film down into scenes and into shots, the next characteristic to determine is to identify camera angle for each shot. Camera angles typically fall into 5 categories.
[0065] Camera angles can be at eye level (which can be identified through facial recognition) and the system can generally assume that most films are shot at eye level for most of the time. This is not always true, but is generally true particularly with most directors today.
[0066] Another camera angle is known as the bird's-eye view. A bird's-eye view is looking straight down upon the subject. There's no sky at all in the shot. There are generally only two classes of shots when a shot is filmed outside, a bird's-eye view and a “high angle”. A “high angle” camera angle is looking down but not quite directly overhead, for example at a 45 degree angle. Again facial recognition may be utilized by the system on these shots. Typically the system will not detect any faces in a bird's-eye view. The system will get only partial recognition of faces at high angle views. The system also detects that, unlike eye level shots, or other shots that show both the ground and the sky or both the floor and the ceiling that there is not a gentle progression of lighting upward. In one or more embodiments, the system may sample an image at an extremely low resolution and perform a low pass filter. This shows blobs representing the people and the trees and the furniture, etc. but there is typically less chance of a gradual progression as when the system observes changes in an image from green to blue for example, looking at an eye level shot or a typical shot of the ground and the sky.
[0067] Another camera angle is a “low angle” shot, where the camera is down low and pointing upward. Again, the system utilizes facial recognition software to help identify this. Also if a camera is outdoors then there tends to be a lot more sky involved than there is of the ground plane. If the camera is indoors the system tends to observe all of the lighting more, meaning a lot more high frequency pointillistic light, whereas with high angles the system does not identify these types of lights as frequently.
[0068] The last camera angle type is an “oblique angle”. An oblique angle is where the camera is actually tilted somewhat. This is also known as the “Dutch angle”. The oblique angle is important because it indicates a temporary change of style is coming. The oblique angle is primarily used for surreal or action shots. For example, in a scene where there is a fight going on and somebody draws a gun and all of a sudden the scene shot at a tilt. Everything is off angle. The ground seems to be tilting away from the viewer. The system is programmed to then look for a sequence of either slow motion or fast cuts and that this is going to be a temporary change. The main point is that the principal lines in the shot are all at angle—typically in the 30 to 45 degree range. The system identifies this by sampling a single frame and then sampling a series of single frames to statistically gather data from a facial database and from sky color and calculating the key lines in the shot in order to determine if the shot uses an oblique angle.
[0069] Embodiments of the invention thus programmatically determine which of the five camera angles a shot is captured with through image analysis as one skilled in the art will appreciate. In addition, one or more embodiments of the system are configured to obtain input from a user to determine or override a camera angle for a shot as calculated by the system.
[0070] Once the system has calculated which of the five shots has been utilized, then the computer determines what type of camera motion has been utilized. There are 5 basic camera motions detected by the system.
[0071] One camera motion type is the “locked down” type. This camera motion is utilized for a shot wherein the shot itself is stable and steady and the camera is not in motion. This is typically the camera motion type utilized for documentaries. This type of camera motion is also utilized when there is a lot of action in front of the camera. One way to identify the locked down type is to look at the edges of the frame in a shot and if system determines that there is low variation going on from frame to frame or virtually none, then the system can assume that the camera is locked down. Locked down shots simplify conversion from 2D to 3D, but prevent the system from taking advantage of temporal coherency where, when the camera is in motion, if there is a gap of missing background information in the process of stereosynthesis, the system can sample images forward and backward in time in order to find missing image data from a previous or subsequent image frame. This enables the system to use valid background image data to use in the current frame when shifting left or right to make the final image pair (or anaglyph). With a locked down shot the system may or may not have this advantage for foreground items that are not moving from frame to frame for example. If there is missing background information that is required for filling a gap when translating a portion of an image horizontally, the system may utilize any type of gap fill. Gap fill is utilized for example to programmatically generate image data if there are no frames that display missing background information when the missing background information is needed to fill a gap for stereosynthesis. Any known type of gap fill may be utilized in one or more embodiments of the invention.
[0072] The second kind of camera motion is the crane type. This camera motion is typically utilized for a shot that has a lift or descent, or some sort of motion in the principal vector along the screen edges, i.e., which is vertical. An alternative to a crane shot could be a left and right shot as well, which is also known as a dolly shot (but could be done on a crane). The system is configured to look at the edges of the image frames and determine what the principal motion vector is during the shot, i.e., left/right, up/down, or diagonally. By determining the camera motion type, it is easier for the system to track objects that are already identified so that the system does not have to identify the particular objects frame by frame.
[0073] The third type of camera motion is the tracking type. A tracking camera motion is utilized for a shot using a motion-stabilized camera, or it may be taken on a dolly or crane. This type of camera motion is utilized where the action is to be followed. The principal characteristic of this from an image-processing standpoint is that the center of the screen is relatively static while the edges of the screen are in fairly dramatic motion. And this is because frequently the motion-stabilized camera operator is walking backwards following a speaking actor looking into the camera so there are a lot of dynamics along the edges of the frame but the center of the frame is basically a locked down shot.
[0074] The fourth type of camera motion is the handheld type. Handheld camera motion is utilized for shots very much like with a crane shot, i.e., is at angle—horizontal, vertical or diagonal. However, the system is programmed to determine over time to determine the direction that the camera is pointing in, which varies greatly with a handheld type of camera motion in general. The direction vector is also not stable so there is a lot of bouncing and motion and a little bit of rotation typically going on in a handheld shot.
[0075] The fifth type of camera motion is a tripod type. Tripod camera motion is typically used for pans and tilts. Tripod type camera motion can be considered a subset of a crane motion type. The primary difference is that the camera is not in motion in this case. The system determines that that the camera is rotating about the center of gravity during the shot. That allows the system to make optimizations because in a crane shot the system does not know where the center of rotation is—the local origin of rotation—but in a tripod shot the system determines that the center of rotation is in fact the location of the camera and that allows the system to understand that there are certain rules and restrictions that are applied to how much something can move when the system is tracking objects in the images.
[0076] The next element of director-style parameters 199 is shot intimacy. So for each shot, the system determines the shot intimacy such as an extremely long shot which is typified by high frequency data and atmospherics. The system determines if the shot is a “long shot”, i.e., for a live theater shot, and if so facial identification is usually fruitless because the shot is a master shot. These extreme long shots typically occur right after a dramatic change of lighting because master shots are frequently end caps on a scene. The director starts with the master shot, the extreme long shot, which then builds into that scene. A director may also start with a long shot instead of an extreme long shot—this is roughly equivalent to a live theater shot in size. From there the scene typically goes into a combination of full, medium, close-up and extreme close-up shots depending upon the action that is occurring. The primary method the system utilizes in identifying these is a combination of the data frequencies that are calculated globally in each shot. Particularly as compared to the data frequency in the center of the shot which is where the system would expect the principal actors to be and also through facial recognition.
[0077] The next element of director-style parameters 199 is actor positions. Once the system has identified the actors and has determined the places where faces occur, the system determines the actor positions. The goal is to understand whether or not the system has a full front, a quarter turn, a profile, a three quarter turn or a back to camera shot. Here the system is configured to appropriately apply a humanoid and face depth maps to the actors automatically by automatic identification of their positions. Any type of face recognition software may be utilized with embodiments of the invention.
[0078] The system then determines the type of lighting, i.e., foreground, mid-ground and background lighting. Many films today are sort of orange in the foreground and teal in the background. Atmospherics also add to that but there are two other types of lighting—ground planes and “skydomes”.
[0079] A ground plane lighting is typically fairly modeled but ground planes are classically brought up to the horizon line. They are classically brought up to either the first line of thirds or the bottom line of thirds or the top line of thirds and the system tries to identify significant changes in lighting between that bottom third and the center, or the center and the top third, to identify where that ground plane is. That's significant because when doing 3D conversion of objects, the system may positions objects that are on the ground plane so as to be in fact locked on the ground plane. That is, for an actor who is standing on the ground, at the point of intersection between the feet and the ground may be set to be at the same distance. Thus, embodiments of the system may identify the ground plane to make sure that actors/objects do not appear to be floating in space or at a distance that differs from where they are actually located on the ground on which they are standing.
[0080] The last type of lighting is skydomes. The system utilizes any type of sky identification software that takes into consideration clouds and modeling and the gradations of sky. In that case the system applies a dome effect of geometry so that the appropriate perspective is utilized and then clouds are brought forward.
[0081] The system is configured to calculate all of these parameters so that human operators do not have to take the time to do so. The depths to use on object can be iteratively applied for progressive refinement.
[0082] One of the largest problems in 2D to 3D conversion is that the work is principally done as a work to price and a work to schedule. Unlike a number of other large human endeavors where it does not matter what a project costs and it does not matter how long a project takes, in the case of 2D to 3D conversion projects, there is typically a requirement to release on a certain date and with a certain price. In that case there are tradeoffs that the system can control. The way that the system does this is through the process of progressive refinement. And that is where the priority of processing based upon director-style characteristics is important. For example, inside all of the lines of thirds, i.e., that is the principal center of the screen, the system may be instructed to spend more processing time in that area than on the edges because the edges are frequently “throwaway”. The edges are throwaway because of different aspect ratios and because the edges are not typically where the viewer's attention is directed.
[0083] Faces are of higher importance. Thus, the system may be implemented to spend more time and more detail in the construction of depth (or Z data) for faces than for almost anything else. A vase sitting on a table has depth accuracy that is significantly less important than the depth accuracy of faces in a frame in part because the human eye is so adapted to identifying problems of human faces. Thus, prioritizing portions of each image to convert may save great amounts of labor and make a project profitable, while still maintaining the acceptable level of 3D depth for objects in a scene.
[0084] The system may also be implemented to spend more attention on items in motion. Items in motion are usually the subject matter that a viewer is interested in. The system can be implemented to remove the pan, or crane or whatever camera motion there is and after the removal of camera motion, identify items that are static in motion by looking at the edges of the frame. Those items that are static in motion are typically principal actors, principal issues and a locked down camera. The things that are in motion are just the opposite. Those are typically the things that viewers are most interested in. A good example would be a locked down shot on the beach and a director is filming a surfer. The surfer in motion is where the system may be configured to spend the majority of the processing power.
[0085] The system may also be implemented to spend additional processing power on things that are bright, i.e., have a high luminosity or are colorful because directors typically use bright and colorful objects as a method of directing our attention. The system can be implemented to offset the sky, particularly for scenes that have heavy backlighting, but certainly in an indoor environment where very frequently the key subjects are often the best lit objects.
[0086] Analyzing a shot from a particular director and applying processing component settings that were previously utilized to successfully convert a similar shot from that director saves a large amount of effort and time.
[0087] FIG. 3 shows a process flow diagram for the Director-style Manager of FIG. 2 . When beginning to convert a new movie from a particular director, director-style manager 211 is configured to obtain director-style characteristics from main memory 106 , secondary memory 112 or database 150 , such as directory-style parameters 199 or from any other location and determine if the current shot to convert is similar to another shot that the particular director has filmed before. If so, the processing components settings for a previously converted similar shot may be utilized to convert the current scene.
[0088] Processing starts at 300 when executable 210 begins executing on processor 107 for example. Step 300 may optionally include breaking a motion picture, such as a movie or television show or video into scenes and shots if the motion picture (for example includes more than one shot). In one or more embodiments of the invention, the system determines camera characteristics such as principal style, camera angle, camera motion, shot intimacy, actor positions based on image analysis and/or by obtaining input from an operator at 302 . For example, a current shot to be converted from 2D to 3D is obtained at 302 and analyzed for camera characteristics as utilized by the director habitually. The shot is analyzed for lighting that is characteristic of the director at 304 . This may include determining which of the 5 types of lighting is utilized as described previously. The shot is then analyzed for color characteristics used by the director at 306 , for example a teal oriented background or orange oriented foreground area. This step may also aid in determining the camera angle for example. After analysis of the shot is complete for as many characteristics as desired, database 150 (or any other memory coupled with processor 107 , such as director-style parameters 199 ) is accessed or searched for a similar shot from the specific director at 308 , i.e., to obtain director-style characteristics associated shots made by the particular director. If a similar shot is found at 310 , then processing continues at 312 with previously utilized director-style settings used to successfully convert the similar shot from the director. If no similar shot is found at 310 , then the system accepts input from a stereographer, for example via Human Input Devices 130 , at 314 . Once the stereographer is satisfied with the depth changes applied by the system, the director-style manager 211 applies the settings obtained from the stereographer, or as obtained from director-style parameters 199 as associated with a similar shot previously converted, at 312 to the processing components or “conversion widgets” at 312 . The executable 210 then converts the shot from 2D to 3D including any subset or all of the images 190 in the shot for example at 316 . After reviewing the conversion, the stereographer may desire to slightly change some settings of the processing components to obtain a more acceptable result. The system accepts modifications to the processing components 200 b - 200 n at 318 and updates director-style parameters 199 with the director-style characteristics with this shot type.
[0089] FIG. 4 shows an embodiment of GUI 250 as shown in FIG. 2 , of the system shown on Display Unit 110 of FIG. 1 , wherein the system is operating on a test pattern to show basic operation of a processing component. First frame 401 in the shot is shown in the upper right of GUI 250 . The settings for the various processing components 200 b - 200 n are shown as graphical user interface elements 403 on the left side of GUI 250 , and which are also shown enlarged in the upper left of the figure. Each processing component can have as many parameter settings as necessary to obtain desired settings for that particular processing component and associated method of converting a 2D image to a 3D image. Input interface 201 of each processing component (see FIG. 2 ) can be queried for the list of parameters needed and the type of interface widget to use, which is then used by executable 210 to create graphical user interface elements 403 on the left side of GUI 250 . Each processing component 200 b - 200 n thus processes each frame input via input interface 201 in each shot according to the settings associated with the respective graphical user interface elements 403 to produce an intermediate depth map to apply to the frames and which are output to the director-style manager via output interface 203 of each processing component. After all processing components 200 b - 200 n operate on 2D image 190 , such as first frame 401 , the 3D image pair, or any other 3D oriented view 402 , such as the perspective view shown, is thus created and displayed in GUI 250 .
[0090] As shown in the left portion of GUI 250 , in the processing component settings area, where graphical user interface elements 403 are displayed, “Hue” and “Hue Value” are set to values that deviate from the nominal setting and “Hue Range” is also set to a value that deviates from the nominal setting. This indicates to the “Hue” processing component that processing should occur for this shot using settings as indicated to convert the frames of the shot from 2D to 3D. As shown in the right portion of graphical user interface 250 , setting “Hue Range” to a larger number (slider set to the right), adds depth to areas of the image that have the color red. Since the pattern has multiple colors and red is shown with a greater depth (to the right in the figure), immediate feedback to the user who is setting depth based on the processing component associated graphical user interface elements 403 is thus achieved. Setting ranges for objects in an image with slightly different colors, for example blue for sky in the background and orange for objects in the foreground enables automatic depth assignment to be performed for directors that utilize this type of lighting in a shot. Although Hue graphical user interface elements can be implemented with a color wheel or other input element to give the stereographer a more intuitive idea of what the settings signify, simple interface elements as shown here, i.e., sliders, can also be used for an extremely simple interface.
[0091] FIG. 5 shows an embodiment of GUI 250 of the system showing workflow graphical user interface components 501 shown zoomed in on the upper left. In addition, frame navigation, keyed values including cell, frame and layer and a timeline of processing component invocations 502 are shown along the bottom of GUI 250 along the bottom of the user interface zoomed in on the bottom left along with a 2D image in the center of the screen, as shown in the right of the figure, to be converted to 3D. The workflow graphical user interface components 501 allow for entry of status such as “submitted”, “needs work”, “CBB” or “could be better”, “approved”, “hold”, “needs rendering”, “needs rework”, “needs review” and “hero” which signifies a particular excellent shot that has been converted from 2D to 3D. Any subset or other set of workflow settings may be utilized in one or more embodiments of the invention to allow for the management of the conversion process to occur. The frame navigation components and keyed value components allow for the traversal of frames and setting of key frame values associated with a cell, frame or layer. Key frames allow for the tweening of values between key frames so that the settings do not need to be entered for every single frame, but rather can be interpolated between key frames. The timeline of processing component invocations are shown for each frame where the processing components are set or altered, so that the processing that occurs in each frame can be visually reviewed as is shown in the bottom right portion of area 502 .
[0092] FIG. 6 shows an embodiment of the invention with a processing component for “bright” invoked. All values over a certain luminosity value are thus pulled forward. This is achieved by setting the processing component settings in 403 to the desired value.
[0093] FIG. 7 shows an embodiment of the invention with the “bright” processing component invoked with a low threshold so that only bright areas over a threshold value somewhat between the brightest and darkest areas of the person in the image are “pulled forward” which means that their depth is set to be nearer the viewer, while darker portions are set to be farther away from the viewer.
[0094] FIG. 8 shows an embodiment of the invention with the “bright” processing component invoked with a low threshold, but with a depth blur processing component also invoked. In this manner brightness can be chosen to control depth as per FIG. 6 , the choice may be performed using a threshold as per FIG. 7 and the depth may be averaged over an area or “depth blurred” as in FIG. 8 . By determining the type of shot that the director is using, i.e., by comparing the color settings, camera settings, and other director-style characteristics (as stored in director-style parameters 199 ) of the shot with statistics from other shots that the director has done before (see FIG. 3 ), automatic conversion is thus accomplished. Since the particular director that shot the shot shown in FIGS. 6-8 has shot many music videos with dark backgrounds and bright characters, this type of conversion, that has been optimized using the processing component settings to obtain the desired depth conversion can be effectively remembered by the system and used again and again for the director's shots.
[0095] FIG. 9 shows an embodiment of the invention with no processing components set to deviate from their default operation, but wherein frame 902 is “tweened” between the image shown in FIG. 8 , i.e., key frame 901 and the image shown in FIG. 10 .
[0096] FIG. 10 shows an embodiment of the invention with the Depth Map Blur Radius set to a higher value, to show how the image in FIG. 9 is “tweened” regardless of the number of processing components set for individual frames between key frame 901 and frame 1001 .
[0097] FIG. 11 shows a partial list of the particular processing components that are invoked in each frame, wherein each of the processing components are “tweened” individually if their settings change in any subsequent frame.
[0098] FIG. 12 shows the optional next level of general depth settings provided by the system executable including allowing particular processing components to work in “depth boxes” or designated areas, or to invoke “depth lines” for cylinder based depth additions, or to set a “depth range” to set the overall max and min ranges for the conversion, or to show the “frequency space” which shows the Fast Fourier Transform of the image, “Color Range Selection” to set the color range of the image and in addition, to show particular work flow “Thumbnails” to allow shots to be graded for workflow purposes.
[0099] FIG. 13 shows a perspective view of the image of FIG. 12 with particular depth range set via the user interface on the left side of the interface.
[0100] FIG. 14 shows altered settings for “depth range” compared to FIG. 13 . The nose and face of the person shown in the figure are nearer, as the “Nearest” slider has set the value of 14.61 as opposed to the 22.78 setting in FIG. 13 for “Nearest”. This has the effect of stretching the object in the frame. These settings can be applied to each frame or to each shot to keep the Nearest and Farthest values for all objects in the frames of the shot within a desired range for example.
[0101] FIG. 15 shows another optional level of depth settings 1501 related to texture based classification of images and the associated depth settings associated with objects that have the same type of texture. Since the object in the screen is a highly rasterized image of a human, characteristic of the director's style, a texture detecting processing component readily is able to detect the object in the frame and apply depth as desired. Any type of texture detector can be utilized with embodiments of the invention in setting depth automatically.
[0102] In addition, any type of image detection object may also be utilized with embodiments of the system by creating a processing component for the type of detector as shown in FIG. 3 . By dropping the processing component in a directory or compiling the processing component into executable 210 , the processing element is thus capable of being utilized by embodiments of the invention to search for director-style characteristics in a shot and also to apply depth in portions of the image determined to be appropriate by the processing component. For example, any type of face recognition software may be utilized as a processing component to determine where a nose, mouth, eyes, etc., is located in an image and appropriately add depth to the image based on the detected coordinates.
[0103] FIG. 16 shows frame parameters user interface 1601 along with the acceptable viewing planes from nearest and farthest from the viewer in GUI 250 , which allows for a stereographer to determine whether too much or too little depth has been added based on the minimum and maximum acceptable amounts of depth for the project. Each frame can have different camera settings applied that are tweened between frames for example.
[0104] FIG. 17 shows the Layer interface for adding layers for any projects that also include masks that embodiments of the invention may process around for example. Each layer may be “squeezed” or stretched and layers may be ordered in the table in the “Layer and Primitive Manipulation” list in the middle of the interface. The layers may be blurred, set to Ground Plane, clamped or otherwise linked in depth to the Ground Plane, have blurred edges in depth for example. Each layer can be rotated, translated or scaled to properly fit the image being converted.
[0105] FIG. 18 shows an interface that the system utilizes to obtain the desired file output type for the converted 3D image(s). Tif, DPX, MOV and EXR formats may be supported along with any other RGBAZ or any other file format desired in the conversion output process depending on the type of technology desired for viewing the converted images.
[0106] FIG. 19 shows the interface that the system utilizes to obtain the desired file output format for the converted 3D image(s). Left/Right Combined, Left/Right Separate, Image+Depth, 8 Image Stereo, QUVIS® Format, MAGNETIC3D ® Format, Left Only or Right Only images may be output. Any other format for output may also be supported by one or more embodiments of the invention as desired.
[0107] FIG. 20 shows the interface that the system utilizes for gap fill for the converted 3D image(s), wherein embodiments of the invention may also utilize a layer with generated image data for any missing data from a frame so that realistic image data may be obtained from the layer instead of synthesized. As shown, smear gap fill takes colors from each side of the gap and combines them to form an acceptable color to fill the gap with. Mirror takes color from each side of the gap and mirrors the colors from each side of the gap about a midpoint of the gap. Synth looks through the whole image for small pixel chunks, for example 4 pixel chunks that could be used to file the gap based on a texture or colors of a group of pixels near the gap. Inpaint is similar to Synth, but uses a polar search area to speed the search for appropriate pixels to use for the gap. “Time” gap fill looks for missing pixels in other frames for the particular area of the gap, i.e., where the background was not covered by a foreground object so as to use the actual image data that is missing in the current frame when shifting a foreground object horizontally for example to add perceived depth during conversion.
[0108] FIG. 21 shows the reviewing status user interface in the middle portion of the figure as presented in GUI 250 that displays and obtains Status of the shot, including Approved, “CBB” which stands for Could Be Better, Hero, meaning that the shot is flagged for promotional use, Needs Rework, etc. The Issues and Totals sections of the reviewing status interface are shown in the bottom portion of the figure as presented in GUI 250 . The Issues may include any type of issue that is observed in the reviewing process for a shot, including “Too Shallow”, “Too Deep”, “Too Far Away”, “Weirdness”, “Force Fields”, “Specular Asymmetry” or any other issue. The Totals area can show how many shots are Incomplete, “CBB” or Could Be Better, Approved or Needs Rework. Along with the status for each shot, the number of shots and run time and percentages for the various shots in each category of completion can also be shown. Any other information related to the shots may also be displayed in this area as desired.
[0109] FIG. 22 shows the user interface that allows for the desired viewing mode to be selected for review of the shots. The modes may be include “2D Ortho”, “2D Left”, “2D Right”, “2D Center”, “2D Side by Side”, “2D Difference”, “3D Perspective”, “3D Anaglyph”, or any other viewing type as shown.
[0110] FIG. 23 shows the workflow interface that shows which shots have been completed or need rework, etc. This concise area allows for a stereographer to quickly see which shots have been completed or not and which shots need to be worked on or reworked.
[0111] While the invention herein disclosed has been described by means of specific embodiments and applications thereof, numerous modifications and variations could be made thereto by those skilled in the art without departing from the scope of the invention set forth in the claims. | Automated or semi-automated conversion of 2D movies into 3D movies through generation and use of director-style statistics or characteristics to determine which processes to apply to convert regions of images based on the director's movie making style, without requiring the creation, moving or reshaping of masks. System works by breaking a movie down into scenes and shots and identifying lighting, lens, camera moves and color schemes habitually utilized by a director. The characteristics or statistical information is stored in a database accessible by a computer over a network for example. Swarms of computers or any other architecture employing any required amount of computing power allows for the desired speed of conversion to take place. Once a director's style has been analyzed, embodiments utilize the director-style characteristics to determine the specific processes to utilize to convert the movie from 2D to 3D. | 6 |
BACKGROUND
The present invention pertains to a device for feeding book blocks into the infeed channel of a subsequent processing arrangement.
A feed device of this type is known from DE 71 25 313 U. Book blocks are supplied while lying flat and positioned upright by a revolving conveyor element, namely in such a way that they stand on their fore edge cut in order to be subsequently transported onward by feeders in the infeed channel of a book production line. The intermittently rotating conveyor element is also referred to as a star feeder and consists of a roller that is divided into disks and features several block receptacles in the form of cutouts that are arranged in a star-shaped fashion and respectively feature perpendicularly aligned first and second locating surfaces. The book blocks are fed to the star feeder essentially tangential referred to the roller and transverse to the rotational axis while lying flat and transported away parallel to the rotational axis after they were positioned upright. DE 71 25 313 U describes a star feeder that is divided into six segments and in which the book blocks are conveyed into the respective cutout by means of a belt conveyor that is inclined by 30° while contacting the first locating surface. As the star feeder begins to rotate, the book blocks are lifted off the belt conveyor by the second locating surface and then positioned upright. Star feeders that are divided into eight segments and position the book blocks upright from a horizontal position within an intermediate stop at a 45° incline were developed for higher cycle capacities.
When processing book blocks consisting of several loosely gathered signatures and/or sheets, in particular, it may occur that the book blocks slide apart due to the centrifugal forces and acceleration forces that act during the rotative uprighting such that the order and alignment of the book blocks is lost. The cycle capacity is also limited due to the fact that the book blocks may lift off the locating surfaces and overturn at an excessively high braking deceleration for the intermediate stop at the 45° incline.
SUMMARY
It is the objective of the present invention to enhance a feed device of the initially described type in such a way that a gentle handling, in particular, of loosely gathered book blocks is ensured at high processing speeds.
According to an aspect of the invention, the star feeder features several clamping jaws that are respectively assigned to the block receptacles and arranged parallel to the second locating surfaces, as well as movable relative to the latter. The book blocks are respectively pressed against the second locating surface of the block receptacles by the clamping jaws and thusly fixed during the uprighting in the block receptacles. The star feeder can be operated with a significantly higher angular acceleration and rotational speed without risking that the book blocks lose contact with the first and second locating surfaces or even overturn. The invention makes it possible, in particular, to process loosely gathered book blocks that now can also be positioned upright with high processing speeds such that the individual signatures and/or sheets are not shifted relative to one another.
The star feeder is preferably in the form of a roller intermittently rotatable about a main axis and comprising a plurality of block receptacles arranged in a star pattern, wherein each receptacle is formed by first and second locating surfaces on each of a plurality of axially spaced disks. The first locating surfaces extend radially and the second locating surfaces extend perpendicular to the first locating surfaces. The upstream book block feeder feeds flat book blocks to the star feeder substantially tangentially to the roller and transversely to the main axis. The star feeder includes a plurality of clamping jaws that are respectively operatively associated with the plurality of block receptacles, each clamping jaw arranged substantially parallel to the second locating surfaces and movable transversely relative to the second locating surfaces in opening and clamping directions. Each receptacle receives a flat book block from the book block feeder while the respective clamping jaw is relatively open, during rotation of the star feeder reorients the flat book block into upright orientation while clamped between a respective jaw and associated second locating surfaces, thereby positioning the upright book block for transport in a direction parallel to the rotation axis, toward the infeed channel.
Book blocks with different block thickness can be processed if the clamping jaws press against the second locating surfaces in a spring-loaded fashion. A block thickness adjustment is not required in this case.
The clamping jaws are preferably closed and opened by means of a control cam. The opening and closing motion is simply generated in that the cam rollers arranged on the clamping jaws or their guide element roll on the control cam during the rotation of the star feeder. Driving means for each individual clamping jaw are not required. In order to at least close the clamping jaws while the star feeder is at a standstill, the control cam can be turned back and forth about the rotational axis of the star feeder in a cyclic fashion by driving means such as, e.g., a pneumatic cylinder such that the respective clamping jaw to be closed in the infeed region of the star feeder is activated by the corresponding cam segment of the control cam before the star feeder starts to rotate again. If the clamping jaws are already opened during the rotational motion of the star feeder just before the book blocks reach their final upright position, the book blocks can be immediately pushed off the star feeder. The push-off motion may be superimposed on the end of the rotational motion of the star feeder such an additional increase of the cycle capacity is achieved.
The respective block thickness of the book blocks positioned upright by the star feeder can be easily determined with an integrated block thickness measuring device by determining the actual position of the respective clamping jaws that are actuated into the closed position in a certain rotational position of the star feeder. This also makes it possible to detect if a block receptacle is unoccupied. The measured block thickness can be used for adjustments of the subsequent processing arrangement that are dependent on the block thickness and/or a thickness control is carried out as part of a completeness check that makes it possible to purposefully sort out rejects prior to subsequent processing.
In another embodiment, it is proposed to assign at least one push-out unit that is driven separately by at least one pusher of the infeed channel to the star feeder. If so required, the star feeder with the at least one separately driven push-out unit can be decoupled from the infeed channel of the subsequent processing arrangement, wherein a book block that was already positioned upright in the infeed channel is not transferred immediately, but rather purposefully to a respective pusher of the infeed channel. In addition, a push-off motion can be defined that allows a gentle start of the push-out unit relative to the book block to be pushed off on the one hand and a synchronous transfer to the continuously moving pusher of the infeed channel on the other hand. In this respect, the push-off motion may be variable in accordance with the format height of the book block. The at least one push-out unit is preferably designed for selectively pushing the book blocks off the star feeder in opposite conveying directions such that, for example, book blocks determined to be faulty can be sorted out and routed into a transverse stack delivery arranged opposite of the infeed channel.
The book block feeder with the separately driven push-out unit may be arranged along the infeed channel of the subsequent processing arrangement if the at least one push-out unit is designed for transferring and conveying the book blocks supplied in the conveying direction of the infeed channel into the infeed channel. A partition wall arranged in the infeed channel in the region of the star feeder makes it possible to join partial book blocks that are supplied in the conveying direction of the infeed channel and supplied by means of the star feeder and to subsequently feed the joined partial book blocks to the subsequent processing arrangement in the form of a complete book block. According to an enhancement, it is proposed that at least two star feeders are arranged on the infeed channel.
BRIEF DESCRIPTION OF THE DRAWING
Exemplary embodiments of the inventive device are described below with reference to the drawing, in which the following schematic representations are presented:
FIG. 1 shows a side view of a book block feeder in the form of a star feeder;
FIG. 2 shows a top view of the star feeder;
FIG. 3 shows a simplified top view of the star feeder with a transverse stack delivery, and
FIG. 4 shows a top view of an arrangement with two star feeders.
DETAILED DESCRIPTION
The feed device 1 illustrated in FIGS. 1 and 2 serves for feeding book blocks 2 to subsequent processing equipment or processes such as a perfect binder, wherein only a section of an infeed channel 11 for the perfect binder is illustrated in the figures. The book blocks 2 are conveyed to the transport clamps of the perfect binder in the equipment or process infeed channel 11 formed by the channel bottom 12 and lateral channel guides 13 , by means of pushers 14 that are arranged on a continuously revolving conveyor chain 15 and equidistantly spaced apart from one another. With respect to its drive, the conveyor chain 15 is coupled to the perfect binder. The feed device 1 may also be arranged in a book production line or another subsequent processing arrangement for book blocks.
The feed device 1 features a book block feeder 30 in the form of a star feeder 31 . Book blocks 2 supplied by a feed conveyor 21 while lying flat are received by the star feeder 31 and positioned upright on their spine 2 a by means of a two-stage rotational motion, as well as ultimately pushed off into the infeed channel 11 . The feed conveyor 21 illustrated in the exemplary embodiment features intermittently advancing pushers 25 that push the book blocks 2 to the star feeder 31 on a slide sheet 22 while they are in contact with a lateral guide 24 . The book blocks 2 may be manually placed onto the feed conveyor 21 or reach the feed conveyor 21 via a conveyor belt. The feed conveyor 21 may also be realized in the form of a belt conveyor.
The book block feeder 30 can be considered a functional unit comprising the combination of the infeed channel 11 , upstream feed conveyor 21 , star feeder 31 .
The star feeder 31 is rotationally driven in an intermittent fashion by a servomotor 35 and consists of a roller that is divided into disks 33 and has a main rotational axis 32 that is oriented parallel to the channel direction. The roller features several block receptacles 34 in the form of cutouts that are arranged in a star-shaped fashion and respectively feature perpendicularly aligned first and second locating surfaces 34 . 1 and 34 . 2 . The individual disks 33 penetrate through openings 23 in the slide sheet 22 and lift the book blocks 2 off the feed conveyor 21 as the rotation of the star feeder 31 begins.
The star feeder 31 features several clamping jaws 36 that are respectively assigned to the block receptacles 34 and arranged parallel to the second locating surfaces 34 . 2 , as well as movable relative to the latter. The book blocks 2 are respectively pressed against the second locating surfaces 34 . 2 by the clamping jaws 36 and thusly fixed during the uprighting in the block receptacles 34 such that they cannot shift or tilt.
The clamping jaws 36 are situated on the end of a rod 37 that is guided in linear guides 38 and acted upon in the clamping direction by a force exerted by a tension spring 39 . The clamping jaws 36 are opened and closed by means of a control cam 41 , on which cam rollers 40 situated on the rods 37 roll during the rotation of the star feeder 31 . The clamping jaws 36 are pressed into a maximally opened position by the control cam 41 and simply released in order to clamp the book blocks 2 .
In order to fix the respective book block 2 in the corresponding block receptacle 34 before the rotation of the star feeder 31 begins, the control cam 41 is turned forward by a certain angular range from the position drawn with broken lines in FIG. 1 into the position drawn with continuous lines by means of a cyclically actuated pneumatic cylinder 42 while the star feeder 31 is at a standstill in order to release the cam roller 40 and therefore the clamping jaw 36 and once again turned back into the initial position during the rotation of the star feeder 31 .
The control cam 41 is realized in such a way that the clamping jaws 36 are opened just before the upright position is reached. In the upright position, the book blocks 2 are placed on a channel bottom 44 while they are laterally supported by the second locating surface 34 . 2 on the one hand and by guide sheets 43 that can be adjusted to the block thickness on the other hand. The respective upright book block 2 is pushed off in the direction of the infeed channel 11 by means of a separately driven push-out unit 51 and quasi transferred to the pushers 14 in synchronism.
In the exemplary embodiment, two push-out units 51 are arranged on a revolving conveyor chain 52 and alternately push off the book blocks 2 . The push-out units 51 are respectively guided by means of a coupler 54 that is also connected to the conveyor chain 52 in such a way that they are always oriented transverse to the conveying direction when they are retracted from the infeed channel 11 after the book blocks 2 were transferred to the pushers 14 of the infeed channel 11 .
The conveyor chain 52 is driven by a separate servomotor 53 such that it is possible to realize a gentle start of the push-out unit 51 relative to the respective book block 2 to be pushed off on the one hand and a synchronous transfer to the continuously moving pushers 14 of the infeed channel 11 on the other hand. The push-off motion may be variable in accordance with the feed position and/or the format height of the book blocks 2 . The separate drive of the push-out unit 51 can also be used for suspending the transfer to the infeed channel 11 or for feeding the book blocks 2 to certain pushers 14 and therefore certain transport clamps of the perfect binder.
In the top view according to FIG. 2 , the star feeder 31 is integrated into the infeed channel 11 . Book blocks 2 supplied at a location of the infeed channel 11 that lies farther toward the rear can be guided past the star feeder 31 by transferring the book blocks 2 from the supply channel section into the continuing channel section by means of the push-out units 51 .
FIG. 3 shows a transverse stack delivery 71 that is arranged opposite of the infeed channel 11 leading to the subsequent processing arrangement. The book blocks 2 that were positioned upright by the star feeder 31 and placed into the infeed channel 11 are selectively pushed off in the opposite direction referred to the infeed channel 11 and fed to the transverse stack delivery 71 for staggered stack formation, for example, in order to exclude book blocks 2 that were determined to be faulty from subsequent processing and to once again feed the book blocks to the subsequent processing arrangement later on by means of the star feeder 31 . The push-out units 51 are designed for conveying in both directions. A second alternative subsequent processing arrangement may be connected to the book block feeder 30 instead of the transverse stack delivery 71 .
FIG. 4 shows the arrangement of a second book block feeder 72 . Second partial blocks 3 . 2 supplied by means of this second book block feeder and first book blocks 3 . 1 supplied by means of the first book block feeder 30 are joined into complete book blocks 2 and transferred to the infeed channel 11 . For this purpose, an intermediate wall 73 is provided in the region of the first book block feeder 30 in order to push the second partial block 3 . 2 next to the first partial block 3 . 1 . The two book block feeders 30 , 72 may also be used for the selective feed of book blocks 2 .
FIG. 1 also shows a block thickness measuring device 45 that is integrated into the star feeder 31 . The respective clamping position of the clamping jaws that are actuated into the closed position is determined during the rotation of the star feeder 31 by means of a stationary magnetic tape reader 46 and magnets 47 arranged on the rods 37 and fed to an evaluation unit. The measured block thickness can be used for adjustments of the subsequent processing arrangement that are dependent on the block thickness and/or a thickness control is carried out as part of a completeness check that makes it possible to purposefully sort out rejects prior to subsequent processing. | In a device for feeding book blocks ( 2 ) into the infeed channel ( 11 ) of a subsequent processing arrangement with an intermittently rotating star feeder ( 31 ) that features several block receptacles ( 34 ) that are arranged on a roller divided into disks ( 33 ) in a star-shaped fashion and respectively feature perpendicularly aligned first and second locating surfaces ( 34.1, 34.2 ), it is proposed that the star feeder ( 31 ) features several clamping jaws ( 36 ) that are respectively assigned to the block receptacles ( 34 ) and arranged parallel to the second locating surfaces ( 34.2 ), as well as movable relative to the latter. The star feeder ( 31 ) can be operated with a significantly higher angular acceleration and rotational speed without risking that the book blocks lose contact in the block receptacles ( 34 ). Even loosely gathered book blocks ( 2 ) can be flawlessly processed. | 1 |
[0001] This application claims the benefit of priority based on U.S. Ser. No. 61/050,351 filed on May 5, 2008, the disclosures of which are incorporated herein by reference in their entirety.
CROSS-REFERENCES TO RELATED APPLICATIONS
[0002] Not applicable.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The present invention relates to a base station, a subordinated station and transmission methods thereof. More specifically, the present invention relates to a base station, a subordinated station and transmission methods thereof complying with an IEEE 802.16m standard.
[0005] 2. Descriptions of the Related Art
[0006] With continuous advancement in science and technology, people are imposing ever higher requirements on communications. Nowadays, more and more importance is being attached to convenience of communications in addition to requirements on quality of communications. Wireless communications are advantageous in that they provide higher mobility by obviating the need of physical communication network wiring. Therefore, wireless-communication-enabled products such as mobile phones, notebook computers and the like are more and more popular in recent years and have become the mainstream products in the consumer electronics market.
[0007] In the conventional wireless networks, there are four kinds of interference types in transmission: data transition in time division duplex (TDD), data transition in frequency division duplex (FDD), the interference in central zone edge, and the interference in cell zone edge.
[0008] Particularly, please refer to FIG. 1 , which is a schematic view of a transmission cell 1 in the conventional wireless network. The transmission cell 1 comprises a plurality of central zones 100 , 104 , 108 , a plurality of cell edge zones 102 , 106 , 110 , a base station (BS) 101 , a plurality of subordinated station (SS) 103 , 105 , 107 , 109 , 111 , 113 , 115 , 117 corresponding to the BS 101 . First, the interference of the data transition in TDD is described. In the different central zones, if down link (DL) and up link (UL) between the BS 101 and the SSs are operated at the same time, the different SSs may have interference in the data transmission.
[0009] The interference of the data transition in FDD occurs in this situation that if the different SSs operate at the same frequency, the SS may receive another SS's signal and get interference. The interference in central zone edge means that if the SS is positioned in the edge of the central zone, it may receive the two kinds of signals from the two different central zones, and one of the signals received by the SS is the interference. For example, the SS 117 may receive the two kinds of signals from the central zones 100 and 104 , and one of the signals received by the SS 117 is the interference. Similarly, the SSs 109 and 113 may meet the same interference as the SS 117 , and will not be described again.
[0010] Finally, the interference in cell zone edge means that if the SS is positioned in cell zone edge and the BS's signal power is lower, it may receive another BS's signal to make interference. For example, the SS 107 is positioned in the edge of the cell zone and the BS's 101 signal power is lower, the SS 107 may receive another BS's signal to make interference. Similarly, the SSs 111 and 115 may meet the same interference as the SS 107 , and will not be described again.
[0011] In summary, the aforementioned interference affects the quality of communications between the BS and the SS in the wireless network seriously. How to reduce the interference in the wireless network efficiently is still an objective for the industry to endeavor.
SUMMARY OF THE INVENTION
[0012] The primary objective of the present invention is to provide a base station for use in a multi-input multi-output (MIMO) network. The MIMO network includes a subordinated station (SS) within a signal coverage of the BS. The BS comprises a storage module, a generation module and a transceiver. The storage module is configured to store resource allocation information about the MIMO network and an SS list. The generation module is configured to generate a super frame corresponding to the SS according to the resource allocation information and the SS list. The super frame comprises a pilot pattern, which is arranged as an identifier of the SS. The transceiver is configured to transmit downlink (DL) data to the SS by the super frame so that the SS may receive the DL data after confirming the pilot pattern of the super frame matches the identifier of the SS.
[0013] Another objective of the present invention is to provide a transmission method for use in a BS of an MIMO network. The MIMO network includes an SS within a signal coverage of the BS storing resource allocation information about the MIMO network and an SS list. The transmission method comprising the following steps of: generating a super frame corresponding to the SS according to the resource allocation information and the SS list, the super frame comprising a pilot pattern, which is arranged as an identifier of the SS; and transmitting downlink (DL) data to the SS by the super frame so that the SS may receive the DL data after confirming the pilot pattern of the super frame matches the identifier of the SS.
[0014] Yet a further objective of the present invention is to provide an SS for use in an MIMO network. The MIMO network comprises a BS. The SS is within a signal coverage of the BS. The BS is transmitting DL data to the SS by a super frame, which comprises a pilot pattern. The pilot pattern is arranged as an identifier of the SS. The SS comprises a transceiver and a confirmation module. The transceiver is configured to receive the pilot pattern of the super frame. The confirmation module is configured to confirm the pilot pattern of the super frame matches the identifier of the SS and then generate a confirmation result. The transceiver is further configured to receive the DL data according to the confirmation result.
[0015] Another objective of the present invention is to provide a transmission method for use in an SS of an MIMO network. The MIMO network comprises a BS. The SS is within a signal coverage of the BS, which is transmitting DL data to the SS by a super frame. The super frame comprises a pilot pattern which is arranged as an identifier of the SS. The transmission method comprises the following steps of: receiving the pilot pattern of the super frame; confirming the pilot pattern of the super frame matches the identifier of the SS; generating a confirmation result; and receiving the DL data according to the confirmation result.
[0016] The present invention arranges a pilot pattern, which comprises a plurality of pilots, of the super frame as an identifier of an SS. No matter data transition in the TDD, FDD, the central zone edge or the cell zone edge, the BS and the SS will confirm whether the pilot pattern of the super frame matches the identifier of the SS which the BS/SS attempts to communicate with. If the confirmation result is positive, the communication will be proceeded. If the confirmation result is negative, the communication will be terminated. By confirming the pilot pattern, interference of transmission in the MIMO network will be reduced effectively, and the quality of communications will be enhanced effectively.
[0017] The detailed technology and preferred embodiments implemented for the subject invention are described in the following paragraphs accompanying the appended drawings for people skilled in this field to well appreciate the features of the claimed invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 illustrates a transmission cell 1 in the conventional wireless network;
[0019] FIG. 2 illustrates a first embodiment of the present invention;
[0020] FIG. 3 illustrates the super frame of the first embodiment;
[0021] FIG. 4A illustrates a configuration of the pilot pattern of the first embodiment;
[0022] FIGS. 4B-4I illustrate variations of the configuration of the pilot pattern of the first embodiment;
[0023] FIG. 5A illustrates another configuration of the pilot pattern of the first embodiment;
[0024] FIGS. 5B-5D illustrate variations of the another configuration of the pilot pattern of the first embodiment; and
[0025] FIGS. 6A-6B illustrate a second embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0026] In the following description, the present invention will be explained with reference to embodiments thereof. However, these embodiments are not intended to limit the present invention to any specific environment, applications or particular implementations described in these embodiments. Therefore, descriptions of these embodiments are only intended to illustrate rather than to limit the present invention. It should be appreciated that, in the following embodiments and the attached drawings, elements not related directly to the present invention are omitted from illustration; and dimensional relationships among individual elements in the attached drawings are illustrated only for ease of understanding, but not to limit the actual scale.
[0027] A first embodiment of the present invention is shown in FIG. 2 , which is a schematic view of an MIMO network 1 . The MIMO network 1 comprises a BS 21 and an SS 23 . The SS 23 is within a signal coverage of the BS 21 . It should be noted that, in this embodiment, the MIMO network 1 just comprises the BS 21 and the SS 23 for description convenience. In other embodiment, the MIMO network may further comprise other BSs and SSs, the operations and functions thereof are similar to those of the BS 21 and the SS 23 . Peoples skilled in the art can understand easily according to the description in this embodiment.
[0028] First, the downlink (DL) transmission between the BS 21 and the SS 23 is described. The BS 21 comprises a storage module 211 , a generation module 213 and a transceiver 215 . The storage module 211 is configured to store resource allocation information 210 about the MIMO network 1 and an SS list 212 . The resource allocation information 210 is used to records how the resource of the MIMO network 1 allocates currently. The SS list 212 is used to record the basic information, such as the identifier (ID), of all SSs (including the SS 23 ) in the MIMO network 1 .
[0029] To transmitting DL data to the SS 23 , the generation module 213 of the BS 21 is configured to generate a super frame 214 corresponding to the SS 23 according to the resource allocation information 210 and the SS list 212 . The super frame 214 being generated by the generation module 213 comprises an interference-reducing (IR) zone. The IR zone comprises a pilot pattern.
[0030] For more details, please refer to FIG. 3 , which is a schematic view of the super frame 214 . In FIG. 3 , FH represents “Frame Header”, F 0 -F 3 represent “Frames 0 - 3 ” respectively, SFM represents “Sub-Frame Map”, DLSF 0 -DLSF 4 represent “DownLink Sub-Frames 0 - 4 ” respectively, IRR represents “Interference Reducing Request” and ULSF 5 -ULSF 7 represent “UpLink Sub-Frames 5 - 7 ” respectively. The super frame 214 further comprises switch points 214 a and 214 b . In the following description, only differences from the conventional techniques will be described, and the portions of the super frame 214 identical with those of the conventional techniques are omitted from description herein and understood by peoples skilled in the art easily.
[0031] To reducing or avoiding interference of the data transmission, the present invention provides the IR zone (i.e. frame F 1 ) in the super frame 214 . The IR zone of the super frame 214 comprises a pilot pattern 216 which is arranged as an identifier of the SS 23 . The pilot pattern comprises a plurality of pilots and data, where each pilot comprises mitigation information, the functions of which will be described later. The configuration of the pilot pattern may be presented as shown in FIG. 4A . In FIG. 4A , the horizontal axis represents “symbol”, the vertical axis represents “subcarrier”, the gray grid represents a pilot and the white grid represents data. In this embodiment, since each of the BS 21 and the SS 23 uses two antennas to communicate, the configuration of the pilot pattern will be simplified as shown in FIGS. 4B-4I which just illustrates the pilot parts of FIG. 4A .
[0032] For example, FIG. 4B illustrates eight possible pilot patterns, each of which has six pilot structures. Since the each of the BS 21 and the SS 23 uses two antennas to communicate, each pilot structure has two pilots ( FIG. 4B shows them in nonwhite grid). Each pilot pattern in FIG. 4B can be considered as an identifier of the SS 23 . In other words, the pilot patterns in FIG. 4B can be identifiers of eight SSs respectively. Similarly, each of the pilot patterns in FIGS. 4B-4I can be an identifier of an SS.
[0033] Please refer to FIG. 5A , which shows another configuration of the pilot pattern. In FIG. 5A , the horizontal axis represents “symbol”, the vertical axis represents “subcarrier”, the gray grid represents a pilot and the white grid represents data. The configuration of the pilot pattern will also be simplified as shown in FIGS. 5B-5D which just illustrates the pilot parts of FIG. 5A . Similarly, each of the pilot patterns in FIGS. 5B-5D can be an identifier of an SS.
[0034] After the generation module 213 of the BS 21 generates the super frame 214 , the transceiver 215 configured to transmit the DL data to the SS 23 by the super frame 214 so that the SS 23 may receive the DL data after confirming the pilot pattern of the super frame 214 matches the identifier of the SS 23 . Particularly, the SS 23 comprises a transceiver 231 and a confirmation module 233 . The transceiver 231 of the SS 23 is configured to receive the pilot pattern 216 of the super frame 214 . Then the confirmation module 233 is configured to confirm whether the pilot pattern 216 of the super frame 214 matches the identifier of the SS 23 and then generate a confirmation result 230 .
[0035] If the confirmation result 230 indicates the pilot pattern 216 of the super frame 214 matches the identifier of the SS 23 , the transceiver 231 is further configured to receive the DL data according to the confirmation result 230 . In addition, since each of pilots in the pilot pattern 216 comprises the mitigation information, the transceiver 231 is further configured to overcome a transmission interference of the DL data according to the mitigation information after receiving the DL data.
[0036] Now the uplink (UL) transmission between the BS 21 and the SS 23 is described. The transceiver 231 of the SS 23 is further configured to transmit a UL data to the BS 21 by the super frame 214 . Similar to the DL transmission between the BS 21 and the SS 23 , the transceiver 215 of the BS 21 is configured to receive the pilot pattern 216 of the super frame 214 and confirm whether the pilot pattern 216 of the super frame 214 matches the ID of the SS 23 . If so, the transceiver 215 of the BS 21 will receive the UL data and further overcome the transmission interference of the UL data according to the mitigation information after receiving the UL data.
[0037] A second embodiment of the present invention is shown in FIGS. 6A-6B , which is a flow chart of a transmission method for use in the MIMO network 1 of the first embodiment. First, step 300 is executed to generate a super frame corresponding to the SS 23 according to the resource allocation information and the SS list. The super frame comprises a pilot pattern being arranged as an identifier of the SS 23 . Step 301 is executed to generate an IR zone in the super frame, where the IR zone comprises the pilot pattern. Step 302 is executed to transmit DL data to the SS 23 by the super frame.
[0038] Then step 303 is executed to receive the pilot pattern of the super frame. Step 304 is executed to confirm whether the pilot pattern of the super frame matches the identifier of the SS 23 and generates a confirmation result. If the confirmation result is negative, step 305 is executed to stop receiving the DL data. If the confirmation result is positive, step 306 is executed to receive the DL data according to the confirmation result. Since the pilot pattern comprises a plurality of pilots, each of which comprises mitigation information, step 307 is executed to overcome a transmission interference of the DL data according to the mitigation information after receiving the DL data.
[0039] Step 308 is executed to transmitting a UL data to the BS 21 by the super frame. Step 309 is executed to receive the UL data after confirming the pilot pattern of the super frame matches the identifier of the SS 23 . Finally, step 310 is executed to overcome a transmission interference of the UL data according to the mitigation information after receiving the UL data.
[0040] In addition to the steps shown in FIGS. 6A and 6B , this embodiment can also execute all the operations and functions of the above embodiments. Those of ordinary skill in the art will readily know how to execute the corresponding operations and functions in this embodiment by considering those in the first embodiment; therefore, a detailed description will be omitted here.
[0041] The method described above may be embodied in a computer readable medium storing the previously described computer program to execute the above steps. The computer readable medium may be a soft disk, a hard disk, a compact disk, a mobile disk, a magnetic tape, a database accessible via a network, or any storage medium that is known to those skilled in the art to have similar functions.
[0042] The present invention arranges a pilot pattern, which comprises a plurality of pilots, of the super frame as an identifier of an SS. No matter data transition in the TDD, FDD, the central zone edge or the cell zone edge, the BS and the SS will confirm whether the pilot pattern of the super frame matches the identifier of the SS which the BS/SS attempts to communicate with. If the confirmation result is positive, the communication will be proceeded. If the confirmation result is negative, the communication will be terminated. By confirming the pilot pattern, interference of transmission in the MIMO network will be reduced effectively, and the quality of communications will be enhanced effectively.
[0043] The above disclosure is related to the detailed technical contents and inventive features thereof. People skilled in this field may proceed with a variety of modifications and replacements based on the disclosures and suggestions of the invention as described without departing from the characteristics thereof. Nevertheless, although such modifications and replacements are not fully disclosed in the above descriptions, they have substantially been covered in the following claims as appended. | A base station (BS), a subordinated station (SS) and the transmission methods thereof for use in a multi-input multi-output (MIMO) network are provided. The BS stores resource allocation information about the MIMO network and an SS list, and generate a super frame according to the resource allocation information and the SS list. The super frame comprises a pilot pattern which comprises a plurality of pilots and data. The BS and SS both considers the pilot pattern as an identifier of the SS. When there are communications occurred between the BS and the SS, the BS/SS will confirm whether the pilot pattern of the super frame matches the identifier of the SS to reduce interference from other stations in the MIMO network. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The field of the invention relates to the command and control of robotic platforms.
2. Description of the Related Art
Conventional approaches to command and control (“C2”) of mobile robotic platforms, including unmanned ground, sea, or air vehicles, typically require constant human interaction or intervention. Generally, the current state of robotic C2 relies on either remote control, teleoperation, or map-based semi-autonomy.
Remote control is conventionally implemented by having a remote operator directly control the robot. Typically, any and all actions executed by the robot are directly controlled by the operator, who is assumed to be in line-of-sight to the robot. The operator watches the robot and controls it through an operator control unit (“OCU”). The OCU is a remote device that can be tethered to the remote platform, but typically is not. The OCU typically has a joystick or other steering controller to control the movement and/or operation of the remote platform. The human operator must visually follow the unmanned vehicle to determine the next course of action and command the unmanned vehicle through the OCU to conduct that course of action. This operation is similar to operation of a remote-control toy car, where operation can be subject to visibility and distance limitations.
In conventional teleoperation of a robotic platform, the OCU typically includes a video display and joystick for a human operator to control the robotic platform. Teleoperation is similar to remote control, but the line-of-sight restriction can be removed by utilizing sensors such as cameras (e.g., a camera on the vehicle viewed through a video display in the OCU) that give the operator a sense of the robot's environment and actions. An operator watches sensor output from the robot and controls the robot's actions with a joystick. In one example, the OCU can have a video display to monitor the actions of the robotic platform and/or the environment. The human operator uses the joystick on the OCU to operate the robot, making observations through the video display.
In conventional semi-autonomous control of a robotic platform, the robot follows a sequence of GPS waypoints using sensors on board the robotic platform to detect and avoid any obstacles it may encounter. Using a conventional map-based OCU, robots are controlled by entering sequences of waypoints and tasks through the OCU. The robot then moves through the waypoints, carries out the tasks autonomously, and requires retasking upon completion or upon encountering circumstances that prohibit completion. For example, a human operator, based on location and limited information regarding the surroundings, designates waypoints on a map or overhead imagery, thereby commanding the robot to travel from a first coordinate to a second coordinate and so on to successive waypoints. The robot can be commanded to perform designated tasks at each waypoint, or along each path between waypoints.
SUMMARY OF THE INVENTION
Summary of the Problem
There are a number of problems associated with conventional operator control of robotic platforms. Remote control of a robot is typically low-cost, but can only be operated in line-of-sight, and full-time operator attention is required. Additionally, although entities can be tracked with sensors and viewed by a human operator, this conventional method fails when an entity goes around a corner and cannot be tracked. Similarly, teleoperation of a robotic platform is also low-cost and full-time operator attention is also required, although teleoperation is not limited to line-of-sight control. The conventional, semi-autonomous map-based system is slow, requires training, is difficult to use to re-plan, and requires a sophisticated OCU, which is often heavy and cumbersome. Additionally, if there is an unforeseen event or circumstance, such as an obstacle or other situation that cannot be handled by its on-board programming, the robotic platform may require human intervention. These conventional systems can require significant and overt human direction of robot actions. As a result, these methods can break down when human operators are stressed or otherwise distracted.
To make robots effective in supporting human teams, the human operator must not only visualize the location of the unmanned vehicle, but also understand the surrounding circumstances or environment. For example, referring to FIGS. 1 a and 1 b , two aerial views of squads in urban situations are illustrated showing soldier locations and the location of an unmanned vehicle. As shown in this example, it can be difficult for a remote operator to determine if the squad is in danger and the location of the threat. If the operator of the unmanned vehicle can only observe the squad via the aerial view of locations illustrated in FIG. 1 b , the remote operator may not be able to discern whether the squad is taking a break or taking cover from enemy fire. Without understanding the situation, the remote operator may be unable to command the robot appropriately.
If the operator is local, the stress of the situation can make it difficult for the operator to command the robot. For example, as shown in FIG. 1 a , a squad of soldiers 100 can be moving down a street in an urban area with an unmanned vehicle carrying spare ammunition and supplies. In order to control the unmanned vehicle, a human operator with the squad or a remote operator through limited visibility must explicitly task the vehicle 120 . In the instance a sniper takes a shot at the squad or an IED explodes near the squad, the soldiers 100 may take cover behind a building or structure 110 , as shown in FIG. 1 b . The unmanned vehicle 120 does not react appropriately and follow the soldiers because the human operator, who is concerned with his or her own life, takes cover rather than using an OCU to command the unmanned vehicle 120 to follow. As a result, the unmanned vehicle 120 may continue to follow its original route and traverse the street away from the squad.
The use of unmanned vehicles or other robotic platforms in military operations can extend a team's area of influence, broaden its situational awareness and understanding, and increase its lethality and survivability, while reducing the physical and cognitive burden on individual team members. However, current unmanned vehicles can require near-constant human supervision and are difficult to retask when events change. As a result, unmanned vehicles are typically been relegated to operations that can be done slowly and deliberately, such as explosive ordinance disposal.
Adding a second unmanned vehicle to a team can require additional equipment, and require a second team member to operate the OCU for that unmanned vehicle. As a result, the team can have one less soldier, rescue worker, or other type of team member for accomplishing a goal.
Controlling an unmanned vehicle through an OCU can be cognitively demanding. In fact, many potential military applications for robots are considered unworkable because of the OCU requirement. As a result, unmanned vehicles may be excluded from high-intensity situations, including those in which the unmanned vehicles can be the most useful to the team.
Summary of the Solution
One solution to these problems can be to enable asymmetric cognitive teams (“ACT”). For example, an ACT can be created by augmenting a mobile robot's sensors with instrumentation of other members of the team, and using this information in a cognitive model to enable the robot to understand the immediate situation and select appropriate behaviors. A robot so equipped would be able to “do the right thing” automatically, thereby eliminating the need for cumbersome OCUs; the robot literally acts like a member of the team, automatically adapting its actions to complement those of the other team members. The solution can reduce the cognitive burden on an operator by providing natural (i.e., human-like) interaction. In the example shown in FIGS. 1 a and 1 b , if the squad of soldiers move to a wall, an ACT-enabled robot can utilize the information about the change in formation along with data such as heart rate, blood pressure, and weapon status to determine whether the soldiers are in a combat situation or are taking a break. The robot can then automatically take the appropriate action, such as providing cover in the case of a combat situation or offering resupply if the team is taking a break. The system can enable robotic entities or unmanned vehicles to operate as effective team members without the need for constant human direction. As a result, each human team member can act according to his/her training, rather than requiring a team member to use an OCU to control a robot.
The exemplary embodiments described herein can provide a command and control paradigm for integrating robotic assets into human teams. By integrating sensors to detect capable of non-humanoid tactics, a potential of about 24 hours per day on-station, capable of rapid and structured information transfer, has a personality-free response, can operate in contaminated areas, and is line-replaceable with identical responses.
In one embodiment, a system for controlling a robotic platform comprises at least one instrumented external entity, at least one sensor on each team member, one perceiver for collecting information from the at least one instrumented external entity; a reasoner for processing the information from the at least one perceiver and providing a directive; and at least one behavior for executing the directive of the reasoner.
In another embodiment, a method for controlling a robotic platform comprises the steps of developing tactical behaviors; determining a mission, situation, disposition, and/or human cognitive or emotional state; driving a cognitive model; inferring current state, goals, and intentions; and selecting an appropriate behavior.
In yet another embodiment, a system for controlling a robotic platform comprises a team sensor system; a software system comprising a perception component for providing information from the sensors; a cognition component for estimate an intent from that information; a playbook action generator component for determining a course of action; a playbook executor component for executing the course of action complementary to the estimated intent; and an unmanned vehicle interface.
In still yet another embodiment, a system for controlling a robotic platform comprises at least one sensor that detects a status; a software component that receives the status from the sensor; and the software component comprising a cognitive model; wherein the cognitive model directs the robot to perform an action.
Additional features and advantages of the invention will be set forth in the description which follows, and in part will be apparent from the description, or may be learned by practice of the invention. The objectives and other advantages of the invention will be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE FIGURES
The present invention will be more clearly understood from a reading of the following description in conjunction with the accompanying exemplary figures wherein:
FIGS. 1 a and 1 b show an aerial view of the location of the members in a squad;
FIG. 2 shows states of a human and a robot according to an embodiment of the present invention;
FIG. 3 shows a communication network between a team and a robot according to an embodiment of the present invention;
FIG. 4 shows a system architecture according to an embodiment of the present invention;
FIG. 5 shows a system architecture according to an embodiment of the present invention;
FIG. 6 shows a system architecture according to an embodiment of the present invention;
FIG. 7 shows components of a cooperative robotic weapon control system according to an embodiment of the present invention;
FIG. 8 shows a system architecture according to an embodiment of the present invention;
FIG. 9 shows an alternative system architecture according to an embodiment of the present invention;
FIG. 10 shows a method of autonomous control according to an embodiment of the present invention;
FIGS. 11 a and 11 b show a playbook and plays for a course of action in the playbook according to an embodiment of the present invention;
FIGS. 14 a to 14 g show a team's ingress on a location according to an embodiment of the present invention; and
FIGS. 15 a to 15 f show a team's positioning when a soldier is wounded according to an embodiment of the present invention.
DETAILED DESCRIPTION
Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings.
The systems and methods described herein can enable robotic platforms to perform appropriate behavior without overt human control. Control of robot platforms occurs without bulky and expensive OCUs. Robots can learn tactics and appropriate behavior from humans. Robots can continue to operate when all humans are distracted or cognitively overloaded. Robots can learn from training (much like humans do), and robots can fully interact with and support human teams. As compared to conventional systems that typically control an unmanned or robotic vehicle through an OCU, the systems and methods described herein can observe a human and/or team behavior and decide appropriate actions without direct tasking from humans. By understanding an individual's or a team's reaction to a situation, rather than understanding the entire environment and situation, the system can command the robot accordingly. Information can be provided about the human or the team by using sensors. A cognitive model on the unmanned vehicles can process the information, determine the appropriate action based on models of human activities, and then execute the action and monitor the result. In one exemplary action, the unmanned vehicle can move with the team as the team moves. If the team halts, the unmanned vehicles know to halt. If the team assumes a tactical formation, the unmanned vehicles know to move to and maintain an appropriate position in the formation.
The architecture of the system uses hardware and software, as well as information flow to produce an approach to robotic command and control. The systems and methods can utilize net-centric information flow and an embedded cognitive model to build a working model of the current situation and a human's or team's intent. The humans and robotic platforms can interact through a communications network. Net-centric resources include sensors or instrumentation of humans and teams. The robotic platform then generates a short-term course of action for the robotic platform to pursue, without overt human control or direction by OCUs. Eliminating an OCU and/or direct control (e.g., RF control) can enable robots to be useful without physically or cognitively burdening human team members. This approach can also reduce training required for robotic platform control and can enable learning of tactics by the robotic platform. As a result, the robotic platforms can become useful members of human teams, while reducing the attention and effort on the part of the humans to direct the robotic platforms. One potential advantage can be to enable robotic platforms to be useful when humans are under stress or otherwise distracted.
Referring to FIG. 2 , coordination between a human and a robot can assist in replacing the burden of explicit control by a human. Coordination can be possible through mutual monitoring and mutual understanding. The system builds a cognitive state model of the human and uses it to determine an appropriate course of action. The human transitions between cognitive states, which can include, but are not limited to, at rest 200 , relaxed 210 , excited 220 , and frightened 230 . The system can make inferences based on known or detectable information, such as the mission, situational awareness and understanding, squad dynamics, posture, physiology, and logistics state. These inferences trigger a transition in the robot's behavioral state, which can include, but are not limited to, stopped 240 , unguarded motion 250 , protect 260 , hide 270 , and guarded motion 280 .
The systems and methods described herein can integrate and control multiple unmanned platforms (i.e., mobile robots or vehicles) into human teams. The unmanned platforms can be interchangeably referred to herein as a robot, robotic platform, or unmanned vehicle. The systems and methods can be applied to any ACT-enabled platform including but not limited to ground, air, water surface, and underwater robotic platforms, which are also referred to herein as unmanned vehicles, including unmanned ground vehicles, unmanned aerial vehicles, unmanned surface vehicles, unmanned subsurface vehicles, or any other type of unmanned vehicle known in the art. The unmanned vehicle is not intended to be limited to only those vehicles that cannot be manned and includes all ground, air, sea, and undersea vehicles that can operate in an unmanned mode. Additionally, the unmanned mode of the unmanned vehicle is not intended to be limited to only when a human is not present on, in, or near the vehicle.
The systems and methods can be domain-independent. For example, the robotic platform can be a supply carrier for a dismounted warfighter. In another example, the robotic platform can be a tank ammunition carrier that can move into position to provide ammunition. In yet another example, the robotic platform can be a surveillance air vehicle drone that stays in position over the battlefield to give situational awareness. The platform can also be a sensor platform and/or a weapons and/or a logistics platform.
Although a soldier or a team member is described herein as a human, a soldier or team member can also include non-human members such as trained animals, robotic platforms, or other vehicles and equipment. In certain configurations, the human being is an individual soldier. In other configurations, the human is a member of a team. The soldier or team member is not intended to be limited to only those configurations where a human acts with other human beings. Additionally, the soldier or team member is not intended to be limited to a human conducting a military operation.
A team or squad is not intended to be limited to a plurality of humans conducting a military operation. A team can include at least two team members, equipment, vehicles, or other entities that function together for a common purpose.
The systems and methods can be used in any applications including, but not limited to, where tightly integrated, real-time cooperation between humans and robots can be required, such as warfare (e.g., support for dismounted infantry or mounted operations), control of non-combatants (e.g., crowd control, peacekeeping patrols), and high-intensity, time-critical operations (e.g., search and rescue after man-made or natural disasters). Additional opportunities for the systems and methods can include tactical military applications, such as a robotic point man, robotic logistics platform, force protection sentries, and similar applications. Other applications can include any application in which a robot can complement or augment human capabilities, such as a construction assistant. Additional opportunities can include site security and patrolling, human/robot First Responder teams, and any other situation where humans can be augmented by mobile robots. Additional military applications can include vehicles used in ground and sea convoys and swarming type attack vehicles (e.g., small boats, ATVs, and Navy Seal activity). Non-military applications can include ground and air vehicles for border patrols and harbor/facility/critical infrastructure patrol vehicles.
As shown in FIG. 3 , a team of soldiers 300 in an environment 310 can communicate with each other and a robot 330 through a wireless network 320 . Such communications can include position, pose, motion, physiological parameters, weapon status, and orientation command and directives. Additionally, robot sensors 360 can detect the environment 310 and the team 300 and report to the robot 330 with information including but not limited to a terrain map, target identification and tracking, range-finding, and designator detection. The robot 330 can control the robot sensors 360 and the robot weapons 340 . The status, behavior, and alerts of the robot 330 can be communicated to the team 300 . The robot 330 can compute formation, tactics, techniques, and procedures, as well as soldier or team cognitive state and goals.
Improving human-robot coordination can be useful in replacing the burden of explicit control, such as through an OCU. Coordination can be possible through mutual monitoring and mutual understanding. The systems and methods herein can build a cognitive state model of the team member or team and can use it to determine the appropriate course of action. The system can use team location, physiology, and weapons status to estimate individual or team cognitive state and goals. That estimate can then be used with triggering events to transition the robotic state model. The robot then can execute tactically appropriate behaviors in response to the state of the individual or team. For example, the robot halts when the individual or team is relaxed. As another example, when the individual or team is frightened, the robot can maneuver between the team and an inferred threat.
As compared to conventional systems, the systems and methods described herein can focus on situationally appropriate behaviors, rather than rote execution of predefined plans. For example, the system can use information from the humans in the form of location, looking and pointing directions, physiological data, and other information sources that may be available (e.g., machine readable high-level plans and situational information). This information is fed to a cognitive model that develops a model of each human in the team as well as the team as a whole in order to estimate the actions and intent of the humans. Once the robotic platform can estimate the intent, the system can then use that estimate of intent to define its own course of action. For instance, if a team of humans is moving through a town in a line formation, the robot will automatically get in line (either at the end or filling a gap) and move with the team—starting, stopping and changing speed with the team.
Generally, the systems and methods can operate as follows. Referring to FIG. 4 , a cognitive model 420 has at least one perceiver 425 , 430 , 435 , 440 and a reasoner 445 . The perceivers can include, but are not limited to, a soldier perceiver 425 , weapon perceiver 430 , team perceiver 435 , and sensor perceiver 440 . The perceivers 425 , 430 , 435 , 440 can be a software and/or a hardware component configured to produce tactical information with confidence metrics that drives the cognitive model 420 to estimate the current tactical state and condition of the team. For example, each perceiver 425 , 430 , 435 , 440 can answer tactical questions about the current situation, such as: are the team members excited, are their weapons safe, are the majority of weapons pointed in the same direction, is anyone in a tactical pose? Information from soldiers 400 , 405 , 410 , 415 can be communicated to the soldier perceiver 425 , the weapons perceiver 430 , and the team perceiver 435 . The perceivers can characterize the team member's state, such as location, posture, physiology, weapon status having the safety on/off, weapon pointing, and trigger pulls. The soldier perceiver 425 queries, for example, whether the soldiers are on alert or whether the soldiers are running or hiding. The weapon perceiver 430 queries, for example, whether the safety is in an “off” position, the weapon is low on ammunition, or if the weapon is pointing at a threat. The team perceiver 435 queries, for example, whether the team is in a formation and which formation, whether the formation is spreading or shrinking, whether the formation is changing, or where should the robot be in the formation. A sensor on a human or a robotic platform can be included in the perceiver or, alternatively, the sensor can be a separate component that provides information to the perceiver. The perceivers combine messages and sensor information from the sensors through the wireless communication system to the reasoner 445 to answer tactical questions.
The reasoner 445 can consider trigger events, confidences, and soldier/squad state to determine appropriate action. The reasoner 445 can be a software and/or a hardware component configured to query the perceivers 400 , 405 , 410 , 415 and uses the information to determine the situation. For example, the reasoner 445 can query the perceivers 400 , 405 , 410 , 415 based on trigger events and state matching, including, for example, increase in heart rate and blood pressure, safeties in an “off” position, trigger pulls, or postures changing to cover postures. Alternatively, the reasoner 445 can respond to a verbal override. Based on the results, the reasoner 445 constructs a tactical picture.
A plurality of behaviors can be used to execute the reasoner's 445 directives to perform tactical actions. Behaviors include, but are not limited to, rally 450 (e.g., move to a coordinate), patrol 455 (e.g., move in a pattern to follow a soldier or other robot), halt 460 (e.g., hold position), and weapon 465 (e.g., aiming and firing of a weapon). Examples of rally behaviors include the robot rally on a soldier, rally to a named waypoint, or rally to a designated position. Examples of patrol behaviors include point, follow soldier, formation move, patrol, and guard. Examples of weapon behaviors include cover fire, suppression fire, sector-free fire, and IFF protection. IFF is identification friend or foe and is a procedure to identify friendly entities. Behaviors are communicated to a reactive obstacle avoidance system 470 , which identifies any obstacles and commands the unmanned vehicle to go around them, and a weapon control 465 , which communicates with a vehicle control unit 475 .
Generally, the system architecture can use on-board sensors to validate and localize information received from the team and to capture information that is not available net-centrically. Periodically or in real-time, the system can be provided with each team member's location, weapon state, and physiological state. In some configurations, the system can utilize the team member's reaction to events, which can be easier to understand than the events themselves. The cognition component fuses all incoming information into a tactical picture and develops an estimate of squad intent. The cognitive model consumes the perception estimate of higher-order team member behavior, which are observable states that indicate the internal state of the team member. This tactical state estimate enables the generation of an action in view of the current intent and short-term goals of the team members.
With regards to the system architecture, referring to FIGS. 5 and 6 , a system has C2 software 500 , 600 a team sensor system (“TSS”) 505 , 605 and an unmanned vehicle interface or integration kit 510 , 610 . The system uses a cognitive framework, fuses perception and net-centric information from the TSS 505 , 605 and other sources into a cohesive estimate of squad intent, generates a short-term robotic plan, then uses tactical behaviors to execute the plan.
The C2 software 500 , 600 provides functionality for perception, cognition, playbook action selection, executing and monitoring, and an interface to the unmanned platform. The C2 software 500 can support at least one unmanned vehicle that can, for example, maneuver with a team, execute behavioral roles, carry supplies, or resupply team members. The C2 software 500 can also enable unmanned vehicles to support coordinated team tactical maneuvering, behavioral roles for sensor coverage, and protection for weapon coverage. The C2 software 500 can provide network information management and dissemination functionality to enable efficient communications between the TSS 505 and the unmanned vehicles.
The C2 software 500 , 600 includes perception software 515 , 615 , cognition software 520 , 620 , playbook action-generation software 525 , 625 , playbook action (or plan) execution 530 , 630 , and playbook action feedback 535 , 636 . Perception software 515 , 615 can provide functionality to sense and analyze the environment for navigational and tactical purposes, such as obstacle detection, local terrain mapping, and tactical perception and symbolization (i.e., representation of the perceived entities in terms useful to the cognitive processing and action generation functions). The perception software 515 , 615 uses net-centric information, as well as information from sensors. Perceivers 611 , such as those described above with respect to FIG. 4 , can operate with a tactical module 612 , which can navigate 613 by using obstacle detection 614 and a terrain map 616 .
Cognitive model software 520 , 620 can provide the functionality to identify the current tactical state of team members, the team's tactical state as a whole, and the ability to share information between multiple cognitive models. The cognitive model 520 , 620 can interact with other parts of the system to direct sensing and perceiving resources to help disambiguate the existing tactical situation. The cognitive model 520 , 620 learns at different levels based on feedback from team members and chunking, or other short-term memory, to support human-based cues that identify when the system should learn a new situation. Cognitive software 520 , 620 can identify the state/role of a team member 621 or a team 622 using semantic pattern recognition 623 , which obtains information from the perceptual synthesis 617 of the perceivers 611 . Semantic pattern recognition 623 can use patterns in memory to recognize an environment and can look for further patterns or clues to further distinguish the type of environment.
Robotic playbook action-generation software 525 , 625 can provide the functionality to generate robotic actions based on the perceived state of the team. The playbook action-generator 525 , 625 can use the output of cognitive models to process tactical state information, draw upon stored databases of tactics, techniques, and procedures (“TTP”) 624 , training materials 626 , and act to identify appropriate tactical actions for unmanned vehicles. Along with training 626 and TTPs 624 , the playbook generator 627 can use current plans 628 , joint plans 629 , and information from the navigation module 613 of the perception software 515 , 615 . This information, along with the tactical state discerned from the semantic pattern recognition 623 , can be provided to a play evaluator 632 . The system uses spatiotemporal reasoning 631 to understand a situation (e.g., a formation) in a time and space analysis and tries to figure out what the team members are doing and why. Spatiotemporal reasoning 631 submits tactical queries to the perceivers 611 .
Playbook action execution software 530 , 630 and feedback software 535 , 635 can provide the functionality to control and sequence the execution of short-term robotic actions, monitor their execution, identify action failures, and identify when squads have abandoned, replaced, or modified behaviors. The play evaluator communicates with a plan or playbook action executor 633 , which also receives information from a play module 634 , to communicate with both a play monitor 636 and a plurality of behaviors 637 in the tactical behaviors module 638 . The feedback manager 535 , 635 evaluates plan feedback in a relevance monitor 639 and communication monitor 641 .
The C2 software 500 , 600 uses TSS data and other information to estimate the squad intent and generate a plan. The TSS 505 can include non-intrusive sensor devices that provide information to the C2 software 500 and allows for feedback to the user. A TSS Feedback Manager 540 can manage a team member state 545 , weapon state 550 , state information and verbal command interface 555 , and alert devices 560 . The TSS feedback manager 540 can control the output (i.e., can decide to send information) from the sensors to the network when there is a change in a sensor's status. The TSS feedback manager 540 can monitor the status of the sensors and send information when there is a change that it deems to be significant.
The team member can use verbal commands to inform the playbook action generator of the team member's state. The TSS 505 can include components and devices for team members to wear or carry that can provide sensor information to the system, as well as provide feedback from the system to the team member. The information can indicate team member location, physiological state, and weapon status information. The components can include, but are not limited to, COTS products such as sensors, worn or carried by the team members, that can provide weapon status information, location (e.g., via global positioning system (“GPS”)), a verbal command interface, and/or information on each team member's physiological state. GPS is global positioning satellite, a satellite navigation system that allows accurate determination of a location. Any discussion of GPS is not intended to be limited only to the global positioning satellite, but can include any position locating or tracking system, including, for example, global navigation satellite system (“GLONASS”) and Galileo.
There can be numerous embodiments for the TSS components. For example, the TSS 505 can be a modification and/or addition to a rifleman's suite, which disseminates information over a wireless network. Haptics can serve as soundless, non-intrusive alert devices. A GPS chipset integrated into a microcontroller box and interfacing with a team member's personal role radio provides digital communications and team member location reporting. A small box with an inertial sensor (e.g., an orienting device) mounted on the weapon can provide weapon pointing information. The soldier's weapon can also be instrumented with safety, trigger, and auxiliary switches, as well as a laser rangefinder or designator. A chest-strap or instrumented t-shirt can provide physiological responses to a tactical situation, fatigue estimation, and estimates of cognitive load. A laser pointer (e.g., a IZLID 1000P laser pointer) mounted on the weapon can be used as a pointing device to select an object of interest (e.g., a possible IED). A non-intrusive “watch fob” display device can display status and imagery. It can be carried on the team member's belt and glanced at for situational awareness and understanding. A minor change to a team member's weapon can provide trigger-pull and safety status to the system. Solid state accelerometers at joints (e.g., back, thigh, ankle, knee, or hip) of the team members can enable deduction of posture, pose, position, or gait. A team member can wear a vest or bodysuit that has strain gauges or sensors to detect heart rate, respiration, and perspiration. The team member's canteen can also have a sensor to monitor the amount of water or fluids consumed from the canteen. The soldier's weapon can be instrumented for cooperative robotic weapon control. For example, as shown in FIG. 7 , when a soldier 700 points and/or fires his weapon 710 in a certain direction, a robotic platform 720 can point a weapon 730 in a substantially similar direction. The robot's weapon 730 can be a surrogate automatic or semi-automatic weapon that can be mounted on a pan-tilt unit. Equipment for TSS may require the team member to carry extra weight, but eliminates bulky OCU equipment.
The TSS 505 , 605 receives task results at an information manager 642 , which transmits information to a verbal command module 643 and an alert manager 644 , which in turn communicates with alert devices 645 . The information manager 642 manages the network, captures messages, and decides which messages to listen to and which messages to send. For example, the information manager 642 can decide whether to send a message to a group or to one person and the best way of sending the message. The information manager 642 also identifies the team member's state 646 , such as geolocation, physiology, and weapon state. The information manager 642 communicates the team data and tasks or commands to the perceivers 611 .
User feedback devices can enable alerts and information transfer back to team members without distracting the team member or obstructing his or her senses. User feedback management software can provide user feedback and manages the information flow to the team members, taking into account available bandwidth, information criticality, the tactical situation, and the estimated cognitive burden.
Unmanned platform interface software 510 , 610 can provide the functionality to provide connectivity from the C2 software 500 , 600 to enable control of the unmanned vehicle. The unmanned vehicle interface kits 510 , 610 can have devices, software, and hardware for integrating the C2 software 500 , 600 with selected unmanned platforms. An unmanned vehicle common interface 510 , 610 can use plug-in interfaces for the capability of controlling current and future unmanned vehicle platforms. The unmanned vehicle interface 510 , 610 has an unmanned vehicle native platform controller 565 , 665 that can control a common command interface 570 , 670 , a common information interface 575 , 675 and a common physical interface 580 , 680 . The native platform controller 565 , 665 takes information from common command interface 570 , 670 and the common information interface 575 , 675 and converts into the custom physical interface 580 , 680 . The common command interface 570 , 670 translates the commands from the plan execution 530 , 630 in a common command language into a native controller language of the platform. The common information interface 575 , 675 collects information and provides products such as video, pictures, audio, and the like, to the feedback manager 535 , 635 . The custom physical interface 580 , 680 can involve the interaction with hardware or mounting, such as determining how to get power or control pan tilt.
Referring to FIG. 8 , an architecture demonstrating the interface between an unmanned vehicle framework 800 and an unmanned vehicle interface 810 is shown. In the unmanned vehicle interface 810 , which can resemble the unmanned vehicle interface 510 , 610 in FIGS. 5 and 6 , an unmanned vehicle native platform controller 820 can control a common command interface 825 , a common information interface 830 , and a custom physical interface 835 . The common command interface 825 has modules such as a JAUS (Joint Architecture for Unmanned Systems) interface (e.g., to convert a command a send it to the platform), teleoperation interfaces (e.g., determine how to teleoperate and convert for the platform), and/or any well-defined interface, whether or not it is a standard. The common information interface 830 has modules such as a 2D (e.g., send pictures from a soldier or sensor, video frames, or streaming media, or a laser line scanner), 3D (e.g., radar, ladar, laser range information including distance), messages that go back and forth, and the like. The custom physical interface 835 has modules such as power, mechanical connections, network power, radio hookups, pan tilt, additional sensors, and/or other additional physical components. In one example of an interaction between the components of the unmanned vehicle interface 810 , if the common command interface 825 and the common information interface 830 require a plug-in for a new device, the custom physical interface 835 may respond by querying whether a new antenna is needed.
The unmanned vehicle interface can convert the system information and control data into native control directives for the base platform. Each protocol can be supported by a plug-in that handles the translation. As a result, this approach can support new platforms and protocols.
The unmanned vehicle framework 800 , which can represent software and/or hardware components shown in the TSS and C2 software shown in FIG. 5 , can have tactical behaviors 840 (e.g., follow soldier or a verbal command) that are commanded to the common information interface 830 . The unmanned vehicle framework can also have a reasoning component 845 , which receives information from the custom physical interface 835 to provide to perceivers, such as a soldier perceiver or navigation perceiver.
The architecture in this exemplary configuration can be applicable to any unmanned vehicle or robotic platform. The architecture can be specifically designed to utilize common interfaces that incorporate platform-specific drivers. The software components interact with these interfaces (e.g., physical, command, and information) and the interfaces utilize platform-specific drivers to accomplish their tasks. For example, the software components may instruct the robotic system to “go forward 10 meters.” This command is passed to the command interface, which translates it to machine instructions via a driver for JAUS, CanBUS, USB, or other similar platform protocols. JAUS is the joint architecture for unmanned systems. JAUS is formerly known as joint architecture for unmanned ground systems (“JAUGS”). CanBUS is a controller area network multicast-shared serial bus standard.
Referring to FIG. 9 , an exemplary architecture is shown for the system. Mounted nodes 910 , other information systems 915 , and dismounted nodes 905 can communicate with an information management component 920 . The mounted nodes 910 can offer information regarding targeting, plans, and detecting enemy soldiers. The other information systems 915 can be used to monitor and analyze current on-the-ground command and control. The dismounted nodes 905 can provide information from soldiers on a battlefield, including the platoon and company level, as well as those soldiers associated with a different unit. The information management 920 can provide both situational awareness 935 as well as information to the perceivers 930 . Sensors 925 can also provide information to the perceivers 930 . The sensors 925 can provide information to an annotated 3D terrain map 965 , which can be used by the perceivers 930 rather than using raw sensor data. The perceivers 930 and the situational awareness 935 can be provided to the cognitive models 940 , which also learn from training 953 , case based learning 963 , and TTPs and mission plans 957 . The cognitive models 940 include intent of a squad 945 and soldier 950 , as described above with respect to the other architectural configurations. The cognitive model 940 has a reasoner 955 that can generate a plan, which is sent to the unmanned vehicle control 960 for execution. An executive 970 can direct the weapon control or vehicle control 985 , through tactical behaviors 975 and mobility behaviors 980 .
Referring to FIG. 10 , a method of autonomous control can proceed as follows. First tactical behaviors can be developed 1010 . Network information can be used to convey information from team members and/or sensors 1020 . A determination can be made as to the mission, situation, squad disposition, and soldier cognitive/emotional state 1030 . A cognitive model can be driven 1040 . The current state, goals, and intentions can be inferred 1050 . An appropriate behavior can be selected 1060 . Soldier/robot TTP and tactical behavior can be mapped 1070 . Optionally, feedback can be provided 1080 . This method is not intended to be limited to only these steps or the order thereof.
The system can enable the robotic platform or unmanned vehicle to understand the tactical situation by observing the team members. The TSS can provide the robot with location, weapon state, posture, and physiology information. Each team member can serve as a sensor for detecting the environment and interpreting it for the unmanned vehicle. The C2 software on each unmanned vehicle can collect information from each team member as well as from the robotic platform's sensors. Using cognitive models, the C2 software reasons about how the team members have positioned themselves, how they are moving, their postures, whether they are pointing their weapons, whether the weapons safeties are off, and the state implied by each team members physiology. In view of this information, the system generates an estimate of squad intent, which is used to develop a short-term, simplistic plan known as the playbook action (“PA”). The system executes the PA and monitors the results. As long as the PA remains valid, the unmanned vehicle continues to execute it. If the system changes the estimate of intent or receives direct feedback from a team member, the system can modify or replace the current PA.
The PA generator derives a short-term play for the platform that is appropriate for the situation, understood and expected by the team members, and consistent with the team's training with the platform. The PA generator evaluates the current tactical state provided by the cognitive model to determine which play to call from the playbook. Plays are short-term action plans, customized to fit the current situation. The playbook approach provides control at a high level of abstraction, but leaves the details of execution to the execution control and monitoring layer of the system architecture. In the C2 paradigm, all team members (human and robotic) share the same definition of a play (e.g., a battle drill) and understand the goals and acceptable behaviors for each member.
The playbook is developed based on current training materials and TTPs. The system selects a play on the fly by a team member's command override or by a situation and intent analysis. Playbooks minimize the necessity for human interaction, while maximizing the capability of humans to interact and control the situation for optimal achievement of mission objectives.
Referring to FIG. 11 a , an exemplary playbook 1100 is shown. In this playbook 1100 , the platform can choose between ammunition resupply, corpsman 911, logistics carrier, formation move, rally, designator teleoperations, IED detection, and breach. In FIG. 11 b , once IED detection is chosen as the course of action, for example, the PA generator has short plays for the current tactical situation, including, but not limited to, detect designated object, discover designated object, calculate heading and distance, laser designation, net-centric designation, move to object, follow path, avoid obstacle, employ IED sensor, deploy IED sensor, wait, and report results.
The execution control and monitoring layer sequences the PA, monitors the intermediate results, and determines if the play is succeeding, failing, or being overtaken by events. The play executive ensures that the PA created by the PA generator is executable and executed. The play sequencer is the primary executive for the platform. The play sequencer has explicit knowledge about the system behaviors and the capabilities of the underlying platform. The play sequencer can be used to create platform and context specific executable robotic actions that will achieve the objectives of the play. Real-time monitoring detects exceptions in execution performance and exception handling provides repair actions for exceptions identified by action monitoring.
The playbook monitor (“PM”) evaluates the status of the current PA, reasoning at the level of abstraction of the original play produced by the PA generator to determine what feedback, if any, to provide to the team member via the feedback manager.
In order to construct a computational cognitive model, the system can use an existing cognitive framework, such as the Sandia Cognitive Framework, or build the cognitive model using languages such as ACT-R or SOAR.
The system can adapt, learn, and train with the team in an effort to avoid obsolescence or being overtaken by events. Learning can be based upon many sources of information. Verbal commands, command overrides, and consent-by-taking-no-action provide feedback to the system on the quality of its understanding and action generation. TTPs, battle drills, x-files, and field manuals offer information on proper actions to take in tactical situations. Additionally, mission-recording and human-in-the-loop after action reviews can provide an environment in which situational understanding and action generation can be assessed and modified.
Training and learning can occur on many levels. Tactical preferences can be minor modifications to the play. Team preferences for certain aspects are not defined in TTP or battle drills. The system can learn to adjust tactical timing (e.g., the time interval between team members crossing the street or a line of sight). The system understands roles, thereby operating at a higher level of abstraction. When a team leader calls plays, a predefined PA is prompted by the PA generator. The cognitive model can learn how to respond to a new situation and how to differentiate the new situation from the known situation (e.g., schema differencing). A team member guides a robot step-by-step through a new process, allowing the PA generator to build a new play. The new play can be associated with a new verbal command, extending the command vocabulary. Behavioral preferences are an extension of play recording. Data can be recorded during training and actual missions to provide adjustments to improve execution and coordination with a given team.
Learning can be test-based on confidence metrics derived from semantic network situational understanding, case-based reasoning (e.g., comparing the current situation with historical cases), learning from training (e.g., parameterization of “playbook” actions, when playbook actions are appropriate, and responsibilities of different squad roles), or reinforcement learning (e.g., feedback from soldiers when inappropriate behavior is produced in the form of real-time verbal feedback or after-action review). The system can also learn from soldier interaction or response to events and objects. The system can learn from a squad-specific approach to tactical situations or soldier-specific physiological and behavioral response to threats. The system stores cases to guide real-time assessment. The system can also collect confirmatory information to validate a situational hypothesis.
Learning of tactics and appropriate action can be enabled whenever a human gives corrective input to the human. This can be in the form of verbal override commands or “after action” analysis of the robot's performance. The human's corrective input can used to define and differentiate a situation where the new behavior is required and to enable the system to detect the appropriate situational markers (e.g., team positioning, team actions, changes in human physiology) that can be used in the future to trigger the new behavior. Referring to FIG. 12 , feedback from both the current robot's behavior and corrections from the human can initiate learning in the robot resulting in modification to the state transition. A robot behavioral model 1210 can utilize inferences from perception 1220 , overt commands, or a human's actions to learn a new behavior. The robot's actions and results are sent as feedback to the human cognitive model 1200 . Both the soldier and the robot can analyze the situation in view of the mission plan, tactical picture, and squad disposition.
For verbal commands, the system can include voice understanding, a fixed command set, command override, the ability to learn new verbal commands, and gesture commands with an instrumented glove. The command vocabulary can include, for example, point, flank, guard, and evac.
The systems and methods can combine long-wave infrared images from an IR-sensitive camera (e.g., a FLIR A20) with corresponding images from other devices (e.g., two cameras in a stereo configuration, such as a PGR Bumblebee, a color camera, and a LADAR scanner) to detect humans. These sensors are integrated in the net-centric environment.
Each soldier or team member can be outfitted with a PDA, wearable computer, or a computer that is implemented in one of their devices, such as a computer in the scope of the weapon. The information regarding the soldier can be transmitted through a wireless network from the computer to the unmanned vehicle or robotic platform.
Tactical maneuvers can include following a team member, rally to a named point or team member, formation movement, maneuver to a fire position, wall hugging, low observability movement, and stealthy movement. The system is also capable of tactical understanding and role-based behavior, including safe operations with instrumented team members or other personnel, simpler roles such as “guard in place,” or more sophisticated roles such as “point man” or “rear guard.”
In one example of this configuration, a team moves through a city with unmanned ground vehicles (e.g., a Talon) moving along with them to augment the team's capabilities in remote inspection, improvised explosive device (“IED”) detection, and ammunition resupply. The team sees an object and designates it as suspicious. The team verbally commands a Talon to inspect the suspicious object. The Talon employs IED sensors and reports back to the team. As a result, a team member does not have to perform continuous operator control of the Talon and can multitask while the Talon moves to and from the suspicious object. The Talon is put in harm's way, rather than a human. Other benefits can include a reduction in time to achieve mission goals and capabilities of those team members due to an automation of repetitive tasks. Additionally, the unmanned ground vehicles assume risks from the team members, which can increase team member survivability.
In another example of this configuration, the team comes under fire during a routine patrol. In this example, an unmanned ground vehicle (e.g., a Gladiator) is in point position and an unmanned aerial vehicle (e.g., a Dragon Eye) is automatically maintaining position a few blocks in front of the squad. When the team gets excited and point safety-off weapons at a location, the Dragon Eye sweeps back to give an overhead situation awareness of the target area. The Gladiator moves towards the threat, drawing fire and moving its sensors into a better position for detection. The Gladiator monitors the street with its onboard sensor suite, alerting the team to new intruders. In this example, the team members do not have to perform any operator control of the unmanned ground/air vehicles or constantly monitor their progress. Additionally, these unmanned ground/air vehicles can augment the team's capabilities in scouting and reconnaissance without a team member on point, just in case an ambush occurs.
In another example of this configuration, the team is on a movement to contact mission and aim their weapons at a threat. The team members verbally command the Gladiator for cover fire. The Gladiator realizes that the team members are stressed, their weapons are safety-off, and they are firing at a threat. The Gladiator triangulates the threat's location and positions itself to cover fire on command. When a team member is wounded, the Gladiator automatically provides cover for him and the corpsmen. On command from a corpsman, the Gladiator acts as a MEDEVAC when the wounded team member is stabilized. In this example, the unmanned ground vehicle can carry additional ammunition and medical supplies for a resupply, even under fire. The unmanned ground vehicle can even provide additional suppressive fire to enable the team members to maneuver.
In another example, the team members designate a vehicle and verbally command the Talon to inspect it. The Talon autonomously approaches the vehicle and employs onboard sensors, reporting results back to the team. The Gladiator provides cover, ready to fire on command. The Gladiator monitors team weapon status to determine threat status and responds accordingly. The Dragon Eye performs reconnaissance several miles ahead, alerting the team of approaching vehicles. In this example, the team members are provided with a greater standoff from potential threats and are provided with an early warning of approaching threats.
In one example of using this configuration, a soldier walks forward and a robot takes point in front of the soldier providing cover in case of a surprise attack. The soldier switches the safety to “off” on the weapon and assumes a tactical posture. The robot tacks back and forth in a general direction to flush out hidden enemies, maintain a view of the soldier to analyze the body pose and hand signals, position itself to provide cover for the crouching soldier, and retreat if necessary when the soldier starts retreating by providing rear guard and cover for the soldier.
Key events and cooperative behaviors can include, but are not limited to, team movement, formation change, verbal override, providing cover fire, ammunition resupply, and protecting a downed (e.g., injured or wounded) soldier. For team movement, the robot can move appropriately into a formation, including line, wedge, or column. For formation change, the robot can detect change in formation and respond accordingly. For verbal override, the robot can change position from default in response to verbal directive. For providing cover fire, the robot can detect soldier/team pose, elevated physiology, weapon orientation and status (e.g., safety “off” or firing), and estimates location of threat to provide cover fire for the team. For ammunition resupply, the robot can detect soldier ammunition as low and move to resupply the soldier with additional ammunition. For protecting a downed soldier, the robot can detect a wounded soldier through pose and physiological status, maneuvering between the wounded soldier and the estimated threat.
In another example, referring to FIG. 13 a , a fire team ingresses an area of building A using a satchel charge to enable an assault on an enemy force T. In FIGS. 13 b and 13 c , the fire team continues to ingress the area and approaches using bounding overwatch. In FIG. 13 d , the soldiers begin firing on the target. In FIG. 13 e , robot R 1 provides cover fire. In FIG. 13 f , robot R 2 runs gauntlet with the satchel charge and drops it at a wall of building A. In FIG. 13 g , robot R 2 moves outside the explosive range and the soldiers detonate the charge. In FIG. 13 h , robots R 1 and R 2 provide cover fire as the soldiers storm the breach.
In yet another example, referring to FIG. 14 a , a plurality of soldiers execute a “through the door” TTP to breach a doorway and enter a room having assaulting enemy forces therein. Referring to FIG. 14 b , soldier 3 breaches the door. Referring to FIG. 14 c , soldier 3 retreats and soldier 1 goes through the door and to the left. Referring to FIG. 14 d , soldier 2 goes through the door to the right. Referring to FIG. 14 e , soldier 3 goes through the door to the left. Referring to FIG. 14 f , soldier 4 does through the door to the right.
In an alternative configuration, robots can assume randomly selected positions or roles in the action. For example, referring to FIG. 14 g , robot R 1 takes the place of soldier 3 and robot R 2 takes the place of soldier 2 .
In still yet another example, a soldier is wounded during an assault and robots work as a team to protect and evacuate the downed soldier. Referring to FIG. 15 a , a fire team is assaulting a defended enemy position. Robots R 1 and R 2 provide rear security. Referring to FIG. 15 b , soldier 2 is wounded. Soldier 2 's impact sensor senses the wound and reports via the network. Referring to FIG. 15 c , robot R 1 provides physical cover and robot R 2 provides wide-area cover fire. Referring to FIG. 15 d , soldier 4 assists to attach soldier 2 to robot R 1 . Referring to FIG. 15 e , robot R 2 moves to provide physical cover. Referring to FIG. 15 f , soldier 4 moves back to cover, robot R 1 drags soldier 2 out of the area, and robot R 2 provides physical cover and cover fire.
When the system is utilized, a robot can perform cooperative, tactically correct behavior without human interaction or cognitive burden. In a dismounted mode, the robot operates as an integrated and trained member of a team, understands team mission and tactics, needs no human intervention during short-term high-intensity conflict, has situational awareness and understanding by discovery and harvesting the net-centric information streams. In a mounted mode, a robotic “wingman” can automatically support and protect a manned vehicle; can understand machine readable mission plans, situational awareness and understanding, and targeting streams; can provide automated net-centric fire platform; and the automatic tactical behavior reduces the need for robotic controllers.
Referring to FIG. 10 , in one configuration, the system is integrated in a small-unit unmanned ground vehicle for high-stress operations, such as military operations on urban terrain (“MOUT”) scenarios, without using an OCU. The system will use tactical behaviors; use netcentric information from instrumented sources to determine the mission, situation, squad disposition, and soldier cognitive/emotional state; monitor the soldiers' positions and poses to detect changes in a tactical state; utilize a cognitive model of the soldier and the squad to infer the current state, goals, and intentions; based on the inference, select the appropriate behavior for the unmanned ground vehicle to support the squad in the current situation; map the soldier/robot TTP and tactical behavior into the current situation and terrain; and provide non-computer, non-RF feedback to the soldier from the robot (e.g., pointing at a suspected enemy location). The system can be constantly updated with information from external sources.
The embodiments described above are intended to be exemplary. One skilled in the art recognizes that numerous alternative components and embodiments that may be substituted for the particular examples described herein and still fall within the scope of the invention. | A system and method can provide a command and control paradigm for integrating robotic assets into human teams. By integrating sensor to detect human interaction, movement, physiology, and location, a net-centric system can permit command of a robotic platform without an OCU. By eliminating the OCU and maintaining the advantages of a robotic platform, a robot can be used in the place of a human without fatigue, being immune to physiological effects, capable of non-humanoid tactics, a longer potential of hours per day on-station, capable of rapid and structured information transfer, has a personality-free response, can operate in contaminated areas, and is line-replaceable with identical responses. A system for controlling a robotic platform can comprise at least one perceiver for collecting information from a human or the environment; a reasoner for processing the information from the at least one perceiver and providing a directive; and at least one behavior for executing the directive of the reasoner. | 6 |
This application is a divisional of application Ser. No. 10/190,965, filed on Jul. 8, 2002, now U.S. Pat. No. 6,609,542 which is a divisional of application Ser. No. 09/646,213, filed Nov. 20, 2000, now U.S. Pat. No. 6,427,872, issued Aug. 6, 2002, which is a 371 of PCT Application No. PCT/AU99/00178, filed Mar. 18, 1999, which claims benefits from Australian Application No. PP-2435, filed Mar. 18, 1998, incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to tote bins and more specifically to devices which enable polymeric liners to be inserted into tote bins and combination of valves and spigot systems for those.
BACKGROUND OF THE INVENTION
A tote bin is a bin or storage system which holds or carries bulk product. Tote bins are generally filled with a bulk product for the purposes of storing and transporting that bulk product to an end user.
Typically, such tote bins are lined with a plastic or polymer liner which holds the bulk product. The liner has an outlet tube or spigot hermetically sealed by a membrane. The outlet spigot allows for connection to a valve so as to fill or empty the product from the liner. The valve may or may not be attached during transport.
The products which are stored and carried in tote bins typically require sanitary or sterile conditions for the filling and emptying procedures. In the case of food product sterile conditions are generally required.
To achieve a required degree of sterility all surfaces which will contact the product need to be sterilised. Thus when filling or emptying the tote bin the valve is attached in a manner so that both the valve and the membrane can be sterilised together.
One of the disadvantages of prior art tote bins which have plastic liners is that the membrane which seals the outlet spigot is arranged on the outlet spigot in such a way that it is not readily sterilisable without a risk that the membrane or its seal to the spigot will be damaged by the fluid used for sterilisation.
A typical arrangement of a prior art outlet spigot and valve is illustrated in FIGS. 1 and 2 . In FIGS. 1 and 2 the outlet spigot is generally indicated by the letter “A” and is illustrated as being attached to a liner indicated with the letter “L”. The outlet spigot A has a membrane E hermetically sealed thereto.
A butterfly valve “B” is connected to the outlet spigot A as depicted in FIG. 2 . The valve B includes a ring shaped cylindrical cutter C having a cut out segment. The cutter C is slidably located in the valve passage D, between a butterfly valve member G and the membrane E. The cutter C is a cylindrical ring with a cut out segment. When the valve B is closed the cutter C will not engage the membrane E until the valve is opened.
Once the valve B has been connected to the outlet A, and upon opening the butterfly valve member G, as illustrated in FIG. 2 , the cutter C is moved to the left of the figure by an edge H of the valve member B. The edge H engages a bar J on the cutter C. The cutter C will then engage and cut the membrane E.
As the cutter C is a cylindrical ring with a cut out segment, it leaves a portion of the membrane uncut, thereby leaving a land which connects the cut portion of the membrane with the uncut. The land forms a hinge arrangement.
The arrangement illustrated in FIGS. 1 and 2 leads to several difficulties during sterilising procedures.
The first is that as soon as the valve B is opened, the membrane E is pierced by the cutter C. This means that for the arrangement of FIGS. 1 and 2 the valve components, seals and membrane cannot be sterilised through the valve.
To overcome this difficulty an additional inlet can be provided to allow the entry of a sterilising medium into the valve between the membrane E and the butterfly valve member G. In this case, prior to the opening of the butterfly valve member G, a sterilising medium is injected into the region between the butterfly valve member G and the membrane E to sterilise the membrane E, the internal portions of the outlet spigot A, the cutter C and some of the internal portions of the valve B. In this situation there will still remain the difficulty mentioned previously that the membrane or the seal between it and the outlet spigot will have the potential to be damaged.
The potential to be damaged dictates the maximum temperature and pressure at which sterilisation occurs. This in turn generally means a lower temperature and pressure sterilisation procedure will have to be used which in turn dictates that a long time will be used to achieve the necessary level of sterilisation.
One of the disadvantages of sterilising at a temperature and or pressure which is not as high as it should optionally be, is that it can take so long to complete the sterilisation process that downstream processes can be delayed.
It is an object of the present invention to provide a combination of a valve and spigot for attachment to a lined tote bin, and/or a method of sterilising and filling or emptying a lined tote bin and/or a cutter for a membrane which ameliorates, at least in part, at least one of the prior disadvantages of the prior art.
SUMMARY OF THE INVENTION
The present invention provides a tote bin liner having a liner wall to form a container, said liner wall including a transfer spigot which provides a passage from inside said liner to the outside thereof, said transfer spigot comprising:
a tubular body which defines said passage, the tubular body having an opening on the distal end thereof; an annular surface located around the opening said annular surface providing a sealing surface adapted to engage a seal on a surface of a valve body when said valve body is assembled therewith; a rupturable membrane sealed to said annular surface by a continuous seal around said opening, said continuous seal being located on said annular surface.
The present invention further provides a tote bin liner having a liner wall to form a container, said liner wall including a transfer spigot which provides a passage from inside said liner to a tote bin outlet, said transfer spigot adapted to have a valve mounted thereto to provide a controlled outlet from the tote bin outlet, the transfer spigot comprising:
a tubular body which defines said passage, the tubular body having an opening on the distal end therethrough; an annular surface located around the opening; a rupturable membrane sealed to said annular surface by a continuous seal around said opening, said continuous seal being located on said annular surface; the tubular body being shaped and configured such that when in use and said valve is mounted to the body, a seal on the valve will clamp the membrane against the annular surface.
Preferably said annular surface is generally perpendicular to the axis of the tubular body so that a seal on a valve clamped to the body will press the membrane against the sealing surface.
Preferably the annular surface has a radially inner portion and a radially outer portion and said continuous seal is located on said radially outer portion whilst the radially inner portion is adapted to have a seal of a valve which is an engagement with the tubular body seal therewith. Alternatively the continuous seal may be located on the radially inner portion and the radially outer portion is adapted to have the seal of a valve engage therewith.
Preferably said annular surface is included on a flange of said body.
The present invention also provides a cutter assembly to cut a membrane which seals a transfer spigot on a container, said cutter assembly having:
a valve including a valve body adapted to engage with said spigot, the valve body including a valve closure member, adapted to be moved between open and closed position to open and close the valve; at least one elongate cutter which terminates in a cutting tip, said cutting tip being adapted to rupture or slit said membrane; actuation means for providing axial movement to said cutter within said valve body; and said actuation means and/or said elongate cutter body being adapted to move said cutter body to cut a membrane independently of the operation of the valve closure member.
Preferably said actuation means is adapted to rotate said cutter about an axis to define an arcuate cutting action.
Preferably said cutting tip is any one of the following: a pointed spike; a blade; a crescent shaped knife; a C-shaped knife; a D-shaped cutter having an open segment.
Preferably said actuation means is adapted to move said cutter to a side of said valve closure member remote from the spigot.
Preferably said cutter is formed in at least two elongate sections, each terminating in a cutting tip, or alternatively the cutter bifurcates into two arms, each arm terminating in a cutting tip.
The cutter and actuation means may be housed in a tubular housing which is adapted to be coaxially mounted to the valve body, the actuation means in use being adapted to move the cutter through the valve body, past valve closure member when the valve closure member is open, into engagement with the membrane in cut said membrane.
The invention extends to an assembly comprising a tubular housing, cutter and actuation means for a cutter assembly according to the invention.
The invention also provides a sterilising, cutting and transfer tube wherein the tube has a cutting assembly as described in any of the paragraphs above.
The present invention provides a method of sterilising an impervious rupturable membrane attached to a tote bin spigot on a liner and subsequently filling or emptying said liner, said impervious rupturable membrane closing a passage which connects the exterior of said liner to the interior of said liner; said method comprising the steps of:
1 attaching a valve having a flow passage therethrough and a valve closure member mounted within the passage moveable between open and closed positions, the valve closure member being spaced away from the membrane; 2 passing a sterilising medium into at least the space between said membrane and the valve closure member to sterilise the outside surface of said membrane and that part of the internal flow passage within said valve between said membrane and the valve closure member; 3 piercing said membrane with a cutter which passes along the flow passage past the valve closure member when the valve closure member is in the open position.
Preferably said valve closure member is in an open position at the start of and for the duration of step 2.
Preferably said sterilising medium sterilises the whole of the internal flow passage within said valve.
Preferably said valve is of the butterfly type.
Preferably said cutter is linked to a rotatory actuator to rotate said cutters.
Preferably the cutter is one of the types described in preceding paragraphs.
BRIEF DESCRIPTION OF THE DRAWINGS
An embodiment of the present invention will now be described, by way of example only, with reference to the accompanying drawings in which:
FIG. 1 illustrates a spigot a valve of the prior art;
FIG. 2 illustrates the assembled spigot and valve of FIG. 1 ;
FIG. 3 illustrates a cross section through an embodiment of the present invention with the valve separated from the spigot;
FIG. 3A illustrates a similar view to that of FIG. 3 but with the valve and spigot connected;
FIG. 4 illustrates the sterilising and entry mechanism and cutting mechanism for use with the spigot and valve of FIG. 3 , with the spigot illustrated without an attached membrane;
FIG. 4A illustrates the apparatus depicted in FIG. 4 from a rear view;
FIG. 4B illustrates a schematic cross section through a part of the apparatus depicted in FIGS. 4 and 4A ;
FIG. 5 is a detailed perspective view of the cutter for the apparatus depicted in FIG. 4 ;
FIG. 6 illustrates a view of the butterfly shaped valve closure member for the valve depicted in FIG. 3 ;
FIG. 7 illustrates schematically the shapes of different cutting members adapted for use with axial movement of the actuator;
FIG. 8 illustrates schematically the shapes of cutting members adapted for use with axial and rotation movement of the actuator;
FIG. 9 illustrates diagrammatically the D shaped flaps formed in a membrane by axial movement of C-shaped cutters.
DETAILED DESCRIPTION OF THE EMBODIMENTS
Illustrated in FIGS. 3 and 3A is an annular transfer spigot 2 which is connectable or formed with a liner 1 such as the liner “L” of FIG. 1 for insertion into a tote bin (not illustrated). Preferably the spigot 2 is made from polyethylene, but other materials could be used, providing they do not lose their structural integrity during or after the sterilisation process which will be described below. The liner is preferably manufactured from polyethylene or may be made from a barrier material such as metallised polyester, or foil depending upon the type of product to be contained by the liner. The spigot 2 includes a tubular body 13 having an axial internal passage 14 therethrough to allow flow communication between the interior and exterior of the liner.
The body 13 is formed with one end having a flange 4 for attachment to the liner. The outer portion of body 13 reduces in diameter to form a neck 3 and then expands to provide an outer flange 8 at the distal end thereof.
The flange 8 has a generally flat annular surface 11 thereon which surrounds the passage 14 through the body. A disc shaped membrane 6 is heat sealed to the annular surface 11 . The heat seal 10 is continuous around the annular surface 11 . The heat seal 10 is preferably formed in the radially outer peripheral section of the annular surface 11 . Preferably the membrane 6 is manufactured from a polyester laminated LPDE material, but other cuttable or rupturable materials such as are known in the art may be used.
The annular surface 11 also includes an annular shaped inner section 12 between the heat seal 10 and internal passage 14 . The flange 8 is preferably not joined or otherwise connected to membrane 6 , in this inner annular section 12 . (Alternatively the membrane can be heat sealed across the full width of the surface”, and this possibility is discussed below).
For typical tote bin applications the internal passage 14 is preferably approximately 50 mm in diameter.
Also illustrated in FIG. 3 is a valve 20 which is of the butterfly type. The valve 20 includes a valve body 21 having a flow passage 23 therethrough and a disc shaped butterfly valve member 22 located in the flow passage 23 (illustrated in more detail in FIG. 6 ) which is rotatable so as to close or open the passage 23 by means of a handle 26 .
On the end of the valve 20 remote from the spigot 2 is a tapered seat union 28 which is of threaded formation to allow for the connection of the valve to one or more of the following: fill station, sterilisation unit, emptying station, a membrane cutter or other device.
The other end of the passage 23 terminates with a flange 30 which has a tapered construction when viewed in cross section. The taper on the flange 30 is similar to the taper on the flange 8 also illustrated in figure 3 to allow a clamping ring 31 (shown broken into separate halves for ease of understanding) to surround and clamp together the flanges 30 and 8 . The flange 30 has a generally planar sealing face 32 of similar dimensions and diameter to the annular surface 11 which is provided with a sealing groove 34 which receives an annular seal 36 . The seal 36 illustrated has a rectilinear side which locates in the groove 34 and an arcuate front side which protrudes from the face 32 . This arrangement of seal is able to maintain its structural characteristics during sterilisation procedures. If desired the groove 34 could be shaped to receive a standard O-ring. The seal 36 may be made of a material such as food grade seal material.
When connected the heat seal 10 surrounds and is spaced radially outwardly from the location of contact (being in the area 12 ) of the seal 36 against the membrane 6 . In use, during sterilisation procedures, this arrangement allows the contact and pressure of seal 36 compressing membrane 6 to flange 8 in the area 12 to isolate the heat seal 10 from the elevated pressure and temperature which the outer face of the membrane is subjected to.
Once the valve 20 and spigot 2 are connected together, a sterilising/cutting/filling assembly 78 (as illustrated in FIG. 4 ) is attached to the valve 20 via nut 80 to the union 28 .
The assembly 78 comprises a tubular housing 79 which contains an axially movable cutter 40 for cutting the membrane 6 , an actuator for moving the cutter, and means for sterilising the interior of the valve body, and the outer face of the membrane 6 . These components are described in more detail below.
Once the assembly 78 is connected to the valve 20 the butterfly valve member 22 is opened and sterilising medium is caused to enter the tubular housing 79 via an inlet connection 82 . The preferred sterilising medium is steam at 148° C. and approximately 3.8 bar of steam pressure. The steam passes through the housing 79 , and into the internal passage 23 in the valve 20 . The steam will act on the outside surface of the membrane and the internal surfaces of the valve 20 which are exposed to the steam.
This high temperature and pressure would ordinarily, in the case of the prior art, cause damage to the heat seal holding the membrane to the spigot (as illustrated in FIGS. 1 and 2 ) due to the elevated pressure and the temperature acting on it. However, as mentioned above, the seal 36 provides a protective barrier for the heat seal 10 , thereby allowing relatively high pressure and temperature conditions to be used for sterilisation.
After the sterilisation process has been conducted for approximately 10 seconds (with the steam at the specified temperature and pressure) the supply of sterilising medium is withdrawn via a steam outlet fitting 77 (which is only partly visible in FIGS. 4 and 4A ) and the cutter 40 will operate. The purpose of the cutter is to rupture the membrane 6 , thereby allowing fluid to pass from, or into, the liner, depending on the application.
FIGS. 3 and 3A illustrate the cutter 40 which is slidable in an axial direction within the valve 20 . The cutter 40 is illustrated in perspective view in FIG. 4 and in more detail in FIG. 5 .
The cutter 40 is of a tubular construction and includes a cylindrical base 42 which can be connected either directly or indirectly to an actuator 43 mounted on or within the housing 79 . The actuator 43 may comprise a pneumatic or hydraulic piston and cylinder assembly, a rotary actuator or other motor driven device and, optionally, a hand operated rotation device.
Extending away from the base 42 are two support arms 44 and 46 , (the latter of which is better illustrated in FIGS. 3 and 3A as the support arm 46 cannot be seen in FIG. 4 or 5 ). The support arms 44 and 46 each have an arcuate shape in cross section which helps to give rigidity and strength thereto.
Arcuate cutting blades 48 and 50 are attached to the distal ends of the support arms 44 and 46 . The cutting blade 48 has a length 52 while the cutting blade 50 has a length 54 which is approximately 2 to 3 times longer than the length 52 . Both cutting blades 48 and 50 have approximately the same circumferential dimensions.
The adjacent side edges of the blades 48 and 50 are separated from each other by a gap 58 at both the top and bottom thereof. The gap 58 extends from the side edges of the blades 48 and 50 back through to the base 42 . The gap 58 is sized to receive the butterfly valve member 22 when the valve member is open, so that the blades 48 and 50 can pass along the internal passage 23 in the valve 20 . The cutter 40 is housed within the tubular housing 79 .
After the interior of the valve 20 has been sterilised the cutter will be moved axially from the housing, past the open valve member 22 , to cut the membrane 6 . The cutter is moved by means of the actuator 43 , also housed within the housing 79 . Preferably the actuator 43 will comprise a hydraulic or pneumatic piston and cylinder assembly. As the blades 48 and 50 engage the membrane 6 , cutting tips 60 on the leading ends of the blades 48 and 50 cut the membrane in two C shaped cuts, depicted in FIG. 9 .
The cutter 40 may then be pushed further into the spigot 2 until the rear end 62 of blade 48 moves past the membrane 6 . It will be noted that, due to part circular shape of the blades 48 and 50 , two diametrically opposite lands 91 and 92 of membrane material retain the central region of the membrane to the outer peripheral region thereof.
Once the end 62 of blade 48 is clear of the membrane 6 , the butterfly valve member 22 will be located in the gap 66 between the rear end 60 of blade 50 and the base 42 of the cutter 40 . The length of the gap 66 , is greater than the diameter of the butterfly valve 22 so that the butterfly valve member 22 is at that stage located in a relatively wide recess, rearward of both blades 48 and 50 .
Once the butterfly valve member 22 is located in the gap 66 , the cutter 40 is rotated by the actuator 43 (see FIG. 4 ) which will rotate the blades 48 and 50 in direction 68 through an angular displacement of some 10° to 30° so that the top edge 70 of cutter 50 , will rotate and cut the closest land to it, so as to sever that land. Once this land is cut, the other land is allowed to remain intact so that the severed central, portion of the membrane 6 remains attached to the radially outer portion of the membrane 6 by means of that intact land.
The width of the remaining land is selected dependent upon the friction which will be applied to that land by the product moving into and or out through the spigot 2 . For many applications a width of 10 mm is sufficient when the membrane is made of laminated polyethylene and polyester, (or a lamination of polyethylene, aluminium foil and nylon or other commonly used laminations which allow the heat sealing of a polyethylene layer to the spigot 2 ), to prevent the movable membrane portion shearing off at the remaining land. If a product used with the spigot 2 will produce a friction of greater magnitude than designed for, the width of land may need to be increased.
After the cutter 40 has completed its cutting of the membrane, the liner can be filled with or emptied of product. This is done by the transfer tube 81 which is illustrated in FIGS. 4 and 4A and in cross section in FIG. 4 B. In FIG. 4B it can be seen that the transfer tube 81 connects to and opens into the tubular housing 79 in the region of the gap 66 between the blade 50 and the base 42 .
Filling of the liner is carried out as follows. The base 42 of the cutter 40 moves back into the tubular housing 79 and is sealed with respect thereto by a sliding seal 45 , so as to prevent steam and product from passing the seal 45 towards the actuator 43 . Once the cutter 40 and its base 42 have been retracted to the position indicated in FIG. 4B , a valve (not illustrated), mounted as close as practicable to the junction of the housing 79 and transfer tube 81 , is opened thus allowing food or other product to pass through the junction and through the gaps in the cutter 40 so as to flow through to the valve and into the liner via the spigot 2 .
Once transfer of product has taken place the nut 80 is disconnected from the union 28 and the operator will allow some or sterilising fluids to enter the housing 79 via the inlet 82 so that the steam or sterilising fluid will flush away any product which may remain inside the housing 79 .
If desired the support arm 44 and blade 48 could be dispensed with and the blade 50 alone utilised. However, if the blade 48 is not present, the blade 50 will need to be rotated through a much larger arc to provide a maximum possible cut. In this arrangement it is envisaged that a cut of approximately 270° can be created by the blade 50 alone.
In some situations and locations a tote bin is filled at a site and is supplied to a customer without a valve being attached. In these cases there is a second spigot on the liner to allow the liner to be filled, but not emptied. In this situation a spigot 2 is used as an outlet only, and will be provided with a hermetically sealed membrane 6 . The spigot 2 may be covered by a cap or other protective covering.
Once at the end users site, the user attaches a valve 20 (or if a valve is already attached but the spigot 2 has not had its hermetic seal broken), the operator connects a sterilising/cutting/emptying assembly (similar or the same as sterilising/cutting/filling assembly 78 except that transfer tube 81 is used to draw the product away). In this way the exposed valve internals and the membrane can be sterilised first, then the cutter passed through the membrane to allow product to flow from the liner through the valve 20 . Once this is done the food or other product in the tote bin can be emptied therefrom.
Otherwise if the membrane is cut at the filling location, once the liner is filled, the butterfly valve is closed and in the region adjacent the union 28 , a wad may be located which will include a germicide, so as to keep sterile any product which may leak through the valve or may be caught on the wrong side of the butterfly valve member 22 . Once a wad is in position, an end cap is placed on the union 28 . When a tote bin prepared in this way arrives at the end user's site, the end user will remove the end cap and wad (if it is present) and then will connect a sterilising/cutting/emptying assembly (similar to assembly 78 ) to sterilise, cut the membrane and empty the tote bin.
If desired instead of rotating the blades 48 and 50 to cut the membrane 6 , the cutter 40 can simply be pushed through the membrane to form two C-shaped cuts as illustrated in FIG. 9 . These will be hinged to the main body of the membrane through a land which is connected at one location on the held membrane and at another diametrically opposite location.
The two C-shaped cuts will form two D-shaped flaps (see FIG. 9 ). These D-shaped flaps will not provide as big an opening as a single land (approximately some 33% in a 50 mm diameter spigot 2 ) and under normal circumstances this reduction would be a restriction in the flow path. To remove the restriction, a larger spigot 2 and larger inlet end to valve 20 could be provided to compensate for the reduction in the size of the opening. Such a valve 20 with a larger inlet end may terminate in a union 28 which is the standard 50 mm DIN union, or it may be a larger union if desired.
If desired, the blades 48 and 50 could be replaced by a single blade mounted on a rotatable arm which is attached to a rotation device so as to rotate the arm and the cutters. Such a single cutter can be in the form of a blade (see item ( 5 ) in FIG. 8 ) or a pointed spike (see item ( 4 ) in FIG. 8 ) for insertion into the membrane and rotated through an arc within the confines of the opening provided by one half of the butterfly valve. Once the cut or slit is scribed, formed, sheared or made into the membrane 6 , the single cutter is retracted then inserted into the membrane 6 , through the other opening on the other side of the butterfly valve member 22 . The single blade is then rotated in an arc and withdrawn. Two C-shaped cuts providing D-shaped flaps will result, such as that illustrated in FIG. 9 .
In another variation, the single blade 50 (see item ( 1 ) in FIG. 8 ) can be provided onto a base 42 . The blade 50 can be inserted into the membrane 6 and then rotated part of the way then retracted and inserted into the other side of the opening provided by the butterfly valve member 22 . The blade 50 can then be rotated the rest of the way to produce a flap connected to a membrane connected to the rest of the membrane by means of a single land.
In the embodiments described above which produce two D-shaped flaps, the D-shaped flaps as illustrated in FIG. 9 are hinged to a rectangular section 93 of membrane material. The rectangular section 93 connects to the radially outer part of the membrane 6 via two lands 91 and 92 located at either end of the rectangular section 93 .
If desired, the membrane 6 can be provided with a line of weakness 90 (as illustrated in FIG. 9 ) adjacent or at the land 91 . The D-shaped flaps hinge to the rectangular section 93 of membrane material between the lands 91 and 92 . In use the line of weakness 90 will break once the product begins to flow out of or into the liner. This will remove the restriction which would be otherwise present. By breaking at a line of weakness 90 , it ensures that the rectangular section 93 will not break simultaneously at two locations. Such simultaneous breakage risks the complete separation of the cut portion of the membrane 6 , with the risk that complete separation will mean that the cut portion of the membrane will be inadvertently included in a manufacturer's final product.
In the preferred embodiment there is only one spigot 2 in the liner, and through which the tote bin is filled and emptied. However, in some arrangements, the valve 20 and spigot 2 are used only as an emptying port, near to the lowest point of the tote bin. In these arrangements the liner may have a filling point at another location which may or may not be formed with a spigot 22 , and then sealed after filling.
The cutter shapes illustrated in FIG. 7 are those that can form two slits simultaneously with axial movement only. Other cutters are indicated in FIG. 8 .
All the cutters illustrated in FIG. 8 are designed to cut one section of membrane at a time, through the openings provided by the butterfly valve member. They will require retraction from the membrane portion first cut and then rotational movement to move to the other opening provided by the butterfly valve member 22 . Once adjacent the other opening, the respective cutters are moved axially to re-engage the membrane 6 and then rotated yet again, to complete the slit.
The cutters of items ( 2 ) and ( 3 ) of FIGS. 7 and 8 , produce a D-shaped flap that connects to the rectangular section 93 of FIG. 9 by a much smaller hinge than that provided by the cutters of item 1 of FIG. 7 or 8 . The helical cutter of item ( 6 ) of FIG. 8 works by both a rotation and axial movement.
In the above preferred and illustrated embodiment, the membrane 6 is heat sealed to the flange 8 by means of an annular band 10 of heat seal. While in the preferred embodiment this heat seal 10 is approximately 3 mm wide, such a heat seal 10 will be more than adequate if placed outside of or under the seal 36 on the valve 20 , when the valve and the spigot 2 are connected.
If desired, the whole of the area 12 can also be heat sealed, with the seal 36 bearing against the membrane. That is all of the outwardly facing surface area of the flange 8 , being that area which will engage the flange 30 of the valve 20 , can be heat sealed to the membrane 6 .
Further, providing sufficient width of heat seal 10 is provided, the heat seal 10 could be located on the flange 8 within the area bounded by the seal 36 . Even though heat and pressure may influence the heat seal 10 of the membrane 6 to the flange 8 , if sufficient surface area is provided then the softening that may occur will not be acting long enough to damage the connection between the membrane 6 and the flange 8 . The exact width of the heat seal 10 will, it is envisaged, be greater than 3 mm. It is expected that a heat seal 10 having a width of some 8 to 10 mm may be sufficient.
It will be understood that the invention disclosed and defined herein extends to all alternative combinations of two or more of the individual features mentioned or evident from the text or drawings. All of these different combinations constitute various alternative aspects of the invention.
The foregoing describes embodiments of the present invention and modifications, obvious to those skilled in the art can be made thereto, without departing from the scope of the present invention. | A tote bin liner has a transfer spigot ( 2 ) through which product may be introduced into or emptied from the liner. The transfer spigot has a membrane ( 6 ) which seals the interior of the liner. The membrane is sealed to the spigot on an outer face ( 11 ) of the spigot which is configured so that the membrane will be clamped in position during piercing of the membrane by a cutter. The invention extends to a cutter assembly for use with a tote bin liner. The cutter assembly ( 40 ) may be adapted to be moved past a valve closure member ( 22 ) for the valve ( 20 ), the assembly furthermore including an arrangement ( 78 ) for sterilising the interior of the valve and the outer face of the membrane, and an actuator ( 43 ) for moving the cutter in order to pierce the membrane. | 1 |
BACKGROUND OF THE INVENTION
0. Definitions Used
Refrigeration Systems: can also include Heat Pumps and Combination Refrigeration and Heat Pump Systems
Refrigerator: can include the alternative appliances, Refrigerator/Freezer or Freezer, in appropriate contexts
Enclosure Heat Exchanger: Heat Absorber In Refrigeration Systems, Heat Supplier In Heat Pumps, Either Or Both In Combination Refrigeration/Heat Pump Systems
Surroundings Heat Exchanger: Heat Suppliers In Refrigeration Systems, Heat Absorbers In Heat Pumps
Heat Absorbers: Evaporators In Vapor Compression Systems And Absorption Systems, Cold Plates In Solid State Systems
Heat Suppliers: Condensers In Vapor Compression Systems, Refrigerant Absorbers In Absorption Systems, Hot Plates In Solid State Systems
1. Field of the Invention
The present invention relates to improved refrigeration systems, and specifically to reducing net operating costs, by increasing the effectiveness of Enclosure Heat Exchangers and, specifically in residential type refrigerators, by recovering the reject heat for heating water.
2. Prior Art
Refrigeration Systems are used for maintaining the contents of enclosed spaces at temperatures below or above the temperature of the surroundings. In some cases the functions of refrigeration and heat pumping are combined to keep the contents of one or more enclosed spaces at relatively low temperatures while also keeping the contents of one or more other enclosed spaces at relatively high temperatures. The objective is frequently to delay deterioration of the contents of the enclosed space, to maintain enclosed spaces at comfortable temperatures for occupation by humans or other animals, or to adjust the temperature of materials in preparation for use.
In the past the contents of the enclosed spaces have been maintained, at the desired temperatures, by Enclosure Heat Exchangers which exchange heat with the contents of the enclosed space. Said heat transfer is required to counteract heat which is transferred (by conduction, convection or radiation) through the enclosing walls, which are normally insulated, in addition to heat transferred along with material exchanged between the surrounding space and the enclosed space and heat generated or absorbed within the enclosed space (e.g. by chemical reaction).
Frequently the contents of said enclosed spaces include gasses, such as air, and the heat is frequently exchanged between the Enclosure Heat Exchangers and said gasses. Except during upset conditions there is frequently little or no net exchange of heat between the gaseous contents and the other contents because their temperatures tend towards equality at equilibrium.
The heat transfer coefficients between heat exchange surfaces, such as the surfaces of said Enclosure Heat Exchangers, and gasses are very low, as is well known to workers in the heat transfer field. Since the heat flow rate is approximately proportional to the product of said coefficient, the heat exchange area, and the temperature differential, it is necessary for the refrigerating means to depress or maintain the temperature of said enclosure heat exchanger so as to maintain a large temperature differential in order to drive the heat exchange between Enclosure Heat Exchangers and gaseous contents. The alternative of providing large heat transfer surfaces is limited by cost and available space. The maintenance of said large temperature differentials, for heat transfer, results in large differences between the temperatures of the Heat Supplier and the Heat Absorber of the Refrigeration System. As is well known to workers in the field of refrigeration, the efficiency of Refrigeration Systems increase as said temperature differences decrease. Consequently the maximum achievable efficiency of the Refrigeration System is very substantially affected by the fact that the heat load must be transferred between said gas and said Enclosure Heat Exchanger.
Typical residential refrigerators operate with heat absorber temperatures about 25° F. below the temperature of the freezer compartment and about 60° F. below the temperature of the storage cabinet. Previous efforts to reduce the effect, of said low heat transfer coefficients, on efficiency, have included the use of large and/or extended surface heat absorbers and suppliers, and forced circulation, of the gaseous contents, across the heat exchange surfaces, to increase coefficients and maintain localized temperature differentials. The use of separate refrigeration systems, for the freezer and cabinet, has been practiced by Schlussler, of Sun Frost, Arcata, Calif., to reduce the temperature difference between the storage cabinet's Heat Supplier and Heat Absorber.
Numerous other efforts have been directed towards reduced energy requirements.
These include insulation improvements, defrost cycle improvements, and compressor and fan efficiency improvements. These also tend to indirectly reduce the effect of the low heat transfer coefficients by reducing the heat load which must be transferred across the available heat exchange surface. In HVAC applications the use of variable speed high efficiency compressors and fans, and alternative heat sinks and/or reservoirs including water and the ground have been applied. Tyree (U.S. Pat. No. 4,498,306) has described a system, including enclosing means, for goods to be transported in a space to be maintained at depressed temperatures, enclosed by said enclosing means which uses means superficially similar to the present invention. Tyree describes tubes, set into the walls of transports, and attached to thermally conductive strips. Heat entering the transport through the insulated walls is "intercepted" by said strips. The heat transferred to said tubes causes refrigerant inside said tubes to evaporate. By thermosyphon, said heat is transferred to solid carbon dioxide or liquid nitrogen etc., which evaporates and is vented, thus discarding said heat to the atmosphere. Tyree's worthy objective is to control the temperature and provide uniform temperatures throughout said transport. Tyree's invention does not achieve improvement in efficiency by use of envelopment except in some extremely limited circumstances. The amount of heat absorbed by the enveloping strips and tubes is not significantly less than that which would be absorbed by a heat exchanger immersed in the atmosphere of the transport, and the amount of carbon dioxide or nitrogen evaporated is proportional to the amount of heat absorbed. Although an "immersed" type heat exchanger might have to operate at a lower temperature than would the enveloping system of strips and tubes the amount of carbon dioxide or nitrogen evaporated is not reduced as a result. The said limited circumstances in which Tyree's invention results in (the equivalent of) improved efficiency comprise circumstances where the temperature desired for the enclosed space is very slightly more than the minimum evaporation temperature of a relatively inexpensive substance such as carbon dioxide. Using Tyree's invention it is possible to achieve said desired temperature by evaporating the less expensive substance while said "immersed" type heat exchanger, which may have to operate at a lower temperature, may require that a lower boiling substance, such as liquid nitrogen be evaporated. Assuming solid or liquid carbon dioxide to be available at a lower cost per unit heat of evaporation, then Tyree's invention would result in the financial equivalent of improved efficiency relative to a heat exchanger immersed in the contents of the transport, under these, and similar, limited range circumstances.
Use has also been made of evaporator tubes, buried in the walls of refrigerator cabinets, to reduce frosting by ensuring that the cooling of the contents of the cabinet, which are frequently maintained slightly above the freezing temperature of water, does not all have to be accomplished by contacting them with a surface which is at a temperature below the freezing temperature of water. However, since this objective was accomplished without also raising the evaporator temperature, efficiency was not increased except possibly by reducing the effect on efficiency of the insulating layer of frost.
Although the above referenced contributions have improved the performance of refrigeration systems, and in some cases have increased efficiency, or in other ways reduced operating costs, none of them have achieved or fulfilled the objectives of the present invention; one of which is to reduce operating costs, by reducing the temperature difference between the heat supplier and the heat absorber, by reducing the temperature differentials required for heat transfer, by use of Enveloping Enclosure Heat Exchangers; and the second of which is by the recovery of the reject heat, specifically, from residential type refrigerators for use in meeting residential type requirements for hot water.
SUMMARY OF THE INVENTION
One objective of the present invention is to increase the efficiency of Refrigeration Systems by reducing the difference between the operating temperature of the Heat Supplier and the operating temperature of the Heat Absorber, said reduction in temperature difference being achieved; by reducing the temperature differentials, required for heat transfer between the contents of the enclosure and the Enclosure Heat Exchanger; which is achieved by shaping and positioning said Enclosure Heat Exchanger so as to envelop or largely envelop the enclosed space. The primary benefit of said feature is that those parts of the heat load, which are transferred (by conduction, convection or radiation) through the enclosing walls, are exchanged directly, thus reducing the amount of heat which must be transferred between the contents of the enclosed space and the Enclosure Heat Exchanger. The secondary benefit of said feature, is the provision of additional, relatively inexpensive and unobtrusive, heat transfer surface between the contents of the enclosed space and the Enclosure Heat Exchanger, said heat transfer surface being rendered relatively inexpensive and unobtrusive because the heat transfer material also serves as part of the enclosing wall. A further objective, specifically regarding residential type refrigerators, is to reduce net overall operating costs for refrigeration and water heating by recovering refrigerators' reject heat for heating water.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a process flow schematic of a refrigeration system, with a largely enveloping Enclosure Heat Exchanger.
FIG. 2 is a process flow schematic of a heat pump system, with a largely enveloping Enclosure Heat Exchanger.
FIG. 3 is a process flow schematic of a combination refrigeration/heat pump system, with largely enveloping Enclosure Heat Exchangers.
FIG. 4 is a process schematic of a combination system for using reject heat from a refrigerator for heating water using a non-enveloping heat supplier, and convective circulation.
FIG. 5 is a process schematic of a combination system for using reject heat from a refrigerator for heating water using a partially enveloping heat supplier.
FIG. 6 is a process schematic of a combination system for using reject heat from a refrigerator for heating water using a largely enveloping heat supplier.
DETAILED DESCRIPTION
As shown in FIG. 1, the present invention includes an improvement; to the refrigeration process, by which the contents of an enclosed space 2, separated from its surroundings, are maintained at a temperature Tc° which is less than T° the temperature of the surroundings; said IMPROVEMENT COMPRISING CONSTRUCTION OF THE HEAT ABSORBER 1 SO AS TO ENVELOP, OR LARGELY ENVELOP, SAID ENCLOSED SPACE, instead of as a heat exchanger immersed in said contents, which increases the efficiency of said refrigeration process; due to effecting the reduced difference between the operating temperatures of the heat supplier and said heat absorber; afforded by the reduction in temperature difference, required to drive the transfer of heat from said contents to said heat absorber; permitted firstly by the reduction in the amount of heat needing to be so transferred, because said enveloping, or largely enveloping, heat absorber intercepts much of the heat entering the enclosure, through containing walls of said enclosure (by means comprising conduction, convection or radiation), said intercepted heat then not contributing to that which is transferred both from said surroundings to said contents and from said contents to said heat absorber, and permitted secondly by the relatively inexpensive, and unobtrusive, increase in heat transfer surface between said contents and said heat absorber, afforded by the enveloping, or largely enveloping, heat absorber being also the liner of said enclosure.
Heat Absorber 1, is maintained at a temperature Tao, which is less than Tc° if envelopment is partial but which could be almost equal to Tc° if envelopment is almost complete.
The enclosure, comprising said Heat Absorber 1 and any sealing material (not shown or numbered in the drawing) which may be necessary to fill any gaps if the envelopment is less than complete, is surrounded by thermal insulation 3.
A Heat Supplier 8, which is immersed in the surroundings, or a heat sink, is maintained at a temperature Ts°, which is greater than the temperature Tsn° of the heat sink.
Heat 12 is transferred from the surroundings 20, through the insulation, directly to the Heat Absorber 1 under the influence of the temperature differential (T°-Ta°). If the envelopment is less than complete then heat 13 is transferred from the surroundings 20 to the contents of the enclosed space 2 under the influence of the temperature differential (T°-Tc°), and from said contents to the Heat Absorber 1 under the influence of the temperature differential (Tc°-Ta°). Heat 11, the sum of heat 13 and heat 12, is the total heat absorbed by the Heat Absorber.
Heat 18 is transferred from the Heat Supplier 8 to the heat sink under the influence of the temperature differential (Ts°-Tsn°). In order to maintain the temperature difference (Ts°-Ta°) energy is supplied to the Refrigeration System at 9.
Since the amount of heat 13, is less than it would be if the Heat Absorber 1 was replaced by a Heat Absorber of the type which is immersed in the contents of the enclosed space, and since the heat transfer area in contact with the contents of the enclosed space, is almost equal to the entire inside area of the lining of the enveloped part of the enclosure, and therefore usually greater than that of a Heat Absorber of said "immersed" type, the temperature differential (Tc°-Ta°) is much less than it would be if a Heat Absorber of said "immersed" type was used. Consequently the temperature difference (Ts°-Ta°) is less than it would be if a Heat Absorber of said "immersed" type was used. Consequently the energy input required at 9 to maintain said temperature difference (Ts°-Ta°) is less than it would be if a Heat Absorber of said "immersed" type was used.
As shown in FIG. 2, the present invention also includes an improvement; to the heat pumping process, by which the contents of an enclosed space 6, separated from its surroundings, are maintained at a temperature Th°, which is greater than T° the temperature of the surroundings; said IMPROVEMENT COMPRISING CONSTRUCTION OF THE HEAT SUPPLIER SO AS TO ENVELOP, OR LARGELY ENVELOP, SAID ENCLOSED SPACE, instead of as a heat exchanger immersed in said contents, which increases the efficiency of said heat pumping process; due to effecting the reduced difference between the operating temperatures of said heat supplier and the heat absorber; afforded by the reduction in temperature difference, required to drive the transfer of heat to said contents from said heat supplier; permitted firstly by the reduction in the amount of heat needing to be so transferred, because said enveloping, or largely enveloping, heat supplier supplies directly much of the heat escaping from the enclosure, through containing walls of said enclosure (by means comprising conduction, convection or radiation), said directly supplied heat then not contributing to that which is transferred both to said surroundings from said contents and to said contents from said heat supplier, and permitted secondly by the relatively inexpensive, and unobtrusive, increase in heat transfer surface between said contents and said heat supplier, afforded by said enveloping, or largely enveloping, heat supplier being also the liner of said enclosure.
Heat Supplier 5, is maintained at a temperature Ts°, which is greater than Th° if envelopment is partial but which could be almost equal to Th° if envelopment is almost complete.
The enclosure, comprising said Heat Supplier 5 and any sealing material (not shown or numbered in the drawing) which may be necessary to fill any gaps if the envelopment is less than complete, is surrounded by thermal insulation 7.
A Heat Absorber 4, which is immersed in the surroundings, or a heat reservoir, is maintained at a temperature Tao, which is less than the temperature Tr° of the heat reservoir. Heat 16 is transferred to the surroundings 20, through the insulation, directly from the Heat Supplier 5 under the influence of the temperature differential (Ts°-T°). If the envelopment is less than complete then heat 17 is transferred to the surroundings 20 from the contents of the enclosed space 6 under the influence of the temperature differential (Th°-T°), and to said contents from the Heat Supplier 5 under the influence of the temperature differential (Ts°-Th°). Heat 15, the sum of heat 16 and heat 17, is the total heat supplied by the Heat Supplier.
Heat 14 is transferred to the Heat absorber 4 from the heat reservoir under the influence of the temperature differential (Tr°-Ta°).
In order to maintain the temperature difference (Ts°-Ta°) energy is supplied to the Heat Pumping System at 9.
Since the amount of heat 17, is less than it would be if the Heat Supplier 5 was replaced by a Heat Supplier of the type which is immersed in the contents of the enclosed space, and since the heat transfer area, in contact with the contents of the enclosed space, is almost equal to the entire inside area of the lining of the enveloped part of the enclosure, and therefore usually greater than that of a Heat Supplier of said "immersed" type, the temperature differential (Ts°-Th°) is much less than it would be if a Heat Supplier of said "immersed" type was used. Consequently the temperature difference (Ts°-Ta°) is less than it would be if a Heat Supplier of said "immersed" type was used. Consequently the energy input required at 9 to maintain said temperature difference (Ts°-Ta°) is less than it would be if a Heat Absorber of said "immersed" type was used. As shown in FIG. 3, the present invention also includes an improvement; to the combination refrigeration/heat pumping process, by which the contents of an enclosed space 2, separated from its surroundings, are maintained at a temperature Tc° which is less than T° the temperature of the surroundings, while the contents of another enclosed space 6, separated from its surroundings, are maintained at a temperature Th° which is greater than T° the temperature of the surroundings; said IMPROVEMENT COMPRISING CONSTRUCTION OF BOTH, OR EITHER, THE HEAT ABSORBER AND HEAT SUPPLIER SO AS TO ENVELOP, OR LARGELY ENVELOP, THEIR RESPECTIVE ENCLOSED SPACES, instead of as heat exchangers immersed in said contents, which increases the efficiency of said refrigeration/heat pumping process; due to effecting the reduced difference between the operating temperatures of the heat supplier and the heat absorber; afforded by the reduction in temperature differences, required to drive the transfer of heat between said contents and said Enclosure Heat Exchangers; permitted firstly by the reduction in the amount of heat needing to be so transferred, because said enveloping, or largely enveloping, heat exchangers exchange heat directly with the surroundings, through containing walls of their respective enclosures (by means comprising conduction, convection or radiation), said directly exchanged heat then not contributing to that which is exchanged both between said surroundings and said contents and between said contents and said heat exchangers, and permitted secondly by the relatively inexpensive, and unobtrusive, increase in heat transfer surface between said contents and said heat exchangers, afforded by said enveloping, or largely enveloping, heat exchangers being also the liners of said enclosures. Heat Absorber 1, is maintained at a temperature Tao, which is less than Tc° if envelopment is partial but which could be almost equal to Tc° if envelopment is almost complete.
Heat Supplier 5, is maintained at a temperature Ts°, which is greater than Th° if envelopment is partial but which could be almost equal to Th° if envelopment is almost complete.
The enclosure, comprising said Heat Absorber 1 and any sealing material (not shown or numbered in the drawing) which may be necessary to fill any gaps if the envelopment is less than complete, is surrounded by thermal insulation 3.
The enclosure, comprising said Heat Supplier 5 and any sealing material (not shown or numbered in the drawing) which may be necessary to fill any gaps if the envelopment is less than complete, is surrounded by thermal insulation 7.
Heat 12 is transferred from the surroundings 20, through the insulation, directly to the Heat Absorber 1 under the influence of the temperature differential (T°-Ta°). If the envelopment is less than complete then heat 13 is transferred from the surroundings 20 to the contents of the enclosed space 2 under the influence of the temperature differential (T°-Tc°), and from said contents to the Heat Absorber 1 under the influence of the temperature differential (Tc°-Ta°). Heat 11, the sum of heat 13 and heat 12, is the total heat absorbed by the Heat Absorber.
Heat 16 is transferred to the surroundings 20, through the insulation, directly from the Heat Supplier 5 under the influence of the temperature differential (Ts°-T°). If the envelopment is less than complete then heat 17 is transferred to the surroundings 20 from the contents of the enclosed space 6 under the influence of the temperature differential (Th°-T°o), and to said contents from the Heat Supplier 5 under the influence of the temperature differential (Ts°-Th°). Heat 15, the sum of heat 16 and heat 17, is the total heat supplied by the Heat Supplier.
To maintain the temperature difference (Ts°-Ta°) energy is supplied to the Combination Refrigeration/Heatpumping System at 9. Since the amounts of heats 13 and 17, are less than they would be if the Enclosure Heat Exchangers 1 and 5 were replaced by "immersed" type exchangers, and since the heat transfer areas in contact with the contents of said Enclosure Heat Exchangers 1 and 5 are almost equal to the entire inside areas of the lining of the enveloped parts of their respective enclosures, and therefore usually greater than those of "immersed" type exchangers, temperature differentials (Ts°-Th°) and (Tc°-Ta°) are less than they would be if exchangers of said "immersed" type were used. Consequently the temperature difference (Ts°-Ta°) is less than it would be if exchangers of said "immersed" type were used. Consequently the energy input required at 9 to maintain said IS temperature difference (Ts°-Ta°) is less than it would be if exchangers of said "immersed" type were used.
As indicated in FIGS. 1 and 2 the function of the heat sink or heat reservoir may, in some cases, be performed by the surroundings. If so Tsn° or Tr° respectively=T°.
In the drawings:
"Refrigeration System" can be: Either a vapor compression system, in which case the energy input at 9 is compression work, 10 is an expansion orifice or other pressure reducer and the heat absorber and supplier are an evaporator and a condenser respectively. Or an absorption system, in which case the energy input shown at 9 depicts the net effect of heat supplied to the generator and heat removed at the absorber, and the heat absorber and supplier are refrigerant evaporator and condenser. respectively. Or a solid state refrigeration system, otherwise known as a thermoelectric refrigeration system, in which case the energy input shown at 9 depicts the electrical energy supplied to the system, and the heat absorber and supplier are cold and hot plates, comprising the cold and hot junctions respectively, of said thermoelectric refrigeration system respectively. The invention can also be used with other refrigeration cycles.
As shown in FIGS. 4, 5 and 6, the present invention also includes, specifically in regard to residential type refrigerators, the recovery of the reject heat for use in heating, and maintaining the temperature of water to meet associated residential type requirements for hot water, said reject heat being frequently well coordinated in amount, temperature, location, and operating cycle, with said water requirements.
Preferred Embodiments of the present invention are numerous and include the following:
Preferred Embodiment Number 1
A vapor/compression refrigerator, suitable for residential or similar use, with evaporator (heat absorber) constructed so as to envelop the enclosed space of each compartment on five, more-or-less, of the six faces (each of the enclosures being approximately cuboidal in shape). The small increase in efficiency due to enveloping the door (i.e. the sixth face of the cuboid) would, in most cases, be outweighed by additional construction complexity and therefore cost), but if necessary this could be accomplished by use of separate refrigeration systems for the doors or by use of readily available flexible connectors.
Compartments operating at significantly different temperatures, such as the freezer and storage cabinets should preferably be served by separate evaporator/compressor/expansion valve systems but this is not essential and not a claim of the present disclosure. The largely enveloping evaporators, in this embodiment, are constructed of two layers of sheet metal, such as steel, copper, stainless steel or aluminum, forming a double wall and joined together by a triangular pitched matrix of resistance welds, and a continuous weld to seal the edges, to contain the pressure of the refrigerant. Five, more-or-less, faces of the inner lining of each compartment are constructed in this way. Each of the faces could be constructed separately and then assembled into five faces of a cuboid but it might be better to construct two approximate cuboids each with one face missing, insert one inside the other and then join the two together to form a single double walled cuboid with one face missing. Typically a gap of 0.01 inch between the two layers of the double wall is adequate. Smaller gaps, down to 0.001 inch (or even less), could be adequate for some heat loads or with independent distribution systems but needs for gaps smaller than 0.001 inch are not likely to be encountered in practice. Larger gaps, up to about 0.2 inch (or even larger), could be used but needs for gaps larger than 0.2 inch are not likely to be encountered in practice.
Such evaporators, when equipped with properly sized compressors and expansion valves, will normally operate at temperatures within about 1° F. below that of the contents of the enclosed space, and will therefore consume less work for compression than conventional "immersed" evaporators operating at temperatures about 25° F. below that of the contents of the enclosed space. Specific action, necessary to effect the energy savings made possible by constructing the heat absorber so as to largely envelop the enclosed spaces by reducing the temperature difference between heat supplier and heat absorber substantially to the minimum value at which the given insulated enclosure, heat absorber and heat supplier, being surrounded by the given surroundings at given temperature, in the absence of other heat absorbers and in the absence of other heat suppliers, could maintain the given space at the given depressed temperatures, can comprise; constructing and operating the refrigerating device to operate at rates which do not substantially exceed needs; in a vapor compression system, constructing and operating the compressor to operate at displacement rates which do not substantially exceed needs; in an absorption systems constructing and operating the generator to be heated at rates which do not substantially exceed needs; or in a thermoelectric system, constructing and operating the hot and cold junctions to operate with electromotive forces which do not substantially exceed needs. An electrically powered refrigerator equipped with largely enveloping evaporators and properly sized compressors and expansion valves, consumes about 30% less electricity for compression than an otherwise similar electrically powered appliance equipped with conventional "immersed" type evaporators and properly sized compressors and expansion valves, both appliances being equipped with separate evaporators, compressors and expansion valves for each compartment, and typically equipped with doors, controls and insulation. This is, of course, only an approximation. The actual improvement depends on the case in question.
Each of the two compartments of Embodiment Number 1 would be similar to the apparatus depicted in FIG. 1, with the unenveloped side of the rectangle representing the door and the three enveloped sides representing the other five, more-or-less, faces of the compartment. The two compartments could be stacked one on top of the other or side by side. Except for the Heat Suppliers, all of the equipment depicted in FIG. 1 could be located inside the appliance's outer casing in the usual way. The Heat Supplier could be mounted on the back, top or underneath of said casing. Variations on these detailed locations are possible.
Preferred Embodiment Number 2
A vapor/compression heat pump, suitable for maintaining the contents of a residence, or similar structure, at about 70° F., with condenser (Heat Supplier) constructed so as to largely envelop the enclosed space on the inside surface of all or most of the outside walls and ceilings. Appropriate gaps are provided for windows and doors.
Apart from obvious differences in geometry, and the fabrication techniques used for construction of residences as opposed to kitchen appliances, the details of construction would be similar to those in Embodiment Number 1.
The structure, of Embodiment Number 2, would be similar to the apparatus depicted in FIG. 2, with the unenveloped side of the rectangle representing numerous doors, windows and other openings and possibly the ground floor, which might not need to be enveloped in some circumstances. The three enveloped sides representing the parts of the outside walls and ceilings which are enveloped. Except for the Heat Absorber, all of the equipment depicted in FIG. 2 could be located inside the structure but it is more usual to locate the compressor 9 outside. The Heat Absorber would usually be located outside of the structure.
Variations on these detailed locations are possible.
As is common practice the heat pump cycle could be reversed to provide refrigeration of the structure when necessary.
The Enclosure Heat Exchangers could be constructed as double walled panels very similar to those described for Embodiment Number 1 but formation of a single, double walled, cuboidal module is likely to be limited to prefabricated structures such as mobile homes and vending kiosks. For site built frame structures and many other types of structure it may be preferable for the Enclosure Heat Exchangers to be constructed as standard size panels similar in size to common building lining materials such as sheet rock or decorative panelling. In some cases the flow path for refrigerant through such panels could be much longer relative to flow cross sectional area, which could necessitate wider gaps, between the two walls of the Enclosure Heat Exchanger panels, than for comparable appliance panels. Even so these gaps will not be large enough to be prohibitive.
Preferred Embodiment Number 3
The reject heat from a residence's refrigerator is used to raise and maintain the temperature of water, to meet the residence's requirements for hot water.
The amount and temperature of heat typically rejected from a residence's refrigerator frequently closely match the amount and temperature of heat required for heating the residence's water requirements for bathing and washing etc. Also the refrigerator and the hot water tank are frequently located close to each other, or if not can frequently be so located. Also the operating cycles of the refrigerator and the hot water tank are frequently compatible. In order to optimize the benefits of this embodiment, the provision of a larger than average hot water tank may prove desirable in some cases, so that the refrigerator's reject heat can slowly heat up the entire working volume of water in the tank over a 24 hour period.
Excess heat may be available under some circumstances and may be discarded through a refrigerant-to-air or hot water-to-air heat exchanger, or by numerous other means many of which are well known. Extra heat may be required under some circumstances and may be provided by conventional means.
The temperature of the hot water system may be maintained, and heat may be supplied to the water, by heat exchangers which may be of largely "enveloping" design, as depicted in FIG. 6 or of other designs, as depicted in FIGS. 4 and 5 for example. Thermal contact may be through a single layer of heat conducting material (not illustrated) or through two layers of heat conducting material separated by a gap, which may be open to atmosphere to preclude cross contamination and to facilitate independent portability and operation, as depicted in FIGS. 4 through 6. The overall thermal efficiency tends to increase as the degree of envelopment increases. That is; the total quantity of energy which must be supplied (1.) to drive the refrigeration system and (2.) to heat the water tends to decrease as the degree of envelopment is increased, although the relative requirements for refrigeration and water heating may, in some circumstances, negate this otherwise advantageous tendency. In this embodiment the refrigerator's Heat Absorber is of the enveloping type. The Heat Suppliers (8 in FIGS. 4 and 5, and 5 in FIG. 6) panels could be constructed similarly to those used for Heat Absorbers, as described in Embodiment Number 1. The Heat Suppliers 8 in FIGS. 4 and 5, could be constructed as vertical panels which would be mounted face to face with the water side heat receiving panels which would be sized, shaped, and located so as to readily mate with the Heat Suppliers. Those shown as item 5 in FIG. 6 would usually be formed as a pair of semi-cylindrical panels fabricated to envelop the vertical cylindrical sides of a typical hot water tank.
Preferred Embodiment Number 4
Residential, or similar, TYPE systems, as described in Embodiment Number 3 applied to non-residential situations such as hotels, schools, offices, hospitals, trains, boats and planes.
Preferred Embodiment Number 5
The use of refrigerators' reject heat, much as described in Embodiment Numbers 3 and 4 for refrigerators equipped with enveloping Heat Absorbers, but for conventional refrigerators equipped with "immersed" type Heat Absorbers.
The energy savings, resulting from recovery of refrigerators' reject heat for water heating, are frequently substantially greater than the energy savings, resulting from adoption of the enveloping heat absorber for the associated refrigerators. Opportunities to exploit the former may be encountered even when the latter cannot be economically justified, and vice versa of course.
Preferred Embodiment Number 6
Improvements, as described for Preferred Embodiments 1-5 and 9, but in which the materials of construction of the Enclosure Heat Exchangers and/or the other Heat Exchangers are not limited to metals. Materials of construction must be compatible with the refrigerants and/or other materials contacted, at expected temperature and pressures. High thermal conductivity is a less critical requirement for "enveloping" type heat exchangers because they are installed so as to avoid large heat flows across gas to exchanger interfaces. Certain plastic or ceramic materials may be found to be suitable for "enveloping" type heat exchangers even though they may not be suitable for "immersion" type heat exchangers.
Preferred Embodiment Number 7
Improvements, as described for Preferred Embodiments 1-6 and 8, but in which the heat exchanger walls are joined by fastening systems other than resistance welding. Such systems include soldering, brazing, arc and torch welding, riveting, bolting and screwing systems.
Preferred Embodiment Number 8
Improvements, as described for Preferred Embodiments 1-7, but in which the heat exchanger walls fasteners are located in patterns other than triangular pitch.
Preferred Embodiment Number 9
Improvements, as described for Preferred Embodiments 1-8, but in which other types of hollow wall construction are used to build the heat exchangers. Such systems include tube wall construction and tubes connected together by thermally conducting strips as described by Tyree in U.S. Pat. No. 4,498,306.
Notes on the Preferred Embodiments in general
In the drawings and Preferred Embodiments reference to some components, which are common to the prior art and the present invention, have been omitted. Kitchen appliances require outer cabinets, protective coatings and other components, and residential type structures require weather protection, doors, windows and numerous other components.
The foregoing descriptions of the Preferred Embodiments of the invention have been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed, Many modifications and variations are possible in light of the above teaching, It is intended that the scope of the invention be limited not by this detailed description, but rather by the claims appended hereto. | In refrigeration; in order to transfer heat from the heat supplier, or to the heat absorber, it is necessary that temperature gradients be maintained between said heat exchangers and the interacting medium. These temperature gradients increase the difference between the temperature of the heat supplier and that of the heat absorber. The efficiency of refrigeration systems decrease as said temperature differences increase. Said mediums, if gaseous, as they frequently are, offer great resistance to heat transfer. This results in large temperature gradients and substantially reduces refrigeration efficiency. The present invention involves enveloping the enclosed space with the enclosure heat exchanger so that less heat has to be transferred through the gaseous contents, and additional, inexpensive, heat transfer surface becomes available. The reduction in temperature gradients result in increased efficiency.
Recovery of reject heat for residential type water heating is also included as a natural extension. | 5 |
BACKGROUND OF THE INVENTION
[0001] 1. Technical Field of the Invention
[0002] This invention relates to control systems and methods for controlling inverter based electrical power generation and feeding of generated power to a grid. This invention particularly relates to an integrated control system and method that integrates a variety of power control functions including state machine control of distinct operational modes, synronization with the grid, power factor control and utility outage ride-through.
[0003] 2. Description of Related Art
[0004] Various control devices for controlling inverter based electrical power generation are known in the art. Typical controllers utilize analog voltage or current reference signals, synchronized with the grid to control the generated wave form being fed to the grid. Such controllers, however, lack distinct control states and the capability of controlling transitions between specifically defined control states.
[0005] Various techniques for synchronizing the frequency of generated power to the frequency of a grid-are also known in the art. Such conventional line synchronizers typically sense the line frequency of the grid and lock to the grid when the generated frequency drifts into synchronization.
[0006] Such conventional line synchronizers, however, do not have the ability to control the rate of phase shift of the generated power or the ability to interface easily with both 50 Hz and 60 Hz grids.
[0007] Various techniques for controlling the power factor are also known in the art. In the context of electrical power generation, for example, Erdman, U.S. Pat. No. 5,225,712, issued Jul. 6, 1993, discloses a variable wind speed turbine electrical power generator having power factor control. The inverter can control reactive power output as a power factor angle or directly as a number of VARs independent of the real power. To control the reactive power, Erdman utilizes a voltage waveform as a reference to form a current control waveform for each output phase. The current control waveform for each phase is applied to a current regulator which regulates the drive current that controls the currents for each phase of the inverter.
[0008] Although the conventional art may individually provide some of these features, the combination of these features particularly when utilized in conjunction with an integrated system utilizing state machine control is not found in the art.
[0009] Other applications distinct from electrical power generation also utilize power factor control devices. For example, Hall, U.S. Pat. No. 5,773,955 issued Jun. 30, 1998, discloses a battery charger apparatus that controls the power factor by vector control techniques. The control loop utilized by Hall controls power delivery to the battery to obtain a desired charge profile by individually controlling the real and reactive components of the AC input current. The AC input current is forced to follow a reference that is generated in response to information received by the battery charge control circuit to supply the desired charging current to and remove discharge current from a battery.
SUMMARY AND OBJECTS OF THE INVENTION
[0010] An object of the invention is to provide an integrated system for controlling all aspects of inverter based electrical power generation and feeding of generated power to a grid. Another object of the invention is to provide a state machine having a plurality of defined control states for electric power transformation including a state controller that controls permitted transitions between the defined control states.
[0011] Another object of the invention is to provide a line synchronization technique that is highly flexible and permits synchronization with either a 50 Hz or 60Hz grid as well as providing smooth transitioning from a stand-alone mode to a grid-connected mode.
[0012] A further object of the invention is to provide a line synchronization technique that can either sense the grid frequency or synthesize a frequency for electrical power generation.
[0013] Still another object of the invention is to control the re-synchronization rate to provide the smooth transition from stand-alone mode to a grid-connected mode.
[0014] A further object of the invention is to provide a method of controlling an electrical power generator during a utility outage.
[0015] Yet another object of the invention is to integrate the inventive method of utility outage ride-through with various other control techniques to provide an integrated system.
[0016] Still another object of the invention is to provide power factor control over generated electrical power wherein a simple DC control signal having two components commanding the real and reactive components of the generated power may be utilized to control the power factor.
[0017] The objects of the invention are achieved by providing a state machine having a plurality of control states for electric power transformation including an initialization state, a first neutral state, a pre-charge state, a second neutral state, an engine start state, a power on-line state, a power off-line state, and a shut down state wherein the state controller controls state transitions such that only permitted transitions between control states are allowed to occur. In this way, a high degree of control can be achieved for electrical power generating and feeding of electrical power to a grid. In this way, the safety and reliability of the system can be ensured.
[0018] The objects of the invention are further achieved by a method of controlling real and reactive power developed by a main inverter in an electrical power generation control device including the steps of sampling the three-phase currents output from the inverter, transforming the sampled three-phase current data to two-phase current data, transforming the two-phase current data to a rotating reference frame, controlling an output voltage according to a comparison result between a DC reference signal having real and reactive reference signal components, transforming the output voltage to a stationary reference frame, transforming the stationary reference frame output voltage to a three-phase reference signal, and controlling the inverter based on the three-phase reference signal. By utilizing such a control method, the DC reference signal can be input by an operator or a utility feeding the grid to thereby designate the real and reactive power output by the controlled inverter.
[0019] The objects of the invention are further achieved by providing a line frequency synchronization apparatus and method that utilizes a frequency sensor that samples the frequency of the grid or a synthesizer that synthesizes a grid frequency. In the case of sampled grid frequency, the frequency sensor signal is converted by an A/D converter that is controlled by initiating the conversion and reading of the digital value at a fixed frequency. This fixed frequency establishes the time base for which the invention can compute the actual frequency of the signal. This is further accomplished by determining when the falling or rising edge of the signal occurs and counting the number of samples therebetween.
[0020] In this way, a synchronization error signal is generated that can be utilized to bring the generated power into synchronization with a grid or the synthesized grid frequency. Furthermore, the synchronization shift rate is preferably limited in order to provide a smooth transition.
[0021] The objects of the invention are further achieved by providing a utility outage ride-through method and apparatus that detects a fault condition indicating that the electrical power generation device should be disconnected from the grid, opens a contactor that connects the device to the grid, clears a time counter, sets a mode to an off-line mode, commands the inverter within the device to perform off-line voltage control, and waits for a predetermined time period after all fault conditions have been cleared before setting the mode to an on-line current control mode, enabling the inverter and thereafter closing the contactor to reestablish the connection to the grid.
[0022] Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus are not limitative of the present invention, and wherein:
[0024] [0024]FIG. 1 is a high-level block diagram illustrating the major components of a microturbine generator system that may be controlled according to the invention;
[0025] [0025]FIG. 2 is a high-level block diagram of a small grid-connected generation facility which is another example of a generation facility that may be controlled according to the invention;
[0026] [0026]FIG. 3 is a system block diagram of an electrical power generator according to the invention illustrating major components, data signals and control signals;
[0027] [0027]FIG. 4 is a detailed circuit diagram of a line power unit that may be controlled according to the invention;
[0028] [0028]FIG. 5( a ) is a state diagram according to a first embodiment of the invention that illustrates the control states and permitted control state transitions according to the invention;
[0029] [0029]FIG. 5( b ) is another state diagram illustrating a second embodiment according to the invention showing the control states and permitted control state transitions according to the invention;
[0030] [0030]FIG. 6( a ) is a block diagram illustrating a line synchronization apparatus according to the invention;
[0031] FIGS. 6 ( b )-( d ) illustrate synchronization and phase-shift angles in a coordinated diagram showing relative positions and transitions of the signals according to the invention;
[0032] FIGS. 7 ( a )-( b ) are flow charts illustrating the line synchronization method according to the invention;
[0033] [0033]FIG. 8 is a flow chart illustrating the utility outage ride-through method according to the invention; and
[0034] [0034]FIG. 9 is a control-loop block diagram illustrating the power factor control method according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0035] [0035]FIG. 1 illustrates the major components of a line-power unit 100 containing the inventive control devices and methods and the overall relationship to a microturbine generator. As shown, the microturbine generator system includes two major components: the turbine unit 10 and the line-power unit 100 may be arranged as shown in FIG. 1.
[0036] The turbine unit 10 includes a motor/generator 15 and an engine control unit 12 . The turbine unit 10 is supplied with fuel. For example, the motor/generator 15 may be constructed with an Allied Signal Turbo Generator™ which includes a turbine wheel, compressor, impeller and permanent magnet generator which are all mounted on a common shaft. This common shaft is supported by an air bearing which has a relatively high initial drag until a cushion of air is developed at which point the air bearing is nearly frictionless.
[0037] The motor (engine) in the motor/generator 15 is controlled by the engine control unit 12 which, for example, throttles the engine according to the demand placed upon the generator. Communication is provided between the turbine unit 10 and the line power unit 100 as shown by the control/data line connecting these units in FIG. 1. This data includes operating data such as turbine speed, temperature etc. as well as faults, status and turbine output.
[0038] The motor/generator 15 supplies three-phase (3φ) electrical power to the line power unit 100 as further shown in FIG. 1. The line power unit 100 also supplies three-phase auxiliary power (3φ Aux) to the turbine unit 10 .
[0039] The line power unit 100 contains three basic components. The line power unit controller 200 , starter 220 and utility interface 240 are all included within line power unit 100 . Furthermore, an operator interface that permits an operator to monitor and control the line power unit is further provided. The operator interface may include a front panel display for displaying critical operating data as well as controls such as a shut down switch and power level command input as further described below.
[0040] A DC bus supplies DC power to the line power unit 100 to permit off-grid starting of the turbine unit. Furthermore, the utility interface 240 supplies three-phase electrical power to the utility grid 99 as well as an optional neutral line. The line power unit 100 also receives utility authorization from a utility company which authorizes connection to the grid 99 .
[0041] [0041]FIG. 2 illustrates a small grid-connected generation facility showing some of the details of the components controlled by this invention. More particularly, a turbine generator 15 generates AC power that is supplied to rectifier 60 . The AC power is then converted into DC power by rectifier 60 and supplied to DC link consisting of DC bus 61 and capacitor 62 connected across DC bus 61 .
[0042] An inverter 70 transforms the DC voltage on the DC link into a three-phase AC waveform that is filtered by inductor 72 and then supplied to the utility 99 via contactor K 1 .
[0043] As further discussed below in relation to FIG. 3, the invention controls the inverter 70 and contactor K 1 as well as other components. FIG. 2 is actually a simplified diagram illustrating the necessary components for utility outage ride-through. Other components illustrated in FIGS. 3 and 4 are necessary for other types of control exercised by the invention such as power factor and synchronization.
[0044] [0044]FIG. 3 is a system block diagram illustrating a generation facility that may be controlled according to the invention. The generation facility includes a turbine generator 15 generating AC power supplied to rectifier 60 . This AC power is converted by rectifier 60 into DC voltage supplied to the DC link. This DC link may have the same construction as shown in FIG. 2. The inverter 70 transforms DC power from the DC link into three-phase AC power that is fed to the grid 99 via inductor unit 72 and contactor K 1 . Power may also be supplied directly to the internal loads via a connection to the output of the inverter 70 .
[0045] The controller 200 receives a sensed voltage from the DC link as well as the output AC current from the inverter 70 as inputs thereto. The controller 200 utilizes these inputs to generate control signals for the inverter 70 . More particularly, the inverter 70 is controlled by pulse width modulated (PWM) control signals generated by controller 200 to output the desired AC waveform. When the generation facility is online, the controller 200 performs feedback current control by utilizing feedback current supplied by a current sensor located at an output side the inverter 70 . When the generation facility is offline, however, the control exercised by the controller 200 changes. Specifically, the controller 200 performs feedforward voltage control by utilizing feedforward voltage supplied by a voltage sensor located at an input side of the inverter 70 . These current and voltage sensors for feedback current control and feedforward voltage control, respectively may be part of the inverter 70 or separate therefrom as shown in FIG. 3.
[0046] The controller 200 also outputs a disconnect control signal to contactor K 1 to control the connection of the generation facility to the utility grid 99 . Further details of the control method implemented by controller 200 are described below.
[0047] [0047]FIG. 4 illustrates the details of a line power unit 100 according to the invention. This line power unit (LPU) 100 includes an LPU controller 200 that may be programmed according to the techniques disclosed herein. FIG. 4 is a particularly advantageous embodiment of a line power unit 100 that may be controlled according to the invention.
[0048] [0048]FIG. 4 shows the details of the inventive line power unit 100 and its connections to the permanent magnet generator 15 , engine control unit 12 and utility grid 99 . The starter unit 220 is generally comprised of start inverter 80 , precharge circuit 78 , transformer 76 , and transformer 82 . The utility interface generally includes the main inverter 70 , low pass filter 72 , transformer 74 , voltage sensor 98 , and contactor K 1 . The LPU controller 200 generally includes phase and sequence detector circuit 97 , transformer 82 , full wave rectifier 83 b , full wave rectifier 83 a , control power supply 84 and LPU controller 200 . Correspondence between the general construction shown in FIG. 1 and the detailed embodiment shown in FIG. 4 is not important. This description is merely for the purpose of orienting one of ordinary skill to the inventive system.
[0049] Turning to the details of the line power unit 100 construction, the permanent magnet generator 15 has all three phases connected to PMG rectifier 60 . A DC bus 61 interconnects PMG rectifier 60 and main inverter 70 . A capacitor 62 is connected across the DC bus 61 .
[0050] The output of the main inverter 70 is connected to transformer 74 via low pass LC filter 72 . A voltage sense circuit 98 is connected to the output of the transformer 74 and supplies sensed voltages to the LPU controller 200 utilizing the data line shown. The voltage sense circuit 98 does not interrupt the power lines as may be incorrectly implied in the drawings. Instead, the voltage sense circuit is connected across the lines between transformer 74 and contactor K 1 .
[0051] A contactor K 1 is controlled by LPU controller 200 via a control line as shown in FIG. 4 and provides a switchable connection between transformer 75 and the utility grid 99 . A neutral line may be tapped from transformer 74 as further shown in FIG. 2 and connected to the grid 99 .
[0052] A separate start inverter 80 is connected to the DC bus 61 and the external DC voltage supply which may be constructed with a battery. The start inverter 80 is also connected to the permanent magnet generator 15 .
[0053] A precharge circuit 78 is connected to the grid via transformer 76 and transformer 82 . Precharge circuit 78 is further connected to the DC bus 61 . The precharge circuit 78 has a control input connected to a control data line that terminates at the LPU controller 200 as shown.
[0054] The line power unit 100 also supplies power to a local grid (e.g., 240 VAC three phase supplying auxiliary of local loads) via transformer 74 . This local grid feeds local loads and the turbine unit including pumps and fans in the turbine unit.
[0055] An auxiliary transformer 77 is also connected to the output of the transformer 74 . The output of the auxiliary transformer 77 is fed to full wave rectifier 83 to supply full wave rectified power to the control power supply 84 . The control power supply 84 supplies power to the engine control unit 12 and the LPU controller 200 as well as the I/O controller 310 .
[0056] The I/O controller 310 is connected via data lines to the LPU controller 200 . The I/O controller 310 is further connected to the engine control unit 12 , display unit 250 , and LPU external interface 320 . The LPU external interface 320 has a connection for communication and control via port 321 .
[0057] The LPU controller 200 has control lines connected to the start inverter 80 , main inverter 70 , precharge circuit 78 , transformer 82 , and contactor K 1 . Furthermore, data is also provided to the LPU controller 200 from control/data lines from these same elements as well as the phase and sequence detector 97 that is connected at the output of contactor K 1 . The LPU controller 200 also communicates data and control signals to the engine control unit 12 .
[0058] The engine control unit is supplied power from the control power supply 84 and communicates with engine sensors as shown.
[0059] State Machine Mode Control
[0060] [0060]FIG. 5( a ) is a state diagram showing the control states and permitted control state transitions. The state diagram shown in FIG. 5( a ) describes a state machine that may be implemented with the LPU controller 200 to control the line power unit 100 with the defined states and control state transitions. This state machine provides mode control for the following modes of operation: initialization, neutral, pre-charge, turbine start, power on-line, power off-line, and shut down.
[0061] The state diagram shown in FIG. 5( a ) assumes that the line power unit 100 is mounted in an equipment cabinet having cooling fans and pumps circulating cooling fluid through cold plates. A cold plate is merely a device that includes a plenum through which cooling fluid is circulated and to which various power conversion devices such as the main inverter 70 and start inverter 80 are mounted. The cold plate acts as a heat sink for these devices and thereby prevents overheating. The alternative shown in FIG. 5( b ) assumes that no such cabinet or cooling system is present and represents a simplified control state diagram for the invention.
[0062] Before describing the state transitions, a description of each control state will first be provided.
[0063] The power on/reset condition 500 is not really a control state but, rather, an initial condition that triggers the state machine. This initial condition includes power on of the line power unit 100 or reset of the line power unit 100 .
[0064] The initialization state 505 occurs after reset or power on and initializes global variables, initializes the serial communication ports including the I/O controller 310 and LPU external interface 320 having serial ports contained therein, executes a built-in-test (BIT), and initializes the real-time interrupt facility and input capture interrupt within the LPU controller 200 .
[0065] The initialization state also starts the line synchronization techniques of the invention which are further described below as well as starting the power factor control method of the invention.
[0066] The neutral state 510 monitors commands from the I/O controller 310 and engine control unit 12 to determine the next mode of operation as well as checking critical system parameters.
[0067] The pre-charge state 515 enables the pre-charge unit 78 to charge the DC link as well as checking on the rate of charging to determine correct hardware function. The pre-charge state 515 also performs diagnostic checks of the main inverter 70 to identify open or short type failures.
[0068] The neutral with pre-charge complete state 520 closes contactor K 1 and performs diagnostic tests of the line power unit 100 .
[0069] The purge cabinet state 525 purges the equipment cabinet in which the line power unit 100 is mounted including turning on any cooling fans and pumps and thereby bring the line power unit 100 into a purged and ready state.
[0070] The neutral with purge complete state 530 is an idle state that waits for an engine start command from the operator that is routed via port 321 to LPU external interface 320 to I/O controller 310 and thereby to LPU controller 200 .
[0071] The start engine state 535 generally performs the function of starting the engine that drives the permanent magnet generator 15 .
[0072] The start engine state 535 resets the start inverter 80 and performs basic diagnostic checks of the line power unit 100 . The start engine state 535 also verifies the DC link voltage and thereafter sets the pulse width modulated control signal supplied to the start inverter 80 to control the maximum speed that the start inverter 80 will drive the permanent magnet generator 15 as a motor to thereby permit the engine to start.
[0073] More particularly, the start engine state enables the start inverter 80 , receives updated speed commands from the engine control unit 12 , monitors fault signals from the start inverter 80 , and checks the speed of the engine and DC current drawn from the start inverter 80 to determine a successful start.
[0074] Actual starting of the engine is under the control of the engine control unit 12 which feeds fuel and any necessary ignition signals to the engine that is being spun by the permanent magnet generator 15 . The start engine state 535 then waits for a signal from the engine control unit 12 to terminate the start operation which involves sending a stop signal to the start inverter 80 .
[0075] Further details of engine starting can be found in related application Attorney Docket #1215-380P which is hereby incorporated by reference.
[0076] The neutral with start complete state 540 is an idle state wherein the engine is started and the permanent magnet generator 15 is being driven by the engine thereby producing three-phase power that is rectified by PMG rectifier 60 to supply DC bus 61 with DC power. The neutral with start complete state essentially waits for a power level command from the operator that is routed via port 321 , LPU external interface 320 , I/O controller 310 to the LPU controller 200 .
[0077] The power on-line state 545 enables the main inverter 70 in a current mode and sends pulse width modulated control signals to the main inverter 70 to output three-phase electrical power having the commanded power level. The power on-line state also performs various system checks to maintain safe operation such as verifying the DC link voltage and cold plate temperatures.
[0078] The open contactor state 550 opens the main contactor K 1 .
[0079] The power off-line state 555 switches the main inverter 70 to a voltage mode and sets the power level command to a nominal level to power the local loads. The power off-line state may perform various system checks to maintain safe operation.
[0080] The shut down state 560 disables the main inverter 70 and reinitializes global variables that are utilized by the state machine to control the line power unit 100 .
[0081] The purge cabinet state 565 performs essentially the same functions as the purge cabinet state 525 and ensures that the equipment cabinet housing the line power unit 100 cools down.
[0082] The open contactor state 570 waits for a nominal cool down period such as 5 minutes as well as controlling the contactor K 1 such that it breaks the connection with the grid 99 thereby ensuring disconnection from the grid 99 .
[0083] The clear faults state 575 clears any fault codes that may have triggered the shutdown.
[0084] The emergency stop indication 580 is not actually a control state, but instead illustrates the receipt of an emergency stop signal. The equipment cabinet housing the line power unit 100 preferably includes an emergency stop button that a user may trigger to shut down the system in an emergency.
[0085] The open contactor state 585 is triggered by the receipt of an emergency stop signal and opens main contactor K 1 thereby breaking the connection to the grid 99 .
[0086] The state transitions are represented in the drawings with arrows. These arrows convey important information. For example an unidirectional arrow such as → indicates a one-direction only permissible state transition. A bi-directional arrow, on the other hand, such as ←→ indicates bi-directional permissible state transitions. This may also be expressed by using the following bi-directional and unidirectional permissible state transition symbologies: (1) neutral state ←→ pre-charge state and (2) power on-line state → power off-line state.
[0087] The operation of the state machine illustrated in 5 ( a ) will now be described.
[0088] After receiving the power on or reset signal 500 , the initialization state 505 is triggered. After completion of the initialization procedures and successful built-in tests, the state machine permits the transition to neutral state 510 .
[0089] The neutral state 510 monitors commands from the operator and engine control unit 12 . Upon receiving an appropriate command, the state machine permits the transition to the pre-charge state 515 from the neutral state 510 .
[0090] As described above, the pre-charge state 515 triggers the pre-charge unit 78 to pre-charge the DC bus 61 to a desired pre-charge voltage. The pre-charge state 515 determines successful pre-charge by monitoring the pre-charge rate and determining whether the pre-charge voltage is within acceptable limits at the end of the pre-charge cycle.
[0091] If the pre-charge state 515 determines that the pre-charge cycle is not successful, then the state machine transitions back to the neutral state 510 as indicated by the fail path illustrated on FIG. 5( a ). Upon successful completion of the pre-charge cycle, however, the state machine permits the transition from the pre-charge state 515 to the neutral with pre-charge complete state 520 .
[0092] The neutral with pre-charge complete state 520 closes the main contactor K 1 thereby connecting the line power unit 100 to the grid 99 . Thereafter, the state machine permits the transition to the purge cabinet state 525 .
[0093] Upon successful purging of the cabinet and passing of any diagnostic tests such as checking the cold plate temperatures, the state machine permits the transition from the purge cabinet state 525 to the neutral with purge complete state 530 . Upon receipt of a start engine command, the state machine permits the transition to the start engine state 535 .
[0094] As described above, the start engine state 535 control the start inverter 80 to drive the permanent magnet generator 15 as a motor to spin the engine at a speed to permit the engine to be started. If the engine fails to start, then the state machine transitions to the neutral with purge complete state 530 . If the engine successfully starts, then the state machine transitions to the neutral with start complete state 540 which waits for the receipt of a power level command from the operator or a remote host.
[0095] Upon receipt of a non-zero power level command, the state machine transitions from the neutral with start complete state 540 to the power on-line state 545 .
[0096] If there is a utility outage, then the state machine transitions to the open contactor state 550 as further described in the utility outage ride-through section below.
[0097] On the other hand, receipt of a zero power level command transitions the state machine from the power on-line state to the neutral with start complete state 540 .
[0098] After the open contactor state 550 completes the operation of opening contactor K 1 , the power off-line state 555 is entered. Upon completion of the power off-line procedures in power off-line state 555 , the state machine transitions to the neutral with start complete state 540 . If a shutdown command is received, the state machine then transitions to the shutdown state 560 . The shutdown state 560 is followed by the purge cabinet state 565 , open contactor state 570 and clear faults state 575 and then the neutral state 510 thereby bringing the line power unit 100 into a neutral state.
[0099] Upon receipt of an emergency stop signal 580 , the open contactor state 585 is triggered. Thereafter, the shutdown state 560 is entered by the state machine and then the purge cabinet state 565 , open contactor state 570 , clear faults state 575 and neutral state 510 are sequentially entered by the state machine.
[0100] [0100]FIG. 5( b ) is a simplified state diagram that simplifies the states and state transitions illustrated in FIG. 5( a ). FIG. 5( b ) generally assumes that there is no cabinet that needs to be purged. The state machine in FIG. 5( b ) also consolidates some of the states illustrated in FIG. 5( a ). States having the same reference numerals are identical to those shown in FIG. 5( a ). The differences are pointed out below.
[0101] The neutral with pre-charge complete state 527 shown in FIG. 5( b ) differs from the neutral width pre-charge complete state 520 shown in FIG. 5( a ) essentially because the purged cabinet state 525 has been eliminated in FIG. 5( b ). The neutral with pre-charge complete state 527 closes the main contactor K 1 and awaits for receipt of a start engine command from an operator or other device such as a remote host.
[0102] Further details of such remote host that may be utilized with this invention are provided by related application Attorney Docket No. 1215-379P the contents of which are hereby incorporated by reference.
[0103] The power off-line state 556 shown in FIG. 5( b ) also differs from the power off-line state 555 shown in FIG. 5( a ). Essentially, the power off-line state 556 combines the open contactor state 550 with the power off-line state 555 shown in FIG. 5( a ). Thus, the power off-line state 556 performs the functions of opening the contactor K 1 , switching the main inverter 70 to a voltage mode and setting the power level to a nominal level to power the local loads. Furthermore, various system checks may be performed to maintain safe operation.
[0104] The operation of the state machine shown in FIG. 5( b ) is essentially the same as that shown in FIG. 5( a ) with differences noted below.
[0105] The main difference is the consolidation of the neutral with pre-charge complete state 520 and the neutral with purge complete state 530 and the elimination of the purged cabinet state 525 from FIG. 5( a ). Thus, when the pre-charge state 515 successfully completes the pre-charge cycle, the neutral with pre-charge state 527 is entered by the state machine.
[0106] Upon receipt of an engine start command, the start engine state 535 is entered by the state machine. Furthermore, upon a utility outage, the state machine transitions directly from the power on-line state 545 to the power off-line state 556 as shown in FIG. 5( b ).
[0107] By utilizing the state machines of either FIGS. 5 ( a ) or 5 ( b ), the invention provides a real-time control method for controlling the line power unit 100 . This real-time control unit includes specifically defined control states that ensure correct and safe operation of the line power unit 100 . Furthermore, various system checks and diagnostics are performed throughout which further ensure safe operation and which further affect state transitions.
[0108] Line Synchronization
[0109] [0109]FIG. 6( a ) illustrates the frequency sensing component of the frequency synthesizing apparatus and method according to the invention in relation to other components of the line power unit 100 and the utility grid 99 .
[0110] The phase and sequence detecting circuit 97 shown in FIG. 4 may have the construction shown in FIG. 6( a ). More particularly, the sequence detector includes a transformer 605 connected to two phases A, B of the utility grid 99 . In this way, transformer 605 inputs the voltage and frequency of the utility grid 99 .
[0111] This sensed voltage from transformer 605 is supplied to a low pass filter 610 and then to an optical isolator 615 . The output of the optical isolator 615 is a uni-polar square wave as shown in FIG. 6( a ) that is supplied to the line power unit controller 200 . Specifically, the line power unit controller includes a vector control board 210 having an A/D converter 215 that accepts the uni-polar square wave from the optical isolator 615 .
[0112] The A/D converter preferably converts this uni-polar square wave into a 10-byte digital signal that is fed to the digital signal processor (DSP) 220 . The output of the DSP 220 is fed to a pulse width modulation (PWM) signal generation device 225 .
[0113] The pulse width modulation signals from PWM 225 are fed to gate drive circuit 230 which drives the IGBT switches 71 located within the main inverter 70 . The main inverter 70 is fed a DC voltage from DC bus 61 as shown in FIG. 4. For simplicity, this connection is not shown in FIG. 6( a ).
[0114] The-output of the main inverter 70 is filtered by inductor 72 . Then, the voltage is stepped up by transformer 74 and supplied to the utility grid via contactor K 1 . The output of the transformer 74 also supplies local loads as shown in FIG. 6 a.
[0115] The frequency synchronization apparatus shown in FIG. 6( a ) operates in the following general manner. The output of the optical isolator 615 is a uni-polar square wave with a voltage swing preferably within the limits of the A/D converter 215 . The DSP 220 controls the A/D converter 215 by initiating the conversion and reading of the digital value at a fixed frequency. This fixed frequency establishes the time base for which the inventive methods can compute the actual frequency of the signal and thereby the actual frequency of the utility grid 99 . This is accomplished by determining when the falling edge of the signal occurred and counting the number of samples between successive falling edges.
[0116] Alternatively, the invention could utilize the rising edge of the signal, but for simplicity this explanation will focus on the falling edge implementation.
[0117] FIGS. 6 ( b )-( d ) illustrate various signals utilized by the invention to perform synchronization. FIG. 6( b ) illustrates the SYNC signal that is the fixed frequency signal utilized by the DSP 220 to control the initiation and reading of the data from the A/D converter 215 . FIG. 6( c ) illustrates the THETA signal which is a variable in software that is utilized to represent the angle of the utility sine wave and ranges from 0° to 360° in a series of stepped ramps each of which runs from 0° at the falling edge of the SYNC pulse to 360° at the next falling edge of the SYNC pulse. FIG. 6( d ) illustrates THETA˜which is the phase shift added to THETA for power factor control as further described below.
[0118] The synchronization method is further illustrated in FIG. 7( a )-( b ). As shown in FIG. 7( a ), the synchronization function is started or called every 64 microseconds at which time step 702 causes the digital signal processor 220 to read the A/D 215 input. As further illustrated in FIG. 7( a ), the input signal is a square wave at the frequency of the grid.
[0119] Then, step 704 sets the minimum, maximum and typical constants which are set according to the selected grid frequency. The grid frequency is chosen between either 50 or 60 hertz which thereby effects the values for the minimum, maximum and typical constants in step 704 .
[0120] Thereafter, step 706 increments the frequency counter which is represented as FreqCount=FreqCount+1. The variable FreqCount is the number of times this routine is called between falling edges of the input signal.
[0121] After step 706 , then step 708 checks whether the FreqCount variable is out of range. If so, the Count variable is set to a typical value in step 710 and the step 712 then clears the status flag that would otherwise indicate that the line power unit 100 is in synchronization with the grid 99 . In other words, step 712 clears this status flag thereby indicating that the line power unit is not in synchronization with the grid 99 .
[0122] After step 712 or if decision step 708 determines that the FreqCount is not out of range, then step 714 then determines whether there is an input from the falling edge detector. Step 714 determines whether the falling edge of the synchronization pulse has occurred. If yes, then the flow proceeds to jump point A which is further illustrated in FIG. 7( b ).
[0123] Step 708 essentially determines whether the grid 99 is present or whether there is a utility outage. If there is utility outage, then the FreqCount variable will exceed the maximum thereby causing the system to set the count value to a typical value in step 710 .
[0124] [0124]FIG. 7( b ) continues the frequency synchronization process beginning with a determination of whether the frequency of the incoming signal, input is within the correct range. Particularly, step 716 determines whether the FreqCount variable is within the minimum and maximum values. If not, then step 722 sets the count variable to a typical value and then step 724 sets a status flag indicating synchronization error.
[0125] On the other hand, if the FreqCount variable is within the correct range as determined by step 716 , then step 718 sets the Count variable equal to 360°/FreqCount. Then step 720 clears the status flag indicating no synchronization error.
[0126] After either steps 720 or 724 , the method executes step 726 which resets the FreqCount variable to 0.
[0127] Thereafter, the method then determines whether THETA is in synchronization with the incoming signal input. THETA should equal 0 at the same time the falling edge of the input signal is detected if synchronization has occurred. This is determined by step 728 which checks whether THETA is substantially equal to 360° or 0°. If not, the status flag is cleared by step 732 indicating that the line power unit is not in synchronization. If yes, then step 730 sets the status flag indicating that the LPU 100 is in synchronization with grid 99 .
[0128] After setting the status flags in step 730 or step 732 then the process adjusts THETA to maintain or achieve synchronization with the input signal. Particularly, step 734 first determines if THETA is less than 180°. If yes, then the error variable is set to minus THETA. If not, then step 738 sets the error variable equal to 360°−THETA.
[0129] After setting the error variable in step 736 or step 738 , then the method proceeds to limit the rate of change of the Error variable. The preferred embodiment shown in FIG. 7 b limits the Error variable to +/−0.7° in step 740 . Thereafter, step 742 sets the THETA variable equal to THETA plus the Error variable.
[0130] After step 742 , the flow returns via jump point B to the flow shown in FIG. 7( a ) beginning with step 744 .
[0131] As further shown in FIG. 7( a ), the process proceeds after jump point B by generating THETA by incrementing THETA by the count variable every 64 microseconds. This process generates the THETA signal shown in FIG. 6( c ). More particularly, step 744 sets THETA=THETA+Count thereby incrementing THETA.
[0132] After step 744 , decision step 746 determines whether THETA is greater than 360°. If yes, step 748 resets THETA to THETA minus 360° to bring THETA within range.
[0133] If not, then step 750 determines the phase shift variable THETA˜by setting THETA˜equal to THETA plus any desired phase shift.
[0134] THETA˜is an optional variable as is step 750 . This optional step 750 permits an operator to adjust the power factor of the three phase power delivered to the grid 99 by utilizing the phase shift variable. In essence, the operator merely needs to input data to set the phase shift variable to thereby adjust the power factor. Step 750 can then adjust the power factor by setting THETA˜=THETA+phase shift.
[0135] After step 750 , the synchronization function has completed its operations as indicated by end of SYNC function step 752 . This routine is again called after 64 microseconds have elapsed since the initiation of the SYNC function in step 700 .
[0136] The inventive methodology illustrated in FIGS. 7 ( a ) and 7 ( b ) outputs a THETA˜that is utilized by a known vector algorithm in the vector board 210 to generate pulse width modulation signals from PWM 225 that are fed to gate drive 230 to thereby control the main inverter 70 . Such pulse width modulation control of the power can then shift the phase of the power output from main inverter 70 and thereby bring the output power into synchronization with the utility grid 99 .
[0137] Instead of sampling the grid frequency, circuit 97 may also synthesize a grid frequency. This is necessary when the line power unit 100 is operating in a stand-alone mode or when the utility grid 99 is not available. Thus, the system must synthesize a frequency when the grid is temporarily disconnected so that the output power frequency is self-regulating.
[0138] One of the advantages of the inventive line synchronization technique is that it limits the resynchronization rate in step 740 . By limiting the resynchronization rate, the invention provides a smooth transition from out-of-SYNC line power unit 100 to an in-SYNC line power unit 100 that is in synchronization with the utility grid 99 . This reduces transient voltages, stress on the components and increases safety.
[0139] As further described above, this line synchronization technique also permits power factor control such that an operator or remote host can input a phase shift data via port 321 and thereby control the power factor of power supplied to the grid 99 .
[0140] Utility Outage Ride-through
[0141] The state machines described in FIGS. 5 ( a )-( b ) include states that are involved in the utility outage ride-through methodology. Specifically, the neutral with start complete state 540 , power on-line state 545 , open contactor state 550 , and power off-line state 555 shown in FIG. 5( a ) are the control states involved in the utility outage ride-through methodology.
[0142] Alternatively, the neutral with start complete state 540 , power on-line state 545 and power off-line state 556 shown in FIG. 5 b are alternative control states that may also be utilized by the utility outage ride-through methodology of this invention.
[0143] The utility outage ride-through methodology may be implemented within a controller such as the controller 200 shown in FIG. 3 or the LPU controller 200 shown in FIG. 4.
[0144] The utility outage ride-through method that may be programmed into the LPU controller 200 is shown in FIG. 8. Furthermore, the utility outage ride-through methodology shown in FIG. 8 may be utilized by the state machine shown in FIGS. 5 a - b to control the state transitions mentioned above.
[0145] The utility outage ride-through method shown in FIG. 8 begins with step 800 . Then, steps 805 , 810 , 815 , 820 , 825 determine the existence of a fault condition. Upon the occurrence of any of these fault conditions, then the flow proceeds to open main contactor step 830 .
[0146] More particularly, step 805 determines whether there is a loss of utility authorization. In general, most electric utilities send authorization data to each electrical power generator supplying power to the grid 99 . In this way, the utility can either authorize or cancel authorization for connection to the grid 99 . Step 805 determines whether the utility authorization has been cancelled.
[0147] Step 810 determines whether there is a loss of phase. This may be performed by sampling the input from the phase and sequence detector 97 . If any of the phases have been lost, then step 810 directs the flow to open main contactor step 830 .
[0148] Similarly, loss of synchronization step 810 determines whether there is a loss of synchronization between the line power unit 100 and the grid 99 . This loss of synchronization may be determined from the status flag “LPU in SYNC” set by the synchronization method described above in relation to FIGS. 7 ( a )-( b ).
[0149] Step 820 decides whether the industrial turbo generator (ITG) host has sent an off-line command via port 321 to the LPU controller. It is not essential that an ITG host be utilized, and this step 820 may be simplified to receive any off-line command by LPU controller 200 .
[0150] Step 825 determines whether the AC voltage of the grid 99 is out of range. The voltage sense circuit 98 senses this AC grid 99 voltage and sends a signal to the LPU controller 200 which can thereby determine whether the VAC is out of range in step 825 .
[0151] If any fault condition has occurred, then step 830 is executed which opens the main contactor K 1 and disconnects the line power unit 100 from the grid 99 .
[0152] Thereafter, step 835 resets or clears a time counter which is preferably a 30 second time counter.
[0153] Then, step 840 sets the operational mode to offline which causes the state machine of FIG. 5( a ) to transition from the open contactor state 550 to the power off-line state 555 . The power on-line state 545 to open contactor state 550 transition occurs in step 830 and is triggered by any of the fault conditions described above.
[0154] Thereafter, off-line voltage control is initiated by step 845 wherein the main inverter 70 is controlled by LPU controller 200 in a voltage control mode for stand-alone operation and feeding of the local loads.
[0155] After setting the off-line voltage control in step 845 , step 850 enables the main inverter 70 to thereby supply power to the local loads. This ends the flow as indicated by step 895 .
[0156] The system then continues checking the occurrence of fault conditions as described above. Continued fault conditions have the effect of clearing the 30 second counter each time.
[0157] When all of the faults have been cleared, then the flow proceeds to step 855 which determines whether the on-line or off-line mode (state) is being utilized by the line power unit 100 . Continuing with this example, the off-line mode is now utilized by the state machine. Thus, the mode determination step 855 directs the flow to step 860 which begins incrementing the 30 second counter.
[0158] If the counter has not yet reached the 30 second time limit, then step 865 directs the flow to off-line voltage control setting step 845 and enable three phase inverter step 850 the effect of which is to return or loop back to the increment 30 second counter step 860 .
[0159] This loop continues until the 30 second counter has elapsed as determined by step 865 . Thereafter, step 870 disables the main inverter 70 . After disabling the main inverter 70 , step 875 closes main contactor K 1 thereby connecting the line power unit 100 to the grid 99 . Then, the mode is set to the online mode which transitions the state machine from the neutral with start complete state 540 to the power on-line state 545 . This also causes the next loop to take the left branch as determined by the mode determination step 855 which will now sense the online mode.
[0160] If the mode is on-line, the flow proceeds from step 855 to on-line current control step 885 which controls the main inverter 70 in a current control mode. Thereafter, step 890 enables the inverter 70 to thereby supply power to the grid 99 via closed contactor K 1 . The process is then completed as indicated by end step 895 .
[0161] By utilizing the utility outage ride-through methodology above, the invention has the capability of detecting a utility outage or other fault condition thereby triggering disconnection from the grid. The invention also provides a smooth transition from a current mode (utility connected) to a voltage mode (utility outage) for the main inverter 70 .
[0162] The benefit is more stability and faster response to wide swings in generator voltage. The invention also has the feature of over-current limiting which is a self-protection function which prevents voltage brown-out at excessive current levels. This method also easily transitions from voltage mode to current mode when reconnecting to the grid thereby minimizing transients on power output to the grid 99 .
[0163] When the line power unit 100 disconnects from the grid 99 , a typical system will vary greatly in speed and output voltage as it is rapidly unloaded. To prevent such large voltage swings from reaching the inverter 70 output, a feed forward technique is utilized as described above to control the inverter 70 output voltage.
[0164] Using such feed forward control, the generator voltage is sampled and used to establish the modulation index of the pulse-width modulated sinusoidal voltage produced by the inverter 70 keeping the sinusoidal output voltage nearly constant. This control technique provides the high level of stability and fast response needed for rapid changes of input voltage. Over-current protection is provided by reducing the modulation index when the maximum allowed output current is reached, producing a brown-out effect.
[0165] When the grid power is restored, the line power unit 100 voltage is first synchronized with the grid voltage. After synchronizing with the grid (as determined by step 815 and implemented by the synchronization techniques described above), normal current controlled power flow into the grid 99 can then resume.
[0166] Power Factor Control
[0167] The system may be further enhanced by providing an apparatus and method for controlling the power factor of power delivered to the grid 99 . Although the synchronization control described above also provides power factor control, the invention also provides an alternative control loop that controls the power factor.
[0168] The power factor control device and methods according to the invention may be applied to a wide variety of grid-connected generation facilities as graphically illustrated by FIG. 2. The current controlled inverter 70 may be controlled with the device shown in FIG. 9.
[0169] [0169]FIG. 9 illustrates a device for controlling power factor that interfaces with a current controlled inverter 70 as shown in FIG. 9 or, alternatively, the current controlled inverter 70 shown in FIG. 2 or 4 .
[0170] This power factor control device includes a sensor 98 that senses the current supplied to the utility 99 from the inverter 70 . All three phases (I a , I b , I c ) of the current supplied to the utility 99 are sensed by sensor 98 and supplied to three-phase to two-phase transformer 905 to output two-phase D-Q coordinate signals I d , I q .
[0171] The two-phase signals I d , I q are then supplied to a stationary-to-rotating reference frame transformation unit 910 that changes the two-phase AC signals (I d , I q ) from the stationary to a synchronously rotating reference frame which converts the signals from AC to DC.
[0172] The DC signals are then compared against reference signals I q Ref , I d Ref by comparators 920 and 925 , respectively. The comparators 920 , 925 are preferably proportional-plus-integral gain stages that perform proportional-plus-integral comparison operations between the reference signals I q Ref , I d Ref and the DC signals I d , I q .
[0173] The reference signals I q Ref , I d Ref may be supplied by the LPU controller 200 which, in turn, may be supplied these reference signals from an operator via port 321 , LPU external interface 320 , I/O controller 310 . In this way, either the LPU controller 200 or the operator can command the power factor.
[0174] Furthermore, the utility may also request a certain power factor to be supplied to the grid 99 by the line power unit 100 . Such a request can be fed to the system via the reference signals I q Ref , I d Ref .
[0175] The proportional plus integral gain stages 920 , 925 output voltage signals V q , V d that are transformed back to a stationary reference frame by rotating to stationary reference frame transforming unit 930 to output AC voltages V q , V d . These AC voltages are then subjected to a two-phase to three-phase transform by unit 935 to thereby output three-phase voltages V a , V b , V c which are then sent to a pulse width modulator which controls the switches in a three-phase, full-wave IGBT bridge within the inverter 70 to produce AC currents (I a , I b , I c ) with a vector that contains the real and reactive components commanded by I d Ref and I q Ref . This power factor control loop provides independent control of the real and reactive components of the current output to utility 99 . This invention draws upon widely known vector control techniques developed for induction motor drives. The desired amplitudes of real and reactive current supplied to the utility 99 are commanded by I q ref and I d ref , respectively. The control loop described above drives the output current to the utility (I a , I b , I c ) so that the magnitude and phase contain the commanded real and reactive current components.
[0176] This is often beneficial in improving the power factor in the utility distribution system 99 . Furthermore, the utility interface 99 may also be a local grid. Such a local grid may also require power factor correction due to large inductive or capacitive loads on the local grid. The poor power factor that such large inductive or capacitive loads cause may be corrected by utilizing the power factor control method and apparatus disclosed herein.
[0177] The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims. | An integrated system for comprehensive control of an electric power generation system utilizes state machine control having particularly defined control states and permitted control state transitions. In this way, accurate, dependable and safe control of the electric power generation system is provided. Several of these control states may be utilized in conjunction with a utility outage ride-through technique that compensates for a utility outage by predictably controlling the system to bring the system off-line and to bring the system back on-line when the utility returns. Furthermore, a line synchronization technique synchronizes the generated power with the power on the grid when coming back on-line. The line synchronization technique limits the rate of synchronization to permit undesired transient voltages. The line synchronization technique operates in either a stand-alone mode wherein the line frequency is synthesized or in a connected mode which sensed the grid frequency and synchronizes the generated power to this senses grid frequency. The system also includes power factor control via the line synchronization technique or via an alternative power factor control technique. The result is an integrated system providing a high degree of control for an electric power generation system. | 8 |
FIELD OF THE INVENTION
[0001] This invention relates generally to anesthesia mask attachments and more specifically to anesthesia mask attachments that give the anesthesia mask a more comforting appearance to children.
BACKGROUND OF THE INVENTION
[0002] When a patient undergoes a surgical or medical procedure, it is often necessary to cause the patient to inhale anesthetic gas for the purpose of numbing pain or sedating the patient for the duration of the procedure. Anesthetic gas is administered through the use of an industry standard anesthesia mask. These masks attach to a patients face with an air-tight seal that prevents the anesthetic gas from escaping the mask. This ensures the patient breathes only the mixture controlled by the anesthesia provider.
[0003] Anesthesia masks are very unattractive. Often patients, especially children, are afraid of these masks because of their bizarre appearance. Additionally, many patients fear the standard anesthesia masks because the patient perceives that the mask will interfere with the patient's breathing. Because of these fears, medical professionals often experience difficulty in convincing younger patients to wear the masks for proper anesthesia delivery.
[0004] Therefore, what is needed is a child friendly anesthesia mask attachment that reduces the effect of the aforementioned problems on the patient. This attachment should obscure the patient's view of some of the more frightening components of the standard anesthesia mask. The attachment should also be aesthetically pleasing to young patients so that the patient may become familiar with the mask and therefore less apprehensive about the mask's function. Additionally, the attachment should not impair the proper functionality of the standard anesthesia mask or hinder any medical professionals involved in the ensuing procedure. Furthermore, other desirable features and characteristics of the present invention will become apparent when this background of the invention is read in conjunction with the subsequent detailed description of the invention, appended claims, and the accompanying drawings.
SUMMARY OF THE INVENTION
[0005] The present invention advantageously fills the aforementioned deficiencies by providing a child friendly anesthesia mask attachment that covers the standard anesthesia mask with animal noses, cartoon characters, or other objects that are comforting to a child.
[0006] In one particular embodiment of the present invention, a child friendly anesthesia mask attachment is placed over the primary gas tube of the standard anesthesia mask. The child is then allowed to play with the mask and attachment to become familiar with the mask's use. When the anesthesia is to be delivered, the attachment may be removed to allow the mask to be attached to an appropriate anesthesia delivery system.
[0007] In another embodiment of the present invention, the child friendly anesthesia mask attachment is constructed with two openings. A connecting tube is then inserted through both openings and connected to the primary gas tube. An anesthesia delivery system may then be attached to the primary gas tube of the mask via the connecting tube without the need of removing the child friendly anesthesia mask attachment.
[0008] The present invention now will be described more fully hereinafter with reference to the accompanying drawings, which are intended to be read in conjunction with both this summary, the detailed description and any preferred and/or particular embodiments specifically discussed. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided by way of illustration only and so that this disclosure will be thorough, complete and will fully convey the full scope of the invention to those skilled in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The drawings contained herein exemplify three of the major embodiments of the claimed invention. It should be noted that the invention is not limited to the embodiments shown. The embodiments shown are purely examples, and the invention is capable of many variations of said embodiments. In the drawings,
[0010] FIG. 1 is an embodiment of a child friendly anesthesia mask attachment placed over the primary gas tube of a standard anesthesia mask.
[0011] FIG. 2 is a standard anesthesia mask and an embodiment of a child friendly anesthesia mask attachment being prepared for attachment to said anesthesia mask.
[0012] FIG. 3 is an embodiment of a child friendly anesthesia mask attachment as attached to a standard anesthesia mask and placed against a child's face.
[0013] FIG. 4 is an embodiment of the child friendly anesthesia mask attachment shown from the back, unconnected to an anesthesia mask, and including an attachment means.
[0014] FIG. 5 is a collection of minor embodiments of the child friendly anesthesia mask attachment featured together.
DETAILED DESCRIPTION OF THE INVENTION
[0015] FIG. 1 illustrates a child friendly anesthesia mask attachment placed on a standard anesthesia mask 2 . In this embodiment, the child friendly anesthesia mask attachment comprises a child attractive member 1 of a cartoon dog face. The child attractive member 1 performs the function of obscuring a patient's view of the standard anesthesia mask. While the present embodiment of the child attractive member 1 depicts a cartoon dog face, the disclosed invention encompasses any item which would distract a child from an impending surgery including but not limited to realistic animal faces, cartoon animal faces, animals, plants, toy automobiles, toy trains, toy farming equipment, toy airplanes, toy boats, seasonal icons, religious icons, food representations, cartoon characters, trading card characters, or video game characters. The preceding list is meant to be illustrative only and should not be construed as an exhaustive list of embodiments of a child attractive member 1 . A child attractive member 1 may be any item that a child would perceive as a toy, is large enough to attract a child's attention, and light-weight enough to not interfere with the standard anesthesia mask's primary function. By way of example, the child attractive member 1 should not interfere with the function of the secondary 95 gas tube 8 of the standard anesthesia mask. The child attractive member 1 may be larger than the standard anesthesia mask 2 and may substantially extend from the mask as would be the case with an elephant trunk. However, the child attractive member 1 should be small enough that it does not interfere with the ability of medical personnel to perform their respective duties. The child attractive member 1 has no medical function other than to attract a patient's attention and encourage the patient to use the mask. The child attractive member 1 may also be treated with appropriate chemicals so that said child attractive member 1 emits a pleasing scent associated with the particular embodiment. Additionally, the child attractive member may be made of any material that would be consistent with the abovementioned criteria. However, in the preferred embodiment the child attractive member is not made of latex because of the possibility of allergic reactions by some patients. Also, the child attractive member may be made of transparent or semitransparent materials to allow medical personnel to view condensation forming on the inside of the mask and ensure that the patient is breathing properly.
[0016] Briefly referencing FIG. 2 , standard anesthesia masks have a primary gas tube 3 . In the embodiment disclosed in FIG. 1 , the child friendly anesthesia mask attachment further comprises a primary opening 4 in one surface of the child attractive member as depicted in FIG. 4 . The primary opening 4 should be large enough to be placed over the primary gas tube 3 of the standard anesthesia mask 2 . This allows a surface of the child friendly anesthesia mask attachment to rest on the front surface 5 of the standard anesthesia mask. The standard anesthesia mask 2 also typically comprises a secondary gas tube 8 . The child friendly anesthesia mask attachment should be shaped so that it will not interfere with the function of the secondary gas tube 8 .
[0017] The embodiment of the child friendly anesthesia mask attachment depicted in FIG. 4 . also comprises an attachment means 6 which is attached to two attachment points 7 on the child attractive member 1 . This attachment means 6 may be stretched around both the standard anesthesia mask 2 and the patient's head. In the preferred embodiment, the attachment means 6 is a strap made of elastic; however, the attachment means 6 may be any device which can temporarily attach the child attractive member 1 to a standard anesthesia mask 2 . In this manner, the patient has the ability to wear and play with both the standard anesthesia mask 2 and the child friendly anesthesia mask attachment prior to surgery. Immediately prior to surgery, the attachment means 6 may be removed from the patient's head. Removing the attachment means allows the child friendly anesthesia mask attachment to be removed from the standard anesthesia mask 2 . The primary gas tube 3 of the standard anesthesia mask 2 can then be connected to an appropriate anesthesia delivery system so that the medical procedure may commence.
[0018] As noted above, FIG. 2 . illustrates a second embodiment of the child friendly anesthesia mask attachment and a standard anesthesia mask 2 . In this embodiment, the child friendly anesthesia mask attachment may remain attached to the standard anesthesia mask 2 during surgery. The child friendly anesthesia mask attachment in this embodiment comprises a cartoon frog's head as the child attractive member 9 . Any item that could function as a child attractive member 1 in the first embodiment could also function as a child attractive member 9 in the second embodiment. In this embodiment, the child friendly anesthesia mask attachment also comprises a secondary opening 10 in addition to the primary opening 4 . The secondary opening 10 is present on a surface of the child attractive member 9 . The primary opening 4 and the secondary opening 10 are connected by a space inside of the child attractive member 9 .
[0019] FIG. 3 illustrates the second embodiment of the child friendly anesthesia mask attachment connected to the standard anesthesia mask 2 and placed against a patient's face 11 . To function during surgery, the standard anesthesia mask 2 must be attached to the pertinent anesthesia delivery system by a connecting tube 12 . In order for the child friendly anesthesia mask attachment to remain on the mask during surgery, the connecting tube 12 is inserted through the secondary opening 10 , the connecting space, and the primary opening 4 . The connecting tube 12 can then be connected to the primary gas tube 3 of the standard anesthesia mask 2 . In this embodiment, the primary opening 4 , the secondary opening 10 , and the connecting space must be large enough to accept the connecting tube 12 without constricting the gas flow. In the preferred embodiment, the primary opening 4 and secondary opening 10 should also be small enough to prevent the child friendly anesthesia mask attachment from sliding down the connecting tube 12 . In this embodiment, the connecting tube 12 functions as an attachment means. Additional attachment means may be added for additional stability if desired.
[0020] In the second embodiment, the child attractive member 9 is not directly attached to the standard anesthesia mask 2 . However, the child attractive member 9 is held in close proximity to the standard anesthesia mask 2 by the connecting tube 12 which functions as an attachment means. Close proximity is any distance at which a child would consider the child attractive member 9 to be a part of the standard anesthesia mask 2 .
[0021] FIG. 5 is a collection of minor embodiments of the child friendly anesthesia mask attachment featured together. In this series of embodiments, the child friendly anesthesia mask attachment features an elephant trunk as the child attractive member 16 . This embodiment features multiple attachment means 6 namely a strap attachment means 6 connected to two attachment points 7 and a connecting tube attachment means 12 .
[0022] The present embodiment also features a universal tube attachment 13 connected to the connecting tube 12 . The universal tube attachment 13 has an interior diameter of approximately eleven millimeters and an exterior diameter of approximately twenty two millimeters. The universal tube attachment 13 uses these dimensions because the primary gas tube 3 of a child size standard anesthesia mask may be inserted into the universal tube attachment 13 and the universal tube attachment 13 may also be inserted into the primary gas tube 3 of an adult size standard anesthesia mask. The presence of the universal tube attachment 13 attached to the connecting tube 12 ensures the child friendly anesthesia mask attachment is capable of connecting to any standard anesthesia mask. As with previous embodiments, the connecting tube 12 and universal tube attachment 13 are inserted into the space between primary opening 4 and the secondary opening 10 .
[0023] The present embodiment also features a primary noise member 14 . The primary noise member 14 functions in the same manner as an animal squeaky toy. When the user presses the portion of the child attractive member 16 containing the primary noise member 14 , the primary noise member 14 will make a squeaking sound. The presence of the primary noise member 14 gives the patient one more item to play with and increases the likelihood that the patient will perceive the child friendly mask attachment as a toy and not as a medical device.
[0024] The present embodiment also features a secondary noise member 15 . The secondary noise member 15 is a standard whistle. When the patient breathes into the standard anesthesia mask, the air will pass through the primary gas tube 3 of the anesthesia mask, into the universal tube attachment 13 , through the connecting tube 12 , and through the secondary noise member 15 , causing the secondary noise member 15 to make a whistling sound. Like the primary noise member 14 , the secondary noise member 15 may be included to increase the likelihood that the patient will perceive the child friendly mask attachment as a toy and not as a medical device. The secondary noise member 15 should be removably attached to the connecting tube so that the secondary noise member 15 may be removed before the connecting tube 12 is attached to an appropriate anesthesia delivery system.
[0025] It should be noted that the multiple features present in FIG. 5 are shown together only to decrease the number of drawings necessary in the present disclosure. Each of the features present in FIG. 5 may be used singly or in concert, in this or any previous or other embodiment. The presence of any feature in FIG. 5 is not intended and does not in any way require that feature to appear together with any other feature presented in FIG. 5 . Any feature in FIG. 5 may be used or omitted from any given embodiment.
[0026] While the present invention has been described above in terms of specific embodiments, it is to be understood that the invention is not limited to these disclosed embodiments. Many modifications and other embodiments of the invention will come to mind of those skilled in the art to which this invention pertains, and which are intended to be and are covered by both this disclosure and the appended claims. It is indeed intended that the scope of the invention should be determined by proper interpretation and construction of the appended claims and their legal equivalents, as understood by those of skill in the art relying upon the disclosure in this specification and the attached drawings. | Children are often frightened by the bizarre appearance of standard anesthesia masks. A child friendly anesthesia mask attachment is disclosed, which covers some of portions of the standard anesthesia mask with child friendly objects. The child can then be encouraged to play with the mask and become familiar with placing it on his or her face prior to a medical procedure. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application takes priority from U.S. Provisional Patent Application Ser. No. 60/576,281 filed on Jun. 1, 2004.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates generally to magnetic bearings and, in particular aspects, to the design of such bearings for resistance to magnetic coil failures.
2. Description of the Related Art
Bearings have a rotatable rotor and a stationary stator within which the rotor rotates. Some means of reducing friction between the rotor and stator is necessary. Magnetic bearings replace ball bearings or lubricants with a magnetic field that maintains the rotor in a spaced relation from the stator and allows the rotor to rotate in an essentially frictionless manner with respect to the stator. Magnetic bearings promise significant improvements for uses in space as, for example, storage of power in flywheels and the like. Magnetic suspensions (MS) satisfy the long life and low loss conditions demanded by satellite and ISS (International Space Station) based flywheels used for Attitude Control and Energy Storage (ACES) service.
Homopolar magnetic bearings are those in which the rotor is exposed to a single magnetic polarity (i.e., north or south). Homopolar magnetic bearings are advantageous since they commonly use permanent magnets for bias flux to increase the actuator's efficiency and reduce heat generation. Points on the surface of the spinning journal in the homopolar bearing do not experience north-south flux reversals thereby reducing rotor losses due to hysteresis and eddy currents. Radial magnetic bearings are bearings in which the rotor is magnetically supported radially with respect to the stator, while “combo” bearings provide magnetic support for the rotor in both the radial and axial directions with respect to the stator.
To create the magnetic field, one or more magnetic coils are disposed within the stator. Often, multiple magnetic coils are placed in the stator to form the magnetic field, as this provides for redundancy. Even with multiple coil stators, however, faults are a problem, and it would be desirable to have a bearing that is fault-tolerant. If one or more of the coils were to fail, the flux coupling that retains the rotor in its spaced relation from the stator may become unstable, allowing contact between the rotor and stator or by a “catcher bearing.”
There are currently no acceptable known techniques for making a homopolar magnetic bearing “fault-tolerant.” The present invention addresses the problems of the prior art.
SUMMARY OF THE INVENTION
In one aspect, the present invention teaches a magnetic bearing for supporting a spinning shaft in the radial direction and/or the axial direction. The magnetic bearing includes a rotor formed on a portion of the shaft and a stator positioned around the rotor. In one arrangement, a plurality of poles in the stator creates a magnetic field that supports the rotor. Each pole produces a pole force and is separated by pole gaps. In embodiments, the poles are shaped to reduce eddy currents and field fringing and are shaped by removing mass in magnetically underutilized regions, the underutilized regions being identified using magnetic field simulations. The number of poles is at least sufficient to provide a set of pole forces that sum to produce a selected control force if there is an at least partial loss of current to one or more of the poles. The number of poles can also be selected by performing a statistical analysis of multiple pole configurations. The bearing also includes a set of permanent magnetic elements associated with the plurality of poles that create a homopolar, bias magnetic field in the pole gaps. The permanent magnetic elements are installed into the stator by applying a force that reduces the magnetic properties of the permanent magnetic element and holding the permanent magnetic element in the stator using a support element. In an exemplary configuration, at least one decoupling choke supplying power to the poles and at least one secondary decoupling choke conditioning the magnetic field created by the poles.
A controller connected to the poles is programmed with instructions to change the current to each pole in response to at least a partial loss of current to one or more of the poles. The controller includes a current distribution matrix for determining a current value for each pole in response to a failure in at least one of the poles. Also, the controller can be programmed to provide a linearized and decoupled relationship between a control voltage applied to the poles and the control force created by the poles.
In other aspects, the invention provides an improved magnetic bearing, system, and method that improves reliability via fault tolerant operation. Flux coupling between poles of a homopolar magnetic bearing is shown to deliver desired forces even after termination of coil currents to a subset of “failed poles”. Linear, coordinate decoupled force-voltage relations are also maintained before and after failure by bias linearization. Current distribution matrices (CDM), which adjust the currents and fluxes following a pole set failure, are determined for many faulted pole combinations. The CDM's and the system responses are obtained utilizing 1D magnetic circuit models with fringe and leakage factors derived from detailed, 3D, finite element field models. Reliability results are presented vs. detection/correction delay time and individual power amplifier reliability for 4, 6, and 7 pole configurations. Reliability is shown for two “success” criteria, i.e. (a) no catcher bearing contact following pole failures and (b) re-levitation off of the catcher bearings following pole failures. An advantage of the method presented over other redundant operation approaches is a significantly reduced requirement for backup hardware such as additional actuators or power amplifiers.
It should be understood that examples of the more important features of the invention have been summarized rather broadly in order that detailed description thereof that follows may be better understood, and in order that the contributions to the art may be appreciated. There are, of course, additional features of the invention that will be described hereinafter and which will form the subject of the claims appended hereto.
BRIEF DESCRIPTION OF THE DRAWINGS
For further understanding of the nature and objects of the present invention, reference should be had to the following drawings in which like parts are given like reference numerals and wherein:
FIG. 1 is a schematic illustration of a six-pole homopolar magnetic bearing.
FIG. 2 depicts an equivalent magnetic circuit for the homopolar bearing shown in FIG. 1 .
FIG. 3 illustrates a flywheel system with a magnetic suspension in accordance with one embodiment of the present invention.
FIG. 4 is a schematic depiction of a magnetic suspension control scheme, in accordance with the present invention.
FIG. 5 is a series of charts depicting rotor displacements in the radial and axial directions for Example 2.
FIG. 6 is a series of charts depicting current responses in a combo bearing for Example 2.
FIG. 7 is a chart illustrating system reliabilities of 4, 6 and 7-pole radial bearings with τ d =20 (ms).
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 depicts an exemplary magnetic bearing assembly, or actuator, 10 in which a magnetic bearing 12 supports a rotor shaft 14 rotatably disposed within a stator 16 . FIG. 1A shows the magnetic bearing in cross-section. The assembly 10 also includes an axial catcher beating 18 that secures the rotor 14 against axial movement with respect to the stator 16 . The stator 16 includes a generally annular body 20 that defines a rotor opening 22 therewithin. The stator 16 has a plurality of electromagnetic coils, or poles, 24 (six shown in FIG. 1 ) that create a magnetic field, which supports the rotor 14 . Power is supplied to the coils 24 flom a secondary coil decoupling choke 26 and amplified by power amplifiers 28 . The secondary coil decoupling choke 26 is operably interconnected to a tertiary coil decoupling choke 30 . The secondary and tertiary decoupling chokes 26 , 30 are inductors that unify and smooth the magnetic flux created by the coils 24 . An air gap 22 is left between the rotor 14 and the stator 16 .
Attractive magnetic bearing actuators as shown in FIG. 1 possess individual pole forces that vary quadratically with current. The net force of the bearing 12 may be linearized with respect to the control voltages by utilizing a bias flux component. Thus the X 1 , X 2 and X 3 forces become decoupled, i.e. dependent only on their respective control voltages (V c1 , V c2 and V c3 ). A generalization of this approach has been provided for heteropolar magnetic bearings (HEMB), which derive their bias flux from electric coils and utilize both N and S at different poles.
Fault tolerant control of HEMB's has been demonstrated on a 5-axis, flexible rotor test rig with 3 CPU failures and 2 (out of 8) adjacent coil failures. Current distribution matrices for HEMB's were extended to cover 5 pole failures out of 8 poles and for the case of significant effects of material path reluctance and fringing. The fault tolerant approach outlined above utilizes a current distribution matrix (CDM) that changes the current in each pole after failure in order to achieve linearized, decoupled relations between control forces and control voltages, i.e.
f cj =K vj V cj j=1,2,3 (1)
A failure configuration is defined by the subset of poles that fail due either to shorting of a turn in a coil or to failure of a power amplifier. In general there exist (2 n −1) number of possible failure configurations for an n pole magnetic bearing.
A unique contribution of the present invention includes extension of a CDM approach to 4, 6 and 7 pole homopolar magnetic bearings (HOMB). The HOMB commonly uses permanent magnets for its bias flux to increase the actuator's efficiency and reduce heat generation. Points on the surface of the spinning rotor journal 14 in the homopolar bearing 12 do not experience north-south flux reversals thereby reducing rotor losses due to hysteresis and eddy currents. A further contribution of the present invention is an investigation of the reliabilities of fault-tolerant HOMBs. The reliabilities presented are system specific for two reasons. First, an exact solution CDM may not exist for certain pole failure configurations. An approximate solution will always exist though and its effectiveness is verified or nullified via failure simulation for the specific system studied. Second, the two types of reliability presented correspond to whether a successful outcome is defined by: Successful Outcome 1 (SO 1 ): No contact between the shaft 14 and catcher bearings 18 during the failure and CDM implementation sequence, or Successful Outcome 2 (SO 2 ): Shaft 14 contact with a catcher bearing 18 then re-levitation occurs during the failure and CDM implementation sequence. Satisfaction of these success criteria will depend on the system studied and the delay time τ d required to identify which poles 24 have failed, to turn off the power amplifiers 28 for these poles and to implement the corresponding CDM for the remaining poles 24 .
Two types of successful outcomes are defined in order to provide the system designer with magnetic bearing component reliabilities estimates that are either independent (SO 1 ) or dependent (SO 2 ) on the accuracy of the catcher bearing simulation model. Therefore reliabilities are presented for the SO 1 and SO 2 conditions and for a range of τ d values.
The specific system employed for this study is a high-speed flywheel under development for energy storage and attitude control applications on satellites or on the ISS. A general result identified from the study is an increase in reliability as the number of poles increase.
Fault Tolerant Control (FTC)
Derivation of the FTC approach requires applications of Ampere's, Ohm's, Faraday's Laws and the Maxwell Stress Tensor to the multi-path magnetic circuit in a magnetic bearing. The physical requirements of FTC include
(a) Decoupling Condition: The x i control voltage (V ci ) does not affect the x j control force (F xj ) unless i=j, where x i =x (radial) x 2 =y (radial) and x 3 =z (axial).
∂ F xj /∂V ci =0 , i≠j and i, j= 1,2,3 (2)
(b) Linearity Condition: The x i control voltage (V ci ) and x i control force (F xi ) are linearly related.
F xi =K vi V ci , i=1,2,3 (3)
where K vi is evaluated at the desired operating location of the shaft in the bearing.
(c) Invariance Condition 1: The gains K vi are not affected by the failure.
(d) Invariance Condition 2: The force/position gains
K pi =(∂ F xj /∂x i )| V cj =0,X j =X j0 ,(j=1,2,3) , i= 1,2,3 (4)
are not affected by the failure. The steady state operating point of the shaft in the bearing has coordinates X j0 .
The FTC requirement (d) is automatically satisfied for a magnetic beating with bias fluxes generated by permanent magnets (PM) 47 . This results since the PM's and the resulting bias flux are unaffected by the failure state of the poles.
A complete derivation of the FTC theory is developed next for a 6-pole homopolar combination (combo, radial and axial forces) magnetic bearing (6PHCB). The FTC theory for the 4 and 7 pole bearings is very similar and is not included.
B. Six (6) Pole Homopolar Combo Bearing (6PHCB)
FIG. 1 depicts a combination (radial/axial) 6PHCB 12 installed on a vertically directed shaft 14 . The actuator 10 has 6 radial poles and coils 24 and 2 axial poles and coils 34 , 36 . The axial coils 34 , 36 are wound circumferentially around the shaft 14 and the radial coils 24 are wound around the poles. The coil leads 38 also form secondary coils around a common de-coupling choke (DC) 26 and the axial leads also form tertiary coils around a second DC 30 . The DC's eliminate mutual inductances and insure that the inductance matrix is non-singular, which insures electric circuit stability. Laminated construction provides for an accurate approximation of infinite bandwidth between currents and fluxes.
Following common practice, the actuator 10 is modeled as an equivalent circuit with derated magnetic strength accounting for leakage and derated gap flux density (B i ) to account for fringing. FIG. 2 shows the 6 flux paths through the radial poles and 2 flux paths through the axial poles. The NI sources 40 represent radial and axial control current flux sources. The H c L pm ( 42 ) and R pm ( 44 ) terms represent the permanent magnet source strength for driving bias flux and the reluctance of the permanent magnet, respectively. The magnetic circuit provides a useful tool to present flux conservation and Ampere Law relations with an equivalent electric circuit model. Kirchhoffs law applied to FIG. 2 yields.
[ R 1 - R 2 0 0 0 0 0 0 0 R 2 - R 3 0 0 0 0 0 0 0 R 3 - R 4 0 0 0 0 0 0 0 R 4 - R 5 0 0 0 0 0 0 0 R 5 - R 6 0 0 R pm R pm R pm R pm R pm R pm + R 6 - R 7 0 0 0 0 0 0 0 R 7 - R 8 1 1 1 1 1 1 1 1 ] [ Φ 1 Φ 2 Φ 3 Φ 4 Φ 5 Φ 6 Φ 7 Φ 8 ] = [ N 1 - N 2 0 0 0 0 0 0 0 N 2 - N 3 0 0 0 0 0 0 0 N 3 - N 4 0 0 0 0 0 0 0 N 4 - N 5 0 0 0 0 0 0 0 N 5 - N 6 0 0 0 0 0 0 0 N 6 - N 7 0 0 0 0 0 0 0 N 7 - N 8 0 0 0 0 0 0 0 0 ] [ I 1 I 2 I 3 I 4 I 5 I 6 I 7 I 8 ] + [ 0 0 0 0 0 H c L pm 0 0 ] R Φ = N I + H ( 5 )
Let A represent a diagonal matrix of pole gap areas then by assuming uniform flux densities in each gap
AB=Φ (6) B=VI+B bias (7) V=A −1 R −1 N (8) B bias =A −1 R −1 H (9)
where the reluctance of gap i is
R i =g i /(μ 0 a i ) (10)
and N i and a i are the number of turns on pole i and the gap-cross section area, respectively. The term V in (8) and the VI term in (7) show that the control flux (VI) varies with control current and with shaft position (gap values), however the bias flux (B bias ) varies solely with shaft position.
Magnetic bearings typically utilize servo power amplifiers (PA) that provide 1.2–2.0 (kHz) bandwidth for inductive loads ranging between 2 (mH) and 8 (mH). Thus it is acceptable to use a constant for the control current per control voltage gain. Let
V c =( V c1 V c2 V c3 ) T (11)
represent the control voltages and the matrix T is the current distribution matrix (CDM). Then in the absence of pole failures
I′=TV c (12)
where T includes the PA gain and the current distribution terms. Fault conditions are represented using the matrix K that has a null row for each faulted pole. Then the failed actuator control currents become
I=KI′=KTV c (13)
For example if coils 1 and 2 fail
K =diag(0 0 1 1 1 1 1 1) (14)
The magnetic forces are determined from the Maxwell stress tensor as;
F j =B T γ j B (15)
where
γ 1 =diag[ a i cos θ i /(2μ 0 )], i= 1˜6, γ 1 (7,7)=γ 1 (8,8)=0 (16)
γ 2 =diag[ a i sin θ i /(2μ 0 )], i= 1˜6, γ 2 (7,7)=γ 2 (8,8)=0 (17)
γ 3 (7,7)=−γ 3 (8,8)= a′/ (2μ 0 ), all other components are zero (18)
Substitute (13) into (7):
B=WV c +B bias ( 19 )
where W=VKT. The magnetic forces are given in terms of control voltages and bias flux density as;
F j =V c T W T γ j WV c +2 B bias T γ j WV c +B bias T γ j B bias for j= 1, 2, 3 (20)
The magnetic forces are proportional to the square of control voltages in (20). The following constraint equations must be satisfied in order to meet FTC requirements (a), (b), and (c).
W T γ 1 W=0 3×3 (21)
2B bias T γ 1 W=[K v1 0 0 ] (22)
W T γ 2 W= 0 3×3 (23)
2B bias T γ 2 W=[0 K v2 0] (24)
W T γ 3 W= 0 3×3 (25)
2B bias T γ 3 W=[0 0 K v3 ] (26)
Let
W=[W 1 W 2 W 3 ] (27)
Then the 27 constraint equations become
W
i
T
γ
j
W
k
=
0
,
i
,
j
,
k
=
1
,
2
,
3
and
k
≥
i
(
28
)
B
bias
T
γ
i
W
j
=
{
0
for
i
≠
j
K
vi
/
2
for
i
=
j
,
i
,
j
=
1
,
2
,
3
and
j
≥
i
(
29
)
Equations (28) and (29) are 18 nonlinear and 9linear algebraic equations for the CDM entries, t ij . The CDM matrix entries are obtained by requiring simultaneous solution of the equations in (28) and (29), and minimization of the Frobenius matrix norm of the CDM matrix. This is typically performed at the magnetic center, i.e. the location where the bias flux balances the static loads on the bearing 12 . The norm of the current vector, I in (13), satisfies the consistency condition
∥ I∥≦∥K∥·∥T∥·∥V c ∥ (30)
where for a Frobenius norm
K
=
∑
i
,
j
K
ij
2
(
31
)
T
=
∑
i
,
j
t
ij
2
(
32
)
V
c
=
∑
i
,
j
V
ci
2
(
33
)
Thus by (30) reduction of ∥I∥ follows from minimizing ∥T∥. The Lagrange multiplier approach is employed to locate a solution of the equations in (28) and (29), that minimize ∥T∥. The cost function is
L = ∑ i = 1 p ∑ j = 1 3 t ij 2 + ∑ k = 1 27 λ k h k ( 34 )
where p is the number of functioning poles and h k are the constraint equations in (28) and (29). The solution condition is;
∂ L ∂ Z m = 0 , Z m ∈ { t ij , λ k } ( 35 )
which implies
F
(
t
ij
,
λ
k
)
=
[
h
1
⋯
h
27
∂
L
∂
t
11
∂
L
∂
t
12
∂
L
∂
t
13
⋯
∂
L
∂
t
p
1
∂
L
∂
t
p
2
∂
L
∂
p
3
]
T
=
0
(
36
)
The total set of equation is over-determined, i.e. more equations than unknowns, therefore a solution exists only in the least square (LS) sense. The nonlinear equation, LS based solver available in MATLAB is employed for this purpose. The effectiveness of each solution in satisfying the FTC requirements must be checked by transient response simulation of the respective fault event since the LS solution is not exact. Fortunately the feedback control action compensates for the presence of residuals in the solution of (35), in many instances.
6 Pole Homopolar Radial Bearing (6PHRB)
A 6 pole homopolar radial bearing (6PHRB) provides force solely in the two transverse (radial) directions. The flux-current relations for this circuit are obtained by applying Kirchoff's laws, which yield
[
R
1
-
R
2
0
0
0
0
0
R
2
-
R
3
0
0
0
0
0
R
3
-
R
4
0
0
0
0
0
R
4
-
R
5
0
0
0
0
0
R
5
-
R
6
R
d
+
R
pm
R
d
+
R
pm
R
d
+
R
pm
R
d
+
R
pm
R
d
+
R
pm
R
d
+
R
pm
+
R
6
]
[
Φ
1
Φ
2
Φ
3
Φ
4
Φ
5
Φ
6
]
=
[
N
1
-
N
2
0
0
0
0
0
N
2
-
N
3
0
0
0
0
0
N
3
-
N
4
0
0
0
0
0
N
4
-
N
5
0
0
0
0
0
N
5
-
N
6
0
0
0
0
0
N
6
]
[
I
1
I
2
I
3
I
4
I
5
I
6
]
+
[
0
0
0
0
0
H
c
L
pm
]
(
37
)
R
d
=
g
0
d
2
-
x
1
2
-
x
2
2
/
(
μ
0
a
d
)
(
38
)
The FTC requirements result in 10 constraint equations
W T γ 1 W=0 2×2 (39)
2B bias T γ 1 W=[K v1 0] (40)
W T γ 2 W=0 2×2 (41)
2B bias T γ 2 W=[0 K v2 ] (42)
These equations are solved for t ij and λ k utilizing the Lagrange multiplier/nonlinear least square solver approach discussed for the 6PHCB.
Decoupling Choke
The inductance matrix of an isolated combo bearing is singular because flux conservation introduces a dependency relation between the fluxes. This produces a potentially unstable operation state for the power amplifiers. Two decoupling chokes are added to the combo bearing according to a known technique referred to as Meeker's approach. By adjusting the parameters (N c1 , N c2 , N c3 , R c1 , R c2 ) of the decoupling chokes 26 , 30 , the inductance matrix becomes full rank and the mutual inductances become zero. Similarly, a single decoupling choke is added to the radial bearing.
Force Linearization
An exact solution for the t ij can be obtained only for a “no-poles failed” case. Consequently the FTC linearization and decoupling conditions are only approximately satisfied and the force expressions in (20) are still somewhat nonlinear. Closed loop, coupled, flexible body simulations of the flywheel rim and shaft, housing, gimbals, and support structure provide predictions of stability, transient and steady-state harmonic responses. Efficient run-times for these models require linearized expressions for the X 1 , X 2 and X 3 magnetic forces. These expressions are obtained by applying a two-term Taylor series expansion about the operating point P 0 ={x j =x j0 ,v cj =v cj0 }. This yields
F i = ∑ j = 1 3 { - K pij ( x j - x j 0 ) + K vij ( v cj - v cj 0 ) } ( 43 ) K pij = [ - 2 B bias T γ i ( ∂ B bias / ∂ x j ) ] ❘ P 0 ( 44 ) K vij = [ 2 B bias T γ i W ( ∂ V c / ∂ v cj ) ] ❘ P 0 ( 45 )
for i, j=1,2,3. The K pij and K vij expressions in (44) and (45) are referred to as “position” and “voltage” stiffnesses respectively. The K vij terms are zero for i≠j, only if equation (36) is satisfied exactly. Equation (20) shows that the K pij , as defined in (44), are independent of the t ij , when V c0 is a null vector, which is typically true.
Flywheel and Magnetic Suspension Dynamics Model
The novel redundant actuators operate within a feedback-controlled system that includes both electrical component and structural component dynamics. A typical application is a flywheel module consisting of a high-speed shaft, integrally mounted motor-generator, composite flywheel rim, magnetic suspension and flexibly mounted housing. FIG. 3 depicts a module model 50 with 9 rigid body structural degrees of freedom: rotor CG translations (X 1r , X 2r , X 3r ), rotor rotations (θ 1r , θ 2r ), housing CG translations (X 1h , X 2h ) and housing rotation (θ 1h ,θ 2h ). The magnetic suspension employs magnetic (MB) and backup (catcher, CB) bearings 52 , 54 , respectively, at both the A and B ends of the module. Magnetic bearing clearances are approximately 0.5 (mm) so small angle motion may be assumed. Let b, d and c denote the magnetic actuator (equation 20), mass imbalance and catcher bearing forces, respectively. The structural equations of motion for the rotor are:
M r X ¨ ir = F ib A + F ib B + F id A + F id B + F ic A + F ic B i = 1 , 2 ( 46 ) M r X ¨ 3 r = F 3 b A - M r g + F 3 c A ( 47 ) I tr θ ¨ 1 r + I pr ω θ . 2 r = M 1 r + M 1 rc A + M 1 rc B ( 48 ) I tr θ ¨ 2 r - I pr ω θ . 1 r = M 2 r + M 2 rc A + M 2 rc B ( 49 )
For the housing the equations of motion are:
M h X ¨ ih = F ie A + F ie B - F ib A - F ib B - F ic A - F ic B i = 1 , 2 ( 50 ) I tih θ ¨ ih = M ih + M ihc A + M ihc B i = 1 , 2 ( 51 )
where
M
1
r
=
-
L
br
A
F
2
b
A
+
L
br
B
F
2
b
B
-
L
dr
A
F
2
d
A
+
L
dr
B
F
2
d
B
(
52
)
M
2
r
=
L
br
A
F
1
b
A
-
L
br
B
F
1
b
B
+
L
dr
A
F
1
d
A
-
L
dr
B
F
1
d
B
(
53
)
M
1
h
=
L
bh
A
F
2
b
A
-
L
bh
B
F
2
b
B
-
L
e
A
F
2
e
A
+
L
e
B
F
2
e
B
(
54
)
M
2
h
=
-
L
bh
A
F
1
b
A
+
L
bh
B
F
1
b
B
+
L
e
A
F
1
e
A
-
L
e
B
F
1
e
B
(
55
)
F
1
e
A
=
-
K
e
(
X
1
h
+
L
e
A
θ
2
h
)
-
C
e
(
X
.
1
h
+
L
e
A
θ
.
2
h
)
(
56
)
F
1
e
B
=
-
K
e
(
X
1
h
-
L
e
B
θ
2
h
)
-
C
e
(
X
.
1
h
-
L
e
B
θ
.
2
h
)
(
57
)
F
2
e
A
=
-
K
e
(
X
2
h
+
L
e
A
θ
1
h
)
-
C
e
(
X
.
2
h
+
L
e
A
θ
.
1
h
)
(
58
)
F
2
e
B
=
-
K
e
(
X
2
h
-
L
e
B
θ
1
h
)
-
C
e
(
X
.
2
h
+
L
e
B
θ
.
1
h
)
(
59
)
More sophisticated models with internal dynamics of races and balls or rollers are available and could also be used in the system dynamics model. Let j=1,2 represent the A and B ends of the flywheel module (not shown), respectively. Also let r j represent the relative displacement between the catcher bearing (not shown) and rotor shaft (not shown) at end j.
r j = ( X 1 rc j - X 1 hc j ) 2 + ( X 2 rc j - X 2 hc j ) 2 ( 60 )
Then if r 0 is the catcher bearing clearance and r j ≧r 0
F n j = K c ( r j - r 0 ) + C c r . j ( 61 ) F 1 c j = - F n j ( cos θ j - μsin θ j ) ( 62 ) F 2 c j = - F n j ( sin θ j + μcos θ j ) ( 63 ) M 1 rc j = ( - 1 ) j L cr j F 2 c j ( 64 ) M 2 rc j = ( - 1 ) j + 1 L cr j F 1 c j ( 65 ) M 1 hc j = ( - 1 ) j + 1 L ch j F 2 c j ( 66 ) M 2 hc j = ( - 1 ) j L ch j F 1 c j ( 67 )
Similarly for the axial direction if |X 3r |≧0.
F
3
c
A
=
-
[
K
c
(
X
3
r
-
r
0
)
X
3
r
/
X
3
r
+
C
c
X
.
3
r
]
(
68
)
The mass imbalance disturbance in the model is described by
F
1
d
A
=
M
r
e
ω
2
cos
ω
t
(
69
)
F
2
d
A
=
M
r
e
ω
2
sin
ω
t
(
70
)
F
1
d
B
=
M
r
e
ω
2
cos
(
ω
t
+
ψ
)
(
71
)
F
2
d
B
=
M
r
e
ω
2
sin
(
ω
t
+
ψ
)
(
72
)
FIG. 4 illustrates the overall feedback control loop for the magnetic suspension. Eight power amplifiers 28 are utilized for a combo bearing and 6 power amplifiers 28 for a radial bearing. Five displacement sensors 62 measure the relative displacements between the rotor 14 and the stator housing 16 . Current distribution matrices (CDMs) 64 for combo and radial bearings are incorporated in a controller 66 to produce reference voltages for the 14 power amplifiers 28 that produce the desired currents in each coil 24 . The nonlinear magnetic forces are determined according with (20).
EXAMPLES
An example flywheel module illustrates operation and reliability of the redundant magnetic suspension. Table 1 lists the geometrical, inertia and stiffness parameters for the model. A suitable catcher bearing contact model can have a stiffness of 10 8 (N/m), a damping of 5,000 (N-s/m) and a dynamic friction coefficient of 0.1. Table 2 shows the magnetic bearing parameters for the MS model.
The 1D magnetic circuit model shown in FIG. 2 must be adjusted to include the effects of recirculation leakage of the flux between the N and S poles of any permanent magnet and for the effect of non-parallel (fringing) flux flow in the air gap of each pole. These adjustments are made with multiplicative factors applied to the gap flux and permanent magnetic (PM) coercive force in the 1D model, as derived from the 3D FE model. The PM coercive force is derated from 950,000 to 514,000 in the combo bearing and from 950,000 to 566,000 in the radial bearing. The air gap 22 fluxes are derated with a fringe factor of 0.9 for both the combo and radial bearings.
The remaining parameters of the system model include displacement sensor sensitivity=7874 (V/m), displacement sensor bandwidth=5000 (Hz), power amplifier DC gain=1 (A/V), and power amplifier bandwidth=1200 (Hz).
TABLE 1
FLYWHEEL MODEL PARAMETER LIST
Paramet
Paramet
er
Value
er
Value
M r
29.644 (kg)
M h
34.428 (kg)
I tr
0.26233 (kg.m 2 )
I pr
0.11129 (kg.m 2 )
I t1h
1.5337 (kg.m 2 )
I t2h
1.3993 (kg.m 2 )
K e
3.5024 × 10 5 (N/m)
C e
5.2535 × 10 3 (kg/s)
ω
60,000 (rpm)
e
2.54 × 10 −6 (m)
L br A
0.14051 (m)
L br B
0.13360 (m)
L dr A
0.14051 (m)
L dr B
0.13360 (m)
L sr A
0.17846 (m)
L sr B
0.16974(m)
L cr A
0.26765 (m)
L cr B
0.28067 (m)
L bh A
0.14051 (m)
L bh B
0.13360 (m)
L sh A
0.17856 (m)
L sh B
0.16974 (m)
L ch A
0.26765 (m)
L ch B
0.28067 (m)
L e A
0.26765 (m)
L e B
0.28067 (m)
ψ
π/2
TABLE 2
MAGNETIC BEARING PARAMETER LIST
Parameter
Combo Bearing
Radial Bearing
air gap
radial: 5.080 × 10 −4 (m)
Radial: 5.080 × 10−4 (m)
axial: 5.080 × 10 −4 (m)
dead pole: 0.00203 (m)
Radial pole face
3.924 × 10 −4 (m 2 )
4.746 × 10 −4 (m 2 )
area
Axial pole face
1.719 × 10 −3 (m 2 )
N/A
area
Dead pole face
N/A
4.962 × 10 −3 (m 2 )
area
total face area
3.178 × 10 −3 (m 2 )
3.844 × 10 −3 (m 2 )
of PM
Length of PM
0.0101 (m)
0.0101 (m)
number of turns
24
24
of radial coil
number of turns
37
N/A
of axial coil
relative per-
1.055
1.055
meability of PM
Coercive force
950000 (A/m)
950000 (A/m)
of PM
These 3D bearing models were also employed to verify the fault tolerant operation predicted with the 1D model. An example of this is the 3 pole failure results shown in Table 3. The control voltage sets in this table are;
TABLE 3
1D AND 3D MODEL COMPARISON OF PREDICTED
FORCES FOR 6 POLE COMBO BEARING
(73)
V
c
=
(
V
c1
V
c2
V
c3
)
T
=
{
(
1
V
0
0
)
T
for
set
1
(
0
1
V
0
)
T
for
set
2
(
0
0
1
V
)
T
for
set
3
Control
Force (N)
Voltage
Force
No Poles Failed
3 Poles Failed
Set
Direction
1D Model
3D Model
1D Model
3D Model
1
X1
11.64
12.95
11.64
12.96
1
X2
0
0.01
−0.14
−0.25
1
X3
0
0.04
0
−0.03
2
X1
0
0.02
0
−0.08
2
X2
11.64
13.3
11.59
13.17
2
X3
0
0.08
0
−0.05
3
X1
0
−0.4
0
−0.4
3
X2
0
0.66
0
0.66
3
X3
8.9
9.4
8.9
9.4
The inductance matrix of the combo bearing with the two decoupling chokes is given in henries as:
L CB =5.59×10 −4 ·diag(1 1 1 1 1 1 10.43 10.43) (74)
The inductance matrix of the radial bearing with a decoupling choke is given in henries as:
L RB =6.76×10 −4 ·diag(1 1 1 1 1 1) (75)
The current produced by a power amplifier (PA) is turned off at the moment of failure, which simulates an open circuit. This is implemented in the model by changing the K matrix in (13) from the identity matrix to its pole-failed value, i.e. a null row j for each failed pole j, while the no-pole failed CDM is retained. The appropriate CDM for the pole-failure configuration being tested is then swapped in following a delay time τ d . The MIMO control law in FIG. 4 is invariant throughout the entire simulation. The combo and radial bearing CDM's for the no pole failed state are:
T
o
A
=
[
0.30789
0.17776
0
0
0.35552
0
-
0.30789
0.17776
0
-
0.30789
-
0.17776
0
0
-
0.35552
0
0.30789
-
0.17776
0
0
0
-
0.11530
0
0
0.11530
]
and
T
o
B
=
[
0.28074
0.16209
0
0.32417
-
0.28074
0.16209
-
0.28074
-
0.16209
0
-
0.32417
0.28074
-
0.16209
]
(
76
)
The new CDM's for the poles 1 – 2 failed case in FIG. 1 are
T
12
A
=
[
0
0
0
0
0
0
-
0.66389
0
0
-
0.23032
-
0.58296
0
-
0.28545
-
0.48360
0
0.33734
-
0.57934
0
0
0
-
0.11530
0
0
0.11530
]
and
T
12
B
=
[
0
0
0
0
-
0.60475
0
-
0.21182
-
0.53041
-
0.34967
-
0.44211
0.30640
-
0.52769
]
(
77
)
The new CDM's for the poles 1 - 2 - 3 - 4 failed case in FIG. 1 are:
T
1234
A
=
[
0
0
0
0
0
0
0
0
0
0
0
0
-
0.60742
-
1.0622
0
1.2224
-
3.6408
×
10
-
3
0
0
0
-
0.11530
0
0
0.11530
]
and
T
1234
B
=
[
0
0
0
0
0
0
0
0
-
0.55379
-
0.96848
1.11460
-
3.3556
×
10
-
3
]
(
78
)
The text below discusses two illustrative examples that assume identical failures in both the radial and combo bearings. Although this represents a rare occurrence it serves to illustrate the method and analysis presented. Example 1 considers failing radial poles 1 and 2 , and example 2 considers failing radial poles 1 , 2 , 3 and 4 in FIG. 1 .
Consequently successful outcome criteria SO 1 is satisfied independent of the delay time τ d . In contrast, example 2's SO 1 is not always satisfied so that the 1 - 2 - 3 - 4 poles failed CDM's (T 1234 A ,T 1234 B ) must be activated after delay time τ d . The reliability for example 2 will be affected by the selection of SO 1 or SO 2 and the delay time τ d .
Successful outcome criteria 2 (SO 2 ) requires that the rotor 14 successfully levitates following contact with the catcher bearings (CB) 18 . This is highly dependent on whether backward whirl (BW) develops during the contact period. The BW state occurs due to friction at the contact interface between the rotor shaft 14 and CB 18 , which forces the shaft 14 to whirl (precess) in a direction opposite to the spin direction. The BW eccentricity is the CB clearance (typically 0.25 mm) for a rigid rotor 14 , and possibly a much larger value for a flexible shaft. The whirl frequency typically ranges from 0.4–1.0 times the spin frequency. This creates a potentially large centrifugal force that can damage the CB's or deflect the shaft into the MB's. The BW condition is mitigated by proper design of the flexible damped support, preload, clearance and friction coefficient for the CB's. Relevitation off of the CB's is very difficult once BW has fully developed.
Reliabilities of Magnetic Bearings
The reliability of a magnetic suspension (MS) is determined by considering the number of failed pole states that still meet the SO 1 or SO 2 criteria. This is dependent on the time delay τ d , modeling assumptions, number of poles in the bearing and the reliability of the power amplifier/coil units that drive and conduct the bearing currents. The 4 pole and 7 pole configurations require 2 less or 1 more power amplifiers than the 6 -pole configuration, respectively. The radial pole and permanent magnet cross-section areas, the number of turns of each radial coil, and the coercive force and the length of the permanent magnets for the 4 and 7 pole bearings are identical to those of the 6 -pole bearing.
TABLE 4
SUMMARY OF SIMULATION FOR RELIABILITY STUDY
Delay time
Delay time
Delay time
τ d
τ d
τ d
No Pole
20 (ms)
60 (ms)
100 (ms)
Failed
No. of
No. of
No. of
No. of
CDM
unfailed
No. of
No. of
SO1 +
No. of
SO1 +
No. of
SO1 +
No. of
n pole
Failed
Poles
Simulation
SO1
SO2
SO1
SO2
SO1
SO2
SO1
Bearing
Bearing
(j)
(I nj )
cases
cases
cases
cases
cases
cases
cases
4
Radial
2
6
4
4
4
4
4
4
4
3
4
4
4
4
4
4
4
4
4
1
1
1
1
1
1
1
1
Comb
2
6
4
4
4
4
4
4
4
o
3
4
4
4
4
4
4
4
4
4
1
1
1
1
1
1
1
1
6
Radial
2
15
12
12
0
12
0
12
0
3
20
20
20
9
20
8
20
8
4
15
15
15
15
15
15
15
12
5
6
6
6
6
6
6
6
6
6
1
1
1
1
1
1
1
1
Comb
2
15
12
12
1
12
0
11
0
o
3
20
20
20
15
20
9
20
8
4
15
15
15
15
15
15
15
12
5
6
6
6
6
6
6
6
6
6
1
1
1
1
1
1
1
1
7
Radial
2
21
16
21
0
21
0
21
0
3
35
33
34
11
29
4
30
0
4
35
35
35
29
35
20
35
14
5
21
21
21
21
21
21
21
21
6
7
7
7
7
7
7
7
7
7
1
1
1
1
1
1
1
1
Comb
2
21
13
14
0
14
0
14
0
o
3
35
28
28
13
28
5
28
1
4
35
35
35
28
35
21
35
11
5
21
21
21
21
21
21
21
17
6
7
7
7
7
7
7
7
7
7
1
1
1
1
1
1
1
1
The no-pole failed CDM's for the 7 pole bearing are:
T
o
A
=
[
0.33071
-
0.017910
-
4.6780
×
10
-
3
0.17799
0.26601
3.6330
×
10
-
3
-
0.067428
0.26396
-
2.7850
×
10
-
3
-
0.26676
0.16181
7.8561
×
10
-
4
-
0.29880
-
0.15575
1.7079
×
10
-
3
-
0.038458
-
0.29204
-
4.2590
×
10
-
3
0.15965
-
0.23855
4.9591
×
10
-
3
0
0
-
0.099552
0
0
0.099552
]
and
T
o
B
=
[
0.28402
0
0.17708
0.22206
-
0.63201
0.27690
-
0.25589
0.12323
-
0.25589
-
0.12323
-
0.063201
-
0.27690
0.17708
-
0.22206
]
(
79
)
The no-pole failed CDM's for the 4 pole bearing are:
T
o
A
=
[
0.52550
0
0
0
0.52550
0
-
0.52550
0
0
0
-
0.52550
0
0
0
-
0.17043
0
0
0.17043
]
and
T
o
B
=
[
0.46539
-
1.07319
×
10
-
3
7.3028
×
10
-
4
0.46371
-
0.46403
-
1.07319
×
10
-
3
7.3028
×
10
-
4
-
0.46571
]
(
80
)
The radial pole failure simulations are conducted with the combo bearing operating in a no-pole failed state, and vice versa. Failure occurs at 0.1 seconds into the simulation and swapping in of the new CDM occurs at a delay time τ d later. The number of j unfailed pole cases for an n pole bearing is given by the formula
I nj = ( n j ) = n ! j ! ( n - j ) ! ( 81 )
Table 4 summarizes the results of these simulations for swapping in the appropriate poles-failed (new) CDM for the delay times τ d of 20, 60, and 100 (ms), respectively. The SO 1 +SO 2 column considers all cases when either SO 1 or SO 2 occurs.
An n-pole, fail-safe, homopolar magnetic bearing is similar to an m-out-of-n system in a reliability model if stable control is maintained (SO 1 or SO 2 ) when at minimum m of the n poles (P.A. plus coil) are unfailed. Let R p represent the reliability of a “pole”, i.e. of the power amplifier plus its pole coil, at some specific point in its expected lifetime. Also assume that “poles” are identical and act independently. The system reliability then become
R S = ∑ k = m n α k R p k ( 1 - R p ) n - k ( 82 )
where α k are the number of SO 1 (or SO 1 +SO 2 ) cases in Table 4. The integer m in (82) is the minimum number of unfailed poles that are required for the n pole bearing to successfully levitate the shaft. The (n,m) pairs determined in this example are (4,2), (6,2) and (7,2). FIG. 7 shows system reliability vs. R p plots for the 4, 6 and 7 pole bearings for SO 1 and (SO 1 +SO 2 ) and τ d equal to 20, 60 and 100 (ms) for the zoomed-in range 0.9<R p <1. Axial control reliability is not considered in these figures since it is typically independent of radial direction control.
Current distribution matrices (CDM) are evaluated based on the set of poles that have failed and the requirements for uncoupled force/voltage control, linearity and specified force/voltage gains that are unaffected by the failure. The CDM algorithm also determines the CDM with a minimum Frobenius norm, which provides reduced effort (current required) operation of the HOMB. An advantage of the HOMB over a HEMB is the automatic invariance of the position stiffness before and after pole failure. This results from the bias flux source being permanent magnets. A simplified catcher bearing model is employed to evaluate the improvement in reliability which results from utilizing a success criterion (SO 2 ) based on re-levitation after catcher bearing contact vs. a criterion (SO 1 ) which excludes all contacts with the spinning shaft. The SO 1 criterion is more conservative since it does not depend on the accuracy of the catcher bearing model used in the simulation.
The numerical example presented exhibits several interesting trends which include (i) the reliability of the 4, 6 or 7 pole bearing is high even if the reliability of the pole decreases with time to 0.90; (ii) increased reliability with increased number of poles, (iii) high reliability without replacing the no-poles failed CDM with the appropriate poles-failed CDM, (iv) successful levitation with only 2 unfailed poles for the n=4, 6 and 7 pole HOMB's, (v)successful fault tolerant operation without changes to the MIMO control in FIG. 4 .
As is known, field fringing lowers the load capacity of the bearing by diverting flux away from the pole gaps. Also, eddy currents generate heat on the rotor that may lead to high temperatures that cause failure of rotor components. Accordingly, one aspect of the present invention includes shaping poles to mitigate both fringing and eddy currents. For example, during the shaping and laminate etching process, the pole tip or edge spacing can be carefully reduced to balance eddy current and fringing reduction with local saturation. The selection of the pole shape is performed at the design stage by utilizing magnetic field simulation software. Etching is a chemical process that removes smeared material that connects (shorts) individual laminates.
In another aspect of the present invention, the number of poles is determined using methodologies that increase reliability. The reliability of magnetic bearings in the presence of pole failures depends on the number of poles utilized. In an exemplary process, the number of poles is based on a statistical search approach. Under this process, This approach considers increasing the number of poles to improve the success rate for shaft levitation considering a myriad of coil failure combinations. The success rate is evaluated via simulations.
In another aspect of the present invention, the force-to-weight ratio of the poles is optimized to provide powerful yet lightweight poles. In one exemplary application, magnetic field simulations are employed to identify regions in the pole that can be removed or reduced without significantly impairing the magnetic field generated by the pole. For example, such regions can occur in the attachment of the magnetic bearings to the machine housing. Advantageously, removal of these magnetically under-utilized regions in the flux circuit that can be removed reduces the weight of the poles but has little, if any, deleterious effect on the magnetic field.
In some embodiments, the weight reduced magnetic bearing utilizes materials that are fragile. To accommodate such fragile material, a suitable assembly procedure includes inserting ceramic magnets into the back iron and stator laminates while reducing the magnetic properties of ceramic magnets using applied forces. Support elements adapted to receive and hold the magnets and bearing parts in precise position while a potting material applied to these parts is vacuum cured.
NOMENCLATURE
a d =
dead pole face area of radial bearing
a′ =
axial pole face area of combo bearing
C e , C c =
housing damping, contact damping
e =
rotor eccentricity
g 0 , g 0d =
radial air gap, air gap of dead pole of radial bearing
H c =
coercive force of permanent magnet
I tr , I pr =
rotor transverse and polar moment of inertia
I t1h , I t2h =
housing transverse moment of inertia
K e , K c =
housing stiffness, contact stiffness
L pm =
length of permanent magnet
M h , M r =
mass of housing, mass of rotor
N c1 , N c2 , N c3 =
number of turns on decoupling chokes
R c1 , R c2 =
air gap reluctance of decoupling chokes
θ i =
the angle of the ith radial pole
μ =
dynamic friction coefficient
Φ =
flux vector
ω =
rotor angular velocity
R p =
pole reliability
r d =
delay time to swap in appropriate CDM after pole
failure event
Those of skill in the art will recognize that numerous modifications and changes may be made to the exemplary designs and embodiments described herein and that the invention is limited only by the claims that follow and any equivalents thereof. | A magnetic bearing for supporting a spinning shaft in the radial direction and/or the axial direction includes a rotor formed on the shaft and a stator positioned around the rotor. Poles in the stator creates a magnetic field that supports the rotor. The number of poles is at least sufficient to produce a selected control force if there is an at least partial loss of current to one or more of the poles. The bearing also includes a set of permanent magnetic elements associated with the poles that create a homopolar, bias magnetic field. A controller connected to the poles is programmed with instructions to change the current to each pole in response to at least a partial loss of current to one or more of the poles and can include a current distribution matrix for determining a current value for each pole in such instances. | 5 |
TECHNICAL FIELD
This invention is related to the protection of confidential computer data against eavesdroppers who try to reconstruct it from the electromagnetic emanations generated by computers.
BACKGROUND OF THE INVENTION
It has been known to military organizations since at least the early 1960s that computers generate electromagnetic radiation which not only interferes with radio reception, but which also makes information about the processed data available to a remote radio receiver (see for example Peter Wright: Spycatcher—The Candid Autobiography of a Senior Intelligence Officer. William Heinemann Australia, 1987, ISBN 0-85561-098-0). Known as compromising emanation or Tempest radiation, this electromagnetic broadcast of data has been a significant concern in security-sensitive computer applications. Compromising emanations of video display units (see for example Wim van Eck: Electromagnetic Radiation from Video Display Units: An Eavesdropping Risk? Computers & Security vol 4 (1985) 269-286; Erhard Möller, Lutz Bernstein, Ferdinand Kolberg: Schutzmaβ nahmen gegen kompromittierende elektromagnetische Emissionen von Bildschirmsichtgeräten [Protective measures against compromising electromagnetic emissions from video display terminals]. Labor für Nachrichtentechnik, Fachhochschule Aachen, Aachen, Germany) and serial data cables (see Peter Smulders: The Threat of Information Theft by Reception of Electromagnetic Radiation from RS-232 Cables. Computers & Security vol 9 (1990) 53-58) have been described in the open literature. One common and expensive countermeasure is to fit metallic shielding to the device, the room, or the entire building (see Electromagnetic Pulse (EMP) and Tempest Protection for Facilities. Engineer Pamphlet EP 1110-3-2, 469 pages, U.S. Army Corps of Engineers, Publications Depot, Hyattsville, Dec. 31, 1990; and Deborah Russell, G. T. Gangemi Sr.: Computer Security Basics. O'Reilly & Associates, 1991, ISBN 0-937175-71-4). Cross-correlation test methods suitable for verifying the effectiveness of such shielding have been described in Wolfgang Bitzer, Joachim Opfer: Schaltungsanordnung zum Messen der Korrelationsfunktion zwischen zwei vorgegebenen Signalen [Circuit arrangement for measuring the correlation function between two given signals]. German Patent DE ˜ 3911155 ˜ C2, Deutsches Patentamt, Nov. 11, 1993, and Joachim Opfer, Reinhart Engelbart: Verfahren zum Nachweis von verzerrten und stark gestörten Digitalsignalen und Schaltungsanordnung zur Durchführung des Verfahrens [Method for the detection of distorted and strongly interfered digital signals and circuit arrangement for implementing this method]. German Patent DE ˜ 4301701 ˜ C1, Deutsches Patentamt, May 5, 1994. Devices that generate a correlated jamming signal in order to make eavesdropping more difficult have been described in John H. Dunlavy: System for Preventing Remote Detection of Computer Data from TEMPEST Signal Emissions. U.S. Pat. No. 5,297,201, Mar. 22, 1994, and Lars Hoivik: System for Protecting Digital Equipment Against Remote Access. U.S. Pat. No. 5,165,098, Nov. 17, 1992.
The electromagnetic data-dependent signals generated by computers and emanated over the air, or via power supply and communication cables, are rather weak and distorted. In addition, if several computers are located in close proximity, their signals will be overlaid. The eavesdropper will therefore use various techniques to separate the signals of interest from the background noise before attempting further decoding (see Markus G. Kuhn, Ross J. Anderson: Soft Tempest: Hidden Data Transmission Using Electromagnetic Emanations, in David Aucsmith (Ed.): Information Hiding, Second International Workshop, IH'98, Portland, Oreg., USA, Apr. 15-17, 1998, Proceedings, LNCS 1525, Springer-Verlag, ISBN 3-540-65386-4, pp. 126-143). Periodic averaging is a very powerful noise elimination technique and can be applied to many signals of particular interest from computer systems that process confidential data. If the signal of interest s(t) has a known period T such that s(t)=s(t+T) most of the time, then the eavesdropper can reconstruct from the received noisy signal r(t)=s(t)+n(t), where n(t) is uncorrelated background noise, a noise-reduced estimate of the signal from a moving average: ζ ( t ) = 1 n 2 - n 1 + 1 ∑ i = n 1 n 2 s ( t + iT ) for 0 ≤ t < T
which has a significantly better signal-to-noise ratio than s(t).
Three periodic signals found in a typical computer may contain confidential information and are thus of particular interest to an eavesdropper:
1. The video display signal is generated by writing the content of the display frame buffer to the display with a period equivalent to the vertical refresh frequency of the cathode-ray tube, liquid crystal panel, or other display device.
2. A microcontroller or a specialized circuit in the keyboard applies voltages in succession to each row of a matrix circuit to which the keys are connected. Scanning the column lines for this voltage allows the microcontroller or specialized circuit to determine which key is currently pressed in order to report the appropriate key code word to the main processor (see Ed L. Sonderman, Walter Z. Davis: Scan-controlled keyboard, U.S. Pat. No. 4,277,780, Jul. 7, 1981). This scan cycle is repeated with high frequency to ensure that no key-press events are missed. The sequence of instructions executed in the scan loop often depends on which key is currently pressed. Therefore the precise shape of the emanations reveals information about key presses, and manually entered text may be reconstructed by an eavesdropper.
3. In most mass storage devices such as magnetic or magneto-optical discs, data is organized into storage tracks and a motor moves the head between them. After data has been read from or written to a track, the head usually remains located on that track until a request to access another track is received. During this time, the readout amplifier receives, amplifies and emits the data content of the storage track periodically, where the period is identical to the rotation time of the disk.
SUMMARY OF THE INVENTION
The present invention is a low-cost means of making it more difficult for an eavesdropper to gain knowledge about the data processed on a normal computer system that features standard components such as a video display, a keyboard and a hard disk. In its most general terms the presents invention proposes that instead of, or in addition to, physical screening of an electronic system, the system should be designed or modified to reduce (or substantially eliminate) the generation of electromagnetic signals which are periodic or otherwise predictable.
Accordingly, the invention may be expressed as a method of obstructing the reconstruction of information contained in an electronic apparatus from electromagnetic emissions, by reducing the energy of certain periodic signals in electromagnetic emissions generated by the system and destroying the periodicity of residual signals or other signals.
These methods may involve only software or firmware changes in the computer system and can therefore be implemented at a much lower cost than the conventional techniques described above, in which electromagnetic radiation is reabsorbed after it has been generated (i.e. physical shielding). They may also be implemented using low-cost hardware devices. Whether they are implemented in software, firmware or hardware, these techniques can also be combined with traditional physical shields in order to provide an independent layer of protection against shield failure.
The general means of protection is to render signals more difficult for an attacker to recover using periodic averaging and cross-correlation techniques. Three specific methods are filtering out from periodic signals those spectral components that cause the highest levels of compromising radiation, spreading the spectrum of the residual information-bearing radiation using a sequence unknown to the attacker, and removing periodic signals directly. We will describe examples of these three techniques in turn.
An example of the first method consists of displaying text on the video display device using a special font that employs a plurality of pixel luminosities in order to represent character glyphs. The use of more than two pixel luminosities to display anti-aliased characters and thus avoid staircase effects in slanted lines and italic characters has been described in Richard B. Preiss, John C. Dalrymple: System and method for smoothing the lines and edges of an image on a raster-scan display, U.S. Pat. No. 4,672,369, Jun. 9, 1987, and Bradley J. Beitel, Robert D. Gordon, Joseph B. Witherspoon III: Anti-alias font generation, U.S. Pat. No. 5,390,289, Feb. 14, 1995}. The innovation in the present invention is to use a font specially designed so that the horizontal spatial frequency spectrum of the glyphs is adapted to the emission spectrum of the video display device so as to reduce the broadcast energy and thus minimize the range within which eavesdroppers can identify the displayed characters.
An example of the second method consists, firstly, of using a random number generator to select one of a number of character glyphs which are visually similar but which are generated by different video signals, in order to make it more difficult to reconstruct the signal using signal processing techniques; and secondly, introducing a variable delay into the keyboard matrix scan cycle, which makes it harder for eavesdroppers to reconstruct the compromising emissions of the keyboard. The innovation in the present invention is to randomise the inadvertently emitted signal and thus make its reconstruction by an attacker more difficult.
An example of the third method is to modify the device driver software or controller firmware responsible for the control of disk drives, or in general any mass storage device that uses moveable read/write heads to access a plurality of storage tracks on the surface of a storage medium. The innovation in the present invention is to park inactive read/write heads on a storage track that does not contain confidential data.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 shows a pixel field containing normal raster text.
FIG. 2 shows a pixel field containing horizontally low-pass filtered raster text, illustrating the application of the second emanation protection method described in this invention.
FIG. 3 shows a magnified photograph of the pixel field in FIG. 1 as it is displayed on a cathode-ray computer monitor.
FIG. 4 shows a magnified photograph of the pixel field in FIG. 2 as it is displayed on a cathode-ray computer monitor.
FIG. 5 shows an excerpt from the video signal generated by the pixel field shown in FIG. 1 .
FIG. 6 shows an excerpt from the video signal generated by the pixel field shown in FIG. 2, taken from the same pixel coordinates as those used in FIG. 5 .
FIG. 7 shows the video signal from FIG. 6 after it has passed a simple analog low-pass filter that has been installed on the computer video adapter output in order to attenuate the aliasing frequencies generated by the discrete nature of the video signal and by the shape of a single pixel pulse.
FIG. 8 shows a photograph of the screen of a Tempest eavesdropping receiver when the computer screen under surveillance contains normal raster text fonts as shown in FIG. 1 .
FIG. 9 shows a photograph of the screen of a Tempest eavesdropping receiver when the computer screen under surveillance contains horizontally low-pass filtered content as shown in FIG. 2, demonstrating the protective effect of this invention.
DETAILED DESCRIPTION
In the case of the video display unit, we shape the spectrum of the periodic video signal by using digital filtering or by combining digital filtering and anti-aliasing techniques to generate a character font with little spectral energy in those frequency ranges in which the computer monitor radiates particularly well. The spectral characteristics of the monitor are first determined by using the graphics adapter of the computer to display test images such as a zoneplate pattern. The emanations are then measured in an electromagnetic compatibility laboratory using a spectrum analyzer or a Tempest monitoring receiver. In one test system described in Markus G. Kuhn, Ross J. Anderson “Soft Tempest: Hidden Data Transmission Using Electromagnetic Emanations” (in David Aucsmith (Ed.): Information Hiding, Second International Workshop, IH'98, Portland, Oreg., USA, Apr. 15-17, 1998, Proceedings, LNCS 1525, Springer-Verlag, ISBN 3-540-65386-4, pp. 126-143) these measurements showed that for a video mode with 95 MHz pixel frequency, most of the emitted energy came from parts of the test image with frequencies in the range 33-47.5 MHZ. The emitted energy was not only present in this frequency range but also as higher harmonics of frequencies in this band.
Preferably, the present invention reduces the amount of emitted information bearing radiation by at least 10 dB, or more preferably by at least 20 dB or even 30 dB. This is because in the zoning model used by many governments to decide which classification of information may be processed on which type of apparatus in which zone of a building, a signal attenuation of 10 dB corresponds to a single zone (see Deborah Russell, G. T. Gangemi Sr.: Computer Security Basics. O'Reilly & Associates, 1991, ISBN 0-937175-71-4). Text displayed with a font in which all horizontal pixel lines have been processed with a digital filter to attenuate frequency components in this range by about 20 dB becomes practically invisible on a Tempest monitor while the display quality and readability of the text by persons in front of the authorised display device is only marginally affected. This processing can be achieved by passing the video signal through a suitable hardware filter, or more conveniently by software graphic processing.
In our typical embodiment, we start out with a high-resolution version of a character font and generate grey-level pixel images of the glyphs, selecting for the background and foreground luminosity 85% and 15% of the available maximal white luminosity in order to prevent overflow or underflow during subsequent filtering. We then apply a normal subsampling filter in both horizontal and vertical directions in order to prevent aliasing by removing all frequency components that are above the Nyquist limit of the final pixel spacing. Our innovation over existing anti-aliasing technology is to apply in the horizontal direction a further filter that attenuates those frequencies at which the video display device radiates compromising RF emanations efficiently. The spectral shape of the anti-emission filter depends on the results of the monitor emission measurements and on a signal energy versus display quality tradeoff.
After these filtering steps, the filtered high-resolution font is subsampled and stored for use by display routines. The resulting filtered glyphs may be significantly wider than the underlying original glyphs and thus the display routine must superpose them using addition, with the background (85%) luminosity treated as zero for the purpose of this addition. An example text that has been generated this way is shown in FIG. 2 as a pixel field and in FIG. 4 as a CRT screen photograph. FIG. 6 shows a typical video signal generated this way, from which further harmonics can be removed by an analog filter at the video adapter output, resulting in a smoother signal such as that shown in FIG. 7 . For best performance, a 30 MHz low-pass hardware filter is used; if the application admits only software countermeasures, then the filters installed in monitor cables for EMC and RFI compliance purposes together with the natural inductance of the cables and the limitations of the video amplifier circuitry have a similar if less controlled effect.
FIG. 9 shows the signal received by the eavesdropping receiver described in Markus G. Kuhn, Ross J. Anderson “Soft Tempest: Hidden Data Transmission Using Electromagnetic Emanations” (in David Aucsmith (Ed.): Information Hiding, Second International Workshop, IH'98, Portland, Oreg., USA, Apr. 15-17, 1998, Proceedings, LNCS 1525, Springer-Verlag, ISBN 3-540-65386-4, pp. 126-143), when the screen content has been low-pass filtered using software only as described by this invention. FIG. 1, FIG. 3, FIG. 5, and FIG. 8 illustrate the corresponding situation found with normal video display units if no protective filtering takes place; this gives a considerably better received signal as shown in FIG. 8 .
To further complicate automated radio frequency character recognition of displayed text using a digital eavesdropping receiver and pattern matching techniques, one typical embodiment utilizes a plurality of fonts that differ slightly in character style, size, and position and it randomly selects for every character of the displayed text one of these font variations.
In the case of the keyboard scan cycle, we adapt the same idea and spread the spectrum of the emanations by adding a variation and a random delay into the scan sequence. Transforming the scan cycle into a non-periodic process spreads the harmonics of the sample cycle frequency in the spectrum such that they cannot be extracted easily by periodic averaging. The random repetition delay between the application of voltages to the rows of the keyboard matrix is accomplished both by varying the order in which rows are scanned and by using delay loops to vary slightly the time that passes between the scan of one row and the next.
The choice of row order and delays depends on the output of a cryptographically strong random number generator that is periodically reseeded by combining its old internal state with keyboard input so as to make its output unpredictable to an eavesdropper. Cryptographic random number generators are described in Bruce Schneier: Applied Cryptography (John Wiley & Sons Inc, 1996, ISBN 0-471-11709-9). The emitted spectrum of the keyboard scan microcontroller and other processors in general can also be spread by slightly frequency modulating the clock signal of this processor using a random noise source, which creates an additional difficulty for eavesdropping receivers. Finally, the scan codes are encrypted for transmission along the keyboard cable to the computer in order to prevent direct eavesdropping of the serial cable emanations as described in Peter Smulders: The Threat of Information Theft by Reception of Electromagnetic Radiation from RS-232 Cables (Computers & Security vol 9 (1990) 53-58).
In the case of the mass storage device, we could also reduce the readability of confidential data in the unavoidable periodic signal that the read amplifiers generate as the device turns, by moving the disk head in a random or pseudorandom manner when it is not in use. However in this case there is available a simpler and deterministic remedy which imposes less mechanical wear on the device. We simply move the read head as soon as possible away from a sensitive track if no further read requests are pending. In our preferred implementation, the head is always moved to safe tracks—tracks that contain either no data at all or non-sensitive data—during disk idle times. The disk driver maintains a list of safe tracks to which the writing of sensitive data is prevented, and where there are a number of mechanically coupled heads to access stacked or otherwise juxtaposed media, there will be allocated a number of sets of safe tracks corresponding to disk head positions at which the writing of sensitive data is similarly not permitted.
Whenever the request queue for a device is empty and the last access was to a sector other than on a safe track, the driver will determine the closest safe track and either move the read head there directly or issue a read instruction to one of the sectors in this track depending on the disk interface. This way, the sensitive data content of the hard disk will only be amplified for the minimal necessary time and the probability that an eavesdropper can successfully reconstruct any of it by periodic averaging is significantly reduced. | A set of methods is specified whereby software reduces compromising electromagnetic emanations of computers that could otherwise allow eavesdroppers to reconstruct sensitive processed data using periodic averaging techniques. Fonts for screen display of text are low-pass filtered to attenuate those spectral components that radiate most strongly, without significantly affecting the readability of the text, while the character glyphs displayed are chosen at random from sets that are visually equivalent but that radiate differently. Keyboard microcontroller scan loops are also furnished with random variations that hinder reconstruction of the signal emanated by a keyboard. Drivers for hard disks and other mass-storage devices ensure that the read head is never parked over confidential data longer than necessary. | 6 |
BACKGROUND OF THE INVENTION
Since hydrocortisone was found to possess anti-inflammatory activity in treating rheumatoid arthritis, numerous synthetic analogues of glucocorticoids have been used to treat inflammatory and/or immune malfunctional diseases.
Although the beneficial effects of natural semisynthetic glucocorticoids have been appreciated for over 40 years, the limiting factor in the use of corticosteroids for the chronic and/or high dose treatment have been their systemic side-effects. Continual research to eliminate these systemic side effects was carried out and one of the side-effects, salt-retaining activity, was successfully abrogated by the introduction of C-1,2 double bond and C-16 methyl or hydroxyl substitutions shown by prednisolone, dexamethasone, betamethasone and triamcinolone. However, little success has been achieved in separating the anti-inflammatory effect of steroids from their adverse side-effects mainly occurred by glucocorticoidal activity.
Therapeutic approaches such as dosage forms for local application, alternate day administration and concomitant protective therapy have been employed to reduce the adverse systemic effects of potent steroids. Although systemic effects are known to be reduced when conventional steroids are applied topically, the use of steroids in large quantities for prolonged periods results in toxic systemic side-effects and all clinically effective topical steroids have the potential to produce adverse effects. Among the patients using steroids, children are particularly prone to the systemic effects of local steroid application and suppression of pituitary-adrenal function including growth retardation has been reported.
One structural modification by Laurent et al. in U.S. Pat. No. 3,944,577 was introducing a 20-carboxyl ester group. These compounds showed reduced systemic effects, however, the anti-inflammatory potency was not sufficient.
Steroid derivatives as described in U.S. Pat. No. 4,762,919 to Lee employed a similar strategy of introducing a carboxylic ester group to the steroid molecule. Several of these compounds showed high anti-inflammatory activity with greatly reduced systemic side-effects, but the synthetic procedures to the final compounds were found to be difficult. Therefore, other improvements were needed to provide acceptance for the new compounds.
It is an object of this invention to provide novel pregnane derivatives having carboxyester and amide groups connected to the cyclic acetal side-chain at strategic 17,21-17,20- or 16,17- positions of steroid molecule as safer anti-inflammatory steroids. It is another object of this invention to provide more convenient procedures for the synthesis of such steroid derivatives. Other objects will appear in the more detailed description which follows.
BRIEF DESCRIPTION OF THE INVENTION
This invention relates to carboxycyclic acetal pregnane derivatives of the formula: ##STR3## wherein X is H, F, Cl, or CH 3 ;
and Y is ##STR4## wherein R 1 is H, alkyl of 1-5 carbon atoms, phenyl, or benzyl;
R 2 is COOR 6 , R 5 COOR 6 , or R 5 CONHR 6 ;
R 3 is H, F, OH, or CH 3 ;
R 4 is CH 2 OH, CH 2 OCOR 6 , COOR 6 , or CONHR 6 ;
R 5 is alkyl of 1-3 carbon atoms;
R 6 is alkyl of 1-5 carbon atoms or benzyl;
represents a single or double bond;
˜ represents α-position, β-position or a mixture of both α-and β-positions; and
--- represents α-position.
In certain preferred embodiments of this invention, the derivatives can be represented by the formula: ##STR5## wherein X, R 1 and R 2 have the same meanings in Formula (I) above and R 7 is CH 2 OH or CH 2 OCOR 6 where R 6 has the same meaning as in Formula (I).
DETAILED DESCRIPTION OF THE INVENTION
The compounds of this invention are described by three formulas given below. ##STR6## wherein all symbols have the same meaning as given for Formula (I) above.
These compounds all provide improved properties for use as an anti-inflammatory drug. The improvement resides principally in greater reductions in the adverse side-effects than have been observed in previously known compounds. All of the compounds are carboxycyclic acetal pregnane derivatives, and more specifically, the derivatives of cortisol or of prednisolone.
The most desirable of all of the compounds of this invention for anti-inflammatory uses with minimal systemic side-effects are those of the formula: ##STR7## wherein x is H, F, Cl, or CH 3 ;
R 8 is H or COR 6 ;
R 9 is H, CH 3 , phenyl, or benzyl;
R 10 is COOR 11 , CH 2 COOR 11 , or CH 2 CH 2 CH 2 COOR 11 ; and
R 11 is alkyl of 1-5 carbon atoms.
Among the specific compounds which are included in this invention are the following illustrative compounds. It is to be understood that the invention is not limited to these named compounds, but that these merely represent various substitutes which may be combined in many ways. The numbering of the compounds follows the structural formula given below: ##STR8## (22R)-11β-Hydroxy-3,20-dioxo-17,21-(methyl, methoxycarbonyl)methylenedioxy-1,4-pregnadiene;
(22S)-11β-Hydroxy-3,20-dioxo-17,21-(methoxycarbonylmethyl)methylenedioxy-4-pregnene;
(22S)-11β-Hydroxy-3,20-dioxo-17,21-(benzyl, methoxycarbonyl-n-propyl)methylenedioxy-1,4-pregnadiene;
(22R)-11β-Hydroxy-3,20-dioxo-17,21-(methoxycarbonyl)methylenedioxy-1,4-pregnadiene;
(22R)-9α-Fluoro-16α-methyl-11β-hydroxy-3,20-dioxo-17,21-(methyl, methoxycarbonyl-n-propyl) methylenedioxy-1,4-pregnadiene;
(22R)-11β,21-Dihydroxy-3,20-dioxo-16α,17-(methyl, ethoxycarbonyl-n-propyl) methylenedioxy-1,4-pregnadiene;
(22S)-11β,21-Dihydroxy-3,20-dioxo-16α,17-(N-n-propylaminocarbonyl-n-propyl)methylenedioxy-4-pregnene;
(22R)-11β,21-Dihydroxy-3,20-dioxo-16α,17-(methoxycarbonyl)methylenedioxy-4-pregnene;
(22R)-6α,9α-Difluoro-11β,21-dihydroxy-3,20-dioxo-16α,17-(methyl, methoxycarbonyl-n-propyl) methylenedioxy-1,4-pregnadiene;
(22S)-9α-Fluoro-11β,21-dihydroxy-3,20-dioxo-16α,17-(phenyl, methoxycarbonyl-n-propyl) methylenedioxy-1,4-pregnadiene;
(22R)-9α-Fluoro-11β,21-dihydroxy-3,20-dioxo-16α,17-(methyl, methoxycarbonyl methyl) methylenedioxy-1,4-pregnadiene;
(22R)-9α-Fluoro-11β,21-dihydroxy-3,20-dioxo-16α,17-(methyl,n-butyloxycarbonylmethyl)methylenedioxy-1,4-pregnadiene;
(22R)-9α-Fluoro-11β,21-dihydroxy-3,20-dioxo-16α,17-(methoxycarbonyl)methylenedioxy-1,4-pregnadiene;
(22R)-9α-Fluoro-11β,21-dihydroxy-3,20-dioxo-16α,17-(methyl, N-methylaminocarbonyl-n-propyl)methylenedioxy-1,4-pregnadiene;
(22R)-6α-Methyl-11β,21-dihydroxy-3,20-dioxo-16α,17-(methyl, methoxycarbonylmethyl)methylenedioxy-1,4-pregnadiene;
(22S)-11β-Hydroxy-21-acetoxy-3,20-dioxo-16α,17-(benzyl, methoxycarbonyl-n-propyl)methylenedioxy-1,4-pregnadiene;
(22R)-11β-Hydroxy-21-acetoxy-3,20-dioxo-16α,17-(methyl,methoxycarbonyl-methyl)methylenedioxy-1,4-pregnadiene;
n-Propyl (20R), (22R)-11β-hydroxy-3-oxo-17,20-(methyl,methoxycarbonyl-n-propyl)methylenedioxy-1,4pregnadien-21-oate;
Methyl (20S), (22R)-11β-hydroxy-3-oxo-17,20-(methyl,methoxycarbonyl-n-propyl)methylenedioxy-14-pregnadien-21-oate;
(20R), (22R)-21-(N-Methylamino)-11β-hydroxy-3,20-dioxo-17,20-(methyl,methoxycarbonyl-n-propyl)methylenedioxy-4-pregnene;
(20R), (22R)-21-Acetoxy-11β-hydroxy-3-oxo-17,20-(methyl,methoxycarbonylmethyl)methylenedioxy-1,4-pregnadiene;
(20S), (22R)-21-acetoxy-11β-hydroxy-3-oxo-17,20-(methyl,methoxycarbonyl-n-propyl)methylenedioxy-4-pregnene.
The process for preparing carboxycyclic acetal pregnane derivatives of this invention cyclicized through the 17,21-positions proceeds as follows:
(1) Hydrocortisone or prednisolone or dexamethasone or betamethasone is reacted with an alkyl acetylalkanoate in a solution of dichloromethane or dioxane in the presence of catalytic amount of perchloric acid to produce the corresponding 17,21-carboxycyclic acetal pregnane derivatives, e.g., when hydrocortisone and methyl acetylformate are used the product is (I) 11β-hydroxy-3,20-dioxo-17,21-(methyl,methoxycarbonyl)methylenedioxy-4-pregnane; when prednisolone and methyl acetylbutyrate are used the product is (II) 11β-hydroxy-3,20-dioxo-17,21-(methyl,methoxycarbonyl-n-propyl) methylenedioxy-1,4-pregnadiene; when dexamethasone and ethyl acetylacetate are used the product is (III) 9α-fluoro-11β-hydroxy-16α-methyl-3,20-dioxo-17,21-(methyl,ethoxycarbonylmethyl)methylenedioxy-1,4-pregnadiene;
(2) Hydrocortisone or prednisolone or dexamethasone or bethamethasone is reacted with an alkyl formylalkanoate in a solution of dichloromethane in the presence of catalytic amount of perchloric acid to produce the corresponding 17,21-carboxycyclic acetal pregnane derivatives, e.g., when hydrocortisone and methyl formylbutyrate are used the product is (IV) 11β-hydroxy-3,20-dioxo-17,21-(methoxycarbonyl-n-propyl) methylenedioxy-4-pregnene; when prednisolone and methyl formylacetate are used the product is (V) 11β-hydroxy-3,20-dioxo-17,21-(methoxycarbonylmethyl)methylenedioxy-1,4-pregnadiene.
The process for preparing carboxycyclic acetal pregnane derivatives of this invention cyclicized through the 16α, 17-positions proceeds as follows:
(1) Hydrocortisone or prednisolone is reacted with triethylorthoacetate and pyridine tosylate in benzene to synthesize a cyclic structure joining the 17- and 21-positions, e.g., (I) 11β-hydroxy-12,21-cyclocabonyloxy-3,20-dioxo-1,4-pregnadiene;
(2) (I) is reacted with sodium acetate buffer in methanol to break the cyclic structure and substitute an acetate group at the 17-position to produce, e.g., (II) 11β,21-dihydroxy-17-acetoxy-3,20-dioxo-1,4-pregnadiene;
(3) (II) is reacted with acetic anhydride in pyridine to incorporate the acetate group on the 21-position to produce, e.g., (III) 11β-hydroxy-17,21-diacetoxy-3,20-dioxo-1, 4-pregnadiene;
(4) (III) is reacted with potassium acetate in dimethylformamide to remove the 17-acetoxy group to produce, e.g., (IV) 11β-hydroxy-21-acetoxy-3,20-dioxo-1,4,16-pregnatriene;
(5) (IV) is reacted with osmium tetroxide to oxidize 16-unsaturated position to make vicinal-diol structure, e.g., to produce (V) 11β,16α, 17-trihydroxy-21-acetoxy-3,20-dioxo-1, 4-pregnadiene; and (V) is saponified with sodium hydroxide in methanol to produce, e.g., (VI) 11β,16α,17,21-tetrahydroxy-3, 3,20-dioxo-1,4-pregnadiene;
(6) (IV) is reacted with potassium permanganate to produce same (V), which is saponified to produce same (VI);
(7) (VI) or triamcinolone is reacted with an alkyl acetylalkanoate in a solution of dichloromethane in the presence of catalytic amount of perchloric acid to produce the corresponding 16α,17-carboxycyclic acetal pregnane derivatives, e.g., when (VI) and methyl acetylbutyrate are used the product is (VII) 11β,21-dihydroxy-3,20-dioxo-16α, 17-(methyl,methoxycarbonyl-n-propyl)methylenedioxy-1,4-pregnadiene; when triamcinolone and methyl acetylbutyrate are used the product is (VIII) 9α-fluoro-11β,21-dihydroxy-3, 20-dioxo-16α,17-methyl,methoxycarbonyl-n-propyl)methylenedioxy-1,4-pregnadiene; when triamcinolone and methyl acetylacetate are used the product is (IX) 9α-fluoro-11β,21-dihydroxy-3,20-dioxo-16α,17-17-(methyl,methoxycarbonylmethyl) methylenedioxy-1,4-pregnadiene; when triamcinolone and methyl acetylformate are used the product is (X) 9α-fluoro-11β,21-dihydroxy-3,20-dioxo-16α,17-(methyl,methoxycarbonyl)methylenedioxy-1,4-pregnadiene;
(8) (VI) or triamcinolone is reacted with an alkyl formylalkanoate in a solution of dichloromethane in the presence of catalytic amount of perchloric acid to produce the corresponding 16α,17-carboxycyclic acetal pregnane derivatives, e.g., when triamcinolone and methyl formylformate are used the product is (XI) 9α-fluoro-11β,21-dihydroxy-3,20-dioxo-16α, 17-(methoxycarbonyl)methylenedioxy-1,4-pregnadiene; when triamcinolone and ethyl formylformate are used the product is (XII) 9α-fluoro-11β,21-dihydroxy-3,20-dioxo-16α,17-(ethoxycarbonyl)methylenedioxy-1,4-pregnadiene;
(9) (X) is reacted with acetic anhydride in pyridine to produce, e.g., (XIII) 9α-fluoro-21-acetoxy-11β-hydroxy-3,20-dioxo-16α,17-(methyl,methoxycarbonyl)methylenedioxy-1,4-pregnadiene;
(10) (VI) or triamcinolone is reacted with an alkyl benzoylalkanoate in a solution of dichloromethane and dioxane in the presence of catalytic amount of perchloric acid to produce the corresponding 16α,17-carboxycyclic acetal pregnane derivatives, e.g., when triamcinolone and methyl benzoylbutyrate are used the produce is (XIV) 9α-fluoro-11β,21-dihydroxy-3,20-dioxo-16α,17-(phenyl,methoxycarbonyl-n-propyl) methylenedioxy-1,4-pregnadiene; when triamcinolone and methyl benzoylpropionate are used the produce is (XV) 9α-fluoro-11β, 21-dihydroxy-3,20-dioxo-16α,17-(phenyl,methoxycarbonylethyl) methylenedioxy-1,4-pregnadiene;
(11) (VI) or triamcinolone is reacted with an acetylalkanoic acid in a solution of dichloromethane in the presence of catalytic amount of perchloric acid to produce the corresponding 16α,17-carboxycyclic acetal pregnane derivatives, e.g., when triamcinolone and acetylacetic acid are used the product is (XVI) 9α-fluoro-11β,21-dihydroxy-3,20-dioxo-16α, 17-(methyl, carboxylicmethyl)methylenedioxy-1,4-pregnadiene; when triamcinolone and acetylbutyric acid are used the product is (XVII) 9α-fluoro-11β,21-dihydroxy-3,20-dioxo-16α,17-(methyl, carboxylic-n-propyl)methylenedioxy-1,4-pregnadiene; (XVII) is reacted with diazomethane to produce same (VIII);
(12) (VI) or triamcinolone is reacted with an acetylcarboxamide in a solution of dichloromethane in the presence of catalytic amount of perchloric acid to produce the corresponding 16α,17-aminocarbonylcyclic acetal pregnane derivatives, e.g., when triamcinolone and acetylpropyl (N-methyl) carboxamide are used the product is (XVIII) 9α-fluoro-11β, 21-dihydroxy-3,20-dioxo-16α,17-(methyl,methylaminocarbonyl-n-propyl)methylenedioxy-1,4-pregnadiene;
The process for preparing carboxycyclic acetal pregnane derivatives of this invention cyclicized through the 17,20-positions proceeds as follows:
(1) Hydrocortisone or prednisolone with 20-hydroxy and 21-acetoxy groups are known, e.g., (I) (20R)-21-acetoxy-11β, 17,20-trihydroxy-3-oxo-1,4-pregnadiene; and (I) is reacted with an alkyl acetylalkanoate in the presence of perchloric acid to produce the corresponding 17,20-carboxycyclic acetal pregnane derivatives, e.g., when methyl acetylbutyrate is used the product is (II) (20R)-21-acetoxy-11β-hydroxy-3-oxo-17,20-(methyl,methoxycarbonyl-n-propyl)methylenedioxy-1,4-pregnadiene;
(2) Hydrocortisone or prednisolone with 20-hydroxy and 20-carboxy groups are known, e.g., (III) methyl (20R)-11β,17, 20-trihydroxy-3-oxo-1,4-pregnadien-21-oate; and (III) is reacted with an alkyl acetylalkanoate or alkyl formylalkanoate in the presence of perchloric acid to produce the corresponding 17,20-carboxycyclic acetal pregnane derivatives, e.g., when methyl acetylbutyrate is used the product is (IV) methyl (20R)-11β-hydroxy-3-oxo-17,20-(methyl,methoxycarbonyl-n-propyl)methylenedioxy-1,4-pregnadien-21-oate; when methyl formylformate is used the product is (V) methyl (20R)-11β-hydroxy-3-oxo-17,20-(methoxycarbonyl)methylenedioxy-1,4-pregnadien-21-oate;
(3) Prednisolone with 20-hydroxy and 20-carboxamide groups are known, e.g., (VI) (20R)-21-(n-propylamino)-11β,17, 20-trihydroxy-3,21-dioxo-1,4-pregnadiene; and (VI) is reacted with an alkyl acetylalkanoate or alkyl formylalkanoate in the presence of catalytic amount of perchloric acid to produce the corresponding 17,20-carboxycyclic acetal pregnane derivatives, e.g., when methyl acetylbutyrate is used the product is (VII) (20R)-21-(n-propylamino)-11β-hydroxy-3,21-dioxo-17,20-(methyl, methoxycarbony-n-propyl)methylenedioxy-1,4-pregnadiene.
The process for separating each isomer at C-22 position (22R- or 22S) of the products in this invention is as follows:
(1) The corresponding (22RS)-isomeric mixture described above, obtained from the procedure for preparing 17,21-carboxycyclic acetal pregnane derivatives or from the procedure for preparing 16,17-carboxycyclic acetal pregnane derivatives or from the procedure for preparing 17,20-carboxycyclic acetal pregnane derivatives is dissolved in small amount of chloroform or chloroform:methanol mixture and applied to silica gel comumn. Elution using chloroform:methanol mixture as a mobile phase give each isomer. When each isomer is not pure from above procedure, the repeated crystallization is used. In several cases, the preparative HPLC separation is used using methanol and water mixture as a mobile phase.
In the following examples, there are illustrations of the above procedures. Part and percentages are by weight unless otherwise specified. Temperatures are in degrees Centigrade unless otherwise specified. Purity of the compounds was checked with TLC and HPLC. The specific identification of the α- or β- or R- or S-isomer is not intended to eliminate the other isomer from the illustration.
EXAMPLE 1
1 g of prednisolone was dissolved in 15 ml of acetone and 5 drops of perchloric acid were added. After 1 day with stirring at room temperature, 400 ml of dichloromethane was added and washed with 500 ml of distilled water twice. The organics was dried over anhydrous sodium sulfate. After evaporation, the product was applied to column chromatography on silica gel (70-230 mesh). Elution with chloroform:methanol (95:5) as a mobile phase gave 280 mg of 11β-hydroxy-3,20-dioxo-17,21-isopropylidenedioxy-1,4-pregnadiene. m.p.=242°-246° C.
EXAMPLE 2
1 g of triamcinolone is dissolved in 20 ml of dichloromethane, and 200 mg of methyl acetylbutyrate and 5 drops of perchloric acid were added. After 5 hrs with stirring at room temperature, 2% NaHCO 3 solution was added to neutralize the solution. The solution was washed twice with 800 ml of distilled water. After drying the organics over anhydrous sodium sulfate, the organics was evaporated to give oilic product. The oilic product was purified with silica gel column using chloroform:methanol (9:1) as a mobile phase. The corresponding fractions were obtained and evaporated to give 22R- and 22S-mixture (12:1) of 9α-fluoro-11β,21-dihydroxy-3, 20-dioxo-16α,17-(methyl,methoxycarbonyl-n-propyl)methylenedioxy-1,4-pregnadiene as a white foam (680 mg) based on the HPLC and NMR peaks.
To separate each isomer, the above R,S mixture dissolved in chloroform was rechromatographed to silica gel column using chloroform:methanol (95:5) as a mobile phase. Two fractions were pooled. The fraction eluted earlier having less polar compound was evaporated and crystallized from acetone-hexane mixture to give (22R)-9α-fluoro-11β,21-dihydroxy-3,20-dioxo-16α17-(methyl,methoxycarbonyl-n-propyl)methylenedioxy-1,4-pregnadiene (242 mg) as a white prism. m.p.=174°-178° C., 1 H-NMR (CDCl 3 ) δ0.89(s,3H,13-CH 3 ), 1.10(s,3H,22-CH 3 ), 1.55(s,3H,10-CH 3 ), 3.60(s,3H,--COOCH 3 ), 4.17-4.65(m,3H,11-H and 20-CH 2 O-), 5.06(m,1H,16-H), 6.12(m,1H,4-H), 6.35(m,1H,2-H), 7.22(d,1H,1-H). The second fraction eluted later having more polar compounds gave 22R- and 22S-mixture (1:3) of 9α-fluoro-11β,21-dihydroxy-3,20-dioxo-16α,17-(methyl,methoxycarbonyl-n-propyl)methylenedioxy-1,4 pregnadiene (80 mg), which was subjected to preparative HPLC using methanol:water (65:35) as a mobile phase to give (22S)-9α-fluoro-11β,21-dihydroxy-3,20-dioxo-16α,17-methyl,methoxycarbonyl-n-propyl)methylenedioxy-1, 4-pregnadiene (18 mg) as white foams, 1 H-NMR (CDCl 3 ) δ0.89 (s,3H,13-CH 3 ), 1.38(s,3H,22-CH 3 ), 1.55(s,3H,10-CH 3 ). 3.65(s, 3H,--COOCH 3 ), 4.17-4.65(m,3H,11-H and 20-CH 2 O-), 5.06(m,1H, 16-H), 6.12(m,1H,4-H), 6.35(m,1H,2-H), 7.22(d,1H,1-H).
EXAMPLE 3
1 g of triamcinolone is dissolved in 15 ml of dioxane and 200 mg of methyl acetylacetate and 5 drops of perchloric acid were added. After 1 day of stirring at room temperature, the solution was neutralized and extracted with 500 ml of dichloromethane. After drying over anhydrous sodium sulfate, the organics was evaporated and subjected to silica gel column chromatography using chloroform:methanol (9:1) as an eluate. The fraction corresponding ester derivatives were pooled and evaporated to dryness which contained small portions of triamcinolone acetonide due to the decarboxylation of ester during reaction. To remove triamcinolone acetonide, the product was rechromatographed with silica gel column. Elution with chloroform:MeOH (95:5) and recrystalligation from acetone gave 380 mg of (22R)-9α-fluoro-11β,21-dihydroxy-3,20-dioxo-16α,17-(methyl,methoxy carbonylmethyl)methylenedioxy-1,4-pregnadiene as a white prism. 1 H-NMR (CDCl 3 ) δ0.89(s,3H,13-CH 3 ), 1.26(s,3H,22-CH 3 ), 1.56(s,3H,10-CH 3 ), 2.73(s,2H,22-CH 2 CO-), 3.65(s,3H,-COOCH 3 ), 4.20-4.67(m,3H,11-H and 20-CH 2 CO-), 5.11(m,1H,16-H), 6.18(m,1H,4-H), 6.32(d,1H,2-H), 7.27(d,1H,1-H).
EXAMPLE 4
Prednisolone (50 g) was dissolved in benzene (1,000 ml) and triethylorthoacetate (50 ml) and pyridine tosylate (1.25 g) were added. After distillation for 1.5 hrs, the solution was stored in refrigerator to give colorless cubic crystal (95 g). Recrystallization twice from benzene gave known pure prednisolone-17,21-ethyl orthoacetate as a colorless needle (54 g), m.p.=188°-189° C.
EXAMPLE 5
To a solution (50 g) of the product of Example 4 in 700 ml of methanol, 400 ml of 0.1N sodium acetate buffer was added. After refluxing for 15 hrs, methanol was evaporated. The residue was extracted with 500 ml of ethyl acetate. After drying over anhydrous sodium sulfate, the organics was evaporated to dryness. Recrystallization from acetone gave 24 g of prednisolone-17-acetate as a colorless hexagonal, m.p.=223°-224° C. 1 H-NMR (CDCl 3 ) δ0.98(s,3H,13-CH 3 ), 1.45 (s,3H,10-CH 3 ), 2.04(s,3H,17-Ac), 3.05(m,1H,21-OH), 4.2-4.4(m,2H,20-CH 2 O-), 4.52(m,1H,11-H), 6.04(s,1H,4-H), 6.29(dd,1H,J=10 and 2 Hz,2-H),7.25(d,1H,J=10 Hz,1-H).
To a solution of prednisolone-17-acetate (10 g) in 30 ml of pyridine, acetic anhydride (4 ml) was added. After 2 hrs at room temperature, 0.5N HCl (150 ml) was added. Extraction with ethyl acetate, washing with water and evaporation gave yellow oil. crystallization from acetone-hexane mixture gave 7.1 g of prednisolone-17,21-diacetate as a colorless hexagonal, m.p.=99.5°-100.5° C., 190°-191° C.
EXAMPLE 6
To a solution of prednisolone-17,21-diacetate (7 g) in 100 ml of dimethylforamide, anhydrous potassium acetate (10 g) was added and reaction was continued at 105°-108° C. under N 2 for 6 hrs. After cooling down, the solution was poured onto ice-water (1,000 ml). After filtering, the filter cake was dissolved in ethyl acetate (300 ml), dried on anhydrous sodium sulfate and evaporated. Recrystallization from acetone gave 4.8 g of 21-acetoxy-11β-hydroxy-1,4,16-pregnatriene (Product 6A) as a yellowish long cubic, m.p.=203°-205° C. 1 H-NMR (CDCl 3 ) δ1.25(s,3H,13-CH 3 ), 1.48(s,3H,10-CH 3 ), 2.18(s,3H,21-Ac), 4.40(m,1H,11-H), 4.83-5.06(m,2H,20-CH 2 O-), 6.02(s,1H,4-H), 6.28(dd,1H,J=10 and 2 Hz,2-H), 6.74(m,1H,16-H), 7.30(d,1H,J= 10 Hz,1-H).
To a solution of above product (100 mg) in methanol (10 ml) was added 4N NaOH (0.1 ml). Reaction was continued in ice-bath for 15 min. Distilled water (200 ml) was added and extracted with 300 ml of dichloromethane. After drying over anhydrous sodium sulfate, the organics were evaporated. Recrystallization from acetone gave 57 mg of 11β,21-dihydroxy-1,4,16-pregnatriene (Product 6B) as a yellowish needle, m.p.=213°-215° C. 1 H-NMR (CDCl 3 ) δ1.25(s,3H,13-CH 3 ), 1.49(s,3H,10-CH 3 ), 4.35-4.55(m,3H,20-CH 2 O- and 11-H), 6.02(s,1H,4H), 6.28(dd,1H,J=10 and 2 Hz,2-H), 6.73(m,1H,16-H), 7.32(d,1H,J=10 Hz,1-H).
EXAMPLE 7
To a solution of a product of Example 6 (Product 6A), 1 g, in 20 ml ethanol, 30 mg of potassium permanganate and 13 mg of MgSO 4 dissolved in 5 ml distilled water were added. After stirring at room temperature for 18 hrs, the solution was filtered and filtrate was extracted with 200 ml of dichloromethane. After drying on anhydrous sodium sulfate, the organics was evaporated. The dried residue dissolved in small amount of chloroform:MeOH (9:1) was poured onto the silica gel column. Chloroform:MeOH (9:1) was used as a mobile phase. The pooled fractions were evaporated to give 380 mg of 21-acetoxy-11β,16α,17-trihydroxy-3,20-dioxo-1,4-pregnadiene (Product 7A), which was saponified with methanolic sodium hydroxide solution in ice bath for 10 min and distilled water (200 ml) was added. After extracting with 300 ml of dichloromethane, the organics was dried over anhydrous sodium sulfate and evaporated to give 203 mg of 11β,16α,17,21-tetrahydroxy-3,20 -dioxo-1,4-pregnadiene (Product 7B) as white form, 1 H-NMR (CDCl 3 ) δ0.88(s,3H,13-CH 3 ), 1.45(s,3H,10-CH 3 ), 4.25-4.63(m,4H,20-CH 2 O-, 11-H and 16H), 5.74(m,1H,16-H), 6.01(s,1H,4-H), 6.26(dd,1H,J=10 and 2 Hz,2-H), 7.21(d,1H,J=10 Hz,1-H)
EXAMPLE 8
To a solution of the Product of Example 7 (Product 7B), 180 mg, in 10 ml of dichloromethane, methyl acetylbutyrate (1 ml) and 3 drops of perchloric acid were added. The reaction was continued until the solution was clear. After neutralizing the solution with 2% NaHCO 3 , the mixture was extracted with dichloromethane (200 ml) and dried over anhydrous sodium sulfate. The organics was evaporated. The residue dissolved in small amount of chloroform was poured to silica gel column and eluted with chloroform:methanol (95:5) as a mobile phase. The eluate gave 86 mg of (22R)-11β,21-dihydroxy-3,20-dioxo-16α,17-(methyl,methoxycarbonyl-n-propyl)methylenedioxy-1,4-pregnadiene, 1 H-NMR (CDCl 3 ) δ 0.88(s,3H,13-CH 3 ), 1.10(s,3H,22-CH 3 ), 1.45(s,3H,10-CH 3 ), 3.61(s,3H,-COOCH 3 ), 4.18-4.02(m,3H,20-CH 2 O- and 11-H), 5.05(m,1H,16-H), 6.03(s,1H,4-H), 6.28(dd,1H,J=10 and 2 Hz, 2-H), 7.23(d,1H,J=10 Hz,1-H).
EXAMPLE 9
Prednisolone (10 g) was dissolved in 750 ml of methanol and 2.25 g cupric acetate in 750 ml of methanol was added. The solution was mixed and set aside for 20 min. While stirring, the reaction was continued with airation for 1 weak. After adding 500 ml of 0.1% NaHCO 3 solution containing 4.5 g EDTA, methanol was evaporated under vacuum. The solution was extracted with ethyl acetate (1,000 ml), dried on anhydrous sodium sulfate and evaporated to dryness (7.5 g). The residue was dissolved in 150 ml methanol and 375 ml water containing 3.75 g NaHSO3 was added. After refluxing for 1 hour, water was evaporated and the residue was extracted with ethyl acetate (500 ml), washed with distilled water, dried on sodium sulfate and evaporated to dryness (3.5 g), which was purified with silica gel column with acetone:dichloromethane:hexane (3:2:5) as a mobile phase. The pooled fraction was evaporated to dryness. Recrystallization four times from methanol gave 1.1 g of methyl (20R)-11β,17,20-trihydroxy-3-oxo-1,4-pregnadien-21-oate (Product 9A) as a colorless platelet, m.p.=254°-255° C., 1 H-NMR (Me 2 SO-d 6 ) δ1.05(s,3H,13-CH 3 ), 1.40(s,3H,10-CH 3 ), 3.62(s,3H,21-OCH 3 ), 4.06(s,1H,20-H), 4.21(m,1H,11-H), 5.91(s,1H,4-H), 6.15(dd,1H,J=10 and 2 Hz,2-H), 7.32(d,1H,J=10 Hz,1-H); MS, m/e 390(M + ). The combined remaining solution was evaporated. After dissolving in small amount of methanol, the solution was subjected to preparative HPLC using methanol:water (6:4) as a mobile phase. The eluate was evaporated and crystallized to give 0.8 g of methyl (20S)-11β,17,20-trihydroxy-3-oxo-1,4-pregnadien-21-oate (Product 9B) as a white prism, m.p.=171°- 173° C. 1 H-NMR (CDCl 3 ) δ1.15(s,3H,13-CH 3 ), 1.45(s,3H,10-CH 3 ), 3.31(s,3H,21-OCH 3 ), 4.36(s,1H,20-H), 4.43(m,1H,11-H), 6.01(s,1H,4-H), 6.28(dd,1H,J=10 and 2 Hz,2-H), 7.28(d,1H,J=10 Hz,1-H); MS, m/e 390(M + ).
EXAMPLE 10
To a solution of the product of Example 9 (Product 9A), 500 mg, in methanol (50 ml), 1N NaOH (1 ml) was added. After 20 min in ice bath, the mixture was neutrlized with 0.1N HCl and 300 ml of distilled water was added. After extracting with ethyl acetate (300 ml), the organics was evaporated and recrystallization from methanol gave 360 mg of (20R)-11β,17,20-trihydroxy-3-oxo-1,4-pregnadien-21-oic acid as white prism, m.p.=213°-214° C. 1 H-NMR (Me 2 SO- 6 ) δ1.03(s,3H,13-CH 3 ), 1.39(s,3H,10-CH 3 ), 3.94(s,1H,20-H), 4.19(m,1N,11-H), 5.90(s,1H,4-H), 6.13(dd,1H,J=10 and 2 Hz,2-H), 7.31(d,1H,J=10 Hz,2-H), 8.30(s,1H,20-COOH).
EXAMPLE 11
To a solution of a product of Example 10 (200 mg) in tetrahydrofuran (3 ml) and dichloromethane (30 ml) were added N,N'-dicyclohexylcarbodiimide (120 mg) and 1-hydroxybenzotriazole (80 mg) in tetrahydrofuran (3 ml). The reaction mixture was stirred at 4° C. for 24 hrs. After filtration, n-propylamine (60 mg) was added to the filtrate, and the reaction was continued at 4° C. After 24 hrs, the mixture was diluted with dichloromethane (300 ml) and dried over anhydrous sodium sulfate, followed by evaporation. The residue dissolved in methanol was applied to silica gel column and eluted with chloroform:methanol (9:1) as a mobile phase. Recrystallization from acetone-hexane gave 130 mg of (20R)-21-(n-propylamino)-11β,17,20-trihydroxy-3,21-dioxo-1,4-pregnadiene, m.p.=251°-253° C. 1 H-NMR (CDCl 3 ) δ0.94(t,3H, J=6 Hz,NHCH 2 CH 2 CH 3 ), 1.15(s,3H,13-CH 3 ), 1.45(s,3 H,10-CH 3 ), 3.2(m,2H,NHCH 2 -), 4.06(s,1H,20-H), 4.39(m,1H,11-H), 6.0(s,1H,4-H), 6.25(dd,1H,J=10 and 2 Hz,2-H), 6.9(m,1H,NH), 7.31(d,1H,J=10 Hz,1-H).
EXAMPLE 12
To a solution of the product of example 9 (Product 9B), 300 mg, in dichloromethane (20 ml), methyl acetobutylate (0.5 ml) and 5 drops of percloric acid were added. After 3 hrs with stirring at 50° C., distilled water (200 ml) was added, extracted with dichloromethane (200 ml) and the organics was dried over anhydrous sodium sulfate. After evaporation, the residue dissolved in small amount of chloroform and methanol was applied to silica gel column and eluted with chloroform:methanol (95:5). Eluate combined gave 88 mg of methyl (20S)-11β-3-oxo-17,20-(methyl, methoxycarbonyl-n-propyl) methylendi-oxy-1,4-pregnadien-21-oate. 1 H-NMR (CDCl 3 ) δ1.07(s,3H,13-CH 3 ), 1.29(s,3H,22-CH 3 ), 1.47(s,3H,10-CH 3 ), 3.66(s,3H,-CH 2 COOCH 3 ), 3.77(s,3H,20-COOCH 3 ), 4.54(m,2H,11-H and 20-H), 6.02(s,1H,4-H), 6.27(dd,1H,J=10 and 2 Hz,2-H), 7.26(d,1H,J=10 Hz,1-H).
EXAMPLE 13
Triamcinolone (400 mg) was dissolved in 10 ml of dichloromethane and 5 ml of dioxane. Methyl benzoylbutyrate (60 mg) and 5 drops of perchloric acid was added. After 5 hrs at room temperature with stirring, the reaction mixture was poured to 300 ml of distilled water and extracted with dichloromethane (500 ml). After drying on anhydrous sodium sulfate, the organics was evaporated to dryness. The residue dissolved in small amount of chloroform was purified with silica gel column using chloroform:methanol (95:5) as a mobile phase. The pooled fraction eluted was evaporated to give 22(R,S) mixture of 22R:22S (1.5:1) based on NMR peak intensities, 9α-fluoro-11β,21-dihydroxy-3,20-dioxo-16α,17-(phenyl,methoxycarbonyl-n-propyl)methylenedioxy-1,4-pregnadiene (207 mg) as white foam. 1 H-NMR (CDCl 3 ) δ0.89 and 1.17(3H,13-CH 3 ), 1.55(s,3H,10-CH 3 ), 3.61 and 3.65(3H,-COOCH 3 ), 4.10-4.92(m,3H,11-H and 20-CH 2 O-), 5.34(m,1H,16-H), 6.12(s,1H,4-H), 6.33(dd,1H,2-H), 7.06-7.97(m,6H,1-H and -C 6 H 5 ).
EXAMPLE 14
Compounds of this invention were tested for pharmacological evaluation. The following procedures were employed. Male Sprague-Dawley rats weighing 120-140 g and male ICR mice (23-28 g) were maintained on standard laboratory chow with water ad libitum and kept under controlled condition for one week prior to their use. Cotton pellet weighing 35±1 mg cut from dental rolls were impregnated with steroid solution in acetone (0.2 ml each) and the solvent was removed by evaporation. The cotton pellets were subsequently injected with 0.2 ml aqueous solution of antibiotics (1 mg penicillie G and 1.3 mg dihydrostreptomycin/ml). Two cotton pellets were implanted s.c., one in each axilla of the rat under light ether anethesia, one of which contained steroid solution and the other one was only received antibiotic solution. Ganuloma inhibition of the pellet containing only antibiotic solution was considered as systemic effects. Seven days later, the animals were sacrificed and the pellets were removed, dried at 37° C. for 4 days and weighed. The increment in dry weight (difference between the initial and final pellet weight) is taken as a measure of granuloma formation. The results are shown in Table 1.
TABLE 1__________________________________________________________________________ DOSAGE DRY WT. OF GRANULOMA RELATIVE mg/cotton GRANULOMA INHIBITON THYMUS WT.COMPOUND pellet mg. % mg/100 g B.W.__________________________________________________________________________None (Control) 0.0 49.0 ± 5.2 -- 282.6 ± 16.6Prednisolone 2.5 20.1 ± 2.3 59.0 167.2 ± 12.3 0.0 24.2 ± 1.7 50.6Prednisolone 1.0 24.9 ± 1.8 49.2 245.7 ± 15.5 0.0 30.2 ± 2.6 38.4Triamcinolone 2.5 27.3 ± 3.9 44.3 246.2 ± 21.3 0.0 28.2 ± 4.4 42.4Triamcinolone 1.0 32.7 ± 1.6 33.3 251.6 ± 8.8 0.0 40.3 ± 3.1 17.8Product of 2.5 25.3 ± 5.6 48.4 268.3 ± 11.6Example 2(22R) 0.0 41.0 ± 3.7 16.3Product of 1.0 27.5 ± 4.3 43.9 273.2 ± 16.2Example 2(22R) 0.0 44.7 ± 5.1 8.8Product of 1.0 34.9 ± 2.6 28.8 269.1 ± 16.9Example 2(22S) 0.0 46.4 ± 4.8 5.3Product of 2.5 37.7 ± 6.7 23.1 293.2 ± 20.6Example 9(20R) 0.0 51.3 ± 3.6 -4.7Product of 2.5 28.5 ± 3.9 41.8 264.8 ± 13.7Example 9(20S) 0.0 49.6 ± 5.4 1.2Product of 1.0 25.0 ± 1.3 49.0 279.9 ± 18.2Example 3 0.0 50.8 ± 5.8 -3.7__________________________________________________________________________
For measuring topical activity of the derivative, the compounds (0.001-0.1 mg) in acetone (25 ul) were applied to the left ear of male ICR mice. After 30 min., 2.5% crotone oil (25 ul each) was applied to both ears of the mice. The ear thickness was measured with Flower precision microgage after 5 hrs and the difference between initial and final thickness was regared as edema formation. The results were shown in Table 2.
TABLE 2______________________________________ DOSAGE EDEMA INHIBITIONCOMPOUND mg/ear %______________________________________Croton oil (control) --Dexamethasone 0.1 82 0.0 78Dexamethasone 0.01 69 0.0 52Dexamethasone 0.001 56 0.0 23Prednisolone 0.1 70 0.0 67Prednisolone 0.01 52 0.0 29Prednisolone 0.001 43 0.0 -2Product of 0.1 69Example 3 0.0 14Product of 0.01 58Example 3 0.0 3Product of 0.001 51Example 3 0.0 8______________________________________
For evaluating the systemic thymolytic effect of the derivatives of this invention in mice through topical administration, the derivatives were applied to left ear of the male ICR mice. After 3 days, mice were sacrificed by cervical dislocation. The thymus tissues were excised and weighed. The results were shown in Table 3. When the derivatives were applied to ICR mice by subcutaneous route, the systemic thymolytic effects were shown in Table 4.
TABLE 3______________________________________ DOSAGE THYMUS REDUCTIONCOMPOUND mg %______________________________________Control --Dexamethasone 0.1 43 0.05 39 0.01 21Prednisolone 0.1 24 0.05 9 0.01 -8Product of 0.1 0Example 3 0.05 2 0.01 0______________________________________
TABLE 4______________________________________ DOSAGE THYMUS REDUCTIONCOMPOUND mg %______________________________________Control --Dexamethasone 0.05 56 0.02 50 0.01 39Prednisolone 0.07 35 0.05 27 0.02 -8Product of 0.5 11Example 3 0.1 0 0.05 1______________________________________
While the invention has been described with respect to certain specific embodiments, it will be appreciated that many modifications and changes may be made by those skilled in the art without departing from the spirit of the invention. It is intended, therefore, by the appended claims to cover all such modifications and changes as fall within the true spirit and scope of the invention. | Compounds of the formula: ##STR1## wherein X is H, F, Cl, or CH 3
and Y is ##STR2## wherein R 1 is H, alkyl of 1-5 carbon atoms, phenyl, or benzyl;
R 2 is COOR 6 , R 5 COOR 6 , or R 5 CONHR 6 ;
R 3 is H, F, OH, or CH 3 ;
R 4 is CH 2 OH, CH 2 OCOR 6 , COOR 6 , or CONHR 6 ;
R 5 is alkyl of 1-3 carbon atoms;
R 6 is alkyl of 1-5 carbon atoms, or benzyl;
represents a single or double bond;
˜ represents α-position, β-position, or a mixture of both α- and β-positions; and
-- represents α-position;
and methods for preparing the same. | 2 |
CROSS REFERENCE TO RELATED APPLICATION
This application claims priority to and the benefit of Korean Patent Application No. 10-2004-0012191, filed on Feb. 24, 2004, which is hereby incorporated by reference for all purposes as if fully set forth herein
BACKGROUND OF THE INVENTION
(a) Field of the Invention
The present invention relates to a UV nanoimprint lithography process and its apparatus, and more specifically, to a UV nanoimprint lithography process and its apparatus capable of repeatedly fabricating nanostructures on a substrate (e.g. wafer, glass, quartz, etc.) with a stamp having the nanostructures engraved thereon.
(b) Description of Related Art
The UV nanoimprint lithography technology is an economical and effective method of fabricating nanostructures It is multidisciplinary, so that it should be supported by various technologies from such fields as nano-scale materials science, stamp fabrication, ant-adhesion layer, etching and measurements. The nano-scale precision control technology is regarded as a basis.
The UV nanoimprint lithography technology is applicable to ultra high-speed metal-oxide-semiconductor field-effect transistors (MOSFETs), metal-semiconductor field-effect transistors (MESFETs), high-density magnetic storage devices, high-density compact disks (CD), nano-scale metal-semiconductor-metal photodetectors (MSM PDs), and high-speed single-electron transistor memory, etc.
In the nanoimprint process, developed by Prof. Chou et al. at Princeton Univ. in 1996, a stamp having embossed structures fabricated by the electron beam lithography process is pressed at high temperature on the wafer coated with a polymethylmethacrylate (PMMA) resist, and is released when the resist is cooled. Thus, the resist is imprinted with the negative patterns of nanostructures of the stamp, and an anisotropic etching process is followed to open the etch window of the wafer. In 2001, a laser-assisted direct imprint (LADI) method, that uses a single 20-ns Excimer laser with a wavelength of 308-nm to instantaneously melt the surface of a silicon wafer or the resist coated on a silicon wafer. Similarly, in a nanosecond laser-assisted nanoimprint lithography (LA-NIL) applied to polymer, nanostructures with a line width of 100 nm and a depth of 90 nm are imprinted to polymer-based resist.
The aforementioned nanoimprint technologies are performed at high temperature. This makes them inapplicable to the implementation of semiconductor devices, a multi-layer process, because thermal deformation occurring in these technologies will hinder multi-layer alignment. Furthermore, high pressure (about 30 atmospheric pressures) required to imprint high-viscosity resist can break or damage previously fabricated nanostructures. Opaque stamps used in these processes are also an obstacle to the multi-layer alignment.
To address these problems, the step & flash imprint lithography (SFIL) process is suggested by Prof. Sreenivasan at the University of Texas at Austin in 1999. This process uses a UV-curable material to fabricate a nanostructure at low pressure and room temperature. is characterized by the fact that UV-transparent materials such as quartz and Pyrex® glass are used for the stamp In the SFIL process, a transfer layer is first spin-coated on a silicon wafer, and a low-viscosity UV-curable resin is filled into the nanostructures while maintaining a certain interval between the UV-transparent stamp and the transfer layer.
Subsequently, at the time of completion of the filling, the stamp is in contact with the transfer layer and the resin is cured by illuminating with UV light. Thereafter, the stamp is separated and the nanostructure is transferred on the wafer by the etching and the lift-off processes.
However, the gap distribution between the stamp and the wafer for use in the UV nanoimprint lithography process is not constant (e.g., Si wafer: 20˜30 μm), so that the resist may be insufficiently pressed by the stamp during imprinting. In the SFIL process using a small-area stamp, the distance between the stamp and the wafer is measured with distance sensors attached at the sides of the stamp before pressing the stamp is used, and, based on the measurements, the stamp is finely rotated to the stamp as parallel as possible to the wafer. In other words, in SFIL, imprinting is performed in such a way that the stamp with nanostructures is manipulated according to the waveness of the wafer surface
The SFIL process is also characterized by the fact that the entire wafer is imprinted not at one time but repeatedly in several times because it uses a small-area stamp, smaller than the wafer in size. This is a sort of the step-and-repeat type imprinting. Since it uses a small-area stamp and the alignment and imprinting should be repeated, it will take a long time to finish imprinting of a large-area wafer.
Further, to imprint a large-area wafer in a short time, a large-area stamp on which nanostructures are fabricated can be used to press the resist deposited on the wafer. However, the larger the stamp and the wafer become, the more serious the error of flatness becomes. This means that some of the resist may be insufficiently pressed and some of the nano structures may be incompletely filled, In addition, the non-uniform residual layer thickness, which occurs because of the error of flatness, can make the etching process difficult or unsuccessful
SUMMARY OF THE INVENTION
The present invention provides a UV nanoimprint lithography process and its apparatus capable of efficiently forming high-precision, high-quality nanostructures irrespective of the error of flatness thereof.
The present invention also provides a UV nanoimprint lithography process and its apparatus capable of yielding a large-area stamp at low cost.
According to an exemplary embodiment of the present invention, there is provided a method of performing a UV (ultraviolet) nanoimprint lithography process for forming nanostructures on a substrate. The method may include preparing a stamp having more than two element stamps. The nanostructures may be formed on the surface of each element stamp. Resist may be applied to the surface of a substrate or on the element stamps. The stamp and the substrate may be mounted on a stamp chuck and a substrate chuck, respectively. In some embodiments the substrate chuck or the stamp chuck may be moved to press the resist on the surface of a substrate or on the element stamps. Pressurized gas may be applyed to some selected regions of the substrate to help complete some incompletely filled element stamps Pressed resists may be cured by illuminating the resists with UV light to cure the resist. The stamp may be separated from the substrate. A relative position between the substrate and the stamp may be changed to continue imprinting another predetermined region of the substrate. By repeating the above steps, nanostructures may be formed all over the surface of substrate.
Here, a wafer or stamp materials (UV-transparent materials) may be used for the substrate.
In addition, applying the resist may be performed by one of the following methods: including but not limited to a spin coating method which applies the resist to all over the surface of the substrate, a droplet dispensing method which directly deposits resist droplets to the surface of each element stamp, and a spraying method which arranges a mask having an opening corresponding to the positions of the respective element stamp and sprays the resist thereon, thereby applying the resist to some portion of region over the substrate.
For the droplet dispensing method or the spraying method, after separating the stamp from the substrate, the resist may be applied to the surface of the element stamp for the second process.
when the resist is imprinted on the predetermined region of the substrate, nanostructures may be transferred to the substrate by etching the upper surface of the substrate having the deposited resist.
According to another exemplary embodiment of the present invention, a UV nanoimprint lithography apparatus for forming nanostructures on a substrate may be included. The UV nanoimprint lighography may include a substrate chuck for mounting a substrate; a stamp made of a transparent material transmitting UV light and having more than two element stamps, wherein nanostructures are formed on a surface of each element stamp; a stamp chuck for mounting the stamp; a UV lamp unit for providing UV light to cure resist applied between the element stamps and the substrate; a moving unit for moving the substrate chuck or the stamp chuck to press the resist on the surface of substrate or on the element stamps; and a pressure supply unit for applying pressurized gas to some selected regions of the substrate to help complete some incompletely filled element stamps.
In addition, the substrate chuck may be arranged to move in the horizontal direction along the guide block and to move in the vertical direction by the moving unit.
In some embodiments, the substrate chuck may be guided by a plurality of guide rods while moving in the vertical direction using the moving unit.
The moving unit may be arranged to move the pressure supply unit in the vertical direction may include a hydraulic cylinder or a motor-driven actuator.
In an embodiment, the pressure supply unit may include: a closure type of housing having a hollow cavity. In addition, a plurality of gas supply holes may be provided in the housing and connected to the hollow cavity. Some embodiments may also include a gas supplier for supplying pressurized gas to the hollow cavity and through holes connected to the plurality of gas supply holes and provided in the substrate chuck.
Furthermore, a sealing member (e.g. an O-ring) may be mounted on the upper surface of the housing to prevent leakage of the pressurized gas supplied to the through-holes via the plurality of gas supply holes.
In addition, the apparatus may further include a gas supply nozzle for spraying gas between the stamp and the substrate to separate the stamp from the substrate when the imprinting is finished.
Furthermore, the stamp may be an elementwise patterned stamp. The element-wise patterned stamp may include at least two element stamps on which nanostructures are engraved. In addition, the element-wise patterned stamp may include a plurality of channels being deeper than the nanostructures between adjacent element stamps, or a well-known planar-type stamp.
According to an embodiment, a resist insufficiently pressed due to the error of flatness between a stamp and a substrate during imprinting can be further pressed by applying pressurized gas. Therefore, the insufficient filling of the resist, which may be generated when the nanostructures are fabricated on a large-area substrate (e.g. 8 inch wafer) in a single-step or step-and-repeat imprinting by using a large-area stamp (e.g. 5 in.×5 in. stamp), can be prevented. Accordingly, it is possible to economically and efficiently form high-precision and high-quality nanostructures in a short time.
Moreover, it is also possible to fabricate the stamp having the same working area with a substrate by using the afore-mentioned apparatus.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other features and advantages of the present invention will become more apparent by describing in detail exemplary embodiments thereof with reference to the attached drawings.
FIG. 1 is a schematic perspective view showing a a UV nanoimprint lithography apparatus according to an embodiment of the present invention;
FIG. 2 is a side view for the UV nanoimprint lithography apparatus of FIG. 1 ;
FIG. 3 is a plan view of an element-wise patterned stamp according to an embodiment of the present invention;
FIG. 4 is a cross sectional view taken along a line A-A′ of FIG. 3 ;
FIGS. 5A to 5D are diagrams showing a sequence of the UV nanoimprint lithography process according to an embodiment of the present invention; and
FIG. 6 is a cross sectional view of a planar stamp according to another embodiment of the present invention
DETAILED DESCRIPTION
Now, embodiments of the present invention will be described with reference to the attached drawings.
FIG. 1 is a schematic perspective view showing a UV nanoimprint lithography apparatus according to an embodiment of the present invention, and FIG. 2 is a side view for the UV nanoimprint lithography apparatus of FIG. 1 .
FIG. 1 depicts the apparatus including a base 10 having upper and lower frames 10 a and 10 b and left and right frames 10 c and 10 d . The base 10 is supported by four supporting corners 12 arranged on the lower plate 10 b.
As shown in FIG. 2 , a stamp chuck 16 mounting an element-wise patterned stamp 14 is fixedly arranged on the upper frame 10 a . The stamp chuck 16 is made of a UV-transparent material and includes a back plate 16 a for vacuum absorption of the element-wise patterned stamp 14 and the main body 16 b mounting the back plate 16 a , as shown in FIG. 2 .
Although not shown in detail, the back plate 16 a includes a vacuum line 16 ′ a for vacuum absorption of the element-wise patterned stamp 14 . The vacuum line 16 ′ a is connected to a vacuum generator (not shown).
In addition, UV lamp unit 18 transmitting the element-wise patterned stamp 14 mounted on the stamp chuck 16 and illuminating the resist with UV light is arranged over the upper frame 10 a at a certain height through two supporting bodies 18 ′. The resist may be pressed by a substrate.
In addition, FIG. 1 shows a guide block 22 guiding horizontal movement of a substrate chuck 20 (e.g., the wafer or the stamp board) arranged on the lower frame 10 b . A slide block 24 ′ of the chuck mounting plate 24 is coupled to a guide rail 22 ′ of the guide block 22 . A plurality of guide rods 26 guiding vertical movement of the substrate chuck 20 as well as supporting the substrate chuck 20 are arranged on the chuck mounting plate 24 .
As illustrated in FIG. 2 , a pressure supply unit 30 supplying pressurized gas to a substrate 28 mounted on the substrate chuck 20 may be positioned below the substrate chuck 20 . The pressure supply unit 30 includes a closure type of housing 30 b having a hollow cavity 30 a , a plurality of gas supply holes 30 c provided in the housing 30 b and connected to the hollow cavity 30 a , a gas supplier (not shown) for supplying gas to the hollow cavity 30 a through a gas supply tube 30 d , and a plurality of through holes 30 e connected to the plurality of gas supply holes 30 c and provided in the substrate chuck 20 . In addition, a plurality of O-rings 30 f are arranged on the housing 32 b closely contacted to the lower surface of the substrate chuck 20 to prevent leakage of the gas discharged from the gas holes 30 c.
The pressure supply unit 30 with the afore-mentioned construction may be arranged such that the housing 30 b can move upward and downward by a moving unit 32 . The moving unit 32 provides a force to move the substrate chuck 20 upward toward the element-wise patterned stamp 14 . The moving unit 32 may include a hydraulic cylinder or a motor-driven actuator.
Further, a stamp mounting jig 34 mounting the element-wise patterned stamp 14 on the stamp chuck 16 is arranged on the left frame 10 c . The stamp mounting jig 34 is interposed between the stamp chuck 16 and the substrate chuck 20 . In addition, a gas spray nozzle (not shown) for intermittently spraying gas (e.g., air or nitrogen) between the substrate 28 and the element-wise patterned stamp 14 may be included to facilitate separation between the substrate 28 and the element-wise patterned stamp 14 .
FIG. 3 is a plan view of an element-wise patterned stamp according to an embodiment of the present invention, and FIG. 4 is a cross sectional view taken along a line A-A′ of FIG. 3 .
As shown in FIGS. 3 and 4 , the element-wise patterned stamp 14 has a plurality of element stamps 14 a arranged like a matrix according to an embodiment of the present invention. A plurality of channels 14 b are provided between the adjacent element stamps. In addition, a plurality of nanoimprints 14 ′ a imprinted by a nanofabrication process such as electron-beam lithography are formed on the respective element stamps 14 a.
Here, the depth h G of the channel 14 b may be in a range from about 2 times to 1000 times as large as the depth h S of the nanostructure 14 ′ a . When the depth h G of the channel 14 b is formed less than twice of the depth h S of the nanostructures 14 ′ a , the resist flowed into the channel 14 b cannot be sufficiently accepted due to the little difference between the depth h G of the channel 14 b and the depth h S of the nanostructures 14 ′ a . Otherwise, when the depth h G of the channel 14 b is 1000 times as large as the depth h S of the nanostructures 14 ′ a , the strength of the stamp 14 is reduced, so that the stamp 13 may be damaged during the nanoimprint process.
Now, a method of performing a UV nanoimprint lithography process using the afore-mentioned apparatus will be described with reference to FIGS. 1 , 4 , 5 A through 5 D.
First, to fabricate the nanostructures on the substrate 28 (e.g., the wafer) resist droplets 36 are applied on the surface of the nanostructures 14 ′ a formed in the element stamps of the element-wise patterned stamp 14 . Here, instead of applying the resist droplet on the surface of the nanostructures 14 ′ a of the element stamps 14 a , a spin-coating or spraying method may be used to apply the resist droplets to some or all regions of the wafer. In addition, it is desirable that the resist be made of a UV curing polymer.
Like this, the element-wise patterned stamp 14 having the deposited resist droplets 36 is mounted on the stamp chuck 16 by using the stamp mounting jig 34 . The wafer is mounted on the substrate chuck 20 . Here, the element-wise patterned stamp 14 is fixedly mounted on the stamp chuck 16 by using a vacuum pressure generated by the vacuum generator.
Next, the moving unit 32 (e.g., the hydraulic cylinder or the motor-driven actuator) operates to move the housing 30 b of the pressure supply unit 30 vertically upward. When the housing 30 b is moved upward, the O-rings 30 f arranged on the surface of the housing 30 b are closely adhered to the lower surface of the substrate chuck 20 .
During this state, when the moving unit 32 keeps operating, the substrate chuck 20 moves upward along with the housing 30 b . The moving unit 32 may move until the surface of the wafer mounted on the substrate chuck 20 presses the resist droplets 36 deposited on the surface of the nanostructures 14 ′ a of the element-wise patterned stamp 14 .
If the surface of the wafer presses the resist droplet by driving the moving unit 32 , then the gas supplier of the pressure supply unit 30 will be driven. In addition, the gas supplied from the gas supplier passes through the gas supply tube 30 d the hollow cavity 30 a , the gas supply holes 30 c , and the through holes 30 e one after another and is selectively supplied to some region of the bottom surface of the wafer. Therefore, some regions of the wafer, preferably, regions facing the element stamps 14 a , are pressed toward the respective element stamps 14 a due to the gas pressure, so that the insufficient filling of the resist into the channels of the nanostructures due to the error of flatness between the element-wise patterned stamps and the wafer can be prevented.
During the gas supply process, the O-rings 30 f prevent gas leakage
Next, the resist 36 is cured by illuminating resist 36 with UV light from the UV lamp unit 18 .
When the resist 36 is cured, the element-wise patterned stamp 14 is separated from the wafer. Due to the channels 14 b of the element-wise patterned stamp 14 , the separation between the element-wise patterned stamp 14 and the remaining cured resist over the wafer surface can be easily made. The gas between the element-wise patterned stamp 14 and the wafer may be intermittently sprayed by using the gas spray nozzle (not shown) to make the separation more effectively.
Next, the resist droplet is applied again to the separated surface of the nanostructures 14 ′ a of the element-wise patterned stamp 14 , and the substrate chuck 20 is moved to perform the second process. Here, the substrate chuck 20 is moved along the guide block 22 . The stamp chuck 16 and the pressure supply unit 30 remain fixed when the substrate chuck 20 is moved. In addition, after the substrate chuck 20 is moved, the resist may be formed in a predetermined region of the wafer by repeating the afore-mentioned process. For example, when the nanostructures are formed in an 8 inch wafer by using the 5×5 inch element-wise patterned stamp, the resist may be formed by repeating the afore-mentioned process four times. Next, the upper surface of the wafer having the deposited resist 36 is etched. When the resist left in the upper surface of the wafer is removed, the nanostructures are formed on the wafer.
Further, when the stamp board rather than the wafer is used for the substrate, the large-area element-wise patterned stamp can be fabricated at low cost by performing the afore-mentioned process.
While the nanostructures fabricated by using the element-wise patterned stamp in the step and repeat method has been described above, the apparatus and process of the present invention can also be achieved by using a planar-type stamp 14 ′ that does not include the channels 14 b of FIG. 4 , as shown in FIG. 6 . However, in this case, to remove defects such as air entrapment, the apparatus according to the embodiment of the present invention should be arranged inside the vacuum chamber and performed under the vacuum ambient.
In addition, when the large-area stamp (planar-type stamp or element-wise patterned stamp) having the same working area with the wafer is fabricated by the stamp board as the substrate 28 , the process can be completed at one time by using the afore-mentioned large-area stamp.
While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims. Therefore, the scope of the invention is defined not by the detailed description of the invention but by the appended claims, and all differences within the scope will be construed as being included in the present invention. | A UV nanoimprint lithography process and its apparatus that are able to repeatedly fabricates nanostructures on a substrate (wafer, UV-transparent plate) by using a stamp that is as large as or smaller than the substrate in size are provided. The apparatus includes a substrate chuck for mounting the substrate; a stamp made of UV-transparent materials and having more than two element stamps, wherein nanostructures are formed on the surface of each element stamp; a stamp chuck for mounting the stamp; a UV lamp unit for providing UV light to cure resist applied between the element stamps and the substrate; a moving unit for moving the substrate chuck or the stamp chuck to press the resist with the element stamps and substrate; and a pressure supply unit for applying pressurized gas to some selected regions of the substrate to help complete some incompletely filled element stamps. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to information systems that produce advice about a design domain in order to help someone designing in the domain. Such systems produce advice by using a "knowledge base" in which information relevant to designing in the domain is stored. Typical domains include the design of software, integrated circuits, mechanical devices, and buildings.
2. Description of the Prior Art
Knowledge-based technology is central to the field of Artificial Intelligence and various application areas that evolved from it (Readings in Knowledge Representation, edited by Ronald J. Brachman and Hector J. Levesque, Morgan-Kauffmann, 1985). This technology has three facets. First are techniques for representing knowledge about the domain (such as configuring computer components) in a computer. Issues of succinctness and completeness arise in the representation of domain knowledge. The second facet is access, techniques for presenting and making accessible appropriate knowledge at appropriate times. The third facet can be called update, maintenance, or evolution; it involves the ability to change the knowledge in response to new or unanticipated conditions in the domain. Note that how the knowledge is represented can greatly impact the second and third facets of knowledge-based technology.
An important application area for knowledge-based technology is the area of design (Report on DARPA-Sponsored Workshop on Design, edited by Saul Amarel, Technical Report no. LCSR-TR-160, Department of Computer Science, Rutgers University, April, 1991). Design is an important engineering activity where objects and artifacts are either designed from scratch or modified (re-design); these objects and artifacts can be physical objects (integrated circuits, bridges), non-physical objects (software, software systems), or even processes (for chemical engineering, manufacturing). The process of design usually involves or results in external representations of the objects and artifacts, such as blueprints, scale models, or block diagrams. Design is very knowledge-intensive: it requires knowledge of the engineering domain, relevant problem-solving knowledge, common sense knowledge, and knowledge of the tools and techniques for external representation. It is very often the case that a large part of the required body of knowledge is only available in the heads of experts in the area and is not written down in any comprehensive fashion. This makes it difficult for novices in the area, or experts unfamiliar with a sub-domain, to locate, understand, and apply design knowledge relevant to a particular design situation.
New technology has resulted in automation of some parts of engineering design, in particular, computer-based graphics workstations for accessing and manipulating the artifacts of design. However, very little work has been done in actually assisting the design process by providing access to design knowledge. Such knowledge remains as organizational "folklore", or represented in voluminous documents which only provide a primitive indexing ability. An alternative approach, the subject of this patent, is to codify design knowledge in a knowledge base and, equally important, provide mechanisms for a user to access that knowledge at relevant portions of the design process and provide mechanisms for the maintenance of the knowledge in the knowledge base.
Assuming the viability of such an approach, a number of important benefits will result. First of all, the availability of appropriate design knowledge will improve the design process and produce superior designs. Second, the codification of design knowledge will allow that knowledge to be efficiently disseminated and re-used, again improving the overall design process within an organization. Third, if a mechanism of updating the design knowledge, also called knowledge maintenance, can be integrated in an organization, this knowledge will remain current and relevant as design situations change.
This latter issue of knowledge maintenance is particularly critical in design. Unlike medical diagnosis or computer configuration domains, the body of relevant design knowledge is both harder to "get right" initially and will change because of changing engineering standards and practices and organizational changes. In addition, the engineering design process is often a process of re-design of existing design objects, and thus is very dependent on the changing state of those objects. This further increases the importance of knowledge maintenance.
One recent organizational development that can ease the maintenance problem is the so-called "quality revolution" in commerce and industry. This movement emphasizes a variety of organizational changes resulting in the notion of an organizational process. Each organizational process can be viewed as discreet unit with a number of inputs (customer requests), outputs (organizational products), and various feedback loops which can be used to evaluate the effectiveness of the process. A process can be further divided, in a hierarchical fashion, into sub-processes. One of the many benefits of this viewpoint is that a process or sub-process can have an owner designated, providing a single point of contact for evaluating and modifying the process. The idea of organizational process can be used to address the problem of maintenance of a design knowledge base if the maintenance problem can be integrated into a new or existing organizational process.
SUMMARY OF THE INVENTION
The above object is achieved by apparatus for producing advice about a design and for annotating designs with the advice produced. Advice is information about the design domain relevant and useful to the design. The apparatus includes
a design document;
a knowledge base for producing information relevant to designing in a particular domain;
means for a designer to request access to the information in the knowledge base;
means for the system to assemble advice in response to the designer's request;
means for identifying the "owner" of each piece of information in the knowledge base; and
means to annotate designs with a trace of the advisory interaction, including system questions, user responses, and system advice.
It is an object of the invention to provide designers with improved access to information.
It is a further object of the invention to support the ongoing evolution of the information in the knowledge base, as new knowledge is generated and as the information already in the knowledge base is found inadequate.
It is an additional object of the invention to support and focus communication among designers, both decreasing the need for communication, and, when communication still is required, ensuring that it occurs directly between a designer who needs help and a designer who can give the help.
These and other objects and advantages of the invention will be apparent to those of ordinary skill in the art after perusing the Detailed Description and Drawing, wherein:
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 illustrates the overall structure of the invention; it includes the principal components of each of the mechanisms in the embodiment and how the mechanisms are employed in the design process;
FIG. 2 illustrates the structure of the knowledge base in a preferred embodiment;
FIGS. 3 and 4, illustrate two methods of interacting with a designer to obtain input required to access relevant information in the knowledge base;
FIG. 5 illustrates the process of computing advice in a preferred embodiment; and
FIG. 6 illustrates a partial trace of an interaction with an application of the apparatus and methods applied to the domain of software design.
DETAILED DESCRIPTION
The following Detailed Description begins with an overview of the invention and then proceeds to a detailed description of a preferred embodiment thereof.
Overview of the Invention: FIG. 1
FIG. 1 shows an artificial intelligence system 102 embedded in a larger design process 101. The artificial intelligence system includes a knowledge base of design information and is implemented using the present invention. The major components are the following:
Design Knowledge Base (DKB) 104 contains the information about designing in a particular domain used to produce design advice;
Design Assistant 103 is a computer program that interacts with a designer to give the designer access to relevant information from DKB 104. Design Assistant 103 consists of two parts, a Query Provider QP and an Advice Provider AP.
Maintenance Assistant 105 is a computer program that interacts with a knowledge base maintainer to add new information to DKB 104;
The Annotated Design Document 106 consists of three parts:
Design 107--a specification of the product to be built;
Trace of interactions with the Design Assistant 108--shows the advice given by Design Assistant 103, in particular, the features of the Design 107 due to advice produced from DKB 104;
Suggested updates to Design Knowledge Base 109--information that a designer believes should be added to DKB 104.
The operation of system 102 within the organizational process 101 is as follows. While constructing a Design 107, a designer interacts with the Query Provider QP part of Design Assistant 103 by providing user input UI 117. On the basis of this interaction, Design Assistant 103 queries DKB 104 with Query 119 to access design information relevant to the designer. The DKB 104 provides Design Information DI 123 to the Design Assistant 103. The Advice Provider AP part of the Design Assistant presents the relevant information as Design Advice DA 121 to the designer as advice. Each item in the advice is labeled with the "owner" of the advice. This advice becomes an annotation 108 to the Annotated Design Document 106. In addition, designers may suggest additions to or modifications of DKB 104 where they believe it to be incomplete or incorrect. These suggestions 109 also become part of the Annotated Design Document 106.
The Annotated Design Document 106 is then subject to a Review 111. The Review 111 is a meeting in which a group of experienced designers in the relevant domain examine the Annotated Design Document 106 to look for problems with the design. The presence of the trace of design advice 108 and suggested updates to the knowledge base 109 is crucial in supporting the evolution of DKB 104. The trace 108 makes problems in the design due to advice based on incorrect information in DKB 104 apparent. The suggested updates 109 also are judged to see if they are consistent with the reviewers' knowledge and may be extended or modified based on the reviewers' examination of the Annotated Design Document 106.
After the Review 111, the Annotated Design Document 106 is given to a human knowledge base maintainer. The process of KB Maintenance 112 involves the knowledge base maintainer interacting with a Maintenance Assistant program 105 to update DKB 104 based on the modifications and additions discovered to be necessary during Design 110 and Review 111 and recorded on the Annotated Design Document 106. For each update of the knowledge base, the person who suggested that update (the "owner") is associated with the new item in the knowledge base.
DETAILED DESCRIPTION OF THE STRUCTURE AND OPERATION OF THE INVENTION
We first describe the organization of information in the Design Knowledge Base (DKB) 104. The DKB 104 must contain information that is relevant to the task of designing in a particular domain. The combination of the organization of information in DKB 104 and the working of the Design Assistant 103 must allow designers easy access to relevant design information. In a preferred embodiment, the DKB 104 contains the following major components (see FIG. 2):
A hierarchy of Design Descriptions 201; in the area of software design, for example, Design Descriptions might include "Designs that consume too many resources" and "Designs that send too many messages"; the second Description would be a specialization of the first;
A set of Design Decisions 202, indexed by Design Description; in the area of software design, for example, a Design Description might be "Should I define a new process or use an existing process?"; and
A set of Advice Items 203, indexed by Design Description and Design Decision.
The meaning of these components is as follows:
IF a Description D escr is determined to be true of a design D,
AND D escr indexes the Decisions D 1 , . . . , D N ,
AND each <D escr , D i >pair (1≦i<N) indexes the Advice Items A i ,1 . . . A i ,M
THEN the advice items A 1 ,1, . . . , A 1 ,M, . . . , A N ,1, . . . , A N ,M are relevant to the design D.
There are three additional aspects to the representation of design information:
Advice items are labeled as either primary or secondary;
Advice items may be labeled as overriding; and
Design Descriptions have an associated establishing question.
The use of this information is discussed below.
In a preferred embodiment, we use CLASSIC (L. A. Resnick, "The CLASSIC User's Manual", AT&T Bell Laboratories Technical Report, 1991; R. J. Brachman, A. Borgida, D. L. McGuinness, P. F. Patel-Schneider, and L. A. Resnick, "Living with Classic: How and When to Use a KL-One-like Language", in J.Sowa, ed., Principles of Semantic Networks: Explorations in the Representation of Knowledge; Morgan-Kauffmann, 1991, pp. 401-456.) as the language for representing the design information described above. The abstract, pictorial presentations of design information shown in FIG. 2 are realized in CLASSIC as follows:
each Design Description 201 is a CLASSIC concept; the CLASSIC relationships parent and child are used to represent the hierarchy;
each Design Decision 202 also is a CLASSIC concept;
each Advice Item 203 is a CLASSIC individual;
the index relationships among Design Descriptions, Design Decisions, and Advice Items are represented by CLASSIC roles, which simply are a means for stating a relationship between two objects; and
roles also are used to represent the additional features of the representation identified above: primary vs. secondary, overriding, and establishing questions.
FIG. 2 also contains an example showing more precisely how Design Descriptions 201, Design Decisions 202, and Advice Items 203 are related. In the example, the nodes in the tree 205 indicate Design Descriptions 207, ovals 209 indicate Design Decisions, and text of the form "A-N" 211 indicates an Advice Item. The indexing relationship is shown informally, by the position of Descriptions, Decisions, and Advice Items. Relationships shown in the example include
Descr-1 indexes Decision 1;
<Descr-1, Decision 1> indexes A-1;
Descr-6 indexes Decision 3, Decision 4, and Decision 5; and:
<Descr-6, Decision 3> indexes A-15 and A-16.
We next discuss the interaction of the Design Assistant 103 with a designer, illustrating
how the interaction gives the Design Assistant 103 sufficient information to access relevant information in the Design Knowledge Base 104; and
how the Design Assistant 103 computes advice based on the interaction with the designer.
The goal of the interaction is to get the designer to classify his or her design under the most specific relevant Design Description; this results in the most specific possible advice. We describe two preferred embodiments for engaging n such an interaction with the designer. The first embodiment, given in FIG. 3, is preferable for very small description hierarchies; the second embodiment, given in FIG. 4, is preferable for all larger hierarchies. We call the algorithm GET-DESIGNER-TO-CLASSIFY-DESIGN. Note that the hierarchical representation of Design Descriptions allows for an economical representation of advice; advice common to a number of Descriptions can be represented at a common parent Description. Exceptions to this general advice can be labeled as being overriding. Overriding advice cancels out or overrides more general advice and replaces the general advice when the advice is presented. For example, in FIG. 2, Advice Item A-13 overrides Advice Item A-12, and Advice Item A-18 overrides Advice Item A-18. If Description Desc-6 is found to be relevant, Advice Item A-13 would be presented to the user and Advice Item A-9, which relates to the save Design Decision, would not be presented. Likewise, if Description D7 was found to be relevant, Advice Item A-18 would be presented to the user and Advice Item A-12 would not be.
After obtaining this information from the designer, the Design Assistant 103, uses algorithm COMPUTE-ADVICE (shown in FIG. 5) to compute the advice that is relevant to the design being constructed. In addition to presenting the advice to the designer, the Design Assistant also produces a trace of the advisory interaction, including the advice produced. This trace 108 then becomes part of the Annotated Design Document 106.
The Annotated Design Document 106 then is examined in the Review 111. In particular, the parts of the design due to the advice generated from the DKB 104 will be examined. Any modifications of or additions to the information in the DKB 104 detected during the Design 110 and Review 111 processes will be examined by a knowledge base maintainer. During the process of KB Maintenance 112, the knowledge base maintainer will use the Maintenance Assistant program 105 to integrate these modifications and additions into the DKB 104.
APPLICATION OF THE TECHNIQUES TO SOFTWARE DESIGN
The described apparatus and methods for providing design advice have been applied to the domain of software design. The specific domain is the use and a particular error reporting and handling mechanism that is used in a software program.
A hierarchy of design descriptions relevant to this error reporting mechanism has been represented in a knowledge base. A set of design decisions relevant to the above mentioned error mechanism have been represented and indexed by design description. Finally, a set of advice items relevant to the use of the error mechanism has been represented and indexed by design description and design decision. These advice items are labelled as either primary or secondary; some are labelled as overriding; and owners of the advice items are stored.
A design assistant was created which uses the algorithm shown in FIG. 3 to obtain information from the designer. The design assistant then uses the algorithm shown in FIG. 5 to compute the advice relevant to the design being constructed. The advice is presented to the designer and a trace of the interaction of the designer with the design assistant is produced. This trace becomes part of the design document as described in this application. FIG. 6 illustrates a Partial Trace 601 of this system. DKT problem question 603 is presented to the user. If the user response is "yes", then Design Advice 605 is presented to the user, consisting of Primary Advice 607 and secondary advice 609.
CONCLUSION
The foregoing Detailed Description has disclosed to those skilled in the arts to which the invention pertains how one may make and use a system for delivering design advice and evolving the knowledge base from which the advice is generated. Other techniques that those disclosed herein for practicing the invention and other areas in which the invention may be applied will be apparent to those skilled in the arts concerned after reading the foregoing disclosure. For example, CLASSIC could be replaced by other representation languages.
In addition, while the interaction of the Design Assistant and the designer described here is based on the Design Assistant asking a question, getting the designer's answer, then acting on the basis of the answer, other methods of interaction would be even more appropriate in other circumstances. For example, if the Design being produced is a formal object, the Design Assistant could apply rules of inference directly to the design in order to classify it, rather than querying the designer. Further, advice could be delivered in many different ways, for example, combinations of text, graphics, video, etc.
Because of the wealth of the possible embodiments of the invention, the foregoing Detailed Description is to be understood as being in every respect illustrate and exemplary, but not restrictive, and the scope of the invention disclosed herein is not to be determined from the Detailed Specification, but rather from the claims as interpreted in light of the Detailed Description and in accordance with the doctrine of equivalences. | A knowledge-based artificial intelligence system which provides design advice. The artificial intelligence system includes a knowledge base of design information. Users of the system indicate an area about which they require design advice. The system provides the relevant advice. Included in the advice is an indication of the "owner" of the advice. The advice and the relationship between the design made by the user are part of a trace of the users' session with the system. The trace becomes part of a design document for the design. When the design is reviewed, the trace is reviewed as well. The system includes an interface for updating the knowledge base, and if the design review indicates a need to correct the knowledge base, the corrections are made using the interface for updating. A preferred embodiment of the system is used to provide advice to designers of a large software system concerning the use of an error reporting and handling system in the system being designed. | 8 |
FIELD OF THE INVENTION
The present invention relates to devices used to aspirate fluids from a patient during surgery, and more specifically to an apparatus which includes both pressure controlled and flow controlled modes.
BACKGROUND OF THE INVENTION
In surgery, and particularly in ophthalmic surgery, there are many applications for aspiration systems which provide an aspiration level responsive to some surgeon-operated control, such as a footpedal. Such aspiration systems may be classified as either pressure-controlled or flow-controlled, depending upon whether it is the pressure (vacuum) level or the flow level which is directly responsive to the surgeon's input. Within the scope of ophthalmic surgery, pressure-controlled aspiration systems have proven to be advantageous for most aspects of vitreoretinal surgery and flow-controlled aspiration systems have proven to be advantageous for most aspects of cataract surgery. Since both types of surgery may be performed in a given medical facility, there is a need for an aspiration system capable of operating in either a pressure-controlled or a flow-controlled mode.
With specific regard to pressure-controlled aspiration systems, the present standard for pressure-controlled aspiration is the venturi system, which is powered by compressed gas at a high flow rate. This requires an external compressor or tank of compressed gas, which limits the portability of the overall system. Accordingly, there is a need for a more portable aspiration system with performance comparable to the best pressure-controlled aspiration systems at a lower power requirement.
Pressure-controlled aspiration systems of the venturi type routinely provide a means of sensing the actual pressure (vacuum) level being delivered without contamination of the non-disposable parts of the system by fluids aspirated from the surgical site. However, peristaltic aspiration systems, which are the present standard for flow-controlled systems, typically must allow aspirated fluid to come in contact with the pressure sensor. Various means, such as filtration to remove bacteria and flushing with clean liquid at the conclusion of the surgery, have been tried to minimize the safety and reliability issues raised by this contamination. There is, however, a need for a better solution to this problem, particularly in view of current concerns over diseases transmitted by viruses, which cannot easily be removed by filtration.
SUMMARY OF THE INVENTION
In accordance with the present invention, the aspiration system having pressure-controlled and flow-controlled modes of the present invention comprises connective plumbing, a collector, a pump, a variable flow resistor, a pressure sensor, and control means. The connective plumbing includes a conduit which communicates with the surgical site from which fluid is to be aspirated. The collector includes a collection bag which receives aspirated fluid from the conduit. The pump is preferably of the peristaltic type, and induces flow of aspirated fluid from the conduit to the collector. The variable flow resistor includes a proportional valve which is disposed in fluid communication with the connective plumbing, the pump, and the collector. The pressure sensor is likewise in communication with the collector, the pump, and the variable flow resistor.
The control means is a circuit which receives an output signal from the pressure sensor and which further controls the variable flow resistor, and the aspiration system in two different modes of operation. In the first mode, the pressure of fluid conveyed by the conduit is controlled; and in the second mode the flow of fluid conveyed by the conduit is controlled. In the first mode, the variable flow resistor is adjusted to maintain a pre-selected pressure according to the output signal from the pressure sensor. In the second mode, the variable flow resistor is adjusted to maintain a pre-selected flow according to a pressure differential in the connective plumbing across the variable flow resistor. The aspiration system further includes a gas source which is inputted into the variable flow resistor to provide a known pressure against which the pressure in the remainder of the connective plumbing is compared to establish the pressure differential.
The connective plumbing includes a first section and a second section separated by a flow director, the first section being in fluid communication with the conduit, the pump, and the collector, and the second section being in fluid communication with the pressure sensor, the variable flow resistor, and the gas source. The flow director permits flow only in the direction from the second section to the first section. The connective plumbing of the first section is disposable after a single patient use.
The present invention also provides as noted earlier an aspiration system capable of operating in either a pressure-controlled or flow-controlled mode. The present invention further provides a more conveniently portable aspiration system with performance comparable to the best pressure-controlled systems at a lower power requirement. Further, the present invention provides connective plumbing which is separable, the portion being in contact with aspirated fluid being disposable to avoid contamination.
Further objects, features, and advantages of the present invention will be apparent from the following detailed description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a block diagram of the aspiration system of the present invention and which has pressure-controlled and flow-controlled modes.
FIG. 2 is a plan view of the collector; the flow director; and portions of the connective plumbing of the aspiration system of the present invention.
FIG. 3 is a fragmentary, plan view of the pump utilized with the aspiration system of the present invention with the stepping motor removed.
FIG. 4 is a fragmentary side elevation view of the pump utilized with the aspiration system of the present invention.
FIG. 5 is a perspective view of the pump utilized with the aspiration system of the present invention, with the associated drawer withdrawn.
FIG. 6 is a top plan view of the variable flow resistor utilized with the aspiration system of the present invention, and shown with the internal passageways in phantom lines.
FIG. 7 is a side elevation view of the variable flow resistor of the aspiration system of the present invention, with the internal passageways being illustrated in phantom lines.
FIG. 8 is a schematic diagram of the control circuit [of] employed with the aspiration system of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
with reference to the drawings, the aspiration system having pressure-controlled and flow-controlled modes of the present invention is shown generally in FIG. 1 at the numeral 10. The aspiration system 10 generally includes a pump 12; a collector 14; a flow director 16; a pressure sensor 18; a variable flow resistor 20; a gas source 22; a control circuit 24; and connective plumbing 26.
The connective plumbing 26 includes conduits 28; 30; 32; 34; 36; 38; 40; and 42. The conduits 28, 30 and 32 are in fluid communication and meet to form juncture point 44. The conduit 28 is disposed in fluid communication with a surgical handpiece (not shown) and is operable to convey aspirated fluid from the surgical site to the juncture point 44. The conduit 30 conveys fluid from the juncture point 44 to the pump 12. The conduit 32 conveys fluid from the flow director 16 to the juncture point 44. The conduit 34 conveys fluid from the pump 12 to the collector 14. The conduits 36, 38, and 40 are connected in fluid communication and meet to form a juncture point 46. The conduit 36 conveys fluid from the juncture point 46 to the flow director 16. The conduit 38 conveys fluid from the juncture point 46 to the pressure sensor 18. The conduit 40 conveys fluid from the variable flow resistor 20 to the juncture point 46, and the conduit 42 maintains fluid communication between the variable flow resistor 20 and the gas source 22.
FIG. 1 further shows a wire connection or electrical pathway at 48 which conveys a signal from the pressure sensor 18 to the control circuit 24; a wire connection or electrical pathway at 50 which inputs a signal which constitutes the vacuum setpoint or maximum vacuum limits; and a wire connection or electrical pathway at 52 which sends an output signal from the control circuit 24 to the variable flow resistor 20.
FIG. 2 illustrates the conduits 28; 30; 32; and 34; the collector 14, and the flow director 16. These parts are intended to be disposed of after a single patient use. The conduit 28 is manufactured of flexible tubing which is connected at one end to the juncture point 44 and which terminates at its opposite end at a connector fitting 54. The conduit 28 may be further extended by connection of additional tubing to the connector fitting 54 or the connector fitting 54 may be directly attached to the surgical handpiece (not shown). The conduits 30 and 34 are collectively formed of a thick-walled flexible tubing intended for use with a peristaltic pump. They are connected at one end to the juncture point 44 and at the other end to an elbow fitting 58, and further extends between the elbow fitting 58 and at the other end to a tube fitting 56. The portion of conduit 34 which extends between the fittings 56 and 58 is preferably manufactured from tubing which is clear or transparent such that movement of aspirated material through the conduit 34 may be observed by a surgeon. The tube fitting 56 is sealed on the collector 14. As should be understood, the elbow fitting 58 facilitates the routing of the peristaltic tubing when the aspiration system 10 is assembled and made ready for operation, as will be explained below. The pump 12 is interposed to act upon the peristaltic tubing between juncture 44 and the elbow fitting 58 in a manner as also explained below, such that the peristaltic tubing between the juncture 44 and the pump 12 forms the conduit 30; and the peristaltic tubing between the pump 12 and the elbow fitting 58, together with the clear tubing between the elbow fitting 58 and the tube fitting 56, forms the conduit 34.
As seen in FIG. 2, the collector 14 includes a collection bag 60; a tube fitting 62; and a hydrophobic filter 64. The hydrophobic filter 64 acts to retain aspirated liquids and solid material within the collection bag 60, yet vents the collection bag 60 to the atmosphere by permitting the escape of air entrapped within the collection bag. The conduit 32 is manufactured of tubing connected at one end to the juncture point 44 and at the other end to an outlet of the flow director 16. The juncture point 44 is formed of a standard "T" fitting. As shown in FIG. 2, the flow director 16 is preferably a one-way or check valve, but other flow directing means such as a hydrophobic filter may be employed in place of same. An inlet of the flow director 16 terminates in a male connector fitting 66 which may be removably connected to the conduit 36.
FIGS. 3, 4, and 5 show various views of the pump 12 of the aspiration system 10. The pump 12 is preferably of the peristaltic type. The pump includes a base 68; a fixed assembly 70; and a drawer 72. The fixed assembly 70 includes a stepping motor 74; a stepping motor mounting bracket 76; and a rotatable hub 78. The stepping motor 74 is mounted upon the stepping motor mounting bracket 76; and the stepping motor mounting bracket 76 is mounted upon the base 68. The rotatable hub 78 includes two disks 80 and four rollers 82. The rollers 82 are arranged in a cross-like pattern about the periphery of the hub 78 and are individually positioned or sandwiched between the disks 80. It is to be understood that there may be other arrangements and numbers of the rollers 82. The rollers 82 are each rotatably attached to the disks 80 by concentric, axially directed pins 84. The rotatable hub 78 is attached about its axis to a drive shaft 86 of the stepping motor 74. The drive shaft 86 extends through an aperture (not shown) in the stepping motor mounting bracket 76. As shown by the arrow in FIG. 5, the stepping motor 74 rotates the hub 78 in a predetermined direction.
The drawer 72 is movable along a predetermined path of travel relative to the stepping motor 74; the hub 78; and the remainder of the fixed assembly 70. FIGS. 3 and 4 show the drawer 72 inserted into a position ready for operation of the pump 12; while FIG. 5 shows the drawer 72 withdrawn from the remainder of the pump 12. The drawer 72 includes a curved backplate which is shaped to substantially conform to the hub 78. Further, the tubing which forms the conduits 30 and 34 is routed or otherwise disposed about the rollers 82 and is thereafter compressed or sandwiched between the rollers 82 and the backplate 88 when the drawer 72 is inserted in a position ready for operation of the pump 12 (FIG. 4). As the stepping motor 74 is energized the hub 78 rotates in a predetermined direction. When this occurs, the rollers 82 engage the tubing which forms the conduits 30 and 34. This action occludes the tubing at the point where it is compressed between one of the rollers 82 and the backplate 88. As this point of occlusion moves, fluid is drawn through the tubing.
The drawer 72 is attached by means of a plate 90 to a slide mechanism 92. The slide mechanism 92 is moveable along a track 94 which is attached to the base 68. The movement of the drawer 72 by means of the slide mechanism 92 is substantially linear. When the drawer 72 is withdrawn, the tubing which forms the conduits 30 and 34 may be released to make the disposable portion of the aspiration system 10 (the collector 14, the flow director 16, and the conduits 30, 32 and 34) accessible for removal or installation. The drawer 72 is normally retained in the position shown in FIG. 3 by a latch mechanism 96 which includes a pin 98, and a bracket 100 which are attached to the drawer 72 by means of the plate 90. The latch further includes a pawl 102 and a bracket 104 which are attached to the base 68. The pawl 102 engages the pin 98 in order to retain the drawer 72 in the position shown in FIG. 3. To withdraw the drawer 72, a solenoid 106 which is connected to the aforedescribed latch mechanism 96, may be electrically activated to disengage the pawl 102 from the pin 98.
FIGS. 3 and 5 further show an interface block 108 which enables fluid communication between the flow director 16 and the conduit 36. The interface block 108 has a first end 110; an opposing second end 112; and a passageway 114 which is bored therethrough between the first end 110, and the second end 112. The interface block further includes an O-ring seal 116 at the first end which is compressed between the male connector fitting 66 and the passageway 114 to form a leak-tight seal. The second end 112 of the interface block 108 terminates in a barb-shaped fitting 118. A passageway 114 is disposed in fluid communication with the barb-shaped fitting 118. The barb fitting 118 facilitates the connection of the conduit 36 such that other portions of the aspiration system 10 not shown in FIGS. 3, 4, and 5 may be connected thereto.
FIGS. 3 and 5 further show a locking mechanism 120 by which the connector fitting 54 may be prevented from rotating. The locking mechanism 120 receives the connector fitting 54 in a mating pocket 122 formed in the drawer 72. The locking mechanism 120 may be slid to the right (according to the orientation of FIG. 3) in order to permit removal of the connector fitting 54 from the drawer 72.
As shown in FIG. 5, the collector 14, is attached to the drawer 72. The attachment of the collector 14 is accomplished by pins 124, which are viewable in FIG. 3. As best seen in FIG. 5, the collector bag 60 is suspended from the drawer 72 and the tube fitting 56 is connected to the conduit 34.
FIGS. 6 and 7 show in greater detail the preferred embodiment of the variable flow resistor 20. The variable flow resistor 20 includes a manifold block 126 having passageways 128, and 130, respectively. The passageway 128 includes a first branch 132; a second branch 134; a third branch 136; a fourth branch 138; and a fifth branch 140, all of which are disposed in fluid communication, one with the other. The first branch 132 of the passageway 128 terminates in a barb-shaped fitting 142, the second branch 134 of the passageway 128 terminates in a barb-shaped fitting 144; the third branch 136 of the passageway 128 terminates in a barb-shaped fitting 146; and the fourth branch 138 of the passageway 128 terminates in an orifice fitting 148. The conduit 36 is connected at one end to the barb fitting 118 (best viewed in FIG. 3) and is connected at its opposite end to the barb-shaped fitting 142. This places conduit 36 in fluid communication with the first branch 132 of the passageway 128. As should be understood, the conduit 38 is actually a double conduit 38A and 38B and is connected to the juncture 46 at one end and is in fluid communication with the pressure sensor 18. Further, the conduit 38A is connected at its other end to the barb fitting 144; and the conduit 38B is connected at its other end to the barb fitting 146. In this arrangement, the conduit 38A is disposed in fluid communication with the second branch 134 and conduit 38B is disposed in fluid communication with the third branch 136. As noted above, the conduit 38 is a double conduit since the pressure sensor 18 is manufactured with two redundant pressure transducers which reduces the potential hazard to the patient from a failure of one of the pressure transducers.
The variable flow resistor 20 includes a fixed flow resistance through the orifice fitting 148, in parallel with a variable flow resistance formed by a proportional solenoid valve 150. The fifth branch 140 of the passageway 128 is connected to the first port of the solenoid valve 150. The fixed flow resistance through the orifice fitting 148 facilitates the maintenance of a small flow of gas required for the flow-controlled mode of operation of the aspiration system 10 of the present invention, described below. The conduit 40 therefore includes the portions of the passageway 128 which communicate with the orifice fitting 148 and with the first port of the proportional solenoid valve 150. The passageway 130 of the manifold block 126 communicates between the second port of the proportional solenoid valve 150 and the ambient atmosphere. The conduit 42 includes the passageway 130 and also the outlet from the orifice fitting 148. As should be understood, the gas source 22 in this instance is the ambient atmosphere. It is to be further understood that it would be possible to add a hose barb fitting (not shown) to the end of the passageway 130 in order to communicate with some other gas source. In this situation, where another gas source is employed, the barb fitting added to the end of the passageway 130 and the existing orifice fitting 148 would be connected to this additional gas source. An example of an alternate gas source includes a reservoir of air maintained by some other control means at a pressure approximately equal to the pressure at the surgical site. In ophthalmic surgery, this is typically 20 to 40 mm Hg above atmospheric pressure. This permits the differential pressure between the surgical site and the conduit 28 to be regulated all the way to zero.
FIG. 8 illustrates in greater detail the preferred embodiment of the control circuit 24. The control circuit 24 includes an integrated circuit 152 (TL494) which is a pulse width modulation circuit designed primarily for use in switching power supplies. In this case, the pulse width modulated output at 52 is also suitable for driving the inductive load of the proportional valve solenoid 150. The degree of opening of the solenoid valve 150 is proportional to the average current through the solenoid 150, which is in turn proportional to the duty cycle of the pulse width modulated signal at 52. The integrated circuit 152 contains all of the active circuitry needed for closed loop control. As should be understood, the setpoint signal at 50 is applied at pin 1 of the integrated circuit 152, which is the non-inverting input of an operational amplifier. A resistor 154 which is used to compensate for input bias current is an optional feature. The feedback signal at 48 is applied through resistor 156 to pin 2 of the integrated circuit 152. The pin 2 is the inverting input of the operational amplifier. The output of the operational amplifier at pin 3 of the integrated circuit 152 is also fed back to pin 2 of the integrated circuit 152 through a resistor 158 and a capacitor 160. The exact values of the resistor 156, the resistor 158, and the capacitor 160 determine the open-loop gain and phase of the control system, and therefore the stability of the closed-loop system. Pin 3 of the integrated circuit 152 is also connected internally to control the pulse width modulation circuitry. Accordingly, increasing the voltage at pin 3 results in a decreasing duty cycle of the signal at 52. The pulse width modulation circuitry is also affected by an aspiration disable signal carried at 162 and applied at pin 4 of the integrated circuit 152. This controls the maximum duty cycle. For example, a voltage greater than a set amount, here 3.5 volts, sets the maximum duty cycle to zero, thereby effectively disabling the control system. To enable the control system, the signal carried at 162 should be near ground potential. Further, a resistor 164 and a capacitor 166 determine the frequency of the pulse width modulated output at 52. Additionally, a diode 168 clamps the signal carried at 52 near ground when the internal drive transistors of the integrated circuits 152 are deenergized. A capacitor 170 bypasses switching currents to reduce the coupling to other circuits through the power supply.
Operation
The operation of the described embodiment of the present invention is believed to be readily apparent and is briefly summarized at this point.
In the operation of the aspiration system 10, the drawer 72 is withdrawn by activation of the solenoid 106. The conduits 28, 30, 32, and 34, the collector 14, and the flow director 16 are installed into the pump 12, these parts being disposable as discussed earlier after a single use. The connector fitting 54 is then locked into place by the locking mechanism 120. The conduits 30, and 34 are routed about the rotatable hub 78 and the remaining connective plumbing is generally laid out as indicated in FIG. 3. The collector bag 60 is hung from the pins 124, and the drawer 72 is "closed" or inserted into the pump 12. When the drawer 72 is inserted into the pump 12, the conduits 30, and 34 are compressed between the rollers 82 and the backplate 88. As described above, the activation of the stepping motor 74 causes the hub 78 to rotate in a predetermined direction along the tubing which forms the conduits 30 and 34. When this occurs, fluid is drawn through the tubing.
The pump 12 induces a flow through the conduits 30 and 34 which is approximately independent of the pressure (vacuum) levels in the conduits 30 and 34. This flow is directed from the conduit 30 to the conduit 34 and is normally greater in magnitude than the flow into the conduit 28 from the surgical site. Thus, there normally is a flow through the conduit 32, which is directed into the conduit 30, and which is equal to the excess of the flow through the conduit 30 into the pump 12 and further above the flow into the conduit 28 from the surgical site. This flow includes gas originating from the gas source 22 and flowing through the conduit 42; the variable flow resistor 20; the conduits 40, and 36, and the flow director 16. The flow director 16 permits this flow, as long as it is directed from the conduit 36 into the conduit 32. As should be understood, the pressure differential between the conduit 40, and the conduit 42 depends upon the magnitude of the flow and the degree of restriction of the variable flow resistor 20. Since the pressure in the conduit 42 is maintained at a more or less constant level by the gas source 22, the pressure (vacuum) level in the conduit 40 can be controlled by the variable flow resistor 20. As should be understood, the pressure (vacuum) level in the conduits 28, 30, 32, 36, 38, and 40 are all approximately equal, so long as the flow resistance of the flow director 16 is negligible. The pressure (vacuum) level applied to the surgical handpiece through the conduit 28, therefore, can be controlled by the variable flow resistor 20. The control circuit 24 subsequently acts upon the variable flow resistor 20 to maintain this pressure (vacuum), as sensed by the pressure (vacuum) sensor 18, at the level set by the signal carried at 50.
When the aspiration system 10 is operated in a pressure-controlled mode, the pump 12 must be operated at a relatively high flow rate which exceeds the maximum expected flow from the surgical site through the conduit 28. The aspiration system 10 is then able to operate, as described above, to maintain the pressure (vacuum) in conduit 28 at the level requested by the surgeon by means of the signal carried at 50.
When the system is operated in a flow-controlled mode, pump 12 must be operated at a flow rate equal to the flow rate through conduit 28, which is requested by the surgeon, plus any additional flow of gas through the conduit 32. In this regard, the variable flow resistor 20 is normally maintained at its maximum resistance (minimum flow). However, under most circumstances, some small flow of gas should be permitted, so that the flow director 16 remains open and the pressure (vacuum) sensor 18 remains in communication with the conduit 28. Further, the maximum resistance of the variable flow resistor 20 should be predetermined so that the rate of flow of gas through the conduit 32 may be calculated from the pressures at the conduits 42 (which must be known or assumed) and 40 (which is sensed by the pressure sensor 18). As described above, the flow rate so calculated must be added to the flow rate requested by the surgeon to determine the flow rate at which the pump 12 should be operated. If desired, a maximum vacuum limit may be set by means of the electrical signal as carried at 50. If the electrical signal as carried at 48 from the pressure (vacuum) sensor 18 exceeds this limit, the control circuit 24 will act upon the variable flow resistor 20 to reduce its resistance and increase the flow of gas through the variable flow resistor 20, such that the pressure (vacuum) is maintained at the established limit.
In the event that the flow rate through the conduit 28 temporarily exceeds the flow rate through the pump 12, as might occur with a failure of the pump 12, the flow director 16 acts to prevent the flow of aspirated liquid from the conduit 32 into the conduit 36. This is required to protect the pressure (vacuum) sensor 18 and the variable flow resistor 20 from contamination.
Upon completion of the surgical procedure, the conduits 28, 30, 32, and 34, and the collector 14, and the flow director 16 are disposed of, as they are not intended for re-use.
It is to be understood that the invention is not confined to the particular construction and arrangement of parts herein illustrated and described, but embraces such modified forms thereof as come within the scope of the following claims. | An aspiration system (10) having pressure-controlled and flow-controlled modes comprises connective plumbing (26), a collector (14), a pump (12), a variable flow resistor (20), a pressure sensor (18), and a control circuit (24). The connective plumbing (26) includes a conduit (28) which communicates with the surgical site from which fluid is to be aspirated and delivered to the collector (14). The pump (12) induces flow from the surgical site to the collector (14). The variable flow resistor (20) and the pressure sensor (18) are in fluid communication with the conduit (28) by the connective plumbing (26). In the pressure-controlled mode, the variable flow resistor (26) is adjusted to maintain a pre-selected pressure according to an output signal (50) from the pressure sensor (18). In the flow controlled mode, the pump (12) is adjusted to maintain a preselected flow according to a pressure differential in the connective plumbing across the variable flow resistor (20). The system (10 ) further includes a gas source (22) which is inputted into the variable flow resistor (20) to provide a known pressure against which the pressure in the remainder of the connective plumbing is compared to establish the pressure differential. The connective plumbing (26) further includes a flow director (16) permitting flow only in one direction to avoid contamination of certain portions of the connective plumbing (26). The contaminated portions of the connective plumbing (26) are discarded. | 0 |
BACKGROUND OF THE INVENTION
As will be recognized by those persons regularly involved in the operations that attend the joining and disjoining of towed vehicles from the associated towing vehicle, each operation (both the joining and the disjoining) is fraught with difficulties among which are alignment, both horizontal and lateral, of the hitch components of towed and towing vehicles.
Vehicle towing is commonly practiced by boating persons who move their craft on land using wheeled vehicles; farming persons who move implements, horse and cattle trailers; traveling motorists moving recreational vehicles, and often a second wheeled passenger vehicle.
Whatever is hitched to be towed is at some subsequent time required to be unhitched and, for example, in the case of a towed recreational vehicle (boat, travel trailer, horse and cattle van and the like), the unhitching will likely be required one or more times during a day.
Regular unhitching of the towed vehicles is a routinely required operation when the towing vehicle must perform duties in addition to that of towing.
Accordingly, the following sections will describe briefly some of the required operations that must be performed by a person hitching and unhitching a towed vehicle using the well-known conventional tongue-load, weight-transfer EAZ-LIFT-type hitch that is widely used for light- and medium-weight towed vehicles such as boat, recreational vehicle, animal and vehicle trailers.
Most travel trailer hitch assemblies are designed to distribute the tongue weight of the travel trailer to both the front and rear axles of the tow vehicle. This is accomplished by the use of two spring bars. One end of each bar is attached to the hitch and the other end is attached to the trailer chassis by means of a chain and tension device.
As tension is applied to the chain, some weight of the trailer is applied to the front axle of the tow vehicle. This also keeps the hitch ball tight in the ball socket.
Each time, when hitching or unhitching, it is necessary to install or remove the following hitch parts: the hitch, shank and ball (approximately 50 pounds); two spring bars with chains (approximately 14 pounds each); and two sway controls (approximately 8 pounds each).
The current method to hitch up the towed vehicle to the towing vehicle is to pick up the heavy hitch assembly (approximately 50 pounds) and push the shank of the assembly into the receiver of the tow vehicle, being careful not to get grease on your hands or clothing, making sure to align the holes in the receiver and the shank; install the pin through the hole in the receiver and shank. Next, back up the tow vehicle until the ball of the hitch is directly under the ball socket of the trailer; lower the trailer, using the trailer jack, until the ball enters the socket. Next, activate the latch, locking the ball in the socket. Jack up the trailer to the full height of the trailer jack and then attach the spring bars by lifting one end of each bar and pushing it up into the socket in the hitch assembly. Each bar (with chain) weighs approximately 14 pounds. Lift the chain (attached to the end of the bar) and attach the chain to the hook on the tension device. Using the hook-up handle, flip the handle over top center of the tension device, putting tension into the spring bars. Install sway controls bars (approximately 10 pounds each). Adjust the sway controls bars. Raise the jack and remove the jack stand. To unhitch, it will be necessary to reverse the hitching procedure.
SUMMARY OF THE INVENTION
The main purposes of this invention are: (1) to eliminate many of the operations that are now necessary in the hitching and unhitching of travel trailers and other types of trailers to and from the towing vehicle; (2) to save time and labor; (3) to prevent contamination of the greased parts by dust, sand, grass, moisture, etc.; and (4) to help prevent soiling of clothing while handling the hitch parts.
The Speedy Hitch Kit is comprised of several parts and can be attached to existing and future trailer hitching systems which couple a trailer to a towing vehicle, resulting in saving time, physical effort, storage space and providing a means for keeping the lubricated, movable parts of the whole hitching system clean.
When unhitching, the Speedy Hitch Kit saves time and physical effort by making it unnecessary to remove the following parts of the hitching system: two spring bars, two sway controls bars, and the heavy ball and hitch assembly; and because these parts were not removed, it will not be necessary to replace them when hitching. Presently, without the Speedy Hitch Kit, it is necessary to remove these parts in order to unhitch, and to replace them when hitching.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevation view of an unhitched travel trailer 10 and tow vehicle 22 with the Speedy Hitch Kit installed.
FIG. 2 is a plan view of an unhitched travel trailer 10 and two vehicle 22 with the Speedy Hitch Kit installed.
FIG. 3 is an elevation view of a hitched travel trailer 10 and tow vehicle 22 with the Speedy Hitch Kit installed.
FIG. 4 is a plan view of a hitched travel trailer 10 and tow vehicle 22 with the Speedy Hitch Kit installed.
FIG. 5 is an isometric drawing of the base-plate assembly.
FIG. 6 is an enlarged isometric drawing of the rotable wheel 26 and axle 43 (wheel axle unit) with attached lever 30, nuts 28, flat washers 29, and spring screws 25.
FIG. 7 is an isometric drawing of the adjustable shank attitude device 32 installed on the stationary vertical member of the tension device 34, in the relaxed position with no tension in the spring bar 36.
FIG. 8 is an isometric drawing of the adjustable shank attitude device 32 installed on the stationary vertical member of the tension device 34, in the lifted position with tension in the spring bar 36.
FIG. 9 is an isometric drawing of the adjustable shank attitude device 32.
FIG. 10 is an isometric drawing of the adjustable shank attitude device 32, installed on a segment of the tension device 34.
FIG. 11 is an isometric drawing showing the range of adjustments of the adjustable shank attitude device 32.
FIG. 12 is an isometric drawing of the adjustable shank sleeve 38 with attached leverage bar 46.
FIG. 13 is an isometric drawing of the trailer hitch 13 with the adjustable shank sleeve 38 with attached leverage bar 46 installed on the hitch shank 16. FIG. 13 also shows section marks A--A.
FIG. 14 is an isometric drawing of the trailer tongue with ball 12 and socket 11, and tow bar structure 40.
FIG. 15 is a section view "A--A" taken from FIG. 13, with spring bars 36 added, ready to be pushed up into the sockets 37 of the hitch 13.
FIG. 16 is an isometric drawing of the complete, uninstalled EAZ-LIFT-type hitch 13, the receiver 17, the sway control 45, the handle 44, the chain hook 48, and the support structure 47. All of the parts shown are standard EAZ-LIFT products.
FIG. 17 is a plan view showing the range of lateral swing in which the tow vehicle 22 can be hitched or unhitched to or from the trailer 10. The pivot point is where the ball 12 is in the socket 11.
FIG. 18 is an elevation view showing the tilting range that is possible in the vertical plane by use of the leverage bar 46.
DESCRIPTION OF THE INVENTION
To properly describe this invention, it must be noted that the Speedy Hitch Kit is made up of the following:
FIG. 5, the base plate assembly;
FIG. 12, the adjustable shank sleeve with attached leverage bar;
FIG. 9, a pair of adjustable shank attitude device.
The above invention will be installed as follows:
1. The trailer 10 will be parked with wheels chocked.
2. The base-plate assembly FIG. 5 will rest on the ground under the trailer jack, with the tongue weight of the trailer bearing down on the base-plate assembly FIG. 5.
3. The adjustable shank sleeve with attached leverage bar
FIG. 12 will be attached to the shank of the hitch as shown in FIG. 13.
4. One of the adjustable shank attitude devices 32 will be installed on each tension device 34 as shown in FIG. 7. A tension device 34 is located on each side of the trailer frame 14 as shown in FIG. 4. FIG. 11 shows the range of adjustment of the adjustable shank attitude devices 32, to raise or lower the spring bars 36 when they are in the resting position as shown in FIGS. 1 and 7. The adjustable shank attitude devices 32 made of a section of rigid material, will be held in place by means of the set screws 33. See FIG. 9. When the adjustable shank attitude devices 32 are adjusted properly, the shank 16 of the trailer hitch 13 will extend outward from the trailer 10 in the correct attitude for alignment with the receiver of the tow vehicle 22 as shown in FIG. 1. FIG. 7 shows the movable part of the tension device 34 resting on the adjustable shank attitude device 32.
5. One end of each spring bar 36 will be pushed up into the sockets 37 of the hitch 13. See FIGS. 15 and 16.
6. The chains 35 will be attached to the hooks 48 of the tension devices 34. See FIG. 8.
7. The ball 12 of the hitch 13 will be installed and locked in the socket 11 of the tow bar structure 40. See FIGS. 13 and 14.
With all of the above installed and adjusted properly, the shank 16 of the hitch 13 will extend forward at an angle approximately parallel to the ground and pointing in the direction of the tow vehicle 22. See FIG. 1.
The trailer 10 is equipped with a tow-bar structure 40 attached to the frame 14, projecting in a forward direction and having a socket 11 designed to accommodate a hitch ball 12 which is attached to the standard trailer hitch 13. The trailer 10 is also equipped with a manual or power jack 15 which is used to raise or lower the front end of the trailer 10 for leveling. This same jack 15, when used with the various parts of this invention installed, will be used to raise or lower the hitch shank 16 in order to horizontally align the shank 16 of the hitch 13 with the receiver 17 of the tow vehicle 22. The jack post 18 of trailer jack 15 rests on the inner ring 19 of the elongated member 20 of the base-plate assembly FIG. 5.
The base-plate assembly FIGS. 5 and 6 consists of the following parts:
1. The base plate 21
2. Slotted vertical walls 31
3. Springs 23
4. Lever 30
5. Screws 25
6. Wheel 26
7. Elongated member 20
8. Set screw 27
9. Nuts 28
10. Washers 29
11. Guide 24
12. Axle 43
13. Inner ring 19
The function of the guide 24 is fit into the groove in the jack post 18, thereby orienting the base-plate assembly FIG. 5 in the correct direction.
The function of the four springs 23 is to automatically return the wheel 26 to the center of the base-plate assembly FIG. 5 when the elongated member 20 and the lever 30 are held in an upright position while placing the base-plate assembly FIG. 5 under the jack post 18 during hitching.
When the tongue weight of the trailer 10 bears down on the base-plate assembly FIG. 5, it is possible with the use of the lever 30, which turns the wheel 26, to move the trailer in a lateral direction, either right or left, making it possible to line up the shank 16 of the hitch 13 with the receiver 17 of the tow vehicle 22 in a lateral way. This travel is limited by the length of the slots 42 in the vertical walls 31 of the base-plate assembly as shown in FIG. 5 each slot 42 supports one of two ends of the axle 43 of the wheel-axle unit.
By using the jack 15, the trailer 10 can be raised or lowered to line up the shank 16 with the receiver 17 of the tow vehicle 22 in a horizontal way.
By using the lever 30 of the base-plate assembly FIG. 5, the trailer 10 can be moved in a lateral way, causing the shank 16 to line up with the receiver 17 of the tow vehicle 22.
In no way will any part of the Speedy Hitch Kit be used during travel.
One feature of this invention is to make it possible to hitch or unhitch without removing the hitch 13, two spring bars 36, and the sway bars 45 (when sway controls 45 are used). It will not be necessary to install any hitch parts before hitching, because they were not removed when the unhitching was done.
Hitching Instructions:
1. Check to be sure the trailer wheel chock is in place.
2. Back up the tow vehicle 22 in the direction of the trailer 10, aligning the hitch shank 16 and the tow vehicle receiver 17 as closely as possible.
3. Using the trailer jack 15, raise or lower the shank 16 until the shank 16 and the receiver 17 are aligned.
4. Using the adjustable shank sleeve 38 with leverage bar 46 attached, adjust the angle of the shank 16 to meet the receiver 17.
5. Back up the tow vehicle 22 until the shank 16 barely enters the receiver 17. At this point, check to see whether the shank 16 is properly aligned for further entry. Lateral adjustment can be made by use of the lever 30 of the base-plate assembly.
6. Rock the leverage bar 46 to detect whether the shank 16 is loose in the receiver 17. When the shank 16 is loose, proceed to back the tow vehicle 22 until the receiver 17 touches the sleeve 38 on the shank 16. If binding occurs, readjust alignment using the jack 15 and the lever 30.
7. Install the pin 41 through the holes in the receiver 17 and the shank 16.
8. Using the jack 15, raise the trailer 10 to a high position.
9. Using the hook-up handle 44 (furnished with the EAZ-LIFT hitch), flip the handle 44 up and over top center of the tension device 34 on both sides of the trailer. See FIG. 8.
10. Adjust the sway controls bars 45.
11. Lower the trailer 10 and remove the base-plate assembly.
12. Store the base-plate assembly in the tow vehicle 22. The hitching is now complete.
Unhitching Instructions:
1. Be sure the trailer wheel chock is in place.
2. Loosen the adjustment on the sway controls bars 45.
3. Place the base-plate assembly FIG. 5 under the jack post 18, aligning the guide 24 of the base-plate assembly FIG. 5 with the groove in the jack post 18.
4. Lower the jack post into the elongated member 20 of the base-plate assembly FIG. 5.
5. Raise the trailer to a high position by use of the trailer jack 15.
6. Lower the two spring bars 36 until the tension devices 34 rest on the adjustable shank attitude devices 32. See FIG. 7.
7. Lower the trailer by using the jack 15 until the ball 12 becomes loose in the socket 11, and stop lowering it before the weight of the trailer bears down on the ball 12 of the trailer hitch 13. This looseness can be detected by rocking the leverage bar 46. See FIG. 12.
8. Remove the pin 41 from the receiver 17.
9. Drive the tow vehicle 22 forward until the shank 16 of the trailer hitch 13 pulls out of the receiver 17. The trailer 10 is now unhitched from the tow vehicle 22. | An integrated group of mechanical aids and a method related to the coupling and the uncoupling of a towed vehicle of the well-known tongue-loaded, weight-transfer type, which aids and method permit the uncoupling of the towed vehicle from a prime mover while allowing all components of the coupling assembly to remain in place and attached to the towed vehicle all positioned for subsequent recoupling. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to provisional U.S. Application No. 61/000,014, filed Oct. 23, 2007, and the priority of provisional U.S. Application No. 61/125,974, filed Apr. 30, 2008, the entire contents of which are incorporated by reference herein in their entireties.
STATEMENT REGARDING FEDERALLY FUNDED PROJECT
[0002] The United States Government owns rights in the present invention pursuant to Grant No. R01 GM065980 awarded by the National Institutes of Health.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The present invention relates to stabilized silica colloidal crystals. In particular, the present invention relates to silica colloidal crystals having improved mechanical strength and durability. The present invention also relates to methods of making stabilized silica colloidal crystals by direct bonding between nanoparticles or between a polymer and nanoparticles through a siloxane bond.
[0005] 2. Discussion of the Background
[0006] Silica colloids naturally deposit in a highly ordered way, and the resulting materials promise to have many uses in biological analysis. These include substrates for microarrays, including oligonucleotides (e.g., DNA, RNA, etc.) proteins and cells, substrates for immunoassays, coatings for microscope slides to probe biological cells, media for capture and preconcentration of proteins and oligonucleotides, and media for chemical separations, such as media for gel electrophoresis, microchip or capillary electrochomatography, and ultraperformance chromatography. However the materials are far too fragile for any practical use as deposited.
[0007] The present inventors previously described a method to stabilize silica colloid crystals by sintering with high temperature (WO 07/127,921 and US 2007/0254161). In sintering, the temperature is high enough to melt just the surface of silica, and the flow of silica binds the adjacent particles after the temperature is lowered. However, there remains a need for a method of producing stabilized silica colloidal crystals, as well as the resultant stabilized silica colloidal crystals, at moderate temperatures where chemical bonds among reagent groups bind the silica surface to adjacent particles without destroying fragile substrates, such as glass or polymers, and without destroying the colloidal crystal by restricting excessive thermal expansion in confined spaces, such as the insides of capillaries.
SUMMARY OF THE INVENTION
[0008] To address the foregoing need, the present inventors have developed a method to process silica colloid materials or silica nanosphere materials chemically at moderate temperatures. Chemical bonds are formed between the particles comprising the crystal to hold it together more stably. By the same technology, the crystal can also be made to adhere to its support.
[0009] The advantage of forming chemical bonds, as in the present invention, instead of sintering the material is that the latter can be performed at lower temperature. This capability is especially enabling for use of silica colloidal crystals in capillaries.
[0010] It is an object of the present invention to provide:
[0011] [1] A method of producing a stabilized silica colloidal crystal comprising cross-linking nanoparticles with a silane reactive group on the surface thereof by reacting said nanoparticles with a silane selected from the group consisting of a di-functional silane and a tri-functional silane.
[0012] [2] The method of [1], wherein said silane is a di-functional silane having the formula RR′SiX 2 , wherein X is independently selected from the group consisting of Cl, methoxy and ethoxy, and R and R′ are independently selected from the group consisting of an alkyl group, a methacrylate, a vinyl groups, cyano, glycidoxy, an amino group, and an aldehyde group.
[0013] [3] The method of [1], wherein said silane is a tri-functional silane having the formula RSiX 3 , wherein X is independently selected from the group consisting of Cl, methoxy and ethoxy, and R is selected from the group consisting of an alkyl group, a methacrylate, a vinyl groups, cyano, glycidoxy, an amino group, and an aldehyde group.
[0014] [4] The method of [1], wherein said stabilized silica colloidal crystal is simultaneously stabilized while bonding to a substrate, such as a glass or silica slide or the interior of a silica capillary. In a preferred embodiment, the substrate is composed of silica, glass, polydimethylsiloxane, or other material bearing silanol groups.
[0015] [5] The method of [4], wherein the substrate is bonded to the colloids through the R groups.
[0016] [6] A stabilized silica colloidal crystal prepared by the process of [1].
[0017] [7] A coated substrate, wherein said substrate is coated with a stabilized silica colloidal crystal of [6].
[0018] [8] The coated substrate of [7], wherein said coated substrate is a substrate for a protein, carbohydrate, oligonucleotide or cell microarray.
[0019] [9] The substrate of [7], wherein said substrate is a substrate making up the bottom surface of a multiwell plate.
[0020] [10] A method of separating materials in a composition comprising packing a cylindrical column with the stabilized colloidal crystal of [1] or a substrate that has been coated with the stabilized colloidal crystal, passing a composition containing a mixture of chemical species through the column, and recovering the fractions obtained thereby for further processing and/or analysis.
[0021] [11] A method of producing a stabilized silica colloidal crystal comprising cross-linking nanoparticles with a silane bearing a reactive group for the initiation of polymerization to cross-link said nanoparticles.
[0022] [12] The method of [11], wherein said silane is a mono-functional silane having the formula R(R′) 2 SiX, wherein X is selected from the group consisting of hydrogen, Cl, methoxy and ethoxy, or any other silanol reactive group, R is a atom-transfer radical polymerization initiator, an acrylate, or a styrene, and R′ is independently selected from the group consisting of an alkyl group, a methacrylate, a vinyl groups, cyano, glycidoxy, an amino group, and an aldehyde group.
[0023] [13] The method of [11], wherein said silane is a di-functional silane having the formula RR′SiX 2 , wherein X is independently selected from the group consisting of hydrogen, Cl, methoxy and ethoxy, or any other silanol reactive group, R is a atom-transfer radical polymerization initiator, an acrylate, or a styrene, and R′ is selected from the group consisting of an alkyl group, a methacrylate, a vinyl groups, cyano, glycidoxy, an amino group, and an aldehyde group.
[0024] [14] The method of [11], wherein said silane is a tri-functional silane having the formula RSiX 3 , wherein X is independently selected from the group consisting of hydrogen, Cl, methoxy and ethoxy, or any other silanol reactive group, and R is a atom-transfer radical polymerization initiator, an acrylate, or a styrene.
[0025] [15] The method of [1]), wherein said stabilized silica colloidal crystal is further bonded to a coverplate selected from the group consisting of a polydimethylsiloxane or an elastomer.
[0026] [16] The method of [15], wherein the coverplate is bonded to the colloids through the R groups.
[0027] [17] The method of [11], where the polymer is patterned with holes for access to the colloidal crystal.
[0028] [18] The method of [11], wherein two or more different types of R groups are used to connect adjacent nanoparticles.
[0029] [19] The method of [11], wherein bis-vinyl groups are added to enhance cross-linking to connect adjacent nanoparticles.
[0030] [20] A stabilized silica colloidal crystal prepared by the process of [11].
[0031] [21] A substrate coated with a stabilized silica colloidal crystal of [20].
[0032] [22] The substrate of [21], wherein said substrate is a substrate for a protein, carbohydrate, oligonucleotide or cell microarray.
[0033] [23] The substrate of [21], wherein said substrate is a substrate making up the bottom surface of a multiwell plate.
[0034] [24] A method of separating materials in a composition comprising packing a cylindrical column with the stabilized colloidal crystal of [11] or a substrate that has been coated with the stabilized colloidal crystal, passing a composition containing a mixture of chemical species through the column, and recovering the fractions obtained thereby for further processing and/or analysis.
[0035] [25] A method of capturing materials in a composition comprising packing a cylindrical column with the stabilized colloidal crystal of [11] or a substrate that has been coated with the stabilized colloidal crystal, passing a composition containing a mixture of chemical species through the column, and recovering the captured fraction obtained thereby for further processing and/or analysis.
[0036] The above objects highlight certain aspects of the invention. Additional objects, aspects and embodiments of the invention are found in the following detailed description of the invention.
BRIEF DESCRIPTION OF THE FIGURES
[0037] A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following Figures in conjunction with the detailed description below.
[0038] FIG. 1A depicts nanoparticles connected by forming siloxane (Si—O—Si) bonds between reagent groups on adjacent nanoparticles.
[0039] FIG. 1B depicts nanoparticles are connected by reaction between functional-groups, R and R on two different nanoparticles. R and R need not be the same group.
[0040] FIG. 2A depicts the nanoparticles bonded to a substrate through siloxane bonds.
[0041] FIG. 2B depicts the nanoparticles bonded to a substrate through organic polymer chains made by surface-initiated atom radical polymerization.
[0042] FIG. 3 shows a photograph of a microtiter plate with a successful deposition of high quality colloidal crystalline layers into the wells of a 96-well plate. The angular-dependent diffraction and the six-fold symmetry of the crystal are clearly visible. This approach of depositing a colloidal crystal into the wells imparts more than a 100× higher surface area to increase the sensitivity of ELISA and microarrays analyses (see Example 1).
[0043] FIG. 4 a shows a photograph of typical silica colloidal crystal packed into a silica capillary. The blue color indicates excellent crystalline packing. Upon stabilization, this capillary holds up to at least 13,000 psi for hours, which is higher than the pressure achievable by most commercial ultrahigh pressure chromatographs. This stabilization allows capillaries to be widely used for ultraperformance liquid chromatography without the use of a frit. The length of the packing we use is typically 2.0 cm. (see Example 2)
DETAILED DESCRIPTION OF THE INVENTION
[0044] Unless specifically defined, all technical and scientific terms used herein have the same meaning as commonly understood by a skilled artisan in chemistry and materials sciences.
[0045] All methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, with suitable methods and materials being described herein. All publications, patent applications, patents, and other references mentioned herein are incorporated by reference in their entirety. In case of conflict, the present specification, including definitions, will control. Further, the materials, methods, and examples are illustrative only and are not intended to be limiting, unless otherwise specified.
[0046] Within the context of the present invention, there are two ways to form covalent bonds across nanoparticles: 1) form siloxane (Si—O) bonds between reagents that are attached to two different particles, and 2) form covalent bonds between functional groups on silanes that are covalently attached to different nanoparticles. These different ways to form covalent bonds are illustrated in FIGS. 1 and 2 .
[0047] In FIG. 1A , nanoparticles are connected by forming siloxane (Si—O—Si) bonds between reagent groups on adjacent nanoparticles. While in FIG. 1B , nanoparticles are connected by reaction between functional groups, R and R on two different nanoparticles. R and R need not be the same group.
[0048] In FIG. 2A , the nanoparticles are bonded to a substrate through siloxane bonds. And, in FIG. 2B , the nanoparticles are bonded to a substrate through organic groups joined by termination of atom-transfer radical polymerization.
[0049] For siloxane bond formation of FIG. 1A and FIG. 2 a , we take advantage of the fact that di- or trifunctional silanes polymerize in the plane of the surface (U.S. Pat. Nos. 5,716,705, 5,599,625 and Wirth, M J; Fairbank, R W P; Fatunmbi, H O, “Mixed self-assembled monolayers in chemical separations” SCIENCE, 275 (5296): 44-47 (1997), and Fatunmbi, H O; Bruch, M D; Wirth, M J, “Si-29 and C-13 NMR characterization of mixed horizontally polymerized monolayers on silica-gel” ANALYTICAL CHEMISTRY, 65 (15): 2048-2054 (1993)), which we use herein to form bridges across particles. For this, we have demonstrated stabilization of the nanoparticles inside a silica capillary using any of a variety of silanes, all of which work well: 3-glycidoxypropyltrimethoxysilane, 3-aminopropyltrimethoxysilane, (chloromethyl)phenylethyltrichlorosilane, n-octadecyltriclilorosilatie, n-butyltrichlorosilane and methyltriclilorosilane. We have also demonstrated successful stabilization using binary mixtures of silanes, including methyltrichlorosilane with n-octadecyltrichlorosilane, methyltrichlorosilane with n-butyltrichlorosi lane, and methyltrichlorosilane with (chloromethyl)phenyl ethyl trichlorosilane. Stabilization was tested by applying at least 1000 psi of pressurized flow through the packed capillary using a syringe pump and determining whether the particles remained intact.
[0050] Another method of making chemical bonds between nanoparticles is to mix nanoparticles bearing one type of functional group with nanoparticles bearing a different type of functional group, choosing the two types to react with one another to form a covalent bond. After the film is deposited, these surface groups will react to form covalent bonds. Examples that are well known in the art are groups that would react with and bond to amino groups, including epoxide, aldehyde, cyanato, isothiocyanate, and succinimidyl ester groups. Other well known examples are groups that react with thiols, including maleimide, alkyl chloride or haloacetimide. The colloidal crystal can be made to adhere to its support, such as glass or fused silica, which can be a slide or a capillary, by treating the surface of the support with either type of functional group
[0051] For bonding through atom-transfer radical polymerization, as depicted in FIGS. 1B and 2B , we use the method of surface-initiated atom-transfer radical polymerization, where a silane covalently bonded to the silica surface bears an initiator for polymerization. This method was developed in our research group (Huang, X Y, Wirth, M J, “Surface-initiated radical polymerization on porous silica”, ANALYTICAL CHEMISTRY, 69 (22): 4577-4580 (1997), and Huang, X Y; Doneski, L J; Wirth, M J “Surface-confined living radical polymerization for coatings in capillary electrophoresis” ANALYTICAL CHEMISTRY, 70 (19): 40234029 (1998)) We have previously showed that the polymerization proceeds with significant termination (Huang, X; Wirth, M J, “Surface initiation of living radical polymerization for growth of tethered chains of low polydispersity” MACROMOLECULES, 32 (5): 1694-1696 (1999)), and the gradual disappearance of the chloro group indicates that many of these termination events are caused by living ends of chains binding together. When this termination of chain ends occurs on polymer chains bound to adjacent nanoparticles, it binds the particles together. We have demonstrated that atom-transfer radical polymerization indeed stabilizes the silica colloidal crystal. For this demonstration, we used a monochlorosilane bearing a benzyl chloride group as the initiator and acrylamide as the monomer, and we found that the resulting material remained stably inside of the capillary.
[0052] Accordingly, in an embodiment of the present invention is provided a reaction of silica colloidal crystal with di- or trifunctional silane to cross-link the silica colloidal crystal particles by forming siloxane bonds to connect adjacent nanoparticles. The silane used in the present invention forms bonds between the silicon atoms of the reagent silicon atoms as they are covalently attached to the surface. The silane suitable for use in the present invention may have the formulae: RR′SiX 2 or RSiX 3 . In the silane of the present invention, X is hydrogen, a halogen, preferably Cl, or a lower alkoxy, preferably methoxy or ethoxy, or any other silanol reactive group. R and R′ in the silane of the present invention can be any desired functional group. Preferred examples include alkyl groups, preferably a C 1 to C 6 -alkyl, for example methyl, methacrylate or other vinyl groups, cyano, glycidoxy, amino or aldehyde groups.
[0053] The conditions (e.g., temperature, concentrations, etc.) would be appreciated by those practiced in the art. The preferred method of the present invention is to use any of the silanes because these silanes accomplish bonding in just one step. There is no preference among the silanes as the silane selected would depend on the desire of the customer.
[0054] In the context of the present invention, the silica colloidal crystals may be reacted with a mono-, di- or trifunctional silane.
[0055] In this embodiment, the silane is represented by the formulae: R(R′) 2 SiX, R(R′)SiX 2 , or RSiX 3 . In these silanes, X is a hydrogen halogen, preferably Cl, or a lower alkoxy, preferably methoxy or ethoxy, or any other silanol reactive group. R′ in this silane can be any desired functional group. Preferred examples include alkyl groups, preferably a C 1 to C 6 -alkyl, for example methyl, methacrylate or other vinyl or allyl groups, cyano, glycidoxy, amino or aldehyde groups. R in the silane of this embodiment a reactive group from which a polymer can grow. Examples of the R group include atom-transfer radical polymerization initiators and vinyl groups, such as the acrylate family or the styrenes, which form covalent bonds between R groups to connect adjacent nanoparticles.
[0056] In the present invention, where there are two or more R, R′, or X groups, the R, R′, and X need not be the same. In other words, each R, R′, and X is independently selected from each other.
[0057] In another embodiment of the present invention, a bis-vinyl group, such as bisacrylamide, may be added to enhance cross-linking to connect adjacent nanoparticles.
[0058] In still another embodiment of the present invention, covalent bonds may be formed in the absence of polymerizable groups. Examples including mixtures of amino and glycidoxy groups, or mixtures of isocyanto and glycidoxy groups, to connect adjacent nanoparticles.
[0059] It is also embraced by the present invention that the aforementioned reactions and the products obtained thereby can be further used for bonding a substrate, including a slide or the walls comprising the interior of a capillary, to the nanoparticles, or the material can be sandwiched between two substrates. The substrate within the context of the present invention can be glass, silica, or polydimethylsiloxane, since each of these bears a silanols group that would react with the silane to form siloxane bonds, as depicted in FIG. 2A , or the material can be any substrate made to bear an initiator to atom-transfer radical polymerization, which includes polymers, metals, and oxides, to form covalent bonds as depicted in FIG. 2B . Thus, any substrate bearing a silanol group (—SiOH), a —SiX group (where X is a hydrogen, Cl, methyoxy, or ethoxy), a vinyl group, or an initiator to atom-transfer radical polymerization may be used in the present invention. For example, the substrate may be a polymer sheet or polymer tube bearing any one of these silane reactive groups. In another embodiment of the present invention is a stabilized colloidal crystal prepared by the aforementioned reactions.
[0060] The substrate upon which the stabilized colloidal crystal of the present invention can be coated can be electrically conductive, e.g., a metal or a semiconductor, or can be electrically insulating, e.g., an insulator, over at least a portion of the substrate. In embodiments, the substrate can be a glass, fused silica, crystallized silica (quartz), sapphire, silicon, indium tin oxide or platinum. The substrate can have a flat, curved, irregular, or patterned surface, on which the stabilized colloidal crystal is deposited. The surface on which the stabilized colloidal crystal is deposited can be an outer surface of the substrate. The surface on which the stabilized colloidal crystal is deposited can also be an inner surface of a substrate, for example the inner surface of a capillary tube or the inner surface of a hole. The cross-section of the inner surface can be circular, oval, elliptical or polygonal (e.g., triangular or square). The surface of the substrate can include regions having different compositions. The substrate serves as a mold for the stabilized colloidal crystal. For example, a flat substrate can produce a colloidal crystal shaped as a flat film, and a capillary tube can produce a colloidal crystal shaped as a cylinder. For capillaries, we have used inner diameters ranging from 20 μm to 4 mm, and silica particle sizes ranging from 200 nm to 1.5 μm, and we encountered no problems, indicating that these extremes are not the limits. For slides, one would reasonably expect that the same thickness ranges and particle sizes to apply, and the chemistry is not subject to particle size or thickness limitations. We have demonstrated stability for colloidal crystal s on slides using colloidal crystals of 10 μm in thickness. The stabilized colloidal crystals on slides can be touched with a latex-gloved hand without damage, in contrast to untreated colloidal crystals on slides. The stabilized colloidal crystals on slides also withstand routine steps used for chemical modification, including boiling in water or other solvents, in contrast to untreated colloidal crystals on slides.
[0061] Identification of unknown chemical species relies upon methods of separation to isolate material to be identified. Separation media have been indispensable in molecular biology for separation biological macromolecules such as proteins and nucleic acids, as well as for determining sequences of polypeptides and nucleic acids. The stabilized colloidal crystal of the present invention can be used as a separation media.
[0062] For example, the stabilized colloidal crystal of the present invention can be used as a separation media in processes which include passing a fluid (liquid or gas) through the sintered silica crystal. Such processes include chromatography processes, for example High Performance Liquid Chromatography (HPLC) and Thin Layer Chromatography (TLC).
[0063] The stabilized colloidal crystal of the present invention can also be used in processes which include passing a fluid through the stabilized colloidal crystal of die present invention and applying an electric potential across the stabilized colloidal crystal of the present invention. Such processes include separation processes such as electrophoresis, electrophoretic sieving, isoelectric focusing and electrochromatography. Such processes are applicable to any charged chemical species, e.g., peptides, proteins, oligonucleotides such as RNA, DNA, and, pharmaceuticals and ionic species that are environmentally important. The electric potential can be applied via electrodes arranged on opposite ends of the stabilized colloidal crystal of the present invention.
[0064] The stabilized colloidal crystal of the present invention can be used to provide increased surface area for reactions or capture (particularly in microarrays for proteomics or genomics). In other words, the stabilized colloidal crystal of the present invention can be used in processes in which a first chemical species is bound to the colloidal silica particles, a fluid passing through the stabilized colloidal crystal of the present invention contains a second chemical species, and the second species is captured on the first chemical species. For example, oligonucleotides can be used to capture other oligonucleotides, antibodies can be used to capture antigens or vice versa, lectins can be used to capture glycoproteins or vice versa, and antibodies can be used to capture various chemical species and vice versa. The stabilized colloidal crystal of the present invention can be used as a substrate for microarrays that use chemically bound capture proteins to capture, e.g., antigens. The stabilized colloidal crystal of the present invention can be functionalized with other chemical species, such as silylating agents, polyacrylamide, other polymers, DNA, antibodies, and proteins.
[0065] Thus, the stabilized colloidal crystal of the present invention are used in printed DNA microarrays, printed protein microarrays, or printed carbohydrate microarrays.
[0066] The stabilized colloidal crystal of the present invention can be used in processes in which living cells are grown on the stabilized colloidal crystal of the present invention. The porosity of the stabilized colloidal crystal of the present invention allows chemical species, such as water, nutrients and drugs, to reach the cell surfaces. The stabilized colloidal crystal of the present invention can also be used in processes in which a lipid bilayer or cell membrane is attached to the stabilized colloidal crystal of the present invention.
[0067] The stabilized colloidal crystal of the present invention can also be used as microporous coatings on microscope slides and coverslips. Cells grown on such microporous coatings can be interrogated by microscopic techniques, such as Total Internal Reflection Fluorescence Microscopy (TIRFM), in which light is passed through the stabilized colloidal crystal of the present invention.
[0068] The stabilized colloidal crystal of the present invention can be used in processes in which an organic material is introduced into the stabilized colloidal crystal of the present invention and the organic material is then vaporized and ionized. Such processes include Matrix-assisted laser desorption/ionization (MALDI) mass spectrometry.
[0069] The stabilized colloidal crystal of the present invention can be used to coat and/or deposit on glass, plastic or polymer bottoms of multiwell plates, such as microwell or microtiter plates, or to fill tubes or capillaries.
[0070] The present invention provides a method for separation of materials by packing a cylindrical column with the stabilized colloidal crystal of the present invention or a substrate that has been coated with the stabilized-colloidal crystal of the present invention, then passing a composition containing a mixture of chemical species through the column, and recovering the fractions obtained thereby for further processing and/or analysis. In this method, the cylindrical column may be used in chromatography, solid phase extraction, or electrophoresis.
[0071] The capillaries or tubes packed with stabilized silica colloidal crystals also have use for capturing and pre-concentrating analytes, such as proteins, oligonucleotides, and carbohydrates. By suitable choice of an R group as in FIGS. 1A and 1B , a protein or an oligonucleotide can be captured, in an analogous manner to the capture process used for a microarray. We have demonstrated that, choosing R of FIG. 1 to be an epoxide group, that an antibody (anti-bovine serum albumin) is covalently bound to the silica colloidal crystals, and further, that this antibody captures bovine serum albumin that is labeled with a fluorophor (Alexa Fluor 647). The capillary becomes fluorescent when the fluorescein-labeled bovine serum albumin is introduced. We used electrophoretic migration of the bovine serum albumin to introduce it into the capillary.
[0072] The method is applicable to any antibody and any protein, provided that the pores of the silica colloidal crystal are sufficiently large. This typically would require the nanoparticles to be at least 200 nm in diameter. It is also advantageous to collect messenger RNA to increase the sample concentration prior to analyses that use gene expression microarrays, or to increase sample concentration of other oligonucleotides. such as RNAi, or genes or gene fragments. This would be achieved by having a suitable complementary R-group of FIG. 1 on the silica surface, such as poly-A for messenger RNA, or a complementary sequence for RNAi, or a primer for binding a DNA oligonucleotide. The colloidal crystal can also be useful in pre-concentrating glycoproteins by choosing a suitable lectin as the R group of FIG. 1 .
[0073] We previously demonstrated that live cells adhere to and can be grown on silica colloidal crystals (Velarde, T R C; Wirth, M J “Silica colloidal crystals as porous substrates for total internal reflection fluorescence microscopy of live cells” APPLIED SPECTROSCOPY, 62 (6): 611-616 (2008)). We disclose herein that a colloidal crystal stabilized by the methods depicted in FIG. 1 can therefore be useful for cell microarrays in place of the gelatins that are used today (Sturzl, M; Konrad, A; Sander, G; Wies, E; Neipel, F; Naschberger, E; Reipschlager, S; Gonin-Laurent, N; Horch, R E; Kneser, U; Hohenberger, W; Erfle, H; Thurau, M. High throughput screening of gene functions in mammalian cells using reversely transfected cell arrays: Review and protocol. COMBINATORIAL CHEMISTRY & HIGH THROUGHPUT SCREENING 11 (2): 159-172. (2008). For this application, the R group of FIG. 1 would be chosen to weakly bind the species to be introduced locally into the cells.
[0074] Thus, the stabilized silica colloid crystals of the present invention are useful in 1) oligonucleotides (such as DNA or RNA), protein, lectin, carbohydrate, peptide, aptamer, tissue, antibody or any other microarray or multiwell plate assays, 2) substrates for immunoassays, 3) electrophoresis media for proteomics or genomics, 4) high performance or ultra-performance liquid chromatography or molecular sieving, 5) material for capture and preconcentration of proteins or oligonucleotides, and 6) substrate for cell growth and cell microarrays.
[0075] The above written description of the invention provides a manner and process of making and using it such that any person skilled in this art is enabled to make and use the same, this enablement being provided in particular for the subject matter of the appended claims, which make up a part of the original description.
[0076] As used herein, the phrases “selected from the group consisting of,” “chosen from,” and the like include mixtures of the specified materials.
[0077] Where a numerical limit or range is stated herein, the endpoints are included. Also, all values and subranges within a numerical limit or range are specifically included as if explicitly written out.
[0078] The above description is presented to enable a person skilled in the art to make and use the invention, and is provided in the context of a particular application and its requirements. Various modifications to the preferred embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments and applications without departing from the spirit and scope of the invention. Thus, this invention is not intended to be limited to the embodiments shown, but is to be accorded the widest scope consistent with the principles and features disclosed herein.
[0079] Having generally described this invention, a further understanding can be obtained by reference to certain specific examples, which are provided herein for purposes of illustration only, and are not intended to be limiting unless otherwise specified.
EXAMPLES
Example 1
[0080] The example in FIG. 3 was made by depositing, into almost every well, 60 μL of a slurry of 300-nm diameter silica nanoparticles, which were made by the method of Stober (Stober, W; Fink, A; Bohn, E, “Controlled Growth of Monodisperse Silica Spheres in Micron Size Range” JOURNAL OF COLLOID AND INTERFACE SCIENCE, 26 (1); 62-69, 1968). The nanoparticles had a concentration of 5 mg/mL in water, and allowed to evaporate in an incubator at 40° C. To stabilize the colloidal crystal, a 5% solution of 3-aminopropyltrimethoxysilane in ethanol was pipetted into the wells, a lid was placed over the microplate, and the reaction was allowed to proceed at 40° C. for three hours, after which the wells were rinsed with ethanol.
Example 2
[0081] A 10-cm capillary was immersed into a slurry of 30% by weight of 300-nm silica nanoparticles in water. The nanoparticles were made in the same Stober method as in Example 1. The vessel was put into a sonicator (VWR 75HT) to keep the particles dispersed. Once capillary forces have brought the slurry up into the entire length of the capillary, the capillary is removed from the slurry. The capillary was taken out of the slurry, and the excess water inside the capillary was removed by overnight at room temperature in a humidity chamber at 50% relative humidity. The loss of water shrunk the crystal to a 2 cm length and formed a high quality colloidal crystal, as evidenced by the blue color, which results from Bragg diffraction. Capillary forces were then used to draw in a solution of 5% n-butyltrichlorosilane in toluene into the colloidal crystal in the capillary, and the reaction was allowed to proceed for 3 hours. The capillary was then rinsed by drawing in dry toluene by capillary forces to remove excess reagent, then heated at 120° C. for two hours to form the siloxane bonds.
[0082] Numerous modifications and variations on the present invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the accompanying claims, the invention may be practiced otherwise than as specifically described herein. | The present invention relates to stabilized silica colloidal crystals. In particular, the present invention relates to silica colloidal crystals having improved mechanical strength and durability. The present invention also relates to methods of making stabilized silica colloidal crystals by direct bonding between nanoparticles or between a polymer and nanoparticles through a siloxane bond. | 1 |
TECHNICAL FIELD
[0001] This description relates generally to installing drivers on computer systems and more specifically to replacing generic drivers with enhanced drivers.
BACKGROUND
[0002] Device drivers can have a large impact on the performance or capabilities of certain devices on a computer. Some device drivers support a “least common denominator” set of features for a broad class of devices. For example, a display driver may support only certain low-resolution modes based on an industry-standard specification such as VGA. MICROSOFT WINDOWS, for example, includes several such drivers, often called “generic drivers.” When a new device is installed, the operating system (OS) will automatically install a generic driver if it is compatible with the device and no better driver is available. For devices that support additional features above and beyond those supported by the generic driver, the generic driver may not provide a satisfactory user experience. There are often manufacturer-provided drivers are available on the web which will take advantage of features supported by a device, but the OS may not notify the user that such drivers are available.
SUMMARY
[0003] The following presents a simplified summary of the disclosure in order to provide a basic understanding to the reader. This summary is not an extensive overview of the disclosure and it does not identify key/critical elements of the subject matter or delineate the scope of the claimed subject matter. Its sole purpose is to present some concepts disclosed herein in a simplified form as a prelude to the more detailed description that is presented later.
[0004] The present example provides a way for notifying a user that a solution, like an enhanced driver with better support for the user's device, is available. This solution may be available over the Internet, an intranet, or over a local area network, for example. When a device is installed and a generic driver is all that known about for the system, the OS may contact a server to check for availability of an enhanced driver. If there is an enhanced driver available, the user may be notified. Such an enhanced driver may be stored on a server on a local area network, on a server available via the Internet, on the target computer, or on a peer of the target computer that is available via a server-based network, a peer-to-peer network, the Internet, or the like. There may be more than one enhanced driver available, and the user notification may include various features available on different enhanced drivers. In at least one alternate implementation, an enhanced driver may be installed without notifying the user. If there are multiple enhanced drivers available, the selection of which driver is optimal to install may be based on additional information about the operating environment, including a version of the operating system, other software installed, indicators of how the computer is used (business or gaming, for example), which generic driver was installed, or the like.
[0005] Many of the attendant features may be more readily appreciated as the same becomes better understood by reference to the following detailed description considered in connection with the accompanying drawings.
DESCRIPTION OF THE DRAWINGS
[0006] The present description may be better understood from the following detailed description read in light of the accompanying drawings, wherein:
[0007] FIG. 1 is a block diagram of an exemplary conventional computer network.
[0008] FIG. 2 is a block diagram of an example of a networked computing system operating environment in which the server contains a service capable of supporting notifying a user that an enhanced device driver is available.
[0009] FIG. 3 is a flowchart of an exemplary implementation for notifying a computer user that a generic device driver is in use and that an enhanced driver is available.
[0010] FIG. 4 is a flowchart of an exemplary implementation for automatically replacing a generic device driver with an enhanced driver.
[0011] FIG. 5 is a block diagram of a device driver.
[0012] FIG. 6 is a block diagram of a device driver with an identification method to indicate that it is a generic driver.
[0013] FIG. 7 is a block diagram of exemplary computer with a generic device driver with access to a process for replacing a generic device driver with an enhanced driver.
[0014] FIG. 8 is a block diagram of exemplary computer with an enhanced device driver after being updated by a process for replacing a generic device driver with an enhanced driver.
[0015] FIG. 9 is a block diagram which illustrates an exemplary computing environment in which the process for replacing a generic device driver with an enhanced driver may be implemented.
[0016] Like reference numerals are used to designate like parts in the accompanying drawings.
DETAILED DESCRIPTION
[0017] The detailed description provided below in connection with the appended drawings is intended as a description of the present examples and is not intended to represent the only forms in which the present example may be constructed or utilized. The description sets forth the functions of the example and the sequence of steps for constructing and operating the example. However, the same or equivalent functions and sequences may be accomplished by different examples.
[0018] The examples below describe a process and a system for notifying a user that an enhanced device driver is available for the user's computer. Although the present examples are described and illustrated herein as being implemented in client PCs and a server with a hard drive system, the system described is provided as an example and not a limitation. The present examples are suitable for application in a variety of different types of variety of different types of computing processors in various computer systems.
[0019] The present example provides a way for a server to provide a device driver capable of providing additional functionality or a better user experience than a generic device driver currently installed on a user's system. Before describing the present example a conventional network will first be described.
[0020] FIG. 1 is a block diagram of a conventional computer network. Such a system may not provide a method to notify a user of the availability of better device drivers for her computer. Local area network 100 may contain server computer 110 , first client computer 102 , second client computer 104 , and nth client computer 106 . Any number of client computers, as well as various hubs, switches, and other network devices may be utilized in such a conventional network.
[0021] The local area network 100 is configured to connect to any number of other local area networks, and such connections could be made a number of ways including, but not limited to, the internet, an intranet, satellite connections, or wireless connections, or any combination of the possible connections. The local area network 100 may also stand alone and not be connected to any other local area networks or wide area networks. A number of other components such as routers, switches and the like may also be present to facilitate networking.
[0022] Server computer 110 is conventionally constructed and includes a mass storage device 108 . Such a mass storage system can include individual hard drives or networked hard drives such as RAID drives or the like.
[0023] Client computers 102 , 104 , and 106 are conventionally constructed and may be initialized by conventional methods. For example the client computers may be conventional PCs, computers, processors, microcontrollers or the like.
[0024] The following figure and description provides an example of a network capable of supporting the process of notifying a user that an enhanced device driver is available.
[0025] FIG. 2 is a block diagram of an example of a networked computing system operating environment in which the server contains a service capable of supporting notifying a user that an enhanced device driver is available. In the following discussion, continuing reference may be made to elements and/or reference numerals contained in previous figures.
[0026] Local area network 200 includes server computer 210 , client computers 202 , 204 , and 206 . The local area network 200 could also include a plurality of servers, hubs, switches, wireless access points, and other network devices, as well as any number of server and client computers.
[0027] Server computer 210 may include a service 220 disposed on a mass storage device 208 . Such a mass storage system can include individual hard drives or networked hard drives such as RAID (Redundant Array of Independent Disks) drives or the like. It is noted that there could be multiple services, such as a plurality of databases containing information about device drivers. There could be one database, or separate databases for different manufacturers, or for different types of devices, for example. Access to the service 220 could take the form of an API provided by an application running on the client machine, an application making a call over a distributed programming model, such as DCOM, a web service call such as those provided by the MICROSOFT .NET FRAMEWORK, or the like. Such a service could match hardware IDs or other identifying properties of devices on a client with device drivers from the manufacturer, or from third party providers. A database could store device drivers internally, elsewhere on the local area network, or point to locations on other networks or on the Internet.
[0028] FIG. 3 is a flowchart of an exemplary implementation 300 for notifying a computer user that a generic device driver is in use and that an enhanced driver is available. In the following discussion, continuing reference may be made to elements and/or reference numerals contained in previous figures.
[0029] The process begins with installing a device driver at block 310 . If the driver is not a generic driver (“No” branch, block 315 ), no further action is necessary, and the process terminates at block 350 . The testing whether a driver is generic (block 315 ) may be done in many ways. For example, a driver could have a bit or some other attribute which may indicate that it is generic. In an alternative implementation there may be a file that describes the driver which includes information on whether or not it is generic. Yet another implementation could have a database of generic drivers which could be searched for the driver in question. If the driver is generic (“Yes” branch, block 315 ), a report is generated at block 320 containing a hardware ID which will identify the device. The report is uploaded to a server at block 325 , where a check is done (block 330 ) to see if a solution, an enhanced driver for example, is available. If no solution is available (“No” branch, block 330 ), then the process terminates at block 350 . If, however, a solution is available (“Yes” branch, block 330 ), the user is notified of the solution at block 335 . The process terminates at block 350 if the user chooses not to install the new driver (“No” branch, bloc, 340 ). If the user chooses to install the new driver (“Yes” branch, block 340 ), the better driver is installed at block 345 , and the process terminates at block 350 .
[0030] FIG. 4 is a flowchart of an exemplary implementation 400 for automatically replacing a generic device driver with an enhanced driver. The process starts at block 410 with the installing of a device driver. If the driver is not a generic driver in block 415 (“No” branch), no further action is necessary, and the process will finish at block 440 . The testing at block 415 of whether a driver is generic may be done in many ways. For example, a driver could have a bit which may indicate that it is generic. In an alternative implementation, there could be a database of generic drivers which could be searched for the driver in question. Yet another implementation may have a file that describes the driver which includes information on whether or not it is generic. If the driver is generic at block 415 (“Yes” branch), a report is generated at block 420 containing a hardware ID which will identify the device. The report is uploaded to a server in block 425 , where a check block 430 to see if a solution, an enhanced driver for example, is available. If so, the better driver may be installed in block 435 , and the process finishes at block 440 .
[0031] FIG. 5 is a block diagram of a device driver, block 500 . Such a device driver is used for many different types of devices, including common devices such as display adapters, keyboards, mice, speakers, USB ports, printers, mass storage devices, and the like, as well as less common components such as lab equipment, speech synthesizers, and any other devices that a user wishes to attach to a computer.
[0032] FIG. 6 is a block diagram of a device driver, block 600 , with a way, block 625 , to indicate that it is a generic driver. This indication could be a bit, a byte, an API for which the driver responds, the name of the file, or any other way of identifying a driver as being generic.
[0033] FIG. 7 is a block diagram of exemplary computer first client 202 with a generic device driver 705 . Generic device driver 705 has an indicator that shows it is generic 710 . First client 202 has access to a process for replacing a generic device driver with an enhanced driver, service 220 . This service is disposed on mass storage device 208 on server computer 210 . First client 202 is coupled to server computer 210 via a local area network 200 .
[0034] After the service 220 has been called, and the generic driver has been replaced with an enhanced driver, we come to FIG. 8 .
[0035] FIG. 8 is a block diagram of exemplary computer first client 202 with an enhanced device driver 805 after being updated by a process for replacing a generic device driver with an enhanced driver, provided by service 220 on server computer 210 over local area network 200 .
[0036] FIG. 9 is a block diagram which illustrates an exemplary computing environment in which the process for replacing a generic device driver with an enhanced driver may be implemented.
[0037] The exemplary computing environment 900 is only one example of a computing system and is not intended to limit the examples described in this application to this particular computing environment.
[0038] A peripheral drive 904 may accept a computer readable media 905 , 906 that includes a copy of the method to suppress dialog boxes from background tabs. The peripheral drive may be coupled to an I/O interface 912 along with an I/O device 903 .
[0039] The I/O interface 912 may be coupled to a bus structure 908 , which also may couple to a hard disk 910 , a processor 907 , system memory 909 , a video adapter 920 and a network adapter 913 .
[0040] Video adapter 920 typically couples a display 922 to the CPU 906 . Network adapter 913 typically couples a local area network 901 to the CPU 906 .
[0041] For example the computer 301 can be implemented with numerous other general purpose or special purpose computing system configurations. Examples of well known computing systems, may include, but are not limited to, personal computers, hand-held or laptop devices, microprocessor-based systems, multiprocessor systems, set top boxes, gaming consoles, consumer electronics, cellular telephones, PDAs, and the like.
[0042] The computer 900 includes a general-purpose computing system in the form of a CPU 906 , display 922 , I/O device 903 , and peripheral drive 904 . The CPU 906 can include one or more processors 907 (including CPUs, GPUs, microprocessors and the like), a conventional system memory 909 , and a conventional system bus 908 that couples the various system components. Processor 907 processes various computer executable instructions, including those to control the operation of computer 900 and allows communication with other electronic and computing devices (not shown). The system bus 908 represents any number of several types of bus structures, including a memory bus or memory controller, a peripheral bus, an accelerated graphics port, and a processor or local bus using any of a variety of bus architectures.
[0043] The system memory 909 may include computer-readable media in the form of volatile memory, such as random access memory (RAM), and/or non-volatile memory, such as read only memory (ROM). A basic input/output system (BIOS) is typically stored in ROM. RAM typically contains data and/or program modules that are immediately accessible to and/or presently operated on by one or more of the processors 907 . Computing device 900 may include other removable/non removable, volatile/non-volatile computer storage media.
[0044] A hard disk drive 910 is also a type of computer readable media that may read from and write to a non-removable, non-volatile magnetic media (not shown). Such a hard disk drive may include a magnetic disk drive which reads from and writes to a removable, non volatile magnetic disk (e.g., a “floppy disk”) 905 , or an optical disk drive that reads from and/or writes to a removable, non-volatile optical disk such as a CD ROM, DVD, or the like. In this example, the hard disk drive 910 , and disk drive 904 are each connected to the system bus 908 by one or more data media interfaces 912 . The disk drives and associated computer readable media provide non volatile storage of computer readable instructions, data structures, program modules, and other data for computing device 900 .
[0045] Mass storage devices (or peripheral drive) 904 are also a type of computer readable media that may be coupled to the computing device or incorporated into the computing device by coupling to the bus 908 . Such peripheral drive 904 may include a magnetic disk drive which reads from and writes to a removable, non volatile magnetic disk (e.g., a “floppy disk”) 905 , or an optical disk drive that reads from and/or writes to a removable, non-volatile optical disk such as a CD ROM 906 or the like. Computer readable media (“CRM”) 905 , 906 typically embody computer readable instructions, data structures, program modules and the like supplied on floppy disks, CDs, portable memory sticks and the like. Such CRM may be used to produce an initialization disk.
[0046] Any number of program modules or processes can be stored on the hard disk 910 , or peripheral drive 904 , including by way of example, backup files, an operating system, one or more application programs, other program modules, and program data. Each of such operating system, application programs, other program modules and program data (or some combination thereof) may include an implementation of the systems and methods described herein.
[0047] A display device 922 can be connected to the system bus 908 via an interface, such as a video adapter 920 . A user can interface with the CPU 906 via any number of different input devices 903 such as a keyboard, pointing device, joystick, game pad, serial port, and/or the like. These and other input devices are connected to the processors 907 via input/output interfaces 912 that are coupled to the system bus 908 , but may be connected by other interface and bus structures, such as a parallel port, game port, and/or a universal serial bus (USB).
[0048] Computer 900 can operate in a networked environment using connections to one or more remote computers through one or more local area networks (LANs), wide area networks (WANs) and the like. The computer 900 is connected to a network 901 via a network adapter 913 or alternatively by a modem, DSL, ISDN interface or the like. | Some device drivers support the “least common denominator” features of a device, such as a generic VGA driver which does not provide access to higher resolution or other features supported by a video card. It may be difficult for computer users to know when an enhanced driver is available. A method is provided to notify a user that a device driver on the user's system is generic and that an enhanced device driver is available. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority to and incorporates by reference the entire contents of Japanese priority document 2007-110290 filed in Japan on Apr. 19, 2007.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a technology for scanning an image of an original or a photographed screen, converting the scanned image into image data to create an image file, and distributing the image file to other devices.
[0004] 2. Description of the Related Art
[0005] Recently, with the aim of saving storage space, or sharing information with other, there is an increasing trend toward digitalizing of paper-based documents. Along with this trend, image reading apparatuses, such as document scanners, and applications for digitalizing paper-based documents have become widely used in many companies and even in ordinary households.
[0006] One of the applications for digitalizing paper-based documents using an image reading apparatus, such as a document scanner, includes a distribution scanner. A distribution scanner is used in the following manner. That is, a user places a paper-based document, which the user wants to digitalize, on an image reading apparatus, and specifies a destination for distributing a digitalized document (hereinafter, “digital document file”). The image reading apparatus acquires a digital document file by scanning the paper-based document and delivers the digital document file to the destination. The digital document file could be in a TIFF format, a PDF format, or some other format. Today, IP networks have become widely available in the world, and a digital document file can be distributed to any information processing terminals anywhere in the world, as long as the image reading apparatus can be connected to an IP network. Unlike known logistics such as a mailing system or a parcel delivery system, one does not need to be aware of the physical distance to the distributed destination.
[0007] As explained above, a distribution scanner is an excellent application that enables the user to deliver a digital document file to information processing terminals located anywhere in the world, by simply placing the paper-based document on the image reading apparatus and performing just few operations. The distribution scanner is also expected to be the most common method for digitizing the paper-based document in the years to come.
[0008] However, when using the distribution scanner, the user needs to perform a cumbersome operation to specify a destination for distributing the digital document file. Examples of the destination include a personal folder created in a network-attached storage (NAS) terminal, an e-mail box, or a desktop on a personal computer (PC). In any of these examples, the location of a destination is specified by a sequence of characters having a given length, such as an IP address, a folder name, or an e-mail address and it is cumbersome for the user to enter the sequence of characters without making any mistakes. Especially, because a small-sized image reading apparatus will have a small liquid crystal display and a few hardware keys as a user interface, an inexperienced user will find it difficult to enter a character sequence smoothly. Of course, the operation can be simplified by using a phone-book feature provided to the image reading apparatus to register destinations in advance, and call the registered destinations upon usage. However, this method is only effective for those who often use a specific image reading apparatus. No destinations are available in the phone book when a user is using an image reading apparatus for the first time or just happens to use the apparatus, thus the phone book cannot be a solution.
[0009] Because advanced technologies, such as high-speed scanners or broadband IP networks, have become available for scanning the paper-based documents, now a days shorter time is required for delivering digital document files to the destinations. However, to improve the productivity or convenience of the distribution scanner, it is necessary to reduce the time for preparations required before starting to scan the paper documents (such as time required for specifying the destinations). As long as the preparation requires time, a single user will occupy the image processing apparatus for a long time, preventing other users from using the apparatus, and the user will also experience inconvenience upon using the distribution scanner.
[0010] One approach could be to omit the task to specify the destination, which is one of the most cumbersome tasks in the preparation. In this approach, however, because the user starts scanning the paper-based document before specifying the destination, a digital document file will be stored in a temporary destination. Then, two types of information are written onto a recording medium that is detachable from the image processing apparatus, such as a secure digital (SD) card or a smart media, and the user receives the information. One of the information is, for example, a thumbnail image of the digital document file that allows the user to easily imagine the contents of the digital document file. The other information is, for example, a hyperlink that allows the user to easily identify where the digital document file is stored. On any information processing terminal, the user can then access the temporary destination to receive the desired digital document file.
[0011] In summary, the convenience improves because the user can use the distribution scanner with simple operations, as long as the user has a portable recording medium. Moreover, the image processing apparatus is occupied for less time, thus improving the productivity.
[0012] Some applications use a network document scanner to create therein an actual image file, which is an image data file scanned by the scanner, and a reduced image file, which is a file smaller in size than the actual image data file, and to provide these files to the user. Examples of these applications are disclosed in Japanese Patent Application Laid-open No. 2001-290695 and Japanese Patent Application Laid-open No. 2003-143359.
[0013] The Japanese Patent Application Laid-open No. 2001-290695 discloses an invention relating to an application that creates an actual image file from image information obtained by scanning a paper-based document, and stores the actual image file in the apparatus. The invention is characterized in that an HTML document is created and provided to the user. When the user requests a list of stored images, the HTML document indicates a path to the actual image file stored in the apparatus, and a reduced image thereof. The Japanese Patent Application Laid-open No. 2003-143359 discloses an invention relating to an application (distribution scanner) that creates an actual image file from the image information obtained by scanning the paper-based document, and distributes the actual image file to an external terminal. This invention is characterized in that, after the paper-based document is scanned, a plurality of reduced image files, each having a different image quality, is created and presented to the user to allow user to select one of the image qualities that the user prefers. Then, the actual image file is created in the selected image quality, and distributed.
[0014] In the file management system disclosed in the Japanese Patent Application Laid-open Number 2001-290695, a user cannot obtain link information and a reduced image unless the user actively makes some kind of action. Because originally, the main purpose of the invention is to create a list of actual image files, it is sufficient if the user instructs the image processing apparatus as required. In the distribution scanner disclosed in the Japanese Patent Application Laid-open No. 2003-143359, the user would makes fewer mistakes, because the user does not need to perform the entire operation all over again when the quality of the actual image file was not as intended or as preferred. Thus, the time for which a user occupies the distribution scanner can be reduced. However, the reduced image file is created only for the purpose to communicate to use how the resultant actual image file will be.
SUMMARY OF THE INVENTION
[0015] It is an object of the present invention to at least partially solve the problems in the conventional technology.
[0016] According to an aspect of the present invention, there is provided an image distributing apparatus including an image reading unit that acquires image data by reading an image; an image file creating unit that creates a first image file from the image data; a transmitting unit configured to transmit the first image file to an external terminal over an IP network; a reduced-size image creating unit that creates a second image file, being smaller in size than the first image file, from the image data; a link information adding unit that adds identification information that uniquely identifies the external terminal to the second image file to obtain an identification information added image file; a medium writing unit that writes the image file into a portable recoding medium; and a controlling unit that causes the medium writing unit to write the identification information added image file into the recording medium if the recording medium is connected to the medium writing unit, while the first image file is transmitted to the external terminal by the transmitting unit.
[0017] According to another aspect of the present invention, there is provided an image forming apparatus including an image distributing apparatus including a document scanner that acquires image data by scanning a document; an image file creating unit that creates a first image file from the image data; a transmitting unit configured to transmit the first image file to an external terminal over an IP network; a reduced-size image creating unit that creates a second image file, being smaller in size than the first image file, from the image data; a link information adding unit that adds identification information that uniquely identifies the external terminal to the second image file to obtain an identification information added image file; a medium writing unit that writes the image file into a portable recoding medium; and a controlling unit that causes the medium writing unit to write the identification information added image file into the recording medium if the recording medium is connected to the medium writing unit, while the first image file is transmitted to the external terminal by the transmitting unit; a printer configured to print an image onto a printing medium; and an image data processing unit that converts the image data generated by the document scanner in the image distributing apparatus to printing image data suitable for printing by the printer, and outputs the printing image data to the printer.
[0018] The above and other objects, features, advantages and technical and industrial significance of this invention will be better understood by reading the following detailed description of presently preferred embodiments of the invention, when considered in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is a block diagram of an image processing system according to a first embodiment of the present invention;
[0020] FIG. 2 is an enlarged plan view of an operation board shown in FIG. 1 ;
[0021] FIG. 3 is a block diagram of network connections established between terminals communicating over an IP network upon using a “distribution scanner” function of a multi-functional copy machine shown in FIG. 1 ;
[0022] FIG. 4 is an enlarged plan view of contents displayed on a liquid crystal touch panel shown in FIGS. 1 and 2 , showing an input screen displayed thereon when the “distribution scanner” function is selected;
[0023] FIG. 5 is another enlarged plan view of contents displayed on the liquid crystal touch panel shown in FIGS. 1 and 2 , showing an input screen displayed thereon when the “distribution scanner” function completes scanning an original image while a memory card is mounted to a media interface unit;
[0024] FIG. 6 is still another enlarged plan view of contents displayed on the liquid crystal touch panel shown in FIGS. 1 and 2 , showing an input screen displayed thereon when the “distribution scanner” function completes scanning an original image while the memory card is not mounted to the media interface unit;
[0025] FIG. 7 is a block diagram of network connections established between the terminals communicating over the IP network and a flow of an image file when the “distribution scanner” function of the multi-functional copy machine shown in FIG. 1 is being used;
[0026] FIG. 8 is a plan view of an image stored in a first image file to be transferred from the multi-functional copy machine to an NAS server, shown in FIG. 1 ; and
[0027] FIG. 9 is a plan view of a thumbnail image in a second image file stored in the memory card shown in FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0028] Exemplary embodiments of the present invention are described below with reference to the drawings. FIG. 1 is a block diagram of an image processing system according to a first embodiment of the present invention. This image processing system includes a multi-functional copying machine MF 1 provided with an image distributing apparatus. In the multi-functional copying machine MF 1 , a color scanner 1 includes a sensor board unit (SBU) 2 and a reading mechanism that projects an original image onto a charge-coupled device (CCD) provided in the SBU 2 . A light source in the reading mechanism irradiates the original with a light, and a light reflected on the original is projected onto the CCD through an optical lens. The CCD is an element for converting strength of a light into an analog electrical signal. The analog electrical signal output from the CCD is converted into image data (quantized data; digital data) by way of an A/D conversion, and output from the SBU 2 .
[0029] A communication controller (CDIC) 3 is a unit that facilitates smooth transmission and reception (transfer) of image data among each of the units provided in the copy machine MF 1 . The SBU 2 and an image processing unit (IPU) 4 transmit and receive image data through the CDIC 3 .
[0030] The IPU 4 is a unit that performs image processes to the digital image data received from the CDIC 3 . The IPU 4 optimizes frequency or gradation characteristics of the image data, for example, depending on the characteristics of the copy machine MF 1 itself or user requests. After being optimized, the digital image is transferred back to the CDIC 3 . When the image is to be output (printed), the IPU 4 converts the image data into recording image data suitable for image representation characteristics of a color printer 23 , and outputs the recording image data directly to the printer 23 .
[0031] A memory controlling unit (IMAC) 6 is a unit that performs processes such as compression or expansion of the image data, and for reading or writing the image data (including the compressed data) from or to a memory (MEM) 7 . The MEM 7 is a unit that stores therein the image data (including the compressed data).
[0032] A media interface unit (MIFU) 8 is a unit that reads and writes digital data from and to a portable recording medium (removable medium). Removable media of various standards are available, and a shape of a medium differs depending on the standard thereof. Therefore, the MIFU 8 has a plurality of slots, each corresponding to each of the shapes. The memory card 9 , which is one of the portable recording media (removable media), is shown in FIG. 1 . Data are recorded to a removable medium following a different scheme that depends on the standard thereof. Therefore, the MIFU 8 reads and writes the data following each of these standards. Especially in a “Memory to Media” operation, which will be described later, the MIFU 8 collects a thumbnail image, a hyperlink, and authentication information of a digital document file, and creates a thumbnail image file with link information.
[0033] A network controlling unit (NCU) 10 is a unit that establishes communications with other information processing terminals connected to an IP network. Upon transmitting data, the NCU 10 segments transmission data into packets according to a communication protocol of the IP network, and outputs the packets over the IP network. Upon receiving data, the NCU 10 reproduces original reception data that has been segmented into packets according to the communication protocol of the IP protocol. In “Memory to Network” operation, which will be described later, the NCU 10 operates to add the authentication function, such as a password, to image data, and to create a digital document file in a generally-available file format.
[0034] A liquid crystal touch panel 12 , provided in an operation board 11 , is a unit that displays information required when the user uses the copy machine MF 1 . The user can make various inputs and settings by touching soft keys displayed on the screen.
[0035] A process controller 19 controls operations of the scanner 1 , the CDIC 3 , the IPU 4 , and the printer 23 . The process controller 19 provides necessary settings to each of these units, and monitors startups, terminations, progress of processes of these units, and the like. A system controller 14 controls operations of the IMAC 6 , the MEM 7 , the NCU 10 , the MIFU 8 , and the liquid crystal touch panel 12 in the operation board 11 . The system controller 14 provides necessary settings to each of these units, and monitors startups, terminations, and progress of processes of these units.
[0036] A random access memory (RAM) 16 and a read only memory (ROM) 17 connected to the IMAC 6 via a local bus 15 store therein information required for execution of processes by the system controller 14 , the IMAC 6 , the liquid crystal touch panel 12 , the MEM 7 , the NCU 10 , and the MIFU 8 . Example of stored information includes character information or bitmap information for displaying characters or pictures on the liquid crystal touch panel 12 , a hyperlink-specified document to be added to a thumbnail image in the reduced image that is a second image file, a password-indicating document, or a total capacity or a remaining capacity that are available in the MEM 7 . A non volatile ram (NVRAM) 22 stores therein an administrator's ID, a user ID, and a temporary destination (external terminal) for temporarily storing therein a digital document file (a first image file), each of which is registered in an initial setting. An example of the temporary destination is an IP address of an NAS server 31 . In the first embodiment, an IP address and a hyperlink-specifying document are “external terminal identifying information”.
[0037] A RAM 20 and a ROM 21 connected to a serial bus 18 store therein information required for execution of processes by the scanner 1 , the CDIC 3 , the IPU 4 and the process controller 19 . Examples of such information include a size of an original to be scanned by the scanner 1 , optical characteristics of the CCD, or parameters for the image processes executed by the IPU 4 .
[0038] As shown in FIG. 2 , in addition to the liquid crystal touch panel 12 , the operation board 11 further includes a numeric key pad 131 , a clear/stop key 132 , a start key 133 , an initial setting key 134 , a mode switching key 135 , a test print key 136 , and a power key 137 . During an inputting stage, where the user enters, sets, or registers a shortened version of a URL, a file name, or a folder name, alphabetical key buttons, with HIRAGANA appended, are displayed on the liquid crystal touch panel 12 . The power key 137 is an operation key for instructing the apparatus to switch from a power saving mode (an idle mode or a low power consumption mode) to a standby mode where the image can be printed, and vise versa. If the power key 137 is pushed down for one time while the power saving mode is selected, the power saving mode is switched to the standby mode. If the power key 137 is pushed down for one time while the standby mode is selected, the standby mode is switched to the idle mode. The test print key 136 is a key for printing a single copy of a document, regardless of the number of copies specified, to allow the user to check the resultant printout.
[0039] The initial setting key 134 allows the user to customize the initial settings of the machine in a given manner. For example, the user can specify an expiration time for switching the machine into the power saving mode, sizes of papers stored in the machine, or conditions to return to when the reset key is pushed down for the copy function. In addition, the initial setting key 134 allows the user to register (write into the NVRAM 22 ) an address (an accessing address of the NAS server 31 ) linked from a hyperlink written into the memory card 9 , which is one of the removable media, along with the thumbnail images in the “Memory to Media” operation, which will be described later. When the initial setting key 134 is operated, selection buttons are displayed so that the user can select from functions, such as an “initial value setting” function for setting various initial values, an “ID setting” function, an “NAS address setting” function, and a “usage history outputting” function. Upon selecting the “NAS address setting” function, the user can register (write into the NVRAM 22 ) the address (an IP address of the NAS server 31 ) linked from a hyperlink written into the memory card 9 along with the thumbnail images.
[0040] The liquid crystal touch panel 12 displays various function keys, input keys for users to enter conditions for performing the selected function, messages and the like. The liquid crystal touch panel 12 displays function selecting keys for selecting a function such as a “copy” function, a “distribution scanner” function, a “write-to-media” function, an “output-to-media” function, and a “facsimile” function, and progress thereof. If the user touches one of the function selecting keys, an input/output screen corresponding to the selected function is displayed on the liquid crystal touch panel 12 .
[0041] For example, if the user selects the “copy” function, function keys corresponding thereto, a specified number of copies, and a message indicating the status of the image forming apparatus are displayed as shown in FIG. 2 . The function keys include keys for specifying the printing colors, such as “black (BK)”, “full-color”, “automatic color selection”, “cyan (C)”, “magenta (M)”, and “yellow (Y)”. When an operator touches one of the keys displayed on the liquid crystal touch panel 12 , the operation board 11 reads the operation as an operator input, and reversely displays the selected function key in gray to indicate that the function has been selected. Subsequently, the user can make a copy by setting an original on the scanner 1 , and pressing down the start key.
[0042] If the user touches the selection key for the “distribution scanner”, the user can distribute an image, by scanning the original using the scanner 1 , and transmitting the scanned image data to the NAS server 31 , and accumulating the data therein. The “distribution scanner” function will be described later in detail.
[0043] The “write-to-media” function is a function to scan an original using the scanner 1 , to generate an image file corresponding to the first image file, and to store the image in a removable medium (for example, the memory card 9 ).
[0044] The “output-to-media” function is a function that reads image data of an image file stored in the removable medium, causes the IPU 4 to convert the image data into a recording image data suitable for image formation performed by the printer 23 , outputs the recording image data to the printer 23 , and causes the printer 23 to form an image onto a printing paper based on the recording image data.
[0045] The “facsimile” function is a function to read an original using the scanner 1 , and to transmit the read original via a facsimile.
[0046] The “distribution scanner” function will be now explained in detail. The “distribution scanner” function includes “Scan to Memory”, “Memory to Network”, and “Memory to Media” operations. If the user touches the “distribution scanner” button, shown in FIG. 2 , displayed on the liquid crystal touch panel 12 of the operation board 11 , the operation board 11 switches the screen displayed on the liquid crystal touch panel 12 to a scanning condition inputting screen shown in FIG. 4 . If the user sets the scanning condition on this screen, and clicks on (touches) the “OK” button, an indicator on the start key 133 turns from red to green. When the user presses down the start key 133 , the system controller 14 executes the “Scan to Memory” operation to scan the original using the scanner 1 and to write the image data into the MEM 7 .
[0047] Upon completing scanning the original, the system controller 14 makes a reference to confirm if a removable medium, such as the memory card 9 , is mounted to the MIFU 8 . If a removable medium is mounted, a selecting screen shown in FIG. 5 is displayed on the liquid crystal touch panel 12 . On this selecting screen, the user can select a data format for the first image file (the actual image file), an authentication setting, and an attaching method for attaching link information to the second image file (the reduced image file). If the user makes predetermined selections and clicks on the “OK” button, the system controller 14 executes the “Memory to Network”. Upon completing the transmission, the system controller 14 executes the “Memory to Media”.
[0048] If no removable medium is mounted on the MIFU 8 upon completing scanning the original, the system controller 14 displays the selections of the data formats for the first image file (the actual image file), the authentication setting, and an IP address to transfer the image file (the IP address registered to the NVRAM 22 ; that is, the IP address of the NAS server 31 ), and an automatically-generated folder name on the liquid crystal touch panel 12 , as shown in FIG. 6 . The user needs to take a note of the IP address and the folder name. In the first embodiment, the folder name is a numeral code that is associated with an IP address and stored in the NVRAM 22 . Every time the IP address is called, the numeral code is incremented by one, and used as a folder name for storing the first image file in the NAS server 31 . If the user clicks on “OK”, the system controller 14 executes the “Memory to Network”. In this scenario, the “Memory to Media” is not executed.
[0049] The “Scan to Memory” is an operation to scan an original using the color scanner 1 , and to accumulate the digital image in the MEM 7 . The user places the original on a platen of the color scanner 1 , and sets various scanning conditions via the liquid crystal touch panel 12 of the operation board 11 (see FIG. 4 ). When the “OK” button is pressed down, the conditions set by the user are transferred to the process controller 19 and the system controller 14 . The process controller 19 stores the transferred scanning conditions to the RAM 20 , and instructs the scanner 1 , the CDIC 3 , and the IPU 4 to operate according to the scanning conditions. The system controller 14 stores the transferred conditions to the RAM 16 , and instructs the IMAC 6 , the MEM 7 , the NCU 10 , and the MIFU 8 to operate according to the scanning conditions.
[0050] When the instructions to each of the units are completed, the scanner 1 scans the document on the platen, and transfers image data to the CDIC 3 . The CDIC 3 forwards the image data, transferred from the SBU 2 , to the IPU 4 . The IPU 4 performs image processes to compensate for optical characteristics of the SBU 2 . After the image processes have been completed, the image data is transferred to the CDIC 3 . The CDIC 3 forwards the image data, transferred from the IPU 4 , to the IMAC 6 via a parallel bus 5 . The IMAC 6 converts the image data to a storing format that is storable in the MEM 7 , and stores the converted image data in the MEM 7 . During these operations, statuses of the color scanner 1 , the IPU 4 , and the CDIC 3 are sequentially notified to the process controller 19 . Statuses of the IMAC 6 and the MEM 7 are sequentially notified to the system controller 14 . Upon completion of storing the image data, the process controller 19 causes the operation board 11 to display the completion thereof, and ends the “Scan to Memory” operation.
[0051] The “Memory to Network” is an operation to create a digital document file, which is the first image file, from the image data accumulated in the MEM 7 , and to transmit the digital document file to an “external terminal”, which is a temporary destination. In the first embodiment, the “external terminal” is the NAS server 31 . The IP address of the NAS server 31 , located in the IP network 30 , is written into or registered to the NVRAM 22 in the initial setting that is initiated when the initial setting key 134 is operated on the operation board 11 .
[0052] To begin with, the user provides settings, such as the file format of the digital document file, the image quality, or the authentication setting, through the operation board 11 (See FIG. 5 ). Upon the “OK” button being pressed, the user settings are transferred to the process controller 19 and the system controller 14 . The process controller 19 stores the received user settings to the RAM 20 , and instructs the CDIC 3 and the IPU 4 to operate according to the user settings. The system controller 14 stores the received user settings to the RAM 16 , and instructs the IMAC 6 , the MEM 7 , and the NCU 10 to operate according to the user settings. When the process controller 19 and the system controller 14 complete giving instructions to each of the units, the IMAC 6 reads the image data from the MEM 7 , and expands the image data into the original image format before being stored in the MEM 7 . The IMAC 6 then transfers the digital image data to the CDIC 3 via the parallel bus 5 . The CDIC 3 forwards the image data received from the IMAC 6 to the IPU 4 . The IPU 4 performs image processes to optimize the frequency or gradation characteristics, or size (the number of pixels) of the image data so that the image data is optimized for the digital document file.
[0053] The image data that has been provided with the image processes in the IPU 4 , is transferred back to the CDIC 3 . The CDIC 3 forwards the image data received from the IPU 4 to the NCU 10 via the parallel bus 5 . The NCU 10 adds authentication information, such as a password, to the image data received from the CDIC 3 , and creates a digital document file in a common file format, such as TIFF, JPEG, or PDF format (See FIG. 8 . However, when a security function is to be added, the file formats are limited to those that can support such addition of the security function.). The NCU 10 then transmits the digital document file (the first image file; the actual image file) to the temporary destination, the NAS server 31 (the external terminal). During these operations, the statuses of the IMAC 6 , the MEM 7 , and the NCU 10 are sequentially notified to the system controller 14 . The statuses of the CDIC 3 and the IPU 4 are sequentially notified to the process controller 19 . When the NCU 10 completes transmitting the digital document file, the system controller 14 causes the operation board 11 to display the completion thereof, and ends the “Memory to Network” operation.
[0054] The “Memory to Media” is an operation to create a thumbnail image file (the second image file), embedded with information for accessing the digital document file stored in the temporary destination, from the image data accumulated in the MEM 7 and to write the thumbnail image file into a removable medium, such as the memory card 9 . To begin with, the user provides settings, such as a method for embedding the information for accessing the digital document file, through the operation board 11 (See FIG. 5 ). When the “OK” button is pressed down, the user settings are transferred to the process controller 19 and the system controller 14 . The process controller 19 stores the received user settings to the RAM 20 , and instructs the CDIC 3 and the IPU 4 to operate according to the user settings. The system controller 14 stores the received user settings to the RAM 16 , and instructs the IMAC 6 , the MEM 7 , and the MIFU 8 to operate according to the user settings. When the process controller 19 and the system controller 14 complete giving instructions to each of the units, the IMAC 6 reads the image data from the MEM 7 , expands the image data into the original image format before being stored in the MEM 7 , and transfers the image data to the CDIC 3 via the parallel bus 5 . The CDIC 3 forwards the image data received from the IMAC 6 to the IPU 4 . The IPU 4 performs image processes to optimize the frequency, gradation characteristics, or a number of pixels of the image data so that the image data is optimized for a thumbnail image file with link information (the second image file; the reduced image file). The image data that are provided with the image processes in the IPU 4 is transferred back to the CDIC 3 . The CDIC 3 forwards the image data received from the IPU 4 to the MIFU 8 via the parallel bus 5 . The MIFU 8 embeds the link information, such as a hyperlink, and the authentication information, such as a password, into the image data received from the CDIC 3 visibly (See FIG. 9 ) or invisibly, by way of digital watermarking, for example, and creates an image file in a common file format, and writes the created image file to the removable medium.
[0055] During these operations, the statuses of the IMAC 6 , the MEM 7 , and the MIFU 8 are sequentially notified to the system controller 14 . The statuses of the CDIC 3 and the IPU 4 are sequentially notified to the process controller 19 . When the MIFU 8 completes writing the thumbnail image with the link information into the removable medium, the system controller 14 causes the liquid crystal touch panel 12 of the operation board 11 to display the completion thereof, and ends the “Memory to Media” operation.
[0056] The “Scan to Memory”, the “Memory to Network”, and “Memory to Media” operations do not necessarily have to be performed in the order described above. For example, if the IP network is congested, or a writing operation to the removable medium is slow, the “Scan to Memory” job can be performed in advance. In this manner, the original can be scanned at a stable speed regardless of congestion of the IP network or the performance of the removable medium. In addition, because some common file formats enable a plurality of scanned images to be stored as a single file (such as the PDF or the TIFF format), the “Scan to Memory” job might not be performed for the same number of times as the “Memory to Network” and the “Memory to Media” jobs. These jobs are managed by the system controller 14 .
[0057] An exemplary operation performed by the “distribution scanner”, in which these basic operations above are combined, will be now explained. As shown in FIG. 3 , the copy machine MF 1 is connected to the NAS server 31 that is the temporary destination to distribute the digital document file, over the IP network. A client terminal owned by the user (the real destination that the user has in mind) can be connected to the IP network as required.
[0058] To begin with, the user inserts a removable medium, such as the memory card 9 , into a dedicated slot on the MIFU 8 . After placing an original the user wants to digitize on the color scanner 1 , the user performs various settings, such as those explained above, through the operation board 11 . When the user completes performing all settings, the “Scan to Memory” and the “Memory to Network” operations are sequentially performed. The scanned paper-based document is temporarily stored in the NAS server 31 (the external terminal) as a digital document file (the first image file) (over a path A shown in FIG. 7 ). Subsequently, the “Memory to Media” operation is performed, and a thumbnail image file with link information (the second image file) is written into the removable medium (portable recording medium).
[0059] It is only up to this point that the user occupies the copy machine MF 1 . Subsequently, the user brings back the memory card 9 (the removable medium) (over a path B shown in FIG. 7 ), and accesses the thumbnail image with link information from a user terminal, for example, a client terminal 32 . As one of the examples, the thumbnail image file with link information includes a reduced image, which is sufficient to enable the user to imagine the contents of the digital document file, and a hyperlink embedded with the IP address of the NAS server 31 (the temporary destination), as shown in FIG. 9 . If the user selects the part with statement “open digital document file” with an underline using a pointing device, such as a mouse, the client terminal 32 starts accessing to the digital document file linked to the hyperlink (over a path C shown in FIG. 7 ). If the client terminal 32 is not connected to the IP network, the connection is established at this point. When the user moves the digital document file from the NAS server 31 (the temporary destination) to the client terminal 32 , the digital document file is delivered to its final destination.
[0060] Because the thumbnail image file (the second image file) is created in a common file format, the thumbnail image file can be reused. For example, after deciding the final location to store the digital document file in the client terminal 32 , the user can edit the thumbnail file to change the hyperlink to the new destination (the client terminal 32 ). In this manner, if, for example, the user wishes to share the digital document file with another person, the user can simply send the thumbnail image file (the second image file), allowing the person to access to the digital document file.
[0061] The “distribution scanner” can be used by the unspecified number of people. Therefore, various digital document files can be stored in the NAS server 31 , and there are risks that someone else could access, download, or edit your digital document file without your permission. To prevent such acts, according to the first embodiment, an authentication function is provided, in which the authentication information is added to the digital document file (the first image file). If such function information is added to the digital document file, the information required for authentication is provided visibly in the thumbnail image file, by way of alphanumerical sequence for example (a password in FIG. 9 ), or invisibly, by way of a digital watermark. As a result, only the user who has the thumbnail image (the second image file) can make operations to the digital document file (the first image file). Especially if the authentication information is embedded invisibly, for example, by way of a digital watermark, the authentication information can be advantageously protected, so that one cannot steal the authentication information easily by obtaining unauthorized access to the thumbnail image.
[0062] According to an aspect of the present invention, a user can display a second image file, which is a reduced image file, recorded in a portable medium on a user terminal, and can receive a first image file to the user terminal by accessing an external terminal based on external terminal identifying information displayed with the reduced image file. Because the user does not need to enter an address of the external terminal upon distribution, the user operation can be simplified upon being distributed with the image.
[0063] According to another aspect of the present invention, when the user displays the second image file, which is the reduced image file, recorded in the portable medium on the user terminal, the external terminal identifying information is a hyperlink. Therefore, the user can access the first image file located at the external terminal just by clicking on the hyperlink. Because the user does not need to enter the address of the external terminal, the user operation can be simplified upon obtaining the first image file.
[0064] According to still another aspect of the present invention, the user can be authenticated to the external terminal on the user terminal, using authentication information provided in the second image file, upon obtaining the first image file. Thus, only the owner of the second image file can obtain the first image file. Therefore, higher confidentiality can be achieved for the first image file.
[0065] According to still another aspect of the present invention, higher confidentiality can be achieved for the external terminal identifying information and the authentication information.
[0066] According to still another aspect of the present invention, even if the user does not have a portable recording medium, the distribution can be performed. According to still another aspect of the present invention, the distribution can be performed using an document scanner. By using a digital camera for the image reading unit, an image of a photograph can be also distributed. According to still another aspect of the present invention, a multi-functional copy machine can also be used.
[0067] Although the invention has been described with respect to specific embodiments for a complete and clear disclosure, the appended claims are not to be thus limited but are to be construed as embodying all modifications and alternative constructions that may occur to one skilled in the art that fairly fall within the basic teaching herein set forth. | In an image distributing apparatus, an image file creating unit creates a first image file, and a reduced-size image creating unit creates a second image file, being smaller in size than the first image file. A link information adding unit adds identification information that uniquely identifies an external terminal to the second image file to obtain an identification information added image file. A medium writing unit writes the image file into a portable recoding medium. A controlling unit causes the medium writing unit to write the identification information added image file into the recording medium if the recording medium is connected to the medium writing unit, while the first image file is transmitted to the external terminal by a transmitting unit. | 7 |
BACKGROUND OF THE INVENTION
The present subject matter relates generally to a firearm storage and transport. More specifically, the present invention relates to a space efficient firearm storage and transport apparatus.
Firearms are an indelible part of American society. While controversial to some, firearms are pervasive throughout the United States and one topic most, if not all, can agree on is the need for firearms to be stored and transported in a safe manner. Currently, the methods for gun storage involve either storing or carrying the weapon inside or outside of a case. Depending on local laws, the carry of firearms outside of a case in public may be prohibited and most gun safety experts agree the safest way to carry and store a firearm is unloaded and locked in a case. When purchased from a manufacturer, some guns come with a case, but when buying a gun secondhand or when a gun is sold without a case by the manufacturer, there arises a need for gun cases which can accommodate and securely transport firearms of any make or model.
Presently, firearm cases most typically consist of hard-bodied cases with foam padding on the interior for smaller weapons like handguns, with larger weapons either being accommodated by a similarly built large hard-bodied cases or padded soft-bodied cases. These soft-bodied cases exist for the sake convenience and ease of transportation which are not pressing concerns when storing or transporting a single weapon, but when storing and transporting multiple weapons, the logistical challenge of accommodating multiple hard-bodied cases becomes quite difficult. Each hard-bodied handgun case is typically designed to be carried with one hand and have the approximate dimensions of 12″×8″×4″ (inches). This means a gun owner can likely carry only two guns in separate cases comfortably at one time and must also find room to store the cases. Given the statistic that the average gun owner in the US owns around eight guns, the current method of utilizing individual hard-bodied or soft-bodied cases hampers the ability of most gun owners to safely carry and store their firearms.
Some firearm cases do allow the storage of multiple guns in one case but almost all of them are an extension of the hard-bodied case with foam padding design. These multi-gun storage cases, while more convenient to carry than multiple separate hard-bodied cases, are themselves larger than a single weapon storage case and do not provide an efficient use of space when storing or transporting the guns. Gun case manufacturers are clearly aware of the need for multi-gun storage but there is currently no existing art which teaches a method for storing multiple firearms in a way which minimizes the space required to, in turn, store the firearms case. Accordingly, there is a need for an apparatus adapted to store and transport multiple firearms safely and in a space efficient manner.
BRIEF SUMMARY OF THE INVENTION
To meet the needs described above and others, the present disclosure provides an apparatus adapted to store and transport multiple firearms safely and in a space efficient manner.
In a preferred embodiment, the apparatus consists of a storage base, storage panels, and storage case. The storage base may be a rectangular piece of hard material approximately two inches in height with a series of grooves cut into the top side of the base. The grooves may be set, at a minimum, the width of a handgun apart from each other and are themselves cut to a width that allows a storage panel to slide and sit in the groove. The grooves may travel the entire length of the base, which is a length equal to or less than that of the storage panels. On the bottom of the storage base, the side opposite to the grooves, there may be rubber feet attached to the base which prevents the base from sliding. The storage panels may also be constructed of hard material and may be rectangular in shape, but are much thinner in width than the base at one fourth of an inch. The panels may also be much taller than the base, with dimensions of approximately twelve inches high and fourteen inches long. As mentioned previously, the panels may be adapted to slide in and out of the grooves in the base and when placed into the base will stand upright with the faces of the panels being perpendicular to the top side of the base.
In this embodiment, the storage panels may also be designed to accommodate two handguns a piece strapped to them. This is accomplished by the use of horizontal and vertical slots which may be cut through the one fourth of an inch wide panel. The slots allow a user to strap two handguns to the storage panel with the use of cinch straps and spacers which fit through the slots and securely fasten the guns to the panel. The storage case may be a soft bodied bag designed to be carried over the shoulder. For example, the storage case may feature a zip top and shoulder strap. On the inside of the bag there may be rows of foam padding with space in-between the rows forming compartments which can accommodate one storage panel per space.
In another embodiment of the gun storage apparatus, the storage panels and base from the previously discussed handgun storage embodiment may be enlarged to accommodate and store both handguns and long guns. In this physically larger embodiment, the base and panels may have the same relative proportions as the smaller handgun embodiment. In contrast to the handgun panel however, both handguns and long guns may be strapped securely to the storage panel by use of cinch straps and spacers. This is accomplished by the use of horizontal and vertical slots which may be cut through the broad face of the panel, also seen in the handgun sized panel. This larger embodiment may feature many more slots cut into the panel when compared to the handgun panel. These extra slots allow for the storage of various sizes of guns with differing types of barrels, stocks, receivers, magazines, and grips. The larger panel may range in size from approximately sixteen inches tall and twenty five inches long to sixteen inches tall and fifty one inches long with the corresponding storage base being scaled to accommodate these proportions. Additionally, in this embodiment of the gun storage apparatus, the gun storage case may be scaled up from the handgun embodiment to accommodate both the larger panels and smaller panels.
Yet other embodiments of the invention exist including a firearm storage apparatus comprising a base including a first groove, a first storage panel removeably supported within the first groove, the first storage panel including a plurality of slots that traverse a face of the first storage panel, and a plurality of adjustable straps, each strap mated to the first storage panel through two of the slots and adjustable in position along the first storage panel and adjustable in degree of tightness to secure a firearm to the first storage panel.
This embodiment may also include a second storage panel removeably supported within a second groove in the base, the second storage panel including a plurality of slots that traverse a face of the second storage panel; one or more spacers removeably and adjustably secured to the panel to further support the firearm secured to the first storage panel; and rectangular storage panels. This embodiment may yes also include a soft-bodied or hard-bodied case for the base and/or a carrying case including compartments sized to receive the first storage panel when removed from the base.
Another embodiment features a firearm storage system comprising a base including a first groove, a first storage panel removeably supported within the first groove, the first storage panel including a plurality of adjustable straps mated to the first storage panel and adjustable to secure a firearm to the first storage panel, and a carrying case including a first compartment sized to receive the first storage panel when removed from the base.
This embodiment may also feature adjustable straps which comprise a holster, adjustable straps which are cinch straps including a releasable closure, and each strap mated to the first storage panel through two of a plurality of slots located in the face of the first storage panel and adjustable in position along the first storage panel. Spacers which are removeably and adjustably secured to the panel to further support the firearm secured to the first storage panel, a second storage panel removeably supported within a second groove in the base, the second storage panel including a plurality of slots that traverse a face of the second storage panel, each strap mated to the first storage panel through two of a plurality of slots located in the face of the first storage panel and adjustable in position along the first storage panel, and spacers which are removeably and adjustably secured to the panel to further support the firearm secured to the first storage panel may also be included in this embodiment.
An object of the present invention is to provide a solution to the problem of safely storing and transporting a large number of firearms in a space efficient manner. With guns being a popular part of American culture and the average gun owner owning multiple guns, there is a need for gun owners to be able to carry and store their firearms in an efficient, safe, and subtle manner.
An advantage of the invention is that it provides users with a space efficient apparatus which can store a multitude of firearms in a compact space compared to traditional gun cases and gun racks. This makes safe gun ownership easier to accommodate and gun owners more likely to practice safe storage methods.
Another advantage of the invention is that is provides convenience for storing and transporting guns. Normally, a gun owner with several different firearms would have to open and close many different weapon cases and reorganize them when they wished to use different guns. Additionally the owner would have to keep track of where each weapon was located, but with this invention the user may freely swap out which guns they wish to carry and can easily take inventory of where each of their guns are located.
Yet another advantage of the invention is that it allows for gun storage and transport in a clandestine manner. A gun owner need not store and carry several bulky gun cases with him when using this invention. The use of a compact carrying case for several guns allows the gun owner to not draw attention to themselves in public and also to not disturb the public by carrying large, and what some may find as threatening, firearm cases.
Still yet another advantage of the invention is that the user no longer has to purchase multiple firearm cases. The design of the invention allows it to be expanded so a user can safely store and transport any new guns they acquire without having to purchase or otherwise acquire a case for their new firearm.
Additional objects, advantages and novel features of the examples will be set forth in part in the description which follows, and in part will become apparent to those skilled in the art upon examination of the following description and the accompanying drawings or may be learned by production or operation of the examples. The objects and advantages of the concepts may be realized and attained by means of the methodologies, instrumentalities and combinations particularly pointed out in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The drawing figures depict one or more implementations in accord with the present concepts, by way of example only, not by way of limitations. In the figures, like reference numerals refer to the same or similar elements.
FIG. 1 is a perspective view of the storage panel sitting in the storage base.
FIG. 2A is an alternative perspective view of the storage base.
FIG. 2B is a side view of the storage base.
FIG. 2C is a diagram that highlights the various features of the storage base.
FIG. 3A is a front view of an unoccupied storage panel.
FIG. 3B is a front prospective view of a fully occupied storage panel.
FIG. 3C is a diagram that highlights the various features of the storage panel.
FIG. 3D front view of an occupied storage panel featuring a holster.
FIG. 3E is a front view of a magazine storage cuff.
FIG. 3F is a perspective view of the magazine storage cuff rolled upon itself.
FIG. 4A is a front view of the exterior of the storage case.
FIG. 4B is a side view of the exterior of the storage case.
FIG. 4C is a top view of the interior of the storage case.
FIG. 4D is a tope view of the storage case.
FIG. 5 is a diagram of a larger gun storage panel.
FIG. 6A is a diagram of a larger gun storage panel with a different slot configuration.
FIG. 6B is a diagram of the exterior of a larger gun storage case.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates an example of a perspective view of the storage panel 200 sitting in the storage base 100 . As shown in FIG. 1 , the storage panel 200 may sit in grooves 110 of the storage base 100 . Further shown in FIG. 1 , two pistols may be strapped to the storage panel 200 via cinch straps 220 which fit through slots 210 cut in the panel 200 . The pistols may be further secured by moveable spacers 230 which may be positioned in the slots 210 .
FIG. 2A illustrates an alternative prospective view of the storage base 100 . As shown in FIG. 2A , the base 100 may include a series of parallel grooves 110 cut along the entire length of the top side of base 100 that may be spaced, at minimum, the width of a handgun apart. In the non-limiting example shown, the series of grooves 110 amounts to five grooves 110 in total cut into the base 100 .
FIG. 2B illustrates a side view of the storage base 100 . As shown in FIG. 2B , the grooves 110 may be cut to a depth of approximately one half the height of the storage base 100 . Also shown in FIG. 2B , rubber feet 120 may be attached to the bottom of the base 100 . The rubber feet 120 permit the base 100 to potentially be placed securely on a smooth surface such as a shelf in a gun locker.
FIG. 2C is a diagram which highlights the features of the storage base 100 . As shown in the diagram, the base may include grooves 110 cut into the top side of the base 100 and rubber feet 120 attached to the bottom of the base 100 .
FIG. 3A illustrates a front view of the storage panel 200 . As shown in FIG. 3A , a handle hole 240 may be cut approximately one inch from the end of the panel 200 . The handle hole 240 may be rectangular in shape with beveled corners and approximately two inches wide by five inches long. The handle hole 240 may be positioned towards the middle of the length of the panel 200 . Further shown in FIG. 3A , there are also slots 210 cut into the storage panel 200 . The slots 210 may come in two varieties, vertical slots 211 and horizontal slots 212 . The vertical slots 211 may be approximately three inches in length by one eight of an inch wide and positioned towards the middle of the length of the panel 200 similar to the hand hole 240 . There may be two sets vertical slots 211 equating to four individual vertical slots 211 in total, with space between the two slots 211 in each set to potentially accommodate a pistol handle being strapped between the two slots 211 . There may also be two sets of horizontal slots 212 amounting to four individual horizontal slots 212 . The horizontal slots 212 may be approximately nine inches wide by one eight of an inch in length. The sets of horizontal slots 212 may be positioned above and below the vertical slots 211 and potentially set wide enough apart to accommodate a pistol barrel being strapped between the two slots 212 in each set. The horizontal 212 and vertical 211 slots may be positioned on the panel 200 relative to each other, beginning about a half inch down from the hand hole 240 . The positioning of the slots 210 is done so that two pistols may be strapped onto the panel 200 at the same time forming a rough square. This may be accomplished by an approximately three inch gap between the two sets of vertical slots 211 , allowing two pistol handles to sit within the two sets of slots 211 , with one of the pistol barrels strapped in the horizontal slots 212 located above the vertical slots 211 and the other pistol barrel to be strapped in the horizontal slots 212 located below the vertical slots 211 . Still further shown in FIG. 3A , cinch straps 220 may fit through the slots 210 and spacers 230 may sit in the vertical slots 212 .
FIG. 3B illustrates a front prospective view of a fully occupied storage panel 200 . As shown in FIG. 3B , the handle hole 240 may accommodate the hand of an adult human. Further shown in FIG. 3B , the storage panel 200 may securely hold two pistols utilizing cinch straps 220 and spacers 230 . The cinch straps may be fed through the slots 210 and the spacers 230 may be positioned along the horizontal slots 212 . One spacer 230 may be positioned within the trigger guard of the pistol while the other spacer 230 may sit above the barrel. The cinch strap 220 may be adjustable via one or more hook and loop fastener, snap buttons, adjustable clasps, etc. It should also be noted the cinch straps 220 are show as rectangular straps of flexible material in this embodiment, but firearms may be attached to the panel 200 by any adjustable means of attachment of a firearm to the panel 200 which is not permanent including holsters (as shown in FIG. 3D , etc.).
FIG. 3C is a diagram that highlights the various features of the storage panel 200 . The relative size of the handle hole 240 and the two types of slots 210 : vertical 211 and horizontal 212 , are shown. Additionally shown in FIG. 3C is a breakdown of the potential components of the spacer 230 . The spacer 230 may consist of a screw 231 , hollow spacer 232 , and nut 233 . The screw 231 may fit through the slots 210 in the panel 200 . When placed into a slot 210 , the head of the screw 231 may rest against the back side of the panel 200 while the threaded portion of the screw 231 may extend from the front side of the panel 200 . The threaded portion of the screw 231 may fit within the cylindrical hollow spacer 232 with some of the threaded portion still being exposed. This exposed threaded portion of the screw 231 may fit into complimentary threads on the nut 233 , allowing the component parts of the spacer 230 to be tightened securely to the panel 200 .
FIG. 3D is a front view of an occupied storage panel 200 featuring a holster 290 . As shown in FIG. 3D , there are other embodiments of the storage panel 200 discussed in FIGS. 3A-3C . In this embodiment, firearms are secured to the panel 200 via a holster 290 . The holster 290 may be integral with the panel 200 , secured to the panel 200 via slots 210 (shown in FIGS. 3A-3C ) and the use of cinch straps 220 (also shown in FIGS. 3A-3C ), or secured to the panel 200 by another means which secures the holster in place for transport and storage. The holster 290 may feature a holster safety strap 291 which holds a firearm securely in the holster 290 . The panel 200 shown in FIG. 3D also features hook and loop fastener strips 280 integral with or secured upon the panel 200 at various points on the face of the panel 200 in order to enable a magazine storage cuff 250 (illustrated in FIGS. 3E-3F ) or other accessories to be affixed to the panel 200 .
FIG. 3E is a front view of a magazine storage cuff 250 . As shown in FIG. 3E , a magazine storage cuff 250 matches up to the length of the storage panel 200 featuring hook and loop fastener discussed in FIG. 3D . The equal lengths of the panel 200 and cuff 250 allow the hook and loop fastener strips 280 on the panel 200 to align with complementary placed hook and loop fastener strips 281 so that the strips 280 , 281 enable the cuff 250 to be affixed to the panel 200 (e.g., one of the strips 280 or 281 ifs the “hook” side of the hook and loop fastener while the other side has the fabric side which receives the hooks). The cuff 250 features a series of elastic bands 252 upon one of its faces which can each accommodate firearms magazines, accessories, or other equipment. Piping 254 encloses the perimeter of the cuff 250 holding the hook and loop fastener 281 , bands 252 , and cuff 250 securely together.
FIG. 3F is a perspective view of the magazine storage cuff 250 rolled upon itself. As shown in FIG. 3F , the magazine storage cuff 250 may be constructed of flexible materials (e.g., nylon) which enable it to be secured to the panel 200 (discussed in FIGS. 3D-3E ) and also rolled upon itself (partially or fully) for ease of transport and handling when not affixed to the panel 200 . One of the hook and loop fastener strips 281 of the cuff 250 may be used to secure the cuff 250 in its rolled state.
FIG. 4A is a front view of the exterior of the storage case 300 . As shown in FIG. 4A , the soft bodied case (or bag) 300 may include a carry handle 350 to allow for easier transportation of the case 300 . The exterior of the case 300 may also feature a number of pouches 360 for additional storage. The pouches 360 may be secured by a closure 361 (hook and loop fastener, snap buttons, etc.) and the face of one or more of the pouches 360 or bag 300 itself may feature a badge 362 used to brand the case 300 , identify its owner, etc. The interior of the case 300 may be accessible via a zip top lid 340 —opened and closed by one of more zippers 341 .
FIG. 4B is a side view of the exterior of the storage case 300 . As shown in FIG. 3B , each side of the exterior of the case 300 may feature a portion of a shoulder strap 330 attached to allow for easier transportation of the case. The shoulder strap 330 of this embodiment features a leather shoulder pad 33 for added comfort when carrying the case 300 . This view of the exterior of the case 300 also highlights the pouches 360 (which may be held closed by a secure closure 361 ; either hook and loop fastener, snap buttons, or any other closure securing functionality as shown in FIG. 4A ), and also demonstrates the potential positioning of the rigid feet 370 from a side view.
FIG. 4C is a top view of the interior of the storage case 300 . As shown in FIG. 4C , the interior of the storage case 300 may consist of panel compartments 310 and padded dividers 320 . The space between padded dividers 320 may create the compartments 310 , the dimensions of these compartments being adequate to accommodate one or more storage panel 200 each. Along with the padded dividers 320 , all other surfaces of the interior of the case 300 may be padded via peripheral padding 321 to protect and secure transported firearms.
FIG. 4D is a tope view of the storage case 300 . As shown in FIG. 4D , the case 300 is topped with a zippered lid 340 which spans the length and width of the case 300 . Pouches 360 adorn three sides of the case 300 , with one of the longer sides of the case 300 without any exterior pouches 360 to allow this side of the case 300 to be held comfortably against the human (or animal) body when carried. The carry handles 350 are shown positioned beneath the shoulder strap 330 and its shoulder pad 331 .
FIG. 5 is a diagram of a larger gun storage panel 500 . As shown in FIG. 5 , the larger gun storage panel 500 may be a scaled up version of the handgun panel 200 . The larger panel 500 may feature both vertical slots 211 and horizontal slots 212 similar to the slots 210 of the handgun panel 200 . The larger panel 500 may however feature more slots 210 than the handgun panel 200 , which may include six horizontal 212 and eleven vertical 211 slots. The slots 210 are positioned relative to each other like the handgun panel 200 to allow guns to be strapped to the panel 500 . The vertical slots 211 may be cut along the midline of the panel 500 , with the horizontal slots 212 positioned above and below the vertical slots 211 in sets of three. The top most slot 512 in the top set and bottom most slot 513 in the bottom set of horizontal slots 212 may be spaced apart from the other two horizontal slots 514 in each set with enough distance to allow the multitude of different barrels and/or stocks found on long guns to be securely strapped to the panel 500 in this space. The other two horizontal slots 514 in each set may be placed relative to the vertical slots 211 to allow handguns to be strapped to the panel 500 with the barrel of the pistol resting between the sets of horizontal slots 514 and the handle between the vertical slots 211 . Also shown in FIG. 5 , the larger panel 500 may have a series of handle holes 540 cut near the top of the panel to allow the panel 500 to be picked up with one hand or two.
FIG. 6A is a diagram of a larger gun storage panel 500 with a different slot 210 configuration. As shown in FIG. 6A , the larger gun storage panel 500 may feature an arrangement of slots 210 which can accommodate long guns with different types of stocks or grips. This may be achieved by using sets of long horizontal slots 212 , vertical slots 211 , and short horizontal slots 515 . The long horizontal slots 212 may be cut in sets of two and positioned above and below the midline of the panel 500 . The long slots 212 are cut relative to the vertical slots 211 and short horizontal slots 515 in a way that allows a long gun barrel to be strapped between the long slots 212 while the gun's grip or shoulder stock is secured by cinch straps fed through the vertical slots 211 and/or short horizontal slots 515 . The vertical slots 211 and short horizontal slots 515 may be cut in sets of two and positioned along the midline of the panel 500 . The vertical slots 211 and short horizontal slots 515 may be cut relative to each other to form a square, with a set of the short vertical slots 515 being two sides of the square and a set of vertical slots 211 forming the other two sides. One of these squares of slots (vertical slots 211 and short horizontal slots 515 ) may be placed towards each end of the length of the panel 500 along its midline allowing various types of long guns to be securely stored and carried. Also shown in FIG. 6A , the larger panel 500 may have a series of handle holes 540 cut near the top of the panel to allow the panel 500 to be picked up.
FIG. 6B is a diagram of a larger gun storage case 600 . As shown in FIG. 6B , a larger gun storage case 600 may be roughly the shape of a large rectangular food cooler. This large rectangular shape may allow the case 600 to store both handgun 200 and long gun 500 storage panels. On the outside of the case 600 , on each side, there may be a carry handle 610 to aid in transport of the case 600 . On the bottom of the case 600 , there may be rubberized feet 620 to ensure the case 600 can be securely positioned during transport and use. Also shown in FIG. 6B , the inside of the case 600 may be accessed via a zipper 341 which runs around the top of the case 600 securing the case lid 640 . Pouches 360 may also adorn the outside of the case 600 and be secured by any number of secure closures 361 (hook and loop fastener, snap buttons, etc.).
It should be noted that various changes and modifications to the presently preferred embodiments described herein will be apparent to those skilled in the art. Such changes and modifications may be made without departing from the spirit and scope of the present invention and without diminishing its attendant advantages. | A firearm storage apparatus comprising a base including a first groove, a first storage panel removeably supported within the first groove, the first storage panel including a plurality of slots that traverse a face of the first storage panel and a plurality of adjustable straps, each strap mated to the first storage panel through two of the slots and adjustable in position along the first storage panel and adjustable in degree of tightness to secure a firearm to the first storage panel. | 0 |
BACKGROUND OF THE INVENTION
Field of the Invention
[0001] The invention lies in the computer technology field. More specifically, the invention relates to a storage device for the computer industry.
[0002] The personal computer revolution of the early 1980's created a need for data storage devices with the ability to read/write and modify data as needed by the computer applications. Before the personal computer revolution, data was saved on magnetic ring units that occupied a large space and had a limited capacity and very low performance levels.
[0003] With the personal computer revolution, the market demanded a larger storage capacity and more compact sized storage device that could be connected to the computer. The first Personal Computer (PC) that was produced by IBM (International Business Machine) in the early 1980's supported a 5.25″ floppy disk with a limited storage capacity and very poor performance. At the time it was the height of technology.
[0004] With the release of the IBM XT, the first Hard File Device—a ST506 5.25″ 10 MB Disk—was introduced in the personal computer market. As software applications began to require more and more storage space and a faster data transfer rate between the computer and the storage device, the computer industry faced a challenge of supplying faster and higher capacity storage devices.
[0005] The computer industry has introduced various types of storage devices such as hard disks, tape drives, optical disks, CD ROMs, DVD players, removable media (floppy drives, Zip drive) with various types of interface formats (ST506, ESDI, IDE, EIDE, ATA, SATA, SCSI, SAS) with the goal of being faster, higher-capacity and more affordable to the user.
[0006] Over time, the computer industry settled on the two common mostly used interfaces: SCSI and ATA/ATAPI. The SCSI interface (Small Computer System Interface) has long been considered the highest performance and highest capacity drive interface. For this reason, SCSI disks are used for high performance systems such as servers and workstations. The ATA/ATAPI (Advance Technology Attachment Protocol Interface) interface is a less expensive alternative to the SCSI interface, with a lower performance levels adequate for the personal desktop computer market as well as other moderately sized computer systems (POS, medical equipment, web server, etc.). Over time, the ATA/ATAPI storage devices interface has improved to close the gap in performance and capacity with the SCSI interface storage devices.
[0007] The early SCSI devices were supported by 50 pin connectors and the ATA/ATAPI by 40 pin connectors. Both storage types are connected via a flat cable to the host computer system. This type of connection is known as parallel connection. The flat parallel cable connection limits the use of these storage devices to internal use due to the limited recommended cable lengths and the complexity of delivering several signals at once.
[0008] To overcome some of the problems caused by the flat cable, (noise, cable length, space, speed of data transfer, air flow limitation, etc.) the computer industry recently introduced the SATA (Serial Advanced Technology Attachment) and the SAS (Serial Attachment SCSI), two new interface formats that transfer data through serial connection but follow the same protocols required by ATA/ATAPI and SCSI interfaces respectively. The protocol compatibility is necessary to allow the existing operating systems and software applications to be compatible with the new storage devices without the need for any software modification. This compatibility allowed the industry to quickly and easily adapt to the new serial interface technologies.
[0009] The desired sharing of data and the increase of a local network at work place and homes started a new category of external devices called Network Attached Storage (NAS). A network-attached storage (NAS) device is dedicated to nothing more than file sharing. A NAS device does not need to be located within the server but can exist anywhere in a LAN.
[0010] It is a safe prediction that networks will always be short of storage capacity. As a clients' storage grow, so do the volumes of data they want to store locally and share on a central server. For a small or medium size business adding storage to a server to keep user happy is a tiresome and often-time consuming business. Far easier, is to buy a network attached storage (NAS) appliance that simply plugs into the network with a minimum setting. In fact this easy of use combined with the dropping cost of storage means that NAS has grown to become a very popular hardware category.
[0011] In today's market, one of the most widely used connections to a network is via the so-called RJ-45 connector. The protocol communication of the attached device can be any given protocol and it should not be used as a limitation to this invention.
[0012] In order to use an ATA/ATAPI/SCSI or any other storage device as a NAS device, a bridge between the storage device and the network port (RJ-45) is needed. The industry quickly filled this need by developing hardware to serve as the bridge to convert the storage devices signals interface to a RJ-45 connector with the desired protocol. There is a tremendous market for NAS devices that connect to the network in this fashion.
SUMMARY OF THE INVENTION
[0013] It is accordingly an object of the invention to provide a native storage device with a RJ-45 connector integrated into the storage device control unit to support a direct connection to a computers network without any limitation to any type of network protocol. This eliminates the need for a hardware bridge between the storage devices and any RJ-45 network port.
[0014] With the foregoing and other objects in view there is provided, in accordance with the invention, a computer storage device assembly, comprising:
[0015] a computer storage device;
[0016] a control unit connected to the computer storage device for reading data from the storage device; and
[0017] at least one native RJ-45 connector configured for receiving an RJ-45 connecting the control unit to a host computer or a computer network.
[0018] In accordance with an added feature of the invention, the storage device is a read and write capable device.
[0019] In accordance with a preferred feature of the invention, the storage device is a device with ATA/ATAPI/SCSI/SAS or any other protocol interface communication. That is, the storage device is a device with any protocol interface communication. The protocol type does not have any significant meaning within this invention and should not be understood as a limitation.
[0020] With the above and other objects in view there is also provided, in accordance with the invention, a computer hard disk drive assembly, consisting essentially of a hard disk, a control unit connected to the hard disk, a power connector, and at least one a RJ-45 female connector configured to receive a RJ-45 male connector for connection to a host computer and or a computer network. Preferably, the assembly is configured as a computer-internal disk drive and dimensioned for installation in any type or form of a drive bay.
[0021] In accordance with an alternative embodiment of the invention, there is provided an external hard drive assembly, consisting essentially of a computer storage device, a control unit connected to the storage device, a housing enclosing the storage device and the control unit, a power connector mounted to the housing, and at least one RJ-45 connector mounted to the control unit and configured to receive a RJ-45 male connector for connecting the control unit to a host computer and or computer network.
[0022] In accordance with a concomitant feature of the invention, the computer storage device is a hard disk drive device, a CD ROM, and/or a DVD.
BRIEF DESCRIPTION OF THE DRAWING
[0023] FIG. 1 shows a storage device.
[0024] FIG. 2 shows the storage device controller unit with electronics components assembled on a PCB.
[0025] FIG. 3 shows a parallel ATA/ATAPI (PATA) storage device.
[0026] FIG. 4 shows a serial ATA/ATAPI (SATA) storage device.
[0027] FIG. 5 shows a RJ-45 Modular Jack Female and Male.
[0028] FIG. 6 shows RJ-45 Modular Wiring Reference.
[0029] FIG. 7 shows an Ethernet bridge that connects any giving storage device interface signals to a RJ-45 connection signals and vice versa.
[0030] FIG. 8 shows a parallel ATA/ATAPI storage device connected via a RJ-45 connector mounted on a bridge to a computer network.
[0031] FIG. 9 shows the invention, a storage device integrated with a control unit that includes a RJ-45 connector connected to a computer network.
[0032] FIG. 10 shows a storage device enclosed in an external enclosure with a RJ-45 connector that connected to a computer network via the RJ-45 connector.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0033] Referring now to the figures of the drawing in detail, FIG. 1 shows a bare storage device 101 without any electronics attached to it. The storage device described in this figure can be a Heads Disk Assembly (HDA) or and type of removable storage device such as a CD-ROM, DVD, tape drive, etc. The figure shows an HDA device that includes magnetic platters, heads and a servo motor protected by a vacuum sealed package to avoid damage from dust and to achieve high speed rotation of the platters. The faster the rotation of the platters, the faster data can be transferred between the HDA, the control unit and the host computer.
[0034] FIG. 2 shows a PCB with electronics forming the Control Unit 102 that includes all components needed to control the storage device 101 for the purpose of transferring data in and out of the storage device 101 . The control unit 102 also includes a 40 pin (male) interface connector 103 (Parallel ATA/ATAPI) that is connected via a 40 pin cable 124 (shown at FIG. 8 ) to the host computer, and a power connector 105 for receiving the power needed to power the control unit 102 and the storage device 101 . The control unit 102 can be with any type of interface connection. FIG. 2 shows the 40 pin signal interface connection 103 without any intention of limitation on the storage device interface.
[0035] FIG. 3 shows a storage device 101 integrated with a control unit 102 forming a parallel ATA/ATAPI storage device 106 with a 40 pin signal interface connector 103 and the legacy power connector 105 .
[0036] FIG. 4 shows a storage device 101 integrated with a control unit 102 forming a serial ATA/ATAPI storage device 109 with a serial ATA interface connectors 107 , 108 that includes the data and power signals and the legacy power connector 105 . The reason for this serial ATA/ATAPI storage device 109 having both types of power connectors is for compatibility purposes only. Only one of the power connectors is actually required for operation at any given time.
[0037] FIG. 5 shows a RJ-45 Modular Jack Female 110 and RJ-45 Modular Jack Male 112 connected to a twisted-pair cable 111 .
[0038] FIG. 6 shows the Modular Wiring Reference as follow:
[0039] 1. 10BASE-T (802.3) 113
[0040] 2. 568B Wiring 114
[0041] 3. 568A Wiring 115
[0042] 4. MMJ Wiring 116
[0043] 5. Token Ring (802.5) 117
[0044] 6. TP-PMD (X3T9.5) 118
[0045] 7. USOC 3 Pair 119
[0046] 8. USOC 4 Pair 120
[0047] FIG. 7 shows an Ethernet bridge 121 that includes a PCB 130 which includes the electronics components, a RJ-45 female connector 122 a 40 pin flat cable 124 with a 40 pin (female) connector 123 .
[0048] FIG. 8 shows a complete assembly of a parallel ATA 106 and an Ethernet bridge 121 to form a storage device to be connected to a computer or computer network via a RJ-45 connector 122 . This Figure also shows a twisted-pair cable 111 that connects at one end to the RJ-45 connector 122 on the Ethernet bridge 121 and at the other end to the computer network 127 to allow data transfer between the parallel ATA Disk 106 and the network computer system.
[0049] FIG. 9 shows the invention that includes a storage device 101 with a control unit 102 that integrates a RJ-45 modular jack female connector 122 forming a native RJ-45 storage device 128 . The native RJ-45 storage device 128 will generate data in any protocol that use the RJ-45 connector as a mean to transmit/receive data via the twisted-pair and the RJ-45 connectors.
[0050] FIG. 10 shows an external storage device in an external enclosure 129 that contains the invention: a native storage device with RJ-45 connector 128 that is connected to the network computer 127 via a twisted-pair cable 111 .
[0051] I consider herein two distinct implementations of the novel configuration, namely:
The “bridge component” and the RJ-45 connectors may be integrated on the storage device control unit; or a new set of components can include, without a limitation, an ASIC (application specific IC) device to be configured and/or assembled to support the storage device heads, the motor and data transfer via a RJ-45 connector, thereby supporting any desired transfer protocol.
[0054] The term “native” as used herein should be understood to include these implementations.
[0055] Those of skill in the pertinent art will be familiar with the RJ-45 plug and socket cable specification and pin assignment. Two wiring standards are conventional for the RJ-45, namely, the T-568A and the T-568B designations. In terms of color, the RJ-45 uses four pairs, namely, orange, green, blue, and brown (one solid, one striped). In that regard, it will be understood that the above-noted pin assignment may be varied within the conceptual boundaries of the invention and that one or several of the pin assignments may be exchanged, replaced with a different standard, or omitted altogether. | A computer storage device has a RJ-45 female connector. In this RJ-45 physical storage device, the RJ-45 connector is integrated into the storage device control unit. This eliminates the need for a hardware bridge between the serial or parallel ATA/ATAPI/SCSI/SAS/Fiber Optic or any other storage device and a computer or computer network. | 6 |
CROSS-REFERENCES TO RELATED APPLICATION
This application claims priority to German patent application DE 10 2008 046 221.7 filed on Sep. 8, 2008, which is hereby incorporated by reference in its entirety.
TECHNICAL FIELD
The present invention relates to an exhaust-gas turbocharger for an internal combustion engine, in particular in a motor vehicle.
BACKGROUND
Document DE 10 2004 057138 A1 discloses such an exhaust-gas turbocharger of the generic type comprising an exhaust-gas side turbine wheel, an intake-side compressor wheel, and a shaft, the compressor wheel being positioned on the shaft and the turbine wheel being connected to the shaft by means of welding. A point of connection between the hub of the turbine wheel and the shaft is arranged in proximity to the bearing. Moreover, cooling ribs are described as machined on the hub, between which ribs a cooling fluid such as air, water or oil is conducted in order to eliminate heat in such a manner that less heat reaches the region of the shaft bearing. The two shaft seals mounted in the grooves of the hub prevent oil from leaking out of the bearing. The exhaust-gas side shaft seal can serve as a sacrificial sealing ring in this configuration. This design engineering is costly and also requires expensive materials.
SUMMARY
The present invention addresses the problem of providing for such an exhaust-gas turbocharger of an internal combustion engine an improved or at least a different embodiment that is characterised in particular in that reduced production and/or assembly costs result from design-engineering optimisation.
This problem is solved according to the invention by the subject matter of the dependent claim 1 . Advantageous embodiments are the subject matter of the dependent claims.
The invention is based on the general concept of replacing a sacrificial sealing ring, which is designated as such in the prior art and serves as a heat shield, with a step that is formed in the housing and in the hub, said step serving to assume the function of a heat shield instead of the sacrificial sealing ring. In dispensing with the sacrificial sealing ring, the manufacturing costs are reduced by the amount required for this sacrificial sealing ring. Since the sacrificial sealing ring furthermore is adversely affected by the effects of the from the exhaust gas and thus eventually wears down over time, which is not the case with heat shield configured as a step, the fail safety of the components in their entirety is improved by dispensing with individual components susceptible to failure.
Additional important features and advantages of the invention can be found in the dependent claims, in the drawings, and in the pertinent description of the figures with reference to the drawings.
It is understood that the features described above and those to be described in what follows can be used not only in the particular cited combination; but also in other combinations or independently without departing from the scope of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the invention are shown in the drawings and are described in more detail in the following description, the same reference numerals referring to components which are the same or functionally the same or similar.
It is schematically shown in
FIG. 1 an exhaust-gas side longitudinal section through an exhaust-gas turbocharger,
FIG. 2 an enlarged figure of the longitudinal section through an exhaust-gas turbocharger in the region of the hub with a hub step and a housing step,
FIG. 3 a representation as in FIG. 2 , however with a housing step inclined toward the hub step,
FIG. 4 the exhaust-gas turbocharger without oil-thrower groove and with a Scania step in the region of the hub,
FIG. 5 the exhaust-gas turbocharger without oil-thrower groove and without a Scania step in the region of the hub,
FIG. 6 the exhaust-gas turbocharger with an especially configured oil-thrower groove,
FIG. 7 the exhaust-gas turbocharger with a labyrinth seal arranged in the region of the hub.
DETAILED DESCRIPTION
Corresponding to FIG. 1 , an exhaust-gas turbocharger 1 for an internal combustion engine comprises an exhaust-gas side turbine wheel 2 , a shaft 3 that connects in a rotationally-fixed manner the turbine wheel 2 to a compressor wheel 27 , as well as a housing 4 . The shaft 3 is mounted in a bearing region 5 , the bearing comprising a bearing device 6 , 6 ′ in a bearing-housing section 7 and a bearing-shaft section 8 , a hub 9 of the shaft 3 between bearing region 5 of the shaft 3 and turbine wheel 2 , and a hub-housing section 10 surrounding the hub 9 as well as a lubrication supply device 11 for supplying the bearing region 5 of the shaft 3 with lubrication.
The turbine wheel 2 is connected with the hub 9 of the shaft 3 to the shaft 3 by means of a connecting device 12 . A sealing ring 14 is positioned in a groove 13 of the hub 9 so as to prevent a flowing of the lubricant for lubricating the bearing device 6 , 6 ′ over and beyond the sealing ring 14 in the direction of the turbine wheel 2 . If the lubricant, for example oil, comes into contact with hot exhaust gas, it can coke, and owing to the coke products, the lubrication of the shaft 3 can no longer be ensured.
An enlarged partial section 15 of FIG. 1 is shown in FIG. 2 . The enlargement makes it easier to recognise the sealing ring 14 in the groove 13 of the hub 9 . Owing to the hub-housing section 10 that closely abuts the sealing ring 14 , the bearing-region side, oil-conducting intermediate chamber 16 arranged between hub 9 and hub-housing section 10 is sealed with respect to the turbine-wheel side, exhaust-gas conducting intermediate chamber 17 . After the sealing ring 14 toward the direction of the bearing region 5 , an annular groove 18 , in particular represented here as a Scania step 19 , is formed in the hub-housing section 10 . As may be seen in FIG. 2 , the Scania step 19 is configured with a first surface 19 a that extends away from the hub 9 , a second surface 19 b that intersects the first surface 19 a and extends toward the direction of the exhaust-gas side, and a third surface 19 c that intersects with the second surface 19 b . The third surface 19 c intersects with the oil conducting intermediate chamber 16 . Since the sealing ring 14 comes into contact with the hot exhaust gas of the internal combustion engine on the side of the exhaust-gas conducting intermediate chamber 17 , this sealing ring 14 must be protected from too great an impact of the heat with a heat-protection shield. To this end, a radial hub step 20 is configured in the hub 9 and a radial housing step 21 , which communicates with the radial hub step 20 , is configured in the hub-housing section 10 . The radial hub step 20 , in co-operation with the radial housing step 21 , forms an effective heat-protection shield for the sealing ring 14 from the hot exhaust gas.
During the use of the exhaust-gas turbocharger 1 , the hot exhaust gases of the internal combustion engine arrive in the exhaust-gas conducting intermediate chamber 17 between the hub 9 and the hub-housing section 10 . There, they bounce with high speed against the housing step 21 and are thrown back against the hub step 20 positioned opposite therefrom. By means of guiding the exhaust gas in the exhaust-gas conducting intermediate chamber 17 , turbulence arise, the flow resistance is increased, and the speed with which the exhaust gas strike the sealing ring 14 is considerably reduced. The hub step 20 and the housing step 21 thus act in the style of a labyrinth seal and the sealing ring 14 is thus better protected from the direct effects of the heat of the exhaust gas. It is self-evident that the exhaust-gas conducting intermediate chamber 17 , together with the housing step 21 and the hub step 20 , is optimised with regard to the above-mentioned effect as a heat shield.
As FIG. 1 shows, the shaft 3 between the bearing-shaft section 8 and the groove 13 can be configured with an oil-thrower groove 22 . This oil-thrower groove 22 has the advantage that oil that penetrates from the lubrication supply device 11 in the direction of the sealing ring 14 and that migrates from the oil-thrower groove 22 upon rotation of the shaft 3 is hurled away from the oil-thrower groove 22 in such a manner that a penetration of the oil into the oil-conducting intermediate chamber 16 is at least reduced (cf. FIG. 2 ).
It can be seen from FIG. 2 that a first intermediate chamber 23 is arranged between the hub step 20 and the housing section 21 . An axial length of the intermediate chamber 23 between the hub step 20 and the housing section 21 can be from 0.2 mm to 0.4 mm. Moreover, a second intermediate chamber 24 can be provided between the hub step 20 and hub-housing section 10 , the radial length of said second intermediate chamber between the hub step 20 and the hub-housing section 10 being between 0.2 mm and 0.4 mm. The sealing ring 14 can have an external diameter of 10 mm to 16 mm.
According to FIG. 3 , it is however also possible that the plane of the of the ring surface 25 oriented toward the turbine wheel 2 is not arranged transversely to the shaft 3 , as is shown in FIG. 2 , but rather that the ring surface 25 runs inclined in the direction of the hub step 20 . If the ring surface 25 runs inclined, it has the shape of frustoconical casing. In this manner, an angle between the ring surface 25 and a casing surface 26 , oriented in the direction of the sealing ring 14 , of the housing step 21 can be up to 180°
A preferred embodiment according to FIG. 4 is equipped with an annular groove 18 in the shape of Scania step 19 ; however, there is not an oil throwing groove 22 between the groove 14 and the bearing-shaft section 8 .
Furthermore, an embodiment shown in FIG. 5 is conceivable that may not have a sealing ring 14 arranged in the groove 13 , but is equipped with neither an oil throwing groove 22 nor with an annular groove 18 configured as a Scania step 19 .
A particular embodiment with a specially configured oil throwing groove 22 , as is shown in FIG. 6 , has at least one annular bead 27 , 27 ′ in the region of the oil throwing groove 22 and configured on the shaft 3 . Preferably the annular bead 27 ′ arranged in the region of the sealing ring 14 borders at least in part an annular gap 28 arranged between hub 9 and hub-housing section 10 and furthermore positioned between the sealing ring 14 and the oil throwing groove 22 . In the region of the annular gap 28 , the hub 9 can be distanced from the hub-housing section 10 by approximately 0.2 mm to 0.4 mm owing to the annular gap 28 .
In a further-developed embodiment, as is shown in FIG. 7 , the hub step 20 and the housing step 21 can be configured in the shape of a labyrinth seal 29 . This can, for example, be achieved by means of concertina-like run of the gap between the hub-housing section 10 and the hub 9 , as shown. | An exhaust-gas turbocharger for an internal combustion engine is described herein, in particular for a motor vehicle. An exhaust-gas side sacrificial sealing ring that serves as a heat shield is replaced by a step formed in a housing and in a hub, the step serving to assume the function of a heat shield instead of the sacrificial sealing ring. This design feature reduces production costs in connection with the outlay for the sacrificial sealing ring. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a sewing device, and more particularly to a sewing device for producing piped openings such as pocket slashes, with or without a pocket flap.
2. Description of Related Art
A sewing device for producing piped openings is disclosed in Federal Republic of Germany No. OS 22 40 617. This device includes horizontally displaceable cutting blocks having angle cutting knives which are movable vertically upward by pressing means to produce gusset cuts. These cutting blocks are mounted for lateral displacement on parallel guide rails which are fixed on a frame. Each cutting block has an adjustable stop which acts as adjustment means. This sewing device, furthermore, has two driving blocks, also horizontally movable, each of which has a driver for moving intermittently against said adjustable stop.
Also known to the art are devices for folding the piping strip, and sewing material transport devices for transporting material between a delivery point, a sewing point, and a cutting point.
By using such devices, precise agreement between the spacing of the angle cutting knives and the length of the flap, in a piped pocket slash having such a flap, is made possible.
However, in actual sewing, tolerances occur in situations such as when the material being sewn has relatively little stability of shape. These tolerances are frequently compensated for by changing the preestablished values which constitute the basic position of the automatic pocket-slash sewing machine; for instance, the points of initial insertion of the angle cutting knives, and possibly the points of the start and/or the end of the seam, according to empirically determined correction values. These readjustments, which are made, for instance, by shifting the aforementioned stops against the cutting blocks, must be manually performed by specially trained persons, and frequently in places with poor accessibility. Another disadvantage of the prior sewing devices is that no guidance aids are associated with the adjustment means for directly and precisely reading the amount of the shift.
Accordingly, a principal object of the invention is to create a sewing device in which changes may be made very simply in the pre-established values which correspond to the basic position of the automatic pocket-slash sewing machine, for changing the points of insertion of the angle cutting knives as well as the center knife, as well as the points of commencement of both seams, by inputting length-related correction values into a control unit which is provided conveniently within the reach of the operator and within his or her field of view.
With the sewing device of the invention it is now possible, starting from the basic operating position of the automatic pocket-slash sewing machine, to move the points of attack of the parallel seams, the center knive, and the angle cutting knives, individually or jointly, forward or backward over a defined path.
A further object is to provide a simplified mechanical arrangement for the device. The sewing device described above is a very suitable embodiment, in which a common drive is provided for the two-needle sewing machine, the sewing-material transport device, and the cutting device. In an alternate preferred embodiment of the invention, the two-needle sewing machine is driven by a first electric motor, and the sewing-material transport device and the cutting device are driven by at least one additional electric motor, which simplifies the mechanism substantially.
According to preferred aspects of the invention, a sewing device for producing piped openings in sewing material comprises motor means; a two-needle sewing machine having a vertically moveable center knife for cutting an opening to be piped; a cutting device including two vertically moveable angled cutting knives for performing gusset cuts; and a material transport device for receiving material to be sewn and transporting it between the sewing machine and the cutting device. The cutting device, the transport device, and the sewing machine are driven by the motor means. Also provided are control means for controlling the above elements to obtain selected interrelated movements thereof. The control means comprises at least one signal generator for generating movement signals that represent movements of the cutting device and the transport device; and a control unit including input means, a microprocessor and a ROM. The ROM stores data that represent a plurality of predetermined movements that may be performed by the various controlled elements; the input means are for receiving input data indicative of the selected movements to be performed; and the microprocessor is for controlling all the controlled elements to produce piped openings in the sewing material.
Advantageously, the input means comprises a plurality of switches. The switches are for selecting aspects of seams to be sewn by the needles, cutting to be performed by the center knive and gusset cuts to be made by the cutting device. Such data include the length of the seams and the cuts and the locations of the gusset cuts.
In one advantageous embodiment, the transport device and the cutting device are interconnected by gearing means for being commonly driven. The above-mentioned signal generator may be coupled to the gearing means for sensing movement thereof to thereby sense movement of the cutting device and the transport device. The motor means may advantageously comprise one motor which is coupled to the gearing means of the cutting device and the transport device, and also coupled to the sewing machine, for commonly driving the same. Alternatively, the motor means may comprise a first motor drivingly coupled to the sewing machine, and a second motor drivingly coupled to at least one of the cutting device and the transport device. These motors are preferably DC motors or stepping motors.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects, features, and advantages of the invention will be understood from the following description of preferred embodiments thereof, with reference to the accompanying drawings, in which:
FIG. 1 is a partially exploded perspective view of a preferred embodiment of a sewing device according to the invention;
FIG. 2 is a front view of a control unit for the device of FIG. 1;
FIG. 3 is a block diagram of a control unit for a sewing device which is particularly suitable for the production of pocket slashes without a flap;
FIG. 4 is a block diagram of a control unit for a sewing device with one common drive motor which is particularly suitable for the production of pocket slashes with a flap;
FIG. 5 is a block diagram of a control unit for an alternate preferred embodiment of the invention, particularly suitable for the production of pocket slashes with a flap, in which the sewing device has two drive motors;
FIG. 6 is a diagrammatic view of a pocket slash;
FIG. 7 is a diagrammatic view of part of a pocket slash in which the points of attack of the angle cutting knife and the center knife have been moved back relative to the start of the seam;
FIG. 8 is a diagrammatic view of a pocket slash with a flap, in which the points of attack of both sewing needles, of the center knife, and of the angle cutting knives have been shifted forward slightly; and
FIG. 9 is a partially exploded perspective view of an alternate preferred embodiment of a sewing device according to the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The sewing device of the invention may be incorporated in an automatic pocket-slash sewing machine such as that described in Federal Republic of German No. OS 22 40 617, the disclosures of which are incorporated herein by reference. Referring to FIG. 1, a sewing device includes a two-needle sewing machine 3, having a vertically cutting center knife 14 provided between the sewing needles 13, which produces a slit 19 parallel to a seam or seams for a pocket-slash opening. The two-needle sewing machine 3 is fastened to an upper tabletop on a frame, not shown in FIG. 1, and is driven by an electric motor 1 which is arranged below the tabletop. A needle positioning drive includes a drive shaft 21, mounted below the tabletop and within the frame, and driven by the motor 1 via a V-belt 20. From this drive shaft, a main shaft 2 of the two-needle sewing machine 3 is driven via a clutch 22 and another V-belt 23.
The drive shaft 21 extends further to a step-down gearing 24. A toothed-belt pulley 26 is rigidly connected to the output shaft 25 of the step-down gearing 24. A toothed belt 27 drives a shaft 28 which is mounted in fixed position on the frame and is arranged above the tabletop. Toothed-belt pulleys 29 and 30 are firmly mounted on the shaft 28. An incremental rotation sensor 6 is also firmly mounted on the shaft 28. The sensor 6 generates pulses which can be read by a control unit 10 mounted on the tabletop, the pulses corresponding to the lateral displacement movement of a horizontally movable sewing-material transport device 4 and the horizontal path of displacement of a movable angle cutting knive 15. The cutting knife 15 is part of a cutting device 5, for the production of the two gusset cuts 31 (see FIG. 6) of the pocket-slash opening.
Another toothed-belt pulley 32 is rotatably secured to the frame above the tabletop. A toothed belt 33 wraps around the toothed-belt pulleys 30, 32. The sewing-material transport device 4 includes two sewing-material clips 34 to which a pneumatically or electromagnetically actuatable clamp 35 is firmly connected. Upon pneumatic or electromagnetic actuation, the clamp 35 is closed on the belt 33 to effect the horizontal displacement of the sewing-material transport device 4.
A suitable cutting device 5 is known from Federal Republic of Germany No. OS 34 04 758, which corresponds to U.S. patent application Ser. No. 699,027, filed Feb. 7, 1985, now U.S. Pat. No. 4,589,358, the disclosures of which are incorporated herein by reference. It includes two angle cutting knives 15, 36 which are arranged below the tabletop and are intermittently movable upward in a vertical direction. The angle cutting knive 36 is mounted in a stationary cutting block 38 while the angle cutting knife 15 is received by a cutting block 37 which is displaceable in a horizontal direction. The displacement of the cutting block 37, which is in a direction opposite to the displacement of the sewing-material transport device 4, is produced by means of a clamp 39 which can be actuated pneumatically or electromagnetically and is firmly attached to the cutting block 37. Upon such actuation, the toothed belt 40 is clamped between the two clamping jaws of the clamp 39. As shown in FIG. 1, the toothed belt 40 wraps around a toothed-belt pulley 41 which is secured to the output shaft 25, and another toothed-belt pulley 42 which is rotatably mounted on the frame below the tabletop.
In FIG. 1 it is seen that the sewing and cutting tools of the two-needle sewing machine 3, as well as the sewing-material transport device 4 and the angle cutting knife 15 of the cutting device 5, have completely synchronous programs of movement after the necessary coupling or clamping steps have occurred. As will be further discussed below, such synchronous operation may also be obtained in a device employing two separate drives, as shown in FIGS. 5 and 9, by regulating the relative speeds of the electric motors 1 and 46.
An important component of the sewing device is a control unit 10, which is fastened on the tabletop within easy reach of the operator and in his or her field of view. A front panel 44 of the control unit 10 is shown in FIG. 2. The panel comprises input elements 9 including several multi-digit preselector switches 43 for setting preselected seam lengths L1, L2 and L3. By means of further multi-digit preselector switches 16, numbers from 0 to 9 may be entered to set the points of attack of the sewing needles 13, the center knife 14 and the angle cutting knives 15, 36 at the start and end of a pocket slash; for example:
1. The preselector switch designated A controls the first penetration of the sewing needles 13 at the start of the seam.
2. The preselector switch designated D controls the last penetration of the sewing needles 13 at the end of the seam.
3. The preselector switch designated B controls the first cut of the center knife 14 in the vicinity of the start of the seam.
4. The preselector switch designated E controls the last cut of the center knife 14 in the vicinity of the end of the seam.
5. The preselector switch designated C controls the position of the gusset cut 31 produced by the angle cutting knife 36 in the vicinity of the start of the seam.
6. The preselector switch designated F controls the position of the gusset cut 31 produced by the angle cutting knife 15 in the vicinity of the end of the seam.
Referring to FIG. 3, control unit 10 includes a microprocessor and a read-only memory (ROM) 8, for example an EPROM or PROM. Machine-related geometrical data are placed in the form of binary coded numbers in the read-only memory 8. The machine-related geometrical data are understood to include:
1. Length measurements, with respect to the point of penetration of the sewing needles 13, which define the arrangement in space of the feed station located in front of the point of sewing, in the vicinity of which--customarily within 180 mm--the pocket slash to be sewn can be placed. In the case of pocket slashes without a flap, this region may be defined by two marker lights arranged in front of the place of sewing. In the case of pocket slashes with a flap, this region may be defined by mechanical stops, one of which serves as a stop point for the front edge of the flap and the other as a stop point for the rear edge of the flap.
2. Length measurements, with respect to the point of penetration of the sewing needles 13, defining the arrangement in space of the center knife 14.
3. Length measurements, with respect to the point of penetration of the sewing needles 13, defining the arrangement in space of the angle cutting knives 15 and 36.
Referring to FIG. 4, for sewing pocket slashes with a flap, a photoelectric cell 11 is provided a given distance in front of the sewing needles 13. The front and rear edges of the flap are scanned with the cell 11, and then the length of the pocket-slash seam to be sewn is derived precisely from the measured length of the flap. The scanning signals from the photoelectric cell 11 are fed, in accordance with FIG. 4, to the microprocessor 7.
As already mentioned, an incremental pulse generator 6 supplies the microprocessor 7 with pulses which correspnd to the displacement movements (travel paths) of the sewing-material transport device 4 and of the angle cutting knife 15. It performs this function both in sewing pocket slashes provided with a flap and pocket slashes without a flap. By means of the pulses from the pulse generator 6, the travel paths of the sewing-material transport device 4 and of the movable angle cutting knife 15 are precisely monitored. In such an arrangement, monitoring may be performed with high precision, in that the pulse generator 6 may supply, for instance, three pulses for a travel path of 1 mm.
Referring to FIGS. 3-4, the sewing device also includes a plurality of output elements 12, which include the electric motor 1, solenoid valves 17 and electromagnetic clutches 18. The closing and opening of the clamps 35 and 39 is effected by the solenoid valves 17. The electromagnetic clutches 18 actuate the clutch 22, which is provided on the drive shaft 21 and effects the turning on of the two-needle sewing machine. They furthermore actuate a clutching arrangement, preferably at least two clutches, provided in the step-down gearing 24 for selecting different speeds of advance.
FIGS. 5 and 9 illustrate an alternate preferred embodiment of the invention, including at least one additional electric motor 46, which may be a DC motor or a stepping motor. As can be noted from FIG. 9, the electric motor 46 drives the sewing-material transport device 4 and the cutting device 5. In this embodiment, the step-down gearing 24, the electromagnetic clutches contained therein, the V-belt 20, the countershaft 21 and the clutch 22 can be dispensed with. Thus a substantially simplified mechanism is achieved.
The manner of operation of the sewing device, which is suitable for producing pocket slashes, with or without a flap, will now be described with reference to FIGS. 6-8.
If all of the preselector switches 16 designated A-F in FIG. 2 have been set to the number 5, an opening is produced whose points A to F assume the positions shown in FIG. 6. A pocket slash developed in this manner corresponds to the basic position of the automatic pocket-slash sewing machine. However, deviations may readily be made from this normal form of the pocket slash, by means of the invention.
Thus, upon the sewing of pocket slashes without a flap, in loosely woven or loosely knitted sewing material, it is advisable to shift the gusset cut 31 produced by the angle cutting knives 15, 36 by a certain distance, i.e. the point C is shifted to behind the point A (See FIG. 7), and the point F is shifted to in front of the point D. (The term "front" is employed herein to mean the direction toward the start of the seam, i.e. leftward in FIGS. 6-8.) Starting from the normal case shown in FIG. 6, the points C and F are thus brought closer together. In this way, the corners of the pocket-slash opening are prevented from tearing and thus unraveling upon the turning of the completed pocket slash. Tearing, which occurs less readily in the case of firmly-woven sewing material, is typical in the case of loosely woven or knitted sewing material.
The moving back of the point C and the moving forward of the point F are achieved by a very simple operation in which the operator sets the number 6 on the preselector switch 16 designated C and the number 4 on the preselector switch designated F.
In principle, the rule applies that if the number set is greater than 5 the function in question will be started later. If the number set is less than 5 then the function in question will be started earlier. If the extent of the backward movement, for instance of the point C, is to be even greater, then a number larger than 6, up to a maximum of 9, is to be set. On the other hand, lower settings than 5 are used when the extent of the forward displacement, for instance of the point F, is to be made greater.
Corresponding to the displacement of the points C and F, the points B and E (see FIG. 6) for the insertion and withdrawal of the center knife 14 should also be shifted by corresponding adjustments of the preselector switches 16 marked B and E.
Before the sewing of a pocket slash with a flap, it may be advisable, starting from the basic position, to move the point A slightly forward and the point D slightly backward, as seen in FIG. 8. In this way the distance between the points A and D is increased. This shifting of the two points should be effected if, in sewing a pocket slash with a flap, bulges appear in the flap 47 after turning. Such bulges may occur primarily in the region 48 of the front edge of the flap and in the region 49 of the rear edge of the flap. In order to avoid the bulges, the operator should set a value of 4 on the preselector switch 16 designated A and a value of 6 on the preselector switch designated D. The points C and F as well as B and E should also be shifted analogously corresponding to the displacement of the points A and D.
Thus, by these embodiments of the invention it is possible to move the points of commencement of the parallel seams, the center knife, and the angle cutting knives, individually or jointly, forward or backward from the basic operating position of the machine, by a simple adjustment of a readily accessible control unit.
Although illustrative embodiments of the invention have been described in detail herein, it is to be understood that the invention is not limited to such embodiments. Rather, variations and modifications of the embodiments may occur to those skilled in the art within the scope of the invention, as limited only by the claims. | A sewing device for producing piped openings such as pocket slashes, with or without a pocket flap. The sewing device includes a two-needle sewing machine having a vertically moveable center knife for cutting an opening to be piped, a cutting device including two vertically moveable angle cutting knives for performing gusset cuts, and a material transport device for receiving material to be sewn and transporting such material between the sewing machine and the cutting device. Also provided is a control system including a microprocessor for adjusting the operating positions of the various components to move the points of commencement of the parallel seams, the center knife, and the angle cutting knives, individually or jointly, forward or backward, to conveniently and selectively change these sewing parameters in response to the specific workpiece. In one embodiment, a common drive motor is provided for the two-needle sewing machine, the transport device, and the cutting device. Alternatively, the mechanism is substantially simplified in a sewing device wherein the two-needle sewing machine is driven by a first electric motor, and the transport device and the cutting device are driven by at least one additional electric motor. | 3 |
CROSS REFERENCE TO RELATED APPLICATIONS
This is a continuation of application Ser. No. 12/431,972, filed on Apr. 29, 2009, the disclosure of which is incorporated by reference in its entirety.
BACKGROUND
The disclosed embodiments relate to a method for controlling operation of a pump unit. The present invention further relates to a pump unit, and to a fluid separation system for separating compounds of a sample fluid in a mobile phase.
U.S. patent application 2006/0219618 A1 relates to solvent supply with a correction of piston movement.
International patent application WO 2006017121 describes a feedback control loop for a high pressure pump that modifies the accumulator velocity and pressure during solvent transfer. The accumulator velocity is adjusted to maintain the system pressure equal to the expected pressure to thereby eliminate the effect of the flow deficit created by a thermal effect.
SUMMARY
It is an object of the invention to provide an improved operation of a pump unit comprising a primary piston pump fluidically connected with a secondary piston pump.
According to embodiments of the present invention, a method for controlling operation of a pump unit is proposed, the pump unit comprising a primary piston pump having a primary piston and a secondary piston pump having a secondary piston. The primary piston pump is fluidically connected with the secondary piston pump. The primary piston pump comprises an inlet valve and an outlet valve, and the pump unit operates periodically according to a pump cycle comprising a deliver-and-fill phase for delivering fluid from the primary piston pump to the secondary piston pump and to a fluidic system located downstream of the pump unit. The method comprises determining a fluid pressure of fluid dispensed by the pump unit, and—during a first time interval of the pump cycle—performing a closed loop control of a position of the primary piston in dependence on the fluid pressure of the fluid dispensed by the pump unit, while a predefined position-versus-time curve is performed by the secondary piston. The first time interval corresponds to the deliver-and-fill phase.
During the first time interval, the closed loop control is applied to the primary piston pump. Accordingly, during the first time interval, corrective movements are superimposed onto the primary piston's movement.
Superposing corrective movements onto the primary piston's movement leads to a number of advantages. First of all, by applying the closed loop control to the primary piston pump, various errors are compensated for at the location where they occur, i.e. at the primary piston pump.
For example, a compression stroke may be performed by the primary piston, According to embodiments of the present invention, in case the compression stroke is too short, an additional downward movement is applied to the primary piston. By applying the additional downward movement to the primary piston, the error is counteracted at the location where it has occurred, i.e. at the primary piston pump. As a result, a continuous prolonged downward movement of the primary piston is obtained.
Also with regard to thermal fluctuations that may lead to volumetric errors, it is proposed to counteract these thermal effects at the location where they occur, i.e. at the primary piston pump. Thus, undesired effects related to temperature fluctuations are kept as small as possible. For this reason, during the first time interval, the closed loop control is applied to the primary piston pump.
Furthermore, when imposing a corrective movement onto the primary piston pump, any discontinuity of flow related to this correction is dampened when passing the fluid from the primary piston pump to the pump system's outlet. The primary piston pump is located upstream of the secondary piston pump, and therefore, the fluid has to pass the additional flow path between the primary piston pump and the secondary piston pump before reaching the pump system's outlet. This additional hydraulic capacitance is sufficiently large to dampen any discontinuity of flow and pressure that occurs when applying a correction onto the primary piston pump's piston movement.
As another advantage, when the closed loop control is applied to the primary piston pump during the first time interval, and not to the secondary piston pump, it is much easier to maintain synchronization between the piston movement of the primary piston pump and the piston movement of the secondary piston pump. The secondary piston pump is permanently exposed to system pressure, and therefore, any correction applied to the secondary piston's movement may affect the pump cycle of the secondary piston pump. In contrast, the primary piston pump is alternatingly coupled to and decoupled from system pressure. In case a corrective movement is superimposed onto the primary piston's movement when the primary piston pump is coupled to system pressure, the corrective movement may also effect the period of time needed for a respective phase of the primary piston pump's operation. However, during the periods of time when the primary piston pump is decoupled from system pressure, the effects imposed onto the timing of the primary piston pump's operation may be compensated for. For this reason, it is possible to maintain a constant pump cycle even in case corrective movements are applied to the primary piston's movement. In this regard, the corrections applied to the piston movement of the primary piston pump do not disturb the synchronization between the primary piston pump and the secondary piston pump. A correction applied to the secondary piston pump would be much more critical in terms of disturbing the synchronization between the two piston pumps.
During the first time interval, the closed loop control of the position of the primary piston is performed while a predefined position-versus-time curve is performed by the secondary piston. Hence, during the first time interval, the closed loop control is solely applied to the primary piston pump.
According to a preferred embodiment, the primary piston pump is configured for delivering, during the first time interval, fluid to the secondary piston pump and to a fluidic system located downstream of the pump unit.
According to a preferred embodiment, the first time interval is said deliver-and-fill phase. As long as the primary piston pump delivers fluid to the secondary piston pump and to the fluidic system located downstream of the pump unit, the corrective movements are superimposed onto the primary piston's movement. Thus, any pressure discontinuities are counteracted at the location where they occur.
According to a preferred embodiment, performing the closed loop control of the primary piston's position comprises determining a first position correction signal for imposing, during the first time interval, a corrective movement onto a regular piston movement of the primary piston.
According to a preferred embodiment, performing the closed loop control of the primary piston's position comprises determining a variance between the fluid pressure of the fluid dispensed by the pump unit and a predetermined target pressure, and deriving, from said variance, a first position correction signal for imposing, during the first time interval, a corrective movement onto a regular piston movement of the primary piston. As an outcome of the closed loop control, the fluid pressure of the fluid dispensed by the pump unit is driven towards the predetermined target pressure.
According to a preferred embodiment, performing the closed loop control of the primary piston's position comprises determining a first position correction signal for imposing, during the first time interval, a corrective movement onto a regular piston movement of the primary piston, and applying, during the first time interval, the first position correction signal to the primary piston pump.
According to a preferred embodiment, during the first time interval, in case the fluid pressure of the fluid dispensed by the pump unit is too small, movement of the primary piston is corrected by superimposing a forward movement onto the primary piston, and in case the fluid pressure of the fluid dispensed by the pump unit is too large, movement of the primary piston is corrected by superimposing a backward movement onto the primary piston.
According to a preferred embodiment, the pump cycle further comprises at least one of: an intake phase for drawing fluid into the primary piston pump; an inlet valve settle phase for closing the inlet valve of the primary piston pump; a compression phase for bringing a fluid contained in the primary piston pump to system pressure; an outlet valve settle phase for closing the outlet valve of the primary piston pump; a decompression phase for bringing a fluid remaining in the primary piston pump from system pressure to an initial pressure.
According to a preferred embodiment, during at least one second time interval of the pump cycle, which is different from the first time interval, a closed loop control of the secondary piston's position is performed in dependence on the fluid pressure of the fluid dispensed by the pump unit.
According to a preferred embodiment, during the at least one second time interval, the closed loop control of the position of the secondary piston is performed while a predefined position-versus-time curve is performed by the primary piston. Preferably, the at least one second time interval does not overlap substantially with the first time interval.
According to a preferred embodiment, the at least one second time interval does not substantially overlap with the deliver-and-fill phase. During the deliver-and-fill phase, the primary piston pump is responsible for supplying fluid at system pressure, and therefore, the closed loop control may e.g. be applied to the primary piston pump. In contrast, during the at least one second time interval, the primary piston pump's outlet valve may e.g. be closed, and the closed loop control may be applied to the secondary piston pump.
According to a preferred embodiment, the at least one second time interval includes at least one of: an intake phase for drawing fluid into the primary piston pump, an inlet valve settle phase for closing the inlet valve of the primary piston pump, a compression phase for bringing a fluid contained in the primary piston pump to system pressure, an outlet valve settle phase for closing the outlet valve of the primary piston pump, a decompression phase for bringing a fluid remaining in the primary piston pump from system pressure to an initial pressure. Any pressure discontinuity that occurs during any one of the above-mentioned phases may be counteracted by superposing a corresponding corrective movement onto the secondary piston's movement.
According to a preferred embodiment, during a subinterval of the pump cycle, said closed loop control is alternatingly applied to the primary piston pump and to the secondary piston pump. According to this embodiment, during the subinterval of the pump cycle, the closed loop control is switched between the primary and the secondary piston pump, in order to yield the best possible results with regard to stabilizing fluid pressure.
According to a preferred embodiment, during a subinterval of the pump cycle, said closed loop control is alternatingly applied to the primary piston pump and to the secondary piston pump, and during a remaining part of the pump cycle, said closed loop control is inactive. For example, during the secondary piston pump's delivery phase, it may not be required to perform any closed loop control of the piston movements.
According to a preferred embodiment, during the pump cycle, said closed loop control is alternatingly applied to the primary piston pump and to the secondary piston pump.
According to a preferred embodiment, at the beginning of the first time interval, the closed loop control is switched from controlling the secondary piston pump to controlling the primary piston pump. According to a further preferred embodiment, at the end of the first time interval, the closed loop control is switched from controlling the primary piston pump to controlling the secondary piston pump.
According to a preferred embodiment, during the first time interval, said closed loop control of the position of the primary piston is performed in a way that the fluid pressure of the fluid dispensed by the pump unit continues to follow its former trend. Thus, the fluid pressure of the fluid dispensed by the pump unit is stabilized.
According to a preferred embodiment, during the first time interval, said closed loop control of the primary piston's position is performed in a way that the fluid pressure of the fluid dispensed by the pump unit is driven towards or substantially kept at a predetermined target pressure.
Preferably, the target pressure is determined by performing an extrapolation of former values of the fluid pressure of the fluid dispensed by the pump unit.
Further preferably, the target pressure is determined by performing an extrapolation of former values of the fluid pressure of the fluid dispensed by the pump unit in a way that the fluid pressure of the fluid dispensed by the pump unit shows a continuous progression.
According to a preferred embodiment, the method further comprises deriving, from the closed loop control of the primary piston's position performed during the first time interval, at least one correction to be applied to a regular piston movement of at least one of the primary piston pump and the secondary piston pump. The corrections imposed onto the piston movements contain information about how the predefined regular piston movement should be modified to accomplish a stable pressure of the fluid dispensed by the pump unit. Therefore, the corrections can be used for modifying and improving the regular piston movement of at least one of the primary and the secondary piston pump.
According to a preferred embodiment, the method further comprises deriving, from the closed loop control of the primary piston's position performed during the first time interval, at least one of the following: a correction of the compression jump and a correction of the fluid's thermal expansion.
According to a preferred embodiment, the method further comprises deriving, from the closed loop control the primary piston's position performed during the first time interval, at least one correction to be applied to a regular piston movement of at least one of the primary piston pump and the secondary piston pump, with said at least one correction being used for modifying a regular piston movement of at least one of the primary piston pump and the secondary piston pump during subsequent pump cycles.
A pump unit according to embodiments of the present invention comprises: a primary piston pump with a primary piston and a secondary piston pump with a secondary piston, the primary piston pump being fluidically connected with the secondary piston pump, the primary piston pump comprising an inlet valve and an outlet valve, and the pump unit operating periodically according to a pump cycle comprising a deliver-and-fill phase for delivering fluid from the primary piston pump to the secondary piston pump and to a fluidic system located downstream of the pump unit. The pump unit comprises a pressure detection unit configured for determining a fluid pressure of fluid dispensed by the pump unit. Further, the pump unit comprises a control unit configured for performing, during a first time interval of the pump cycle, a closed loop control of a position of the primary piston in dependence on the fluid pressure of the fluid dispensed by the pump unit, while a predefined position-versus-time curve is performed by the secondary piston. The first time interval corresponds to the deliver-and-fill phase.
A fluid separation system for separating compounds of a sample fluid in a mobile phase according to embodiments of the present invention comprises a pump unit as described above, the pump unit being configured for driving the mobile phase through the fluid separation system, and a separation unit, preferably a chromatographic column, configured for separating compounds of the sample fluid in the mobile phase.
According to a preferred embodiment, the fluid separation system further comprises at least one of: a sample injector configured for introducing the sample fluid into the mobile phase; a detector configured for detecting separated compounds of the sample fluid; a collection unit configured for collecting separated compounds of the sample fluid; a data processing unit configured for processing data received from the fluid separation system; a degassing apparatus configured for degassing the mobile phase.
Embodiments of the invention can be partly or entirely embodied or supported by one or more suitable software programs or program code, which can be stored on or otherwise provided by any kind of computer readable storage medium, and which might be executed in or by any suitable data processing system. The computer readable storage medium may utilize optical, magnetic, chemical, electrical, or any other suitable properties for receiving, storing, or delivering instructions and commands, and may include magnetic media, such as a diskette, disk, memory stick or computer hard drive, which is readable and executable by a computer. In other embodiments, the computer readable storage medium may include optical disks, read-only-memory (“ROM”) floppy disks and semiconductor materials and chips, or any suitable technology for implementing the embodiments disclosed herein. Software programs or routines can be preferably applied for controlling respective movements of at least one of the primary piston and the secondary piston.
BRIEF DESCRIPTION OF DRAWINGS
Other objects and many of the attendant advantages of embodiments of the present invention will be readily appreciated and become better understood by reference to the following more detailed description of embodiments in connection with the accompanied drawing(s). Features that are substantially or functionally equal or similar will be referred to by the same reference sign(s).
FIG. 1 shows a dual piston serial type pump comprising a primary piston pump and a secondary piston pump;
FIG. 2 shows the piston movements of the primary piston and the secondary piston as a function of time;
FIG. 3 shows a set up of a pump system according to embodiments of the present invention;
FIG. 4 indicates when the first position correction signal is active and when the second position correction signal is active;
FIG. 5 shows position-versus-time curves for the primary and the secondary piston;
FIG. 6 depicts both the first position correction signal and the second position correction signal as a function of time; and
FIG. 7 shows the first position correction signal and the second position correction signal after a modification of the regular piston movements.
DETAILED DESCRIPTION
FIG. 1 shows a dual piston serial-type pump comprising a primary piston pump 100 that is fluidically connected in series with a secondary piston pump 101 . The primary piston pump 100 comprises an inlet 102 with an inlet valve 103 , a piston 104 that reciprocates in the primary piston pump 100 , and an outlet 105 with an outlet valve 106 . The outlet 105 is fluidically connected with an inlet 107 of the secondary piston pump 101 . A piston 108 reciprocates in the secondary piston pump 101 . The secondary piston pump 101 further comprises an outlet 109 for delivering a flow of fluid.
In the upper portion of FIG. 2 , the primary piston's position p 1 is depicted as a function of time, and in the lower portion of FIG. 2 , right below the primary piston's position p 1 , the secondary piston's position p 2 is shown as a function of time. During an intake phase 200 of the primary piston pump 100 , the primary piston 104 performs an upward stroke, as indicated by arrow 110 . The inlet valve 103 is opened, and fluid at atmospheric pressure is drawn into the primary piston pump 100 .
During an inlet valve settle phase 201 , the inlet valve 103 is closed. Then, starting at the point of time 202 , the primary piston 104 performs a compression stroke 203 in the downward direction, as indicated by arrow 112 , and the fluid contained in the primary piston pump 100 is compressed to a system pressure of several hundred or even more than thousand bar. During the compression phase 203 , both the inlet valve 103 and the outlet valve 106 are closed.
At a point of time 204 , the fluid contained in the primary piston pump 100 has reached system pressure, and the outlet valve 106 opens. In a subsequent delivery phase 205 of the primary piston pump 100 , the primary piston 104 continues its downward movement, and a flow of fluid is dispensed at the outlet 105 of the primary piston pump 100 . Accordingly, during a deliver-and-fill phase 206 indicated in the lower portion of FIG. 2 , the flow of fluid provided by the primary piston pump 100 is supplied to the secondary piston pump 101 and to the fluidic system located downstream of the pump unit, and the secondary piston pump's pump chamber is filled up.
During the deliver-and-fill phase 206 , fluid may e.g. be supplied to the secondary piston pump 101 at a flow rate of about 5 to 20 ml/min. As a consequence of this large resupply rate, the deliver-and-fill phase 206 can be quite short. In the examples shown in FIG. 2 , the deliver-and-fill phase 206 only extends over a small portion of a pump cycle 211 . For example, the deliver-and-fill phase may extend over less than 10% of the pump cycle.
At the point of time 207 , the downward stroke of the primary piston 104 is finished, and during an outlet valve settle phase 208 , the outlet valve 106 is closed. At the end of the primary piston's downward stroke, a certain dead volume of fluid remains in the pump chamber of the primary piston pump 100 , said dead volume of fluid being at system pressure. To decompress this dead volume of fluid, the primary piston 104 performs a decompression stroke 209 , which is a fast movement in the upward direction. At the point of time 210 , the dead volume of fluid is approximately at atmospheric pressure, and the inlet valve 103 opens. Now, the pump cycle 211 is finished, and a new pump cycle 212 starts. During an intake phase 213 of the primary piston pump 100 , the primary piston 104 performs an upward stroke, as indicated by arrow 110 , and fluid at atmospheric pressure is drawn into the primary piston pump 100 .
The lower portion of FIG. 2 shows the position p 2 of the secondary piston pump's piston as a function of time. During a delivery phase 214 of the secondary piston pump 101 , the secondary piston 108 performs a downward movement, as indicated by arrow 111 , and dispenses a continuous flow of fluid at the outlet 109 of the secondary piston pump 101 .
Then, at the point of time 204 , the outlet valve 106 is opened. During an intake phase 215 of the secondary piston pump 101 , the secondary piston 108 performs an upward stroke, as indicated by arrow 113 , and draws in fluid supplied by the primary piston pump 100 . During the intake phase 215 , the flow of fluid supplied by the primary piston pump 100 is partly used for filling up the fluid chamber of the secondary piston pump 101 and partly used for maintaining a continuous flow of fluid at the outlet 109 . At the point of time 207 , the pump chamber of the secondary piston pump 101 is filled with fluid. Then, during a subsequent delivery phase 216 , the secondary piston 108 performs a downward stroke, as indicated by arrow 111 , and a flow of fluid is dispensed at the outlet 109 .
The primary piston pump 100 and the secondary piston pump 101 may e.g. perform predefined regular piston movements as shown in FIG. 2 . The pump system may e.g. comprise an actuation mechanism for operating the primary and the secondary piston in accordance with these predefined piston movements. However, especially in the time interval around the deliver-and-fill phase 206 , the flow of fluid dispensed by the pump system may fluctuate, and accordingly, the pressure at the outlet may be subjected to fluctuations as well.
To counteract these fluctuations observed at the pump system's outlet and to stabilize pressure and flow of the dispensed fluid, corrective movements are superimposed onto at least one of the predefined regular piston movements shown in FIG. 2 . According to embodiments of the present invention, a closed loop control is set up for controlling at least one of the piston movements in accordance with a fluid pressure detected at the pump system's outlet. The pressure at the outlet may e.g. be compared with a predefined setpoint value indicating a target pressure. In case the actual pressure is too small, an additional forward displacement may be imposed onto at least one of the primary and the secondary piston's movement. In case the pressure detected at the outlet is too large, an additional backward displacement may be imposed onto at least one of the primary and the secondary piston's movement. By adaptively controlling the piston positions in accordance with a closed loop control, fluid pressure at the outlet of the pump system is stabilized, and fluctuations of fluid pressure are reduced.
FIG. 3 shows a pump system according to embodiments of the present invention. The pump system comprises a pump unit 300 and a control unit 301 adapted for performing a closed loop control of the pump unit's operation. The pump unit 300 comprises a primary piston pump 302 that is fluidically connected in series with a secondary piston pump 303 . The primary piston pump comprises a primary piston 304 , the primary piston 304 being driven by a first actuator mechanism 305 . The primary piston pump 302 further comprises an inlet valve 306 and an outlet valve 307 . The secondary piston pump 303 comprises a secondary piston 308 , the secondary piston 308 being driven by a second actuator mechanism 309 .
The pressure of the fluid dispensed by the pump unit 300 is determined (or detected, or measured) by a pressure detection unit 310 located downstream of the pump unit 300 . The actual pressure value 311 determined by the pressure detection unit 310 is forwarded to the control unit 301 . There, the actual pressure value 311 is compared with a setpoint value 312 that indicates a desired target pressure. The setpoint value 312 may for example be obtained by extrapolating a plurality of former pressure values. The control unit 301 may further receive phase information 313 indicating a phase of operation of the first actuator mechanism 305 and/or of the second actuator mechanism 309 .
The control unit 301 is configured to determine, based on the variance between the actual pressure value 311 and the setpoint value 312 , at least one position correction signal for imposing a corrective movement onto a regular piston movement of at least one of the pistons 304 and 308 . In the embodiment shown in FIG. 3 , two position correction signals 314 , 315 are generated, the first position correction signal 314 being provided to the first actuator mechanism 305 , and the second position correction signal 315 being provided to the second actuator mechanism 309 . The corrective movements imposed onto the regular piston movements are chosen such that the fluid pressure at the outlet of the pump system is driven towards the target pressure indicated by the setpoint value 312 . Thus, the fluid pressure at the outlet of the pump system is stabilized.
The closed loop control shown in FIG. 3 does not have to be active during the entire pump cycle. For example, during the intake phases 200 , 213 of the primary piston pump, the secondary piston pump dispenses a steady flow of fluid. During the intake phases 200 , 213 of the primary piston pump, the flow of fluid obtained at the pump system's outlet is quite stable. Therefore, during these intervals of the pump cycle, it is not necessary to perform a closed loop control of output pressure.
According to preferred embodiments of the present invention, during a pump cycle, position correction signals are alternatingly applied to the piston movement of the primary piston 304 and to the piston movement of the secondary piston 308 . For example, during the compression phase 203 shown in the upper portion of FIG. 2 , the second position correction signal 315 may be active. Hence, during the compression phase 203 , a corrective movement is imposed onto the movement of the secondary piston 308 , whereas the primary piston 304 performs a predefined regular piston movement.
At the point of time 204 , the outlet valve 307 of the primary piston pump is opened, the primary piston pump 302 starts dispensing fluid, and the closed loop control is switched from the secondary piston 308 to the primary piston 304 . During the deliver-and-fill phase 206 , corrective piston movements are solely applied to the primary piston 304 , while the secondary piston 308 performs a predefined regular movement.
At the point of time 207 , the deliver-and-fill phase 206 is terminated, and the closed loop control is switched back from the primary piston 304 to the secondary piston 308 . During the outlet valve settle phase 208 and the decompression phase 209 , the closed loop control is solely applied to the secondary piston 308 , while the primary piston 304 performs a predefined regular movement.
At the point of time 210 , the decompression phase 209 is finished, and the primary piston's intake phase 213 is started. During the primary piston's intake phase 213 , a steady flow of fluid is dispensed by the secondary piston pump, and hence, no closed loop control of the piston movement is necessary. Therefore, according to a preferred embodiment of the present invention, the closed loop control of the secondary piston's movement is switched off at the point of time 210 , or right after the point of time 210 .
Hence, according to a preferred embodiment of the present invention, the closed loop control is switched back and forth between the primary piston pump 302 and the secondary piston pump 303 . According to a further preferred embodiment, the closed loop control is only active during a subinterval of a pump cycle.
In FIG. 4 , which is located right below FIG. 2 , it is indicated when the first position correction signal 314 is active, and when the second position correction signal 315 is active. During the compression phase 203 , the second position correction signal 315 is active, which is indicated by a hatched segment 400 . Then, at the point of time 204 , the closed loop control is switched from the secondary piston pump 303 to the primary piston pump 302 . During the deliver-and-fill phase 206 , the second position correction signal 315 is inactive, and the first position correction signal 314 is active, which is indicated by the hatched segment 401 . Then, at the point of time 207 , the closed loop control is switched back from the primary piston pump 302 to the secondary piston pump 303 . Hence, the first position correction signal 314 becomes inactive, whereas the second position correction signal 315 is activated, as indicated by the hatched segment 402 . Hence, during the outlet valve settle phase 208 and the decompression phase 209 of the primary piston pump, the closed loop control is applied to the secondary piston pump. Then, during the intake phase 213 of the primary piston pump, both the first position correction signal 314 and the second position correction signal 315 are inactive, and no corrective movements are superimposed onto the regular piston movements of the primary piston 304 and the secondary piston 308 .
FIG. 5 depicts both the position vs. time curve 500 of the primary piston pump and the position vs. time curve 501 of the secondary piston pump for a subinterval of the pump cycle in which the closed loop control of the pump system is active.
During the inlet valve settle phase 502 , the closed loop control is not active yet. At the point of time 503 , the closed loop control of the secondary piston pump is started. During the compression phase 504 , the outlet valve of the primary piston pump is still closed, and the volume of fluid contained in the primary piston pump is compressed to system pressure. During the compression phase 504 , the closed loop control is applied to the secondary piston.
Then, at the point of time 505 , the outlet valve of the primary piston pump opens, and the closed loop control is switched from the secondary piston pump to the primary piston pump. During the deliver-and-fill phase 506 , the closed loop control is applied to the primary piston pump. During the deliver-and-fill phase 506 , the primary piston pump supplies a flow of fluid to the secondary piston pump and to the fluidic system located downstream of the pump unit, and the volume of fluid is taken in by the secondary piston pump.
At the point of time 507 , the deliver-and-fill phase 506 is finished, and the closed loop control is transferred from the primary piston pump back to the secondary piston pump. During the outlet valve settle phase 508 and the decompression phase 509 , the pressure at the outlet of the pump system is stabilized by imposing corrective movements onto the secondary piston's movement. At the end of the decompression phase 509 , the closed loop control is switched off, and during the primary piston's intake phase, the closed loop control remains inactive.
FIG. 6 shows both the first position correction signal 600 for the primary piston pump and the second position correction signal 601 for the secondary piston pump as a function of time, whereby the pump phases indicated in FIG. 6 correspond exactly to the pump phases shown in FIG. 5 .
Before the point of time 602 , none of the position correction signals 600 , 601 is active. Then, during the compression phase 603 , the second position correction signal 601 is active. At the point of time 604 , the primary piston pump's outlet valve is opened, the second position correction signal 601 becomes inactive, and the first position correction signal 600 becomes active. Then, during the deliver-and-fill phase 605 , the closed loop control of the fluid pressure is solely performed by the first position correction signal 600 . Hence, during the deliver-and-fill phase 605 , the closed loop control is solely applied to the primary piston pump.
In the example shown in FIG. 6 , the compression stroke performed during the compression phase 603 has been too short. Therefore, the fluid pressure determined by the pressure detection unit at the point of time 604 is below the desired target value. To drive the fluid pressure towards the desired target pressure, the first position correction signal 600 imposes an additional downward displacement 606 onto the primary piston's regular movement. This additional downward displacement 606 may be seen as an extension of the compression stroke performed during the compression phase 603 .
Both the compression stroke performed during the compression phase 603 and the additional downward displacement 606 cause a temperature increase of the fluid contained in the primary piston pump. Hence, after the fluid has been compressed, the fluid's temperature is increased. Now, temperature relaxation processes take place, and the fluid slowly cools down, which leads to a corresponding volumetric contraction of the volume of fluid in the primary piston pump.
To compensate for the thermal contraction of the volume of fluid, the first position correction signal 600 shows a slow decline, which is indicated by the dashed line 607 . The slow decline of the first position correction signal 600 superimposes an additional downward movement onto the primary piston's regular movement. The additional downward movement compensates for the slow thermal contraction of the volume of fluid and stabilizes the fluid pressure at the outlet of the pump system.
At the point of time 608 , the deliver-and-fill phase 605 is finished, and the closed loop control is switched from the primary piston pump back to the secondary piston pump. Accordingly, at the point of time 608 , the first position correction signal 600 becomes inactive, as indicated by the straight line 609 , and the second position correction signal 601 is activated. During the outlet valve settle phase 610 and the decompression phase 611 , the closed loop control of the fluid pressure at the pump system's outlet is solely performed by the second position correction signal 601 . For example, corrective movements 612 of the secondary piston may compensate for thermal effects or for errors that occur when closing the outlet valve. After the decompression phase 611 , the second position correction signal 601 becomes inactive.
According to a preferred embodiment of the invention, the information contained in the first position correction signal 600 and the second position correction signal 601 may be used for modifying the regular piston movements of the primary and the secondary piston in subsequent pump cycles. The first position correction signal 600 and the second position correction signal 601 contain information about the deviation between the required piston movements and the regular piston movements. From the first position correction signal 600 and the second position correction signal 601 , information about the errors of the regular piston movements may be derived, and said information may be used for modifying the regular piston movements. As a result, in subsequent pump cycles, the extent of required corrections is reduced.
For example, in the example shown in FIG. 6 , the compression stroke has been too small, and therefore, it has been necessary to impose an additional downward movement 606 onto the primary piston's movement. The additional downward movement 606 indicates that the compression stroke defined in the regular piston movement is too small. In fact, the additional downward movement 606 may be seen as an extension of the regular compression stroke performed during the compression phase 603 . Therefore, the additional downward movement 606 can be used as an indication showing how to adapt the regular piston movement in a way that during the following pump cycles, the magnitude of the correction signals will be reduced. In particular, during the next pump cycle, the regular compression stroke may be extended, which means that the additional downward movement is added to the regular compression stroke. As a consequence, during the next and all the following pump cycles, the magnitude of the correction signals will be reduced.
In addition to the additional downward movement 606 shown in FIG. 6 , also the slow additional downward movement that is employed for counteracting the thermal contraction of the volume of fluid in the primary pump chamber may be used for modifying the regular piston movements. In particular, by including the additional slow downward movement into the regular piston movement of the primary piston, the magnitude of the corrective movements imposed during the next pump cycles can be further reduced.
By modifying the regular piston movements of the primary and the secondary piston, the corrections imposed by the position correction signals can be reduced during the next and all the following pump cycles. This is shown in FIG. 7 . FIG. 7 shows both the first position correction signal 700 and the second position correction signal 701 during a subsequent pump cycle, which occurs after the regular piston movements of the primary and the secondary piston pump have been modified.
During a compression phase 702 , a compression stroke is performed, with the closed loop control being applied to the secondary piston pump. At the point of time 703 , the compression phase 702 is finished, and the closed loop control is transferred from the secondary piston pump to the primary piston pump. The first position correction signal 700 is activated, whereas the second position correction signal 701 becomes inactive.
At the point of time 703 , the pressure measured at the pump system's outlet is still smaller than system pressure, and therefore, an additional downward movement 704 is imposed onto the primary piston's movement.
However, as shown in FIG. 7 , the additional downward movement 704 is significantly smaller in magnitude than the corresponding additional downward movement 606 shown in FIG. 6 , because in the meantime, the magnitude of the compression stroke of the primary piston pump's regular piston movement has been modified. In particular, the compression stroke of the primary piston pump's regular piston movement has been increased, and therefore, the magnitude of the additional downward movement 704 is decreased.
Furthermore, also the slow decline of the first position correction signal 600 , which is indicated by the dashed line 607 in FIG. 6 , has been used for modifying the primary piston pump's regular piston movement. As a result, in the first position correction signal 700 shown in FIG. 7 , the slow decline is no longer present. Instead, during the deliver-and-fill phase 705 , the first position correction signal 700 is substantially kept constant, as indicated by the dashed line 706 . The reason is that the thermal contraction has already been considered in the primary piston pump's regular piston movement.
At the point of time 707 , the deliver-and-fill phase 705 is finished, and the closed loop control is handed over to the secondary piston pump. During the outlet valve settle phase 708 and the decompression phase 709 , the second position correction signal 701 is activated, and the closed loop control is applied to the secondary piston pump.
Hence, as a result of transferring corrective movements to the regular piston movements, the extent of the corrections applied according to FIG. 7 is considerably smaller than the extent of the corrections shown in FIG. 6 . | A method for controlling operation of a pump unit, where the pump unit includes a primary piston pump having a primary piston and a secondary piston pump having a secondary piston. The primary piston pump is fluidically connected with the secondary piston pump. The primary piston pump includes an inlet valve and an outlet valve, and the pump unit operates periodically according to a pump cycle. The method includes determining a fluid pressure of fluid dispensed by the pump unit, and performing a closed loop control of a position of the primary piston in dependence on the fluid pressure of the fluid dispensed by the pump unit during a first time interval of the pump cycle. | 5 |
TECHNICAL FIELD
[0001] This invention relates to the field of motor graders and, more particularly, to an attachment that adapts such machines for laying down, in one pass, a finished layer of aggregate material such as base rock or cold mix asphalt onto roads, streets, parking lots or driveways.
BACKGROUND
[0002] The known method of laying down base rock or cold mix asphalt involves a two-step operation in which the material is first dumped from a truck onto the ground or roadbed. A motor grader then comes along and spreads the material back and forth using its moldboard until the material is at the desired depth, width and slope. Typically, excess material slips into ditches on either side of the roadbed and is wasted. Significant, time-consuming working and reworking of the material may be necessary in order to achieve the desired depth, width and crown of the roadbed, which not only slows the overall process but also increases the likelihood of wasting significant amounts of material. Moreover, excessive handling and manipulation of base rock material can result in the limestone fines becoming separated from the aggregate and settling to the bottom of the layer, detracting from their ability to solidify when wet and hold the aggregate in a solid matrix that provides a better roadbed. Generally speaking, the less handling the better when laying down gravel material.
SUMMARY OF THE INVENTION
[0003] The present invention converts a motor grader into a machine that is capable of laying down in one pass a finished layer of aggregate material such as base rock or asphalt that has the desired thickness, width and profile of the finished product. By laying down the finished product on-the-go in a one-pass operation, significant time and labor savings can be achieved, as well as better control. Furthermore, less handling means a better quality roadbed where base rock is the material being deposited.
[0004] The present invention contemplates attaching a special distribution hopper to the front end of the motor grader ahead of the front wheels and a special screed to the moldboard behind the front wheels. As the motor grader advances, the hopper continuously receives material from a dump truck being pushed along the roadbed ahead of the grader by the hopper, and such material is continuously metered out onto the roadbed or other surface to form a swath located between the front wheels. The discharged swath of materials is then acted upon by the trailing screed, which skims off excess material from the top of the swath and spreads it laterally outwardly in opposite directions to produce a layer that is wider than the front wheels. Outermost shields at opposite left and right ends of the screed limit the width of the outwardly spreading materials to prevent spillage into ditches alongside the roadbed. The screed is mounted on the front side of the moldboard so as to be in a position to engage and work the materials instead of the moldboard. However, since the moldboard is adjustable in a variety of directions through various hydraulic actuators on the grader, manipulation and adjustment of the moldboard by the actuators can be used to correspondingly adjust the screed. Because the screed is pointed with a pair of diverging wings, adjustment of the nose of the screed upwardly or downwardly relative to the rear ends of the wings results in changes in the shape of the crown that is on the layer of materials being deposited and spread. In one preferred embodiment of the invention, such crown can range from a six inch negative crown to a flat or level crown and to a six inch positive crown at the other extreme.
[0005] The two wings of the screed can be extended and retracted hydraulically from the seat of the motor grader so as to correspondingly adjust the width of the material being laid down. The discharge outlet at the bottom of the distribution hopper has of a pair of side-by-side metering gates that can be independently adjusted so as to correspondingly vary the rate of discharge from the hopper. An operator's platform is provided on the backside of the distribution hopper to enable an extra worker to ride the machine at that location and operate controls for the metering gates as he observes loading and discharging of the hopper. A rotary agitator inside the hopper helps assure an orderly and even discharge flow from the hopper.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] [0006]FIG. 1 is a side elevational view of a motor grader provided with material distribution apparatus in accordance with the principles of the present invention, a dump truck being illustrated fragmentarily and in phantom at the front end of the apparatus;
[0007] [0007]FIG. 2 is a top plan view thereof illustrating the manner in which materials are discharged from the metering hopper and are then spread out to the desired width by the trailing screed, the screed being shown with its wing portions fully extended;
[0008] [0008]FIG. 3 is an enlarged, fragmentary rear perspective view of the left wing of the screed in its extended condition, illustrating details of construction and showing the moldboard in broken lines;
[0009] [0009]FIG. 3 a is a fragmentary, further enlarged view of the structure shown in FIG. 3;
[0010] [0010]FIG. 4 is a fragmentary top plan view of the screed in its extended condition corresponding to the rear perspective view of FIG. 3;
[0011] [0011]FIG. 5 is a fragmentary transverse cross-sectional view through the screed taken substantially along line 5 - 5 of FIG. 4;
[0012] [0012]FIG. 6 is a front elevational view of the distribution hopper taken substantially along line 6 - 6 of FIG. 1 with the front wall broken away to reveal details of construction;
[0013] [0013]FIG. 7 is a vertical cross-sectional view through the distribution hopper taken substantially along line 7 - 7 of FIG. 6;
[0014] [0014]FIG. 8 is a further enlarged fragmentary cross-sectional view through one portion of the distribution hopper taken substantially along line 8 - 8 of FIG. 6 and with a sloping internal sidewall of the hopper removed to reveal details of construction of the drive mechanism for the agitating rotor of the hopper; and
[0015] [0015]FIG. 9 is a schematic front elevational view of the screed in operation illustrating the manner in which a positive crown may be imparted to the material being laid down on the roadbed, such view being taken substantially along line 9 - 9 of FIG. 1.
DETAILED DESCRIPTION
[0016] The present invention is susceptible of embodiment in many different forms. While the drawings illustrate and the specification describes certain preferred embodiments of the invention, it is to be understood that such disclosure is by way of example only. There is no intent to limit the principles of the present invention to the particular disclosed embodiments.
[0017] Referring to the figures, a motor grader is shown generally at 10 and includes a wheeled chassis 12 having a pair of laterally spaced front wheels 14 and two pairs of laterally spaced rear wheels 16 and 18 . An engine 20 drives rear wheels 16 , 18 to propel the motor grader along a roadbed 22 or other ground surface, and an operator cab 24 is supported on chassis 12 just ahead of engine 20 .
[0018] As well understood by those skilled in the art, a fore-and-aft drawbar 26 is attached to the front of the chassis 12 by a ball joint or the like (not shown). Drawbar 26 extends rearwardly from the front ball joint and underneath the upwardly arched chassis 12 to support a blade or moldboard 28 that can be adjusted in a number of different directions to assume a variety of adjusted positions. In this regard, as is conventional, moldboard 28 can be adjusted upwardly and downwardly by a pair of left and right lift cylinders 30 and 32 , each of which can be independently operated so as to change the left-to-right tilt of moldboard 28 . A side shift cylinder (not shown) enables moldboard 28 to be shifted laterally to the left or right relative to drawbar 26 , and a fore-and-aft tilt cylinder 34 (FIG. 1) is coupled to moldboard 28 in such a manner that moldboard 28 can be tipped forwardly or rearwardly about a lower transverse axis to adjust its angle of attack relative to the ground. Moldboard 28 can also be rotated about a vertical axis by means not shown to place moldboard 28 in an oblique attitude relative to the direction of travel of the motor grader, although in connection with the present invention moldboard 28 will normally be perpendicular to the path of travel as illustrated in the plan view of FIG. 2.
[0019] In connection with the present invention, motor grader 10 is provided with a material distribution attachment comprising two primary components, i.e., a distribution hopper 36 at the front of the machine and a screed 38 attached to moldboard 28 in the middle of the machine. Dealing first with hopper 36 , it will be seen that such structure generally comprises an open top receptacle having a set of ground engaging wheels 40 . The upper front edge 42 of hopper 36 is lower than the upper rear edge 44 thereof so as to facilitate loading of hopper 36 with granular materials from a dump truck 46 during operation as illustrated in FIG. 1 and as will subsequently be explained in more detail. The exterior of hopper 36 includes a pair of opposite, left and right sidewalls 48 and 50 respectively, an upright exterior front wall 52 , and an upright rear wall 54 that begins at the upper rear edge 44 and extends part way down the back of hopper 36 . A sloping bottom wall 56 extends downwardly and forwardly from the lower extremity of rear wall 54 generally toward front wall 52 but terminates a short distance rearwardly from front wall 52 . A horizontal, relatively short lowermost wall 58 interconnects the lower extremity of front wall 52 and the forward extremity of bottom wall 56 .
[0020] Inside hopper 36 , a downwardly and rearwardly sloping interior front wall 60 extends from a point part way up exterior front wall 52 down to the forward extremity of bottom wall 56 . A pair of downwardly and inwardly sloping interior sidewalls 62 and 64 converge toward the center of the hopper and intersect bottom wall 56 and the front interior wall 60 . Front wall 52 carries a pair of horizontal rollers 66 that bear against the rear tires 70 of dump truck 46 during operation as illustrated in FIG. 1.
[0021] The discharge outlet of hopper 36 is broadly denoted by the numeral 70 and is located in bottom wall 56 adjacent the intersection with front interior wall 60 . Outlet 70 is controlled by a pair of side-by-side metering gates 72 and 74 that are independently shiftable along inclined paths of travel parallel to bottom wall 56 between positions opening and closing respective left and right halves of outlet 70 . In FIGS. 2,6 and 7 , gates 72 and 74 are shown in their open position. A pair of independently operable hydraulic piston and cylinder assemblies 76 (only one being illustrated; see FIG. 7) actuate gates 72 , 74 between their open and closed positions, the rear ends of the cylinders 76 being attached to rearwardly projecting, horizontally disposed mounts 78 and 80 on the rear of hopper 36 (FIGS. 2 and 7).
[0022] A transverse agitating rotor 82 spans outlet 72 a short distance thereabove for the purpose of keeping materials agitated and loose near the bottom of hopper 36 to facilitate their discharge through outlet 70 . Opposite ends of rotor 82 pass through interior sidewalls 62 and 64 for ultimate rotational support by suitable bearings located behind such interior walls. The drive for rotor 82 is located outboard of interior sidewall 62 and inboard of outer sidewall 48 as illustrated in FIGS. 6 and 8. Such drive includes a hydraulic motor 84 (FIG. 8) having an output shaft (not shown) that carries a sprocket 86 . An endless chain 88 is entrained around sprocket 86 and around a second sprocket 90 that is fixed to the outboard end of rotor 82 . An adjustable idler sprocket 92 engages the slack side of chain 88 to maintain tension in the chain.
[0023] Hopper 36 is attached to the front end of chassis 12 by mounting apparatus broadly denoted by the numeral 94 . Apparatus 94 comprises a centrally disposed, upright tower or mast 96 that is fixedly secured to the chassis 12 by suitable means such as bolts (not shown). An upright hydraulic cylinder 98 (FIG. 7) within mast 96 is operably coupled with the upper backside of hopper 36 via suitable coupling means broadly denoted by the numeral 100 so that extension and retraction of cylinder 98 causes hopper 36 to be raised and lowered relative to mast 96 . It is contemplated that during normal working operations, hopper 36 will be fully lowered so that ground wheels 40 are touching the ground and supporting the load of hopper 36 and its contents. On the other hand, for transport purposes between job sites, hopper 36 may be elevated along mast 96 and supported in a raised, transport position (not shown).
[0024] An operator seat 102 is attached to the backside of hopper 36 near the left end thereof and at such a height that an operator stationed at seat 102 can observe both loading of hopper 36 and discharging of material from the hopper. A set of controls 104 (FIG. 2) are easily accessible to the operator positioned on seat 102 , such controls 104 being operably connected to gate cylinders 76 so that the operator may regulate the positions of gates 72 and 74 . The lift cylinder 98 which raises and lowers hopper 36 is controlled by a suitable control (not shown) located in cab 24 . A pair of upwardly and rearwardly projecting indicator rods 106 and 108 are fixed to respective doors 72 and 74 to provide a visual indication for the operator at seat 102 of the position of gates 72 , 74 , which can be important when outlet 70 is covered by material within hopper 36 . It will be noted from FIG. 2 in particular that outlet 70 is slightly narrower than the width of the space between front wheels 14 such that material discharged through outlet 70 forms what may be termed a ribbon or swath of material having a width no greater than the space between the wheels. Because outlet 70 is centered between wheels 14 , the wheels become disposed on opposite sides of the material swath during discharging and spreading operation.
[0025] A hook 110 at the front end of hopper 36 (FIGS. 1 and 2) may be used to detachably secure the truck 46 to the front end of hopper 36 . Hook 110 is operated manually by a linkage 112 that runs across the hopper 36 and up the left side thereof outboard of left sidewall 48 . Linkage 112 terminates at its upper end in an operating handle 114 positioned for actuation by the operator stationed on seat 102 .
[0026] The screed 38 is generally V-shaped in overall configuration when viewed in plan, presenting a pointed body having a nose 116 and a pair of oppositely extending, swept-back, left and right wings 118 and 120 . Generally speaking, the wings 118 and 120 present a forwardly pointed lower screeding edge 122 (FIG. 5) that determines the thickness or depth of the layer of materials formed by the screed. Each of the wings 118 , 120 has as its primary component a tubular, square in cross-section beam 124 that is joined at its inner end with the beam 124 of the other wing. An upright panel or wall 126 is secured to and extends along the front of each beam 124 to prevent material from flowing up and over the top edge of the beam during operation. Wall 26 is secured to beam 124 by a fence 128 that includes four uprights 130 , 132 , 134 and 136 . Each of the uprights 130 - 136 is securely affixed at its upper end to wall 126 but is spaced slightly rearwardly from such wall below the point of attachment so as to define a transverse slot 138 between fence 128 and the backside of wall 126 for a purpose yet-to-be-explained. A slide strip 140 is fixed to the top surface of beam 124 along the front edge thereof and is generally co-extensive in length with fence 128 .
[0027] Each wing 118 , 120 is adjustably extendable and retractable to vary its effective length, thus adjusting the overall width of screed 38 . In this regard, each wing 118 , 120 includes an extendable and retractable wing tip 142 that is shifted in or out by a hydraulic cylinder 144 housed within beam 124 . Each wing 142 is formed in part by a second tubular beam 146 that is of rectangular cross-section and has slightly smaller dimensions than main beam 124 . Thus, wing tip beam 146 is telescopically received within main beam 124 and is guided in its telescoping reciprocation by a pair of spacer plates 148 and 150 (FIG. 5) fixed to front and bottom walls of main beam 124 respectively (FIGS. 3, 3 a and 5 ).
[0028] Each wing tip beam 146 has its own front wall extension 152 that is received within horizontal slot 138 between fence 128 and front wall 126 . The lower edge of front wall extension 152 rides upon slide strip 140 on main wing beam 124 . Each front wall extension 152 is welded at its outer vertical edge to an upright member 154 that is in turn welded along its bottom edge to the wing tip beam 146 .
[0029] Each main beam 124 has three generally L-shaped brackets 156 , 158 and 160 welded to the top surface thereof and projecting rearwardly therefrom at spaced locations therealong. The downturned outer legs of brackets 156 , 158 and 160 support a guide strap 162 that extends parallel to main beam 124 in rearwardly spaced relation thereto. Guide strap 162 bears against and reciprocably guides a trailing tubular, rectangular in cross-section wing tip beam 164 that is spaced slightly behind and extends parallel to the first wing tip beam 146 . As illustrated in FIG. 5, trailing wing tip beam 164 projects downwardly below the level of wing tip beam 146 to the same extent as the main beam 124 . Thus, even though the lower extremity of the front wing tip beam 146 is not quite as low to the ground as main beam 124 , this difference is made up for by the trailing wing tip beam 164 such that, in effect, the lower front edge 122 of screed 38 is at the same level along the full length of the wing from the inner end to the outer end thereof, even when the wing tip 142 is fully extended.
[0030] The trailing wing tip beam 164 is fixed at its outer end to the front wing tip beam 146 via a fore-and-aft extending plate 166 (FIGS. 3, 3 a and 4 ) that spans the outer ends of beams 146 and 164 and is welded thereto and to the upright member 154 . At its inner end the trailing wing tip beam 164 has a rectangular lug 167 welded thereto that projects forwardly into overlying relationship with the top surface of main beam 124 , for the purpose of helping to support and guide trailing wing tip beam 164 during its extension and retraction. A long guide strip 168 is welded to the rear face of main beam 124 and bears against the front face of trailing wing tip beam 164 during adjusting reciprocation of the latter. Thus, during such adjusting movement of trailing wing tip beam 164 , the beam is trapped between rearwardly disposed guide strap 162 on the one hand and forwardly disposed guide strip 168 on the other.
[0031] Trailing wing tip beam 164 is also supported by a relatively short rectangular plate 170 that is housed within trailing wing tip beam 164 and bears against the upper inside surface of the top wall of such beam. At its inboard end, plate 170 is supported by an upright bolt 172 that passes through a slot 174 in the top wall of trailing wing tip beam 164 . Bolt 172 is suspended from the rear end of a support plate 176 that is fixed at its front end to the upper surface of main wing beam 124 . At its outboard end the plate 170 is supported by an upright bolt 178 that hangs from the rearwardly extending, horizontal leg 180 of a generally L-shaped mounting bracket 182 having an upright leg 184 that is attached to the lower rear extremity of moldboard 28 via attaching bolts 186 and 188 . Mounting bracket 182 is not fixed to but instead merely overlies main beam 124 . Support plate 178 has an upstanding handle 190 of generally T-shaped configuration that projects upwardly through slot 174 in trailing wing beam 164 . The head of handle 190 is wider than slot 174 such that when bolts 172 and 178 are removed, support plate 170 cannot fall to the inside bottom surface of trailing wing tip beam 164 and become inaccessible. In addition to this keeping or retaining function, the head of handle 190 is also adapted to be grasped manually during assembly and disassembly operations.
[0032] The outermost ends of wings 118 and 120 are provided with upright shields 192 and 194 respectively that confine the material as it is being leveled and spread laterally by screed 38 . Each of the shields 192 , 194 is bolted to the fore-and-aft plate 166 of wing tip 142 and projects forwardly a substantial distance therefrom. Each shield 192 , 194 can be height adjusted by virtue of a slotted relationship with the bolts that secure the shield to plate 166 .
[0033] The two mounting brackets 182 at opposite ends of moldboard 28 serve as components of mounting structure that secure the screed 38 to moldboard 28 . In addition to brackets 182 , such mounting structure also includes an upstanding lug 196 on screed 38 at nose 116 , a corresponding lug 198 fixed to the backside of moldboard 28 at the lateral center thereof near its top edge, and a rigid link 200 pivotally connected at its opposite ends to lugs 196 and 198 . Screed 38 is thus securely attached to moldboard 28 and is held against significant movement relative thereto. However, by virtue of the various hydraulic cylinders that adjust moldboard 28 , screed 38 can likewise be adjusted.
[0034] Operation
[0035] Operation and use of the distribution attachment in accordance with the present invention should be apparent from the foregoing description. With particular reference to FIGS. 1 and 2, however, a brief further description of the operation is in order.
[0036] During use, one operator is positioned within cab 24 and a second operator is positioned at seat 102 . The operator in cab 24 controls forward motion of grader 10 , as well as lifting and lowering of hopper 36 , extension and retraction of wings 118 , 120 , up and down adjustment of screed 38 , and fore-and-aft tilting of screed 38 for controlling the crown applied to the material, if any. Depending upon the depth of the layer of material to be placed on roadbed 22 , screed 38 will be adjusted closer to or further above the roadbed. A corresponding adjustment of side shields 192 and 194 may be necessary to assure that the lower edges thereof are engaging and riding along roadbed 22 during forward movement of the grader.
[0037] A dump truck 46 is backed up to the grader until its tires 70 come into abutting engagement with rollers 66 on the front of hopper 36 , which has previously been lowered sufficiently to place its wheels 40 in contacting engagement with roadbed 22 . As the bed of truck 46 is raised as illustrated in FIG. 1, material is discharged from the bed into and through the open top of hopper 36 where it begins to issue from discharge outlet 70 . As the grader is then advanced, the grader pushes truck 46 along with it so that the contents of the truck are continuously discharged into the awaiting hopper 36 at a rate determined by the tilt angle of the truck bed.
[0038] The operator situated on seat 102 observes the ongoing process and adjusts gates 72 and 74 as may be necessary or desirable to suitably regulate the flow of material as it emanates out of the bottom of hopper 36 . As illustrated in FIG. 2, such discharged material forms a swath 202 that is disposed between front wheels 14 of the grader, due to the central location of outlet 70 and the fact that it is no wider than the distance between such front wheels.
[0039] As the screed 38 then engages the discharged swath 202 , the top portion of the swath is skimmed off and deflected laterally outwardly in opposite directions due to the swept back nature of wings 118 and 120 of screed 38 . Swath 202 is thus widened out and leveled down to produce in one pass a final layer 204 behind screed 38 having a width determined by the outboard shields 192 and 194 .
[0040] This process of unloading materials from truck 46 , metering them out of hopper 36 , and spreading them with screed 38 continues on an ongoing, non-stop basis until the truck is empty. At that time, forward motion of the grader is halted, and the truck pulls away to obtain a new supply of material, during which time the next loaded truck maybe backed into position at the front of hopper 36 . Once the next truck is properly positioned, the grader begins to advance again, continuing the process that was temporarily halted when the previous truck became empty.
[0041] In many instances there will be no need to engage the retaining hook 110 with the truck. However, where the roadbed or other surface is sloping down hill, it may be advisable to secure the hook 110 onto the truck to assure maintenance of the proper relationship between the truck and hopper 36 .
[0042] [0042]FIG. 9 illustrates one example of a crown that can be imparted to the layer of materials 204 on roadbed 22 . By cocking up screed 38 to a slight extent at its leading extremity, the nose 116 of screed 38 will be slightly higher than the outer ends of its wings 118 , 120 . Consequently, layer 204 will be provided with a positive crown that is somewhat higher in the center than at its outer ends, and there will be a gentle slope in opposite left and right directions from the central crown. In one preferred embodiment, the crown can be varied between a six-inch negative crown and six-inch positive crown. Of course, layer 204 can also be configured to have essentially no crown at all and to instead be essentially perfectly flat from one lateral extremity to the other. It is also contemplated that the wings 118 and 120 maybe extended to such an extent that the overall width of screed 38 can be varied from twelve feet to twenty feet.
[0043] Although preferred forms of the invention have been described above, it is to be recognized that such disclosure is by way of illustration only, and should not be utilized in a limiting sense in interpreting the scope of the present invention. Obvious modifications to the exemplary embodiments, as hereinabove set forth, could be readily made by those skilled in the art without departing from the spirit of the present invention.
[0044] The inventor(s) hereby state(s) his/their intent to rely on the Doctrine of Equivalents to determine and assess the reasonably fair scope of his/their invention as pertains to any apparatus not materially departing from but outside the literal scope of the invention as set out in the following claims. | A motor grader can be adapted for laying down a layer of granular material such as base rock or cold mix asphalt by mounting a dispensing hopper attachment onto the front of the motor grader and a spreading and leveling screed onto the moldboard. As the motor grader advances, it pushes a dump truck that continuously loads materials into the hopper. Those materials are in turn continuously discharged at a metered rate of flow through the bottom of the hopper and onto the roadbed. The resulting swath of materials passes between the front wheels of the grader as the grader continues to advance, whereupon the screed engages the swath and spreads the materials in opposite lateral directions while leveling them to the desired depth. The screed has swept-back wings that may be extended as necessary to adjust the overall width of the screed, and outboard shields on the outermost ends of the wings confine the spread materials to the roadbed and prevent their accidental discharge into ditches and the like alongside the roadbed. The crown of the deposited layer can be varied by tipping the nose of the screed upwardly or downwardly to the extent necessary or desired. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a national phase entry under 35 U.S.C. §371 of International Application No. PCT/US2010/052632 filed Oct. 14, 2010, published in English, which claims priority from Chinese Patent Applications Nos. 200920183323.3, 200920183324.8, and 200920183325.2 filed on Oct. 15, 2009 in the Chinese Intellectual Property Office, all of which are incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to aerators for generating bubbles in a flow of water. More particularly, the present invention relates to kitchen aerators including flow compensators which are capable of providing improved flow patterns.
BACKGROUND OF THE INVENTION
Aerator nozzles, faucets, kitchen aerators, spray heads, shower heads, and the like for controlling the fluid flow of water are well known in the art. Aerator faucets, for example, such as those for use in the kitchen, are generally complicated mechanical devices having numerous parts including water discharge heads that can be rotated to regulate the discharge spray of water from the discharge spray head. Since these types of rotating spray heads can easily break down in view of the numerous internal moving component parts therein, kitchen aerators have been improved upon. Thus, for example, in U.S. Pat. No. 7,252,248 (“the '248 Patent”), assigned to the assignee of the present application, there has been provided a kitchen aerator which includes a flow compensator for increasing the flow rate of water at low pressures and which utilizes a flip lever to regulate the water flow rate. The pressure compensator is thus capable of regulating the flow rate or maintaining the flow rate regardless of pressure variations in the stream of water. It can also ensure that the flow rate does not exceed the maximum rated flow rate for the particular device in question.
The disclosure of the '248 Patent is therefore incorporated herein by reference thereto in its entirety. In FIGS. 1 and 2 hereof, which correspond to FIGS. 3 and 3a of the '248 Patent, the kitchen aerator or faucet aerator 10 is shown in detail. These figures show this prior art device, which includes a flow compensator assembly 30 , including flow compensator member 32 , as well as a ball joint 36 and a pin 40 with a water flow opening 41 which is adjusted by flip lever 46 . The device shown in the '248 Patent also includes a spray subassembly 60 connected to the flow compensator subassembly 30 . This spray subassembly includes a chrome spray adjusting ring 80 and a rubber spray adjusting ring 82 which are used to produce either a needle spray pattern or a bubble stream (full) spray pattern by lateral movement thereof. The water out seat member 84 thereof includes water openings 85 to produce the desired spray patterns.
The search, however, has continued to improve upon these aerators and to provide superior products in terms of the materials used and the costs for producing same.
SUMMARY OF THE INVENTION
In accordance with the present invention, these and other objects have now been realized by the invention of an aerator for generating bubbles in a flow of water comprising an aerator body, a diverter having an upper portion and a lower portion attached to the aerator body, the diverter including a plurality of orifices for receiving the flow of water, each of the plurality of orifices including a decreasing pore size in a direction from the upper portion of the diverter towards the lower portion of the diverter, and a lower body portion including a water chamber having an inner surface and an outer surface for receiving and aerating the flow of water from the plurality of orifices in the diverter. In a preferred embodiment, the inner surface of the water chamber includes a plurality of baffles interrupted by a corresponding plurality of trenches therebetween for increasing the aeration of the flow of water exiting from the plurality of orifices.
In accordance with one embodiment of the aerator of the present invention, the diverter includes an upper diverter portion including the plurality of orifices and a lower diverter portion extending into the lower body portion. Preferably, the lower body portion is movable between a lower position in which the lower body portion is in sealable contact with the lower portion of the diverter, thereby preventing the flow of water from flowing therebetween, and an upper position in which the lower body portion is separated from the lower portion of the diverter thereby permitting the flow of water therebetween. In a preferred embodiment, the water chamber includes a plurality of water openings on the outer periphery thereof, whereby when the lower body portion is in the lower position the flow of water flows through the plurality of water openings, and when the lower body portion is in the upper position, the flow of water ceases through the plurality of water openings, thereby causing the flow of water to draw air through the plurality of water openings and further aerate the flow of water thereby.
In accordance with another embodiment of the aerator of the present invention, the aerator includes an inner frame surrounding the diverter and contained within the lower body portion. In a preferred embodiment, the inner frame includes an upper threaded portion, and including an upper body portion threadably affixed to the inner frame. In a preferred embodiment, the upper body portion includes an upper opening, and including a ball joint rotatably mounted within the upper opening in the upper body portion for rotatable mounting of the aerator. Preferably, the ball joint comprises a plastic ball joint.
In accordance with another embodiment of the aerator of the present invention, the aerator includes a pressure compensator mounted on the upper portion of the diverter for regulation of the maximum flow of the flow of water. Preferably, the aerator includes a screen associated with the pressure compensator for filtering the flow of water through the pressure compensator.
In accordance with the present invention, other objects have now been realized by the invention of an aerator for generating bubbles in a flow of water comprising an aerator body, a diverter having an upper portion and a lower portion attached to the aerator body, a pressure compensator mounted on the upper portion of the diverter for regulation of the maximum flow of the flow of water therethrough, the aerator body including an upper portion including a ball joint opening, and a ball joint including an upper ball joint portion including threads for connection to a faucet and a lower ball joint portion mounted within the ball joint opening for swiveling movement therein, the lower ball joint portion comprising plastic and the upper ball joint portion comprising metal. In a preferred embodiment of the aerator of the present invention, the lower ball joint portion is capable of swiveling in a 360° rotation in the ball joint opening.
In one embodiment of the aerator of the present invention, the diverter includes a plurality of orifices for receiving the flow of water. Preferably, the plurality of orifices includes a decreasing pore size in a direction from the upper portion of the diverter towards the lower portion of the diverter.
In accordance with another embodiment of the aerator of the present invention, the aerator includes a lower body portion including a water chamber having an inner surface and an outer surface for receiving and aerating the flow of water from the plurality of orifices in the diverter. Preferably the inner surface of the water chamber includes a plurality of baffles interrupted by a corresponding plurality of trenches therebetween for increasing the aeration of the flow of water exiting from the plurality of orifices.
In accordance with another embodiment of the aerator of the present invention, the diverter includes an upper diverter portion including the plurality of orifices and a lower diverter portion extending into the lower body portion. Preferably the lower body portion is movable between a lower position in which the lower body portion is in sealable contact with the lower portion of the diverter, therefore preventing the flow of water from flowing therebetween, and an upper position in which the lower body portion is separated from the lower portion of the diverter thereby permitting the flow of water therebetween. In a preferred embodiment, the water chamber includes a plurality of water openings on the outer periphery thereof, whereby when the lower body portion is in the lower position, the flow of water can flow through the plurality of water openings, and when the lower body portion is in the upper position, the flow of water ceases through the plurality of water openings, thereby causing the flow of water to draw air through the plurality of water openings and further aerate the flow of water thereby.
In accordance with another embodiment of the aerator of the present invention, the aerator includes an inner frame surrounding the diverter and contained within the lower body portion. Preferably the inner frame includes an upper threaded portion, and including an upper body portion threadably affixed to the inner frame.
In accordance with another embodiment of the aerator of the present invention, the aerator includes a screen associated with the pressure compensator for filtering the flow of water through the pressure compensator.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention may be more fully appreciated with reference to the following detailed description which in turn refers to the figures in which:
FIG. 1 is a side, perspective exploded view of a kitchen aerator in accordance with the prior art;
FIG. 2 is a side, perspective, exploded view of a kitchen aerator of the prior art;
FIG. 3 is a side, elevational, sectional view of the exit portion of an aerator in accordance with the present invention;
FIG. 4 is a top, perspective view of a lower body portion of the aerator shown in FIG. 3 ;
FIG. 5 is a side, elevational, sectional view of an aerator in accordance with the present invention including a pressure compensator;
FIG. 6 is a side, elevational, sectional view of a kitchen aerator in accordance with the present invention including a ball joint attachment, and in which the lower body portion is toggled to the lower portion;
FIG. 7 is a side, elevational view of the kitchen aerator shown in FIG. 6 ;
FIG. 8 is a top, elevational view of the kitchen aerator shown in FIG. 7 ;
FIG. 9 is a bottom, elevational view of the kitchen aerator shown in FIG. 7 ;
FIG. 10 is a side, elevational, partial sectional view of a portion of a kitchen aerator of the present invention including the ball joint therefor; and
FIG. 11 is a side, elevational, sectional view of the kitchen aerator shown in FIG. 6 , with the lower body portion toggled to the up position.
DETAILED DESCRIPTION
Referring first to FIG. 3 , an aerator body 1 , is shown in this figure, which is intended to alternate between two positions, one of which is effective to generate a large amount of bubbles, in this case to provide softer and smoother bubble formation than has been possible in the past. The aerator body 1 has an inner frame 4 which can be attached to the upper body portion (see discussion below) by means of threads 4 a in a manner discussed below. The inner frame 4 is attached to a lower body portion 2 . This is accomplished during assembly by the inner frame 4 being pushed downwardly into the lower body portion 2 . In doing so, and since the lower body portion 2 includes an O-ring 2 c which snaps into a corresponding slot 4 c in the outer surface of the inner base 4 , not only are these two parts attached to each other, but the leakage of water is prevented through this connection. Within the inner frame 4 is contained a diverter 3 including a lower diverter portion 3 a having an increased diameter portion at the bottom thereof, and an upper diverter portion 3 b . Preferably, the diverter 3 is a one-piece unit including both the upper and lower diverter portions 3 b and 3 a , respectively. During assembly, the diverter 3 is thus pushed downwardly into the top of the inner frame 4 , and is then pressed into the lower body portion 2 . Since the diameter of the lower diverter portion 3 a is slightly greater than the inner diameter of the lower body portion 2 , it is necessary to force fit the diverter thereinto. Furthermore, since the diverter is preferably a one-piece unit, it is therefore able to hold these parts together by these pressure fits alone. Furthermore, as discussed in more detail below, and since the lower diverter portion 3 a is on the lower side of the lower body portion 2 , it can create an inner seal therebetween.
The upper diverter portion 3 b is intended to equally distribute water flow throughout the entire body of the aerator body 1 . The lower diverter portion 3 a , as noted, creates a seal against the lower body portion 2 , which toggles the water flow to the center bubble stream or the outer spray streams, as discussed in detail below. The diverter 3 directs the flow of water down to the lower surface of the water chamber for expulsion in the appropriate aerated manner. The upper portion of the diverter 3 includes an open mounting portion 7 , and a plurality of pores 31 therebelow for the flow of water therefrom. Preferably, these pores are disposed in a circular pattern around the entire floor of the open mounting portion 7 , thus distributing the flow of water as discussed above. The upper mounting portion will contain a pressure compensator (not shown in FIG. 3 ) as will be discussed in more detail below. These evenly distributed pores form an important element of the present invention in that they are of decreasing diameter as the water flows downwardly through them. This decreasing diameter can be step-wise, as shown in the drawings, or it can be of a continuous or semi-continuous decreasing diameter. This results in an increase in the rate of flow of the water which exits the diverter 3 as it passes through these pores 31 for aeration purposes. In the case where a two-step set of pores 31 are utilized, in a preferred embodiment the upper pores will have a diameter of about 1.2 mm, and the lower pores will then have a stepped-down diameter of about 0.6 mm. These stepped-down or reduced diameters thus create a venturi effect in which the water velocity will increase through the smaller diameter stepped portion. This, in turn, creates a much more powerful stream of water exiting from the device without changing the overall water volume itself.
In the lower portion of the aerator body 1 there is disposed lower body portion 2 which is shown in FIG. 4 , and which includes an inner water chamber 2 a . The lower body portion 2 , including inner water chamber 2 a , can be toggled between two positions, an upper position, as is shown in FIG. 11 , and a lower position, as is shown in FIGS. 3 , 5 and 6 . The user can simply slide the lower body portion 2 between these two positions by grasping its outer surface and sliding it up or down, as desired. In the down position, as in FIG. 3 , a seal is created between the lower diverter portion 3 a and the inwardly directed portion 2 b of the inner water chamber 2 a . This seal, in turn, prevents the water exiting the pores 31 from passing between the lower diverter portion 3 a and the inner water chamber 2 a , but the flow of water is thus directed radially outwardly, through a series of outlet ports 33 contained around the inner circumference of the lower body portion 2 . This water flow then freely exits the aerator body 1 .
On the other hand, when the lower body portion 2 is moved into an up position, as shown in FIG. 11 , the seal between the lower diverter portion 3 a and the inner water chamber 2 a is broken, allowing the water to flow from the pores 31 directly downwardly to the central portion 2 c of the lower body portion 2 , as can be seen by the arrows in FIG. 11 . The flow of water thus exits the pores 31 and impinges on the surface of the lower water chamber 2 a . Furthermore, in this configuration, all of the water is flowing around the lower diverter portion 3 a through the center of this device, and essentially no water is flowing through the outlet ports 33 . Therefore, these outlet ports 33 leave an open channel for the movement of air. Therefore, the central flow itself will draw air from the outlet ports 33 into the aerator device, where air can then mix into the flow of water to create the increased aeration of this invention. As can also be seen in FIG. 4 , along the outer periphery of the inner wall of the inner water chamber 2 a are located a plurality of circumferential baffles 51 separated by trenches 53 therebetween. The exits for the pores 31 are thus specifically directed so that the flow of water therefrom will impinge directly onto the baffles 51 , thus creating even greater aeration. In this manner, as the water rapidly exits from the decreased diameters pores 31 , it is mixed with air in the manner discussed above, and it then strikes against the baffles themselves inside inner the water chamber 2 a , thus mixing more air with the water and generating even more evenly distributed bubbles. These bubbles then flow out of the lower end 3 a of the diverter 3 and are sprayed out from the screen at a maximum size and angular dimensions to create more desirable bubble columns therein. In this manner, the problems of disturbed effluent and insufficient bubbles which are faced in the prior art are overcome.
Referring next to FIGS. 6 and 11 , a dual function aerator is shown utilizing the aerator body of FIGS. 3 and 5 . This device, such as that of the '248 Patent discussed above, includes a flip lever 10 for controlling the flow through the device itself. As can be seen in these figures, the aerator itself comprises an upper body portion 11 which can be affixed by corresponding threads to the inner frame 4 discussed above and as shown in FIG. 6 . The upper body portion 11 is fixed to a ball joint 12 , preferably for rotary movement thereabout. In this manner, the aerated water exiting from the water chamber 5 can be directed in any desired angle by the user, such as in a 360° rotation about its axis. Once again, the lower body portion 2 is fixed to the inner frame 4 in the manner discussed above, and the diverter 3 is again fixed to the inner frame 4 . The inner frame 4 is bolted to the upper body portion 11 as discussed above. As shown in FIGS. 5 and 6 a pressure compensator 6 is mounted between the ball joint 12 and the diverter 3 . A seat 7 is maintained within the upper portion 3 a of the diverter 3 for mounting of the pressure compensator 6 therein. Furthermore, a conical screen 8 is mounted on top of the pressure compensator 6 for filtering the water entering the pressure compensator itself. In this manner, the screen can filter out any sediment or other debris from the flow of water itself which could create clogging in the body of the aerator. The angled conical design of this screen 8 provides increased surface area for the device and allows for a longer period of time for sediment to build up before the screen requires cleaning. This particular design as shown in FIGS. 5 and 6 includes ribs on the underside of the screen for reinforcement purposes, thus allowing it to hold its shape even in extremely high water pressure applications. As compared, for example, to the pressure compensators employed in the prior art, such as in the '248 Patent, in this case access to the pressure compensator 6 and to the screen 8 is readily obtained by merely unscrewing the upper body portion 2 from the inner frame 4 . The screen 8 , for example, can thus be readily cleaned. To match the conically shaped upper portion of the diverter 6 , the screen 8 is also conically shaped, as shown in FIGS. 5 and 6 . The overall external upper and lower views of the aerator shown in FIGS. 5 and 6 are shown in FIGS. 7 , 8 and 9 .
Turning next to FIG. 10 , the upper portion of the aerator is shown, including the ball joint 12 as shown in the partial enlarged view thereof. The upper joint 13 for attachment to a kitchen tap, for example, is a copper fixture with threads as shown thereon. The body of the ball joint 12 , however, is preferably made of plastic, which is attached to the copper joint 13 in the manner shown. Thus, the lower end of the copper joint 13 includes an inwardly extending flange 13 a and the upper portion of the ball joint 2 includes an outwardly extending flange 12 a , which is captured by the inwardly extending flange 1 a in the manner shown therein. The body of the ball joint 2 itself is connected to the aerator 3 in the manner shown hereinabove.
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.
INDUSTRIAL APPLICABILITY
Aerators are provided by this invention for the aeration of water in connection with aerator nozzles, faucets, kitchen aerators, spray heads, shower heads, and the like. The aerators can include adjustable flow control mechanisms for altering the flow through the aerator, and for producing greater aeration in one mode as compared to another, thus providing aerated water flow for each of these devices. | Aeration devices for generating bubbles in a flow of water are disclosed including an aerator body ( 1 ), a diverter ( 3 ) including orifices ( 31 ) for receiving the flow of water, each of the orifices ( 31 ) including a decreasing pore size in the direction from the upper portion of the diverter ( 3 b ) towards the lower portion of the diverter ( 3 a ), and a lower body portion ( 2 ) including a water chamber ( 2 a ) for receiving and aerating the flow of water from the orifices ( 31 ) in the diverter ( 3 ). Aeration devices are also disclosed including a pressure compensator ( 6 ) mounted on the upper portion of the diverter ( 3 b ) for regulation of the maximum flow of water therethrough, the aerator body ( 1 ) including a ball joint opening ( 11 ) and a ball joint ( 12 ) mounted within the ball joint opening ( 11 ), the ball joint ( 12 ) comprising plastic and the upper ball joint ( 13 ) comprising metal. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application claims priority under 35 U.S.C. 119 and 35 U.S.C 365 to Korean Patent Application No. 10-2008-0017608, filed Feb. 27, 2008 and Korean Application No. 10-2008-0017609, filed Feb. 27, 2008, which is hereby incorporated by reference for all purposes as if fully set forth herein.
BACKGROUND
The present disclosure relates to an ice making assembly for a refrigerator and a method for controlling the ice making assembly.
Refrigerators are domestic appliances used for storing foods in a refrigerated or frozen state. Recently, various kinds of refrigerators have been introduced into the market. Examples of recent refrigerators include: a side-by-side type refrigerator in which a refrigerator compartment and a freezer compartment are disposed in the left and right sides; a bottom-freezer type refrigerator in which a refrigerator compartment is disposed above a freezer compartment; and a top-mount type refrigerator in which a refrigerator compartment is disposed under a freezer compartment.
Furthermore, many of recently introduced refrigerators have a structure that allows a user to access food or drink disposed inside a refrigerator compartment through an alternate access point without having to open a primary refrigerator compartment door. A compressor, a condenser, and an expansion member are disposed inside a refrigerator, and an evaporator is disposed on the backside of a refrigerator main body, as refrigeration-cycle components of the refrigerator.
In addition, an ice making assembly can be provided inside the refrigerator. The ice making assembly may be mounted in a freezer compartment, a refrigerator compartment, a freezer compartment door, or a refrigerator compartment door.
To satisfy consumers' increasing demands for transparent ice, much research has been conducted on ice making assemblies that can provide transparent ice.
In an ice making assembly of the related art, an additional water tank is disposed at a predetermined side of a refrigerator and is connected to an ice making tray through a tube to supply water to the ice making tray, or a tap of an external water source is directly connected to the ice making tray through a tube.
SUMMARY
The disclosed embodiments provide an ice making assembly for a refrigerator that can produce transparent ice easily and maintain the amount of water supplied to make ice at a constant level for each ice making cycle, and a method for controlling the ice making assembly.
The disclosed embodiments also provide an ice making assembly for a refrigerator in which a supply of water is automatically interrupted for preventing overflow when the water supplied to an ice making tray reaches a set level, and a method for controlling the ice making assembly.
The disclosed embodiments also provide an ice making assembly for a refrigerator that can maintain the amount of supplied water at a constant level regardless of water pressure variations occurring at the location the ice-making assembly is installed, and a method for controlling the ice making assembly.
The disclosed embodiments also provide an ice making assembly for a refrigerator that can reduce unnecessary power consumption by immediately detecting a water supply error when water is not supplied to an ice making tray due to, for example, malfunctioning of a water supply valve, and a method for controlling the ice making assembly.
The disclosed embodiments provide an ice making assembly for a refrigerator and a method for controlling the ice making assembly as follows.
In one embodiment, there is provided an ice making assembly for a refrigerator, the ice making assembly including: a tray comprising a water supply part and a plurality of ice recesses; a plurality of fins above the tray; a plurality of rods inserted in the ice recesses through the fins and configured to be lifted and titled together with the fins after a freezing operation; and a water level sensor at one of the ice recesses.
In another embodiment, there is provided an ice making assembly for a refrigerator, the ice making assembly including: a tray comprising a water supply part and a plurality of ice recesses; a plurality of fins above the tray; a plurality of rods inserted in the ice recesses through the fins and configured to be lifted and titled together with the fins after a freezing operation; and a water level sensor at one of the ice recesses, wherein the water level senor includes: an earth electrode at a lowermost side; an intermediate level electrode disposed at a position upward from the earth electrode for detecting an intermediate water level; and a full level electrode disposed at a position upward from the intermediate level electrode for detecting a full water level.
In another embodiment, there is provided a method for controlling an ice making assembly of a refrigerator, the method including: disposing a rod vertically at an upper side of a tray in which an ice recess is formed; moving the rod down into the ice recess; supplying water to the ice recess; allowing the water to reach a height at or below which an earth electrode and at least one electrode of a water level sensor are located; and detecting a level of the water by detecting a capacitance variation between the earth electrode and the at least one electrode.
By using the ice making assembly for a refrigerator and the method of controlling the ice making assembly according to the present disclosure, transparent ice can be easily made.
Furthermore, water can be supplied at a constant level for each ice making cycle regardless of water pressure variations at the installed location of the refrigerator. Therefore, water supply overflow, freezing of overflowed water in the refrigerator, and leakage of overflowed water from the refrigerator can be prevented.
Furthermore, although different amounts of water remain in the ice recesses of the tray, water can be supplied to the ice recesses at an equal level.
Moreover, when water is not supplied to the tray due to malfunctioning of a water supply valve, such a situation can be immediately detected for reducing unnecessary power consumption.
In addition, the ice making assembly can detect the level of water using existing components without the need for an additional device. This reduces the manufacturing costs of the ice making assembly.
The details of one or more embodiments are set forth in the accompanying drawings and the description below. Other features will be apparent from the description and drawings, and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 and 2 are perspective views illustrating an ice making assembly structure for a refrigerator according to an embodiment of the invention.
FIG. 3 is a perspective view illustrating an ice making assembly according to an embodiment of the invention.
FIG. 4 is a perspective view illustrating the ice making assembly, according to an embodiment of the invention, just before ice is transferred to a container.
FIG. 5 is a perspective view illustrating a tray of the ice making assembly according to an embodiment of the invention.
FIG. 6 is a perspective view illustrating a water level sensor of the ice making assembly according to an embodiment of the invention.
FIG. 7 is a sectional view taken along line I-I′ of FIG. 5 for illustrating the increasing level of water supplied to the tray of the ice making assembly according to an embodiment of the invention.
FIG. 8 is a graph illustrating variations of circuit capacitance with respect to the level of water in the ice making assembly of FIG. 7 .
FIGS. 9 to 12 are views for illustrating variations of the level of water supplied to the tray of the ice making assembly according to an embodiment of the invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
Hereinafter, an ice making assembly for a refrigerator will be described in detail according to the disclosed exemplary embodiments of the present disclosure with reference to the accompanying drawings.
In the following description, an ice making assembly is mounted at a freezer compartment door. However, the ice making assembly can be mounted at other places such as a freezer compartment, a refrigerator compartment, and a refrigerator compartment door without departing from the scope of the invention.
FIGS. 1 and 2 are perspective views illustrating an ice making assembly structure for a refrigerator according to an exemplary embodiment of the invention.
Referring to FIGS. 1 and 2 , an ice making assembly 20 may be mounted on the backside of a door 10 , and the backside of the door 10 may be recessed to form an ice making space 11 for accommodating the ice making assembly 20 . A cooling air supply hole 111 may be formed at a side of the ice making space 11 for allowing inflow of cooling air from an evaporator (not shown), and a cooling air discharge hole 112 may be formed in the side of the ice making space 11 to allow the cooling air from the ice making space 11 to flow back the evaporator.
In detail, the ice making assembly 20 may be mounted at an upper portion of the ice making space 11 , and a container 30 may be mounted under the ice making assembly 20 to store ice made by the ice making assembly 20 . The ice making assembly 20 may be protected by an ice making cover 31 . The ice making cover 31 may also provide guidance for the ice separated from the ice making assembly 20 so that it follows a path directly to the container 30 .
FIG. 3 is a perspective view illustrating the ice making assembly 20 according to an embodiment of the invention, and FIG. 4 is a perspective view illustrating the ice making assembly 20 , according to an embodiment of the invention, just before ice is transferred to the container 30 .
Referring to FIGS. 3 and 4 , the ice making assembly 20 of the current embodiment may include: a tray 21 having a plurality of ice recesses 211 for making ice in a predetermined shape; a plurality of fins 24 stacked above the tray 21 and capable of vertical and rotational movement; a plurality of rods 23 configured to be inserted into the ice recesses 211 through the fins 24 ; an ice ejecting heater 25 provided at the lowermost of the plurality of fins 24 ; a supporting plate 27 configured to support the ice ejecting heater 25 , the remainder of the plurality of fins 24 , and the rods 23 as one unit; a water supply part 26 disposed at an end of the tray 21 ; and a control box 28 disposed at another other end of the tray 21 . A heater (not shown) may be mounted at the bottom of the tray 21 to maintain the temperature of the tray 21 at a temperature above freezing. A supporting lever 271 may extend from a front end of the supporting plate 27 , and a hinge 272 may be disposed at an end of the supporting plate 27 . During an ice making operation, as shown in FIG. 4 , ice cubes (I) having a shape corresponding to the shape of the ice recesses 211 may be formed around the rods 23 .
A cam 29 and a driving motor may be disposed inside the control box 28 . The driving motor may drive a rotational movement of the cam 29 . The hinge 272 is coupled to the cam 29 so that the hinge 272 can be used and rotated by rotating the cam 29 . The ice ejecting heater 25 may have a plate-like shape and may contact the rods 23 . Alternatively, the ice ejecting heater 25 may be embedded within the rods 23 . The supporting plate 27 may act to close an open-top of the tray 21 ( FIG. 3 ) such that water supplied to the tray 21 is indirectly cooled by cooling air supplied to the ice making space 11 and flowing about the fins 24 and rods 23 .
Hereinafter, ice making and ice ejecting operations of the ice making assembly 20 will be described.
First, the heater attached to the tray 21 may be operated to maintain the tray 21 at a temperature higher than 0° C., to create an environment that can make transparent ice in the ice making assembly 20 .
When water is rapidly frozen by cooling air supplied from an evaporator, air dissolved in the water cannot escape from the water before it is frozen. Thus, when water is frozen together with the gas that is trapped inside the water, the resulting ice is not transparent.
However, in the ice making assembly 20 of the disclosed exemplary embodiments, the tray 21 may be maintained at a temperature above freezing so that the water freezes slowly, starting at the freezing rod 23 . The air in the water is then able to escape before the water is completely frozen. Thus, transparent ice, which is preferred by the user, may be produced.
According to one embodiment, either before or after water is supplied to the tray 21 , the rods 23 may be inserted into the ice recesses 211 of the tray 21 , and a freezing operation may be started. In general, the freezing operation may be started after a predefined volume of water is added to the tray 21 . The freezing operation may be started by supplying cooling air to the ice making space 11 . The temperature of the fins 24 may then be reduced to below the freezing temperature by conduction heat transfer with the supplied cooling air. The temperature of the rods 23 may also be reduced to below the freezing temperature by conduction heat transfer with the fins 24 . Portions of the rods 23 inserted in the ice recesses 211 are submerged in the water. Therefore, the water is gradually frozen starting from a region closest to the rods 23 . As the water freezes, the frozen region becomes attached to the rods 23 . The freezing of the water then proceeds outwardly from the outer surfaces of the rods 23 to the inner surfaces of the ice recesses 211 .
After the freezing of the water is completed, the cam 29 may be rotated to move the rods 23 , and the ice cubes formed thereon, out of the ice recesses 211 . That is, the cam 29 is rotated to lift the rods 23 vertically upward, thus the formed ice cubes (I) may be completely removed from the ice recesses 211 . The cam 29 may be further rotated to tilt the rods 23 to a predetermined angle.
The completion of the freezing of the water may be determined by the passage of a predetermined amount of time. More specifically, if a predetermined time passes after the start of the freezing of the water, this may determine that the freezing is completed.
Another method of determining the completion of freezing, involves lifting rods 23 , via cam 29 , to a predetermined height after a predetermined time from the start of freezing. The predetermined height may be a height at which ice attached to the rods 23 is not yet fully separated from the ice recesses 211 . Once the rods 23 are lifted, the amount of water remaining in the ice recesses may be detected. In one embodiment, the amount of water remaining in the ice recesses 211 may be detected using a water level sensor mounted on the tray 21 . If the amount of water remaining in the ice recesses 211 is equal to or less than a predetermined amount, it may be determined that the freezing is completed. On the other hand, if the amount of water remaining in the ice recesses 211 is greater than the predetermined amount, the rods 23 may be moved down to their original positions to continue the freezing of the water. The water sensor will be described later with reference to the accompanying drawings. As described above, after the freezing of the water is completed, the cam 29 may be rotated such that it moves the rods 23 vertically upward out of the ice recesses 211 . After ice cubes (I) are completely removed from the ice recesses 211 , the cam 29 is further rotated to effect rotation of the rods 23 . More specifically, the hinge 272 is rotated by the cam 29 to rotate the rods 23 to a predetermined angle.
Once the rods 23 are rotated to the predetermined angle, such as the angle shown in FIG. 4 , the ice ejecting heater 25 may be operated.
When the ice ejecting heater 25 is operated, the temperature of the rods 23 increases, and thus the ice cubes (I) are separated from the rods 23 . The separated ice cubes (I) may then fall into the container 30 .
FIG. 5 is a perspective view illustrating the tray 21 of the ice making assembly 20 according to an embodiment of the invention.
As illustrated in FIG. 5 , the ice recesses 211 may be arranged in the tray 21 of the ice making assembly 20 . Channels 213 having a predetermined depth may be formed between the ice recesses 211 .
Water can travel between neighboring ice recesses 211 through the channels 213 . Bottoms of the channels 213 are spaced apart from bottoms of the ice recesses 211 .
A guide 212 may be formed at an end portion of the tray 21 to guide water supplied from the water supply part 26 to the tray 21 and to the ice recesses 211 . Water may be supplied to the ice recesses 211 closest to the guide 212 and may gradually travels to the ice recess 211 farthest from the guide 212 .
A water level sensor 40 may be mounted at a side of the ice recess 211 farthest from the guide 212 , e.g., at a side of the ice recess located at an end of the tray 21 opposite to the guide 212 . Further, a temperature sensor 50 may be mounted at a side of the tray 21 and may be used in conjunction with a subassembly to maintain the tray 21 at a constant temperature. A tray heater (not shown) may be installed at the tray 21 . The tray heater may be installed at the tray 21 in an embedded manner or attached manner.
FIG. 6 is a perspective view illustrating the water level sensor 40 of the ice making assembly 20 according to an embodiment of the invention.
Referring to FIG. 6 , the water level sensor 40 provided at the ice making assembly 20 according to an embodiment of the present disclosure may be mounted at the side of the ice recess 211 as described above. The water level sensor 40 is a capacitive sensor capable of detecting the existence of an object by sensing the capacitance of the object using multiple electrodes disposed at a side of the object. The capacitance water level sensor 40 is a more reliable method of detecting water levels as it is not subject to instantaneous, temporary water level changes, for example caused by opening and closing the refrigerator door housing the ice making device.
In the disclosed embodiment electrodes are provided at a side of ice recess 211 so that the level of water supplied to the tray 21 can be detected using the water level sensor 40 . In more detail, as illustrated in FIG. 6 , the water level sensor 40 , of the exemplary embodiment, includes a plurality of electrodes, and output terminals 41 . The output terminals 41 may extend from the electrodes and may connect to the control unit 45 , which may be a control unit for operation of the refrigerator in general. The plurality of electrodes are covered with a waterproof layer 42 ( FIGS. 6 and 7 ) so that water cannot function as a conductor having resistance between the electrodes. Hereinafter, an explanation will be given of an exemplary embodiment where the water level sensor 40 includes three electrodes.
In detail, the water level sensor 40 includes an upper electrode A, a middle electrode B, and a lower electrode C. When the water level sensor 40 is attached to the tray 21 , the electrode A may be located at a position slightly lower than the highest water level of the ice recess 211 , and the electrode C may be located at a position higher than the bottom of the ice recess 211 . For example, the electrode C may be located at the same height as the bottom of the channel 213 , which is the channel through which water can flow from one ice recess to a neighboring ice recess. As described above, the electrodes A, B, and C cannot make direct contact with water due to the waterproof layer 42 . Electrode C is grounded, and an electric charge can be stored between the electrodes B and C or the electrodes A and C according to the level of water.
FIG. 7 is a sectional view taken along line I-I′ of FIG. 5 for illustrating the increasing level of water supplied to the tray of the ice making assembly according to an embodiment of the invention, and FIG. 8 is a graph illustrating variations of circuit capacitance with respect to the level of water in the ice making assembly of FIG. 7 . Referring to FIGS. 7 and 8 , when the ice recess 211 of the tray 21 is not filled with water, the capacitance between electrodes A and C or electrodes B and C is the capacitance (Ca) of air. In this state, no signal is transmitted to the control unit 45 through the output terminals 41 . Similarly, when the level of water in the ice recess 211 is between the electrodes B and C, no signal is transmitted to the control unit 45 through the output terminals 41 because the electrode C is grounded and the water level has not yet reached electrode B.
As water is supplied to the tray 21 and the water in ice recess 211 reaches electrode B, the capacitance between the electrodes B and C changes. That is, the capacitance between the electrodes B and C changes from the capacitance Ca of air to the capacitance (Cw) of water. Accordingly, a sensor signal is sent to the control unit 45 through the output terminal 41 of the electrode B.
As shown FIG. 8 , since the capacitance Cw of water is greater than the capacitance Ca of air, the capacitance between the electrodes B and C will change when the level of water reaches the height of the electrode B. Then, the control unit 45 detects the variation of the capacitance and determines that the level of water has reached the height of the electrode B.
If the level of water further increases to the height of electrode A, the capacitance between electrodes A and C will change, similar to the change described above with respect to electrodes B and C. That is, the medium between electrodes A and C changes from air to water, and thus the capacitance between electrodes A and C changes. A sensor signal corresponding to the capacitance change is sent to the control unit 45 through the output terminal 41 (connected to the electrode A). The control unit 45 thus may determine that the level of water has reached the height of electrode A.
FIGS. 9 to 12 illustrate water level variations of the tray 21 of the ice making assembly 20 when water is supplied to the tray 21 . For ease of illustration, rods 23 are not depicted in FIGS. 9 to 12 . It will be understood, depending on whether water is added before or after rods 23 are inserted into the ice recesses 211 , that the displacement of water attributable to the rods 23 may be considered in determining the positioning of electrodes A, B, and C.
Referring to FIG. 9 , after a predetermined amount of time has passed after the water supply has begun, the level of water in the tray 21 at a side of the tray 21 adjacent the guide 212 is different from a water level at a side of the tray 21 opposite to the guide 212 .
In more detail, water is first filled in the ice recess 211 A closest to the guide 212 . When the level of water in the closest ice recess 211 A exceeds the bottom of the channel 213 , the supplied water then travels to the adjacent ice recess 211 B. However, a large amount of water is not transferred to the neighboring ice recesses all at once due to the narrow width of the channel 213 and the surface tension of the water. Therefore, at the beginning of the water supply, the level of water in the ice recess 211 A closest to the guide 212 is considerably different from the level of water in the ice recess 211 C, which is where the water level sensor 40 is installed. The ice recess 211 C maybe the ice recess farthest from the guide 212 .
As illustrated in FIG. 9 , at the moment when the level of water is detected at electrode B, the level (a) of water in the ice recess 211 A, differs greatly from the level (b) of water in the ice recess 211 C (h 1 =a−b, where h 1 is the water level difference). While the water is being supplied, the level of water may slope as illustrated in FIG. 9 .
Given this level difference during water supply, if the water is continuously supplied until it is detected that the ice recess 211 C is filled, oversupply and overflow of at least ice recess 211 A may result. More specifically, if the water supply is stopped only when a full water level is detected in ice recess 211 C, the stabilized final water level may exceed the full water level in ice recesses closer to the guide 212 (such as ice recess 211 A) and cause overflowing of water from the ice tray 21 . This is because the water being supplied to ice recess 211 A from guide 212 does not immediately transfer to the farthest ice recess 211 C. Therefore, to prevent overflow, the water supply is temporarily stopped after water is supplied for a predetermined amount of time sufficient to fill ice recess 211 C to the level of the electrode B.
Referring to FIG. 10 , when the level of water is detected through the electrode B, the water supply is temporarily interrupted. The water level is then stabilized at a level (c) for a predetermined time. In the exemplary illustration of FIG. 10 , the stabilized water level (c) is higher than the height of the electrode B yet lower than the height of electrode A. The predetermined amount of time that the water supply is stopped may be adjusted according to the pressure of water and the size of the channel 213 .
Referring to FIG. 11 , if water is supplied again after the predetermined amount of time has passed, the level of water changes to result in a water level difference h 2 between ice recess 211 A, closest to guide 212 , and ice recess 211 C, farthest from guide 212 .
However, in this example, the water level difference h 2 is not as large as the initial water level difference h 1 because water is re-supplied after the level of water has increased to some degree. That is, since the intermediate water level h 1 is somewhat higher than the bottom of the channel 213 , the water travels between all ice recesses, 211 A through 211 C, more smoothly than it did in the earlier stage of water supply. In addition, the influence of surface tension of water is less as compared with the earlier stage of water supply.
After a predetermined amount of time has passed from the start of the re-supply of water, the increasing water level is detected at the electrode A. Then, the supply of water is suspended again to stabilize the water level.
As shown in FIG. 12 , the stabilized final water level (d) is higher than the height of the electrode A.
Therefore, by placing the electrode A at a position slightly lower than a full water level, overflowing can be prevented at the end of a water supply operation.
In the above-described embodiments, at least two electrodes may be used to detect a capacitance variation between the two electrodes and suspend a supply of water at an intermediate water level. The water supply suspending time may be shortened or extended depending to the position of the electrode B. In the exemplary embodiments and illustrations just described, the spacing between electrodes C and B appears to be equal to the spacing between electrodes A and B; however, the spacing need not be equal. It is within the scope of the invention to adjust the position of, and spacing between, electrodes A, B, and C. The electrodes may thus be spaced apart at regular or irregular intervals.
In addition, the amount of water remaining after an ice making operation is complete is determined by the position of electrode B. More specifically, according to an embodiment of the present disclosure, the rod 23 may be slightly lifted after a predetermined amount of time has passed from the start of an ice making operation so as to detect the amount of remaining water. If the amount of remaining water is equal to or smaller than a set amount, it is determined that ice is completely made, and the ice is ejected. If the amount of remaining water is greater than the set amount, the rod 23 is moved down to continue the ice making operation.
Thus, the amount of remaining water is determined by the position of the electrode B. If the level of water in the ice recesses 211 is lower than the height of the electrode B, the control unit 45 will determine that there is no water in the ice recess 211 , because the control unit 45 cannot detect a capacitance variation. That is, as the position of the electrode B becomes lower, the amount of remaining water will be reduced, and as the amount of remaining water is reduced, the size of ice pieces will increase.
As described above, by using the capacitive sensor 40 capable of sensing capacitance variations, the level of water can be precisely detected, and by supplying water in multiple steps, overflowing of supplied water can be prevented.
In addition, if a capacitance variation is not detected after a predetermined amount of time passes after the start of a water supply operation, it may be determined that there is a water supply error. Thus, the supply of cooling air may be suspended to reduce unnecessary power consumption.
Although embodiments have been described with reference to a number of illustrative embodiments thereof, it should be understood that numerous other modifications and embodiments could be devised by those skilled in the art that will fall within the spirit and scope of the principles of this disclosure. More particularly, various variations and modifications are possible in the component parts and/or arrangements of the subject combination arrangement within the scope of the disclosure, the drawings, and the appended claims. In addition to variations and modifications in the component parts and/or arrangements, alternative uses will also be apparent to those skilled in the art. | An ice making assembly for a refrigerator and a method for controlling the ice making assembly are provided. The ice making assembly and the method of controlling the ice making assembly provides a constant amount of water supply for each ice making cycle regardless of environmental conditions such as the varying water supply pressure of different installation locations. Furthermore, overflowing can be prevented during water supply with the use of a capacitance water level sensor. | 5 |
FIELD OF THE INVENTION
[0001] The invention concerns a brush, comprising a brush head, which is connected with bristles, and also refers to a use of the brush.
BACKGROUND OF THE INVENTION
[0002] Brushes with bristles are generally known and can be used in various areas; for example, as washing brushes.
[0003] Previously known washing brushes frequently can be washed out, after their use, only with great effort and only with limited success—particularly if, beforehand, pasty, highly viscous soilings were removed from dishes. Frequently, these soilings settle firmly on the shaft of the bristles or bristle bundles, in the transition area to the brush head. Often, in makeshift fashion, the soilings are then removed with the aid of scissors or knives, wherein there is also the danger of irreparably damaging the brushes.
[0004] If during the washing of the washing brush, flowing water strikes the brush head from above, there is a large amount of spray, which is unpleasant for the user of the washing brush. Furthermore, the water sprays into the surroundings in an undesired and uncontrollable manner.
[0005] If, on the other hand, the attempt is made to clean the previously known brushes by washing out from the side, then it is frequently the case that the soilings are moved still further between the bristles in the direction of the brush head and in this way, settle even more firmly between the bristles.
BRIEF SUMMARY OF THE INVENTION
[0006] A goal of the invention is to further develop a brush of the foregoing type that can be cleaned more easily and rapidly following its use. The undesired formation of spray water should thereby be minimized during the cleaning process of the brush.
[0007] To this end, a brush is provided, whose brush head has at least one opening, designed as a cleaning channel, for the cleaning of the bristles.
[0008] What is advantageous with a brush according to the invention is that the brush can be cleaned more easily and rapidly following its use. The cleaning of the brush can take place by conducting a cleaning agent, for example, flowing water, onto the bristles from above, through the cleaning channel in the brush head. In this way, the soilings which are found between the bristles can be washed out. The advantageous effect can be attributed to the fact that the washing out of the soilings practically takes place in the opposite direction, relative to the direction in which the soilings arrived between the bristles. There is no danger—as in the case of prior art bristle brushes—that the soilings settle even more firmly between the bristles while the bristles are being cleaned.
[0009] Surprisingly, it has been found that the openings designed as cleaning channels facilitate not only an easier washing out of the bristles, but also that the cleaning channels designed as openings significantly reduce the formation of spray water, for example, during the washing out of the brush under flowing water. This can probably be attributed to the fact that the water jet does not strike a plane, closed surface—as is common with prior art brushes—and is deflected from there and, in part, is hurled back; the water jet striking the broken surface of the brush head is split and spray water formation is minimized.
[0010] Preferably, the brush head has several cleaning channels. Using several cleaning channels, further improves the removal of soilings from the bristles and further reduces the formation of spray water.
[0011] The cleaning channels can be arranged so that they will be uniformly distributed in the brush head. All bristles of the brush can be largely cleaned of soilings equally well in this way; dead spots not penetrated by the cleaning liquid are thereby avoided.
[0012] The cleaning channels can penetrate the brush head in the washing direction, essentially vertically. Such aligned cleaning channels permit a horizontal washing out of the brush head—for example, under flowing water—and in this way, a very rapid washing out. Within a short time, most soilings are washed out of the bristles, residue-free.
[0013] The cleaning channels can have a gradual but constantly diminishing cross-section in the washing direction. In a manufacturing sense, this is advantageous. Furthermore, the jet of the cleaning liquid can be directed in a more targeted manner onto the critical places of the bristles in this way, where the soilings have settled when the brush is used.
[0014] The cleaning channels have an essentially rectangular or oval cross section. In this way, the cleaning channels are shaped like slits. On the underside of the brush head, it is then possible to extend bristles or bristle bundles along the circumferential limitation of the cleaning channels.
[0015] According to one embodiment, it is possible to make provisions so that the cleaning channels are arranged transverse to the longitudinal direction of the bristle head and are extended almost over the entire width of the brush head. Here, it is advantageous that the bristles or bristle bundles arranged over the entire width of the brush head are cleaned well.
[0016] The ratio between the width of the brush head and the width of the cleaning channels can be 1.1-1.5. For most applications, such a ratio has proved advantageous, with regard to an easy cleaning of the brush.
[0017] The ratio of the width of the cleaning channels to their length on the surface of the bristle head is preferably 3-6. Because of the comparatively small width of the cleaning channels, a lot of material of the brush head remains on which the bristles or bristle bundles can be affixed. A large number of bristles or bristle bundles provides an effective cleaning of the surfaces to be cleaned.
[0018] At least some of the bristles can be joined together to form bristle bundles.
[0019] According to another preferred embodiment, provisions can be made so that all bristles are joined together to form bristle bundles. The joining together to form bristle bundles is particularly advantageous if the bristle head has the openings, in accordance with the invention, because the fastenings of the bristle bundles can be grouped well around the openings. Although the bristle bundles are very densely packed in the area of their fastenings, the bristle bundles fan out on their side turned away from the bristle head so as to attain a good cleaning performance.
[0020] The bristles and/or the bristle bundles can be arranged at an incline, relative to the vertical washing direction in the bristle head.
[0021] With respect to the vertical washing direction, the bristles and/or the bristle bundles preferably define an angle which is 30-60°.
[0022] In comparison to bristles or bristle bundles which are arranged in the washing direction in the brush head, not just the cleaning performance of the brush is improved. The washing out of soilings is also improved by the bristles and/or bristle bundles being arranged at an incline to the washing direction, because a larger area is impinged on with cleaning liquid, wherein when the bristle bundles are used, the inner area of the bristle bundles is also effectively washed out in this way.
[0023] According to a preferred embodiment, provisions can be made so that at most two rows of bristle bundles are located between cleaning channels adjacent to one another. All bristle bundles can be washed out well in this way, because the bristle bundles of both rows are located in the effective area of the cleaning channels. If substantially more rows of bristle bundles were located between cleaning channels adjacent to one another, the cleaning would be complicated, because not all bristle bundles would be impinged on equally with the cleaning liquid through the cleaning channels.
[0024] The brush head can be shaped on its upper side, turned away from the bristles and/or bristle bundles. The advantage hereby is that the upper side of the bristle head can also be cleaned well.
[0025] According to another embodiment, the brush head can also be shaped in a concave manner on its upper side, turned away from the bristles and/or bristle bundles and transverse to its longitudinal direction. If, for example, the brush is cleaned by water flowing underneath, then the water jet is channeled by the concave shape of the upper side of the brush head practically in the direction of the openings so that formation of spray (with cleaning fluid) is further diminished and a better washing of the brush is provided.
[0026] The brush head can have a convex underside in its longitudinal and/or transverse direction in which the bristles and/or bristle bundles are affixed. With respect to effectiveness of the brush, such a development is advantageous. The bristles of the bristle bundle project both in the longitudinal as well as in the transverse direction over the circumferential border of the brush head, so that soilings can also be removed without any problems even on sites which can be accessed only with difficulty, for example, in the transition area from the bottom of a pot to the side wall of the pot.
[0027] To remove stubborn soilings, the brush head can have, on the front, a scraper which is curved forwards and upwards against the bristles and/or bristle bundles. Encrustations which could not be removed in the first operation by the bristles or bristle bundles of the brush alone can be first broken up by the scraper and subsequently be more easily removed by the bristles or bristle bundles.
[0028] With reference to the scraper on the front, the brush head can also have a handle.
[0029] After a first shaping, the brush head and the handle can go over into one another, as one piece, and be made of a uniform material. With regard to a simple and low-cost manufacturing capacity, the brush head can be made of a polymeric material. Due to its low weight, the brush can be handled with ease and when used as a washing brush is also rust-free and resistant to moist soilings and cleaning liquids. Due to the integrity of the brush head and the handle, separation seams in the brush are avoided; hygiene is thus improved.
[0030] According to another embodiment, the brush head and the handle can be joined with one another in a detachable and nondestructive manner. Such a development is advantageous, for example, if differently shaped brush heads and/or brush heads with differently shaped bristles and/or bristle bundles are to be used, according to need and the particular application, with one and the same handle. Even if the bristles and/or bristle bundles of the brush head are subject to a particularly high wear and tear, for example, in that rough impurities are to be removed from particularly rough surfaces, it is advantageous that, as needed, a new brush head can be joined with the handle which is subject to practically no wear and hear.
[0031] The invention also encompasses the use of a brush as was previously described. A brush with a brush head having at least one opening for the cleaning of the bristles and is shaped like a cleaning channel is used in accordance with the invention as a washing brush. Especially for this use, a brush which can be washed out well is particularly advantageous. Even pasty, highly viscous soilings, which settle between the bristles and/or between the bristles of the bristle bundles, following the cleaning of surfaces to be cleaned, can be washed out well due the shape of the brush head, in accordance with the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] A brush according to the invention, and its use as a washing brush is described in more detail below with the aid of FIGS. 1-4 . These figures show the following:
[0033] FIG. 1 is a top view of a washing brush in accordance with the invention;
[0034] FIG. 2 is a perspective view of the washing brush of FIG. 1 ;
[0035] FIG. 3 is a bottom a view of the washing brush of FIG. 1 ; and
[0036] FIG. 4 is a partial side sectional view of the front brush head of FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
[0037] FIG. 1 shows an exemplary embodiment of a brush that can be used as a washing brush. The washing brush includes a brush head 1 , which is connected with bristles 2 . In the illustrated embodiment, all of the bristles 2 are joined together to form bristle bundles 10 . Embodiments of the invention using part bristles 2 and par, bristle bundles 10 or only bristles 2 can also be used depending on the application.
[0038] In the illustrated embodiment, the brush head 1 is made of a polymeric material and has a unitary construction with the handle 14 with both the head and the handle being made of the same material.
[0039] Three openings 4 , in the form of cleaning channels 3 , are located in the brush head 1 . The openings completely penetrate the brush head 1 in the washing direction 5 . The cleaning channels 3 are shaped as slits, which are arranged transverse to the longitudinal direction 6 of the brush head 1 , and extend almost over the entire width of the brush head 1 .
[0040] The ratio between the width 7 of the brush head 1 and the width 8 of the cleaning channels 3 is 1.3 in the illustrated embodiment. The ratio of the width 8 of the cleaning channels 3 to their length 9 on the upper side 11 of the brush head 1 is 4.5.
[0041] At the end opposite the handle 14 in the longitudinal direction of the brush head 1 , the brush head 1 has a scraper 13 which is curved forwards and upwards against the bristle bundles 10 . The scraper 13 is provided, to first break up stubborn encrustations, before the remaining broken-up soilings can be removed from the bristle bundles 10 .
[0042] The upper side 11 of the brush head 1 is shaped in a con concave manner either plane or transverse to its longitudinal direction 6 . If the washing brush is washed under flowing water after it has been used, as shown in FIG. 2 , flowing water, in the washing direction 5 , strikes the upper side 11 of the brush head 1 . The water passes through the cleaning channels 3 and arrives at the bristle bundles 10 and there, washes even pasty, highly viscous soilings from the bristle bundles 10 . In the illustrated embodiment, two rows of bristle bundles 10 are arranged adjacent to one another between the washing canals 3 . In this case, the two rows of bristle bundles 10 can be impinged on with cleaning liquid (e.g., flowing water) via a cleaning channel 3 .
[0043] The location of the cleaning channels 3 , relative to the bristle bundles 10 can be seen in FIG. 3 . In FIG. 3 , one can also see, in addition to the convex underside 12 in the transverse direction 7 of the brush head 1 , that the bristles 2 of the bristle bundles 10 define with the vertical washing direction 5 an angle α, which is 30-60° in the illustrated embodiment.
[0044] This connection is also shown in FIG. 4 . In FIG. 4 , an portion of the brush head 1 is shown in which the vertical washing direction 5 through the cleaning channels 3 is viewed in the longitudinal direction 6 of the brush head 1 , with which bristles 2 and/or bristle bundles 10 define the angle α.
[0045] As a whole, the washing brush, in accordance with the invention, has very good properties during a long period of use, because the bristles 2 and/or the bristle bundles 10 can be cleaned simply and effectively by means of the cleaning channels 3 , and the formation of undesired spray water during the cleaning of the brush via the cleaning channels 3 that penetrate the upper side 11 of the brush head 1 is minimized. | A brush, comprising a brush head ( 1 ) that is connected to bristles ( 2 ). The brush head ( 1 ) has at least one opening ( 4 ) designed in the form of a rinsing channel ( 3 ) for cleaning the bristles ( 2 ). The brush can be used as a dishwashing brush. | 0 |
FIELD OF THE INVENTION
The present invention relates to a deflection compensated roll for a paper/board or finishing machine, comprising a stationary roll shaft, and a, roll shell adapted to be rotatable around the same and mounted with slide bearing elements upon the roll shaft, said slide bearing elements being provided with hydraulic fluid feeding means for loading the slide bearing elements with a hydraulic fluid, and said roil being intended to form a nip together with a counter roll.
BACKGROUND OF THE INVENTION
FI patent 98320 describes a slide bearing assembly for a deflection compensated roll, wherein the roll shell is able to shift or perform a stroke relative to the roll shaft both in a main loading plane and in a lateral bearing plane perpendicular thereto. One implementation of such a “movable shell” roll will be described more closely hereinafter in reference to FIGS. 1-3. On the other hand, Finnish patent application No. 990329 discloses a solution for fitting a roll with slide bearings in such a way that the shell is not able to move relative to the shaft, the roll shell bearing assembly allowing substantially no stroke. This type of solution will be described more closely hereinafter in reference to FIG. 4 .
FIGS. 1 and 2 show in schematic elevations a prior art tubular roll with slide bearings, such that FIG. 1 is an axial elevation of the roll and FIG. 2 is a sectional view taken along a line II—II of the roll depicted in FIG. 1 . In FIGS. 1 and 2 the deflection compensated roll is generally designated with reference numeral 110 and it comprises a stationary roll shaft 111 , upon which is rotatably fitted a roll shell 112 which is supported on the roll shaft by means of hydraulic loading elements 117 . The hydraulic loading elements 117 work in the direction of a nip plane and enable an adjustment of the roll shell 112 regarding its contour and a control of the roll regarding its axial nip profile.
The roll 110 has its bearing system implemented by means of slide bearing elements, whereof the slide bearing elements, acting in the direction of loading, in the case of a roll shown in FIGS. 1 and 2 in the direction of a nip plane, are designated with reference numerals 114 and 114 a . The first slide bearing elements 114 work in the direction of a nip, i.e. against loading, and the second slide bearing elements 114 a work in the opposite direction. The exemplary embodiment of FIGS. 1 and 2 further shows that the roll 110 is also provided with slide bearing elements 115 , 115 a working laterally relative to the loading direction and acting in opposite directions. The roll 110 is a roll totally furnished with slide bearings, which is also provided with slide bearing elements 116 , 116 a acting in directions axially opposite to each other and abutting against roll ends 113 , 113 a through the intermediary of an oil film. As shown in FIGS. 1 and 2, the radially acting slide bearing elements 114 , 115 , 114 a , 115 a abut against the inner surface of the roll shell 112 through the intermediary of an oil film. In the representation of FIG. 1, the radially acting slide bearing elements 114 , 114 a , 115 , 115 a are arranged in pairs, such that there are two specimens of each slide bearing element set side by side in axial direction. From the functional point of view, however, such an arrangement is not an absolute necessity as the bearing system can also be implemented by using just single slide bearing elements.
On the other hand, FIG. 2 suggests that the slide bearing elements 114 , 114 a , 115 , 115 a be adapted to act in the direction of loading and in the direction lateral thereto. However, there could be additional slide bearing elements adapted to work radially in various angular positions.
FIG. 3 shows schematically and in partial section one prior art arrangement for supporting a slide-bearing mounted roll and for fitting the same with bearings in a loading direction, i.e. in the direction of a nip plane regarding the roll 110 depicted in FIG. 1 . In FIG. 3, the roll shaft is also designated with reference numeral 111 and the roll shell with reference numeral 112 . The following description deals first with the support system of FIG. 3 in terms of its construction and then with the support system in terms of its function.
The roll shell 112 is supported against an inner surface 112 ′ of the roll shell by means of loaded slide bearing elements 114 , 114 a which, as shown in FIG. 3, work actively in opposite directions, such that the first slide bearing element 114 loads the roll shell 112 toward an external load applied to the roll shell, i.e. toward a nip, and the second slide bearing element 114 a in the opposite direction, respectively. In the construction of FIG. 3, the slide bearing elements 114 , 114 a are provided with pressurizable cavities 61 , 61 a , and for each slide bearing element 114 , 114 a the roll shaft 111 is fitted with body blocks 63 , 63 a which penetrate into said cavities 61 , 61 a of the slide bearing elements, the body blocks 63 , 63 a being sealed relative thereto by means of packings 63 ′, 63 ′ a so as to allow a movement of the slide bearing elements 114 , 114 a relative to the body blocks 63 , 63 a . In structural sense, the slide bearing elements 114 , 114 a are conventional by having the outer surface thereof provided with oil pockets 64 , 64 a which are in communication with the cavities 61 , 61 a by way of capillary borings 65 , 65 a extending through the slide bearing elements. Thus, the pressurized cavities 61 , 61 a release through the capillary borings 65 , 65 a a pressure fluid, particularly oil, into the oil pockets 64 , 64 a for establishing an oil film between the slide bearing elements 114 , 114 a and the inner surface 112 ′ of the roll shell.
In the representation of FIG. 3, the first slide bearing element 114 acting in the loading direction is provided with an adjustment means 66 , comprising a bore 76 made in the body block 63 of the slide bearing element and movably fitted with a three-section slide valve 69 , 70 , 71 , including a middle slide-valve section 69 , a first end section 70 , and a second end section 71 . The slide-valve sections 69 , 70 , 71 are linked by a spindle rod 67 , which holds the slide-valve sections apart from each other and which spindle rod 67 abuts against a floor 62 of the cavity in the first slide bearing element 114 . The bore 76 has its bottom underneath the second slide-valve end section 71 fitted with a spring 68 , which stresses said spindle rod 67 against the cavity floor 62 . Hence, the adjustment means 66 is constituted by a valve, which is supplied with a pressure fluid through a central passage 120 a and a supply passage 119 a and which distributes the pressure and flow rate of the supplied pressure fluid at a desired and predetermined ratio through flow paths 72 and 73 defined by the slide-valve sections 69 , 70 , 71 of the adjustment means 66 , as well as through a connecting channel 118 a and pressure passages 75 , 75 a made in the body blocks 63 , 63 a of the slide bearing elements 114 , 114 a into the cavities 61 , 61 a of the slide bearing elements. The bore 76 is further provided with an annular groove 74 at a confluence between the supply passage 119 a and the bore 76 .
The roll shell 112 is capable of moving radially relative to the roll shaft 111 also in the direction of loading. In the case of FIG. 3, the roll shell 112 is depicted in a middle position, and from this middle position the roll shell 112 is allowed to travel a certain distance in either direction. For example, when dealing with the deflection compensated roll 110 of FIG. 1, which constitutes a nip with a counter roll, a suitable permissible stroke for the roll shell 112 is for instance 25 mm in either direction. Of course, this distance is only given by way of example. The adjustment means 66 is used to control strokes of the roll shell 112 in the appropriate direction of loading and to limit the stroke to a maximum distance desired therefor. As perceivable from FIG. 3, the middle slide-valve section 69 of the adjustment means 66 has an axial length which exceeds that of the annular groove 74 made in the bore 76 , and this dimensioning, explicitly, has a crucial significance in controlling the roll shell 112 as regards its strokes or movements.
In the condition shown in FIG. 3, wherein the roll shell 112 is in its middle position, the middle slide-valve section 69 covers the annular groove 74 completely. When the roll shell 112 commences its stroke from the position of FIG. 3 in either direction, for example downward in FIG. 3, the first slide bearing element 114 loaded through an oil film against the inner roll shell surface 112 ′ accompanies the roll shell 112 in its stroke and uses the spindle rod 67 to press the slide valve of the adjustment means 66 in the same direction against the loading force of the spring 68 . The middle slide-valve section 69 has its axial length dimensioned such that, as the roll shell 112 approaches its permissible extreme position, the slide valve 69 , 70 , 71 has shifted to such a position that pressure fluid is allowed to flow from the supply passage 119 a through the annular groove 74 past the middle slide-valve section 69 into the first flow path 72 and thence further along the pressure channel 75 into the cavity 61 . This develops a braking pressure for the stroke of the roll shell 112 , which ultimately stops the roll shell 112 in its permissible extreme position. This preferably results in a closure of pressure channels used for a regular setting pressure and extending to the slide bearing elements 114 , 114 a . An advantage offered by this configuration is that it enables controlled strokes for the roll shell 112 without external control and, furthermore, it protects the oil films of the slide bearing elements 114 , 114 a also in the extreme positions of the roll shell 112 . The arrangement has naturally an equivalent operation when the roll shell 112 performs its stroke in the opposite direction.
The representation of FIG. 3 is incomplete in the sense that said figure only discloses the way of controlling and decelerating strokes of the roll shell 112 . It is quite obvious, however, that, in addition to pressure connections depicted in FIG. 3, the cavity 61 , 61 a of each slide bearing element 114 , 114 a must be supplied, also in the middle position shown in FIG. 3, with a normal setting pressure for loading the slide bearing elements 114 , 114 a against the inner roll shell surface 112 ′ also in the condition shown in the figure. As perceivable from FIG. 3, the supply of a setting pressure cannot be handled through the supply passage 119 a as the annular groove 74 is completely covered by the middle slide-valve section 69 blocking the flow of a pressure fluid to either flow path 72 , 73 . For the introduction of setting pressures, each body block 63 , 63 a must simply be provided with an extra channel connected to a pressure source, the pressure fluid supplied thereby not passing through the adjustment means 66 .
FIG. 4 illustrates an arrangement according to application 990329 for fitting a roll shell with bearings without stroke. The figure depicts a stationary roll shaft 1 , around which is rotatably mounted a roll shell 2 , the external load applied thereto being designated with reference symbol F. The bearing assembly acting in a plane of loading comprises a slide bearing element 3 working against the load, as well as a slide bearing element 4 working in the loading direction. These slide bearing elements 3 , 4 of the load bearing assembly are controlled by a control valve 7 , which is supplied with a hydraulic fluid pressure along a feed line 8 , the valve 7 distributing the pressure for a cavity 12 of the slide bearing element 3 and along a line 9 for a cavity 13 of the slide bearing element 4 . The cavities 12 , 13 have pressure measuring/standby lubricating lines 11 and 10 , respectively, connected therewith. The operation of such a non-stroke bearing assembly has been described in more detail in the above-mentioned FI application 990329 and the operation of such a non-stroke bearing assembly is old and well known in the art and no further explanation is needed for the understanding of the non-stroke bearing assembly by a person of ordinary skill in the art. The roll, shell has its lateral bearing system implemented by means of lateral bearing elements 5 and 6 as described for example in FI patent 98320 and the operation of such a lateral bearing system implemented by means of lateral bearing elements is old and well known in the art and no further explanation is needed for the understanding of the non-stroke bearing assembly by a person of ordinary skill in the art.
In certain calendar applications there is a need to run two movable shell rolls oppositely to each other, whereby one of the rolls must be securely immobilized. In this case, the nip forces are created by loading the movable shell roll against a counter roll having its shell immobilized.
OBJECTS AND SUMMARY OF THE INVENTION
It is one object of the present invention to provide a solution, whereby, if necessary, the bearing system of a movable shell roll can be converted into a non-stroke system in a relatively simple fashion, the shell becoming immobilized relative to the roll shaft in the loading direction.
In order to accomplish this object, a roll of the invention is characterized in that the hydraulic fluid feeding means are provided with control elements, whereby the slide bearing elements acting in the direction of a nip load are loadable in such a way that the roll shell is optionally able to perform a stroke relative to the roll shaft radially of the roll or to remain substantially immobilized relative to the roll shaft.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described in more detail with reference to the accompanying drawings, in which
FIGS. 1 and 2 show in schematic elevations one tubular roll of the prior art fitted with slide bearings,
FIG. 3 shows in a schematic view one arrangement of the prior art for supporting a roll shell in a loading direction, said arrangement allowing the roll shell to perform a stroke relative to the roll shaft,
FIG. 4 shows in a schematic view another arrangement of the prior art for supporting a roll shell in a loading direction, which maintains the roll shell immobilized relative to the roll shaft, and
FIG. 5 shows in a schematic view a solution of the invention for supporting a roll shell in a loading direction.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1 and 2 show in schematic elevations a prior art tubular roll with slide bearings, such that FIG. 1 is an axial elevation of the roll and FIG. 2 is a sectional view taken along a line II—II of the roll depicted in FIG. 1 . In FIGS. 1 and 2 the deflection compensated roll is generally designated with reference numeral 110 and it comprises a stationary roll shaft 111 , upon which is rotatably fitted a roll shell 112 which is supported on the roll shaft by means of hydraulic loading elements 117 . The hydraulic loading elements 117 work in the direction of a nip plane and enable an adjustment of the roll shell 112 regarding its contour and a control of the roll regarding its axial nip profile.
The roll 110 has its bearing system implemented by means of slide bearing elements, whereof the slide bearing elements, acting in the direction of loading, in the case of a roll shown in FIGS. 1 and 2 in the direction of a nip plane, are designated with reference numerals 114 and 114 a . The first slide bearing elements 114 work in the direction of a nip, i.e. against loading, and the second slide bearing elements 114 a work in the opposite direction. The exemplary embodiment of FIGS. 1 and 2 further shows that the roll 110 is also provided with slide bearing elements 115 , 115 a working laterally relative to the loading direction and acting in opposite directions. The roll 110 is a roll totally furnished with slide bearings, which is also provided with slide bearing elements 116 , 116 a acting in directions axially opposite to each other and abutting against roll ends 113 , 113 a through the intermediary of an oil film. As shown in FIGS. 1 and 2, the radially acting slide bearing elements 114 , 115 , 114 a , 115 a abut against the inner surface of the roll shell 112 through the intermediary of an oil film. In the representation of FIG. 1, the radially acting slide bearing elements 114 , 114 a , 115 , 115 a are arranged in pairs, such that there are two specimens of each slide bearing element set side by side in axial direction. From the functional point of view, however, such an arrangement is not an absolute necessity as the bearing system can also be implemented by using just single slide bearing elements.
On the other hand, FIG. 2 suggests that the slide bearing elements 114 , 114 a , 115 , 115 a be adapted to act in the direction of loading and in the direction lateral thereto. However, there could be additional slide bearing elements adapted to work radially in various angular positions.
FIG. 3 shows schematically and in partial section one prior art arrangement for supporting a slide-bearing mounted roll and for fitting the same with bearings in a loading direction, i.e. in the direction of a nip plane regarding the roll 110 depicted in FIG. 1 . In FIG. 3, the roll shaft is also designated with reference numeral 111 and the roll shell with reference numeral 112 . The following description deals first with the support system of FIG. 3 in terms of its construction and then with the support system in terms of its function.
The roll shell 112 is supported against an inner surface 112 ′ of the roll shell by means of loaded slide bearing elements 114 , 114 a which, as shown in FIG. 3, work actively in opposite directions, such that the first side bearing element 114 loads the roll shell 112 toward an external load applied to the roll shell, i.e. toward a nip, and the second slide bearing element 114 a in the opposite direction, respectively. In the construction of FIG. 3, the slide bearing elements 114 , 114 a are provided with pressurizable cavities 61 , 61 a , and for each slide bearing element 114 , 114 a the roll shaft 111 is fitted with body blocks 63 , 63 a which penetrate into said cavities 61 , 61 a of the slide bearing elements, the body blocks 63 , 63 a being sealed relative thereto by means of packings 63 ′, 63 ′ a so as to allow a movement of the slide bearing elements 114 , 114 a relative to the body blocks 63 , 63 a . In structural sense, the slide bearing elements 114 , 114 a are conventional by having the outer surface thereof provided with oil pockets 64 , 64 a which are in communication with the cavities 61 , 61 a by way of capillary borings 65 , 65 a extending through the slide bearing elements. Thus, the pressurized cavities 61 , 61 a release through the capillary borings 65 , 65 a pressure fluid, particularly oil, into the oil pockets 64 , 64 a for establishing an oil film between the slide bearing elements 114 , 114 a and the inner surface 112 ′ of the roll shell.
In the representation of FIG. 3, the first slide bearing element 114 acting in the loading directions is provided with an adjustment means 66 , comprising a bore 76 made in the body block 63 of the slide bearing element and movably fitted with a three-section slide valve 69 , 70 , 71 , including a middle slide-valve section 69 , a first end section 70 , and a second end section 71 . The slide-valve sections 69 , 70 , 71 are linked by a spindle rod 67 , which holds the slide-valve sections apart from each other and which spindle rod 67 abuts against a floor 62 of the cavity in the first slide bearing element 14 . The bore 76 has its bottom underneath the second slide-valve end section 71 fitted with a spring 68 , which stresses said spindle rod 67 against the cavity floor 62 . Hence, the adjustment means 66 is constituted by a valve, which is supplied with a pressure fluid through a central passage 120 a and a supply passage 119 a and which distributes the pressure and flow rate of the supplied pressure fluid at a desired and predetermined ratio through flow paths 72 and 73 defined by the slide-valve sections 69 , 70 , 71 of the adjustment means 66 , as well as through a connecting channel 118 a and pressure passages 75 , 75 a made in the body blocks 63 , 63 a of the slide bearing elements 114 , 114 a into the cavities 61 , 61 a of the slide bearing elements. The bore 76 is further provided with an annular groove 74 at a confluence between the supply passage 119 a and the bore 76 .
The roll shell 112 is capable of moving radially relative to the roll shaft 111 also in the direction of loading. In the case of FIG. 3, the roll shell 112 is depicted in a middle position, and from this middle position the roll shell 112 is allowed to travel a certain distance in either direction. For example, when dealing with the deflection compensated roll 110 of FIG. 1, which constitutes a nip with a counter roll, a suitable permissible stroke for the roll shell 112 is for instance 25 mm in either direction. Of course, this distance is only given by way of example. The adjustment means 66 is used to control strokes of the roll shell 112 in the appropriate direction of loading and to limit the stroke to a maximum distance desired therefor. As perceivable from FIG. 3, the middle slide-valve section 69 of the adjustment means 66 has an axial length which exceeds that of the annular groove 74 made in the bore 76 , and this dimensioning, explicitly, has a crucial significance in controlling the roll shell 112 as regards its strokes or movements.
In the condition shown in FIG. 3, wherein the roll 112 is in its middle position, the middle slide-valve section 69 covers the annular groove 74 completely. When the roll shell 112 commences its stroke from the position of FIG. 3 in either direction, for example downward in FIG. 3, the first slide bearing element 114 loaded through an oil film against the inner roll shell surface 112 ′ accompanies the roll shell 112 in its stroke and uses the spindle rod 67 to press the slide valve of the adjustment means 66 in the same direction against the loading force of the spring 68 . The middle slide-valve section 69 has its axial length dimensioned such that, as the roll shell 112 approaches its permissible extreme position, the slide valve 69 , 70 , 71 has shifted to such a position that pressure fluid is allowed to flow from the supply passage 119 a through the annular groove 74 past the middle slide-valve section 69 into the first flow path 72 and thence further along the pressure channel 75 into the cavity 61 . This develops a braking pressure for the stroke of the roll shell 112 , which ultimately stops the roll shell 112 in its permissible extreme position. This preferably results in a closure of pressure channels used for a regular setting pressure and extending to the slide bearing elements 114 , 114 a . An advantage offered by this configuration is that it enables controlled strokes for the roll shell 112 without external control and, furthermore, it protects the oil films of the slide bearing elements 114 , 114 a also in the extreme positions of the roll shell 112 . The arrangement has naturally an equivalent operation when the roll shell 112 performs its strokes in the opposite direction.
The representation of FIG. 3 is incomplete in the sense that said figure only discloses the way of controlling and decelerating strokes of the roll shell 112 . It is quite obvious, however, that, in addition to pressure connections depicted in FIG. 3, the cavity 61 , 61 a of each slide bearing element 114 , 114 a must be supplied, also in the middle position shown in FIG. 3, with a normal setting pressure for loading the slide bearing elements 114 , 114 a against the inner roll shell surface 112 ′ also in the condition shown in the figure. As perceivable from FIG. 3, the supply of a setting pressure cannot be handled through the supply passage 119 a as the annular groove 74 is completely covered by the middle slide-valve section 69 blocking the flow of pressure fluid to either flow path 72 , 73 . For the introduction of setting pressures, each body block 63 , 63 a must simply be provided with an extra channel connected to a pressure source, the pressure fluid supplied thereby not passing through the adjustment means 66 .
FIG. 4 illustrates an arrangement according to application 990329 for fitting a roll shell with bearings without stroke. The figure depicts a stationary roll shaft 1 , around which is rotatably mounted a roll shell 2 , the external load applied thereto being designated with reference symbol F. The bearing assembly acting in a plane of loading comprises a slide bearing element 3 working against the load, as well as a slide bearing element 4 working in the loading direction. These slide bearing elements 3 , 4 of the load bearing assembly are control by a control valve 7 , which is supplied with a hydraulic fluid pressure along a feed line 8 , the valve 7 distributing the pressure for a cavity 12 of the slide bearing element 3 and along a line 9 for a cavity 13 of the slide bearing element 4 . The cavities 12 , 13 have pressure measuring/standby lubricating lines 11 and 10 , respectively, connected therewith. The operation of such a non-stroke bearing assembly has been described in more detail in the above-mentioned F1 application 990329 and, thus, shall not be explained further in this context. The roll, shell has its lateral bearing system implemented by means of lateral bearing elements 5 and 6 in a per se known manner as described for example in FI patent 98320 and, thus, its operation shall not be described in further detail, either.
FIG. 5 depicts one preferred embodiment of the invention, wherein the pressure feed line 8 shown in the solution of FIG. 4 is provided with a shut-off valve 14 , by means of which the feed pressure control valve 7 can be closed. At this time, the pressure measuring/standby lubricating lines 11 , 10 extending to the cavities of the load bearings 3 , 4 are actively deployed. Pressure regulating valves are used for supplying the lines with bearing pressures by using a control system similar to what is employed in a normal movable-shell roll. Thus, the control valve 7 functions as a shuttle valve, which isolates the bearing zones to function separately from each other. By means of this solution, the non-stroke bearing assembly of FIG. 4 can be designed as a stroke performing assembly, whereby the roll must naturally be provided with bearing mounting elements and a control valve in such a way that for example a + −20 mm stroke relative to the middle position becomes possible. When the shut-off valve 14 is re-opened and the lines 11 , 10 are set in a regular pressure measuring/standby lubricating operation, the roll becomes a non-stroke shell roll, wherein the shell position in radial direction relative to the roll shaft can be selected by means of a piston fitted in the control valve 7 underneath the load bearing 3 . The control valve 7 can also be designed to have its position adjustable relative to the roll shaft.
The locking of a movable-shell roll in one extreme position is also conceivably effected by running so much overload on the slide bearing elements on one side of the loading bearing zones that the shell does not commence its stroke in response to a nip load. In this type of function, however, the calendar may be subjected to such a loading condition that the shoes on the opposite side relative to shell holding shoes will be subjected to maximum pressures through a brake valve, the shell being subjected to a major stretching force, which may damage the shell. | A deflection compensated roll for a paper/board or finishing machine includes a stationary roll shaft ( 1 ), and a roll shell ( 2 ) structured and arranged to be rotatable around the same and mounted with slide bearing elements ( 3-6 ) upon the roll shaft ( 2 ). The slide bearing elements are provided with hydraulic fluid feeding means for loading the slide bearing elements with a hydraulic fluid. The roll is intended to form a nip together with a counter roll. The hydraulic fluid feeding device is provided with control elements, whereby the slide bearing elements ( 3, 4 ) acting in the direction of a nip load (F) are loadable in such a way that the roll shell ( 2 ) is able to perform a stroke relative to the roll shaft ( 1 ) radially of the roll or to remain substantially immobilized relative to the roll shaft ( 1 ). | 3 |
BACKGROUND
[0001] Protective horn wraps are often used in the rodeo sport of team roping, to protect a steer's horns, ears and head from damage as a result of the tightening of the rope or lariat around the horns.
[0002] Horn wraps generally include a pair of separate, side head pads that are connected to each other when in use by a strap system. The strap system includes a relatively short strap with a buckle, extending from one of the pads, and a much longer strap extending from the other pad. The long strap is configured to be looped around the bottom of the steer's neck and around the steer's horns (e.g., in a figure eight) and then fastened to the buckle on the other strap. An example of this type of horn wrap is shown in U.S. Pat. No. 5,535,707.
[0003] Typically, to apply a conventional horn wrap to a steer it is necessary to place each of the pads over one of the steer's horns, and then fasten the strap system around the steer's head, all while the steer is fidgeting and swinging its head back and forth.
[0004] Because the two pads are attached only by the single long strap, if that strap fails or becomes unfastened one or both pads will tend to come off of the steer. The steer may also trip over or become entangled in the long strap, or the strap may get caught on stationary objects. For this reason, and because this type of horn wrap is uncomfortable to the steer, such horn wraps are typically removed from the steer after each roping event or practice.
SUMMARY
[0005] The present invention features horn wraps that can be easily and safely applied to a steer, can be left on the steer for an extended period of time, and have a relatively long use life due to the replaceability and interchangeability of the parts of the horn wrap.
[0006] In one aspect, the invention features a horn wrap that includes a pair of protective elements, configured to be positioned on opposite sides of a steer's head and each having an opening configured to receive one of the steer's horns, and an attachment system configured to join the protective elements together around the steer's head, the attachment system comprising hook and loop fasteners.
[0007] Some implementations include one or more of the following features.
[0008] The hook and loop fasteners may be carried by a pair of releasable closures, each releasable closure extending between the protective elements and being configured to draw the protective elements together around the steer's head. Each of the releasable closures may comprise an elongated strap that is folded in thirds when in use. The strap may include a first portion that has fastener elements on both of its broad surfaces, and be configured such that when the releasable closure is folded into thirds the first portion is captured between second and third portions of the strap that carry fastener elements that engage the fastener elements on the first portion.
[0009] The horn wrap may further include an elastomeric strap attached to and extending between the protective elements, the elastomeric strap being positioned on the protective elements so that it will extend across the throat of the steer in use. The elastomeric strap may comprise a continuous loop of flat elastomeric material, e.g., it may comprise a Dally rubber.
[0010] In some cases, each protective element comprises a side portion which protects the steer's horn and defines the opening, and a rear portion, which protects the back of the steer's head and neck, and one of the releasable closures is configured to draw together the side portions, and the other releasable closure is configured to draw together the rear portions.
[0011] In another aspect, the invention features a horn wrap that includes (a) a pair of protective elements, configured to be positioned on opposite sides of a steer's head and each comprising a side portion which protects the steer's horn and defines an opening configured to receive the horn, and a rear portion, which protects the back of the steer's head and neck; and (b) an attachment system configured to join the protective elements together around the steer's head, the attachment system comprising a front releasable closure configured to draw together the side portions, and a rear releasable closure configured to draw together the rear portions.
[0012] Some implementations include any one or more of the features discussed herein, including the features mentioned above in connection with the first aspect of the invention.
[0013] The invention also features methods of using the horn wraps disclosed herein. In one aspect, the invention features a method comprising (a) placing a first protective element of a horn wrap over one horn of a steer; (b) placing a second protective element of the horn wrap over the other horn of the steer; and (c) fastening a pair of releasable closures to secure the two protective elements together around the steer's head.
[0014] In some cases, each of the releasable closures is partially fastened to one of the protective elements prior to placing the protective element over the steer's horn. The method may further comprise positioning an elastomeric strap extending between the protective elements adjacent the throat of the steer.
[0015] The term “steer,” as used herein, refers to all horned roping cattle and is not gender-specific.
DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a front view of a horn wrap according to one embodiment.
[0017] FIG. 2 is a front view showing the horn wrap on a steer.
[0018] FIG. 3 is a rear perspective view of the horn wrap.
[0019] FIG. 4 is a rear perspective view showing the horn wrap on a steer.
[0020] FIG. 5 is a perspective view of the releasable closure used on the horn wrap shown in FIGS. 1-4 , in the open position.
[0021] FIG. 6 is a perspective view of the releasable closure with one portion in the closed position.
[0022] FIG. 7 is a perspective view of the releasable closure with two portions in the closed position.
DETAILED DESCRIPTION
[0023] FIGS. 1-4 show a horn wrap 10 that includes a pair of protective elements 12 , 14 , which are mirror images of each other and which are configured to be positioned on a steer's head. Each of the protective elements includes a horn opening 16 ( FIG. 3 ), through which the steer's horn 18 extends during use, as shown in FIGS. 2 and 4 . Each of the protective elements is comprised of a side portion 20 , which protects the steer's horn and defines the opening 16 , and a rear portion 22 , which protects the back of the steer's head and neck, as shown in FIGS. 2 and 4 , and which helps to hold the protective element in position. The protective elements may be made, for example, of an inner padding material, such as needled felt, foam or the like, covered by a durable outer layer such as a ripstop or ballistic material, as is well known.
[0024] The protective elements 12 , 14 , are secured together by three separate attachment devices, each of which is readily removable and replaceable, as will be discussed below. The use of three attachment devices provides redundancy—should one of the devices fail there will still be two remaining to retain the horn wrap on the steer's head. The horn wrap is configured so that only one of the devices need be fastened in order to put the horn wrap on a steer's head, allowing easy application of the horn wrap to a restless animal.
[0025] The three attachment devices are: a front releasable closure 40 , a rear releasable closure 41 , and an elastomeric strap 30 . The releasable closures will be discussed in further detail below. These closures can be easily replaced should they become worn or if a different color or design is desired. The closures are also easy to open and close, making it easy to apply the horn wrap to a steer's head.
[0026] The elastomeric strap is positioned on the protective members so that it will extend across the throat of the steer during use ( FIG. 4 ), generally at the lowest edge of the rear portions 22 . The elastomeric strap 30 may be, for example, a dally rubber (also known as a dally wrap). A Dally rubber is a continuous circle of flat rubber that is used by ropers to protect their saddle horns and to prevent the rope from slipping around the saddle horn. Accordingly, replacements are readily available. However, other loops of elastomeric material may be used. Preferably, the elastomeric strap is attached to the protective members by girth hitching the strap through a pair of D-rings 32 that are secured to the protective members. This method of attaching the strap allows for quick and easy replacement should the strap break or appear worn. The D-rings may be secured to the protective members by a loop of webbing 34 that is stitched to each protective member ( FIG. 3 ). In addition to being readily replaceable and facilitating easy application of the horn wrap to the steer, the elastomeric strap enhances safety by breaking away if caught on a stationary object.
[0027] The releasable closures are preferably attached to the protective members using rectangular rings 36 . The rectangular rings are attached to the protective members by loops of webbing 37 that are stitched to the protective members. The rings 36 are positioned so that the upper releasable closure 40 extends across the steer's head approximately level with the horns ( FIG. 2 ), aligned with the center top of the horn opening 16 , and the rear releasable closure 41 extends across the upper portion of the steer's neck several inches behind the horns ( FIG. 4 ), aligned with the furthest rear parallel edges of rear portions 22 . As a result, the front releasable closure 40 holds the side portions 20 together while the rear releasable closure 41 holds the rear portions 22 together, snugly and comfortably securing the horn wrap to the steer's head. This secure attachment prevents the horn wrap from chafing against the steer's hide, enhancing comfort and in some cases allowing the horn wrap to be worn for an extended period of time. The use of two relatively small and narrow replaceable closures, rather than several wraps of a heavy webbing strap—e.g., as disclosed in U.S. Pat. No. 5,535,707—makes the horn wrap cooler to wear, enhancing comfort of the steer during hot weather.
[0028] In the preferred implementation shown in FIGS. 5-7 , releasable closures 40 , 41 each include a substantially planar elongated band of material having first and second portions. The first portion 140 includes loop fasteners on both of its opposite surfaces 43 and 44 . This may be achieved, for example, by attaching two pieces of loop material back-to-back, or by providing a two-sided loop material. The second portion 142 , which extends lengthwise from the first portion, includes two side-by-side surfaces 42 and 45 , both of which carry hook elements. In preferred implementations the opposite surface 46 of the second portion is free of fastener elements, and may be smooth or may have any desired texture. This configuration allows the releasable closure to be folded in thirds such that when the releasable closure is closed the first portion 140 is captured between the two surfaces 42 and 45 of the second portion, and the generally smooth surface 46 is exposed.
[0029] Referring to FIGS. 5 and 6 , to initially position the releasable closure 40 on the horn wrap, e.g., when replacing the releasable closure, the releasable closure 40 is looped through the rings 36 and the surface 43 is folded over on to surface 42 ( FIG. 6 ). Preferably, surface 43 includes loop fasteners and surface 42 includes complementary hook fasteners as shown. The interaction of these two surfaces forms a strong releasable bond, which would generally only be disengaged when the releasable closure 40 needs to be replaced due to material deterioration or damage. Leaving the releasable closure in place as shown in FIG. 6 allows quick and easy application and removal of the horn wrap without losing the releasable closure.
[0030] Referring to FIGS. 6 and 7 , to fasten the horn wrap on an animal the second portion 142 of the releasable closure is threaded through the ring 36 and hook-carrying surface 45 is folded over onto the corresponding loop fasteners on surface 44 , capturing the first portion 140 of the releasable closure between surfaces 42 and 45 as discussed above.
[0031] The strength of the bond between the first and second portions, and thus the force required to disengage the releasable fastener, can be increased or decreased by altering the amount of interaction between the complementary surfaces 45 and 44 . This can be done by the animal's handler, by only partially overlapping the complementary surfaces, or by the manufacturer, e.g., by providing fewer complementary fasteners, less aggressive hook fasteners, or bands of hook fasteners rather than a continuous array of hook fasteners.
[0032] In some implementations, the releasable closure 40 utilizes woven nylon hook and loop material measuring from ¾ to 3 inches in width, but preferably e.g. 2 inches in width.
[0033] The releasable closures can be easily replaced when worn or damaged. Moreover, the releasable closures can be interchanged with replaceable closures of a different color, e.g., to allow steers to be sorted into different pens, or to indicate something about the steer, for example that it is a “bounty steer” for competition purposes.
Other Embodiments
[0034] A number of embodiments have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the disclosure.
[0035] For example, the arrangement of hook and loop fasteners on the releasable closures may be different, e.g., the hooks can be replaced by loops and vice versa.
[0036] Moreover, while D-rings and rectangular rings are shown, other types of attachment devices may be used to join the releasable closures and/or the elastomeric strap to the protective members.
[0037] Accordingly, other embodiments are within the scope of the following claims. | Horn wraps are disclosed for protecting the horns and head of a steer, e.g., during team roping. The horn wraps can be easily and safely applied to a steer, can be left on the steer for an extended period of time, and have a relatively long use life due to the replaceability and interchangeability of the parts of the horn wrap. In some implementations, the horn wraps are attached to the steer using an attachment system that includes replaceable closures having hook and loop fasteners. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a U.S. national stage application of a PCT application PCT/RU2008/000578 filed on 28 Aug. 2008, published as WO/2009/038498, whose disclosure is incorporated herein in its entirety by reference, which PCT application claims priority of a Russian Federation application RU2007134923 filed on 19 Sep. 2007.
FIELD OF THE INVENTION
[0002] The invention relates to methods and devices for spraying liquid during production processes requiring a uniform dispersion mixture, in particular in internal combustion engines requiring a fine fuel-air mixture, in the chemical industry for apparatuses for rinsing gas with liquid that require a uniform coarse-dispersion mixture for reducing the drop entrainment of a rinsing liquid.
BACKGROUND OF THE INVENTION
[0003] Many devices are known for spraying liquid during production processes that use the method of pneumatic spraying and belong to jet devices. Jet devices are those where a process of exchanging kinetic energy from one flow to another takes place by immediate mixing. Despite a variety of jet device constructions the following basic elements can be noted: an active nozzle, a mixing chamber, a diffusor, an input part of the throat for passive flow, which is usually made in the form of a confusor (New reference book for chemist and technologist. Processes and apparatuses for chemical technology, part 1, St. Peterburg, ANO NPO “Professional”, 2004, on page 405). A disadvantage of such devices is the inhomogeneity of the resulting mixture, i.e. diameter of particles vary widely and the particle size distribution is very non-uniform. For example, there are not many large particles but they have the most part of fuel mass (Morozov K. A. Matuhin L. N. Feeding systems of modern petrol engines, Manual, MADI, M., 1988, on page 7).
[0004] One device is known from inventor's certificate of USSR No 797783 of 1981. The device comprises air-supply and fluid-supply systems, a spray chamber with input and output pipes, sprayers and a liquid collector. Sprayers are chordally installed in the spray chamber. Disadvantages of this device are high aerodynamic resistance, large size and high material consumption, and impossibility of production of a homogeneous coarse-dispersion mixture. The following cause these disadvantages. The cylindrical part of the spray chamber, where sprayers are chordally installed, enforces rotary moving gas inside the chamber. It results in high aerodynamic resistance in comparison with laminar unidirectional gas flow. The spray chamber has to measure a certain size to set up rotary movement of a gas flow. It is necessary to enlarge the diameter of the cylindrical part in order to reduce aerodynamic resistance. The large size of the device predetermines its high material consumption. When a gas flow is moving in a rotary manner, particles of all sizes except the smallest ones are collected on the internal side of the chamber. The smallest particles are held in the rotary gas flow, not for their low sedimentation velocity, which is determined by the relation of aerodynamic forces to mass of a particle, but due to mechanism of Brownian movements acting, as it is known, on particles of sizes that do not exceed many times the sizes of gas molecules.
[0005] One more device is known from inventor's certificate of USSR No 246200 of 1969 (point 2). The device comprises a case, a water sprayer and a water collector connected to the water sprayer. The water sprayer is made in the form of a set of pipes with perforated sides. Pipes are placed in the case and are parallel to the air flow direction. A disadvantage of this device is inhomogeneity of the resulting mixture. The following cause this disadvantage. A liquid goes out of the end faces and many apertures in the pipe sides. A liquid is broken down into particles of various sizes that are carried away so it forms a set of spray cones. Sectors with prevailing large, medium and small particles can be found in every spray cone except spray cones from the pipe end faces. Many spray cones overlay one upon another in an irregular way and form a flow of a liquid spray where particles of various sizes are distributed uniformly. As a result, large, medium and small particles are collected in a nonselective way on the sides of the case. The collected particles form, when accumulated, a liquid that is returned for re-spraying.
[0006] The most similar to technical essence of the inventive method is the method for spraying liquid (prototype), described in the book Morozov K. A. Matuhin L. N. Feeding systems of modern petrol engines, Manual, MADI, M., 1988, on page 7. The method consists in injecting liquid at an angle into a gas flow. A disadvantage of the method is inhomogeneity of the resulting mixture that increases fuel consumption in internal combustion engines because of incomplete combustion of large particles of fuel.
[0007] The most similar to technical essence of the inventive device is the device for spraying liquid (prototype), described in the book Dmitrievskij A. V., Kamenev V. F. Automobile carburetors. M: Mechanical engineering, 1990, on pages 76-77. The device comprises a body with an internal channel, which is made in the form of a Venturi pipe, and a spray nozzle placed in the narrow part of the internal channel at an angle to the gas flow direction. A disadvantage of this device is inhomogeneity of the resulting mixture that increases fuel consumption in internal combustion engines because of incomplete combustion of large particles of fuel.
SUMMARY AND BRIEF DESCRIPTION OF THE INVENTION
[0008] The present invention solves the problem of homogeneous enhancement for a mixture, which is produced in spraying liquid by injection of a liquid into a gas flow. In order to solve the problem, spraying is carried out by injection of a liquid into a gas flow at an angle to the gas flow direction but not parallel. The gas flow breaks down a liquid flow into particles of various sizes and carries them away so it forms a spray cone. The trajectories of large particles deviate from a spray nozzle further than the trajectories of small particles do. It is due to an action of the field of aerodynamic forces and the initial momentum of a liquid, which goes out of the nozzle at an angle to the gas flow direction and is broken down into particles. It brings to the non-large, medium and small particles are formed. The illustration of dividing the spray cone into sectors with particles of various sizes is given in FIG. 3 .
[0009] Particles of specified sizes in the resulting spray cone are selected (removed), i.e. particles of such sizes that are undesirable for whatever reason. If large and medium particles in the spray cone are removed then small particles remain. If medium and small particles are removed then large particles remain. If medium particles are removed then large and small particles remain. Selection (removal) of particles is carried out as follows. A collector for particles of a liquid spray is installed at some distance from the spray nozzle. The collector is made and placed to be able to collect particles of specified sizes in those sectors of the spray cone that are appropriate to particle sizes. It is necessary and sufficient for selection (removal) of particles of specified sizes that the collector collects all particles of a liquid spray. In addition, the collector should be placed in the appropriate sectors of the spray cone. Particles, which are collected by the collector for particles of a liquid spray, form, when accumulated, a liquid that is returned for re-spraying (recirculating). The processes of spraying liquid and selecting (removing) particles of specified sizes in the spray cone are carried out in one section of a laminar gas flow, which has no turns and rotations.
[0010] The technical result is the production of a mixture that is more homogenous in terms of the particle sizes due to removing particles of specified sizes in the spray cone where specified sizes depend on a variant of the method usage or the purpose of the device.
[0011] The inventive concept consists in departure from known technical decisions where at first a liquid is sprayed and a flow with large and small particles uniformly distributed is obtained. Further, particles of specified sizes in a flow are separated and removed. Instead of doing so, liquid is sprayed in such a manner that spatial separation of particles of various sizes takes place in the very spray cone at the same time as spraying liquid. In this case removing particles of specified sizes reduces to removing particles of all sizes in the appropriate sectors of the spray cone. Mathematical modeling proves the efficiency of such approach to solving the problem of homogeneous enhancement for spraying liquid. It shows that the determinant influence for the whole trajectory has only the initial phase of the trajectory where particles appear from a liquid flow and have minimum velocity. The less velocity a particle has the more easily its trajectory can be changed. As a particle of a liquid accelerates, it becomes more difficult to change its trajectory.
[0012] According to the invention, the technical result for the method (production of a mixture that is more homogeneous in terms of particle sizes) is achieved due to spraying liquid by injection of a liquid through a spray nozzle at an angle to the gas flow direction. In addition, a process of selection of (removal of) particles of specified sizes is carried out in a spray cone simultaneously with the process of spraying. The process of selection is carried out by a collector for particles of a liquid spray that is installed at some distance from the spray nozzle and it is made and placed to be able to collect particles of a liquid spray in those sectors of the spray cone that are appropriate to particle sizes. The processes of spraying liquid and selection of (removal of) particles of specified sizes are carried out in one section of a laminar gas flow, which has no turns and rotations. Particles of a liquid spray, which are collected by the collector, form, when accumulated, a liquid that is returned for re-spraying.
[0013] The common element with the known method for spraying liquid is spraying liquid by injection through a spray nozzle at an angle to the gas flow direction.
[0014] The new elements, which differentiate the inventive method from the prototype, are the following:
the process of selection of (removal of) particles of specified sizes is carried out in the spray cone simultaneously with the process of spraying; the process of selection (removal) is carried out by the collector for particles of a liquid spray that is installed at some distance from the spray nozzle and it is made and placed to be able to collect particles of a liquid spray in those sectors of the spray cone that are appropriate to particle sizes; the processes of spraying liquid and selection of (removal of) particles of specified sizes are carried out in one section of a laminar gas flow, which has no turns and rotations; particles of a liquid spray, which are collected by the collector, form, when accumulated, a liquid that is returned for re-spraying.
[0019] According to the invention, the technical result for the device of variant No 1 (production of a mixture that is more homogeneous in terms of particle sizes) is achieved due to a device comprising: a body with an internal channel, a spray nozzle, which is placed at an angle to the gas flow direction and is connected to a liquid feed pipe, a collector for particles of a liquid spray, which is installed at some distance from the spray nozzle and it is made and placed to be able to collect particles of specified sizes in those sectors of the spray cone that are appropriate to particle sizes. The internal channel is made to be able to provide a laminar gas flow, which has no turns and rotations, in the section that starts before the spray nozzle and ends at the collector for particles of a liquid spray. The collector for particles of a liquid spray is connected to a pipe for returning a liquid for re-spraying.
[0020] The common elements with the device known from prototype are:
the body with the internal channel; the spray nozzle, which is placed at an angle to the gas flow direction and is connected to the liquid feed pipe.
[0023] The new elements, which differentiate the inventive device from the prototype, are:
the collector for particles of a liquid spray which is installed at some distance from the spray nozzle and it is made and placed to be able to collect particles of specified sizes in those sectors of the spray cone that are appropriate to particle sizes; the internal channel, which is made to be able to provide a laminar gas flow, which has no turns and rotations, in the section that starts before the spray nozzle and ends at the collector for particles of a liquid spray; the collector for particles of a liquid spray, which is connected to the pipe for returning a liquid for re-spraying.
[0027] According to the invention, the technical result for the device of variant No 2 (production of a mixture that is more homogeneous in terms of particle sizes) is achieved due to a device comprising: a body with an internal channel, a spray nozzle, which is placed at an angle to the gas flow direction and is connected to a liquid feed pipe, a collector for particles of a liquid spray, which is installed at some distance from the spray nozzle and it is made and placed to be able to collect particles of specified sizes in those sectors of the spray cone that are appropriate to particle sizes. The internal channel is made to be able to provide a laminar gas flow, which has no turns and rotations, in the section that starts before the spray nozzle and ends at the collector for particles of a liquid spray. The collector for particles of a liquid spray is connected via a pipe for returning a liquid for re-spraying to an additional spray nozzle, which is made and placed to be able to overlay the appropriate sectors of the spray cones regarding those sectors of both spray cones where particles are collected.
[0028] The common elements with the device known from prototype are:
the body with the internal channel; the spray nozzle, which is placed at an angle to the gas flow direction and connected to the liquid feed pipe.
[0031] The new elements, which differentiate the inventive device from the prototype, are:
the collector for particles of a liquid spray, which is installed at some distance from the spray nozzle and it is made and placed to be able to collect particles of specified sizes in those sectors of the spray cone that are appropriate to particle sizes; the internal channel, which is made to be able to provide a laminar gas flow, which has no turns and rotations, in the section that starts before the spray nozzle and ends at the collector for particles of a liquid spray; the collector for particles of a liquid spray is connected via the pipe for returning a liquid for re-spraying to the additional spray nozzle, which is made and placed to be able to overlay the appropriate sectors of the spray cones regarding those sectors of the both spray cones where particles are collected by the collector for a liquid spray.
BRIEF DESCRIPTION OF THE DRAWINGS
[0035] FIG. 1 shows the device of variant No 1.
[0036] FIG. 2 shows the device of variant No 2.
[0037] FIG. 3 is an illustration of dividing the spray cone into sectors with particles of various sizes.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0038] The inventive method is carried out as follows. A liquid is injected through a spray nozzle at an angle of 90° to the gas flow direction. The gas flow breaks down the liquid flow, which goes out of the spray nozzle, into particles of various sizes and carries them away so that it forms a spray cone. The trajectories of large particles deviate from the spray nozzle further than the trajectories of small particles do. It is due to an action of the field of aerodynamic forces and the initial momentum of a liquid, which goes out of the nozzle at an angle to the gas flow direction, and is broken down into particles. It brings to the non-uniform particle size distribution in the spray cone and different sectors with prevailing large, medium and small particles being formed. The illustration of dividing the spray cone into sectors with particles of various sizes is given in FIG. 3 . The process of selection of (removal of) particles of specified sizes in the spray cone is carried out simultaneously with the process of spraying. The process of selection (removal) is carried out by a collector for particles of a liquid spray that is installed at some distance from the spray nozzle and it is made and placed to be able to collect particles of specified sizes in those sectors of the spray cone that are appropriate to particles of specified sizes. The processes of spraying liquid and selection (removal) of particles of specified sizes in the spray cone are carried out in one section of a laminar unidirectional gas flow. Particles of a liquid spray, which are collected by the collector, form, when accumulated, a liquid, which is returned for re-spraying. After selection (removal) of particles of specified sizes in the spray cone, it is characterized as more homogeneous in terms of particle sizes.
[0039] The spray nozzle is made in the form of the end of a pipe. Other embodiments of the spray nozzle are possible. It is necessary and sufficient to realize that the function of the spray nozzle is to direct a liquid flow. This function in combination with other elements provides the possibility to achieve the technical result.
[0040] The angle between the spray nozzle and the gas flow direction is 90°. Other values of the angle are possible. It is necessary and sufficient that a liquid flow is not parallel to the gas flow direction. It provides the non-uniform distribution of large and small particles in the spray cone. The angle in combination with other elements provides the possibility to achieve the technical result.
[0041] The collector for particles of a liquid spray is made in the form of the end of a pipe. The collector is installed at some distance from the spray nozzle. It is made and placed to be able to collect particles of a liquid spray in those sectors of the spray cone that are appropriate to particles of specified sizes. There is some distance between the end of the pipe and the spray nozzle. Some distance is necessary for starting the process of breaking down a liquid flow into particles. The end of the pipe is made and placed in those sectors of the spray cone that are appropriate to particles of specified sizes. It is possible to embody the collector for particles of a liquid spray in the form of socket pipes, rings, plates, parts of the internal channel and other embodiments. It is necessary and sufficient to realize that the function of the collector for particles of a liquid spray is to select (remove) particles of a liquid spray in those sectors of the spray cone that are appropriate to particles of specified sizes. This function in combination with other elements provides the possibility to achieve the technical result.
[0042] The processes of spraying liquid and selecting particles of specified sizes in the spray cone are carried out in one section of a laminar unidirectional gas flow. This condition of passing processes is achieved due to the arrangement of the spray nozzle and the collector for particles in the rectilinear channel. Other known methods are possible. It is necessary and sufficient to provide just the condition but not a particular method or material means. This condition in combination with other elements provides the possibility to achieve the technical result.
[0043] According to variant No 1, the inventive device comprises a body 1 with an internal channel 2 , made in the form of a Venturi pipe. There is a spray nozzle 3 in the narrow part of the internal channel 2 . The spray nozzle is placed at an angle of about 90° to the gas flow direction and it is connected to a liquid feed pipe 6 . A collector for particles of a liquid spray 4 is installed at some distance from the spray nozzle 3 . It is made and placed to be able to collect particles of specified sizes in those sectors of the spray cone that are appropriate to particle sizes. The collector for particles of a liquid spray 4 is connected to a pipe for returning a liquid for re-spraying 5 .
[0044] The device works as follows. A gas flow goes through the internal channel 2 where its rate increases and depression takes place. A liquid goes through the feed pipe 6 to the spray nozzle 3 and goes out of it under the influence of this depression. The gas flow breaks down the liquid flow, which goes out of spray nozzle 3 , into particles of various sizes and carries them away so it forms a spray cone. The trajectories of large particles deviate from a spray nozzle further than the trajectories of small particles do. It is due to an action of the field of aerodynamic forces and the initial momentum of a liquid, which goes out of the nozzle at an angle to the gas flow direction and is broken down into particles. The non-uniformly sized particles are distributed in the spray cone, i.e. the different sectors with prevailing large, medium and small particles are formed. The illustration of dividing the spray cone into sectors with particles of various sizes is given in FIG. 3 . Particles of specified sizes are collected in the appropriate sectors of the spray cone by the collector for particles of a liquid spray 4 . The collector is installed at some distance from the spray nozzle 3 . It is made and placed to be able to collect particles of specified sizes in those sectors of the spray cone that are appropriate to particles of specified sizes. Particles of a liquid spray are collected in the collector 4 . They form, when accumulated, a liquid, which goes under the influence of aerodynamic forces to the pipe for returning a liquid for re-spraying 5 . It means re-spraying by the spray nozzle 3 . Particular detail is not specified as it is easy to do and it is not essential for this invention. After collecting (removing) particles of specified sizes in the spray cone, it is characterized as more homogeneous in terms of particle sizes.
[0045] The spray nozzle 3 is made in the form of the end of a pipe 6 . Other embodiments of the spray nozzle 3 are possible. It is necessary and sufficient to realize that the function of the spray nozzle is to direct a liquid flow. This function in combination with other elements provides the possibility to achieve the technical result.
[0046] The angle between the spray nozzle 3 and the gas flow direction is about 90°. Other values of the angle are possible. It is necessary and sufficient that a liquid flow is not parallel to the gas flow direction. It provides the non-uniform distribution of large and small particles in the spray cone. The angle in combination with other elements provides the possibility to achieve the technical result.
[0047] The internal channel 2 is made in the form of a Venturi pipe. This form of the internal channel 2 gives the possibility of providing a laminar unidirectional gas flow in the section that starts before the spray nozzle and ends at the collector for particles of a liquid spray. Secondly, it makes depression in the narrow part of the channel 2 and provides moving a liquid to the spray nozzle 3 . It is possible to embody the internal channel 2 in the form of pipes having round, square and other section, in the form of confusor, diffusor and other forms, which provides a laminar unidirectional gas flow in the section that starts before the spray nozzle 3 and ends at the collector for particles of a liquid spray 4 . It is necessary and sufficient to realize that the function of the internal channel 2 is to provide a laminar unidirectional gas flow in the section that starts before the spray nozzle 3 and ends at the collector for particles of a liquid spray 4 . This function in combination with other elements provides the possibility to achieve the technical result.
[0048] The collector for particles of a liquid spray 4 is made in the form of the end of the pipe 5 . The collector is installed at some distance from the spray nozzle 3 . It is made and placed to be able to collect particles of a liquid spray in those sectors of the spray cone that are appropriate to particles of specified sizes. There is some distance between the end of the pipe 5 and the spray nozzle 3 . Some distance is necessary for starting the process of breaking down a liquid flow into particles. The end of the pipe 5 is made and placed in those sectors of the spray cone that are appropriate to particles of specified sizes. It is possible to embody the collector for particles of a liquid spray 4 in the form of socket pipes, rings, plates, parts of the internal channel 2 and other embodiments. It is necessary and sufficient to realize that the function of the collector for particles of a liquid spray 4 is to select (remove) particles of a liquid spray in those sectors of the spray cone that are appropriate to particles of specified sizes. This function in combination with other elements provides the possibility to achieve the technical result.
[0049] According to variant No 2 the inventive device comprises a body 1 with an internal channel 2 , made in the form of a Venturi pipe. There is a spray nozzle 3 in the narrow part of the internal channel 2 . The spray nozzle is placed at an angle of about 90° to the gas flow direction and it is connected to a liquid feed pipe 6 . A collector for particles of a liquid spray 4 is installed at some distance from the spray nozzle 3 . It is made and placed to be able to collect particles of specified sizes in those sectors of the spray cone that are appropriate to particle sizes. The collector for particles of a liquid spray 4 is connected via a pipe for returning a liquid for re-spraying 5 to an additional spray nozzle 7 that is placed at an angle of 90° to the gas flow direction nearly to the spray nozzle 3 .
[0050] The device works as follows. A gas flow goes through the internal channel 2 where its rate increases and depression takes place. A liquid goes through the feed pipe 6 to the spray nozzle 3 and goes out of it under the influence of this depression. The gas flow breaks down the liquid flow, which goes out of spray nozzle 3 , into particles of various sizes and carries them away so it forms a spray cone. The trajectories of large particles deviate from a spray nozzle further than the trajectories of small particles do. It is due to an action of the field of aerodynamic forces and the initial momentum of a liquid, which goes out of the nozzle at an angle to the gas flow direction and is broken down into particles. The non-uniformly sized particles are distributed in the spray cone, i.e. the different sectors with prevailing large, medium and small particles are formed. The illustration of dividing the spray cone into sectors with particles of various sizes is given in FIG. 3 . Particles of specified sizes are collected in the appropriate sectors of the spray cone by the collector for particles of a liquid spray 4 . The collector is installed at some distance from spray nozzle 3 . It is made and placed to be able to collect particles of specified sizes in those sectors of the spray cone that are appropriate to particles of specified sizes. Particles of a liquid spray are collected in the collector 4 . They form, when accumulated, a liquid, which goes under the influence of aerodynamic forces to the pipe for returning a liquid for re-spraying 5 and further to the additional spray nozzle 7 . The additional spray nozzle 7 forms its spray cone in such a manner that the appropriate sectors of both spray cones from the spray nozzle 3 and the additional spray nozzle 7 are coincident. After selecting (removing) particles of specified sizes in the spray cone, it is characterized as more homogeneous in terms of particle sizes.
[0051] The spray nozzle 3 is made in the form of the end of a pipe 6 . Other embodiments of the spray nozzle 3 are possible. It is necessary and sufficient to realize that the function of the spray nozzle is to direct a liquid flow. This function in combination with other elements provides the possibility to achieve the technical result.
[0052] The angle between the spray nozzle 3 and the gas flow direction is about 90°. Other values of the angle are possible. It is necessary and sufficient that a liquid flow is not parallel to the gas flow direction. It provides the non-uniform distribution of large and small particles in the spray cone. The angle in combination with other elements provides the possibility to achieve the technical result.
[0053] The internal channel 2 is made in the form of a Venturi pipe. This form of the internal channel 2 gives the possibility of providing a laminar unidirectional gas flow in the section that starts before the spray nozzle and ends at the collector for particles of a liquid spray. Secondly, it makes depression in the narrow part of the channel 2 and provides moving a liquid to the spray nozzle 3 . It is possible to embody the internal channel 2 in the form of pipes having round, square and other section, in the form of confusor, diffusor and other forms, which provide a laminar unidirectional gas flow in the section that starts before the spray nozzle 3 and ends at the collector for particles of a liquid spray 4 . It is necessary and sufficient to realize that the function of the internal channel 2 is to provide a laminar unidirectional gas flow in the section which starts before the spray nozzle 3 and ends at the collector for particles of a liquid spray 4 . This function in combination with other elements provides the possibility to achieve the technical result.
[0054] The collector for particles of a liquid spray 4 is made in the form of the end of the pipe 5 . The collector is installed at some distance from the spray nozzle 3 . It is made and placed to be able to collect particles of a liquid spray in those sectors of the spray cone that are appropriate to particles of specified sizes. There is some distance between the end of the pipe 5 and the spray nozzle 3 . Some distance is necessary for starting the process of breaking down a liquid flow into particles. The end of the pipe 5 is made and placed in those sectors of the spray cone that are appropriate to particles of specified sizes. It is possible to embody the collector for particles of a liquid spray 4 in the form of socket pipes, rings, plates, parts of the internal channel 2 and other embodiments. It is necessary and sufficient to realize that the function of the collector for particles of a liquid spray 4 is to select (remove) particles of a liquid spray in those sectors of the spray cone that are appropriate to particles of specified sizes. This function in combination with other elements provides the possibility to achieve the technical result.
[0055] The additional spray nozzle 7 is made in the form of the end of the pipe 5 . It is made and placed to be able to overlay the appropriate sectors of the spray cones regarding those sectors of both spray cones where particles of specified sizes are collected by the collector for particles of a liquid spray. The end of the pipe 5 is made and placed in such a manner that the appropriate sectors of both spray cones are coincident. Other embodiments and placement of the additional spray nozzle 7 are possible. It is necessary and sufficient to realize that the function of the additional spray nozzle 7 is to spray a liquid with the possibility of overlaying the appropriate sectors of the spray cones regarding those sectors of both spray cones where particles of specified sizes are collected by the collector for particles of a liquid spray. | The invention relates to methods and devices for atomising liquid during production processes using an uniform dispersion mixture, in particular in internal combustion engines requiring a fine fuel-air mixture, in the chemical industry for devices for rinsing gas with liquid which use an uniform coarse-dispersion mixture for reducing the drop entrainment of a rinsing liquid. The inventive method consists in collecting, during the liquid atomisation which is carried out by supplying a liquid jet at an angle to a gas flow, particles from the areas of spray flair which corresponds to the specified particle sizes. The particle atomisation and collecting processes are carried out at one section of a laminar unidirectional gas flow. The collected particles form, when accumulated, a liquid which is returned to re-atomisation. The inventive device comprises a body ( 1 ) with an internal channel ( 2 ) for producing a laminar unidirectional gas flow, an atomising nozzle ( 3 ) which is positioned at an angle to the gas flow direction and is connected to a pipe for supplying a liquid to be atomised ( 6 ) and a particles collector ( 4 ) which is designed and located in such a way that it is able to collect the particles from the areas of spray flair which corresponds to the specified particle sizes. In the first variant, the collector is coupled to a pipe ( 5 ) for returning the liquid to re-atomisation, and in the second variant, the collector is coupled to an additional spraying nozzle ( 7 ) made in the internal channel of the body. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an image display method and a device for displaying different aspect ratio images on one screen by sampling input video signals sequentially.
2. Related Art
Since a liquid crystal display device, which is a typical example of an image display apparatus, has such advantageous features as thinness, light weight and low power consumption, it has many applications in personal computers, wordprocessors, television receivers, car navigation devices, projection type display apparatus and the like. An active matrix type liquid crystal display device, above all, has a transistor switching element for each pixel to realize a good quality image without cross-talk between neighboring pixels so that vigorous research and development thereof are still carried out.
The effective display area of a conventional display device has the aspect ratio of 4/3 which is defined by its lateral axis length to its longitudinal axis length. In recent years, however, many display devices have the aspect ratio of 16/9 which effective display are is extended in the horizontal scanning direction and is visually recognized to be large.
There are several known methods of displaying an image with the aspect ratio of 4/3 on the effective display area of a liquid crystal display device with that of 16/9.
According to a first display method, a video signal with the aspect ratio of 4/3, as shown in FIG. 13(a), is sampled sequentially in response to a sampling clock signal to display an image entirely with the aspect ratio of 16/9 as shown in FIG. 13 (b). This method does not require any specific circuit but the original video with the aspect ratio of 4/3 cannot be faithfully reconstructed because the displayed image is deformed in the horizontal scanning direction as schematically shown in 13(b).
A second display method is, as shown in FIG. 13(c) or 13(d), to divide an effective display area with the aspect ratio 16/9 into one with that of 4/9 and another with that of 12/9 (=4/3) where a video signal consisting of an image information with the aspect ratio of 4/3 is displayed.
In this case, however, it is necessary to allocate at least 0.8 H to the display area with the aspect ratio of 12/9 for the sampling period of each horizontal scanning line where H is one NTSC horizontal scanning period and 0.2 H or less to the display area with the aspect ratio of 4/9 for the remaining sampling period. To comply with this requirement, sequential sampling and display are performed based on a video signal which is processed in advance by using frame memories. It does not achieve a less expensive display device of this sort primarily because the frame memories are relatively expensive.
A third display method is described in a Japanese Unexamined Patent Publication (Tokkai Hei) 8-289232. This method is to divide the effective display area with the aspect ratio of 16/9 into two areas, i.e., one with that of 4/9 and another with that of 4/3, and to set sampling clock signals with different frequencies from each other.
In more detail, the frequency of the first sampling clock signal is "3fCK/4" while that of the second "3fCK/2" in the case of the frequency "fCK" of a sampling clock signal used for displaying a video signal with the aspect ratio of 16/9 on the effective display area with that of 16/9.
In order to generate those sampling clock signals, as shown in FIG. 14, a sampling clock generator includes a voltage controlled oscillator VCO, frequency dividers, a phased lock loop PLL with a horizontal synchronous signal input terminal, and a switching circuit SW.
Since the voltage controlled oscillator generates a reference signal with a quite high frequency, it is influenced by outer circuits so easily as to causes various disadvantages in which, for instance, sampling clock signals become unstable, its power consumption increases, and it also generates spurious electromagnetic waves.
SUMMARY OF THE INVENTION
This invention overcomes such technical problems and its object is to provide a less expensive, high accuracy method and apparatus for displaying image information on a display screen in such a way that the aspect ratio for the image information is different from that for the display screen.
This invention is applied to an image display device which includes a plurality of display pixels to form a plurality of horizontal pixel lines, a display screen with a predetermined aspect ratio, a horizontal scanning circuit to derive out signal voltages in accordance with a sampling clock signal and supply the same to the display pixels in the horizontal pixel line, a vertical scanning circuit to select the horizontal scanning lines, and a controller to supply the sampling clock signals to the horizontal scanning circuit.
An image display device of the present invention is primarily directed to the control circuit which is provided with a divider circuit to multiply a reference clock signal by first and second dividing ratios, and a selector circuit to select either a combination of the reference clock signal and a first output multiplied by the first dividing ratio at the divider circuit within one horizontal scanning period or a second output multiplied by the second dividing ratio at the divider circuit.
An image display method of the present invention performs multiplying a reference clock signal by first and second dividing ratios, selecting either a combination of the reference clock signal and a first output multiplied by the first dividing ratio within one horizontal scanning period or a second output multiplied by the second dividing ratio, displaying an image derived from a video input signal on a display screen including display pixels to form horizontal pixel lines in response to a clock signal.
According to the invention, a less expensive, high accuracy image display method and apparatus for displaying image information on a screen, the aspect ratio of which is different from that of the image information.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram to show a liquid crystal display device of one embodiment of the present invention;
FIG. 2 is a sectional view of a part of a liquid crystal display panel shown in FIG. 1;
FIG. 3 is a circuit diagram of an X-driver unit shown in FIG. 1;
FIG. 4 is a circuit diagram of a Y-driver unit shown in FIG. 1;
FIG. 5 is a block diagram of a control circuit shown in FIG. 1;
FIG. 6 is a circuit diagram of a horizontal clock signal generator in the control circuit;
FIG. 7 is a table to describe relationship between a control signal and frequencies of the horizontal clock signal;
FIGS. 8 and 9 are diagrams of waveforms generated in the horizontal clock signal generator;
FIG. 10 is a schematic diagram to show a liquid crystal display device of another embodiment of the invention;
FIG. 11 is a block diagram of a control circuit shown in FIG. 10;
FIG. 12 is a block diagram of waveforms generated by a horizontal clock signal generator shown in FIG. 10;
FIG. 13(a) through 13(d) are diagrams to describe various display forms; and
FIG. 14 is a circuit diagram of a conventional horizontal clock signal generator.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A liquid crystal display device of the present embodiment will be explained hereinbelow with reference to the attached drawings.
The liquid crystal display device 1, as shown in FIG. 1, is provided with an effective display area 103 which is of 6 inches diagonal length and the aspect ratio of 16/9, and performs either one of display forms shown in FIGS. 13(b) and 13(c) in response to an NTSC video signal "Vd".
The liquid crystal display device 1 further includes a liquid crystal display panel 101, 4 X-driver circuits 201-1 through 201-4 electrically connected to the liquid crystal panel 101 to sample the video signal "Vd", a Y-driver circuit 301, and a control circuit 401.
As shown in FIGS. 1 and 2, the liquid crystal display panel 101 has a thin film transistor (called "a TFT") array and counter substrates 110 and 150 between which a twisted nematic liquid crystal layer 185 is held and the peripheral edges of which are hermetically sealed up by a sealing material (not shown). On the outer surfaces of the substrates 110 and 150, polarizers 191 and 193 are disposed in such a manner that the polarization axes cross at right angles each other. The array substrate 110 has 480×3 signal lines Xi, (i=1, 2, 3, . . . , 1440), and 240 scanning lines Yj, (j=1, 2, 3, . . . , 240) which cross substantially in right angles with the signal lines Xi. In the vicinity of the cross point between each signal line Xi and each scanning line Yj, an inverted staggered type thin film transistor is provided with a gate line of part of the scanning line Yj, an active layer 123 of an amorphous silicon thin film formed on a gate insulation layer 122, a channel protection layer 124 formed on the active layer 123, a drain electrode 125 connected to the active layer 123 and the signal line Xi, and a source electrode 126 connected to the active layer 123. The source electrode 126 of the TFT 121 is also connected to an indium tin oxide (ITO) pixel electrode 131. The array substrate 110 is provided with storage capacitor lines Cj, (j=1, 2, 3, . . . , 240) running in parallel with the scanning lines Yj and overlapped with part of the pixel electrodes 131. The pixel electrode 131 and the storage capacitor line Cj define a storage capacitor Cs. The counter substrate 150 includes light locking layers 153 disposed in a matrix form to block light passing through the gaps defined between the signal line Xi and the pixel electrodes 131, and the gaps between the scanning lines Yj and the pixel electrodes 131, respectively, and a color filter layer 155 consisting of red (R), green (G) and blue (B) components, each of which is provided between the light blocking layers 153 formed on the color filter layers 155, and ITO counter electrodes 157.
The display area 103 of the liquid crystal panel 101 includes 240 horizontal pixel lines, each of which has 480 picture elements. Further, each picture element contains display pixels of red (R), green (G), and blue (B).
The control circuit 401 supplies a horizontal clock signals "XCK", a horizontal start signal "XST", and the video signal "Vd" to the X-driver circuits 201-1 through 201-4, and a vertical clock signal "YCK", and does also a vertical start signal "YST" to the Y-driver circuits.
The X-driver circuit 201-1 includes, as shown in FIG. 3, a shift register S/R consisting of 120 flip-flop circuits to transfer the horizontal start signal "XST"sequentially in response to the horizontal clock signal "XCK", sampling circuits 211 including sampling transistors STFT to sample the video signal "Vd" in accordance with outputs of the shift register S/R, and latch and buffer circuits 221 and 231 to hold video signal voltages "Vsig" sampled through the sampling circuits 211. The other X-driver circuits 201-2 through 201-4 are substantially the same in construction and the explanation thereof is therefore omitted.
The Y-driver circuit 301 has, as shown in FIG. 4, a shift register S/R consisting of 240 flip-flop circuits to transfer the vertical start signal "YST" sequentially in response to the vertical clock signal "YCK", and a buffer circuit 311.
The control circuit 401 includes, as shown in FIG. 5, a horizontal clock signal control circuit 411 to output the horizontal clock signal "XCK" in accordance with a display area switching signal "SEL". The horizontal clock signal control circuit 411 is provided with a control signal generator 421 to generate control signals "A", "B", and "C" in response to a switching signal "SEL", a clock signal oscillator 431 consisted of a phase locked loop circuit, for instance, to generate a 14 MHz clock signal in response to the horizontal and vertical synchronous signals "H/Vsync", and a horizontal clock signal generator 441 (see FIG. 6) controlled with the control signals "A", "B", and "C", the reference clock signal "CK" and an inverted reference clock signal "ICK" inverted through an inverter 433.
The horizontal clock signal generator 441 will be next explained in detail with reference to FIG. 6. The control signal "A" and an output signal of a first flip-flop circuit 443 are supplied to a NOR gate 464 which, in turn, is supplied to a NAND gate 466. The control signal "B" and an output signal of an inverter 469 are supplied to an OR gate 465. The inverter 469 inverts an output signal Q of a second flip-flop circuit 445. The OR gate 465 supplies output signal to the NAND gate 466.
The first flip-flop circuit 443 is the clocked D type which has D and CK (clock) input terminals, and Q and Q output terminals. The flip-flop circuit is controlled in response to an output signal of the NAND gate 466 and the reference clock signal "CK" supplied to the D and CK clock input terminals, respectively. Its output signals Q (i.e., an output "D" shown in FIG. 8) and Q are provided to a NOR gate 455 and a D input terminal of a third flip-flop circuit 447, respectively. The output signal Q of the flip-flop circuit 443 is fed back to the NOR gate 464 and a NAND gate 467. The flip-flop circuit 447 is also the same clocked D type as of the flip-flop circuit 443. The flip-flop circuit 447 is controlled in response to an output signal Q of the flip-flop circuit 443 and the inverted reference clock signal "ICK" supplied to the D and CK input terminals thereof, respectively. An output Q (i.e., an output "F" shown in FIG. 8) of the flip-flop circuit 447 is supplied to OR gates 451 and 453.
The control signals "A" and "B" are supplied to the NAND gate 467 through inverters 461 and 462, respectively. An output signal of the NAND gate 467 and the reference clock signal "CK" are provided to D and CK input terminals of a second flip-flop circuit 445, respectively, which is the same type as of the other flip-flop circuits 443 and 447. Output signals Q (i.e., an output "E" shown in FIG. 8) and Q are provided to a NOR gate 457 and the OR gate 465 through an inverter 469, respectively.
The control signal "B" is also supplied to the OR gate 451. An output signal of the OR gate 451 and the output signal Q of the flip-flop circuit 443 are provided to a NOR gate 455 which produces an output signal "G" shown in FIG. 8. The control signals "B" and "C" are supplied to a NOR gate 468 through inverters 462 and 463, respectively. An output signal of the NOR gate 468 is supplied to the OR gate 453 which also receives the output signal Q of the flip-flop circuit 447. An output signal of the OR gate 453 is supplied to the NOR gate 457 which also receives the output signal Q of the flip-flop circuit 445. The NOR gate 457 produces an output signal "H" shown in FIG. 8. The output signals "G" and "H" of the NOR gates 457 are supplied to an EXOR (Exclusive OR) gate 459 to form an output signal "XCK" as shown in FIG. 8.
The control signal "A" controls an output period of the horizontal clock signal "XCK" of the horizontal clock signal generator 441. The control signal "B" and "C" control a frequency of the horizontal clock signal "XCK" of the horizontal clock signal generator 441 in such a manner as shown in FIG. 7. When the control signal "B" is a high level (H) and that "C" is either a high (E) or low (L) level, the horizontal clock signal generator 441 generates the horizontal clock signal "XCK" with the frequency of "2fCK/3" where the "fCK" is a frequency of the reference horizontal clock signal "CK". In the case that the control signals "B" and "C" are high (H) and low (L) levels, respectively, the horizontal clock signal generator 441 derives the horizontal clock signal "XCK" with that of "fCK". Further, in the case that the control signals "B" and "C" are high (E) levels, the horizontal clock generator 441 outputs the horizontal clock signal "XCK" with that of "fCK/2".
The frequency "fCK" of the reference horizontal clock signal "CK" is determined by a product of a horizontal scanning frequency and the number of horizontal dots. In the case of this embodiment, since the NTSC horizontal scanning frequency (fH) is 15.734 kHz, each of the pixels of red (R), green (G), and blue (B) has 480 dots per a horizontal scanning line, and the ratio of an effective video signal for each scanning period is about 8/10, the frequency "fCK" of the reference clock signal "CK" is derived out from an equation of {(fH)×[480/(8/10)]}×2/3, i.e., approximately 14 MHz. When the display device receives PAL video signals, however, the frequency of its clock signal is adjusted in accordance with the PAL horizontal scanning frequency and the number of horizontal dots used therefor in substantially the same way as set forth above.
Operation of the liquid crystal display device 1 will be described hereinafter. First, it is set forth in the case that the liquid crystal display device 1 displays on the display area 103 a video signal "Vd" consisting of image information with the aspect ratio of 16/9 or 4/3 as shown in FIG. 13(b).
The clock signal oscillator circuit 431 of the control circuit 401 generates the reference clock signal "CK" with the frequency of 14 MHz. The clock signal "CK" and the inverted reference clock signal "ICK" inverted through the inverter 433 are provided to the horizontal clock signal generator 441.
The control signal generator 421 is provided with the reference clock signal "CK", the selection signal "SEL", and the horizontal/vertical synchronous signal "H/Vsync" to generates the horizontal start signal "XST", and the control signals "A","B", and "C" which are in turn provided to the horizontal clock signal generator 441.
In response to the control signals, the flip-flop circuit 443 of he horizontal clock signal generator 441 outputs a divided reference clock signal "CK/3" as the signal "D" which duty ratio of a high level to a low level is 1:2. The flip-flop circuit 445 outputs the signal "E" consisting of the signal "D" but delayed by one clock period in accordance with the reference clock signal "CK". The flip-flop circuit 447 derives out the signal "F" consisting of the signal "D" but delayed by 1/2 clock period.
The NOR gate 455 outputs the signal "G" which is a divided reference clock signal "CK/3" and which duty ratio of a high level to a low level is 1:1 in response to the signal "D", and the output signal of the OR gate 451 consisting of the control signal "B" and the signal "F". Controlled by the output signal of the OR gate 453 consisting of low (L) level signals derived from the control signals "B" and "C" and the signal "F", and the signal "E", the NOR gate 457 outputs the signal "H", which is a divided reference clock signal "CK/3" and is delayed in phase by 1/2 clock period with respect to the signal "G". In response to the input signals "G" and "H", the EXOR 459 outputs the horizontal clock signal "XCK" consisting of a divided reference clock signal "2CK/3" with the frequency of "2fCK/3" which duty ratio of a low level to a high level is 2:1 (see various waveforms shown in FIG. 8).
In accordance with the horizontal clock signal "XCK", the input video signal "Vd" is sampled at 480 points for each color of every one horizontal period (1H) and is reconstructed on the display area 103 as image information with the aspect ratio of 16/9.
Next, the operation of the liquid crystal display device 1 is further described in the case that the display area is divided into two display regions, i.e., a first region A with the aspect ratio of 12/9 (=4/3) and a second region B with that of 4/9 and an NTSC video signal with the aspect ratio of 4/3 is displayed on the first region A.
In this particular case, as shown in FIG. 9, one video signal "Vd" corresponding to the first region with the aspect ratio of 4/3 is sampled during 0.8 H for each horizontal scanning period H and another video signal corresponding to the second region B with that of 4/9 is sampled during the remaining horizontal scanning period of 0.2 H. The latter video signal is set to display an entire black display, for instance, on the second region B in the case.
The control signal generator 421 outputs high level control signals "B" and "C" during 0.8 H in accordance with the selection signal "SEL" so that the clock pulse signal "XCK" with the frequency of fCK/2. In the horizontal clock signal generator 441, the flip-flop circuit 443 outputs the signal "D" consisting of a divided reference clock signal "CK/2" with the phase shift of 180° from the reference clock signal "CK". The flip-flop circuit 445 outputs the signal "E" with a high level (H) when the control signals "A" and "B" are a low level. The flip-flop 447 provides the signal "F" consisting of the signal "D" delayed by 1/2 clock period on a basis of the reference clock signal "CK". The NOR gate 455 is provided with the signal "D", and the outputs of the OR gate 451 consisting of the control signal "B" and the signal "F" to produce the signal "G" consisting of the signal "D" but shifting the phase of 180° therefrom. The NOR gate 457 outputs a low level signal "H" in accordance with the signal "E" and the output signal of the OR gate 453 which is provided with the signal "F" and high level signals based on the control signals "B" and "C". The EXOR gate 459 outputs the horizontal clock signal "XCK" consisting of a divided reference clock signal "CK/2" with the duty ratio of a low level to a high level of 1:1.
The video signal "Vd" corresponding to the first region A with the aspect ratio of 4/3 is sequentially sampled in accordance with the horizontal clock signal "XCK" during the period of 0.8 H.
As shown in FIG. 9, the control signal "C" is set to be a low level and the horizontal clock signal "XCK" with the same frequency "fCK" as of the reference clock signal "CK" is derived out from the horizontal clock signal generator 441.
In this case, the flip-flop circuit 443 outputs the signal "D" consisting of a frequency divided clock signal "CK/2" with the phase shift of 180° from the reference clock signal. The flip-flop circuit 445 produces the signal "E" with the high level in the case of the control signals "A" and "B" with the low level. The flip-flop circuit 447 provides the signal "F" consisting of the signal "D" delayed by a half of one clock period in accordance with the reference clock signal "CK". The NOR gate 455 is provided with the signal "D" and the output of the OR gate 451 and outputs the signal "G" consisting of the signal "D" but shifting the phase of 180° therefrom. The NOR gate 457 receives the signal "E" and the output of the OR gate 453, which is provided with the signal "F" and a low level signal concerning the control signals "B" and "C", and outputs the signal "H" consisting the signal "F" but shifting the phase of 180° therefrom. The EXOR gate 459 produces the horizontal clock signal "XCK" with the same frequency "fCK" as of the reference clock signal "CK" in response to the signals "G" and "H".
The video signal "Vd" corresponding to the second region with the aspect ratio 4/9 is sampled in accordance with the clock signal "XCK" during the remaining period of 0.2 H. As set forth above, the video signal "Vd" consisting of image information with the aspect ratio of 4/3 is displayed on the first region A with the same aspect ratio as thereof within one horizontal scanning period by changing the frequency of the horizontal clock signal.
According to the liquid crystal display device 1, such display forms as shown in FIGS. 13(b) and 13(c) can be performed by merely changing the frequency of the horizontal clock signal. It is unnecessary to use an expensive memory for the display device.
Further, the unique structure of the control circuit enables the reference clock signal to be a lower frequency. It provides, therefore, various features in which it is quite little affected by outer circuits, generates reliably the horizontal clock "XCK" and achieves low power consumption. In addition, a lower frequency reference horizontal clock signal can suppress spurious electromagnetic waves.
A liquid crystal display device of another embodiment of the invention will be further explained hereinbelow with reference to the drawings. The liquid crystal display device 1 of the embodiment can carry out a display as shown in FIG. 13(d) in addition to those explained above.
As shown in FIGS. 10 and 11, the display device 1 is substantially the same in structure as in the first embodiment but, additionally, a switching circuit 501 is provided between the X-driver circuits 201-1 and 201-2, and the control circuit 401 outputs horizontal start signals "XST1", "XST2" and a switching signal "SE" to control the switching circuit 501. In short, the switching circuit 501 couples either the horizontal start signal "XST1" of the final stage flip-flop circuit of the X-driver circuit 201-1 to the X-driver circuit 201-2 or the horizontal start signal "XST2" of the control circuit 401 to the X-driver circuit 201-2 in response to a switching signal "SE" of the control circuit 401.
Based on such structure and additional functions, the operation of the liquid crystal display device 1 will be described first with respect to the display of an NTSC video signal "Vd" consisting of image information with the aspect ratio 16/9 (or 4/3) on the display area 103 as shown in FIG. 13(b).
In this particular case, the switching circuit 501 is selected to connect the X-driver circuit 201-1 to the X-driver circuit 201-2 in response to the switching signal "SE" so that the horizontal start signal "XST1" is supplied from the final stage of the X-driver circuit 201-1 to the first stage of the X-driver circuit 201-2. In other words, the X-driver circuits 201-1 through 201-4 coupled together in cascade.
In the same manner as in the first embodiment, the control circuit 401 outputs the horizontal clock signal "XCK" derived from the reference clock signal "CK". The frequency thereof is "2fCK/3" where the frequency "fCK" of the reference clock "CK" is about 14 MHz. The duty ratio of clock signal "XCK" is 2:1 where that is defined by a ratio of a low level to a high level of the clock signal "XCK".
The video signal "Vd" is sampled in accordance with the clock signal "XCK" to display image information with the aspect ratio of 16/9 on the display area 103 of the display device 1 in which the number of such sampling is 480 for each color at every horizontal scanning line.
The display device 1 further operates in such a way that the display area 103 is divided into the region A with the aspect ratio of 12/9 (=4/3) and the region B that of 4/9 as shown in FIG. 13(c) and an NTSC video signal "Vd" consisting of image signal with the aspect ratio of 4/3 is displayed on the region A.
In this case, switching circuit 501 is also selected to connect the X-driver circuit 201-1 to the X-driver circuit 201-2 in response to the switching signal "SE" so that the first horizontal start signal "XST1" is supplied from the final stage of the X-driver circuit 201-1 to the first stage of the X-driver circuit 201-2 and the X-driver circuits 201-2, 201-3, and 201-4 are connected each other in cascade.
In the same manner as set forth above, the control circuit 401 outputs the horizontal clock signal "XCK" with the frequency of fCK/2 to sample the video signal "Vd" corresponding to the region A with aspect ratio of 4/3 during the period 0.8 H. The control circuit 401 outputs the horizontal clock signal "XCK" with the frequency of fCK during the remaining period of 0.2 H. The whole sampling of all the pixels is thus completed for one horizontal scanning line. The video signal "Vd" consisting of image information with the aspect ratio of 4/3 is displayed on the region A without any aspect change.
The display device 1 also carries out such a display as shown in FIG. 13(d) in which the display area 103 is divided into the region A with the aspect ratio of 4/9 and the region B with that of 12/9 (=4/3) and an NTSC video signal "Vd" consisting of image information with the aspect ratio of 4/3 is displayed on the region B.
The switching circuit 501 is selected to couple the horizontal start signal "XST2" of the control circuit 401 to the X-driver circuit 201-2 in response to the switching signal "SE". The control circuit 401 outputs the horizontal clock signal "XCK" with the frequency of "fCK/2" to sample the video signal "Vd" corresponding to the region B with the aspect ratio of 4/3 during the period of 0.8 H within one horizontal scanning period (1H) as shown in FIG. 12. The X-driver circuits 201-2 through 201-4 complete the sampling of the video signal "Vd" in response to the horizontal start signal "XST2" and the clock signal "XCK". The control circuit 401 outputs the horizontal clock signal "XCK" with the frequency of "fCK". The X-driver circuit 201-1 samples the video signal "Vd" corresponding to the region A in accordance with the horizontal start signal "XST1" and the horizontal clock "XCK" during the remaining period of 0.2 H. Thus, the sampling is completed for all the pixels for one horizontal scanning line (1H). In this way, the video signal "Vd" consisting of image information with the aspect ratio of 4/3 is displayed on the region B with the aspect ratio of 4/3 with no aspect change.
As described above, the liquid crystal display device 1 can display the video signal as shown in FIG. 13(d) in addition to such other display forms as explained in the first embodiment.
The present invention is not limited to the specific embodiments. The video signal "Vd" is based on not only the NTSC system but also other various systems. The display area may be divided into a few effective display regions on which a few different video signals may be displayed, respectively. Further, the active matrix type liquid crystal display device 1 includes TFTs connected to the pixels but metal insulator metal switching elements (MIMs) may be in place thereof.
According to an image display method and an apparatus of the present invention, image information with different aspect ratios can be displayed on a few display areas with desired aspect ratios in a less expensive, accurate way. | A method of displaying an image on a display screen and a image display device are described. The display device includes a display screen, horizontal and vertical scanning circuits, and a control circuit. The display screen has a predetermined aspect ratio of its lateral axis length and its longitudinal axis length. The horizontal scanning circuits derive signal voltages from a video signal in accordance with a clock signal and provide the same to pixels of horizontal pixel lines. The vertical scanning circuits select the horizontal pixel lines. The control circuit includes a divider circuit to divide a reference clock signal by first and second dividing ratios, and a switching circuit to select either a combination of the reference clock signal and an output signal of the divider circuit by the first dividing ratio or an output of the divider circuit divided by the second dividing ratio so that it may supply the clock signal to the horizontal scanning circuit. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. provisional application Ser. No. 61/691,130 filed Aug. 20, 2012, the contents of which is incorporated herein by reference in its entirety.
BACKGROUND
[0002] Sweatshirts are important protective garments during the cool seasons. Sweatshirts are among the most popular garments in the sporting world, worn by athletes at all levels of competition in practice and off the field during cold, windy weather. Many sweatshirts are hooded sweatshirts, where a hood is sewn to the collar of the sweatshirt to provide additional head warming.
[0003] However, one disadvantage of sweatshirts is that they feature loose-fitting collars, and cold air can readily enter through these openings. While hoods ameliorate this problem to some extent, they do not solve it as hood openings are also broad and loose-fitting. Sweatshirt hoods are generally constructed from large, thick pieces of material. Although existing solutions such as drawstrings or cords allow sweatshirt hoods to be tightened, these solutions still do not achieve ideal fits. Thus, existing sweatshirts, including hooded sweatshirts, are generally limited as casual wear as they do not provide thorough protection against cold weather and winds, especially in outdoor sporting settings.
SUMMARY
[0004] The invention provides a hooded sweatshirt with an elongated protective collar situated within the hood. The elongated collar can be attached to the hooded sweatshirt at the neck circumference of the hooded sweatshirt inside the hood or attached to the neck circumference of the hooded sweatshirt through a yoke disposed between the elongated collar and the neck circumference of the sweatshirt.
[0005] In one aspect, the invention provides a hooded sweatshirt that includes a hood seamed to the sweatshirt at a neck circumference of the sweatshirt and an elongated collar seamed to the sweatshirt at the neck circumference interior to the hood. In some embodiment, the hooded sweatshirt has an elongated collar that is seamed to the neck circumference at both circumferential edges of the elongated collar. In some embodiment, the elongated collar is seamed to the neck circumference at one circumferential edge of the elongated collar. In some embodiments, the hooded sweatshirt is made of a material that includes a knitted fabric. In some embodiments, the hooded sweatshirt is made of a material that includes cotton, cotton and polyester, fleece, wool or any combination thereof. In some embodiments, the hooded sweatshirt includes a front muff pocket and/or a drawstring enclosed in a casing at the opening of the hood.
[0006] In some embodiment, the elongated collar of the hooded sweatshirt is seamed to the neck circumference through a circular strip of material, the circular strip of material having a first circumferential edge to which the elongated collar is seemed and a second circumferential edge which is seemed to the neck circumference. In some embodiment, the circular strip of material is a ribbing band or a knit-ribbed band. In some embodiment, the circular strip of material is an elastic band. In some embodiment, the elongated collar is seamed to the circular strip of material at both circumferential edges of the elongated collar. In some embodiment, the elongated collar is seamed to the circular strip of material at one circumferential edge of the elongated collar. In some embodiment, the hooded sweatshirt is made of material that includes a knitted fabric. In some embodiment, the hooded sweatshirt is made of material that includes cotton, cotton and polyester, fleece or wool. In some embodiment, the hooded sweatshirt includes a front muff pocket.
[0007] In another aspect, the invention provides a hooded sweatshirt comprising: a sweatshirt; a hood seamed to the sweatshirt at a neck circumference of the sweatshirt; and an elongated collar seamed to the sweatshirt at the neck circumference interior to the hood. In some embodiments, the elongated collar is seamed to the neck circumference at a first circumferential edge of a circular band of material, and the circular band of material is seamed at a second circumferential edge to the neck circumference. In some embodiments, the circular strip of material is a ribbing band or a knit-ribbed band. In some embodiments, the circular strip of material is an elastic band. In some embodiments, the elongated collar is seamed to the neck circumference at both circumferential edges of the elongated collar. In some embodiments, the elongated collar is seamed to the neck circumference at one circumferential edge of the elongated collar. In some embodiments, the elongated collar is seamed to the circular band of material at both circumferential edges of the elongated collar. In some embodiments, the elongated collar is seamed to the circular band of material at one circumferential edge of the elongated collar.
[0008] One or more of the embodiments of the present invention provide a hooded sweatshirt with an elongated protective collar. While the hood of the sweatshirt provides one layer of cold protection, the elongated collar, situated within the hood, further buffers cold air from the body, especially the neck. The elongated collar is connected to the circumference of the neck of the sweatshirt by a yoke. The yoke is a circular band of material seamed to the circumference of the neck and the circumference of the elongated collar. The yoke may be an elastic band serving to draw in the circumference of the neck. The elongated collar may be a ribbing band or knit-ribbed band, and may be a mock turtleneck collar or a turtleneck collar.
[0009] Any feature or combination of features described herein are included within the scope of the present invention provided that the features included in any such combination are not mutually inconsistent as will be apparent from the context, this specification and the knowledge of one of ordinary skill in the art.
[0010] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. In case of conflict, the present specification, including definitions, will control. In addition, the materials, methods, and examples are illustrative only and not intended to be limiting. Although methods and materials similar or equivalent to those described herein can be used to practice the invention, suitable methods and materials are described below.
[0011] All patents and publications referenced or mentioned herein are indicative of the levels of skill of those skilled in the art to which the invention pertains, and each such referenced patent or publication is hereby incorporated by reference to the same extent as if it had been incorporated by reference in its entirety individually or set forth herein in its entirety. Applicants reserve the right to physically incorporate into this specification any and all materials and information from any such cited patents or publications.
[0012] Other features and advantages of the invention will be apparent from the following detailed description and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIGS. 1A and 1B are front and rear views, respectively, of sweatshirt 100 according to an embodiment of the present invention.
[0014] FIG. 2 is a top perspective view of the neck area of sweatshirt 100 showing elongated collar 140 attached to yoke 130 and disposed in the neck area of sweatshirt 100 inside hood 120 according to an embodiment of the present invention.
[0015] FIGS. 3A and 3B are top perspective views of the neck area of sweatshirt 100 showing elongated collar 140 attached to yoke 130 as viewed from the outside of sweatshirt 100 ( 3 A, hood and sweatshirt shown in dotted lines) and as viewed when sweatshirt 100 is turned inside out ( 3 B).
DETAILED DESCRIPTION
[0016] The invention provides a hooded sweatshirt with an elongated protective collar situated within the hood. The elongated collar can be attached to the hooded sweatshirt at the neck circumference of the hooded sweatshirt inside the hood or attached to the neck circumference of the hooded sweatshirt through a yoke disposed between the elongated collar and the neck circumference of the sweatshirt.
[0017] FIGS. 1-3 illustrates a sweatshirt 100 according to an embodiment of the present invention. The sweatshirt 100 has a neck circumference 110 ( FIG. 1A , 2 ). Hood 120 is seamed to neck circumference 110 at neck seam 111 at the circumferential edge of neck circumference 110 ( FIG. 1A , 2 , 3 A). Yoke 130 is further seamed, at its bottom circumferential edge, to neck circumference 110 at neck seam 111 ( FIG. 2 , 3 A- 3 B). Yoke 130 is a circular band of material, which may be formed from a ribbing band or knit-ribbed band, which is a flexible and stretchable strip of material knitted in a rib pattern. Yoke 130 may furthermore be an elastic band, which is a band of fabric knitted or woven from a core stretchable substance, such as rubber or synthetic fiber strands, as well as one or more other fibers such as cotton, polyester, silk, yarn, synthetic fibers, or any combination thereof. Yoke 130 is cut to a predetermined length, which, in embodiments of the present invention, may be between 26 and 40 inches. Yoke 130 is established at neck seam 111 to draw in the edge of neck circumference 110 to the predetermined length of yoke 130 . Elongated collar 140 is seamed to the yoke 130 at the top circumferential edge of the yoke 130 at seam 113 ( FIG. 2 , 3 A- 3 B).
[0018] Sweatshirt 100 may be formed from a knitted, woven, or napped fabric structure, such as fleece or any other fabric structure suitable for warmth retention and wind protection. The fabric structure may be formed from natural, synthetic, or semi-synthetic fibers such as cotton, polyester, wool, nylon, rayon, acrylic, or any other fiber suitable for knitted, woven, or napped fabric structures, as well as any combinations of the foregoing fibers. Sweatshirt 100 may further include a piece of material seamed to its front to form muff pocket 160 .
[0019] Elongated collar 140 is a circular collar ( FIG. 1-3 ). Elongated collar 140 may be formed from a ribbing band or knit-ribbed band. The ribbing band or knit-ribbed band may have a height of at least 2 ½ inches and may have a circumference between 12 and 18 inches. Elongated collar 140 may be a mock turtleneck collar, where an elongated, circular collar is folded over once and seamed to yoke 130 at both ends. Elongated collar 140 may also be a turtleneck collar, where an elongated, circular collar is seamed to the yoke 130 at one end but is free at the other end.
[0020] Hood 120 may be any hood suitable for wearing with a sweatshirt. Hood 120 may have a drawstring or cord 150 for controlling the circumference of hood 120 , enclosed by casing 155 established at the opening of hood 120 . The base of hood 120 is seamed to neck circumference 110 at neck seam 111 so as to coincide with the base of yoke 130 .
[0021] In embodiments of the present invention, all seaming at an edge of any material seamed may provide a seam allowance from the edge of the material seamed. For example, a seam allowance may be ⅜ of an inch from the edge of the material seamed.
[0022] The present invention provides a cold protection garment that provides a loose layer of warming material, along with an inner close-fitting collar that protects against cold air and winds. While providing comfortable casual wear appropriate for athletic settings, it also secures a major area of heat loss, the neck, from cold weather. The practicality of this invention makes it suitable as work clothing for a variety of professions involving outdoor work during fall, winter, and spring.
[0023] Summary of items shown in the drawings:
[0000]
Item No.
Description
FIG. No.
100
Sweatshirt
1A-1B
110
Neck circumference
1A, 2
111
Neck seam
1A, 2, 3A-3B
113
Collar-yoke seem
2, 3A-3B
120
Hood
1A, 1B, 2
130
Yoke
2, 3A-3B
140
Elongated collar
1A, 2, 3A-3B
150
Drawstring
1A, 2
155
Drawstring casing
1A
160
Muff pocket
1A
[0024] The specific embodiments of the invention described above do not limit the scope of the invention described in the claims.
OTHER EMBODIMENTS OF THE INVENTION
[0025] While the invention has been described in conjunction with the detailed description, the foregoing description is intended to illustrate and not limit the scope of the invention, which is defined by the scope of the appended claims. The specific elements, embodiments and applications described herein are exemplary and not intended as limitations on the scope of the invention. Other objects, aspects, and embodiments will occur to those skilled in the art upon consideration of this specification, and are encompassed within the spirit of the invention as defined by the scope of the claims. Varying substitutions and modifications may be made to the invention disclosed herein without departing from the scope and spirit of the invention. The invention illustratively described herein suitably may be practiced in the absence of any element or elements, or limitation or limitations, which is not specifically disclosed herein as essential. As the terms and expressions that have been employed are used as terms of description and not of limitation, and there is no intent in the use of such terms and expressions to exclude any equivalent of the features shown and described or portions thereof. Thus, it will be understood that although the present invention has been specifically disclosed by preferred embodiments and optional features, modification and variation of the concepts herein disclosed may be resorted to by those skilled in the art, and that such modifications and variations are considered to be within the scope of this invention as defined by the appended claims. Under no circumstances may the patent application be interpreted to be limited to the specific examples or embodiments or methods specifically disclosed herein. In addition, the invention has been described broadly and generically herein. Each of the narrower species and subgeneric groupings falling within the generic disclosure also form part of the invention. Further, as used herein and in the appended claims, the singular forms “a,” “an,” and “the” include plural reference unless the context clearly dictates otherwise. | The invention provides a hooded sweatshirt with an elongated collar for improved cold protection. The elongated collar resides within the interior of the hood of the sweatshirt and provides a close fit at the neck region. | 0 |
BACKGROUND OF THE INVENTION
Field of the Invention
[0001] The present disclosure relates in general to a system and method for compressing gas from a hydrocarbon producing well, where the gas is compressed in multiple stages, and conditioned between stages.
Description of the Prior Art
[0002] Hydrocarbons produced from subterranean formations are often multiphase fluid mixtures of gases and liquids. The liquids from these multiphase mixtures are usually collected and transported to processing facilities for further refinement. However, as it is not always economical to store or transmit the produced gases, they are sometimes sent directly to flare instead of being captured. When the gases are captured they are often processed to remove moisture and other undesirable compounds. Hydrate inhibitors, such as methanol, are occasionally used to prevent hydrate formation within the gas. However, the hydrate inhibitors can be difficult to separate from the gas and thus introduce added complexities when trying to obtain a marketable gas product.
SUMMARY OF THE INVENTION
[0003] Described herein is an example method of producing compressed natural gas which includes obtaining fluid from a wellbore; where the fluid contains liquid and gas, and also includes a mixture of higher molecular weight hydrocarbons and lower molecular weight hydrocarbons. The gas from the wellbore is pressurized to an interstage pressure, and moisture is removed from the gas while the gas is at the interstage pressure to form a dry gas. Higher molecular weight hydrocarbons are removed from the gas while the gas is at the interstage pressure to isolate natural gas, and the processed natural gas is pressurized to form compressed natural gas. Removing moisture from the gas can involve contacting the gas with a hygroscopic agent that couples with the moisture, and separating the moisture and hygroscopic agent from the gas. The step of separating the higher molecular weight hydrocarbons from the gas can include cooling the gas, flashing the gas across a flow restriction so that the higher molecular weight hydrocarbons condense to from a liquid, and separating the liquid from the gas. In this example, during the step of cooling heat from the liquid is transferred to the gas. Alternatively, the step of cooling includes directing the gas through a chiller. The liquid can be transferred to an offsite location that is remote from the wellbore. The step of removing moisture from the gas can include contacting the gas with a molecular sieve. The compressed natural gas can be transferred to a container, where the container is transported to a location remote from the wellbore. The steps of pressurizing the gas can take place proximate the wellbore. Moisture can be removed from the gas prior to the step of pressurizing the gas to the interstage pressure.
[0004] Another example method of producing compressed natural gas involves receiving an amount of gas directly from a wellbore, pressurizing the gas to an interstage pressure, dehumidifying the gas at the interstage pressure to form a dry gas, and compressing the dry gas to form compressed natural gas. The dry gas can include a mixture of higher molecular weight hydrocarbons and lower molecular weight hydrocarbons, the method may further involve separating the higher molecular weight hydrocarbons from the dry gas at the interstage pressure. In this example, the step of separating the higher molecular weight hydrocarbons includes cooling the dry gas with a lower temperature fluid selected from the group consisting of liquid comprising the higher molecular weight hydrocarbons, a chilled fluid, and combinations thereof. The step of dehumidifying the gas at the interstage pressure may include contacting the gas with a hygroscopic agent.
[0005] Also disclosed herein is an example of a system for producing compressed natural gas which is made up an interstage conditioning system with a dehumidifying system for removing moisture from gas from a wellbore, a booster compressor having a suction line in communication with the gas from the wellbore and a discharge line in communication with the interstage conditioning system, and a compressor having a suction line in communication with an exit of the dehumidifying system and a discharge line having compressed natural gas. The system can also have a separation tank in the interstage conditioning system for separating higher molecular weight hydrocarbons from the gas. The dehumidifying system optionally has a tank with an injection system for a hygroscopic agent. The dehumidifying system optionally includes a tank having a molecular sieve.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] Some of the features and benefits of the present invention having been stated, others will become apparent as the description proceeds when taken in conjunction with the accompanying drawings, in which:
[0007] FIG. 1 is a schematic view of an example of a system for processing fluid from a wellbore.
[0008] While the invention will be described in connection with embodiments, it will be understood that it is not intended to limit the invention to the embodiments. On the contrary, it is intended to cover all alternatives, modifications, and equivalents, as may be included within the spirit and scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION OF THE INVENTION
[0009] The method and system of the present disclosure will now be described more fully hereinafter with reference to the accompanying drawings in which embodiments are shown. The method and system of the present disclosure may be in many different forms and should not be construed as limited to the illustrated embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey its scope to those skilled in the art. Like numbers refer to like elements throughout. In an embodiment, usage of the term “about” includes +/−5% of the cited magnitude. In an embodiment, usage of the term “substantially” includes +/−5% of the cited magnitude.
[0010] It is to be further understood that the scope of the present disclosure is not limited to the exact details of construction, operation, exact materials, or embodiments shown and described, as modifications and equivalents will be apparent to one skilled in the art. In the drawings and specification, there have been disclosed illustrative embodiments and, although specific terms are employed, they are used in a generic and descriptive sense only and not for the purpose of limitation.
[0011] An example of a compressed natural gas (CNG) system 10 is schematically illustrated in FIG. 1 . The CNG system 10 is downstream of a wellhead assembly 12 shown mounted over a wellbore 14 that intersects a formation 16 . Hydrocarbons, both liquid and gas, from the wellbore 14 are produced through the wellhead assembly 12 and transmitted from wellhead assembly 12 via a connected production line 18 . Production line 18 terminates in a header 20 . The header 20 may optionally be the destination for other production lines 22 , 24 , 26 that also transmit production fluid from other wellhead assemblies (not shown). A feed line 28 provides a communication means between the header 20 and CNG system 10 . The end of feed line 28 distal from header 20 terminates in a knockout drum 30 and which optionally provides a way of separating water and other liquids from the feedline 28 . A drain line 32 connects to a bottom of knockout drum 30 and directs liquids separated out from the fluid flow in feed line 28 . The gas portion of the fluid in feed line 28 directed into knockout drum 30 exits knockout drum 30 through an overhead line 34 shown extending from an upper end of knockout drum 30 . The end of overhead line 34 distal from knockout drum 30 connects to a suction line of a compressor 36 . In the example of FIG. 1 , compressor 36 includes a booster compressor 34 and a CNG compressor 40 . In this example, overhead line 34 terminates at a suction end of booster compressor 38 so that the gas in line 34 can be pressurized to an interstage pressure.
[0012] The interstage gas discharged from booster compressor 38 is treated in an interstage conditioning system 42 . More specifically, a discharge line 46 provides communication between a discharge side of booster compressor 38 to a dehydration unit 48 . In one alternative, an injection line 50 for injecting hygroscopic agent into the intermediate stage gas flow stream is shown connected to dehydration unit 48 . In one example the hygroscopic agent includes triethylene glycol (TEG), and extracts moisture contained within the interstage gas. A discharge line 52 is shown connected to dehydration unit 48 , and provides a means for moisture removal from the intermediate stage gas. Overhead line 54 is shown connected to an upper end of unit 48 and which is directed to a heat exchanger 56 . Within heat exchanger 56 , fluid from within overhead line is in thermal communication with fluid flowing through a bottoms line 58 ; where bottoms line 58 connects to a lower end of natural gas liquid (NGL) tank 60 . Downstream of heat exchanger 56 , overhead line 54 connects to a heat exchanger 62 . Flowing through another side of heat exchanger 62 is fluid from an overhead line 64 , where as shown overhead line 64 attaches to an upper end of NGL tank 60 . An optional chiller 66 is shown downstream of heat exchanger 62 in line with overhead line 54 . Further in the example of FIG. 1 is a control valve 68 illustrated in overhead line 54 and just upstream of where line 54 intersects with NGL tank 60 . Liquid within line 58 is transmitted to offsite 70 , and is controlled to offsite 70 via a valve 72 also shown set within line 58 . Valve 72 can be motor or manually operated.
[0013] Overhead line 64 is shown connected to a suction end of CNG compressor 40 and where the gas within overhead line 64 is compressed to a CNG pressure. A discharge line 74 connects to a discharge side of CNG compressor 40 and provides a conveyance means for directing the compressed natural gas from CNG compressor 40 to a tube trailer 76 . Optionally, a valve 78 is provided in discharge line 74 and for regulating flow through discharge line 74 , and to selectively fill tube trailer 76 . Alternatively, each booster compressor 38 may include a first stage 80 and second stage 82 . In this example, discharge from first stage 80 flows through suction of second stage 82 for additional pressurization. Similarly, CNG compressor 40 contains a first stage 84 and second stage 86 , wherein gas within first stage 84 is transmitted to a suction side of second stage 86 for additional compression. Examples exist wherein the booster compressor 38 and CNG compressor 40 are reciprocating compressors and wherein each have a number of throws, wherein some of these throws may be what is commonly referred to as tandem throws.
[0014] In one example of operation, a multiphase fluid from well 14 flows through lines 18 , 20 , 28 and is directed to knockout drum 30 . Embodiments exist where the fluid flowing through these lines contains at least an amount of flare gas, which might commonly be sent to a flare and combusted onsite. An advantage of the present disclosure is the ability to economically and efficiently produce an amount of compressed natural gas that may be captured and ultimately marketed for sale. Liquid within the fluid in line 28 out flows to a bottom portion of knockout drum 30 and is separated from gas within the fluid. From within drum 30 , the gas is directed into overhead line 34 . Line 34 delivers the gas to the suction of booster compressor 38 , where in one example the gas is pressurized from an expected pressure between 50 to 100 psig to a pressure of 400 psig, and which forms the interstage gas. Gas, which may include hydrocarbons, is directed through line 46 into dehydration unit 48 . For the purposes of discussion herein, lower molecular weight hydrocarbons are referred to those having up to two carbon atoms, wherein higher molecular weight hydrocarbons include those having three or more carbon atoms. To remove moisture from within the interstage gas in line 46 , hygroscopic agent is directed from injection line 50 into dehydration unit 48 and allowed to contact the gas within dehydration unit 48 . Alternatively, a molecular sieve 88 may be provided within dehydration unit 48 .
[0015] Hygroscopic agent, or sieve 88 , can then absorb moisture within the interstage gas. Sieve 88 may be regenerated after a period of time (by pressure swing adsorption or temperature swing adsorption) to remove the moisture captured within spatial interstices in the sieve 88 .
[0016] To remove higher molecular weight hydrocarbons from the interstage gaseous mixture in line 54 , the fluid making up the mixture is cooled within exchangers 56 and 62 and flashed across valve 68 . Cooling the fluid stream, and then lowering the pressure across valve 68 , is an example of a Joule-Thompson method of separation and can condense higher molecular weight hydrocarbons out of solution and into tank 60 . The resulting condensate can be gravity fed from within tank 60 and to offsite 70 . An optional flare 90 is schematically illustrated in communication with fluid from the wellbore 14 via an end of header 20 . Fluid in header 20 can be routed to flare 90 when system 10 is being maintained or otherwise out of service.
[0017] In alternatives employing the optional chiller 66 , the higher molecular weight hydrocarbons are separated from the fluid stream by a mechanical refrigeration unit instead of the Joule-Thompson method of gas conditioning. In examples where the Joule-Thompson method is employed, the discharge from the booster compressor 38 can be at about 1,000 psig. In examples using the mechanical refrigeration method, the discharge from the booster compressor 38 can be at a pressure of around 400 psig. An advantage of treating the gas at the interstage pressure is the ability to remove additional moisture from the gas as well as to optimize the separation of the higher molecular weight hydrocarbons. As such, a higher quality of compressed natural gas can be obtained and delivered via line 74 into the tube trailer 76 . Moreover, a higher quality of NGL can be delivered to offsite 70 . In currently known processes, methanol is sometimes added to the gas mixture to prevent the formation of hydrates during the gas treatment process. However, the addition of methanol is not only costly, but also reduces the quality and marketability of the end products.
[0018] The present invention described herein, therefore, is well adapted to carry out the objects and attain the ends and advantages mentioned, as well as others inherent therein. While embodiments of the invention have been given for purposes of disclosure, numerous changes exist in the details of procedures for accomplishing the desired results. These and other similar modifications will readily suggest themselves to those skilled in the art, and are intended to be encompassed within the spirit of the present invention disclosed herein and the scope of the appended claims. | A system and method captures and processes flare gas so that the gas is usable as compressed natural gas (“CNG”). The flare gas is pressurized by a combination of a booster compressor and a CNG compressor. While interstage and between the booster compressor and the CNG compressor, the gas is treated to remove moisture and to separate out higher molecular weight hydrocarbons. The moisture is removed by contacting the interstage gas with a hygroscopic agent within a dehydration unit. The moisture free hydrocarbon fluid is expanded, and/or externally cooled and directed to a knock out drum. Higher molecular weight hydrocarbons are separated from the fluid in the knock out drum. Gas from the knock out drum is compressed in the CNG compressor. | 4 |
This application is a continuation of application Ser. No. 10/057,922 (now U.S. Pat. No. 6,453,871), filed Jan. 29, 2002 which is a continuation of application Ser. No. 09/709,404, filed Nov. 13, 2000 (now U.S. Pat. No. 6,343,585), which is a continuation of application Ser. No. 09/549,180, filed on Apr. 13, 2000 (now abandoned), which is a continuation of application Ser. No. 09/236,321, filed on Jan. 25, 1999 (now U.S. Pat. No. 6,148,791), which is a continuation of application Ser. No. 08/850,012, filed May 1, 1997 (now U.S. Pat. No. 5,875,761), which, in turn, is a divisional of application Ser. No. 08/362,878, filed Dec. 23, 1994 (now U.S. Pat. No. 5,666,916), the entire disclosures of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to a spark-ignition internal combustion engine, and more particularly to an apparatus for and a method of controlling a spark-ignition internal combustion engine of the type in which fuel is injected directly into a cylinder.
2. Related Art
There is known a conventional system (Japanese Patent Unexamined Publication No. 2-153257) in which fuel is injected directly into a cylinder by use of the air pressure. A conventional diesel engine utilizes a stratified combustion, and therefore the maximum output or power is low although the fuel consumption under a partial load is enhanced. On the other hand, a conventional gasoline engine has a drawback that although the maximum output or power is high because of a premixture combustion, the fuel consumption under a partial load is worsened because of a pumping loss.
SUMMARY OF THE INVENTION
It is an object of this invention to provide an apparatus for and a method of controlling an internal combustion engine, in which under a partial load, a pumping loss is eliminated by a stratified combustion, thereby enhancing the fuel consumption, and during a maximum-output operation, the output or power is increased by a premixture combustion, and an engine torque is controlled to improve the operability (drivability), the fuel consumption and an exhaust cleaning effect.
In order to overcome the above problem of the prior art, under a partial load, an ignition source is provided in the vicinity of a fuel injection valve, and after the fuel is injected, the mixture is ignited, and a resulting flame is caused by a spray of the fuel to spread into a cylinder, thereby effecting a stratified combustion. On the other hand, when the load increases, so that soot and so on are produced in the stratified combustion, the fuel injection is effected a plurality of times in a divided manner, and a premixture is produced within the cylinder by the former-half injection, and a flame, produced by the latter-half injection, is injected into the cylinder to burn this premixture. Thus, the premixture is burned in a short period of time. When changing the gear ratio of a transmission, the amount of the fuel is changed so that a step will not develop in a torque.
When the amount of injection of the fuel is small as in a partial-load operation, the initiation of the injection and the ignition timing can be relatively close to each other, and therefore the fuel is not so much spread within the cylinder, and the combustion (stratified combustion) takes place in a relatively narrow range. In accordance with the increase of the load, the initiation of the injection is made earlier, so that the range of formation of the mixture (premixture) increases, and a premixture combustion takes place, thereby increasing the produced torque.
In accordance with the drive torque, the gear ratio of the transmission is selected, and if the drive torque need to be further increased, the gear ratio of the transmission is increased. When changing the gear ratio, the fuel injection amount is controlled so that the drive torque will not be varied. The fuel is injected into the combustion chamber of the engine by a fuel injection valve having a port (opening) therein, and therefore the fuel will not deposit on an intake manifold and other portions, and the speed of inflow of the fuel is high, and the engine torque can be controlled with a good response. The air/fuel ratio can be set to a large value, and therefore a throttle valve opening degree can be increased to reduce a pumping loss, thereby enhancing a fuel consumption. Moreover, since the air/fuel ratio can be increased, the amount of CO and HC in the exhaust gas can be reduced.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view of a control system according to a first embodiment of the present invention;
FIG. 2 is a vertical cross-sectional view of a combustion chamber;
FIG. 3 is a diagram showing the correlation between the air/fuel ratio A/F and HC in exhaust gas, as well as the relation between A/F and NOx in the exhaust gas;
FIG. 4 is a vertical cross-sectional view of a combustion chamber as in FIG. 2, but showing a second embodiment of the invention;
FIG. 5 is a chart showing a fuel injection timing;
FIG. 6 is a flow chart for the calculation of a fuel injection time;
FIG. 7 is a block diagram of a fuel pressure control device;
FIG. 8 is a view showing an EGR control system;
FIG. 9 is a diagram showing the construction of a control system according to a third embodiment of the invention;
FIG. 10 is a time chart showing the operation of an intake valve;
FIG. 11 is a perspective view showing rocker arms;
FIG. 12 is a map diagram for selecting a cam in connection with the relation between an engine speed and an accelerator opening degree;
FIG. 13 is a map diagram for selecting a cam in connection with the relation between the engine speed and an engine torque;
FIG. 14 is a diagram showing the correlation between the air/fuel ratio A/F and the engine torque;
FIG. 15 is a diagram showing the correlation between the fuel amount and the engine torque;
FIG. 16 is a block diagram of a control system according to a fourth embodiment of the invention;
FIG. 17 is a block diagram of a control system according to a fifth embodiment of the invention;
FIG. 18 is a map diagram showing the relation between the target air/fuel ratio and the engine torque;
FIG. 19 is a diagram showing the correlation of a throttle valve opening degree with the engine speed and the intake air amount;
FIG. 20 is a block diagram of a control system according to a sixth embodiment of the invention;
FIG. 21 is a block diagram of the control system, according to an embodiment of the invention, similar to the system of FIG. 20;
FIG. 22 is a top plan view showing the construction of a cylinder gasket of an engine in a seventh embodiment of the invention;
FIG. 23 is a vertical cross-sectional view of the construction of FIG. 22;
FIG. 24 is a view showing another embodiment of the invention;
FIG. 25 is a diagram showing the correlation between a required torque and an engine torque;
FIG. 26 is a diagram showing the correlation between a throttle valve opening degree and the required torque;
FIG. 27 is a diagram showing the correlation between the required drive torque and the gear position;
FIG. 28 is a diagram showing the correlation between a vehicle speed and the engine torque;
FIG. 29 is a flow chart for the control of a transmission and the engine;
FIG. 30 is a diagram showing the correlation between an accelerator opening degree and the required drive torque;
FIG. 31 is a diagram showing the correlation between the accelerator opening degree and the vehicle speed;
FIG. 32 is a diagram showing the correlation between the engine speed and the engine torque;
FIG. 33 is a diagram showing the correlation between the engine speed and the engine torque;
FIG. 34 is a time chart showing the change of the engine torque and the throttle valve opening degree with time;
FIG. 35 is a control block diagram of still another embodiment of the invention;
FIG. 36 is a time chart showing the change of the fuel amount and the vehicle acceleration with time; and
FIG. 37 is a time chart showing the change of the air amount, the fuel amount and the vehicle acceleration with time.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows the construction of a control system according to a first embodiment of the invention. Fuel is fed from a fuel tank 1 to a fuel pump 2 , and the fuel is pressurized by this pump 2 . A pressure sensor 3 detects the pressure of the pressurized fuel, and feeds a pressure signal to a control circuit 5 . The control circuit 5 compares the fuel pressure with a predetermined target value, and if the fuel pressure is higher than this predetermined value, a spill valve 4 of the fuel pump 2 is opened to control the fuel pressure to the target pressure. The pressurized fuel is fed to a fuel injection valve 13 . A signal (torque signal) intended by the driver is fed from an accelerator pedal 19 to the control circuit 5 . In response to this signal, the control circuit 5 calculates an amount of one injection, taking a signal from an engine speed sensor 10 into account, and feeds a signal to an injection valve drive portion 20 of the fuel injection valve 13 . As a result, the fuel injection valve 13 is opened to inject the fuel into a combustion chamber 7 . The timing of injection of the fuel and the amount of injection (injection time) at this time are optimally determined by the control circuit 5 . A signal is fed from the control circuit 5 to an ignition circuit 22 at an optimum timing, and a high voltage is produced by the ignition circuit 22 , and is fed to an ignition plug 14 , so that the ignition plug 14 produces a spark to ignite the fuel injected into the combustion chamber 7 . The pressure within the combustion chamber 7 increases, and acts on a piston 9 to impart a rotational force to a crankshaft 16 , and tires 18 a and 18 b are driven through a transmission 15 and a differential gear 17 , thus causing a vehicle to travel. With respect to the torque produced by an engine 6 , the combustion pressure within the combustion chamber 7 is detected by a pressure sensor 8 , and is fed to the control circuit 5 , and is compared with the signal of the accelerator pedal 19 intended by the driver. The result of this comparison is reflected on the next or subsequent fuel injection in the cylinder. An amount of the air in the engine 6 is measured by an air amount sensor, and the flow rate of the air is controlled by a throttle valve. The air is also controlled by a swirl control valve 28 , provided in an intake manifold 27 , so that a suitable turbulence can be formed in the cylinder. A valve lift of an intake valve 12 is controlled by a valve lift control device 11 . Combustion gas is discharged from an exhaust valve 21 .
The first embodiment of the present invention will now be described with reference to FIG. 2 which is a vertical cross-sectional view of the combustion chamber. The fuel injection valve 13 and the ignition plug 14 are provided at an auxiliary combustion chamber 23 formed at an engine head 25 . With respect to the positional relation between the fuel injection valve 13 and the ignition plug 14 , it is preferred that the ignition plug 14 be disposed downstream of the spray emitted from the fuel injection valve 13 . With this arrangement, a flame core produced by the ignition plug 14 is liable to be spread by the spray to the combustion chamber 7 and a cavity 24 formed in the piston 9 . However, if the ignition plug 14 is disposed too close to the spray, the ignition plug 14 gets wet with the spray, so that an incomplete ignition may be caused. Therefore, it is important to properly determine the above positional relation. By throttling an outlet portion 26 of the auxiliary combustion chamber 23 , the speed of injection or jetting-out of the flame core can be adjusted. In this case, if the throttling is excessive, a pressure loss develops, so that the heat efficiency is lowered.
FIG. 3 shows the relation between the air/fuel ratio A/F and the exhaust gas (HC, NOx). When the fuel injection timing is a crank angle of 90°, the peak value of NOx is obtained when A/F is nearly 16 . Such a change in the amount of discharge of NOx tends to be seen in a uniform mixture. The reason is that when the fuel injection timing is a crank angle 90° or up to an intermediate stage of the intake stroke, the injection spray spreads out over the entire area in the cylinder because of flows of the air within the cylinder which flows are caused by the movement of the piston and the intake operation. As the injection timing defined by the crank angle becomes greater, the air/fuel ratio, at which the peak value of NOx is obtained, becomes larger. At the same time, the production of NOx becomes gentle. Also, the amount of discharge of HC varies. Comparing the injection timing 90° with the injection timing 180°, the amount of HC at the injection timing 90° at A/F of nearly 15 is 3,800 ppmC while the amount of HC at the injection timing 180° at A/F of nearly 15 is 6,500 ppmC. The reason why the amount of HC thus differs at the same air/fuel ratio is that the air/fuel ratio at the region where the combustion is effected is different. Namely, the air/fuel ratio at the region where the combustion is actually effected at the injection timing 180° is smaller. Therefore, when the air/fuel ratio increases, a combustion failure (extinction or flame-out) occurs at the injection timing 90° at the smaller air/fuel ratio. The reason why the air/fuel ratio, enabling a stable combustion (the amount of HC does not increase), increases with the increase of the injection timing is that the increased fuel injection timing approaches the ignition timing, so that the fuel becomes less liable to spread, thus providing the stratified mixture. By thus selecting the injection timing, the uniform mixture and the stratified mixture can be formed freely. Therefore, when the engine torque is small, the injection timing is increased to be brought near to the ignition timing. As the torque increases, the injection timing is decreased to bring the mixture close to a uniform one.
FIG. 4 shows a vertical cross-sectional view of a combustion chamber of a second embodiment. In this embodiment, a fuel injection valve 13 is projected into the combustion chamber 7 , and an injection port is so formed that the fuel can spread widely within a cylinder. In this case, when the fuel is injected when a piston is lowered to a point near to a bottom dead center, the fuel impinges directly on a wall surface of the cylinder to form a wall flow. In this condition, a good combustion can not be expected. Therefore, where the injection valve injects a wide spray, the fuel need to be injected at such a timing that a cavity 24 is disposed near to an upper dead center, and that the fuel can be blown into the cavity 24 . For example, the injection of the fuel can be effected a plurality of times in a divided manner, as shown in FIG. 5 . An early injection is effected at a crank angle of nearly 0° to form a uniform mixture. A combustion initiator is produced by a late injection effected at a timing near the ignition timing, and the uniform mixture produced by the early injection is rapidly burned thereby. The injection amount can be adjusted by any of the late injection and the early injection, and therefore the injection can be effected in the optimum condition. In the case where the injection is thus divided into the two injections (that is, the early injection and the late injection), the effect can be obtained also with the injection valve (FIG. 2) having a small injection angle.
FIG. 6 shows a flow chart for calculation of the fuel injection time in the case where the early injection and the late injection are effected. In Step 101 , an accelerator opening degree α and an engine speed Ne are read. At this time, if the air amount is measured, the air amount Qa may be also read. In Step 102 , the fuel amount Qf is calculated. In Step 103 , Qf>Qf 1 is judged. If the judgment result is “NO”, the program proceeds to Step 109 in which the injection time Tp 2 is calculated by adding an invalid injection amount Qx to Qf. In Step 110 , the fuel for Tp 2 is injected at the timing of the late injection, and the program is finished. If the judgment result in Step 103 is “YES”, the program proceeds to Step 104 in which Qf 2 is calculated by subtracting a minimum injection amount Qf 0 from Qf. In Step 105 , the injection time Tp 1 is calculated by adding the invalid injection amount Qx to Qf 2 . The fuel for Tp 1 is injected at the timing of the early injection. In Step 107 , Tp 2 is calculated by adding Qx to Qf 0 , and the fuel for Tp 2 is injected at the timing of the late injection. Thus, for each of the early and late injections, it is necessary to add the invalid injection amount Qx.
FIG. 7 shows a control system for controlling the fuel pressure. Fuel for the fuel pump 2 is fed from the fuel tank 1 . The fuel pump 2 is driven by a motor 30 , and the pressurized fuel is fed to a high-pressure pipe 34 . Injection valves 13 a to 13 d , an accumulator 33 , the fuel pressure sensor 3 , and a relief valve 32 are mounted on the high-pressure pipe 34 . Gas is sealed as a damper in the relief valve 33 , and when the fuel pressure increases, the fuel flows into the accumulator 33 . When the pressure decreases, the accumulator 33 discharges the fuel into the high-pressure pipe 34 . When the fuel pressure becomes unduly high, the relief valve 32 allows the fuel to flow therethrough, thereby preventing the pressure increase. The fuel pressure sensor 3 feeds a signal, proportional to the pressure, to the control circuit 5 , and in response to this signal, the control circuit 5 feeds a signal to the electromagnetic spill device 4 to control the discharge amount of the fuel pump 2 , thereby controlling the fuel pressure. Also, in response to the signal from the pressure sensor 3 , the control circuit 5 feeds a signal to a controller 31 of the motor 30 to control the rotational speed of the fuel pump 30 , thereby controlling the fuel pressure. In this embodiment, although the electromagnetic spill device 4 and the controller 31 are both provided, the fuel pressure can be controlled by one of them. However, in the case where the fuel pump 2 is driven by the engine, only the electromagnetic spill device 4 is used for this purpose since the motor 30 is not provided.
FIG. 8 shows a control system diagram of EGR. The air enters the engine 6 through an air flow meter 35 , a throttle valve 37 and the intake manifold 27 , and is discharged as exhaust gas to exhaust pipe 41 . A catalyzer 39 is provided in the exhaust pipe 41 . Here, when EGR becomes necessary, the control device 5 feeds a signal to an EGR valve 38 to open the same. The control device 5 also feeds a signal to a throttle valve actuator 36 to close the throttle valve 37 to thereby reduce the pressure of the intake manifold 27 to a level lower than the atmospheric pressure. As a result, the exhaust gas flows from the exhaust pipe 41 to the intake manifold 27 through the EGR valve 38 in proportion to the negative pressure of the intake manifold. The rate of flow of the exhaust gas at this time is proportional to the negative pressure of the intake manifold, and therefore the pressure of the intake manifold is detected by an intake manifold pressure sensor 40 , and a signal is fed from this sensor 40 to the control device 5 , and the degree of opening of the throttle valve 37 is adjusted by the throttle valve actuator 36 . By controlling the degree of opening of the throttle valve 37 , the pressure of the intake manifold 27 can be controlled, and the EGR amount can be accurately controlled by a feedback control.
FIG. 9 shows a third embodiment of the present invention. The air is controlled by a throttle valve 213 , and is drawn into an engine through an intake manifold 214 . A lift of an intake valve 208 can be changed by switching cams 203 of different shapes. The switching of the cams 203 is effected by switching rocker arms 210 by a hydraulic control valve 202 . The hydraulic control valve 202 is operated, for example, by a solenoid. The degree of opening of the throttle valve 213 is controlled by a motor 212 . A sensor 220 for detecting a pressure within a cylinder is mounted on the engine. An injection valve 204 for injecting the fuel directly into the cylinder is mounted on the engine. A sensor 205 for detecting the air/fuel ratio of exhaust gas is mounted on an exhaust pipe. A catalyzer is also provided in the exhaust pipe. Preferably, the catalyzer or catalyst is of a type which can remove NOx even when an excessive amount of oxygen is present. Also, function of a three-way catalyst, which can remove HC, CO and NOx at the same time under the condition of a stoichiometric air/fuel ratio, is needed. Part of the exhaust gas is controlled by valves 215 and 218 which control the flow rate in the exhaust pipe. With this arrangement, the combustion temperature is decreased, thereby reducing the amount of NOx. These control valves are controlled by a control device 201 . In order to reduce the fuel consumption, it is preferred that the pressure within the intake manifold be reduced to a level close to the atmospheric pressure, thereby reducing a pumping loss. For this purpose, the throttle valve 213 is fully opened as much as possible. However, in the case where the exhaust gas is recirculated through a pipe 216 , it is necessary that the pressure within the intake manifold should be lower than the pressure within the exhaust pipe, and therefore the throttle valve is closed.
FIG. 10 shows the operation of the third embodiment of the present invention. According to the operating conditions, the lift of the intake valve cam is changed, as shown in FIG. 10 . When a large amount of the air is required, the lift of the intake valve is set as at A. When the amount of the air is small, the lift of the intake valve is changed into a lift B or a lift C. By changing the lift, the overlap with an exhaust valve is also changed. During a high-output or power operation, the period of overlap between the exhaust valve and the intake valve is made longer. With this arrangement, the amount of the air can be changed by the lift of the intake valve.
FIG. 11 shows one example of the construction of rocker arms 221 , 223 and 224 and cams 225 , 226 and 227 . The rocker arm 223 and the cam 225 drive the intake valve for reciprocal movement. The rocker arm 226 and the cam 224 are not fixed to each other, and are in a free condition. When switching the cams, the rocker arm 224 and the cam 226 drive the intake valve for reciprocal movement. The rocker arm 223 and the cam 225 are not fixed to each other, and are in a free condition. With this construction, the cams can be switched. In this example, although the lift of the cam is changed, the shape of the cam may be changed so as to control the valve opening timing and the valve closing timing at the same time.
FIG. 12 shows a map for selecting the cam in connection with the degree of opening of an accelerator and the engine speed. In this example, the cam switching can be effected in a three-stage manner. When the engine speed is low, with the accelerator opening degree kept low, a cam A for a small lift is selected. As the engine speed and the accelerator opening degree increase, the cam is sequentially switched to those providing a larger lift.
FIG. 13 shows a map for selecting the cam in connection with the engine torque and the engine speed. In this example, the cam switching can be effected in a three-stage manner. The engine torque has target torque values predetermined with respect to the accelerator opening degree. When the engine speed is low, with the engine torque kept small, a cam A for a small lift is selected. As the engine speed and the engine torque increase, the cam is sequentially switched to those providing a larger lift.
FIG. 14 shows a method of controlling the amount of the intake air when switching the air/fuel ratio A/F. When the full-opening of the throttle valve or the cam for a large lift is selected, the fuel amount increases with the decrease of the air/fuel ratio, so that the engine torque (output torque) increases. At the air/fuel ratio of around 16, the amount of discharge of NOx tends to increase, and therefore the air/fuel ratio is skipped from 18 to 15. At this time, if the air/fuel ratio is switched to 15, with the air amount kept intact, the amount of the fuel increases, so that the engine torque increases as at C. This gives a sense of difference or a feeling of physical disorder. Therefore, when switching the air/fuel ratio, the air amount is reduced to prevent the increase of the fuel amount, and the engine torque is changed from A to B (FIG. 14 ), thereby reducing a shock. The air amount is adjusted by the throttle valve or by switching the cam. If this is effected by the throttle valve, the pressure within the intake manifold is decreased, thereby increasing the pumping loss. Therefore, preferably, this is done by switching the cam as much as possible. Also, when the engine torque decreases to such a level that the target engine torque is not achieved even if the air/fuel ratio is not less than 70, the air amount is adjusted by the cam or the throttle valve.
FIG. 15 shows the relation between the amount of the fuel and the engine torque (output torque). The engine torque can be increased by increasing the fuel amount, and therefore the engine torque can be controlled by the fuel amount.
FIG. 16 shows a fourth embodiment of the present invention. The amount Qf of injection of fuel is determined by an engine condition detection portion 301 (which detects the conditions of an engine such as an accelerator opening degree α and an engine speed N) and a fuel injection amount calculation portion 302 which calculates the amount Qf of injection of the fuel. In accordance with a charging efficiency map 303 , the amount of the air of the engine is calculated at a portion 304 , and the air amount by each cam is determined, thus calculating the air/fuel ratio. It is judged at a portion 305 whether or not the air/fuel ratio is within a combustible range. The cam is selected at a portion 306 , and the degree of opening of a throttle valve is determined at a portion 307 . If the air amount is excessive, the mixture becomes too lean, and therefore the cam is switched to one providing a smaller lift. In the injection within the cylinder, since the mixture within the cylinder is directly controlled, the limit of the lean mixture can be expanded as compared with a conventional intake port injection system, and therefore the range of the engine torque which can be controlled by the fuel amount is wider. Therefore, the engine torque can be controlled by the fuel amount without the need for finely controlling the air amount as in the conventional system.
FIG. 17 shows a fifth embodiment of the present invention. An accelerator opening degree is detected by a detection means 311 , and a target torque is determined by a calculation means 312 . An amount of fuel is determined by a fuel amount calculation means 313 in accordance with the target torque. If the air/fuel ratio is predetermined with respect to the engine torque (output torque) T at a portion 314 , the air amount Qa can be derived. The air/fuel ratio is judged by a judgment means 316 . If the air/fuel ratio is not less than 18, a throttle valve is fully opened, i.e. its opening degree θth→θmax, at a portion 318 , and the torque of the engine is detected by a torque detection means 319 , and the fuel injection amount is controlled so that the target torque can be obtained. On the other hand, if the air/fuel ratio is less than 18, the air amount is controlled by the throttle valve 321 so that the target air/fuel ratio can be achieved. The air amount is controlled, for example, by the throttle valve opening degree θth or the lift by a cam. Here, the air amount may be detected by an air amount sensor 322 to control the air amount to a target value thereof.
FIG. 18 shows a map of the target air/fuel ratio. The air/fuel ratio is decreased with the increase of the engine torque (output torque) T. However, at point B, the air/fuel ratio is switched to a point C in a manner to skip over the air/fuel ratio value 16 . For further increasing the torque, the air/fuel ratio is reduced toward a point D. If the air/fuel ratio is further reduced, the mixture becomes too rich. Therefore, preferably, at this region, the air amount is detected, and the air/fuel ratio is controlled.
FIG. 19 shows the relation of the throttle valve opening degree θth with the engine speed N and the intake air amount Qa. For controlling the air amount by the throttle valve, the throttle valve opening degree is found from a map for the intake air amount. For effecting a more precise or fine control, the air amount is detected, and a feedback is effected.
FIGS. 20 and 21 shows a sixth embodiment of the present invention. If the air/fuel ratio is not less than 18, the mixture is so lean that the drivability and an exhaust cleaning effect may be lowered. Therefore, a combustion variation is detected, and a throttle valve opening degree or a cam lift are so set as to reduce the air amount.
FIG. 22 shows a seventh embodiment of the present invention. An electrode or terminal 234 is embedded in a cylinder gasket 231 of an engine, and a high voltage is applied thereto from an electrode or terminal 232 . Screw holes 233 are formed in the gasket.
FIG. 23 is a vertical cross-sectional view of the portion of FIG. 22. A high voltage is applied across electrodes 238 and 239 from an ignition coil, thereby producing a spark discharge. With this arrangement, the mixture is ignited at a point near a cylinder wall surface and at other points as well, so that the combustion speed increases. Moreover, since the combustion is started adjacent to the wall surface, a so-called quench region near the wall surface is reduced, so that an amount of unburned hydrocarbon is reduced, and also a knocking is less liable to occur. Insulating layers 235 and 237 are provided on upper and lower surfaces of the gasket, respectively. If the electrode 239 is an earth or ground electrode, the insulating layer 237 may be omitted.
An embodiment of the present invention will now be described with reference to FIG. 24 . The amount of the intake air is measured by an air flow meter 501 mounted on an intake manifold. An engine speed is detected by a crank angle sensor 509 . In accordance with the amount of the intake air into a cylinder, as well as the engine speed, the amount of fuel is determined, and the fuel is injected into the cylinder by a fuel injection valve 502 . The air amount is controlled by a throttle valve 551 , connected to an accelerator wire, and a throttle valve 550 controlled by a motor. The air amount may be controlled only by the throttle valve 550 ; however, if the throttle valve 551 connected to the accelerator wire is provided, the air amount will not become excessive even in the event of an abnormal operation of the throttle valve 550 . A catalyzer 506 , which can oxidize CO and HC, and can reduce NOx in an oxidizing atmosphere, is provided at an exhaust pipe 512 . Therefore, even if oxygen is present in the exhaust gas as in a lean combustion, NOx can be reduced. The air/fuel ratio is detected by an air/fuel ratio sensor connected to the exhaust pipe, and it is examined whether or not a target air/fuel ratio is achieved. If the air/fuel ratio is more lean that the target value, the fuel amount is increased. HC is required for reducing NOx in an oxidizing atmosphere, and the temperature of the catalyzer is so controlled that a maximum cleaning efficiency of the catalyzer can be achieved. Therefore, the temperature of the catalyzer is detected by a temperature sensor 528 , and the fuel injection amount and the ignition timing are so controlled that the target catalyzer temperature and HC can be obtained. A charging operation of a charger 514 can be controlled from the outside by a control device 508 . The charging operation is effected during a deceleration, thereby recovering a deceleration energy. The amount of the intake air into the engine can be increased by a supercharger 511 . The operation of the catalyzer is also influenced by the oxygen concentration in the exhaust gas, and therefore an air introduction passageway 534 is provided at an inlet of the catalyzer, and the air amount is controlled by a control valve 534 . The air may be supplied by an air pump 535 . When the air amount is increased, the catalyzer is cooled by the air, and therefore the air may be used for controlling the temperature of the catalyzer.
FIG. 25 shows the relation between a required torque Tv and the engine torque Te. The description will be given with respect to an example in which a transmission (gearbox) has a five-stage (five-speed) gear ratio. In a fully-opened condition of the throttle valve, the fuel amount is changed. When the required torque Tv is small, a 5th speed (5th gear) with a small or low gear ratio is selected. When the required torque Tv becomes larger, the fuel amount is increased to increase the engine torque Te. At this time, in order to achieve a stable combustion, the fuel amount is within a lean combustion limit, and the air/fuel ratio is varied in the range of 30 to 20 so that the amount of NOx can be kept small. However, in view of the cleaning or removing property of the NOx catalyzer, the range of the air/fuel ratio may be changed. Also, if the stable combustion limit allows the air/fuel ratio to be further increased, the air/fuel ratio may be more than 30. A pumping loss is reduced when the operation is effected with a large air/fuel ratio, and the fuel consumption is enhanced. When the required torque Tv becomes further larger, the gear ratio is increased into a 4th speed. At this time, if the gear is changed with the air/fuel ratio kept at 20, the drive torque becomes excessive, so that a step develops in the torque, thereby adversely affecting the drivability. Therefore, the fuel amount is reduced to decrease the torque to be produced, thereby preventing a stepwise change in the drive torque. Similarly, as the required torque is increasing, the gear is sequentially changed. The drive torque can be obtained in the following:
(Drive torque)=(Engine torque)×(Gear ratio)
Namely, the larger the gear ratio becomes, the larger the drive torque becomes. If the air/fuel ratio range of between 20 and 30 is fixedly selected, the gear ratio is selected so that a torque step will not develop. Assuming that the air/fuel ratio is 20 at a 1st speed, when a larger torque than that is required, the air/fuel ratio is further decreased. The required torque Tv is determined, for example, by the degree of opening of an accelerator. When the accelerator opening degree is large, the required torque Tv is large.
FIG. 26 shows the relation between the degree θ of opening of the throttle valve and the required torque Tv. When the required torque Tv is small, the throttle valve opening degree θ is decreased to reduce the engine torque. When the required torque becomes larger, the throttle valve opening degree θ is fully increased, and the gear ratio is sequentially changed. At the 1 st speed, the air/fuel ratio is skipped in view of the amount of production of NOx, so that a torque step develops. Therefore, the throttle valve opening is controlled in a closing direction so as to minimize a torque step. The throttle valve opening degree is controlled by a motor or the like. Since the control of the throttle valve can be made only in the closing direction of the valve, the engine torque will not increase against the driver's will. It is preferred that the throttle valve be fully opened, but if the operation can be effected in the fully-opened condition because of the performance of the engine, the operation is effected, with the throttle valve opened as much as possible.
FIG. 27 shows the relation between the required torque Tv and the gear position V for the vehicle speed. The gear position V is changed in accordance with the vehicle speed. The gear position V is increased with the increase of the vehicle speed. When the gear position V is decreased, the drive torque can be increased. The description will be given with respect to an example in which the vehicle speed is increased from a low speed, with the throttle valve fully opened. When the vehicle speed increases from the 1st speed (1st gear) to the lower limit of the 2nd speed, the air/fuel ratio is changed from 30 to 20, thereby minimizing or avoiding a torque step. As the required torque decreases, the air/fuel ratio is changed from 20 to 30. When the vehicle speed further increases, the gear is changed to the 3rd speed, and at this time the air/fuel ratio is changed to 20, thereby avoiding a torque step. A similar operation is repeated until the 5th speed. When the required torque is to be changed at the 1st speed, the air/fuel ratio is brought into 30 in the fully-opened condition of the throttle valve. When the torque need to be further increased, the fuel amount is increased to change the air/fuel ratio to 20. When the torque is small, the throttle valve opening degree is reduced to decrease the air amount. When the air/fuel ratio is constant, the fuel amount decreases with the decrease of the air amount, so that the torque is reduced. When the required torque is small, but is larger than that of the lower limit vehicle speed of the 5th speed, the 5th speed is selected. When the vehicle speed is made lower than the lower limit vehicle speed of the 5th speed, the engine speed becomes too low. When at the 5th speed in the fully-opened condition, a larger torque is required than that obtained with the air/fuel ratio of 20, the 4th speed is selected if the vehicle speed is higher than the lower limit of the 4th speed. At this time, the air/fuel ratio is changed to 30, thereby avoiding a torque step. When at the 4th speed in the fully-opened condition, the torque is to be made smaller than that obtained with the air/fuel ratio of 30, the throttle valve is closed. Similarly, when the required torque is to be increased, the gear is changed to the 3rd speed. The torque is controlled by sequentially changing the gear to the 1st speed in a similar manner.
FIG. 28 shows the relation between the vehicle speed lower than the lower limit vehicle speed of the 1st speed and the engine torque Te at an outlet of a torque converter. Below the lower limit vehicle speed, when the transmission (gearbox) is kept in an engaged condition, the engine speed becomes too low, and in an extreme case, the engine is stopped. In such a speed region, a so-called lock-up (by which the transmission and the engine are directly connected together) is released, and the transmission is connected to the engine through the torque converter. When the vehicle speed decreases, there develops a slip region where there is a difference in rotational speed between the inlet and outlet of the torque converter. In the slip region, the torque is increased, and the engine torque at the outlet of the torque converter is increased. The engine torque can be changed by the air/fuel ratio. When the engine torque is, for example, not higher than 800 rpm, the lock-up is released. However, if the torque converter involves a slip, the torque converter produces a loss of transmission of the energy, so that the fuel consumption is worsened.
FIG. 29 shows a flow chart of the control of the transmission and the engine. The engine speed is calculated from the accelerator opening degree and the vehicle speed where number of gear shift positions r=5. When the engine speed is, for example, not more than 800 rpm, the gear position is shifted down by one speed (one gear) so that the engine speed will not be below 800 rpm. In the flow chart, although the gear position is sequentially shifted down, the gear position may be determined in accordance with the minimum allowable engine speed and the vehicle speed. Tf the gear position is larger than the 1st speed (1st gear), the lock-up is effected. When the gear position is the 1st speed, the gear position can not be shifted down any further even if the engine speed is lower than the minimum allowable engine speed, and therefore the lock-up is released. After the gear position is determined, the required engine torque (required torque) for the drive torque required by the driver is calculated. The fuel amount is calculated from the required torque, and the air/fuel ratio when fully opening the throttle valve is calculated. If the air/fuel ratio is not less than 30, the combustion becomes unstable, and therefore the throttle valve opening degree is so determined by calculation that the air/fuel ratio becomes 30. The associated actuators (the fuel injection valve, the throttle valve and the transmission) are so controlled that the fuel amount, throttle valve opening degree and gear position thus determined can be obtained. On the other hand, if the air/fuel ratio is not more than 20, the gear position is determined as (r−1), and the engine speed is calculated again. At this time, the fuel amount is controlled not to produce a drive torque step. Also, when the gear position is the 1st speed (1st gear), the gear position can not be shifted down any further, and therefore the air/fuel ratio is changed from 12 to 15. Since the air/fuel ratio is skipped at this time so as to reduce the amount of discharge of NOx, the throttle valve opening degree is so determined by calculation that a drive torque step will not develop, and the actuators are controlled.
FIG. 30 shows the relation between the accelerator opening degree and the required drive torque. As the accelerator opening degree decreases, the required drive torque is decreased. At the same accelerator opening degree, the required drive torque is decreased as the vehicle speed increases. That the required torque can have a negative value means an engine brake. At the same accelerator opening degree, the higher the vehicle speed is, the more effectively the engine brake acts.
The required drive torque is determined for the accelerator opening degree and the vehicle speed, as shown in FIG. 31 . These values are stored as a map in a memory of a computer for control purposes. For example, the accelerator opening degree, as well as the vehicle speed, is divided into 16, and 256 values of the required drive torque are stored.
FIG. 32 shows the relation between the engine speed and the engine torque. At the same engine speed, the larger the throttle valve opening degree is, the larger the torque is. By controlling the throttle valve opening degree, the engine torque can be controlled. Also, since the engine torque varies depending on the air/fuel ratio, the torque is controlled by changing the throttle valve opening degree and the fuel amount.
As to other advantageous effects of the present invention, the amount of the intake air is larger when using supercharging than when not using the supercharging, and the engine torque increases as shown in FIG. 33 . If an exhaust turbo charger is used as the supercharging means, regardless of the driver's will, the torque characteristics with the supercharging are represented by a curve (a) while the torque characteristics without the supercharging are represented by a curve (b). Therefore, the engine output or power is abruptly increased when effecting the acceleration, and this gives a sense of difference or a feeling of physical disorder.
FIG. 34 is a time chart showing the change of the engine torque and the throttle valve opening degree with time. When an accelerator pedal is pressed down, the amount of the air is increased, so that the fuel injection amount is increased. When the supercharging is effected, the air amount is abruptly increased, the torque is increased as shown by (b) of FIG. 34 regardless of the driver's will, and this gives the sense of difference. When the supercharging is not effected, the time-dependent change of the engine torque with respect to a time-dependent change of the throttle valve opening degree is represented by (a) in FIG. 34 . Thus, a certain period of time is required because of the inertia force before the speed by the supercharging becomes high, and therefore the supercharging becomes effective halfway during the acceleration.
FIG. 35 shows a control block diagram according to another embodiment of the present invention. The acceleration of the vehicle body is detected by an acceleration sensor, and if a desired drive torque is not obtained, the gear ratio (transmission ratio) of the engine is changed.
FIG. 36 shows the change of the fuel amount and the vehicle body acceleration with time. In order to determine the target acceleration for the accelerator opening degree as shown in this Figure, the fuel amount is increased to increase the engine torque. In the injection within a cylinder, the fuel can be injected directly into the cylinder, and therefore the fuel will not deposit on an intake manifold and the like, and the torque can be controlled with a good response. The acceleration is detected, and the fuel amount is so controlled that the target acceleration can be achieved.
FIG. 37 shows the change of the intake air amount, the fuel amount and the vehicle body acceleration with time. In order to determine the target acceleration for the accelerator opening degree as shown in this Figure, the fuel amount and the intake air amount are increased to increase the engine torque. The intake air amount is controlled by the throttle valve opening degree, but a delay occurs due to a volume of an intake manifold, so that the torque can not be controlled in a good response. Therefore, a large change of the engine torque is controlled by the air amount, and the control for small variations is effected by the fuel amount. In such a control, the range of change of the air/fuel ratio can be narrowed, and also the engine torque can be controlled over a wide range.
In the present invention, since the throttle valve full-open region is much used, the engine brake is less liable to act effectively at the time of the deceleration. Therefore, at the time of the deceleration, the electric charger is operated, thereby effecting an electric charging control. By doing so, the engine brake is achieved at the time of the deceleration, and also the energy at the time of the deceleration can be recovered. With respect to the decelerated condition, for example, when an injection pulse Tp is not greater than a predetermined value Tpc, the throttle valve opening degree is not greater than a predetermined value, and the engine speed Ne is not less than a predetermined value, it is judged that the deceleration occurs, and the electric charging operation is effected. Also, when the accelerator opening degree is not lower than a predetermined value, the charging operation is effected regardless of whether or not the injection pulse is below the predetermined value. During the charging operation, the charging target voltage is increased to increase a charging load. Other load such as a fuel heater may be used as the charging load. When the throttle valve is used, the throttle valve is closed during the deceleration.
In the present invention, the combustion time is shortened, the knocking is prevented, the compression ratio of the engine is increased, the heat efficiency is enhanced, and the fuel consumption is enhanced. The production of unburned hydrocarbon can be prevented by the stratified intake. The response to the fuel is enhanced by the fuel injection within the cylinder. Without increasing the pumping loss, the engine output or power can be controlled in a good response, thereby enhancing the drivability. | Under a partial load, a pumping loss is reduced by a stratified combustion to enhance a fuel consumption, and during the maximum output operation, the output is increased by a premixture combustion, and the output of an engine is controlled, thereby enhancing the drivability. Under the partial load, an ignition source is provided in the vicinity of a fuel injection valve, and after the fuel is injected, the mixture is ignited, and a resulting flame is caused by a spray of the fuel to spread into a cylinder, thereby effecting a stratified combustion. When the load increases, so that soot and so on are produced in the stratified combustion, the fuel injection is effected a plurality of times in a divided manner, and a premixture is produced within the cylinder by the front-half injection, and a flame, produced by the latter-half injection, is injected into the cylinder to burn this premixture. | 5 |
TECHNICAL FIELD
[0001] The present invention relates to an electric parking brake device and, in particular, an electric parking brake device configured such that a parking lever in a drum brake is driven from a return position to an operating position by forward drive of an electric actuator to drive a brake shoe from a return position to an operating position and the parking lever is driven from the operating position to the return position by reverse drive of the electric actuator to drive the brake shoe from the operating position to the return position.
BACKGROUND ART
[0002] The electric parking brake device of this type is described in, for example, the following Patent Literature 1. A parking brake switch is actuated and operated to make it possible to drive an electric actuator forward and to make it possible to drive a parking lever from a return position to an operating position (more specifically, to set a parking brake in an operating state (lock state)). When the parking brake switch is operated to be released to make it possible to reversely drive the electric actuator and to make it possible to drive the parking lever from the operating position to the return position (more specifically, to set the parking brake in a release state (release state)).
CITATION LIST
Patent Literature
[0003] Patent Literature 1: Japanese Unexamined Patent Publication No. H11-105680
[0004] In the electric parking brake device described in the Patent Literature 1, an electric motor (motor) included in the electric actuator is rotated forward to make it possible to drive the electric actuator forward, and when a predetermined current or more flows in the forward-rotating electric motor, the electric motor is stopped to make it possible to always obtain a predetermined parking brake force. The Patent Literature 1 also describes that the electric motor (motor) included in the electric actuator is reversely rotated to make it possible to reversely drive the electric actuator, and, when a current flowing in the reversely rotating electric motor is a no-load current, a power supply to the electric motor is disconnected.
SUMMARY OF INVENTION
[0005] In the electric parking brake device described in the Patent Literature 1, depending on a current value flowing in the electric motor, an operation/stop state of the electric motor can be advantageously controlled (a sensor for electrically detecting the state of a parking lever is advantageously unnecessary). However, the brake shoe of the drum brake generally includes a return spring biasing the brake shoe toward the return position. For this reason, when the parking brake is released, the reverse drive of the electric actuator is assisted by the return spring.
[0006] Thus, a timing at which a current flowing in the reverse-rotating electric motor becomes a no-load current may be disadvantageously different from a timing at which the parking lever returns to the return position. For this reason, when the parking brake is released, the parking lever may be incompletely returned or excessively returned disadvantageously. When the parking lever is incompletely returned, for example, the brake is disadvantageously dragged. When the parking lever is excessively returned, for example, a drawback such as a delay of response in the next operation of the parking brake may occur.
[0007] The present invention has been made to solve the above problem (to prevent a parking lever from being incompletely returned or excessively returned in a release state of the parking brake), and has as its object to provide
[0008] an electric parking brake device configured such that a parking lever in a drum brake is driven from a return position to an operating position by forward drive of an electric actuator to drive a brake shoe from a return position to an operating position and the parking lever is driven from the operating position to the return position by reverse drive of the electric actuator to drive the brake shoe from the operating position to the return position, wherein
[0009] the electric actuator includes
[0010] an electric motor which can be rotationally driven forward/reversely and the operation of which can be controlled by a motor control unit depending on a rotational load,
[0011] a conversion mechanism which can convert rotational motion into linear motion, can move the parking lever from the return position to the operating position in a forward drive state in which the electric motor rotates forward, and can move the parking lever from the operating position to the return position in a reverse drive state in which the electric motor reversely rotates, and
[0012] a load applying mechanism drives a constituent member of the conversion mechanism after the parking lever moves from the operating position to the return position by reverse rotation of the electric motor to apply a rotational load increasing depending on a drive amount of the constituent member to the electric motor, and
[0013] the motor control unit includes a calculation unit which calculates a rotational load determination value to determine whether a rotational load applied to the electric motor by the load applying mechanism when the electric motor reversely rotationally drives is a set value or more on the basis of a current supplied to the electric motor, and a reversely rotational drive stop unit which stops the reversely rotational drive of the electric motor when the rotational load determination value is a reference value or more a set time after the reversely rotational drive of the electric motor is started.
[0014] In the electric parking brake device according to the present invention, the motor control unit can obtain a parking brake operation such that the electric motor is rotated forward by an actuating operation of the parking brake switch, and the forward-rotating electric motor is stopped by a current value obtained when a rotational load acting on the forward-rotating electric motor becomes a set value. At this time, when the parking brake switch is actuated and operated, the electric motor rotates forward, and the parking lever at the return position is driven from the return position to the operating position by forward drive of the electric actuator to drive a brake shoe from the return position to the operating position. At this time, since the device is set such that the forward-rotating electric motor is stopped by a current value (target current value) obtained when the rotational load (load obtained when the brake shoe moves to the operating position and is brought into press contact with the brake drum) acting on the forward rotating electric motor becomes the set value, predetermined parking brake force can be always obtained.
[0015] The motor control unit is set such that the electric motor is reversely rotated by a releasing operation of the parking brake switch, and the reversely rotating electric motor is stopped by a current value obtained when a rotational load acting on the reversely rotating electric motor becomes a set value, so as to make it possible to release the parking brake. At this time, when the parking brake switch is released, the electric motor reversely rotates, and the parking lever at the operating position is driven from the operating position to the return position by reverse drive of the electric actuator to drive the brake shoe from the operating position to the return position. At this time, since the device is set such that the reversely rotating electric motor is stopped by a current value obtained when the rotational load (load obtained by the load applying mechanism) acting on the reversely rotating electric motor becomes the set value, the parking lever can always be stopped in a state in which the parking lever is always returned to the predetermined return position.
[0016] Thus, in the electric parking brake device according to the present invention, the parking lever can be prevented from being incompletely returned or excessively returned when the parking brake is released. In this manner, a drawback (for example, drag of the brake) caused by incomplete return of the parking lever can be prevented, and a drawback caused by excessive return of the parking lever (for example, delay of response in the next operation of the parking brake) can be prevented.
[0017] In the electric parking brake device according to the present invention, the operation/stop of the electric motor can be advantageously controlled by a current value supplied to the electric motor (a sensor for electrically detecting the state of the parking lever is advantageously unnecessary), and the motor control unit can be simply configured at low costs. Since the motor control unit includes the calculation unit and the reversely rotational drive stop unit, the reversely rotational drive of the electric motor can be accurately stopped, and a rotational load required by the load applying mechanism can be set to be small. As a result, the load applying mechanism can be miniaturized and manufactured at low costs.
[0018] In execution of the present invention described above,
[0019] the rotational load determination value is a current value supplied to the electric motor, and a sum of a no-load current value detected in a reversely rotational drive state of the electric motor and a preset predetermined current value can also be defined as the reference value.
[0020] In this case, a sum of the no-load current value and the preset predetermined current value is defined as the reference value, and the no-load current value serves as a part of the reference value. For this reason, a fluctuation in performance caused by a manufacturing error or the like in the conversion mechanism or the load applying mechanism can be excluded. Thus, determination accuracy when the reversely rotational drive of the electric motor is stopped can be improved, and a rotational load required by the load applying mechanism can be reduced. As a result, the load applying mechanism can be miniaturized and manufactured at low costs.
[0021] In execution of the present invention described above,
[0022] the rotational load determination value is a differential value of a current value supplied to the electric motor, and the preset predetermined value can also be defined as the reference value.
[0023] In this case, since the rotational load determination value is the differential value of the current value supplied to the electric motor, in comparison with the case in which the sum of the no-load current value detected in the reversely rotational drive state of the electric motor and the preset predetermined current value is defined as the reference value, a stop timing can be more quickly determined. For this reason, determination accuracy when the reversely rotational drive of the electric motor can be improved, and the load applying mechanism can be further miniaturized and manufactured at low costs.
[0024] In each of the cases of the present invention,
[0025] the motor control unit can also include an abnormal-state reversely rotational drive stop unit which, when it is determined that the rotational load determination value is a reference value or more within the set time except for an operation initial time zone in which a current supplied to the electric motor is unstable from the start of the reversely rotational drive of the electric motor, stops the reversely rotational drive of the electric motor, and an abnormality notification unit which notifies of abnormality. In this case, the abnormal electric actuator in the device can be rapidly detected to stop the abnormal operation and to make it possible to notify of the abnormal operation.
BRIEF DESCRIPTION OF DRAWINGS
[0026] FIG. 1 is a perspective view showing an embodiment of an electric parking brake device according to the present invention.
[0027] FIG. 2 is a front view of the electric parking brake device shown in FIG. 1 .
[0028] FIG. 3 is a sectional view showing a configuration of an electric actuator in the electric parking brake device shown in FIG. 1 and FIG. 2 , and shows a cross-sectional plan view of a coupling part between a parking lever and a rod along 3 - 3 line in FIG. 4 .
[0029] FIG. 4 is a front view showing the parking lever and the rod shown in FIG. 3 and a coupling mechanism coupling the parking lever and the rod.
[0030] FIG. 5 is a flow chart showing a main routine executed by an electric control device shown in FIG. 3 .
[0031] FIG. 6 is a flow chart showing a sub-routine executed in a lock control process shown in FIG. 5 .
[0032] FIG. 7 is a flow chart showing a sub-routine executed in a release control process shown in FIG. 5 .
[0033] FIG. 8 is a flow chart showing a sub-routine executed in an in-abnormal-state process shown in FIG. 7 .
[0034] FIG. 9 is a flow chart showing a sub-routine executed in an in-normal-state process shown in FIG. 7 .
[0035] FIG. 10 is a graph showing a relationship between a time (time in which the electric motor reversely rotates) in which the sub-routines shown in FIG. 7 , FIG. 8 , and FIG. 9 are executed and a motor current (current supplied to the electric motor).
DESCRIPTION OF EMBODIMENTS
[0036] Embodiments of the present invention will be described below with reference to the accompanying drawings. FIG. 1 to FIG. 4 show an embodiment of an electric parking brake device according to the present invention. The electric parking brake device according to the embodiment includes a drum brake 10 having a parking brake mechanism and an electric actuator 20 driving the parking brake mechanism.
[0037] The drum brake 10 , as shown in FIG. 1 and FIG. 2 , includes a disk-like back plate 11 , one pair of brake shoes 12 and 13 assembled on the back plate 11 , an anchor block 14 , a wheel cylinder 15 , and the like. The back plate 11 is configured to be fixed to an attaching part (not shown) on a vehicle body side.
[0038] The brake shoes 12 and 13 are assembled on the back plate 11 such that the brake shoes 12 and 13 can move in a specific direction (direction along a plate plane) with reference to the back plate 11 , and integrally include arc-shaped linings 12 a and 13 a pressed against a brake drum (not shown) in a brake operating state, respectively. A coupling member 16 with adjustment mechanism and return springs S 1 and S 2 are assembled between the brake shoes 12 and 13 .
[0039] The brake shoe 12 on the left in FIG. 1 and FIG. 2 is configured to be engaged with a left piston (not shown) of the wheel cylinder 15 at an upper end of the brake shoe 12 , engaged with the anchor block 14 at the lower end, and pressed and spread to the left toward the brake drum (not shown) in a brake operation state. A parking lever 17 is swingably assembled on the brake shoe 12 .
[0040] On the other hand, the brake shoe 13 on the right in FIG. 1 and FIG. 2 is configured to be engaged with a right piston (not shown) of the wheel cylinder 15 at an upper end of the brake shoe 13 , engaged with the anchor block 14 at the lower end, and pressed and spread to the right toward the brake drum (not shown) in a brake operation state. A return spring S 3 (the spring S 3 has an upper end locked on the back plate 11 and a lower end locked on the brake shoe 13 ) is assembled on the brake shoe 13 .
[0041] The anchor block 14 is fixed to a lower part of the back plate 11 in the drawing by using one pair of fixtures 14 a and 14 b . The wheel cylinder 15 is fixed to an upper part of the back plate 11 in the drawing by using one pair of fixtures 15 a and 15 b . The wheel cylinder 15 includes one pair of pistons (not shown) which come away from the left and right sides in the operation of the brake to open the left and right brake shoes 12 and 13 , the wheel cylinder 15 housing the pair of pistons therein.
[0042] A coupling member 16 is tiltably engaged with an upper part of the brake shoe 12 at a left-end part and tiltably engaged with an upper part of the parking lever 17 , and tiltably engaged with an upper part of the brake shoe 13 at a right-end part. The coupling member 16 is configured to have a length which can be automatically adjusted (increasable) by a known adjustment mechanism 16 a depending on amounts of abrasion of the linings 12 a and 13 a.
[0043] The parking lever 17 is disposed along the left brake shoe 12 in the drawing and tiltably (rotatably) coupled to the brake shoe 12 at the upper-end part by using a pin 17 a and a clip 17 b . The parking lever 17 is configured such that the parking lever 17 , at the lower end, as shown in FIG. 3 , is engaged with a coupling mechanism 29 on the electric actuator 20 and driven in the left-right direction by the coupling mechanism 29 (rotatably driven around the pin 17 a ).
[0044] The electric actuator 20 , as shown in FIG. 1 and FIG. 2 , is disposed in the drum brake 10 . The electric actuator 20 , as shown in FIG. 3 , includes an electric motor 21 , a conversion mechanism 22 , and a stopper 27 and a disk spring assembly 28 which function as a load applying mechanism, and also includes the coupling mechanism 29 . The electric motor 21 can be rotationally driven forward/reversely, and is configured to be operated with a motor control unit (electric control device) ECU depending on a current value changing depending on a rotational load. The current value depending on the rotational load can be detected by a current monitor IM included in the motor control unit (electric control device) ECU.
[0045] The conversion mechanism 22 can convert rotational motion of the electric motor 21 into linear motion of a rod (screw shaft) 22 e (swinging operation of the parking lever 17 through the coupling mechanism 29 ), can axially move the rod 22 e from a return position (position in FIG. 3 ) to an operating position (position on the right of the position in FIG. 3 by a predetermined length) in a forward drive state in which the electric motor 21 rotates forward, and can axially move the rod 22 e from the operating position to the return position in a reverse drive state in which the electric motor 21 reversely rotates.
[0046] The conversion mechanism 22 includes a pinion 22 a integrally disposed on a rotating shaft 21 a of the electric motor 21 , a first intermediate gear 22 b 1 and a second intermediate gear 22 b 2 which are rotationally driven with the pinion 22 a , an output gear 22 c rotationally driven with the second intermediate gear 22 b 2 , a screw mechanism 22 d disposed at the center (center of axis) of the output gear 22 c , and the rod 22 e coupled to the output gear 22 c through the screw mechanism 22 d . The first intermediate gear 22 b 1 and the second intermediate gear 22 b 2 decrease rotation of the rotating shaft 21 a to transmit the rotation to the output gear 22 c.
[0047] The first intermediate gear 22 b 1 , the second intermediate gear 22 b 2 , and the output gear 22 c are rotatably assembled in a housing 22 g . A thrust bearing 22 h which receives reaction force (force to the left in FIG. 3 ) from the parking lever 17 is assembled between the output gear 22 c and the housing 22 g . The output gear 22 c is configured to be able to move in an axial direction with reference to the housing 22 g . The electric motor 21 and the housing 22 g are fixed to the back plate 11 by using a fixture (not shown).
[0048] The screw mechanism 22 d includes a female screw part formed at the center (center of axis) of the output gear 22 c and a male screw part formed from an intermediate part of the rod 22 e to the right end thereof, and the female screw part and the male screw part are meshed with each other. In the screw mechanism 22 d , when axial movement (movement to the left in the drawing) of the output gear 22 c is regulated, rotation (rotational motion) of the output gear 22 c is converted into axial movement (linear motion) of the rod 22 e . When axial movement (movement to the left in the drawing) of the rod 22 e is regulated by the stopper 27 , rotation (rotational motion) of the output gear 22 c is converted into axial movement of the output gear 22 c.
[0049] In the screw mechanism 22 d , leads of the female screw part and the male screw parts are arbitrarily set, and the output gear 22 c is set not to be rotated by reaction force (axial force) from the parking lever 17 . The male screw part formed on the rod 22 e is covered and protected with a boot 22 j disposed between the distal-end part (left-end part) of the rod 22 e and the housing 22 g . The boot 22 j is configured to extend and contract with the axial movement of the rod 22 e.
[0050] The stopper 27 and the disk spring assembly 28 which function as the load applying mechanism are designed to function after the parking lever 17 moves from the operating position to the return position, and the stopper 27 is fixed to the back plate 11 by using a fixture (not shown). The stopper 27 , after the parking lever 17 moves from the operating position to the return position, as shown FIG. 3 , is engaged with a first coupling pin 29 a of the coupling mechanism 29 to regulate axial movement of the rod 22 e in a return direction (to the left in the drawing).
[0051] By reverse rotation of the output gear 22 c with reverse rotation of the electric motor 21 , after the parking lever 17 moves from the operating position to the return position, in a state in which the first coupling pin 29 a is engaged with the stopper 27 to regulate the axial movement of the rod 22 e with the stopper 27 , when the output gear 22 c moves from the return position in an operating direction (to the right in the drawing) in FIG. 3 with the reverse rotation of the output gear 22 c , the disk spring assembly 28 is engaged with the right end of the output gear 22 c to elastically regulate the axial movement (movement to the right) of the output gear 22 c so as to apply a rotational load to the output gear 22 c . The rotational load described above increases depending on a drive amount (axial movement) of the output gear 22 c , and the rotational load applied to the electric motor 21 increases accordingly.
[0052] The disk spring assembly 28 , in the housing 22 g , is disposed coaxially with the output gear 22 c between the housing 22 g and the right end of the output gear 22 c . The disk spring assembly 28 includes a holder 28 a , three disk springs 28 b , and a thrust plate 28 c . The holder 28 a is to movably support the three disk springs 28 b and the thrust plate 28 c in a small-diameter cylindrical part, is disposed coaxially with the output gear 22 c , and is fixed to the housing 22 g in a large-diameter part.
[0053] The three disk springs 28 b are disposed between the large-diameter part of the holder 28 a and the thrust plate 28 c alternatively as shown in the drawing (such that the large-diameter parts contact with each other and the small-diameter parts contact with each other), and are almost freely disposed in the illustrated state. The thrust plate 28 c is disposed between the disk spring 28 b at the left end in the drawing and the right end of the output gear 22 c , and can rotatably bear the right end of the output gear 22 c . The thrust plate 28 c , at the position in FIG. 3 , is fixed to the small-diameter cylindrical part of the holder 28 a not to be removed therefrom (not to move to the left).
[0054] The coupling mechanism 29 , as shown in FIGS. 3 and 4 , includes the first coupling pin 29 a , a second coupling pin 29 b , and one pair of coupling plates (coupling members) 29 c . The first coupling pin 29 a is assembled on a distal end (end part) of the rod 22 e , orthogonal to the rod 22 e , and disposed in parallel with the pin (support shaft) 17 a of the parking lever 17 . An intermediate part of the first coupling pin 29 a is integrally fitted and fixed to an attaching hole 22 e 1 formed in the distal end (end part) of the rod 22 e . Both the end parts of the first coupling pin 29 a are assembled on first hole parts 29 c 1 each having an oval shape and formed in the coupling plates 29 c such that both the end parts can relatively rotate and move in a long-diameter direction (left-right direction in FIG. 3 and FIG. 4 ). When the rod 22 e returns and moves to the return position, as shown in FIG. 3 , both the end parts of the first coupling pin 29 a are set to be able to contact with the stopper 27 .
[0055] The second coupling pin 29 b is assembled on a swinging end part 17 c of the parking lever 17 and disposed in parallel with the first coupling pin 29 a . The second coupling pin 29 b is relatively rotatably assembled on a circular assembling hole 17 c 1 formed in the swinging end part 17 c at the intermediate part and relatively rotatably assembled on circular second hole parts 29 c 2 formed in coupling plates 29 c at both the end parts. The second coupling pin 29 b has both ends each having a diameter larger than that of the intermediate part to prevent the second coupling pin 29 b from being removed.
[0056] Each of the coupling plates 29 c can rotate in a first hole part 29 c 1 assembled in the first coupling pin 29 a in the circumferential direction of the first coupling pin 29 a with reference to the end part of the rod 22 e , can rotate in the second hole part 29 c 2 assembled in the second coupling pin 29 b in the circumferential direction of the second coupling pin 29 c 2 with reference to the parking lever 17 , and couples the first coupling pin 29 a and the second coupling pin 29 b to each other.
[0057] In the configuration, on the parking lever 17 and the rod 22 e coupled by the coupling mechanism 29 , a swinging surface of the parking lever 17 and an axial line of the rod 22 e are disposed on the same plane. For this reason, in the embodiment, driving force of the electric actuator 20 can be smoothly transmitted to the swinging end part 17 c of the parking lever 17 .
[0058] The motor control unit (electric control device) ECU, for example, has a function of stopping an operation (forward rotational drive) of the electric motor 21 when a rotational load reaches a set value (obtained by moving the parking lever 17 to the operating position) in a forward rotational drive state of the electric motor 21 , and a function of stopping an operation (reversely rotational drive) of the electric motor 21 when the rotational load reaches a predetermined value in a reversely rotational drive state of the electric motor 21 .
[0059] The motor control unit (electric control device) ECU is configured such that the motor control device ECU is also connected to a parking lock switch SW 1 and a parking release switch SW 2 (when any one of the switches is turned on, the other is turned off) which are disposed in the driver seat of the vehicle (see FIG. 3 ), and, as shown in FIG. 5 , when the parking lock switch SW 1 is turned on in a state in which a parking brake release state (release state) is stored, a lock control process in step 100 and an end process in step 99 are executed to end the program. When the parking release switch SW 2 is turned on in a state in which a parking brake operating state (lock state) is stored, a release control process in step 200 and the end process in step 99 are executed to end the program. The release state is configured to be stored when the reversely rotational drive of the electric motor 21 is normally completed, and the lock state is configured to be stored when the forward rotational drive of the electric motor 21 is normally completed.
[0060] When the motor control unit (electric control device) ECU executes the lock control process in step 100 in FIG. 5 , a lock control process routine in FIG. 6 is executed. In the lock control process routine in FIG. 6 , the process is started in step 101 , forward rotational drive of the electric motor 21 is started in step 102 , and an elapsed time T is counted up (Tup) in step 103 . In step 104 , it is determined whether the elapsed time T is a predetermined value T1 or longer. The predetermined value T1 corresponds to a time required until a current supplied to the electric motor 21 at the beginning of the forward rotational drive of the electric motor 21 becomes stable, and steps 103 and 104 are repeatedly executed until the elapsed time T reaches the predetermined value T1.
[0061] In this manner, when the elapsed time T reaches the predetermined value T1, step 105 is executed to determines whether a current value A (This is calculated on the basis of an output from the current monitor IM.) supplied to the electric motor 21 is a target current value A1 or more. The target current value A1 is obtained when the parking lever 17 moves from the return position to the operating position to make a rotational load (load obtained when the brake shoes 12 and 13 move to the operating positions to bring the linings 12 a and 13 a into press contact with the brake drum) obtained by the forward rotational drive of the electric motor 21 becomes a set value, and steps 105 and 106 are repeatedly executed until the current value A reaches the target current value A1. In step 106 , a condition establishment duration Ta is reset.
[0062] When the current value A reaches the target current value A1, steps 107 and 108 are executed to determine whether the condition establishment duration Ta is a predetermined value T2 or more. The predetermined value T2 is to determine a stop timing of the electric motor 21 , and is arbitrarily set. Steps 105 , 107 , and 108 are repeatedly executed until the condition establishment duration Ta reaches the predetermined value T2. When the condition establishment duration Ta reaches the predetermined value T2, “Yes” is determined in step 108 , steps 109 to 112 are executed to return the ECU to the main routine in FIG. 5 . The forward rotational drive of the electric motor 21 is stopped in step 109 , the lock state is stored in step 110 , and the elapsed time T and the condition establishment duration Ta are reset in step 111 . In step 112 , the return process is performed to end the program in step 99 in FIG. 5 .
[0063] On the other hand, when the motor control unit (electric control device) ECU executes the release control process in step 200 in FIG. 5 , a release control process routine in FIG. 7 is executed. In the release control process routine in FIG. 7 , the process is started in step 201 , reversely rotational drive of the electric motor 21 is started in step 202 , and the elapsed time T is counted up in step 203 . In step 204 , it is determined whether the elapsed time T is a predetermined value T3 or longer. The predetermined value T3 corresponds to a time required until a current supplied to the electric motor 21 at the beginning of the reversely rotational drive of the electric motor 21 becomes stable (see T3 in FIG. 10 ), and steps 203 and 204 are repeatedly executed until the elapsed time T reaches the predetermined value T3.
[0064] In this manner, when the elapsed time T reaches the predetermined value T3, step 205 is executed to determine whether the current value A supplied to the electric motor 21 is an abnormality determination current value A2 or more. The abnormality determination current value A2, for example, is obtained when rotational load obtained by the reversely rotational drive of the electric motor 21 is an abnormal value (see a virtual line and A2 in FIG. 10 ) when the parking lever 17 moves from the operating position to the return position (for example, an abnormally high rotational resistance is generated on the screw mechanism 22 d of the conversion mechanism 22 ). At this time, “Yes” is determined in step 205 to execute an in-abnormal-state process in step 210 .
[0065] When the motor control unit (electric control device) ECU executes the in-abnormal-state process in step 210 in FIG. 7 , an in-abnormal-state process routine in FIG. 8 is executed. In the in-abnormal-state process routine in FIG. 8 , the process is started in step 211 , and an abnormal condition establishment duration Tb is counted up (Tbup) in step 212 . In step 213 , it is determined whether the abnormal condition establishment duration Tb is a predetermined value T4 or more. The predetermined value T4 is to determine a stop timing of the electric motor 21 (see T4 in FIG. 10 ), and is arbitrarily set. Until the abnormal condition establishment duration Tb reaches the predetermined value T4, “No” is determined in step 213 , and step 205 in FIG. 7 and steps 211 to 213 in FIG. 8 are repeatedly executed.
[0066] When the abnormal condition establishment duration Tb reaches the predetermined value T4, “Yes” is determined in step 213 , and steps 214 to 217 are executed. The electric motor 21 is stopped in step 214 , an alarm for abnormality is generated in step 215 , and the elapsed time T and the abnormal condition establishment duration Tb are reset in step 215 . In step 217 , the return process is performed to end the program in step 99 in FIG. 5 .
[0067] In a period in which the elapsed time T falls within the range of the predetermined value T3 to a set value T5, when the current value A supplied to the electric motor 21 does not increase not to reach the abnormality determination current value A2 (more specifically, as indicated by a solid line or a broken line in FIG. 10 , when the electric motor 21 normally operates), steps 205 to 208 in FIG. 7 are repeatedly executed. “No” is determined in step 205 , the elapsed time T is counted up in step 206 , the abnormal condition establishment duration Tb is reset in step 207 , and “No” is determined in step 208 . The set value T5 is set on the basis of a time required when the parking lever 17 moves from the operating position to the return position by normal reversely rotational drive of the electric motor 21 .
[0068] In this manner, when the elapsed time T reaches the set value T5, “Yes” is determined in step 208 in FIG. 7 , and an in-normal-state process is executed in step 220 . When the motor control unit (electric control device) ECU executes the in-normal-state process in step 220 in FIG. 7 , an in-normal-state process routine in FIG. 9 is executed. In the in-normal-state process routine in FIG. 9 , the process is started in step 221 , a no-load current value Ao is calculated in step 222 , and it is determined in step 223 whether the current value A supplied to the electric motor 21 is a load determination current value (Ao+A3) or more. The no-load current value Ao is a current value supplied to the electric motor 21 before the first coupling pin 29 a is brought into contact with the stopper 27 by the reversely rotational drive of the electric motor 21 (more specifically, in a no-load state set until the first coupling pin 29 a contacts with the stopper 27 after the elapsed time T becomes the set value T5). A predetermined value A3 corresponds to a current value increasing depending on an increase in load obtained by the load applying mechanism (the stopper 27 and the disk spring assembly 28 ), and is arbitrarily set. Until the current value A reaches the load determination current value (Ao+A3), “No” is determined in step 223 , and steps 223 to 229 in FIG. 9 are repeatedly executed. In step 229 , a load condition establishment duration Tc is reset.
[0069] Until the current value A reaches the load determination current value (Ao+A3), “Yes” is determined in step 223 , and steps 224 to 225 are executed. The load condition establishment duration Tc is counted up in step 224 (Tcup), and it is determined in step 225 whether the load condition establishment duration Tc is a predetermined value T6 or more. The predetermined value T6 is to determine a stop timing of the electric motor 21 (see T6 in FIG. 10 ), and is arbitrarily set. Until the load condition establishment duration Tc reaches the predetermined value T6, “No” is determined in step 225 , and steps 223 to 225 are repeatedly executed.
[0070] When the load condition establishment duration Tc reaches the predetermined value T6, “Yes” is determined in step 225 , steps 226 to 228 are executed. The reversely rotational drive of the electric motor 21 is stopped in step 226 , the release state is stored and the elapsed time T and the load condition establishment duration Tc are reset in step 227 , and the return process is performed in step 228 to end the program in step 99 in FIG. 5 .
[0071] In the embodiment described above, although the determination is made by setting the durations Ta, Tb, and Tc to avoid an erroneous determination caused by signal noise or the like, the determination can also be made without setting the durations Ta, Tb, and Tc (executed such that, after T becomes T1, the forward rotational drive of the electric motor 21 is stopped when A reaches A1, the reversely rotational drive of the electric motor 21 is stopped when T is T3 to T5 and A reaches A2, and the reversely rotational drive of the electric motor 21 is stopped after T becomes T5 and when A reaches (Ao+A4)).
[0072] As described above, in short, in the embodiment, in the electric parking brake device according to the present invention, the operation/stop of the electric motor 21 can be advantageously controlled by a current value A supplied to the electric motor 21 (a sensor for electrically detecting the state of the parking lever 17 is advantageously unnecessary), and the motor control unit (electric control device) ECU can be simply configured at low costs. Since the motor control unit (electric control device) ECU includes the calculation unit (steps 222 and 223 ) and the reversely rotational drive stop unit (steps 223 to 226 ) and is configured to stop the reversely rotational drive of the electric motor 21 when it is determined that the rotational load determination value (current value A) is the reference value (Ao+A3) or more the set time after the reversely rotational drive of the electric motor 21 is started (T=0) (T≧T5), the reversely rotational drive of the electric motor 21 can be accurately stopped, and a rotational load required for the load applying mechanism (the stopper 27 and the disk spring assembly 28 ) can be set to be small. As a result, the load applying mechanism (the stopper 27 and the disk spring assembly 28 ) can be miniaturized and manufactured at low costs.
[0073] In the embodiment, the sum (Ao+A3) of the no-load current value Ao and the preset predetermined current value A3 is defined as a reference value for reversely rotational drive stop determination of the electric motor 21 , and the no-load current value Ao serves as a part of the reference value. For this reason, a fluctuation in performance caused by a manufacturing error or the like in the conversion mechanism 22 or the load applying mechanism (the stopper 27 and the disk spring assembly 28 ) can be excluded. Thus, determination accuracy when the reversely rotational drive of the electric motor 21 is stopped can be improved, and a rotational load required by the load applying mechanism (the stopper 27 and the disk spring assembly 28 ) can be reduced. As a result, the load applying mechanism (the stopper 27 and the disk spring assembly 28 ) can be miniaturized and manufactured at low costs.
[0074] In the embodiment, when it is determined that the rotational load determination value (current value A) is the reference value (A2) or more within the set time (time zone from T3 to T5) except for an operation initial time zone (time zone from 0 to T3) in which a current is unstable from the start of the reversely rotational drive (T=0) of the electric motor 21 , the abnormal-state reversely rotational drive stop unit (step 214 ) for stopping the reversely rotational drive of the electric motor 21 and the abnormality notification unit (step 215 ) for notifying of abnormality are included in the motor control unit (electric control device) ECU. For this reason, abnormality in the electric actuator 20 in the device is detected to make it possible to stop an abnormal operation and to notify of the abnormal operation.
[0075] In the embodiment, the program is executed such that the sum (Ao+A3) of the no-load current value Ao and the preset predetermined current value A3 is defined as the reference value for determining a timing of stopping the reversely rotational drive of the electric motor 21 and the current value A supplied to the electric motor 21 is defined as the rotational load determination value. However, in execution of the present invention, a differential value of the current value A supplied to the electric motor 21 may be employed as the rotational load determination value. In this case, the stop timing can be determined rapidly more than that in the embodiment, determination accuracy at which the reversely rotational drive of the electric motor 21 is stopped can be improved, and the load applying mechanism can be further miniaturized and manufactured at low costs.
[0076] In the embodiment, the determination is made such that the sum (Ao+A3) of the no-load current value Ao and the preset predetermined current value A3 is defined as the reference value for determining a timing of stopping the reversely rotational drive of the electric motor 21 and the current value A supplied to the electric motor 21 is defined as the rotational load determination value. However, in execution of the present invention, the determination can also be made such that the set value A4 (see FIG. 10 ) larger than (Ao+A3) is employed as the reference value.
[0077] In the embodiment, an abnormality determination is made by the current value A supplied to the electric motor 21 . However, for example, the abnormality determination can also be made by a differential value of the current value A supplied to the electric motor 21 , and various changes can be effected without departing from the contents described in the scope of claims. | Electric parking brake devices are configured such that a parking lever is driven by an electric actuator. The electric actuator is provided with: an electric motor drivable in a forward/reverse direction and operationally controlled by a motor control unit according to rotational loads; a conversion mechanism capable of converting a rotational motion into a linear motion, moving the parking lever from a return position toward an operating position through forward rotation of the electric motor, and moving the parking lever from the operating position toward the return position through the reverse rotation of the electric motor; and a load applying mechanism (a stopper and a disc spring assembly) for applying a predetermined rotational load to the electric motor by driving a constituent member of the conversion mechanism after the parking lever is moved from the operating position to the return position through the reverse rotation of the electric motor. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation of U.S. patent application Ser. No. 12/758,228, filed on Apr. 12, 2010, which is a continuation of U.S. patent application Ser. No. 11/386,113, filed on Mar. 22, 2006, now U.S. Pat. No. 7,695,861, which claimed priority from U.S. Provisional Application No. 60/664,592, filed on Mar. 24, 2005, and UK Patent Application No. 0505790.6, filed on Mar. 22, 2005, all of which are incorporated by reference herein in their entireties.
TECHNICAL FIELD
[0002] The present invention relates to electrochemical power engineering, and in particular to chemical sources of electrical energy (batteries) comprising a negative electrode (anode) utilizing the oxidation-reduction pair Li + /Li 0 , a positive electrode (cathode) utilizing the oxidation-reduction pair S 0 /S −2 , and a non-aqueous aprotic electrolyte. Embodiments of the invention also relate to the composition of the depolarizer substance of the positive electrode.
BACKGROUND OF THE INVENTION
[0003] Throughout this application various patents and published patent applications are referred to by an identifying citation. The disclosures of the patents and published patent applications referred to in this application are hereby incorporated into the present disclosure by reference to more fully describe the state of the art to which this invention pertains.
[0004] An electroactive material that has been fabricated into a structure for use in a battery is referred to as an electrode. Of a pair of electrodes used in a battery, herein referred to as a chemical source of electrical energy, the electrode on the side having a higher electrochemical potential is referred to as the positive electrode, or the cathode, while the electrode on the side having a lower electrochemical potential is referred to as the negative electrode, or the anode.
[0005] An electrochemically active material used in the cathode or positive electrode is referred to hereinafter as a cathode active material. An electrochemically active material used in the anode or negative electrode is hereinafter referred to as an anode active material. A chemical source of electrical energy or battery comprising a cathode with the cathode active material in an oxidized state and an anode with the anode active material in a reduced state is referred to as being in a charged state. Accordingly, a chemical source of electrical energy comprising a cathode with the cathode active material in a reduced state, and an anode with the anode active material in an oxidized state, is referred to as being in a discharged state.
[0006] There is a significant requirement for new types of rechargeable batteries, having high specific energy, long cycle life, safety for the user and the environment, as well as low cost. One of the most promising electrochemical systems is the lithium-sulphur system, which has high theoretical specific energy (2600 Wh/kg), safety and low cost. Sulphur or sulphur-based organic and polymeric compounds are used in lithium-sulphur batteries as a positive electrode depolarizer substance. Lithium or lithium alloys are used as depolarizer substances in the negative electrode.
[0007] Elemental sulphur (U.S. Pat. No. 5,789,108; U.S. Pat. No. 5,814,420), sulphur-based organic compounds (U.S. Pat. No. 6,090,504) or sulphur-containing polymers (U.S. Pat. No. 6,201,100, U.S. Pat. No. 6,174,621, U.S. Pat. No. 6,117,590) usually serve as a depolarizer for the positive electrode in lithium-sulphur batteries. Metallic lithium is normally used as a material for the negative electrode (U.S. Pat. No. 6,706,449). It has been suggested that it might be possible to make use of materials that can reversibly intercalate lithium for the negative electrode material. These materials include graphite (D. Aurbach, E. Zinigrad, Y. Cohen, H. Teller; “A short review of failure mechanism of lithium metal and lithiated graphite anodes in liquid electrolyte solutions”; Solid State Ionics; 2002; vol. 148; pp. 405-416), and oxides and sulphides of some metals (U.S. Pat. No. 6,319,633). However, the present applicant has not been able to find specific examples of intercalation electrodes for lithium-sulphur batteries in the available literature. It must be stressed out that it is only possible to use intercalation electrodes (negative or positive) when they are present in lithiated form. It is also necessary to take into account that intercalated compounds (where lithium is involved) are chemically active and have chemical properties close to the properties of metallic lithium.
[0008] One of the disadvantages of lithium-sulphur batteries (limiting their commercialization) is a moderate cycle life caused by a low cycling efficiency of the lithium electrode. Accordingly, twice to ten times the theoretically required amount of lithium is usually provided in lithium-sulphur batteries so as to provide a longer cycle life. In order to improve cycling of the lithium electrode, it has been proposed to add various compounds to the electrolyte (U.S. Pat. No. 5,962,171, U.S. Pat. No. 6,632,573) or to deposit protective layers of polymers (U.S. Pat. No. 5,648,187, U.S. Pat. No. 5,961,672) or non-organic compounds (U.S. Pat. No. 6,797,428, U.S. Pat. No. 6,733,924) on the electrode surface. The use of protective coatings significantly improves the cycling of the lithium electrode but still does not provide a sufficiently long cycle life for many commercial applications.
[0009] It is known that graphite intercalate electrodes possess good cycling capabilities (D. Aurbach, E. Zinigrad, Y. Cohen, H. Teller; “A short review of failure mechanism of lithium metal and lithiated graphite anodes in liquid electrolyte solutions”; Solid State Ionics; 2002; vol. 148; pp. 405-416). However, in order to use such electrodes as a negative electrode, it is necessary to have a source of lithium ions. In traditional lithium-ion batteries, this may be lithiated oxides of transition metals, cobalt, nickel, manganese and others that are depolarizers for the positive electrode.
[0010] It is theoretically possible to use the end products of sulphur electrode discharge (lithium sulphide and disulphide) as the source of lithium ions. However, lithium sulphide and disulphide are poorly soluble in aprotic electrolyte systems, and are thus electrochemically non-active. Attempts to use lithium sulphide as a depolarizer for the positive electrode in lithium-sulphur batteries have hitherto been unsuccessful (Peled E., Gorenshtein A., Segal M., Sternberg Y.; “Rechargeable lithium-sulphur battery (extended abstract)”; J. of Power Sources; 1989; vol. 26; pp. 269-271).
[0011] Lithium sulphide is capable of reacting with elemental sulphur in aprotic media so as to produce lithium polysulphides, these being compounds that have good solubility in most known aprotic electrolyte systems (AES) (Shin-Ichi Tobishima, Hideo Yamamoto, Minoru Matsuda, “Study on the reduction species of sulphur by alkali metals in nonaqueous solvents”, Electrochimica Acta, 1997, vol. 42, no. 6, pp. 1019-1029; Rauh R. D., Shuker F. S., Marston J. M., Brummer S. B., “Formation of lithium polysulphides in aprotic media”, J. inorg. Nucl. Chem., 1977, vol. 39, pp. 1761-1766; J. Paris, V. Plichon, “Electrochemical reduction of sulphur in dimethylacetamide”, Electrochimica Acta, 1981, vol. 26, no. 12, pp. 1823-1829; Rauh R. D., Abraham K. M., Pearson G. F., Surprenant J. K., Brummer S. B., “A lithium/dissolved sulphur battery with an organic electrolyte”, J. Electrochem. Soc., 1979, vol. 126, no. 4, pp. 523-527). The solubility of lithium polysulphides in an aprotic electrolyte system depends on the properties of the components (solvents and salts) thereof, as well as on the length of the polysulphide chain. Lithium polysulphides may undergo disproportionation in solutions according to the following schema:
[0000]
[0012] Accordingly, lithium polysulphides of various lengths may be found simultaneously in the electrolyte solution at the same time, being in thermodynamic equilibrium with each other. A molecular mass distribution of the polysulphides is governed by the composition and physical/chemical properties of the electrolyte solution components. These solutions of lithium polysulphides possess high electroconductivity (Duck-Rye Chang, Suck-Hyun Lee, Sun-Wook Kim, Hee-Tak Kim “Binary electrolyte based on tetra(ethylene glycol) dimethyl ether and 1,3-dioxolane for lithium-sulphur battery”, J. of Power Sources, 2002, vol. 112, pp. 452-460) and high electrochemical activity (Taitiro Fujnaga, Tooru Kuwamoto, Satoshi Okazaki, Masashi Horo, “Electrochemical reduction of elemental sulphur in acetonitrile”, Bull. Chem. Soc. Jpn., 1980, vol. 53, pp. 2851-2855; Levillain E., Gaillard F., Leghie P., Demortier A., Lelieur J. P., “On the understanding of the reduction of sulphur (S 8 ) in dimethylformamide (DMF)”, J. of Electroanalytical Chemistry, 1997, vol. 420, pp. 167-177; Yamin H., Penciner J., Gorenshtain A., Elam M., Peled E., “The electrochemical behavior of polysulphides in tetrahydrofuran”, J. of Power Sources, 1985, vol. 14, pp. 129-134; Yamin H., Gorenshtein A., Penciner J., Sternberg Y., Peled E., “Lithium sulphur battery. Oxidation/reduction mechanisms of polysulphides in THF solution”, J. Electrochem. Soc., 1988, vol. 135, no. 5, pp. 1045-1048).
[0013] It has been proposed to use polysulphide solutions in AES as liquid depolarizers for lithium-sulphur batteries (Rauh R. D., Abraham K. M., Pearson G. F., Surprenant J. K., Brummer S. B., “A lithium/dissolved sulphur battery with an organic electrolyte”, J. Electrochem. Soc., 1979, vol. 126, no. 4, pp. 523-527; Yamin H., Peled E., “Electrochemistry of a nonaqueous lithium/sulphur cell”, J. of Power Sources, 1983, vol. 9, pp. 281-287). Such batteries are generally known as “lithium-sulphur batteries with liquid cathodes”. The degree of sulphur utilization in such batteries with liquid sulphide cathodes depends on the nature and polarization conditions of the AES. In many cases it is close to 100% if counting full sulphur reduction and lithium sulphide formation (Rauh R. D., Abraham K. M., Pearson G. F., Surprenant J. K., Brummer S. B., “A lithium/dissolved sulphur battery with an organic electrolyte”, J. Electrochem.Soc., 1979, vol. 126, no. 4, pp. 523-527). An energy output of liquid cathodes based on lithium polysulphides is determined by their solubility. In some solvents (tetrahydrofuran, for example) sulphur solubility in the form of lithium polysulphides can reach 20M (Yamin H., Peled E., “Electrochemistry of a nonaqueous lithium/sulphur cell”, J. of Power Sources, 1983, vol. 9, pp. 281-287). The energy output of such liquid cathodes is more than 1000 Ah/l. The cycle life of lithium-sulphur batteries is also determined by the metal lithium electrode behaviour and is limited by the cycling efficiency of this electrode, which is about 80-90% in sulphide systems (Peled E., Sternberg Y., Gorenshtein A., Lavi Y., “Lithium-sulphur battery: evaluation of dioxolane-based electrolytes”, J. Electrochem. Soc., 1989, vol. 136, no. 6, pp. 1621-1625).
SUMMARY OF THE INVENTION
[0014] Investigations made by the present applicant have shown that the cycle life of lithium-sulphur batteries with liquid cathodes could be improved by using graphite as the negative electrode. But in this case a source of lithium ions is needed. Solutions of long-chain polysulphides (Li 2 S n where n≧8) are normally used as liquid sulphur cathodes. In such molecules, eight or more atoms of sulphur are due to one ion of lithium. Accordingly the cycling depth of lithium-sulphur batteries with liquid cathodes will be low and is determined by the length of the polysulphide chain. Reducing the length of the lithium polysulphide chains will increase the cycling depth of lithium-sulphur batteries with a liquid cathode based on lithium sulphides. However, the shorter the chain lengths of the lithium polysulphides, the lower their solubility in an aprotic electrolyte system, and hence the energy output of the liquid sulphide cathode is decreased.
[0015] The present applicant has found that a solution of lithium polysulphides will be formed during contact of an aprotic electrolyte system with a mixture of lithium sulphide with sulphur. The concentration of the polysulphides in the solution and the length of the polysulphide chains will be determined on the one hand by the molar ratio between lithium sulphide and sulphur, and on the other hand by the nature of the aprotic electrolyte system. Generally, complete dilution of sulphide will not occur in the presence of a small quantity of sulphur. However, during charging of the cell accompanied by oxidation of soluble polysulphides to elemental sulphur, further dilution of lithium sulphide will occur as a result of the reaction with the generated sulphur until complete dilution of the lithium sulphide.
[0016] According to a first aspect of the present invention, there is provided a chemical source of electrical energy comprising a positive electrode (cathode) made of an electrically conductive material, a permeable separator or membrane, a negative electrode (anode) made of an electrically conductive material or a material that is able reversibly to intercalate lithium ions, and a mixture of lithium sulphide and sulphur, wherein an aprotic electrolyte comprising at least one lithium salt in at least one solvent is provided between the electrodes.
[0017] The mixture of lithium sulphide with elemental sulphur serves as a positive electrode depolariser substance (electroactive substance) and addresses the problems (cycle life and manufacturing costs) inherent in using a material that can reversibly intercalate lithium ions as the negative electrode.
[0018] The lithium sulphide/sulphur mixture may be incorporated directly in the positive electrode during its manufacture, or may be provided as a colloid solution or suspension added to the electrolyte, or a semi-solid emulsion, ointment or powder composition.
[0019] The positive electrode is preferably porous, highly electrically-conductive and advantageously has a developed surface.
[0020] In other embodiments, the positive electrode may have a substantially or generally smooth surface, and/or be of a non-porous configuration or construction.
[0021] The positive electrode may be made of carbon or graphite, or of a metallic or other, preferably highly, electrically conductive material (optionally with high porosity) that is resistant to corrosion in sulphide media. Semiconductive or semiconductor materials, such as silicon, may alternatively or additionally be used to fabricate the positive electrode.
[0022] The permeable separator or membrane may be made of a porous film or non-woven material, for example microporous polypropylene (Celgard® separator) or non-woven polypropylene.
[0023] Where the lithium sulphide/sulphur mixture is provided in the form of a suspension or colloid, the solids content of the suspension or colloid is preferably from 5 to 50%. The content of lithium sulphide in the colloid or suspension is preferably from 10 to 99%, or 10 to 90%, by weight of the content of sulphur.
[0024] The aprotic electrolyte may comprise a solution of one or more of: lithium trifluoromethanesulphonate, lithium perchlorate, lithium trifluoromethanesulphonimide, lithium hexafluorophosphate, lithium hexafluoroarsenate, lithium tetrachloroaluminate, lithium tetraalkylammonium salt, lithium chloride, lithium bromide, and lithium iodide in one or several solvents selected from the group consisting of: dioxolane, tetrahydrofuran, dimethoxyethane, diglyme, triglyme, tetraglyme, dialkyl carbonates, sulfolane, and butyrolactone.
[0025] According to a second aspect of the present invention, there is provided a method of manufacturing a chemical source of electrical energy, the method comprising the steps of:
[0026] i) providing a cathode;
[0027] ii) providing a mixture of lithium sulphide and sulphur in an aprotic electrolyte comprising at least one lithium salt in at least one solvent;
[0028] iii) applying a coating of the mixture to the cathode;
[0029] iv) applying a permeable separator or membrane over the coated cathode;
[0030] v) applying a coating of an aprotic electrolyte comprising at least one lithium salt in at least one solvent over the permeable separator or membrane;
[0031] vi) providing an anode on the coating of aprotic electrolyte, the anode being made of an electrically conductive material or a material that is able reversibly to intercalate lithium ions;
[0032] vii) providing terminal connections for the anode and cathode and hermetically sealing the structure obtained by the steps of the method.
[0033] The cathode may have a developed or roughened or smooth surface. Preferably the cathode is porous, but in some embodiments the cathode is non-porous.
[0034] The mixture of lithium sulphide and sulphur is preferably applied as a suspension, colloid, semi-solid emulsion, ointment or powder.
[0035] In step v), the aprotic electrolyte may optionally also contain a mixture of lithium sulphide and sulphur as in step ii), or it may be free of a mixture of lithium sulphide and sulphur.
[0036] The structure may be folded or shaped as desired prior to sealing.
[0037] An important distinction of embodiments of the present invention over the prior art is that the positive electrodes (cathodes) of the prior art all comprise sulphur-containing components (sulphur, metal sulphides, organic sulphur compounds including polymers) which directly form the cathode. In other words, these sulphur-containing components are intrinsically bound up in the cathode. In embodiments of the present invention, in contrast, a mixture (e.g., a colloid solution, suspension, semi-solid emulsion or ointment, or powder) of lithium sulphide and sulphur in an aprotic electrolyte is coated onto or applied to an electron conductive inert material (e.g., carbon, graphite, metal, silicon). No sulphur-containing components are intrinsically bound up in the cathode. In particular, the prior art does not disclose a cell in which a mixture of lithium sulphide and sulphur in an aprotic electrolyte is coated onto or applied to the cathode and in which a permeable separator or membrane is then placed over the coating.
[0038] Moreover, embodiments of the present invention utilise a different electrochemical process from known prior art systems. In the prior art systems, the anode is formed from lithium, lithium alloys or other materials containing lithium ions from the outset, and the cathode is made from sulphur-containing components from the outset. The cell reaction is of the form xLi+S═Li x S. In embodiments of the present invention, the anode from the outset does not contain metallic lithium or lithium ions. Lithium ions only become incorporated in the anode upon charging the cell. Likewise, the cathode contains no sulphur from the outset. In simple terms, the lithium-sulphide system of embodiments of the present invention has a cycle starting at the point where the cycle of existing lithium-sulphur cells ends, and in which lithium is oxidised at the anode and sulphur is reduced at the cathode during discharge.
BRIEF DESCRIPTION OF THE DRAWINGS
[0039] For a better understanding of the present embodiments and to show how they may be carries into effect, reference shall now be made by way of example to the accompanying drawings, in which:
[0040] FIG. 1 shows a charge-discharge plot for a first embodiment; and
[0041] FIG. 2 shows a charge-discharge plot for a second embodiment.
DETAILED DESCRIPTION OF THE INVENTION
[0042] The following description is presented to enable one of ordinary skill in the art to make and use the invention as provided in the context of a particular application and its requirements. Various modifications to the described embodiments will be apparent to those with skill in the art, and the general principles defined herein may be applied to other embodiments. Therefore, the present invention is not intended to be limited to the particular embodiments shown and described, but is to be accorded the widest scope consistent with the principles and novel features herein disclosed. In other instances, well-known methods, procedures, and components have not been described in detail so as not to obscure the present invention.
[0043] It is known that lithium sulphide, in the presence of aprotic solvents, reacts with sulphur to produce lithium polysulphides of various lengths:
[0000]
[0044] Lithium polysulphides are well soluble in most known aprotic electrolyte systems and possess high electrochemical activity. In solution, they undergo multi-step dissociation:
[0000] Li 2 S n →Li + +LiS − n
[0000] LiS − n →Li + +S 2 n
[0045] During charging of a cell comprising a mixture of lithium sulphide with sulphur constructed according to the scheme:
[0000] Inert electrode/Li 2 S+nS+salt solution/Inert electrode
[0000] there will take place a reaction of lithium reduction on the negative electrode:
[0000] Li + +e→Li 0
[0000] and a reaction of sulphur oxidation at the positive electrode:
[0000] S n −2 −2 e→nS
[0046] During discharging of the cell, the reverse reactions will take place on the electrodes.
[0047] At the negative electrode:
[0000] Li 0 −e→Li +
[0048] At the positive electrode:
[0000] nS−2ne→nS −2
[0049] The power intensity and cycling efficiency of such a cell will be strongly affected by the molar ratio of lithium sulphide and sulphur. On the one hand this ratio has to provide a high energy density, and on the other hand it has to provide a long cycle life.
EXAMPLE 1
[0050] Lithium sulphide, 98% (Sigma-Aldrich, UK) and sublimated sulphur, 99.5% (Fisher Scientific, UK) were ground at a mass ratio of 90:10 in a high speed mill (Microtron MB550) for 15 to 20 minutes in an atmosphere of dry argon (moisture content 20-25 ppm). The ground mixture of lithium sulphide and sulphur was placed into a flask and an electrolyte was added to the flask. A 1M solution of lithium trifluoromethanesulphonate (available from 3M Corporation, St. Paul, Minn.) in sulfolane (99.8%, standard for GC available from Sigma-Aldrich, UK) was used as the electrolyte. The liquid to solid mass ratio was 10:1. The content of the flask was mixed for 24 hours by means of a magnetic stirrer at room temperature. The liquid phase was separated from the non-dissolved solid phase by filtration. Then the sulphur in the form of sulphides and the total sulphur content were analysed. The content of the total sulphur in the initial electrolyte was also analysed and taken into account.
[0051] The Analysis Results:
[0000]
The total sulphur content in the initial
25.8 ± 0.1
electrolyte, % by mass
The total sulphur content in the electrolyte
26.9 ± 0.1
after the reaction with the mixture of sulphur
and lithium sulphide, %
Content of sulphide sulphur in the electrolyte
0.18 ± 0.015
after the reaction with the mixture of sulphur
and lithium sulphide, %
[0052] The results of the analysis enabled the composition of lithium polysulphides to be calculated after the reaction of lithium sulphide and sulphur in electrolyte as well as the concentration of lithium polysulphide in electrolyte.
[0053] Calculation Results:
[0054] Polysulphide composition: Li 2 S 6,1
[0055] Concentration: 0.18%
EXAMPLE 2
[0056] The solution of polysulphides in electrolyte was prepared as described in the Example 1 (1M solution of lithium trifluoromethanesulphonate in sulpholane) and the total amount of sulphur and sulphide was chemically analyzed. The mass ratio of Li 2 S:S was 50:50.
[0057] The Analysis Results:
[0000]
The total sulphur content in the initial
25.8 ± 0.1
electrolyte, % by mass
The total sulphur content in the electrolyte
31.8 ± 0.1
after the reaction with the mixture of the sulphur
and lithium sulphide, %
The content of sulphide sulphur in electrolyte
0.96 ± 0.05
after the reaction with the mixture of sulphur
and lithium sulphide, %
[0058] The content and the composition of lithium polysulphides in the electrolyte after the reaction of lithium sulphide with sulphur were calculated based on the analysis results.
[0059] Calculation Results:
[0060] Polysulphide composition: Li 2 S 6,25
[0061] Concentration: 0.96%
EXAMPLE 3
[0062] The solution of polysulphides in electrolyte was prepared as described in the Example 1 (1M solution of lithium trifluoromethanesulphonate in sulpholane) and the amount of sulphur and sulphide sulphur was chemically analysed. The mass ratio of Li 2 S:S was 10:90.
[0063] The Analysis Results:
[0000]
The total sulphur content in the initial
25.8 ± 0.1
electrolyte, % by mass
The total sulphur content in electrolyte
29.9
after the reaction with the mixture of sulphur
and lithium sulphide, %
The content of sulphide sulphur in electrolyte
0.7
after the reaction with the mixture of the sulphur
and lithium sulphide, %
[0064] The composition of lithium polysulphides in the electrolyte after the reaction of lithium sulphide with sulphur and the concentration of lithium polysulphide in electrolyte were calculated based on the analysis results.
[0065] Calculation Results:
[0066] Polysulphide composition: Li 2 S 5,86
[0067] Concentration: 0.7%
EXAMPLE 4
[0068] A porous electrode made up of 50% electroconductive carbon black (Ketjenblack EC-600JD, available from Akzo Nobel Polymer Chemicals BV, Netherlands) and 50% polyethylene oxide (PEO, 4,000,000 molecular weight, available from Sigma-Aldrich, UK) as a binder was prepared according to the following procedure.
[0069] A mixture of dry components was milled in a high speed grinder (Microtron MB550) for 15 to 20 minutes. Acetonitryl was then added to the mixture as a solvent for the binder. The resulting suspension was then mixed for 15 to 20 hours in a DLH laboratory stirrer. The solids content of the suspension was 5%. The suspension thus produced was deposited by an automatic film applicator (Elcometer SPRL) to one side of an 18 μm thick aluminum foil with an electroconductive carbon coating (Product No. 60303 available from Rexam Graphics, South Hadley, Mass.) as a current collector.
[0070] The carbon coating was dried in ambient conditions for 20 hours. After drying, the electrode was pressed at a pressure of 1000 kg/cm 2 . The resulting dry cathode layer had a thickness of 8 μm after pressing and contained 0.47 mg/cm 2 of carbon-PEO mixture. The volume density of the carbon layer was 590 mg/cm 3 and the porosity was 72%.
EXAMPLE 5
[0071] A suspension comprising a mixture of lithium sulphide with sulphur in an electrolyte was produced. Lithium sulphide, 98% (Sigma-Aldrich, UK) and sublimated sulphur, 99.5% (Fisher Scientific, UK) were ground at a mass ratio of 90:10 in a high speed mill (Microtron MB550) for 15 to 20 minutes in an atmosphere of dry argon (moisture content 20-25 ppm). The ground mixture of lithium sulphide and sulphur was placed into a ball mill, and an electrolyte was added to the mill. A solution of trifluoromethanesulphonate of lithium (available from 3M Corporation, St. Paul, Minn.) in sulfolane (99.8%, standard for GC available from Sigma-Aldrich, UK) was used as the electrolyte. The liquid to solid ratio was 10:1.
EXAMPLE 6
[0072] The hard composite cathode from Example 4 was used in a small cell producing electric current with an electrode surface area of about 5 cm 2 . The electrode was dried in a vacuum at 50° C. for 5 hours before being installed in the cell. Celgard 2500 (a trade mark of Tonen Chemical Corporation, Tokyo, Japan, and also available from Mobil Chemical Company, Films Division, Pittsford, N.Y.) was used as a porous separator. A copper foil was used as a current collector for the negative electrode.
[0073] The cell was assembled in the following way:
[0074] A thin even layer of the lithium sulphide and sulphur suspension in the electrolyte from Example 5 was deposited onto the porous carbon cathode from Example 4 in a quantity of about 7.5 mg/cm 2 of the cathode surface. Then one layer of Celgard 2500 was placed onto the the electrode over the deposited suspension. An electrolyte comprising a solution of trifluoromethanesulphonate of lithium (available from 3M Corporation, St. Paul, Minn.) in sulfolane (99.8%, standard for GC available from Sigma-Aldrich, UK), but without any lithium sulphide-sulphur suspension, was deposited onto the separator in a quantity of 1 μl/cm 2 . A copper current collector was placed on top of the “sandwich” structure thus produced. Finally, the cell was hermetically sealed.
[0075] The cell was kept at ambient room conditions for 24 hours and then charged at a current density of 0.05 mA/cm 2 to a voltage of 2.8V.
[0076] Thereafter, the cell was cycled. Charge and discharge was conducted at a current density of 0.1 mA/cm 2 with discharge termination at 1.5V and charge termination at 2.8V. The charge-discharge plots are shown in FIG. 1 . The charge-discharge plots are similar to those obtained for lithium-sulphur cells using elemental sulphur as a cathode depolariser (electroactive substance). The efficiency of lithium-sulphur utilisation is 55 to 65%.
EXAMPLE 7
[0077] The solid state composite cathode from Example 3 was used in an electrochemical cell having a cathode surface area of approximately 5 cm 2 . The electrode was dried for 5 hours under vacuum at 50° C. prior to assembly of the cell.
[0078] A porous Celgard 2500 separator was used (Tonen Chemical Corporation, Tokyo, Japan, also available from Mobil Chemical Company, Films Division, Pittsford, N.Y.).
[0079] A 20 micrometer aluminium foil was used as a current collector for the negative electrode.
[0080] The cell was assembled as follows:
[0081] A porous carbon electrode was coated with a thin uniform layer of the suspension of lithium sulphide and sulphur in electrolyte obtained as described in the Example 2 in an amount of approximately 7.5 mg per 1 sq cm. Then one layer of Celgard separator was placed on top of the electrode coated with the suspension. The electrolyte was deposited onto the separator in the quantity of 1 microlitre per 1 cm 2 . A disk of copper foil was placed on the top. Then the cell was sealed.
[0082] The cell was kept at room temperature for 24 hours and then charged at a current density of 0.05 mA/cm 2 up to 2.8 V.
[0083] Then the cell was cycled at a current density of 0.1 mA/cm 2 , with discharge being terminated at 1.5V and charge being terminated at 2.8V. The resulting charge-discharge curves are shown in FIG. 2 .
[0084] The preferred features of the invention are applicable to all aspects of the invention and may be used in any possible combination.
[0085] Throughout the description and claims of this specification, the words “comprise” and “contain” and variations of the words, for example “comprising” and “comprises”, mean “including but not limited to”, and are not intended to (and do not) exclude other components, integers, moieties, additives or steps.
[0086] Throughout the description and claims of this specification, the singular encompasses the plural unless the context otherwise requires. In particular, where the indefinite article is used, the specification is to be understood as contemplating plurality as well as singularity, unless the context requires otherwise.
[0087] The foregoing description of the embodiments of the invention has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. It should be appreciated by persons skilled in the art that many modifications, variations, substitutions, changes, and equivalents are possible in light of the above teaching. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention. | A chemical source of electrical energy may include a positive electrode (cathode) made of an electrically conductive material, a mixture of lithium sulphide and sulphur, a permeable separator or membrane, and a negative electrode (anode) made of an electrically conductive material or a material that is able reversibly to intercalate lithium ions, wherein an aprotic electrolyte comprising at least one lithium salt in at least one solvent is provided between the electrodes. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention concerns the spinning of bobbins of yarn to remove moisture or liquids therefrom, particularly when they leave the autoclaves wherein the yarn is dyed or other heat treatment and prior to being introduced into the driers for finishing, and it relates more particularly to the positioning of these bobbins inside the rotatable baskets of centrifuges and to the removal thereof from these baskets at the end of the centrifugation operation.
SUMMARY OF THE INVENTION
The invention has for its object an improved device adapted to ensure the loading and unloading of bobbins of yarn into a centrifugal dryer are operations which are accomplished entirely automatically.
The device according to the invention comprises a hollow hub adapted to be axially fixed inside the basket of the centrifuge, which hub has at least one longitudinal slot cut out therein, in which slides a finger carried by a fork which is vertically reciprocal with the aid of an appropriate pusher element. This fork is secured with an annular plate which surrounds the hub and which is adapted to form support for each of the bobbins of yarn to be rotated within the centrifuge.
The reciprocating displacement of the pusher element is calculated so that the annular plate is disposed in high position at the level of a loading table which includes an opening adapted to permit the passage of the plate, and in low position is positioned against the bottom of the rotating basket of the centrifuge.
BRIEF DESCRIPTION OF THE DRAWING
The invention will be more readily understood on reading the following description with reference to the accompanying drawings, in which:
FIG. 1 is a partial axial section schematically showing the general arrangement of a centrifuge of which the basket is equipped with a loading and unloading device according to the invention.
FIG. 2 is a view in perspective of the different elements constituting this device, shown prior to assembly thereof.
FIG. 3 reproduces FIG. 2 after assembly of the constituent elements.
FIG. 4 illustrates in perspective a variant embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, FIG. 1 schematically shows at 1 the fixed vessel of a conventional centrifuge, provided with a vertical-axis basket 2 disposed inside the vessel 1 and a liquid drain shown at 1'. The bottom of the basket 2 is secured with the upper flange 3a of a hollow shaft 3 maintained inside a fixed part 4 of the general frame of the machine. This shaft 3 is driven in rotation in any appropriate manner, for example by a belt transmission 5. It will be observed that the open upper part of the basket 2 is surmounted by a table 6 in which is cut out an opening 6a allowing access to the basket.
A loading and unloading device according to the invention comprises a vertical hub 7 mounted axially inside the basket 2 with which it is secured to a lower flange 7a applied against the bottom of the basket. As shown in FIGS. 2 and 3, this hub 7 has longitudinal slots 7b cut out therein, four in number in the embodiment shown, which start from the lower flange 7a but which stop, on the contrary, at a certain height below the upper end of the hub in order to form a centering endpiece 7c.
Into the blind axial bore of the hub 7 there is slidably engaged a fork 8, provided with four fingers 8a in the same arrangement as the slots 7b so as to be able to be introduced thereinto. On these fingers 8a is fixed a plate 9 pierced with a central opening 9a for the passage of the hub 7. Opposite this plate 9, the fork 8 is secured, for example by screwing, with the end of a pusher element 10 which axially traverses the hollow shaft 3 to cooperate with an actuating member which, in FIG. 1, has been schematized in the form of a double arrow F and which is adapted to displace it along its axis, in vertically reciprocating motion. This member F may in particular be constituted by a pneumatic or hydraulic jack, of the double-effect type.
Operation of the device described above follows from the foregoing explanations and will be readily understood.
When the actuating member F is at the upper end of stroke for which the fingers 8a surround the endpiece 7c of the hub 7, the plate 9 is disposed at the height of table 6, so that it may receive, by a simple lateral thrust, a bobbin of yarn to be rotated within the centrifuge, such as the one indicated at A in FIG. 1. Once the bobbin A has been placed on the plate 9, the plate lowers by an effect on traction exerted by the pusher element 10, until the fork 8, whose downward slide is guided by the cooperation of the fingers 8a and slots 7b, abuts against the lower flange 7a of the hub. The bobbin is thus brought to position A', inside the basket 2 which may effect spinning or spin drying thereof as soon as it is driven in rotation at high speed by transmission 5.
At the end of spinning, the plate 9 may, of course, be returned to the high position by the pusher element 10 so that the bobbin can be evacuated laterally onto the table 6, and it will be understood that all the operations for loading and unloading the basket 2 are carried out entirely automatically, without any manual intervention.
It goes without saying that the number of fingers 8a of fork 8 and of the slots 7b of hub 7 may vary to a wide extent, in particular as a function of the diameter of the hub and of the weight of the bobbins to be treated.
It must, moreover, be understood that the foregoing description has been given only by way of example and that it in no way limits the domain of the invention which would not be exceeded by replacing the details of execution described by any other equivalents.
In particular, when the bobbins to be treated with the centrifuge present a spindle of which the internal diameter is largely greater than the outer diameter d of the hub of the basket, the hub may be provided with a dismountable sleeve of the type referenced 11 in FIG. 4. This sleeve 11, of external diameter D, is provided to be tubular so as to engage on the hub, here referenced 17, carried by the bottom of the basket 2, and it has longitudinal slots 11a cut out therein, identical in number and in disposition to the slots 17b of the hub, while its top is provided with a centering endpiece 11b which covers the endpiece 17c of the hub. It will be observed that this endpiece 17c is secured to an offset vertical pin 17d adapted to be introduced into a corresponding perforation 11c made in the endpiece 11b to effect positive drive of the sleeve 11 by the hub 17.
Axial fixation of the dismountable sleeve 11 is ensured with the aid of a screw 12 which passes through a hole 11d in the endpiece 11b to cooperate with an axial tapping 17e in hub 17; it will be noted that, when this latter is used without sleeve 11, its endpiece 17c receives a cap 13 pierced at 13a and at 13b to allow engagement of pin 17d and of screw 12 respectively, thus giving assembly 17-13 the same height as that presented by assembly 17-11. In addition, the base of sleeve 11 is maintained in an annular groove 17f made in the lower flange 17a of hub 17. It goes without saying that the opening 9a of plate 9 must present a diameter sufficient to allow passage of the sleeve 11. | A device for loading and unloading a rotating basket in a centrifuge for spin drying bobbins of yarn wherein a hub is provided centrally of the basket and which guides an annular bearing plate which is vertically shiftable with respect to the basket so as to be selectively engageable with and supportive of a bobbin of yarn which is lowered into the basket, subjected to centrifugal action, and thereafter raised to a discharge position above the basket. | 3 |
FIELD OF THE INVENTION
The invention relates to a golf club head. More particularly, the invention is related to a golf club head with a multi-radius face.
BACKGROUND OF THE INVENTION
The design of club heads has long been studied. Among the more prominent considerations in club head design are loft, lie, face angle, horizontal face bulge, vertical face roll, face progression, sole curvature, center of gravity location, and overall head weight. Although all of these aspects may be considered in golf club engineering, several are often accorded more weight in the design process due to their significant impact on club performance.
The shape and sizing of a club face is quite complex. Of particular interest in club head design are two characteristics of the face, the horizontal face bulge and the vertical face roll. Horizontal face bulge radius is measured from the heel to toe or along the horizontal plane of the face, and is important because it compensates for a golfer's hitting of the ball off of the centerline of the face. If a ball is hit at an off-center location, the bulge effectively compensates for this misalignment that would otherwise cause hooking or slicing. A typical wood has a horizontal face bulge radius of between 8 and 16 inches.
Vertical face roll radius is measured from the top of the face to the bottom of the face in a vertical position, and this factor affects the trajectory of the ball off the face. A typical wood has a vertical face roll radius of between 12 and 18 inches.
The presence of bulge and roll radius, and the degree of radius applied to the face, are critical to the performance of the club. As perfection in the golf swing is not attained by most golfers, off-center hits are common. Yet, proper club head design, particularly with respect to the face geometry, can help compensate for the imperfect swing. There are trade-offs, however, in setting the face geometry. Too much horizontal face bulge, for example, can lead to poor directional control. In addition, club heads having too much vertical face roll can detrimentally exacerbate the trajectory of the ball upon impact.
Typically, golf clubs are designed with a single bulge. However, some club heads have been designed with multiple bulge radii. U.S. Pat. No. 6,093,115 discloses a golf club head having an asymmetric ball striking face such that one side of the face, as measured from the center of the face, has a first bulge radius and the other side of the face has a second bulge radius. One of the heel portion and the toe portion of the ball striking face has a bulge radius of 8 inches, while the other has a bulge radius of 24 inches. U.S. Pat. No. 5,415,405 discloses a hitting surface of a golf club head that is divided into three adjacent portions, each portion forming an arc of a circle with a different radius. The radii of the various portions range between 7 and 20 inches.
Japanese Publication 11042301 discloses a golf club head with three different bulge radii. The central part of the club face has a bulge radius that is greater than that of either adjacent part, with the difference in bulge radii ranging from about 1.27 to 2.95 inches.
Golf clubs are also typically designed with a single roll radius. However, some club heads have been contemplated to include multiple roll radii. For example, U.S. Pat. No. 4,162,074 discloses a putter with a face that forms a convex striking surface. The surface is generally parabolic or exponential, and thus does not have a constant roll radius.
Moreover, U.S. Pat. No. 4,508,349 discloses a golf club with a striking face that has a central portion with accentuated roll. The central roll portion has a radius of curvature between 0.70 and 1 inch. Grooves extend parallel to the accentuated roll portion on opposite sides thereof, while flat surfaces extend along the striking face above and below the upper and lower grooves respectively. The design is claimed to provide for increased compression of the golf ball resulting in an unexpectedly long drive.
Despite the several aforementioned club head designs, there remains a need for a wood-type golf club with a club face designed to optimize launch conditions for various ball impact locations on the face. In particular, there remains a need for a golf club face with dual roll radii. Such a golf club design allows for improvement in performance such that ball launch conditions degrade less as the impact point of the ball departs from the center of the club face. In addition, there remains a need for a golf club face combining multiple bulge radii with multiple roll radii.
SUMMARY OF THE INVENTION
The present invention relates to a metal wood golf club head adapted for attachment to a shaft. The head includes a shell defining an inner cavity and further including a face. The face has at least two roll radii disposed adjacent each other and defined about a horizontal line proximate the center of the face, with a first roll radius above the line and a second roll radius below the line. Preferably, the first roll radius is smaller than the second roll radius. The first roll radius may be less than about seventy percent of the second roll radius. The first roll radius may be between about 4 inches and about 12 inches, and the second roll radius may be between about 8 inches and about 16 inches. In a preferred embodiment, the first roll radius is about 6 inches, and the second roll radius is about 10 inches.
The present invention also relates to a metal wood golf club head adapted for attachment to a shaft, including a shell defining an inner cavity and further including a face. The face has at least two roll radii disposed adjacent each other and defined about an alignment line on the face that extends from the heel end to the toe end. Preferably, a first roll radius above the alignment line is smaller than a second roll radius below the alignment line. A first roll radius above the alignment line may be less than about seventy percent of a second roll radius below the alignment line.
In another embodiment of a metal wood golf club head, the face has at least two roll radii and at least two bulge radii. The roll radii are disposed adjacent each other and defined about an alignment line on the face extending from the heel end to the toe end. Preferably, the face includes a first roll radius above the alignment line and a second roll radius below the alignment line, with the first roll radius being smaller than the second roll radius.
The present invention further relates to a metal wood golf club head adapted for attachment to a shaft. The head includes a shell defining an inner cavity and further including a face. The face has vertical and horizontal center lines proximate its center. The face also has a toe-side alignment line parallel to the vertical center line and disposed about half-way between a toe region of the shell and the vertical alignment line, and a heel-side alignment line parallel to the vertical center line and disposed about half-way between a heel region of the shell and the vertical alignment line. The face has a central region with a first bulge radius between the toe-side and heel-side alignment lines, and peripheral regions adjacent the central region. The first bulge radius of the central region of the face is substantially larger than the bulge radius of the peripheral regions of the face. In one embodiment, the bulge radius of the peripheral regions of the face is about 10% to about 40% smaller than the first bulge radius.
In addition, the present invention relates to a method of forming a metal wood golf club head, comprising the steps of: forming a shell defining an inner cavity and further including a face having a horizontal center line that extends from a heel end to a toe end, the horizontal center line defining an upper portion and a lower portion, and forming the upper portion of the face with a roll radius that is smaller than a roll radius of the lower portion of the face. The method may further include the step of forming substantially the entire upper portion of the face with a first roll radius, and forming substantially the entire lower portion of the face with a second roll radius. The face additionally may be formed with at least two bulge radii disposed about a vertical center line that extends from a crown region to a sole region, the vertical center line defining a proximal portion having a first bulge radius and a distal portion having a second bulge radius.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a perspective view of a golf club head with a face having a single roll radius;
FIG. 2 shows a side view of a golf club head constructed according to the present invention with a face having multiple roll radii;
FIG. 3 shows a perspective view of another golf club head constructed according to the present invention with a face having multiple roll radii and multiple bulge radii; and
FIG. 4 shows a perspective view of another golf club head constructed according to the present invention with a face having multiple bulge radii.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, wood-type club 10 includes a head 12 with a body 14 and a face 16 , along with a shaft 18 . Head 12 has a heel end 20 and a toe end 22 . Although not shown in detail, club 10 may include a hosel, crown plate, and/or sole plate. The head is preferably formed of metal such as titanium and alloys thereof, and may be formed from separate body and face portions that are integrated, such as by welding. If such a multi-piece head is used, preferably the face is forged or stamped, while the body is cast. Alternatively, the face and body may both be cast as a single unit, providing for separate crown and/or sole pieces, or the club head may be only formed from forged or stamped components. Grooves may also be provided on the face.
As shown in FIG. 1, a typical wood includes a face with a single roll radius R 1 . Such a club may, for example, be a number 1 wood, with a face nominally having a roll radius of about 10 inches.
In the preferred embodiment of the present invention, a wood-type club is provided with a face having multiple roll radii. As shown in FIG. 2, wood-type club 20 has a face 26 with two different roll radii R 2 and R 3 . Preferably, the change between the roll radii occurs substantially at the center of the face at mid-line MID, which is located approximately halfway between the uppermost and lowermost points of the face and extends from the heel region 20 to the toe region 22 . Preferably, a smaller roll radius is chosen above line MID than below line MID. More preferably, above line MID, a relatively smaller radius between 4 and 12 inches is selected, while below line MID, a relatively larger radius between 8 and 16 inches is selected. In an alternate embodiment, the change between radii may occur along an alignment line that is not centered on the face, yet extends from the heel end to the toe end.
Advantageously, the selection of different roll radii above and below the face mid-line MID can impact the quality of a golfer's shot. The quality of the shot is predicated on several ball launch parameters, including initial velocity, backspin, and launch angle. Geometrically, the center point of the club face may be defined as the point on the face at which a line projected through the center of gravity perpendicular to the face intersects the face. Impacts above the center point result in a degraded ball backspin, and thus it is desirable to launch the ball higher so that maximum ball carry may be achieved. In the alternative, when a ball is struck below the center point of the face, the smaller roll radius tends to launch the ball too low, resulting in degraded ball flight performance. As a result, it is preferable to have a larger roll radius below the face center than above it.
EXAMPLES
These and other aspects of the present invention may be more fully understood with reference to the following non-limiting examples, which are merely illustrative of embodiments of the present invention golf club head, and are not to be construed as limiting the invention, the scope of which is defined by the appended claims.
The test results enumerated in Tables 1-3 were generated using computational techniques, which included finite element analysis models. In particular, the general purpose, explicit finite element program LS-DYNA was employed. When computer modeling the exemplary club heads, the following fixed parameters were used: a mass of 200 g, a center of gravity located 2.11 inches behind the center of the ball with the center of the face aligned along this line, a loft of 11 degrees, static and dynamic friction of 0.3, and a head speed of 109 mph. In addition, fixed heel-toe, droop, and vertical gear axis inertia terms were selected. The finite element models were used to predict ball launch conditions and a trajectory model was used to predict distance and landing area. Thus, the modeling allows a determination of the variation in launch angle, backspin, and carry distance as a function of roll and relative vertical impact position on the club face.
Club heads with Comparative Club Faces “A,” “B,” and “C” are configured and dimensioned with roll radii of 6 inches, 10 inches, and 14 inches, respectively. For purposes of comparison, the performance of Comparative Club Faces “A”-“C” has been normalized with respect to golf balls impacting Comparative Club Face “B” at the center of the club face. Thus, the normalized value of the ball launch angle for a golf ball hitting Comparative Club Face “B” at the face center is 1.00.
TABLE 1
TEST RESULTS FOR BALL LAUNCH ANGLE
Ball Launch
Ball Launch
Ball Launch
Relative Impact
Angle with
Angle with
Angle with
Position on
Comparative
Comparative
Comparative
Club Face
Club Face “A”
Club Face “B”
Club Face “C”
(inches)
R A = 6 inches
R B = 10 inches
R C = 14 inches
+0.25
1.376
1.290
1.247
0.00
1.032
1.000
0.978
(Face Center)
−0.25
0.667
0.688
0.699
−0.50
0.312
0.387
0.419
As shown in Table 1, when club head performance is measured as a function of golf ball launch angle, a similar trend is generally found for each Comparative Club Face. In particular, for a given roll radius, as the golf ball impact position on the club face increases, the launch angle increases. More specifically, for example, a golf ball hit at a location 0.25 inch above the center of Comparative Club Face “B” launched at approximately a 29% higher angle than a ball hit at the center of club face. In contrast, a ball hit at locations 0.25 inch and 0.50 inch below the center of Comparative Club Face “B” launched at approximately 31% and 61% lower angles respectively than a ball hit at the center of the club face.
TABLE 2
TEST RESULTS FOR BALL BACKSPIN
Ball
Ball
Ball
Relative Impact
Backspin with
Backspin with
Backspin with
Position on
Comparative
Comparative
Comparative
Club Face
Club Face “A”
Club Face “B”
Club Face “C”
(inches)
R A = 6 inches
R B = 10 inches
R C = 14 inches
+0.25
0.79
0.63
0.55
0.00
1.06
1.00
0.97
(Face Center)
−0.25
1.35
1.39
1.41
−0.50
1.61
1.74
1.79
Although it is generally preferable to increase the launch angle of a golf ball, the quality of an impact must be evaluated using additional criteria. For example, aerodynamics dictates that the carry distance of a golf ball is a function of the ball's backspin, launch angle, and initial velocity. As shown in Table 2, for a club face having a given roll radius, as the golf ball impact position on the club face increases, backspin decreases. For example, a golf ball hit at a location 0.25 inch above the center of Comparative Club Face “B” had approximately a 37% lower backspin than a ball hit at the center of the club face. Balls hit at locations 0.25 inch and 0.50 inch below the center of the Comparative Club Face “B,” however, had increased backspins of approximately 39% and 74% respectively over a ball hit at the center of the club face.
TABLE 3
TEST RESULTS FOR BALL CARRY DISTANCE
Ball Carry
Ball Carry
Ball Carry
Relative Impact
Distance with
Distance with
Distance with
Position on
Comparative
Comparative
Comparative
Club Face
Club Face “A”
Club Face “B”
Club Face “C”
(inches)
R A = 6 inches
R B = 10 inches
R C = 14 inches
+0.25
0.993
0.989
0.978
0.00
1.004
1.000
1.000
(Face Center)
−0.25
0.989
0.986
0.986
−0.50
0.932
0.939
0.939
In addition, as shown in Table 3, for a club face having a given roll radius, impacting a golf ball at locations away from the center of the club face results in a decrease in carry distance. For example, a golf ball hit at a location 0.25 inch above the center of Comparative Club Face “B” had approximately a 1% decrease in carry distance as compared to a ball hit at the center of the club face. Golf balls hit at locations 0.25 inch and 0.50 inch below the center of the club face had a decrease in carry distance of approximately 1.5% and 6%, respectively.
Referring to Tables 1-3, an examination of the performance of Comparative Club Face “A” (with a roll radius of 6 inches) and Comparative Club Face “C” (with a roll radius of 14 inches) demonstrates that for ball hits occurring at the same locations above the center of the club faces, the club face with the smaller roll radius launches a golf ball at a higher ball launch angle, a higher backspin, and a longer carry distance. With regard to hits occurring below the center of the club faces, however, the club face with the smaller roll radius launches a golf ball at a lower launch angle and a lower backspin.
Based on the variations in performance of club heads with Comparative Club Faces “A”-“C,” the configuration of an inventive club head may be chosen. Preferably, the roll radius above the center of an inventive club head face is selected to be about 4 to 12 inches, while below the center of the face, the roll radius is selected to be about 8 to 16 inches, such that the roll radius above the center is smaller than the roll radius below it. More preferably, the roll radius above the center of an inventive club head face is selected to be about 5 to 7 inches, while below the center of the face, the roll radius is selected to be about 9 to 11 inches. Thus, an inventive club head face may have a 6 inch roll radius above the face center and a 10 inch roll radius below the face center. As previously demonstrated with respect to Comparative Club Faces “A”-“C,” a ball impacting such an inventive club head face at a location 0.25 inch above the center point has an improved performance of approximately a 37.6% increase in launch angle, while experiencing only a 21% decrease in backspin. The overall carry of the ball is reduced by only 0.7%, as compared to 1.1% for a face with a 10 inch roll radius, and as a result there is a recovery of about 36% of the carry distance lost by striking the ball above the face center. In addition, the dual roll face addresses the problem encountered when a ball is hit below the face center point. The larger the roll radius used below the center of the face, the less the degradation of launch angle. Although backspin continues to be a factor affecting the overall performance of the golf shot, a larger roll radius above the center point improves the distance on below face center impacts.
As mentioned previously, a number 1 wood typically has a face with a roll radius of about 10 inches. The inventive club face of the present invention maintains this “normal” roll radius below the face center point, but has a lower roll radius above the face center point.
Golf club heads designed in accordance with the present development may alternatively include more that two roll radii. As the trends in performance have shown that a lower roll radius is desirable above the face center point, a graduated decrease in the roll radius may be chosen across the face in this region. For example, above the face center point, a roll radius of 8 inches may transition to a roll radius of 6 inches. This permits additional tailoring of the club head performance.
The present development also is directed to a golf club face combining multiple roll radii with multiple bulge radii. As shown in FIG. 3, wood-type club 30 has a face 36 with two different roll radii R 4 and R 5 and two different bulge radii R 6 and R 7 . Preferably, the change between the roll radii occurs substantially at the center of the face at horizontal mid-line MID, and a smaller roll radius is chosen above line MID than below line MID. Preferably, the change between the bulge radii occurs substantially at the center of face 36 at central line CEN, which extends vertically from crown region 38 to sole region 40 . In an alternate embodiment, the change between roll radii may occur along an alignment line that is not centered on the face, yet extends from the heel end to the toe end. While variations in the bulge radii across the face can improve the directional control of golf shots, faces that also have multiple roll radii can provide improved performance such as improved ball launch angles. More than two roll radii and more than two bulge radii may also be provided in other embodiments.
In addition, the present development is directed to a golf club face combining multiple bulge radii. As shown in FIG. 4, wood-type club 50 has a face 56 with four bulge radii R 8 , R 9 , R 10 and R 11 . Alignment line ALI 1 is disposed about halfway between vertical central line CEN and toe region 22 at horizontal mid-line MID, while alignment line ALI 2 is disposed about halfway between central line CEN and heel region 20 at horizontal mid-line MID. Preferably, bulge radius R 8 is bounded by lines CEN and ALI 1 and bulge radius R 9 is bounded by lines CEN and ALI 2 . In a preferred embodiment, bulge radii R 8 and R 9 are substantially the same, while bulge radii R 10 and R 11 are substantially the same and are substantially smaller than bulge radii R 8 and R 9 . In a more preferred embodiment, bulge radii R 8 and R 9 are substantially the same, while bulge radii R 10 and R 11 are each about 10% to 40% smaller than bulge radii R 8 and R 9 . Face 56 may have a single roll radius, or multiple roll radii, for example, as described herein with respect to other embodiments of the present invention. In one embodiment, the roll radius above horizontal mid-line MID is smaller than the roll radius below it.
While various descriptions of the present invention are described above, it should be understood that the various features of each embodiment can be used singly or in any combination thereof. Therefore, this invention is not to be limited to only the specifically preferred embodiments depicted herein. Further, it should be understood that variations and modifications within the spirit and scope of the invention may occur to those skilled in the art to which the invention pertains. Accordingly, all expedient modifications readily attainable by one versed in the art from the disclosure set forth herein that are within the scope and spirit of the present invention are to be included as further embodiments of the present invention. The scope of the present invention is accordingly defined as set forth in the appended claims. | A metal wood golf club head adapted for attachment to a shaft is disclosed, including a shell defining an inner cavity and further including a face. The face of the club head has at least two roll radii disposed adjacent each other and defined about an alignment line on the face that extends from the heel end to the toe end. The roll radius above the alignment line is smaller than the roll radius below the alignment line. The face may also include multiple bulge radii. | 0 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This U.S. patent application claims priority to German Patent Application DE 10 2010011887.7, filed Mar. 18, 2010, which is incorporated by reference herein in its entirety.
FIELD OF THE INVENTION
[0002] The invention relates to a method for controlling a drivetrain of a motor vehicle having an automatic clutch, such as is known from WO 02/094601 A2.
BACKGROUND OF THE INVENTION
[0003] WO 02/094601 A2, which is incorporated by reference, relates to a method for controlling a drivetrain having an automatic clutch, with the internal combustion engine being decoupled from the drive wheels in the presence of predetermined operating conditions when the motor vehicle is travelling in order to permit travel without drive. Such travel without drive is referred to as coasting. WO 02/094601 A2 describes coasting as the intentional disengagement of the clutch in overrun operating phases in which neither the accelerator pedal nor the brake pedal is actuated. The disengagement of the clutch is carried out with the aim of saving fuel. In the clutch-disengaged state, the vehicle rolls without losing kinetic energy through the braking action of the internal combustion engine. Here, the internal combustion engine is operated at idle. A precondition for the transition into the coasting operating mode is that the vehicle speed is higher than a limit value and that neither a brake pedal nor an element which determines a supply of fuel (for example an accelerator pedal) is actuated.
[0004] DE 198 23 764 A1, which is incorporated by reference, discloses a method for controlling the start of opening of an automatic clutch situated in the drivetrain of a motor vehicle, with at least one variable which is positively related to the rotational speed of the internal combustion engine being measured, and with the rotational speed being calculated therefrom and an actuator which opens the clutch being set in operation if the rotational speed has fallen below a predetermined limit value. Here, the change in rotational speed over time is determined, and the opening value is selected to be higher the further the rotational speed has decreased over time.
[0005] DE 10 2008 005 644 A1, which is incorporated by reference, describes a method for saving fuel utilizing a freewheel.
SUMMARY OF THE INVENTION
[0006] The problem on which the present invention was based is that of improving the possibility of saving fuel, and at the same time not permitting any losses in comfort during driving operation.
[0007] Said problem is solved by means of the method according to aspects of the invention, in which the decoupling of the transmission and therefore the separation of the drivetrain input section from the drivetrain output section is carried out so precisely in terms of time that the motor vehicle does not enter into overrun operation.
[0008] The present invention has the advantage that, when there is no demand for power, the clutch is open and therefore the drivetrain input section and drivetrain output section are separated. For this purpose, the accelerator pedal position is detected and, when the driver is not depressing the accelerator pedal, a corresponding signal “activate the coasting mode” is generated in the transmission control unit, such that a corresponding actuating signal is then directly output to the clutch in order to separate the drivetrain input section and drivetrain output section.
[0009] A further advantage of the solution according to aspects of the invention is that, to realize a high level of driving comfort, the driver does not sense any jerk during the disengagement and re-engagement of the drivetrain input section and drivetrain output section. This is the case if the clutch torque transmitted by the transmission at the time of opening of the clutch is approximately zero.
[0010] The present invention therefore has the advantage that, in the coasting mode, the drive input unit is separated from the drive output unit by opening the clutch, without energy being lost in an overrun mode, and as a result of the corresponding actuation during the engagement and disengagement, no jerk is perceptible to the driver, and therefore a high level of driving comfort is ensured.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
[0011] The invention is best understood from the following detailed description when read in connection with the accompanying drawings. Included in the drawings is the following figures:
[0012] FIG. 1 shows a basic design for carrying out the method,
[0013] FIG. 2 shows a diagram of the different torques at the clutch over time, and
[0014] FIG. 3 shows a diagram of the engine rotational speed over time.
DETAILED DESCRIPTION OF THE INVENTION
[0015] FIG. 1 illustrates in a simplified manner the basic design of the components according to aspects of the invention, with a transmission control unit (G-SG) being supplied with various input variables such as for example rotational speed n, accelerator pedal position, temperature and characteristic variables of the drivetrain input section 11 and of the drivetrain output section 12 . In FIG. 1 , all the input variables are provided symbolically with the reference numeral 10 .
[0016] If the accelerator pedal position indicates that the driver is not demanding power, then the process “activate coasting” takes place in the transmission control unit. In the transmission control unit, the optimum time for the separation of the drivetrain input zo section and drivetrain output section is then calculated, and a corresponding actuating signal is output to the clutch 13 , which then separates the drivetrain input section 11 and drivetrain output section 12 for the coasting process. In FIG. 1 , this is depicted symbolically by the switch 14 . When the switch 14 is open, no power is transmitted from the drive input unit to the drive output unit.
[0017] Below, the aspects of the invention will be explained on the basis of FIG. 2 . FIG. 2 shows a diagram over time, with the different curves 21 , 22 and 23 illustrated here representing different rates of change in the accelerator pedal position.
[0018] The change in the accelerator pedal position is made by the driver. On account of the different driving behaviors, in the solution according to aspects of the invention, a distinction is made between a sporty, a normal and a smooth driving behavior.
[0019] Therefore, the following rates of change in accelerator pedal position are illustrated in FIG. 2 : smooth 21 , normal 22 and sporty 23 .
[0020] The accelerator pedal position and therefore the rate of change in accelerator pedal 35 position is measured in the transmission control unit G-SG and forms the basis for the determination of the time of initiation of the coasting mode.
[0021] The time between the measurement and processing of the input variables 10 in the transmission control unit and the output of the signal and the opening of the clutch for a separation of the drivetrain input section and drivetrain output section is substantially always constant regardless of the driving behavior, and is referred to hereinafter as the separating time t SEP . These separating times t SEP are illustrated in FIG. 2 for the curves 21 , 22 and 23 .
[0022] To avoid energy losses, it must be ensured that the motor vehicle does not enter into the overrun mode. Therefore, the separation of the drivetrain input section and drivetrain output section must take place before the clutch torque M Clutch assumes a negative value.
[0023] On account of the different curve profiles of the clutch torque for different rates of change in the accelerator pedal position, and the approximately constant separating time, it is necessary, when the conditions for the coasting mode are present, for the signal for separation of the drivetrain input section and drivetrain output section to be output to the clutch significantly earlier if the change in accelerator pedal position takes place quickly (sporty 23 ) than if a slow change in the accelerator pedal position (smooth 21 ) takes place.
[0024] Ideally, the actual separation of the drivetrain input section and drivetrain output section takes place in a region in which the clutch torque is approximately zero.
[0025] On account of the different curve profiles of the torques for different rates of change of accelerator pedal position, said rate of change of accelerator pedal position must correspondingly be taken into consideration when determining the time for opening the clutch.
[0026] When the coasting conditions are present, the length of time it will take until the clutch torque has reached the desired value of 0 is precalculated. This precalculated time is combined with the time t SEP which can be read out from a characteristic map, so that the signal for separation of the clutch is output such that the “clutch open” signal to the actuating element 15 takes place when the torque in the drivetrain input section is approximately zero.
[0027] Said signal is defined such that the torque in the drivetrain output section reduced by the first derivative multiplied by the time t sEp is less than or equal to a predefinable limit value 1. This yields the following relationships:
[0000]
M
Clutch
=
M
Engine
-
ω
_
Engine
·
J
Engine
=
(
M
Wheel
+
ω
_
Engine
·
J
Engine
)
1
/
J
Transmission
[0028] The control unit has stored in it different characteristic curves for the time t SEP which are determined by application. When the coasting conditions are present, the corresponding variable t SEP is then read out from said characteristic map, and the optimum time for outputting the separating signal for the clutch is determined by means of the precalculation of the engine torque as a function of further conditions which are likewise stored in the control unit, such as for example the moment of inertia of the engine.
[0029] It is self-evident that the characteristic variables stored here are merely an example, and in the situation in which further variables must be taken into consideration, for example if the air-conditioning system of a vehicle is switched on, said characteristic variables are incorporated jointly in the calculation.
[0030] Finally, it should be stated that the re-engagement, that is to say the coupling of the drivetrain input section to the drivetrain output section, takes place analogously to the disengagement. The methods are applied analogously, such that, depending on the clutch closing time, the engine run-up is graded as sporty to comfortable or smooth. The aim is an end of closing at the synchronous rotational speed. Depending on the rotational speed gradient (curve profile of the engine run-up), the closing with the predicted closing time must be initiated at the correct time. The closing time is a value zo which is dependent on the operating point of the engine and which varies according to the clutch state. FIG. 3 illustrates the increase in engine rotational speed proceeding from the idle rotational speed n idle . The three curves 31 , 32 , 33 represent the different driving behaviors sporty 33 , normal 32 , smooth 31 , which have been defined already during the separation of the drivetrain input section from the drivetrain output section. On account of the different rotational speed profiles and the substantially constant closing time t close , the outputting of the clutch signal takes place at different times. | A method for triggering a signal for the separation of the drivetrain input section and drivetrain output section of a motor vehicle having an automatic clutch, characterized in that as a function of the change in clutch torque, and with a time (t SEP ) being taken into consideration which can be applied and which indicates the time period required by the system from the triggering of the signal for separation of the clutch until the final separation of the drivetrain input section and drivetrain output section. | 5 |
FIELD OF THE INVENTION
The present invention is based on a method for receiving messages, and on an electrical device for carrying out the method, according to the species defined in the independent claims.
Methods and devices with which so-called short message services (SMS) can be transmitted to the individual subscribers of the radio network are known from mobile radio technology. A short message of this kind has, for example in the E-network, a maximum length of 160 characters. The arrival of a message of this kind is made known via an audio sequence. A message of this kind can easily be transmitted in a radio network, since a digital mobile radio device maintains contact with radio stations as long as it is activated.
It is also known that traffic data, emergency transmissions, etc. can be delivered via broadcast radio to users of radio devices. The radio signals sent in this fashion are equipped by the transmitter with an identifier, and are recognized by the radio devices. In the specific case of an emergency transmission, however, there is no guarantee that the person being sought is indeed receiving the message.
German Patent Application No. 41 18 970 describes an automobile radio and a method for receiving messages, the messages, for example, consisting of special data such as radio traffic messages, which are transmitted as part of a broadcast radio program, and are recorded by way of a recorder device of the automobile radio. For control purposes, i.e., in order to activate and deactivate the recorder device, a signal tone transmitted as part of the broadcast radio program at the beginning and end of a special message is analyzed.
SUMMARY
The method according to the present invention, has the advantage that the message is stored in a memory, and operation of the device is interrupted until the time at which the user acknowledges receipt of the message.
This has the advantage of ensuring that an emergency call has a higher probability of reaching the person being sought. Because of the necessity of acknowledging receipt of the information, the information is forwarded to the user in all cases, even if he or she is not currently in the vehicle.
According to one embodiment of the present invention, the message is transmitted via broadcast radio.
According to the present invention, an improvement is achievable if a message directed to a radio receiver equipped with an identifier can be passed on and accepted. It is particularly advantageous if the message received by way of the radio receiver is supplemented with a spoken message which was sent via broadcast radio. Broadcast radio data are thereby combined in simple fashion with data that are received via the direct radio connection.
A digital radio receiver can advantageously be used in this context. For example, according to one embodiment of the present invention the radio receiver has an identifier corresponding to the vehicle license plate number.
It is further advantageous if the entire message is transmitted via the radio receiver to the device in the vehicle. A further advantage consists in displaying the message on a display device, or playing the message through a voice output.
According to one embodiment of the present invention, the presence of a message is indicated by an audio sequence or by a luminous indicator. Confirmation of receipt of the message can be accomplished by using an input key or also speaking a voice command into a microphone which is particularly advantageous.
According to one embodiment of the present invention, the data which are received via the radio receiver can be supplemented by referencing this data against data on a storage device such as a CD (compact disk) For this purpose, the address and the person being sought can be associated with a known telephone number stored on the storage device which may contain, for example, names and addresses.
According to one embodiment of the present invention, an electrical device such as an automobile radio device, has the advantage that it can interrupt audio reproduction by way of a switching mechanism, and that confirmation of receipt of the message is also provide.
It is furthermore advantageous that the device can be addressed in direct and personalized fashion via an additional radio receiver. According to one embodiment of the present invention, the automobile radio device advantageously may include an additional radio receiver.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a flowchart of steps for the transmission of a message to a person being sought according to one embodiment of the present invention.
FIG. 2 is a block diagram of an automobile radio device according to one embodiment of the present invention.
DETAILED DESCRIPTION
The present invention proposes an expanded functionality of existing receiving systems, such as an automobile radio device or a navigation system in a motor vehicle. FIG. 1 is a flowchart of steps for the transmission of a message to a person being sought according to one embodiment of the present invention. In Step 20 , the need to convey a message is ascertained. According to one embodiment of the present invention, when a person is being sought, the request for a search is transmitted by telephone at the ADAC central office Step 21 . In Step 22 , the search message is forwarded via a suitable transmission system and a signal is sent out to the additional receiver of the automobile radio device that is being used by the person being sought using the indentifier for that radio device. In Step 23 , the radio device used by the persons being sought records both the directly transmitted radio signals and the voice signal received via the radio.
According to one embodiment of the present invention, the identifier of the automobile radio device 15 , for example, a manufacturer's serial number or the motor vehicle license plate number. According to one embodiment of the present invention, upon receipt of a message, operation of the automobile radio device is interrupted by a suitable circuit. According to an alternative embodiment the motor vehicle itself is rendered in a deactivated state by way of the known electronic drive lock. In step 24 , the user can confirm receipt of the message and thereby cancel the operating inhibition on his or her device. The return message can then be sent directly by the person being sought 25 . According to one embodiment of the present invention, in addition to the broadcast radio text of the emergency transmission, the relevant telephone number is also forwarded directly to the device of the person being sought. If the broadcast radio receiver possesses a so-called Traffic Information Memory (TIM) function, the broadcast radio messages are stored in a special memory, and can then be retrieved. If the user does not have a device of this kind available, it is often sufficient simply to have the calling number transmitted.
According to one embodiment of the present invention, the spoken broadcast radio message interrupts operation of the device.
According to one embodiment of the present invention, a received telephone number is compared with personal and address data using a mass memory. All that is needed for this functionality is a CD player, in the trunk of the vehicle, which contains a CD on which all addresses, names, and telephone numbers are stored. By comparing the transmitted telephone number with the data on the CD, it is easy to determine the address of the person to be contacted.
FIG. 2 is a block diagram of an automobile radio device according to the present invention. Broadcast radio signals 9 are accepted and received by receiver 1 . The signals are transmitted via switch 7 to the normal voice output via loudspeaker 6 . If the receiver has the Traffic Information Memory (TIM) function, the messages, characterized by an audio sequence, are sensed by a voice module 2 and are stored by analysis unit 13 in a special memory 3 . These data are then always available upon request. The device according to the present invention possesses, in addition to broadcast radio reception section 1 , a receiver for radio signals 11 . If additional messages are received via receiver 11 , analysis unit 13 recognizes this fact and temporarily stores the information, again in memory 3 . Switch 7 or 8 is simultaneously actuated so that normal operation of the broadcast radio device is interrupted. Not until the user acknowledges the message via a key 4 is the message reproduced from memory 3 via the display or, selectably, also via the loudspeaker. Confirmation of the message can also be accomplished via a microphone 12 and voice module 2 . If only a telephone number were to be transmitted via the direct radio connection, it is also stored in memory 3 . Analysis unit 13 can then, by way of CD player 14 , perform a data comparison with a telephone directory. | A method and system for receiving messages with a receiver in a motor vehicle, wherein receipt of the message interrupts audio reproduction by the device, and receipt must be confirmed by the user. The device may include an interrupt feature for interrupting audio reproduction and for confirming receipt of a message. | 7 |
FIELD OF THE INVENTION
[0001] The present invention relates to a method of communication between a transmitter and a receiver based on frames and communication node.
BACKGROUND OF THE INVENTION
[0002] The Mobile Industry Processor Interface alliance MIPI has defined a standard for chip-to-chip networks based on high-speed serial links, i.e. the Unified Protocol UniPro (www.mipi.org). The Unified Protocol UniPro relates to a general purpose protocol dealing with high-speed interconnect issues, e.g. like error handling, flow control, routing and arbitration.
[0003] The Unified Protocol UniPro may be used as a communication protocol for a digital link e. g. between the radio frequency RF chip and baseband BB chip in electronic devices with a two-chip modem solution. Such a two-chip solution is preferably used in mobile devices. The modem solution may include 802.11 modems WiFi, video on mobile TVoM or WiMAX protocols.
[0004] Within the unified protocol UniPro, error handling capabilities must be provided as for example mobile devices like mobile phones often operate in a noisy environment where various kinds of errors may occur. Such errors may include bit errors (one of the transmitted bits is inverted), burst errors (a sequence of bits is received erroneously), stuck-at errors (a sequence of bits with the same value is received), and synchronization errors (one or more bits is deleted or duplicated leading to a loss of the symbol boundary).
[0005] The error rates that may occur can be relatively high, e.g. the bit error rate of the MIPI D-Phy layer is expected to be 10 −12 or in other words one bit can be erroneous in every 15 to 20 minutes. Therefore, a mechanism to recover from errors must be provided to enable a reliable communication.
[0006] In UniPro, the error handling is performed within the data link layer L2. The transmission in this layer is performed based on transmission units or frames. FIG. 1 shows a basic representation of the data frame structure according to the unified protocol UniPro. This frame comprises reserved bits RB, and a frame sequence number FSN.
[0007] In every UniPro frame, a 16-bit CRC cyclic redundancy check is provided. These CRC bits are added by the transmitter of the frame. At the receiver's side, the CRC is calculated and verified to determine whether any errors have occurred during the transmission of the frame. If the CRC received by the in the frame and computed by the receiver are the same, no errors have been detected, i.e. the transmitted and received frame correspond to each other. Furthermore, a 5-bit sequence number FSN is introduced into the frame to identify the packets. If a TC frame is transmitted, a copy of the transmitted frame is stored in a replay buffer at the transmitter's end.
[0008] The receiver will acknowledge a correct packet receipt to the transmitter by forwarding the sequence number of the frame in an Acknowledgement and Flow Control frame AFC. The structure of such an Acknowledgement and Flow Control Frame is depicted in FIG. 2 . It should be noted that also multiple frames can be acknowledged at the same time if a sequence number is considered to acknowledge all frames having a sequence number equal to or less than the currently transmitted sequence number. If the transmitter has received an Acknowledgement and Flow Control Frame AFC, it can remove all frames which are being acknowledged by the AFC frame from its replay buffer.
[0009] However, if the receiver detects e.g., by means of the CRC that the received frame does not correspond to the transmitted frame, it can forward a Negative Acknowledgement Frame NAC. FIG. 3 shows a schematic representation of the structure of a Negative Acknowledgement frame NAC. The Negative Acknowledgement Frame NAC may acknowledge all correctly received frames but may signal that an error has been detected. In such a case, the receiver can remove all acknowledged frames from its replay buffer and may retransmit all unacknowledged frames.
[0010] However, it may also happen that the AFC or the NAC frames are not correctly received due to errors during the transmission over the link. It should be noted that these frames are not protected by the sequence numbers. Therefore, a mechanism must be provided such that the information with respect to the sequence number is retrieved at the data-frame transmitter side. If a frame re-transmission is initiated, the AFC frames are transmitted to update any potential miscommunication in the past. Thereafter, if no positive or negative acknowledgement has been received for a long time, a replay timer triggers a retransmission and assumes that an error has occurred in the data frame or in the transmission of the AFC frame.
[0011] Furthermore, it should be noted that the Unified Protocol UniPro allows a retransmission at almost any time, e.g. in-between frames, in the middle of a data frame, possibly pre-empting a lower-priority frame. However, a retransmission is not permitted in the middle of an AFC or NAC frame. Moreover, the Unified Protocol UniPro does not provide a mechanism in the receiver to detect a re-transmission.
[0012] In other words, a re-transmission can start at any given time and cannot be detected by the receiver, for example the receiver cannot know if it is part of a pre-emption or a frame retransmission when a frame starts. Therefore, the receiver cannot check if a correct symbol sequence is received which may lead to a delayed error detection. Furthermore, the verification of a correctness of the receiver's implementation is very difficult as transmission errors are captured only after numerous state transitions which may lead to the need for numerous and long stimulations.
SUMMARY OF THE INVENTION
[0013] It is therefore an object of the invention to provide a method of communication with an improved error handling capability.
[0014] This object is solved by a method of communication between a transmitter and a receiver according to claim 1 and a communication node according to claim 15 and 16 .
[0015] Therefore, a method of communicating between a transmitter and a receiver based on frames is provided. An error detection code is added to each frame to be transmitted by the transmitter. The frames to be transmitted by the transmitter are transmitted and the transmitted frames are received by the receiver. An error detection code is re-computed based on the received frames by the receiver. At least one frame which has been correctly received based on a comparison of the error detection code of each frame with the re-computed error detection code of each received frame is acknowledged. An error indication frame is sent by the receiver when an error is detected based on the comparison result. If a retransmission condition is detected by the transmitter by receiving an error indication frame from the receiver or if no acknowledgement frame was received by the transmitter from the receiver in a predetermined time interval, the currently transmitted frame is aborted and the transmitter inserts a trailer.
[0016] Accordingly, the possibilities for a re-transmission are restricted such that the method of communicating according to the present invention becomes easier.
[0017] According to an aspect of the invention, erroneous error detection code is inserted into a trailer of a frame by the transmitter in order to indicate a frame abortion. Therefore, the receiver can easily detect a frame abortion.
[0018] According to a further aspect of the invention, the transmitter inserts a special code into a trailer of a frame in order to indicate a frame abortion. Here, also the detection of a frame abortion by the receiver is facilitated.
[0019] According to a preferred aspect of the invention, the communication is based on a unified protocol (UniPro).
[0020] According to a further aspect of the invention, the special code for frame abortion used by the transmitter is an unused escape value according to the Unified Protocol. Hence, a value already present in the Unified Protocol can be used to indicate a frame abortion.
[0021] According to a further aspect of the invention, the special code used for frame abortion by the transmitter is an unused value of a control ID according to the unified protocol.
[0022] According to a further aspect of the invention, the currently received frame is discarded by the receiver when the receiver detects an error or an aborted frame.
[0023] According to a further aspect of the invention, each frame comprises a sequence number. The sequence number is used by the receiver to acknowledge that at least one frame is correctly received. Accordingly, the receiver can acknowledge that it has received a plurality of frames by merely using the sequence number of the last acknowledge frame. The transmitter will then know that all previously transmitted frames are correctly received.
[0024] The invention also relates to a method of communicating between a transmitter and a receiver based on frames. An error detection code is added to each frame to be transmitted to the transmitter. The frames are transmitted and received by the receiver. An error detection code is re-computed by the receiver based on the received frames. At least one frame is acknowledged which has been correctly received based on a comparison of the error detection code of each frame with the re-computed error detection frame of each received frame. An error indicating frame is sent by the receiver when an error is detected based on the comparison results. If a re-transmission condition is detected by the transmitter, for example by receiving an error indicating frame from the receiver or if no acknowledgement frame from the receiver was received by the transmitter in a predetermined time interval, the start of a retransmission of frames is indicated using a retransmission indicator. Unacknowledged frames are retransmitted.
[0025] The invention also relates to a communication node comprising a transmitting unit for transmitting frames, for inserting an error detection code to each frame. The inserting unit furthermore is adapted to detect a retransmission condition if an error indication frame has been received from a further communication node or if no acknowledgement frame has been received by the further communication node. If the retransmission condition is detected, a trailer is inserted to indicate a frame abortion and the unacknowledged frames are retransmitted.
[0026] The invention also relates to a communication node comprising a receiving unit. The receiving unit receives transmitted frames and computes an error detection code based on the received frames. The error detection code in the received frames is compared to the re-computed error detection code. If no error is detected, at least one frame is acknowledged. If an error is detected, an error indicating frame is sent.
[0027] An electronic device according to the invention may also be based on a communication of the communication nodes such that it may comprise an above transmitting unit and an above receiving unit.
[0028] The invention relates to the idea to restrict the possibilities where a re-transmission can start and/or to explicitly notify the receiver if a retransmission has started.
[0029] Further aspects of the invention are subject of the dependent claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] Advantages and embodiments of the invention will now be described in more detail with reference to the figures.
[0031] FIG. 1 shows a schematic representation of a frame structure in a Unified Protocol UniPro,
[0032] FIG. 2 shows a schematic representation of a AFC frame structure in a Unified Protocol UniPro according to the prior art,
[0033] FIG. 3 shows a basic representation of the NAC frame structure in a Unified Protocol UniPro according to the prior art,
[0034] FIG. 4 shows a basic representation of a AFC frame according to the first embodiment,
[0035] FIG. 5 shows a basic representation of a message sequence chart according to a second embodiment,
[0036] FIG. 6 shows a basis representation of a message sequence chart according to a third embodiment,
[0037] FIG. 7 shows a representation of a state machine of a receiver according to a fourth embodiment,
[0038] FIG. 8 shows a representation of a state machine for a transmitter according to a fifth embodiment, and
[0039] FIG. 9 shows a basic representation of a state machine for a transmitter according to a sixth embodiment.
DETAILED DESCRIPTION OF EMBODIMENTS
[0040] FIG. 4 shows a schematic representation of an AFC frame according to a first embodiment. The communication according to the first embodiment is based on the unified protocol UniPro designed by the Mobile Industry Processor Interface Alliance MIPI. The frame structure according to the first embodiment will enable an explicit notification of the receiver when a retransmission of data starts. The frame comprises a frame sequence number FSN, reserved bits RB and credit values CV.
[0041] To allow an early frame termination and thereby a re-transmission of a data frame, the receiver may be explicitly notified that a re-transmission is started or will be started. Such a notification may be performed by means of special line states, escape characters or bits in any existing frames.
[0042] In the Unified Protocol UniPro, AFC frames will be transmitted before a re-transmission is initiated. Accordingly, a bit in the AFC frame can be used to distinguish an AFC frame at the beginning of a re-transmission. Accordingly, the receiver only has to check for this bit in the AFC to determine whether a re-transmission is initiated. A retransmission bit RB can be used to distinguish the AFC frames. Such a retransmission bit RB may be mapped to one of the reserved bits of the AFC frame as depicted in FIG. 4 .
[0043] In addition or alternatively, a second escape character ESC_DL 2 or a new unused value of the CTRL_ID may be used for retransmission.
[0044] According to a second embodiment of the invention, the points of possibilities where a re-transmission can start can be restricted to the situation when no frames are transmitted, i.e. a re-transmission may start in between two frames. On the other hand, such a solution is disadvantageous as a retransmission of data has to wait until the currently transmitted frame has been transmitted, i.e. the retransmission has to wait until the frame transmission ends.
[0045] To solve this problem, a data frame termination can be forced if a retransmission of data needs to be started.
[0046] The frame transmission can be initiated by sending an end-of-frame EOF symbol immediately without having to wait for an end-of-frame condition. Thereafter, an incorrect CRC is transmitted. This is performed to ensure that the artificially terminated data frame is discarded as the re-computed CRC of the received frame will not correspond to the CRC of the transmitter. The terminated frame may by completely discarded or may be at least partly buffered or stored until the rest of the frame is transmitted again or until a retransmission of the frame is initiated.
[0047] Alternatively, instead of transmitting an end-of-frame symbol EoF followed by an incorrect CRC, this abrupt termination of a frame can be indicated using a second escape character (ESC_DL 2 ), or using one of the reserved values of the CTRL_ID. In both cases, a valid CRC will follow, but the receiver will know that the received data frame is only partial, and it will be discarded. It should be noted that the second escape character ESC_DL 2 can be the same or different from the previously mentioned ESC_DL 2 used for AFC.
[0048] FIG. 5 shows a basic representation of a message sequence chart according to a second embodiment. Here, a message exchange between a first and second node N 1 , N 2 is depicted. Each node N 1 , N 2 comprises a transmitter Tx and a receiver Rx. A first data frame DF 1 having start of frame SoF symbol, CPortID and DeviceID symbol, several data symbols data, end of frame symbol EoF and a CRC symbol is transmitted from the first node N 1 to the second node N 2 . As the frame is correctly received, a correct CRC CCRC is calculated and an AFC together with a CRC symbol is transmitted from the second node N 2 to the first node N 1 . In the meantime, a second data frame DF 2 is transmitted from the first node N 1 to the second node N 2 . However, an erroneous CRC ECRC is calculated by the second node N 2 and the second node N 2 transmits a NAC together with a CRC to the first node N 1 . When the NAC from the second node N 2 is received by the first node N 1 , the transmission of the third data frame is aborted F 1 , for example by intentionally introducing an erroneous CRC ECRC. When the second node N 2 receives the erroneous CRC, the third frame DF 3 is discarded. The first node N 1 will flag an AFC and will start the replay sequence by sending the frame AFC 1 . Therefore, the second data frame DF 2 will be re-transmitted from the first node N 1 to the second node N 2 . If the second data frame DF 2 is correctly received and a correct CRC is calculated, the second node N 2 may forward an AFC.
[0049] FIG. 6 shows a basis representation of a message sequence chart according to a third embodiment. The message sequence chart according to the third embodiment substantially corresponds to the message sequence chart according to the second embodiment. Therefore, a first data frame DF 1 is transmitted by a first node N 1 and is correctly received by a second node N 2 which then forwards an AFC to the first node N 1 . However, if the second data frame DF 2 is not correctly received by the second node N 2 , the second node N 2 will forward a NAC to the first node N 1 . If the first node N 1 receives a NAC, the frame which is currently being transmitted is aborted F 1 , abortion which is flagged to N 2 using an e.g., second End Of Frame symbol EOF 2 . The retransmission sequence is started by an AFC frame, flagged as the beginning of a frame replay. Here, the second node N 2 may receive a correct CRC CCRC but, as it receives a second end of frame symbol EoF 2 , the second node N 2 will discard the currently received frame.
[0050] FIG. 7 shows a representation of a state machine of a receiver according to a fourth embodiment. In a first step R 1 , the receiver will wait for a frame. If a correct data frame is received in step R 6 , the frame is delivered in step R 2 . If an error is detected (Step R 9 ), an NAC is sent in step R 3 . If a NAC frame is received, some of the transmitted frames may be acknowledged (Step R 5 ), and a retransmission starts with the first unacknowledged frame in step R 10 . If in step R 7 a correct AFC frame is received, credits in the receiver and the sequence number will also be updated in step R 4 .
[0051] FIG. 8 shows a basic representation of a state machine of a transmitter according to a fifth embodiment. In step S 1 , the transmitter TX is in the idle state when it is outside a frame and in the data frame state or transmission state (step S 11 ) when it is inside a data frame transmission. When the transmitter is in the idle state, it can send frames with the following priority, namely NAC (step S 2 ), retransmission (step S 5 ), forwarding an AFC (step S 3 ) and it may send a data frame (step S 4 ). In step S 3 , an AFC may be send but no retransmission is initiated and no NAC is sent. In step S 4 , the data frames DF are sent but no AFC is sent, no retransmission is initiated and no NAC are sent. In step S 5 , a retransmission is initiated and no NAC is sent. If in step S 2 a NAC is to be sent, the NAC will be transmitted in step S 6 and the flow will return to step S 1 . If in step S 3 an AFC is to be sent, the AFC will be transmitted in step S 7 wherein a replay flag will not be set. If in step S 4 a data frame is to be sent, a start of frame SoF symbol is transmitted in step S 8 . If in step S 5 a retransmission is initiated, in step S 9 an AFC is transmitted wherein the replay flag is set. Then the flow continues to step S 10 where the sequence number of the next frame to the last acknowledged frame is set. Accordingly, in step S 9 and S 10 , an AFC will indicate a replay or retransmission of a data frame. It should be noted that a AFC and an NAC frame are not pre-emptable, accordingly they are depicted as an atomic block. However, data frames may be pre-empted by NAC or AFC frames. In the case of a link using multiple traffic classes, a data frame may also be preempted by a data frame with a higher priority. After a NAC or AFC frame, a data frame will continue with a COF symbol.
[0052] If a retransmission of a frame is required in the middle of the frame transmission, the frame will be aborted and a retransmission will start. The retransmission may also carry a retransmission indication, namely the replay flag.
[0053] If the transmitter is in the data frame state (step S 11 ) and if a NAC is to be sent in step S 12 , the flow will continue to step S 16 where a NAC is transmitted. Thereafter, the flow will continue to step S 20 where a COF symbol is transmitted.
[0054] In step S 13 , an AFC is to be sent (no NAC is sent and no retransmission is initiated) the AFC is transmitted with a replay flag which is not set. Thereafter, the flow will continue to step S 21 and a COF symbol is transmitted.
[0055] If in step S 14 a data frame is to be transmitted (no AFC and no NAC is transmitted and no retransmission is initiated), the flow will continue to step S 18 where it is determined whether the end of the packet has been reached. If the end of the packet is not present, a data symbol will be transmitted in step S 22 . However, if the end of packet has been reached, an EOF end of frame symbol is transmitted in step S 23 and the flow will continue to step S 27 where a CRC is transmitted.
[0056] If in step S 15 a retransmission is initiated and no NAC is sent, the flow may continue to step S 19 where an EOF end of frame symbol is transmitted. The flow will then continue to step S 24 where an erroneous CRC is transmitted. Accordingly, the steps S 19 and S 24 will be used to abort the frame. After step S 24 , the flow will continue to step S 25 where an AFC is transmitted wherein the replay flag is set. After step S 25 the flow will continue to step S 26 where the sequence number of the next frame is set to the last acknowledged frame. Accordingly, in the steps S 25 and S 26 , the AFC is used to indicate a replay.
[0057] FIG. 9 shows a basic representation of a state machine of a transmitter according to a sixth embodiment. The state machine according to the sixth embodiment substantially corresponds to the state machine according to the fifth embodiment, merely the steps S 19 , S 24 , S 25 and S 26 are replaced by the steps S 30 -S 33 . Accordingly, if in step S 15 a retransmission is initiated, the flow will continue to step S 30 where a second EOF 2 end of frame symbol is transmitted. The flow will then continue to step S 31 where a CRC is transmitted. Accordingly, the steps S 30 and S 31 will be used to abort the frame. After step S 31 , the flow will continue to step S 32 (which substantially corresponds to the step S 25 in FIG. 8 ). Thereafter, the flow will continue to step S 33 which substantially corresponds to the step S 26 in FIG. 8 .
[0058] It should be noted that the above-mentioned embodiments illustrate rather than limit the invention, and that those skilled in the art will be able to design many alternative embodiments without departing from the scope of the appended claims. In the claims, any reference signs placed between parentheses shall not be construed as limiting the claim. The word “comprising” does not exclude the presence of elements or steps other than those listed in a claim. The word “a” or “an” preceding an element does not exclude the presence of a plurality of such elements. In the device claim enumerating several means, several of these means can be embodied by one and the same item of hardware. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage.
[0059] Furthermore, any reference signs in the claims shall not be constrained as limiting the scope of the claims. | A method of communicating between a transmitter and a receiver based on frames is provided. An error detection code is added to each frame to be transmitted by the transmitter. The frames to be transmitted by the transmitter are transmitted and the transmitted frames are received by the receiver. An error detection code is re-computed based on the received frames by the receiver. At least one frame which has been correctly received based on a comparison of the error detection code of each frame with the re-computed error detection code of each received frame is acknowledged. An error indication frame is sent by the receiver when an error is detected based on the comparison result. If a retransmission condition is detected by the transmitter by receiving an error indication frame from the receiver or if no acknowledgement frame was received by the transmitter from the receiver in a predetermined time interval, the currently transmitted frame is aborted and the transmitter inserts a trailer. As a further possibility instead of inserting a trailer, the start of retransmission can be indicated by using a retransmission indicator. | 7 |
The present invention relates generally to diffusion barriers and more particularly to a titanium nitride diffusion barrier which is useful in non-silicon technologies. Non-silicon technologies include technologies based on compound semiconductors, for example, gallium arsenide (GaAs) or indium phosphide (InP). The invention has particular application in the field of high power semiconductor laser diodes.
Diffusion barriers are commonly used in semiconductor devices for purposes of preventing device degradation as a result of the tendencies of certain types of materials to diffuse into or react with adjacent material layers. As an example, in a semiconductor structure including a gold layer immediately adjacent to a gallium arsenide layer or separated from the gallium arsenide layer by an adhesion layer, the gold has a tendency to diffuse into the layer of gallium arsenide while the gallium arsenide has a tendency to diffuse into the gold layer. In a gallium arsenide laser diode including this layer structure, diffusion of the gold into the gallium arsenide can cause significant degradation of the laser diode in a relatively short time frame. At the same time, it should be appreciated that simply avoiding the use of materials such as gold is problematic since gold is commonly used as the outermost layer in metallized ohmic contact structures of optoelectronic devices (i.e., structures for use in making external electrical connections with the overall device). The usefulness of the outermost gold layer resides in its ability to form a suitable adhesion surface for the attachment of bonding wires. Underlying layers of the ohmic contact structure (including most diffusion barrier layers) do not exhibit adhesion characteristics which are compatible with the attachment of bonding wires. Gold also provides a low resistivity material for integrating multiple devices on a single chip.
In the past, platinum and chromium have served as a diffusion barrier within contact structures in many compound semiconductor device technologies. Unfortunately, however, it has been discovered that, for example, platinum diffusion barrier layers exhibit certain problems, as will be seen at an appropriate point below.
It should be mentioned that current semiconductor devices such as laser diodes are encountering power limitations which may be related to the stability of the ohmic contact and specifically in a direct way to the use of the diffusion barrier layers. In particular, as manufacturers push devices to ever higher power and with that higher current levels, the devices operate at higher temperatures. It has been found that platinum diffusion barrier layers become somewhat inefficient in resisting the phenomenon of diffusion at the anticipated operating temperatures of future devices. Moreover, platinum is a very expensive material. Thus, avoiding the use of platinum can lead to a decrease in material and production costs.
As will be seen hereinafter, the present invention provides a highly effective diffusion barrier layer for use in non-silicon technologies that does not exhibit the problems which have been discovered with regard to the use of platinum diffusion barrier layers. As another advantage, the diffusion barrier layer of the present invention provides an effective barrier at temperatures which significantly exceed effective maximum temperatures that are associated with prior art platinum diffusion barrier layers.
SUMMARY OF THE INVENTION
As will be described in more detail hereinafter, there is disclosed herein a titanium nitride diffusion barrier layer and associated method for use in non-silicon semiconductor technologies. In one aspect of the invention, a semiconductor device includes a non-silicon active surface. The improvement comprises a contact serving to form an external electrical connection to the non-silicon active surface in which the contact includes at least one layer consisting essentially of titanium nitride.
In another aspect of the invention, a semiconductor ridge waveguide laser is disclosed which includes a semiconductor substrate and an active layer disposed on the substrate. A cladding layer is supported partially on the substrate and partially on the active layer. The cladding layer includes a ridge portion disposed in a confronting relationship with the active region. A metallization structure substantially covers the ridge portion and includes at least one layer consisting essentially of titanium nitride.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention may be understood by reference to the following detailed description taken in conjunction with the drawings briefly described below.
FIG. 1 is a diagrammatic representation, in perspective, of a waveguide ridge laser diode incorporating the titanium nitride diffusion barrier of the present invention.
FIG. 2 is a diagrammatic elevational view illustrating one method of forming the diffusion barrier of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Attention is immediately directed to FIG. 1, which diagrammatically illustrates a waveguide ridge laser diode, generally indicated by the reference numeral 10 , manufactured in accordance with the present invention. It should be appreciated that laser diode 10 represents only a single category of device which benefits from the advantages of the present invention. Therefore, it is to be understood that laser diode 10 is used for exemplary purposes only and that the present invention is contemplated for use in any non-silicon technology either currently in use or to be developed which requires a stable diffusion barrier layer, as will be described in further detail at an appropriate point below.
Continuing to refer to FIG. 1, laser diode 10 includes a substrate 12 which may be formed for example from gallium arsenide (GaAs) or indium phosphide (InP). A layered structure 14 is grown on the substrate in a manner which is known in the art. Structure 14 includes an n-type cladding layer 16 , an active region 18 and a p-type cladding layer 20 . Materials from which the cladding layers and active region may be formed include, but are not limited to GaAs, AlGaAs, InGaAs and other ternary or quaternary III-V materials. A ridge waveguide 22 is formed in the upper cladding layer 20 in a known way, for example, by etching or by other suitable methods. The upper surface of ridge waveguide 22 usually comprises a heavily doped contact layer 23 which helps to facilitate low resistance contact formation. A suitable dielectric material 24 such as, for example, silicon dioxide (SiO 2 ), is applied in a known way such that only the uppermost surface of ridge 22 is exposed for electrical contacting purposes. During application of operating voltages and currents to the laser diode, the configuration of ridge 22 cooperates with the injected current to cause light to be emitted from an area 26 along the edge of active region 18 in the direction indicated by an arrow 28 .
Still referring to FIG. 1, an ohmic contact metallization structure 30 (sometimes referred to as a p-contact in the instant application) is applied to the p-type cladding layer 20 . Ohmic contact structure 30 is formed on ridge layer 20 in a way which covers ridge waveguide 22 . Ohmic contact structure 30 includes a layer of titanium 32 which is supported (deposited) in part directly on the uppermost surface of ridge 22 and on the uppermost surface of dielectric 24 . Titanium (hereinafter Ti) layer 32 serves as an adhesion layer which effectively bonds with ridge 22 in a known way and may be formed for example by evaporation or sputter deposition. Thereafter, in accordance with the present invention, a highly advantageous titanium nitride (hereinafter TiN) layer 34 is formed on Ti layer 32 . TiN layer 34 includes a thickness of approximately 100 nm such that the layer serves as an effective diffusion barrier. Further descriptions of the characteristics of TiN layer 34 will be provided below. It should be noted that the present example considers an ohmic contact to a p-doped material. However, the present invention is equally applicable for use with Schottky contacts to n-doped materials, as will be further described. In both cases, the TiN prevents inter-diffusion of the metal and semiconductor materials, making the contact more reliable at elevated temperatures and/or under stress conditions.
Continuing with a description of ohmic contact 30 of the present invention, a gold layer 36 is disposed on TiN layer 34 . Gold layer 36 may be applied in any suitable manner such as, for example, by evaporation or sputter deposition. As described above, the purpose of outermost gold layer 36 is to provide a suitable binding surface for attaching bonding wires so as to allow for electrically connecting the device to the outside world.
Turning now to FIG. 2 and still considering the highly advantageous ohmic contact of the present invention, one suitable technique for applying TiN layer 34 has been found to be reactive sputtering. Accordingly, laser diode 10 is illustrated at an intermediate phase of manufacture in a confronting relationship with a reactive sputtering source 40 in an evacuable chamber 42 . At this stage of manufacture, it should be appreciated that laser diode 10 forms a single semiconductor die as part of an overall wafer 44 . Portions of adjacent laser diodes 10 a and 10 b are illustrated by dashed lines. A mixture of nitrogen and argon atmosphere having a pressure of, for example, 1 millibar is present in chamber 42 . The sputtering source includes a titanium target (not shown). In operation, the target is bombarded with argon and nitrogen ions which “knock” titanium off of the target. Depending on various factors including, for example, the nitrogen pressure in chamber 42 , gas flow, and sputter power, a percentage of the titanium atoms react with the nitrogen gas such that a beam 46 including a mixture of titanium atoms and titanium nitride molecules is emitted from source 40 and deposited onto laser diode 10 so as to form TiN layer 34 . In the present example, TiN layer 34 is illustrated as being deposited across the entire surface of wafer 44 . Thereafter, gold layer 36 may be deposited (not shown) across the entire wafer surface.
Still referring to FIG. 2, any suitable method either known or to be developed may be used for removing that portion of layer 34 which resides between laser diodes 10 and 10 a, as indicated by reference number 48 . For example, patterning of the p-contact 30 can be accomplished e.g. by a “lift-off” process. In this case, a photoresist (not shown) or other such suitable layer is applied to the wafer surface prior to formation of the ohmic contact layers. The photoresist is applied only in areas where the deposited layers are to be removed. After formation of the ohmic contact layers onto the surface of wafer 44 , the underlying photoresist is then dissolved using an appropriate solvent thus causing the deposited layers in, for example, area 48 to detach or lift-off.
It should be appreciated that process conditions during reactive sputtering deposition may be varied in any number of ways in order to adjust the nitrogen content of TiN layer 34 . In fact, anything from very low nitrogen content titanium to nitrogen saturated TiN may be achieved by reactive sputtering. One suitable nitrogen content, based on actual testing, has been found to be Ti:N=0.9:1.0. Other suitable methods may alternatively be used to form TiN layer 34 . For example, a sputtering source may be used in conjunction with a titanium nitride target (neither of which are shown). Plasma enhanced chemical vapor deposition PECVD (not shown) may also be used for depositing TiN.
Having described prior art platinum diffusion barrier layers and the way in which a contact is formed in accordance with the present invention, a discussion of the advantages of this contact will now be provided. Remarkably, it has been empirically discovered that the TiN diffusion barrier of the present invention provides efficient barrier layer on initial deposition and exhibits little, if any, degradation, even under significant temperature stress. Anneal tests and analysis of the TiN diffusion barrier of the present invention show stability at temperatures up to at least 460° C. Long term tempering tests (460° C. for 70 hours) show that the TiN provides an effective diffusion barrier in a non-silicon structure such as that of laser diode 10 (FIG. 1 ). For comparison, contacts with Pt barriers show significant degradation even under less stringent tempering conditions. These advantages may result since the layer is compressive as compared with the tensile stressed platinum layers which are typical of the prior art. Moreover, since the TiN layer is reactively sputtered, coverage even over irregular features is superior to coverage provided by prior art evaporated platinum layers. Improved coverage is particularly important with regard to covering device features such as, for example, ridge 22 of laser diode 10 (FIGS. 1 and 2 ). Contact resistance of ohmic contact 30 of the present invention has been shown to be at least as low as that obtained using prior art platinum barrier layers. While reactive sputtering is preferred for deposition of layer 34 , it is to be understood that any suitable method of forming this layer either currently available or to be developed is contemplated by the present invention such as, for example, PECVD.
It should be noted that the resistance of the ohmic contact of the present invention to high temperatures is a significant advantage in and by itself. As noted above, manufacturers are continually striving to increase the light output power of laser diodes. As with most device types, producing a higher light output power necessitates a higher electrical input power, resulting in higher device operating temperatures due to the device's inherent conversion inefficiency. It is submitted that the temperature resistant ohmic contact of the present invention fills an important need with regard to the upcoming generations of higher power semiconductor devices due to the temperature limitations imposed by the platinum diffusion barrier layer of the prior art.
While the diffusion barrier layer of the present invention is preferred to be formed from titanium nitride, it is to be understood that other materials may also be found to be useful. For example, one alternative material is titanium tungsten (TiW). It is submitted that the latter is not as effective a diffusion barrier as TiN, however, by making appropriate variations in stoichiometry and layer thickness, a suitable diffusion barrier may nevertheless be formed in accordance with the teachings herein.
It is recognized that TiN layers are utilized in silicon based fabrication technologies of the prior art. However, the TiN layer is often deposited using PECVD which must be performed at high temperatures. Additionally, the TiN is typically used as a barrier between silicon or silicon dioxide and an overall metallization layer such as aluminum. Material properties of aluminum and silicon are very dissimilar to those of materials which are utilized by the present invention such as GaAs and gold. Moreover, it is recognized that high temperature PECVD deposition is not workable within certain aspects of the present invention due, at least in part, to temperature requirements which would destroy an optoelectronic device such as, for example, laser diode 10 . A high temperature process also excludes the use of a lift-off process that requires the presence of photoresist, on the wafer, during metal deposition. Therefore, a “cold” process such as reactive sputtering must be employed. Remarkably, once this technique is used, it has been discovered that the resulting TiN layer serves as an effective diffusion barrier for GaAs based materials. Moreover, the present invention contemplates the use of “cold” deposited TiN layers in other non-silicon (compound semiconductor) technologies such as, for example Heterojunction Bipolar Transitors (HBT's) or any other electrical or optical devices that require a temperature stable contact. The TiN barrier could equally well be applied in the formation of a temperature stable Schottky contact to n-doped non-silicon semiconductor materials for such applications as the GaAs MESFET (metal-semiconductor field effect transistor) or GaAs based or InP based HEMTs (high electron mobility transistors).
Since the diffusion barrier layer disclosed herein may be provided in a variety of different non-silicon technologies and produced using a number of different methods, it should be understood that the present invention may be embodied in many other specific forms without departing from the spirit or scope of the invention. Therefore, the present examples and methods are to be considered as illustrative and not restrictive, and the invention is not to be limited to the details given herein, but may be modified within the scope of the appended claims. | As will be described in more detail hereinafter, there is disclosed herein a titanium nitride diffusion barrier layer and associated method for use in non-silicon semiconductor technologies. In one aspect of the invention, a semiconductor device includes a non-silicon active surface. The improvement comprises an ohmic contact serving to form an external electrical connection to the non-silicon active surface in which the ohmic contact includes at least one layer consisting essentially of titanium nitride. In another aspect of the invention, a semiconductor ridge waveguide laser is disclosed which includes a semiconductor substrate and an active layer disposed on the substrate. A cladding layer is supported partially on the substrate and partially on the active layer. The cladding layer includes a ridge portion disposed in a confronting relationship with the active region. A metallization structure substantially covers the ridge portion and includes at least one layer consisting essentially of titanium nitride. | 8 |
BACKGROUND OF THE INVENTION
The present invention relates to a device for the distribution of weft threads and also to a series shed loom having a weft thread distribution device.
Published European application EP-A-433 216 discloses a device for the distribution of weft threads, which comprises a fixed part and a part rotating with the rotor, which are disposed axially and at a distance from one another so that there is a gap between the opposite faces of the parts. The fixed part is retained by energy storing devices in an operating position in order to perform, with low acceleration forces, the distribution of the weft threads and the transfer to the different weft ducts of a rotor.
This device has the great disadvantage that the removal of faults, e.g. weft thread breakages, clogging of the ducts by weft threads, is only possible with considerable expense and the gap between the parts cannot be adjusted.
SUMMARY OF THE INVENTION
An object of the present invention is to create a device for the distribution of weft threads which does not have the said disadvantage above.
This object is achieved in accordance with the invention an operating mechanism (3) for axially displacing the fixed part (8) in relation to the rotating part (7) against a spring force to thereby uncover the transfer and connecting ducts (10, 11) for the weft supply.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a section of an embodiment of a device according to the invention in the operating position,
FIG. 2 shows the device of FIG. 1 in the position for the removal of faults and/or cleaning,
FIG. 3 is a fragmentary view taken along line 3--3 of FIG. 1 and shows an adjustable support unit for the second part, and
FIG. 4 is an end view of the ring which mounts the adjustable support structure shown in greater detail in FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1 and 2 show a portion of a series shed loom having a shaft 1, a rotor 2 and a device for the distribution of weft threads.
The device comprises a substantially tubular housing part 5 having a flange 6, which is attached to the rotor 2 and rotates with the rotor 2.
The device contains an annular first part 7, which is attached to the flange and rotates with the rotor 2, and an annular second part 8, which is fixed with respect to the first part 7, which are disposed coaxially and at a distance from one another so that there is a gap 9 between the front faces lying opposite one another in order to avoid friction therebetween. The device also includes an operating mechanism 3 for displacing or opening the second part 8 out of an operating position (FIG. 1) into a position for the removal of faults (FIG. 2).
To perform the distribution of the weft threads, the opposite front sides of the first and second parts 7, 8 include channel-shaped recesses 10, 11 which are open to the front side in the form of arcs of circles. The recesses in the first part 7 are connected via a duct 12 to the rotor 2, while the recesses 10 in the second part 8 are connected via ducts (not represented) with thread supply devices (not represented either).
The second part 8 is pivoted on the operating mechanism 3, which is disposed in an axially displaceable manner in relation to the rotor 2. For this purpose the second part 8 has a projection 13 into which a rolling bearing 14 is inserted. The rolling bearing 14 is further disposed on a ring bearing 15 and retained thereon by means of a ring 16.
On its end opposite the flange 6, the housing part 5 has a cylindrical projection 17. The ring bearing 15 is disposed in an axially displaceable manner on this projection and is prevented from twisting by a wedge guide 18. This wedge guide 18 is at the same time used to guide operating device 3 with the second part 8 during tile axial displacement. In the ring bearing 15 are constructed six blind holes 19, which are equally spaced along a circular line. On the free end of the projection 17 is a clamping ring 20 which has a radially inwardly directed projection 21. The projection 21 of the clamping ring 20 abuts the front end of projection 17 and is secured by a pin 32, which is disposed in the clamping ring 20 and protrudes into a recess in the projection 17. The clamping ring 20 also includes blind holes 23 which are aligned with blind holes 19 in the ring bearing 15. Pressure springs 24 in blind holes 19, 23 retain the second part 8 connected to the ring bearing 15 in its operating position.
To displace the second part 8, the operating mechanism 3 comprises a piston arrangement having a housing part 25 and a piston 26. The housing part 25 is substantially a hollow cylinder with a first portion 27, which is bolted to the second part 8 and is mounted on the rolling bearing 14, and a second portion 28 in which the piston 26 is disposed so that it can move up and down.
The piston 26 has a hollow cylindrical portion having a sealing ring on the periphery and at one end a flange having a sealing ring on the periphery. The second portion 28 has two partial portions with different internal diameters, so that there is a shoulder in which an inlet duct 29 is constructed so that the sealing rings disposed at the hollow cylindrical section and at the flange tightly abut the inner faces of the partial portions and with the shoulder form an annular operating chamber, into which the inlet duct 29 opens.
As already mentioned, there is a gap 9 between the first and second parts 7, 8, if the latter assumes the operating position. To maintain and adjust this gap 9, the second part 8 is provided with three support units 30 which form a three-point support and abut a shoulder 31 on housing part 5. At the support point there is an insert member 32 made from hard metal.
As FIG. 3 shows, the support unit 30 consists of a supporting screw 33 and a ball 35, which is rotatably held at the free end of the supporting screw 33. The supporting screw 33 is screwed into a threaded bore (not represented) so that the ball 35 protrudes from the threaded bore. With the supporting screw 33 is associated an arrangement which includes two straining screws 34 and a slot 36, and which is located at the point on ring bearing 15 provided for the three-point support. The slot 36 penetrates the ring bearing 15 in the radial direction. The dimensions of the slot 36 are such that both the supporting screws 33 and also the straining screws 34 pass through the slot in the axial direction. The straining screws 34 are disposed on both sides of the supporting screws 33 and adjacent to the screw head comprise a shaft 37 and at the free end a threaded portion 38, which have such dimensions that the transition portion of the thread lies inside the slot 36. After the adjustment of the supporting screw 33, the slot can be deformed by means of the straining screws 34, i.e. its width can be reduced, as a result of which the clearance between the turns of the threaded bore in the ring bearing and the supporting screw screwed into it is abolished. In this manner a perfect and exact adjustment of the gap 9 with respect to the gap width and plane parallelism between the first and second part 7, 8 is guaranteed, and the supporting screw 33 is fixed and secured.
Between the annular first part 7 and the flange 6 on the one hand and the periphery of the housing part 5 on the other hand there is a radial or axial gap 41, 42. This measure effects an automatic removal of fiber fluff (FIG. 1).
To guarante a faultless distribution of the weft threads in a series shed loom a mechanism monitors the width of the gap 9 between the first and second parts 7 and 8. In a preferred embodiment as disclosed in allowed U.S. application Ser. No. 08/239,100 this mechanism includes a sensor nozzle 40 which senses changes in the dynamic pressure in gap 9 as a result of changes in the width of the gap.
The mode of operation of the device described above is explained below.
FIG. 1 shows the device in its operating position in which the rotor 2, the housing part 5, the first part 7, the ring bearing 15, the ring 16 and the clamping ring 20 rotate. The second part 8 and the piston arrangement are stationary. The weft threads are supplied via the stationary second part 8 and inserted by the rotating first part 7 into the weaving sheds (not represented).
By eliminating of the clearance between the turns, a precise adjustment of the gap between the first and second parts 7, 8 in the magnitude of 0.01 mm becomes possible. Once set, the gap is maintained because of the fixing of the supporting screws 33. As a result a faultless supply of weft yarn with little loss of air is gauranteed.
Faults, e.g. mispicks, are readily corrected by placing the device in the open position, shown in FIG. 2. The second part 8 is displaced with the piston arrangement by supplying the annular working chamber with a pressurized medium, preferably compressed air. The compressed air flowing through the inlet duct 19 into the operating chamber forces the piston 26 against the clamping ring 20 and then pulls the housing part 25 and the second part 8 bolted thereto away from the first part 7. At the same time the ring bearing 15 is retracted against the action of the pressure springs 23. Thus the transfer and connecting ducts 10 and 11 are uncovered. After the removal of a fault the second part 8 is advanced by the pressure springs 23 by reversing the compressed air supply until the support units abut the insert members.
To pull the piston 26 away from the clamping ring 20, negative pressure is produced in the annular working chamber by means of an injector (not represented), as a result of which the piston 26 comes to abut the shoulder of the second portion 28 and no friction occurs between the piston and the clamping ring 20. After this readjustment the parts 7, 8 again assume the previous position, i.e. separated by the gap. | A device for the distribution of weft yarns into weft ducts of a rotor of a series shed loom has a first part (7) rotating with the rotor (2) with transfer ducts (11) for the weft yarns and a second part (8) which is nonrotatable in relation to the rotor (2) and has connecting ducts (10) for the weft yarns. The parts (7, 8) are axially aligned and movable with respect to one another and energy storing devices (24) hold them in an operating position so that there is a gap between opposing faces of the first and second parts (7, 8). An adjustable support structure permits adjustment of the gap width and then keeps it constant. The second part is connected to an operating mechanism (3) which pulls the second part (8) into an open position to thereby provide access to the transfer and connecting ducts (10, 11) for the weft yarns. | 3 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation application to U.S. patent application Ser. No. 13/861,309, titled: “Roller Hockey Goalie Apparatus,” filed on Apr. 11, 2013.
BACKGROUND
[0002] 1. Background of In-line Hockey
[0003] In the latter part of the 19 th century, ice hockey is said to have been first played on frozen ponds or lakes, with two stones frozen on each opposite end. As many as thirty players on each side would use sticks of wood with flat blades to try to score a goal by getting a puck in between the two stones. The popularity of the sport spread from North American to other continents. Ice hockey rules were eventually standardized, calling for five players and a goalie to represent each opposing team in the ice rink at a time.
[0004] Early ice hockey players yearned to continue playing the “on-ice” sport even when warmer weather melted their ice rinks. Consequently, and due to the invention of quad roller skates (comprising two wheels in front, two wheels in back), the game of roller hockey was developed. Quad roller skates had their limitations, however, such as not allowing players to move with the same speed as “on-ice” play. Roller hockey rules attempted to compensate for these differences by, among other changes, requiring that the game be played with four players and a goalie at a time (per team), to allow for more freedom of movement.
[0005] Over the ensuing decades, the game of roller hockey gained popularity culminating in 1984, when an improved alternative to quad roller skates came about with the filing of a patent for “inline” skates: “boots equipped with longitudinally aligned rollers used for skating.” Inline skates allowed hockey players to more closely simulate the “on-ice” feel than quad roller skates by allowing, for example, greater maneuverability and speed. Due to the advantages of inline skates over quad roller skates, inline hockey has since become more popular than roller hockey in the U.S.
[0006] 2. Background of Hockey Goalie Leg Protective Members
[0007] Although inline skates helped replicate the “on-ice” feel for most inline hockey players, there was no similar advancement in technology applicable to hockey goalies playing on dry surfaces. This was probably at least in part due to the fact that the techniques and on-ice movements of ice hockey goalies, and the related designs of their leg protective members, have significantly evolved since inline skates were created and started gaining popularity.
[0008] Specifically, older styles of hockey goalie leg protective members were tightly strapped to the legs. The goalie using this older style of protective members, to block pucks from entering the goal, would go straight from a standing position to a kneeling position. In so doing, the face of the leg protective members above the knees would remain facing outward towards the shooter. Below the knees, however, the face of the leg protective members would be parallel with, and face directly towards, the ice surface. In other words, hockey goalies using older goalie technique and styles of leg protective members did not rotate their legs, and leg protective members were designed accordingly. Since such a non-rotating, reactionary, movement would not leave exposed much (if any) of the goalie's inner legs, the designs of older styles of goalie leg protective members did not include much padding protecting the inner legs.
[0009] Starting around 2000, however, “box” style leg protective members became popular as goaltending playing technique evolved from a reacting style to a “blocking” style. Specifically, instead of simply reacting to a shot on goal by kneeling straight down from a standing position, in modern hockey play a goalie will prevent a puck from entering the goal (among other techniques) by using leg protective members to maximize the blocking area of the lower part of a goal. This modern “blocking” technique is accomplished by simultaneously kneeling and extending the part of the legs below the knees away from the body, with the inner part of the lower legs facing the surface and both lower legs pointing in opposite directions (the legs together essentially forming an upside down “T”). This position is colloquially referred to as the “butterfly” position.
[0010] Since a hockey goalie in the “butterfly” position can maximize blocking area by keeping the face of the protective member perpendicular with the ice surface, the design of goalie leg protective members evolved into more of a “box” style, where the edge between a face of the protective member and the inside edge is square-shaped. Thus, the modern box style of hockey goalie leg protective member anticipates that the pad may move or rotate from a vertical position (when the goalie is standing) to a horizontal position, when the goalie is in a kneeling (or rather in the “butterfly”) position. In this manner, all of a “face” of the leg protective member may be directed straight towards the shooter, rather than the ice.
[0011] Thus, modem hockey goalie leg protective members are designed with padding in the inner knee and inner calf/shin areas, which padded areas are called “landings” or “wraps.” Such padding softens impact in the primary locations where much of the goalie's body weight may fall when transitioning from the standing to kneeling position. “Landings” are not only intended to soften impact, but also to allow a goalie to move over an ice surface in a fluid manner.
SUMMARY OF THE INVENTION
[0012] There is a need for some apparatus that would allow a hockey goalie's motion during play on a dry surface to simulate “on-ice” motion. A hockey goalie playing on a dry surface may often have to repeat a standing and the kneeling movement in order to achieve certain positions that might otherwise be attained more quickly and easily on an ice surface. Such excessive and potentially burdensome movements can lead to undue exertion, pain, stress, and injury to a goalie's knees, hips and lower back. Furthermore, the added concentration and time necessary to perform blocking movements on a dry surface can make the difference between blocking and failing to block a puck from entering the goal.
[0013] In the prior art, there are no apparatuses utilizing rolling means that sufficiently allow a hockey goalie to simulate the motion experienced on an ice surface, on a dry surface, especially when the goalie is moving to or is in a kneeling or “butterfly position.” Additionally, there is also a need in the market for such an apparatus that can attach to existing protective leg members, without a hockey goalie having to purchase a separate set of hockey goalie leg protective members made specifically for play on a dry surface. This need is felt not only by hockey goalies for hockey play on a dry surface but is also felt by ice hockey goalies, who may lack access to an ice hockey rink for training purposes, yet wish to train on a dry surface.
[0014] An object of the invention is to assist a roller hockey goalie simulate “on ice” motion on a dry surface. In addition to forward and backward motion, such “on ice” simulated motion may also include lateral (or semi-lateral) motion, even when a goalie is transitioning from a standing to a kneeling position, or in a position colloquially referred to by hockey enthusiasts as the “butterfly” position (kneeling with the lower legs below the knees pointed in opposite directions away from the body, with the inner legs facing the dry surface).
[0015] Such an apparatus allowing “on-ice” motion by rolling may attach to a roller hockey goalie leg protective member or may also be incorporated into a roller hockey goalie leg protective member. The apparatus may be located in areas of a protective leg member that may be in contact with a dry surface, or where the weight of a hockey goalie's body and equipment is most likely to impact the dry playing surface. Given currently prevalent designs of hockey goalie leg protective members, it is anticipated that these areas of likely impact with a dry surface may be the “landings” of a hockey goalie protective leg member.
[0016] An apparatus that allows simulation of “on-ice” motion may accomplish such motion through utilization of ball bearings, and designs allowing the ball bearings to roll easily (and continue to roll easily) over a dry surface even when (or after) absorbing impact. Embodiments of the apparatus may utilize any rigid, loose spherical or rounded object that protrudes from one surface of the apparatus, but is basically contained in and rolls easily within the apparatus in at least one (and preferably every) direction, even after absorbing impact.
[0017] Each individual ball bearing may be contained in the apparatus within a cavity. A plurality of such cavities may perforate a plate component of the apparatus. This plate may be comprised of a self lubricating plastic, such as, by way of example, Ultra High Molecular Weight (UHMW) Polyethylene. (It is anticipated, however, that many different materials may comprise the apparatus and the parts thereof, according to cost of production concerns, coefficients of friction, self-lubrication, impact tolerance, durability, etc.). The cavities in the plate may be partially closed at one end, with the aperture being less wide than the diameter of the ball bearing, thus allowing the ball bearing to protrude yet not allowing it to escape from the aperture.
[0018] Additionally, inside each cavity may be a small amount of extra space, in addition to that necessary to house the ball bearing and keep it loose enough to roll, which may allow for impact absorption (i.e., allow the ball bearing to move further into the cavity) without substantially impeding the freedom of the ball bearing to roll. A cap piece may also be placed on the opposite side of the plate (opposite from the end with the aperture less wide than a ball bearing's diameter), which may be made of somewhat flexible material, thus allowing for additional impact absorption and freedom of the ball bearing to roll.
[0019] Different embodiments are anticipated where the pluralities of ball bearings and cavities have different configurations and designs to allow for greater desired mobility. For example, certain patterns of ball bearings may facilitate movement more aligned with a hockey goalie's leg, foot, and knee axes. Rectangular and/or other arrays of ball bearings may also present certain advantages.
[0020] Alternative embodiments may also be presented according to playing surface (e.g., the density, or coefficient of friction, of the surface) and environment. For example, one embodiment of the apparatus may be designed for use during actual roller hockey play on a dry surface, while other embodiments may be specifically designed for use on concrete, or carpets. Such alternative designs might include varying sizes of ball bearings and degrees to which the ball bearings may protrude. Larger ball bearings may raise a protective member higher off the ground in some embodiments, which may allow for greater mobility, while smaller ball bearings might bring the protective member closer to the floor while still allowing a desired amount of mobility (on the other hand, bringing a protective member closer to the floor in some embodiments might be desirable). For use on an asphalt surface, or even on a carpeted surface, less mobile plastic ball bearings (or ball bearings with greater resistance to movement) may be desired. Similarly, other embodiments might not use ball bearings at all, but rather use other rolling or other means (e.g., nubs), for achieving a similar type of motion.
[0021] Furthermore, although two preferred rolling embodiments of the apparatus are described below, for use in the knee area and in the calf/shin/foot area, different sizes and shapes of the apparatus are anticipated, according to (among other things) the area or type of protective member, or depending on whether the embodiment of the apparatus is incorporated into or attached to the roller hockey goalie leg protective member. For example, for an embodiment of the apparatus that is incorporated into a roller hockey goalie leg protective member, there may be smaller plates with less of a profile, several added rows of ball bearings, and/or more or less than two apparatuses incorporated into a leg protective member.
[0022] For example, there may be separate apparatuses of various shapes for the foot, calf & knee areas, with ball bearings throughout each. An embodiment of an apparatus for use in the shin area of a leg protective member may have a roughly rectangular shape, with an embodiment of an apparatus for use in the foot area of a leg protective member possibly having a curved shape. Plates may also be “anatomically” curved to fit the leg pad along the outer edges, regardless of the number of apparatuses used.
[0023] Apparatuses may attach or be incorporated into a roller hockey goalie leg protective member in a variety of ways. For example, such means for attaching are anticipated that would allow for easy and/or quick attaching and detaching of the apparatus. An embodiment of an apparatus that may attach by straps may also be strategically designed to avoid contact (and friction) with the straps and a dry surface. For example, strategically placed indented portions and/or slits or slots, and varying strap materials, may be utilized. One embodiment also may include straps with Velcro style fastening.
[0024] Although the preferred embodiment of the apparatus described herein may comprise a size and shape intended for standard-sized adult roller hockey goalie leg protective members (which according to current NHL rules, may be a maximum of 11 inches in width), different sizes intended for hockey goalie leg protective members are also anticipated (e.g., small, medium, large, or adult, junior, and youth). Certain shapes of the apparatus may also be implemented in a variety of ways in order to not interfere with the movement and flexion of the roller hockey goalie leg protective member (e.g., not necessary rectangular shapes, or with cut-off corners). Other shapes may be implemented to take advantage of similarities in goalie pads presented by different brands and models.
[0025] The above description and listed alternative embodiments are considered that of some embodiments only. It is understood that the embodiments shown in the drawings and described above are merely for illustrative purposes and not intended to limit scope. Alterations and modifications, therefore, and such further applications as would occur to those skilled in the relevant art(s), are also contemplated.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] FIG. 1A is a perspective view of an unassembled roller apparatus for a lower area of a roller hockey goalie leg protective member.
[0027] FIG. 1B is a perspective view of an unassembled roller apparatus for a knee area of a roller hockey goalie leg protective member.
[0028] FIG. 2A is a front view of the assembled roller apparatus in FIG. 1A .
[0029] FIG. 2B is a front view of the assembled roller apparatus in FIG. 1B .
[0030] FIG. 3A is a rear view of the roller apparatus in FIG. 1A .
[0031] FIG. 3B is a rear view of the roller apparatus in FIG. 1B .
[0032] FIG. 4A is a front perspective view of the roller apparatus in FIG. 1A .
[0033] FIG. 4B is a front perspective view of the roller apparatus in FIG. 1B .
[0034] FIG. 5A is a rear perspective view of the roller apparatus in FIG. 1A .
[0035] FIG. 5B is a rear perspective view of the roller apparatus in FIG. 1B .
[0036] FIG. 6 is a cutaway front perspective view of a portion of the roller apparatus in FIG. 1A .
[0037] FIG. 7A is a top side view of the roller apparatus in FIG. 1A .
[0038] FIG. 7B is a top side view of the roller apparatus in FIG. 1B .
[0039] FIG. 8A is a bottom side view of the roller apparatus in FIG. 1A .
[0040] FIG. 8B is a bottom side view of the roller apparatus in FIG. 1B .
[0041] FIG. 9A is a right side elevation view of the roller apparatus in FIG. 1A . FIG. 9B is a right side elevation view of the roller apparatus in FIG. 1B . FIG. 10A is a left side elevation view of the roller apparatus in FIG. 1A . FIG. 10B is a left side elevation view of the roller apparatus in FIG. 1B .
[0042] FIG. 11 is a front perspective view of the roller apparatuses in FIG. 1A and FIG. 1B shown in their environment of use installed on a roller hockey goalie leg protective member.
[0043] FIG. 12 is a perspective view of the roller apparatuses in FIG. 1A and FIG. 1B shown in their environment of use by a roller hockey goalie.
[0044] FIG. 13 is an enlarged cross sectional view of a ball bearing in a cavity of either of the apparatuses in FIG. 1A and FIG. 1B .
[0045] FIG. 14 is a view of the patterning of the ball bearings in rectangular arrays aligned with the player's knee and shin and feet axes.
[0046] FIG. 15 is a front perspective view of a roller hockey goalie leg protective member, with roller apparatuses incorporated into the landing areas of the protective member.
DETAILED DESCRIPTION
[0047] “Roller hockey” is defined herein as a hockey-related activity played on a dry surface, whether players wear inline skates, quad roller skates, or no genre of skates at all. A “roller hockey goalie leg protective member” refers to a leg protective member intended for a goalie to use in “roller hockey.”
[0048] Referring to the drawings, FIG. 1A illustrates an unassembled rolling apparatus for the lower area of a roller hockey goalie leg protective member 16 , which may comprise three main components. A first component may be a plate 17 , roughly resembling the shape of a “J” (or the mirror image thereof), or roughly the shape of a boot. Stated differently, the plate 17 may in the shape of a rectangle, except one of the shorter sides 18 of the rectangle is not straight but rather curved in a convex manner and extended on one side beyond the (continued) line of one of the long sides of the rectangle. A plurality of recesses that may form a plurality of cavities 19 may perforate the plate 17 , with (as shown in FIG. 13 ) each cavity 34 passing through both the front (or top) planar surface 36 and the back (or bottom) planar surface 38 of the plate 17 .
[0049] Along the perimeter of three of the sides of the plate 17 (including the convex side 18 , but not including the side 20 opposite of the convex side 18 ) may be several rectangular recesses 21 , indented below the front (or top) planar surface 36 of the plate 17 (also shown in FIG. 6 and in FIG. 13 ). To the interior of each indented rectangular recess 21 may be a rectangular-shaped slit or hole 22 , the hollow portion of which extends through to the back (or bottom) planar surface 38 of the plate 17 (also shown in FIG. 6 and in FIG. 13 ).
[0050] In the middle portion of the plate 17 may also be rectangular recesses 23 , indented below the front (or top) planar surface 36 , and two parallel rectangular slits or holes 24 within each interior rectangular recess 23 (also shown in FIG. 6 and in FIG. 13 ). Each slit or hole 24 may be located along the edge or side of each interior rectangular recess 23 that is roughly-parallel with the side of the apparatus 20 that may not have any rectangular recesses 21 located along its perimeter. The hollow portion of each slit or hole 24 may extend through to the back (or bottom) planar surface 38 of the plate 17 (as shown in FIG. 13 ). This may create an indented bar or board 25 within each rectangular recess 23 , contiguous to the edges or sides of the interior rectangular recess 23 that are roughly-perpendicular to the side of the apparatus 20 that does not have any rectangular cavities 21 located along its perimeter.
[0051] A second component may be a plurality of ball bearings 26 ( i ). A third component may be a cap piece 27 , which might be roughly in the shape of a “T.” The bottom cap piece 27 may be placed against the back (or bottom) surface 38 of plate 17 , holding each ball bearing 26 within a cavity 34 (as shown by FIG. 13 ). Attaching the cap piece 27 to the plate 17 may be facilitated by recesses for fasteners 27 ( i ) in the cap piece 27 , as shown by back view FIG. 3A and back perspective view FIG. 5A of the assembled apparatus 16 shown by FIG. 1A .
[0052] Accordingly, a plurality of ball bearings 26 ( i ) may be secured within a plurality of cavities 19 formed by the top plate 17 and bottom cap piece 27 components of the assembled apparatus for the lower area of a roller hockey goalie leg protective member 16 , as shown in front view FIG. 2A and front perspective view FIG. 4A , and in cutaway perspective FIG. 6 . The plurality of ball bearings 26 ( i ) may partially extend beyond the planar surface of apparatus 16 facing views FIG. 2A and FIG. 4A , or in other words beyond the front or top planar surface 36 as shown in FIG. 13 .
[0053] FIG. 1B illustrates an unassembled rolling apparatus for the knee area of a roller hockey goalie leg pad 28 , which may also comprise three main components. A first component may be a plate 29 , roughly in the shape of a rectangle with the corners cut off of one of the shorter sides of the roughly-shaped-rectangle. A plurality of recesses that may form a plurality of cavities 30 may perforate the plate 29 , with (as shown in FIG. 13 ) each cavity 34 passing through both the front (or top) planar surface 36 and the back (or bottom) planar surface 38 of the plate 17 .
[0054] Along the perimeter of all of the sides of the roughly-shaped rectangle may be rectangular recesses 31 (possibly similar to rectangular cavities 21 ), indented below the front or top planar surface 36 of the plate 29 . Each rectangular indented recess 31 may have, along its side opposite the perimeter of the plate 29 (or, in other words, along the side of the indented rectangular recess 30 that is closest to the interior of the plate 29 ), a rectangular-shaped slit or hole 32 , with the hollow portion of each slit of hole 32 extending through to the back (or bottom) planar surface 38 of the plate 29 .
[0055] A second component of an unassembled rolling apparatus for the knee area of a goalie leg pad 28 may be a plurality of ball bearings 26 ( ii ). A third component may be a bottom cap piece 33 , which might be roughly in the shape of a rectangle, with the corners on one of the shorter sides of the rectangle omitted according to the shape of the plate 29 . The bottom cap piece 33 may be placed against the bottom surface 38 of plate 29 , holding each ball bearing 26 within a cavity 34 (as shown by FIG. 13 ). Attaching the cap piece 33 to the plate 29 may be facilitated by recesses for fasteners 33 ( i ) in the bottom cap piece 33 , as shown by back view FIG. 3B , and back perspective view FIG. 5B of the assembled apparatus of FIG. 1B 28 .
[0056] Accordingly, as shown in front view FIG. 2B and front perspective view FIG. 4B , a plurality of ball bearings 26 ( ii ) may be secured within a plurality of cavities 30 of the plate 29 component of the assembled apparatus for the knee area of a roller hockey goalie leg protective member 28 . The plurality of ball bearings 26 ( ii ) may slightly protrude beyond the planar surface of apparatus 28 that is facing views FIG. 2B and FIG. 4B , or in other words beyond the front (or top) planar surface 36 , as shown in FIG. 13 .
[0057] More specifically, as shown in FIG. 13 , each ball bearing 26 of the pluralities of ball bearings 26 ( i ), 26 ( ii ) (shown in FIG. 1A and FIG. 1B ) sits within a cavity 34 . An aperture 35 in the cavity 34 extends through the front (or top) planar surface 36 of the plate 17 or 29 . The width of the aperture 35 may be less than the diameter of the ball bearing 26 , preventing the ball bearing 26 from escaping the cavity 34 through the aperture 35 , yet allowing the ball bearing 26 to partially extend or protrude from the aperture 35 . The ball bearing 26 may at times be centered in the aperture 35 and partially extend out of the aperture 35 through some force acting on the ball bearing from the opposite side, such as the force of gravity.
[0058] Another aperture 37 of the cavity 34 along the bottom (or back) surface 38 of the plate 17 or 29 may be obstructed by a cap piece 27 or 33 , preventing the ball bearing 26 from escaping the cavity 34 through the bottom aperture 37 . A recess 34 ( i ), or extra space within the cavity 34 may also be provided, which may allow the ball bearing 26 to absorb impact and move farther into the cavity, yet still be free to a greater degree to roll in one or all directions. The cap piece 27 or 33 may be made of a self-lubricating material that may also flex when a ball bearing 26 is pressed against the bottom cap piece 27 or 33 . The parts of the plate 17 or 29 defining a cavity 34 may be made of a self-lubricating material.
[0059] As shown in FIG. 7A , FIG. 8A , FIG. 9A , FIG. 10A , and in FIG. 11 , the plurality of ball bearings 26 ( i ) of the assembled apparatus in FIG. 1A 16 may be patterned in arrays according to the shape of a shin landing 39 of a roller hockey goalie leg protective member 40 , and as shown more particularly in FIG. 14 , in arrays aligned with a roller hockey player's leg axis 49 and foot axis 50 . Similarly, as shown in FIG. 7B , FIG. 8B , FIG. 9B , FIG. 10B , and in FIG. 11 the plurality of ball bearings 26 ( ii ) of the assembled apparatus in FIG. 1B 28 may be patterned in arrays (e.g., rectangular arrays) according to the shape of a knee landing 44 of a roller hockey goalie leg protective member 40 , and as shown more particularly in FIG. 14 , in arrays aligned with a hockey player's knee axis 51 (which arrays may facilitate movement in e.g., in both forward and backward, as well as lateral and semi-lateral directions).
[0060] As shown in FIG. 11 , the assembled apparatus of FIG. 1A 16 may be placed on the shin-area landing 39 of a roller hockey goalie leg protective member 40 , with the plurality of ball bearings 26 ( i ) facing away from the landing 39 , and the convex side of the apparatus 18 pointing away from the knee area landing 39 of the roller hockey goalie leg protective member 40 . Horizontal straps 41 may pass through the slits 22 of the rectangular indented portions 21 of the apparatus 16 , and wrap around the landing 39 and the face of the goalie leg protective member 42 , and around the lower leg of the goalie (as shown in FIG. 12 ) (being tightened and secured through means known in the relevant art(s), such as the use of Velcro). Vertical straps 43 may pass through the interior slits 24 and bars 25 of the interior rectangular indented portions 23 of the apparatus 16 , pass over the top of the landing 39 and also connect to the slits 22 located in the indented rectangular portions 21 on the convex side of the apparatus 18 .
[0061] As also shown in FIG. 11 , the assembled apparatus 28 shown in FIG. 1B may be placed on a side of the knee-area landing 44 of a roller hockey goalie leg protective member 40 that may face a dry surface, with the plurality of ball bearings 26 ( i ) facing away from the landing 44 . Also, a horizontal strap 41 may pass through slits 32 and wrap around the landing 44 and the face of the leg pad 42 , as well as a hockey goalie's upper leg, knee, and or lower thigh area 46 (shown in FIG. 12 ). A vertical strap 45 may pass through slits 32 and wrap around the landing 44 .
[0062] As FIG. 12 illustrates, when playing on a dry surface 47 , a roller hockey goalie 48 wearing roller hockey goalie leg protective members 40 may place, attach, or strap roller apparatuses 16 , 28 to knee and shin area landings 39 , 44 . This may be accomplished, for example by using straps 41 , 43 , 45 and slits 22 , 24 , 32 on apparatuses 16 , 28 . Indented recesses 21 , 23 , 31 containing the slits 24 , 32 where the straps 41 , 43 , 45 pass through, may assist to avoid undesired contact of the straps 41 , 43 , 45 with the playing surface 47 . The same rolling apparatuses 16 , 28 , but mirror images of one another, may be used on the roller hockey goalie's opposite leg protective member.
[0063] As shown in FIG. 12 , the pluralities of protruding ball bearings 26 ( i ), 26 ( ii ) of apparatuses 16 , 28 may be in contact with a dry surface 47 , allowing the ball bearings to roll on the dry surface 47 . This rolling, combined with configurations of ball bearings aligned with the goalie's leg 49 , foot 50 , and knee 51 axes (as shown in FIG. 14 ), may assist a roller hockey goalie 48 simulate on-ice motions and movements (when, for example, moving from a standing position to a “butterfly” or half “butterfly” position, or when already kneeling in the butterfly position and trying to move to block a puck from entering the goal).
[0064] FIG. 15 illustrates embodiments of the roller apparatuses 53 and 54 , incorporated into a roller hockey goalie leg protective member 52 , which function to allow movement substantially similar to that described in the preceding paragraph. | A roller apparatus integrated with one or more inner side protective landings of a roller hockey goalie's leg protective member. The apparatus may include a first planar layer having a first plurality of openings arranged in a planar array, a second planar layer having a second plurality of openings aligned with the first plurality of openings of the first layer; and a plurality of roller bearings shaped and sized for positioning in the aligned first plurality of openings and second plurality of openings, with outer surfaces of the roller bearings projecting outwardly from the first plurality of openings of the first planar layer of the roller assembly to enable rolling movement of the roller assembly when engaged in contact with a dry surface. Also described are methods of configuring a roller assembly, such as the aforementioned roller apparatus. | 0 |
RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser. No. 14/214,654, filed Mar. 14, 2014, which claims the benefit of U.S. Application No. 61/782,659, filed Mar. 14, 2013, which are hereby incorporated by reference as if set forth in their entireties.
FIELD OF INVENTION
[0002] This invention is in the field of water reclamation and conservation, collecting rain and snow water run-off and used grey water, purifying the collected water, and recycling for varied usage in residential, commercial, and agricultural applications.
BACKGROUND OF INVENTION
[0003] Water is a life sustaining and necessary resource rapidly becoming scarce. The world's aquifers are increasingly at risk of exhaustion and collapse. To help avoid disastrous water shortage, methods, equipment and components are needed for water reclamation and conservation, such as collecting rain and snow run off, waste water, used grey water, and treating the collected water for varied usage must be developed, made available off-the-shelf, promoted, and implemented. A lack of availability of methodology, systematic approach, tools and equipment, and off-the-shelf components have made the implementation of water reclamation and conservation difficult and costly to implement. The present invention provides methods and systems of that are automated and standardized, can be easily made commercially available, such that builders, property owners, farmers and townships can readily install and implement the water reclamation and conservation measures stated in the present invention.
SUMMARY
[0004] The present invention proposes standardized methods, analysis algorithm, calculation equations and formula to determine an efficient run-off and grey water reclamation and reuse strategy and system. Pre-manufactured, standardized, off-the-shelf components and equipment that can be assembled on site to collect rain/snow run-off and waste water, systematically process the collected water for various reuses are also proposed. A computerized automation method and system takes topographical survey data of a contiguous land, intended building sizes and estimated water usage, guidance for owner preferences and desired landscape layout (for example: leaving large space for gardens, locations and types of trees, vegetation, and garden types, place buildings in what orientations and locality, long or short driveway preferred, etc.,) as well as data bases on local ordinances and setback requirements, vegetation water needs, building energy and water needs, local per person water consumption needs, area rain and snow fall data as input to determine optimized options for building sites, drive way and parking locations, run-off water collection strategies, collection ditch and storage tank locations and sizes, purification needs, methods and stages for various usages, as well as their interconnections. The present invention also proposed components and equipment for making water reclamation and reuse easier to execute. The automation program also performs calculation of needed components and equipment for the proposed options, and presentation of the lists of components and equipment needed, as well as costs and estimated man-hour needed for installation. Various representative methods, components, equipment, and their interconnections are proposed and illustrated.
BRIEF DESCRIPTION OF ILLUSTRATIONS
[0005] FIG. 1 shows location and size of an optimized ground run-off water collection system are determined by taking as input data a combination of a property topographic survey map, water usage needs for occupants and vegetation, area rain and snowfall data, estimated total water usage volume per week, and a list of available standardized and off-the-shelf components and equipment and prices thereof, as well as owner preferences, and analyzes and calculates against a set of rules, equations, and formula. An automation program is written to automate the analysis and calculations. Adjoining properties—such as a neighborhood or a township can share a common reclamation and purification system using the same methodology and automation program.
[0006] FIG. 2 illustrates the Pre-manufactured inter-connectable pipe sections for run-off water collection. Also illustrated are pipe covers and mesh pre-filters that are compatible with the pipes.
[0007] FIG. 3A illustrates a proposed inlet pre-filter with replaceable and exchangeable filter cartridge.
[0008] FIG. 3B Illustrates a proposed inlet pre-filter arrangement with sedimentation debris bucket and charcoal gravel pre-filter for the initial treatment of run-off collected water.
[0009] FIG. 3C illustrates a water reclamation, purification, and storage system containing: a storage container body of a desired capacity, a removable tank cover which further comprises sub-sections that can be separately removed, for installing and accessing equipment in the tank, and performs routine maintenance. Installed inside the storage tank are: a pre-filter (as described in FIGS. 3A and 3B ), a water stirrer, a sump-pump, optional anti-microbial chemical dispenser, and an optional ultra-violet light generator or Ozone generator. The sedimentation debris bucket and charcoal gravel pre-filter can be periodically removed for cleaning or replacement. The Sump-pump is used to pump water from a collection/storage container to a higher level filtration/purification and storage system, for overflow to a backup container, or for usage. With appropriate piping and float arrangement, an external pump can be used in place of the Sump Pump.
[0010] FIG. 4 illustrates the further purification of the pre-treated water as described in the previous Figures to make it suitable for human consumption. A next level purification system receives pressurized water from the pre-treated water storage, further filters and treats it before it is pumped and piped into a storage tank. The source of water to enter the house can now be selected from the on-site treated reclaimed water or from the municipal (external) water connection.
[0011] FIG. 5A illustrates the roof run-off water guided into gutters and downspout locations. FIG. 5B illustrates how run-off water from roof and gutters can be piped directly to a separate above ground storage and filtration station. Multiple down-spout/leader can be converge into one storage and filtration station by running horizontally or near horizontally after a predetermined length of downward direction to converge to a predetermined large capacity convergent downspout.
[0012] FIG. 6 shows an in-building waste water drainage system is separated into two subsystems: 1) toilet waste drainage subsystem ( 601 ), and 2) sink, shower, and bath drainage subsystem ( 602 ). The toilet drainage can be connected to a municipal sewage system, on-site septic tank, or if so desired, to a separate on-site sewage treatment system for the purpose of producing clean organic fertilizers. The sink, shower, and bath waste water is piped to a grey water collection and pre-treatment system as described in FIG. 3 for lower grade usage. The pre-treated water can be pumped to higher grade purification and storage system as described in 4 and 5 for higher grade uses as needed. The toilet flushing water supply line can be separated from personal hygiene and drinking and cooking water supply line, and be supplied from a lessor grade reclaimed water source. Household cleaning water supply line can also be separated and therefore separately supplied, or supplied along with the toilet flushing supply line.
[0013] FIG. 7 shows a whole house, in-building water purification and treatment system removes trace amounts of potentially harmful substances such as chloride and fluoride, acids and other chemicals, pharmaceutical drugs, excess minerals, microbial such as fungus, bacteria and that may have been missed by the treatment and purification systems described earlier. This in-building system can be shared between treating the public water and reclaimed water as described in FIGS. 4 and 5 . At this stage important and beneficial minerals can also be injected into the water, and the PH level of the water adjusted as desired.
DETAILED DESCRIPTION OF THE INVENTION
[0014] As illustrated in FIG. 1 , a property topographic survey map indicating the property boundary lines, its lines of elevations, and approximate foot print of intended buildings (or if already built, the actual foot print and location of the buildings), setback requirements, water usage needs, and area rain and snowfall data, owner preferences and budge are taken as input. Analysis are made against a set of rules, equations, and formula to calculate run-off speed and rate of flow at various localities of the property, water accumulation volume and speed for a given configuration and location of a water collection ditch, pump horse power needed, storage tank size needed, filter filtration rate needed, and component and equipment needs and costs. Several feasible systems each optimized for a set of chosen factors, such as highest collection rate and storage capacity, or collection rate and costs and flexibility, etc. are determined and configured through the analysis. The natural topography is analyzed, building and driveway locations identified, and if needed economic modification of topography computed and proposed. Optimized run-off collection method, collection ditch locations, driveway run-off lanes, and storage tank locations and sizes are computed and presented along with purification methods and components and equipment needed and costs thereof, as well as estimated men-hour labor requirement and costs. Computerized automation program and accompanying databases are used to automate the analysis, calculation, presentation of proposals along with graphs, simulated pictures, pictures and specifications of components, the pros-cons and cost estimation of each. Even though the example illustrated in FIG. 1 is a residential property, commercial and agricultural properties, and a “community” of adjoining properties, such as a neighborhood or a township can share a common reclamation and purification system using the same methodology and automation program.
[0015] The highest elevation of the illustrated property is 505′ between elevation line ( 101 ) and the flat area around the Pool House ( 103 ) site. The elevation of the planned driveway entrance gate ( 105 ) is 500′. The elevation of area from the North edge of the Pool House ( 103 ) midway toward the Main House ( 107 ) ranges between 504′ to 500′. The natural ground elevation at the Main House and Garage sites is close to 498′. The primary slopes of the property slope down from East toward West and South East toward Northwest. The Main House sits on a knoll top, with relatively flat areas around it, and slopes down toward all sides. A computer program is designed to read as input the topographical survey of a property, its intended number and the approximate foot prints and usage of intended buildings to be built on the property, as well as rain fall and snow fall data of the area, and approximate water usage needs of the buildings and grounds, automate the determination of optimal options for the location and elevation of driveway, the width and depth of a driveway run-off lane, the location of a collection ditch, its depth, width, and pitch, the location and size of a collection/storage container/tank, and the filtering/purification/treatment needs and stages. Multiple containers can be used if the available land area is large to reduce the bulk and excavation depth of the storage containers. If buildings on the property are not yet built, the computer program also determines optimized locations for building sites and grading, building and roof orientations, gutter size, pitch and leader and the size and location of a storage tank for collecting roof run-off water, as well as driveway locations and grades, all optimized for water drainage, collection, usage, as well as energy sourcing, collection, storage and usage efficiencies.
[0016] A computer program is designed to read the topographical survey of a property, the intended number of buildings to be built on the property, and the approximate foot prints and usage of the buildings, as well as rain fall and snow fall data of the area, and approximate water usage needs of the buildings and grounds, including the intended vegetation, ornamental and edible, and local ordinance and set back requirements. Algorithms automate the determination of optimal options for the location and elevation of buildings and driveway, the location of ornamental trees and plants, edible fruit trees and plants, and locations of vegetable and herb gardens if desired. The width and depth of a driveway run-off lane, the location of a collection ditch, its depth, width, and pitch, the location and size of a collection/storage container/tank, and the filtering/purification/treatment needs and stages. Multiple containers can be used if the available land area is large to reduce the bulk and excavation depth of a storage container. If buildings on the property are not yet built, the computer program also presents several optimized options for building sites and related grading proposals, building and roof orientations, gutter size, pitch and leader and the size and location of a storage tank for collecting roof run-off water, as well as driveway locations and grades, balancing owner/user needs and preferences, water drainage needs, water conservation, reclamation and usage, as well as energy conservation, sourcing, collection, storage and usage efficiencies.
[0017] To optimize the water drainage and collection, the driveway is graded to be at 500′ elevation. If not already naturally so, the land immediately south of buildings ( 107 ) and East of ( 108 ) needs to be graded to be sufficiently higher in elevation than the driveway, and to slope gently down away from the buildings. The natural elevation at the south side of the main house ( 107 ) is at approximately 498′, which, aside from the area marked for basement and foundation, should be filled to near 500′. This can be done after the foundation and basement walls and floors are completed. The ground slopes down from there toward East and Northeast to 493.5′ at the Northeast corner of the property and continues down-slope toward the East and North neighbor properties. To the West of Building ( 107 ), the elevation also drops toward West and Northwest. The Northwest corner is the lowest at 485′. A natural ravine is formed near the West property line going from 500′ at the Southwest corner to the Northwest corner's 485′. The main run-off water collection ditch ( 121 ) is dug from the West end of the driveway entry catch basin ( 113 ) under catch basin gridded metal cover ( 112 ) toward the nature gully near the West property line, and along the West property line to flow into a collection container ( 130 ). The collection container is placed in-ground at the Northwest corner of the property. A secondary run-off water collection ditch ( 123 ) is dug along the North property line and inject into storage tank ( 130 ). A third run-off collection ditch ( 125 ) can be dug along the Northeast property lines, to join the secondary collection ditch ( 123 ) at Northeast corner ( 117 ). Collection ditch ( 127 ) can be dug at the 498′ elevation line, the lowest area between Pool House ( 103 ) and Main House ( 107 ), and connect ( 127 ) to ( 125 ). Garage building ground floor can be elevated a few inches above the 500′elevation of the driveway. The Parking Area surface adjacent to buildings ( 107 ) and ( 108 ) should be at approximately 2″ above 500′ and gently grade down toward the 500′ of the predominant driveway surface elevation. The floor level of Car Port ( 109 ) and Garage ( 108 ) Driveway can be another few more inches above the 500′2″ of the driveway surface immediately adjacent to the Car Port and Garage. Anywhere between 500′4″ to 500′6″ is a reasonable level for a smooth up-bump to drive across into the Car Port or Garage, while providing an adequate water barrier.
[0018] The Parking Area is graded with an incline toward the end section of the driveway connecting to the parking area. The driveway can be further refined to comprise a slight down-grade from the East edge toward the West edge of the driveway where the natural elevation is lower. A slight down grade from the Main House and Garage toward the driveway entry at the Southwest corner of the property is also desirable. A paved shallow driveway run-off drainage lane ( 110 ) is installed on a side of the driveway. In the case of this example property, the driveway run-off lanes are along both sides of the driveway:
[0019] 1, along the East side of the driveway to catch run-off from the grounds uphill to the driveway;
[0020] 2, along West side of the driveway to catch run-off from the driveway.
[0021] The run-off water drainage lanes are indented (concaved) lanes graded with a down slope length-wise from buildings ( 107 ) and ( 108 ) areas toward the driveway entry, paved, and connected to the run-off water collection system. Grounds around the Pool House ( 103 ) is higher than the drive way. Water from that area will flow down toward the driveway run-off lane, and with its downgrade inclination toward the driveway entrance, inject into a catch basin under its metal cover ( 112 ), and fed into the run-off collection ditch ( 121 ) at the West side of the driveway run-off drainage lane ( 110 ) and ( 111 ), and the downward grade of drainage lane ( 110 ) toward the driveway entrance near the Southwest corner of the property, and inject into the main run-off water collection pipe ( 110 ). While it is not necessary in the illustrated topography, in other situations one may choose to install driveway run-off drainage lanes only on one side of the driveway.
[0022] The first floor of Main House ( 107 ) can be built at an elevation anywhere between 500′5″ to 500′24″, approximately a slight bump-up to three 7″ steps higher than the edge of the Parking Area adjacent to the building. The grounds immediately surrounding the building needs to be lower than the first floor elevation, but higher than the driveway elevation. A terrace at a desired elevation below the elevation of the first floor of Main House 107 can be installed with a very slight incline away from the Main House ( 107 ). If wheel chair entry is desired, a walkway can be devised to incline up smoothly to the terrace from the parking/driveway area. Otherwise, appropriately spaced steps can accomplish the purpose of easy entry and water barrier during heavy rainfall or snow-melt.
[0023] For the property illustrated, the predominant run-off flows are from East to West, and from Southeast toward Northwest. The secondary run-off flow is from South to North. The main run-off water collection ditch ( 121 ) is dug along the West end of the driveway entry catch basin ( 113 ) underneath its cover grate ( 112 ) toward the nature gully near the West property line, then parallel to the gully to flow into a collection container ( 130 ). The collection container is placed at the Northwest corner of the property. If so desired, a secondary run-off water collection ditch ( 123 ) can be dug along the North property line, and ( 125 ) along the East property line, to join the collection ditch ( 123 ) at Northeast corner ( 117 ). Collection Ditch ( 123 ) injects into the storage tank ( 130 ). Driveway run-off water collected in a run-off water lane along a side of the driveway graded to flow toward the East end of the driveway and inject into the catch basin ( 113 ) with basin cover ( 112 ). Rain or snow water on the driveway turn-around and parking area ( 109 ) flows toward the driveway run-off lane to the East of 109 , when 109 is graded just a couple of inches from right in front of the garage to its east edge where the East side driveway run-off collection lane begins.
[0024] An additional run-off collection ditch ( 127 ) can be dug at the lower elevation area between Pool House ( 103 ) and Main House ( 107 ) as indicated. The elevation of the top of this ditch begins at the edge of the driveway at approximately 500′, and joints collection ditch ( 125 ) at 498′. Additional space in the ditch can be dug and allocated for installation of pipes to pipe water from the storage container ( 130 ) located at the lowest elevation area of the property upward to the next level purification and storage station near a building, as well as to where desired for usage, such as near turn-around and parking area ( 109 ).
[0025] Once the location and size of the run-off collection ditch are determined and the ditch dug, one may simply cement the ditch, and cover the cemented ditch with mesh and grate to keep out the debris and protect the ditch from traffic. This, however, requires the employment of masons, and there is presently no standardized commercially and economically available system of mesh and grates to cover cemented run-off water collection ditch. Cemented ditch also makes future changes or modifications difficult.
[0026] FIG. 2 shows one method for completing the construction of the run-off water collection ditch:
[0027] A ditch edging strip is installed along the earthen edge of the raw ditch, and then a plastic liner is installed to line the raw ditch. A pre-manufactured, standardized flexible or rigid plastic drainage pipe of a standardized diameter for a needed collection capacity, with sufficiently large water flow-through holes on a top section of the pipe is laid in the plastic lined run-off water collection ditch. The pipe is then covered with flow-through landscaping fabric. The ditch is then covered with gravel. Alternately, the edging strip can be installed during the gravel-fill stage between the plastic liner and the gravel. If so desired for aesthetics and foot traffic, sufficiently porous artificial turf can be laid on top of the graveled ditch, and if desired extending to the surrounding grounds according to landscaping design.
[0028] Another method is to use Interconnect-able and stackable rigid half pipe sections of a pre-determined standard widths and lengths. These pipe sections are easier and cheaper to manufacture, store, and transport. An example of water-tight capable interconnection mechanisms is a tongue-in-groove mechanism. Another example is a sleeve-insertion interconnection. A sturdy cover with appropriately sized through-holes protects the half pipe and the ditch, while also allows adequate water flow-through. If so desired, a mesh with holes smaller than the lid through-hole can further prevent solid matters of sizes larger than the mesh holes and smaller than the lid through holes from wash through into the collection pipes, while still allows adequate water flow-through can be installed with the ditch cover. half-pipe sections as exemplified in ( 201 ), ( 202 ), ( 203 ) and ( 204 ). Semi-circular cross section, rectangular cross section, and other shapes, such as semi-oval can be used as the ditch lining pipe sections. A short piece of half pipe ( 203 ) serving as a connector, having its outer diameter/circumference that can be snug fit into the inner diameter/circumference of a run-off collection half-pipe, connects one run-off collection half-pipe with another. The smaller diameter short half-tube connector is the insert, and the run-off collection half-pipes are the sleeves. Tongue-in-groove interconnect can also be used. Another option of constructing the ditch liner half-pipe A sturdy lid such as ( 205 ) or ( 207 ) with substantial flow-through grids or holes covers and protects the ditch opening, as well as serving as a safety measure for human and animals who may walk across the ditch. The cover also serves to keep out debris larger than the flow-through holes from entering the collection ditch, while still allow adequate water flow-through capacity. For additional filtering of debris, a mesh ( 213 ), or ( 215 ) can be stacked beneath the lid. Since the ditch has a down-flow grade, an insertion-in-sleeve or a tongue-in-groove interconnecting mechanism will suffice. The simpler sleeve insertion interconnection mechanism as shown in ( 203 ) is easier to manufacture, and easier to use when replacing a damaged section when need arises. This and other interconnection mechanisms can be further sealed with an appropriate sealant.
[0029] Whole pipes with water flow-through holes on the upper half of the pipes can be used. In this case, the remaining space of the ditch should be filled with gravel for the protection of the pipe, the ditch, as well as human, pets, and animals that may walk around the grounds. Other options include sturdier and interconnect-able half-pipe sections made with higher grade material in combination with matching protection flow-through cover and filter mesh.
[0030] FIGS. 3A, 3B & 3C show treatment options for the collected water: Collected run-off water flows through the down sloping collection pipes toward the in ground storage container ( 301 ) positioned at the lowest elevation area of the property. An adaptor connects the collection pipe to a flexible hose with a water tight connection. The hose is connected to a first stage filter using a charcoal, gravel, and sand filter ( 303 ), which is set through a feed-through hole on the lid of the storage tank ( 301 ), into the storage tank, and secured on the lid with the lip on the top of the filter housing. Both the filter housing ( 309 ) and filter cartridge ( 307 ), which contains the charcoal, gravel, and sand used for filtering action, is removable for cleaning or replacement. The filtered water flowing out of the gravel/sand/charcoal filter cartridge is fed into the in-ground storage container ( 301 ) through the sieve-like walls of the cartridge housing. The charcoal, gravel, and sand can be removed from the cartridge and cleaned or replaced. The flow-through filter housing ( 309 ) has a lip at the top to be secured at the through-hole rim on the storage tank-lid for mounting filter ( 303 ). The filtered water out of the filter cartridge ( 307 ) flows through the entire sieve-like walls of the filter housing ( 309 ) into the storage tank ( 301 ).
[0031] The storage tank ( 301 ) can be made with precast plastic without seams. A sump pump ( 313 ) is installed in the storage container through a feed-through ( 311 ) in the storage container lid. The pump action can be selected to turn on or off, or automatically set for when a stored water level in the tank reaches a certain height, or for when the stored level of the next stage purified water is low to pump the stored water to the next stage purification and storage station, or for usage of the stored water in the container. The outlet of the pump can be divided into multiple streams using a divider ( 315 ) with adjustable-flow control valves ( 317 ), ( 319 ), ( 321 ). The flow division between the multiple flows can be pre-set for typical usage and rainfall conditions and adjustable either manually or automatically according to detected stored levels of the water stored in the various storage containers, and/or according to the detected rainfall conditions.
[0032] As an example, out flow from one valve ( 317 ) can be used directly turn on or off for access for an intended usage, valve ( 319 ) diverted to an additional over-flow storage container, and out flow from another valve ( 321 ) can be piped to the inlet of the next stage purification and storage facility. A mechanical stirrer ( 323 ) is installed through a tank-lid feed-through inside the storage container. The stirrer ( 323 ) is programmed to turn on periodically to give movement to the stored water to prevent bacteria, mold, and vegetation growth. While not necessary in this stage, an optional UV light or Ozone generator ( 325 ) can also be installed inside the storage container to further kill microbes. A dedicated generator provides electricity needed to operate the station. The generator can be run by compressed natural gas, solar, or gasoline. The cover for the storage tank has sub-sections removed that have lips to serve as feed through holes for the in-tank equipment described above: the filter cartridge housing, the mechanical stirrer, the sump pump, and an UV or Ozone generator. The lids for these feed through holes are separated in two halves, each having a half shaft hole that can go over the shaft, cables and pipes of the intended equipment, and are separately removable, such that the in-tank equipment can be easily removed for servicing or cleaning.
[0033] Water collected through the collection pipes can also be accumulated in an interim container ( 341 ). A sump pump ( 342 ) is installed in interim container ( 341 ) to pump the accumulated water to the main treatment filter ( 303 ) in ( 301 ). In this case, the pressure feed of pretreated water pumped from the interim storage tank enables one to use an above the ground tank for storage tank ( 301 ) if so desired. Also, a higher performance accordion style filter or a combination of activated carbon and membrane filter can be used with storage tank ( 301 ). However, the cheaper charcoal/gravel/sand filter may still be a preferred choice for this stage, albeit one may use finer grade charcoal, gravel, and sand. With pressure feed, the charcoal/gravel/sand cartridge can also filter at a higher throughput. The cartridge can also be lined with a membrane to achieve a higher level of filtration. The interim container also can include a removable basket ( 343 ) to collect the sediment and debris that would sink to the bottom of the basket. Basket ( 343 ) can be lifted out of container ( 341 ) to clean out the accumulated sediment and debris. The interim container ( 341 ) can also include a charcoal/gravel pre-filter ( 345 ) with sand as an optional filtering medium, which can also be lifted out of ( 341 ) for cleaning and service.
[0034] The components described are all manufactured to fit together and available as tools and components in kits for easy installation of a water reclamation system with capacities for land areas with a range of rain and snow fall, and designed for residential, commercial, or agricultural uses with desired grade of purification.
[0035] FIG. 4 illustrates further purification and pre-usage storage:
[0036] A next level purification and storage station ( 401 ) receives pressurized water from a sump-pump outlet of the initial reclamation stage ( 301 ). A conventional removable accordion style filter with pleated filtering fabric or membrane pack ( 403 ), or a vertically stacked filter discs ( 405 ), housed in a cylindrical housing ( 407 ) can be used in this case. After filtration, the filtered water is piped into storage tank ( 411 ). Station ( 401 ) can be located at a higher elevation near a primary building on the property. As an example a flat roof top of a utility storage cabinet ( 413 ) built outside of a side or back wall of a building near where the public water enters the building, or flat area on the roof of a garage can serve as a place where ( 407 ) and ( 411 ) can be located. Filter ( 403 ) for this stage preferably is separate from the storage tank ( 411 ) for easy access. An outlet located at the side of a lower portion of storage tank ( 411 ) feeds filtered water into the house line. A valve and a meter can be installed at this outlet, so that water usage from the reclaimed water versus from the public water can be monitored.
[0037] A commercially available in house whole house water filtration and purification system utilizing a combination of activated carbon and hollow-fiber membrane filtration, or a combination of nano-filtration membrane and reverse-osmosis can be installed to filter either the reclaimed water from storage tank ( 411 ), or public water piped in through the water main. Complete and balanced nutrient trace-mineral can be added at this stage if so desired.
[0038] FIG. 5 illustrates a roof run-off water collection system. In a conventional gutter and leader system that collects the roof run-off, a leader is a downward pipe connected to a horizontal gutter at a select location on the gutter that takes the rain or snow melt run-off water from the roof that collects in the gutter down to the ground. A conceptual example of a roof, gutter, and leader relationship is show in FIG. 5A . Gutters ( 501 )—front, ( 503 )—side, ( 505 )—side, ( 507 )—back, and leaders ( 511 ), ( 513 ), ( 515 ), ( 517 ), collect the run-off water from the roof. The conventional leaders are installed vertically down to the ground level, are connected to drainage pipes near the ground level either above or below ground to pipe water away from the building. The collected roof run-off water is discharged at a place where the ground slopes away from the building and the water eventually flow away outside of the property to street catch basin and public rain water drainage system, or discharged to the edge of the street, or a street side catch basins, which is connected to public rain water drainage system. At the most basic level, one can collect the rain/snow run-off water from the roof/gutter/leader system by terminating each leader into a water storage tank. From there one can interconnect the storage tanks, and use a pump to pump water to a shared treatment and storage station such as described in FIG. 4 . One can also inter connect the leaders at the ground level with a ground level piping loop, which terminates into an interim storage tank on the ground level. A sump pump pumps the stored water from the interim storage tank to a treatment and storage station. The treated water is then connected to the house water system through a valve.
[0039] In a more direct approach for a simpler roof, one can bend the leaders after a predetermined downward length, and route it against and along the building's walls horizontally, or with a slight downward angle from horizontal toward a selected position at the back of the house where the leaders converge into a larger capacity vertical leader, which then injects the collected water enter into storage tank. This would reduce the number of storage tanks needed to one, or two in number. The rain water storage tank can also be located a desired elevation above ground to take advantage of gravity feed for processing and usage. The processed water is then connected to the main water intake pipe of the building through a control valve. The public water also feeds into the main water intake pipe through its own control valve.
[0040] For example, leader ( 511 ) for gutters ( 501 ) and ( 503 ) makes a curved bend using a bend-adapter ( 523 ) from the initial short conventional vertical section of ( 511 ), runs horizontally or nearly horizontally along wall beneath gutter 503 toward leader ( 513 ). If leader ( 513 ) location is chosen to be storage site, ( 511 ) is then connected to a large capacity leader ( 513 ), which is connected to a storage tank ( 533 ). Similarly leader ( 515 ) for gutters ( 501 ) and ( 505 ) makes a bend using the bend-adapter ( 523 ) and runs horizontally or near horizontally on the wall underneath gutter 505 to join leader ( 517 ), if the position of leader ( 517 ) is also chosen to be a storage site. Leader ( 517 ) is then connected to a storage tank ( 537 ). In this case, the cross section of leaders ( 513 ) and ( 517 ) is twice the cross section size of leaders ( 511 ) and ( 515 ) to accommodate the added water volume from leaders ( 511 ) and ( 515 ). If one chooses to use only one storage tank, for example if at site ( 513 ), leader ( 517 ) makes a bend and runs along back wall underneath gutter 507 toward leader ( 513 ), and connects to it. In this case the cross section of leader ( 513 ) needs to be 4 times of the cross section of leaders ( 511 ) and ( 515 ), and leader 517 is twice that of 511 and 515 . Leader ( 513 ) then feeds into an above ground storage tank of adequate capacity. In this case, the capacity requirement of the storage tank will be twice as large as when two storage tanks are used at two back wall leader locations. The storage tank can be equipped with a pre-filter as in 301 , if so desired and allocated budget allows. The primary filter for stored rain water is located in line between the stored rain water and the building where the water will be used. If feasible, the storage tank can be located above where the public water is pipe into the building to minimize the energy requirement of pumping the reclaimed water into the building. If it is placed above the main floors of the building, as in an elevated “balcony, or on top of an exterior closet or attached garage roof as described in FIG. 4 , even more pumping energy can be saved. The stored rain water can also be filtered and pumped into a storage container located on the roof top of the building, or an elevated water tower. This water would be available for in-building use through gravity feed even when both public electricity and the generator electricity become unavailable after prolonged power outage.
[0041] FIG. 6 illustrates the separation of in-building drain pipes into grey-water and sewage-water.
[0042] Toilet drain pipes ( 601 ), ( 603 ) feed into the sewage drain system ( 611 ) of the building. For buildings that are connected to public sewage system, ( 611 ) is most economically piped directly to the public sewage system. For a large campus of multiple buildings, or on agriculture properties, ( 611 ) can be piped to an onsite sewage treatment system. Grey-water drain pipes under sinks, showers, and tubs, is collected in a separate in-house grey water drainage, collection, treatment, and storage system, treated and stored for reuse.
[0043] A serious public sewage water problem is caused by building occupants or employees dumping seriously polluting substances such as medicine, cleaning chemicals, paint thinners, thinned paint, pesticides, and other toxic but common chemicals into sink drains. This should certainly be excluded from the water reclamation system. A separate chemical dump sink with a separate drain that collects such wastes into a dedicated container that can be picked up by commercial or public treatment facility for separate and specialized treatment, for example, using plasma-arc gasification technology.
[0044] Toilet flushing water supply line can be separated from the personal hygiene, drinking and cooking water supply line, and be supplied from a lessor grade purified reclaimed water. Household cleaning water supply line can also be separated and separately supplied, or supplied along with the toilet flushing supply line.
[0045] FIG. 7 illustrates a by-passable whole house water purification and enhancement system.
[0046] This system can be used for both incoming public water, as well as the reclaimed water. Commercially available systems, such as activated carbon and membrane, Nano-membrane, reverse osmosis, hollow-fiber membrane are highly effective down to 0.1 micron size in removing impurities including chlorine and chlorine disinfection by-products, trace organic pharmaceutical, trace toxic substances such as mercury, lead, aluminum, and Fluoride, as well as microbes such as fungi spores, mold, parasite, etc. Sodium Chlorite and Chlorine Dioxide, as well as Ultraviolet Light or Ozone kills micro bacteria and viruses. Activated carbon alone also kills a very large percentage of microbes. The purified water fit for drinking can be further treated for a slightly basic PH, and added to it balanced mineral nutrients that are lacking in the geographic area. The bi-product of converting neutral PH water to a slightly basic PH level is slightly acidic water on the other hand, which can be used for chemical free household cleaning. | A water reclamation system includes a drainage lane overlaying a downward graded area of land and configured to receive water run-off from the land. At least one collection ditch coupled to the at least one drainage lane is configured to receive water from the drainage lane. At least one collection pipe housed is within and extends outwardly from the at least one collection ditch. A first container is coupled to the at least one collection pipe and configured to receive water from the at least one collection pipe. Housed within the first container is at least one water purifying filter and a pump configured to evacuate at least a portion of water within the container to a destination. A second container is in communication with the first container and is configured to: subject water received from the first container to a purification process; and store the purified water. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a process and an apparatus for producing an optically uniform, i.e., optically homogeneous, highly transparent coating or the like from a mixture of a plurality of components which can be flow-molded and which react to form a polyurethane.
2. Description of the Prior Art
In certain cases, objects comprised of plastic material must satisfy extremely stringent specifications with regard to the uniformity of the plastic material. For example, certain coatings, films, or laminating sheets are required to be free of optical defects and distortion. Such highly transparent coatings, films, and sheets are employed, e.g., as films to protect against fragmentation, on window panes comprised of silicate glass; or as coatings to improve the abrasion resistance of plastic objects. Examples of such safety glass window panes and abrasion-resistant plastic sheets, as well as examples of production of such coatings and the like from specific polyurethane materials, are described, e.g., in Ger. OS No. 20 58 504, Ger. AS Nos. 22 28 299, and 26 29 779.
In reactive flow-molding processes of this type, employing a plurality of components, the homogeneity and thus the optical quality of the polyurethane sheet or film is basically determined by the mixing operation which immediately precedes the molding of the said coating. As soon as the reactants come into contact, the polyaddition reaction effectively begins. Since the reacted portions of the mixture have a different viscosity from that of the reaction components (i.e., the unreacted reaction mixture), striae form within the molding mass which are visible in the sheet or film when the reaction is finished. Therefore, it is important to produce a mixture of the reaction components which is as homogeneous as possible, in the shortest possible time, in order to bring about uniform reaction in the molded mass so as to avoid formation of striae. There is an additional difficulty presented in mixing the reaction components in the case of polyurethane, in that the two components, viz. the polyol and the isocyanate, have substantially different viscosities, differing, according to measurements, by a factor of 4 to 8 or more.
Therefore, a need continues to exist for a process for mixing two or more components of a system of a plurality of components, in particular components of a reaction mixture containing and/or resulting in a polyurethane molding resin, whereby in the process an optically homogenous mixture is produced in the minimum time possible following the combination of the reaction components which satisfies the stringent requirements of physical and chemical homogeneity.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a process for mixing two or more components of a system of a plurality of components, in particular components of a reaction mixture containing and/or resulting in a polyurethane molding resin, whereby in the process an optically homogeneous mixture is produced in the minimum time possible following the combination of the reaction components.
It is also an object of this invention to provide such a process which produces an optically homogeneous mixture which satisfies the stringent requirements of physical and chemical homogeneity.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects, features and attendant advantages of the present invention will be more fully appreciated as the same becomes better understood from the following detailed description when considered in connection with the accompanying drawings in which like reference characters designate like or corresponding parts and wherein:
FIG. 1 is a process diagram of the process according to the invention;
FIG. 2 is a cross section of a static mixing tube;
FIG. 3 is a longitudinal cross section of a dynamic mixer;
FIG. 4 is a detailed view of region IV of FIG. 3;
FIG. 5 is a partial cross-sectional view of the dynamic mixer through line V--V of FIG. 3;
FIG. 6 is a detailed view of region VI of FIG. 5; and
FIG. 7 is a cross section of the mixing chamber of the dynamic mixer through line VII--VII of FIG. 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
According to the present invention, after the reaction components are combined, they are mixed first in a mixer operating on the basis of a static mixing principle, and then in a dynamic mixer which immediately follows the static mixer.
The inventive process yields transparent sheets or films which are free of striae and are of optimal optical quality. This result is achieved by a specific combination of two known mixing operations conducted in a specific order, which results from the finding that additional advantagers in improved mixing accrue to certain preferred arrangements of the apparatuses employed.
The present invention is based on the discovery that the use of known mixing processes does not lead to the desired result in the case of the particular problems described, and that it is impossible to produce films or the like free from optical distortion, i.e., free from striae, by known means. If, for example, one employs static mixing processes making use of various known mixers for mixing liquids in the laminar flow regime, it is found that a relatively long mixing length is needed to produce sufficient mixing of the reaction components. The reaction mixture requires a relatively long time to pass through this long mixing length. Meanwhile, the polyaddition process, already begun, continues to proceed. Further, the long mixing length aggravates differences in residence time among different localized flow paths, whereby at the downstream end of the mixing length different reaction states and conditions pertain across the entirety of the cross section. If, in place of a static mixing tube one employs a dynamic mixer, with the aim of reducing the mixing time, the result is no more satisfactory. This is due to the fact that under low mixing intensity regimes, the quality of mixing is inadequate but under high mixing intensity regimes the temperature of the reaction mixture is increased by frictional heating, whereby local fractions of the mixture are generated which are of an advanced degree of polymerization. This is very detrimental to the optical properties of the molded sheet or film. The overall acceleration of the polyaddition reaction increases the viscosity of the molding mixture (on a gross scale as well), which can be very detrimental at the stage of the molding operation, since it becomes virtually impossible to produce a uniform molded sheet or film within the mold space or volume. The abovementioned drawbacks are avoidable only by the inventive process, whereby after the reaction components are combined they pass for a distance through a static mixer which is so short that only good premixing and nothing more is achieved but it is achieved in a short time and without an increase in temperature; then the statically premixed reaction mixture is immediately fed to a dynamic mixing apparatus wherein mixing takes place to the degree of homogeneity (well-mixing) required.
As a general rule, a catalyst and possibly other adjuvants, e.g., a stabilizer to increase resistance to U.V. radiation, are added to the reaction mixture. In another advantageous embodiment of the invention, the adjuvants are uniformly mixed into one or more of the reaction components before the reaction components are combined. It has been found that this technique enables one to reliably eliminate defects in homogeneity attributable to the manner in which the adjuvants are fed.
A particularly advantageous embodiment of an apparatus suited for carrying out the inventive process comprises a dynamic mixer wherein the mixing shaft is coupled to drive means via a coupling employing permanent magnets, wherewith the reaction mixture flows between the wall of the casing of the mixer and an interior ring element of the magnetic coupling, which ring is connected to the mixing shaft, and wherewith the said interior magnetic coupling ring is driven by an exterior magnetic coupling ring disposed exterior to the casing of the mixer. A dynamic mixer of this construction has the advantage that the reaction mixture is driven in essentially plug flow through the mixer, as a consequence of the fact that the mixer is free of stagnant regions wherein portions of the reaction mixture may have longer residence times than in other regions. Another advantage is that one may increase the pressure of the reaction mixture passing through this mixer to a substantial degree without facing problems of sealing. The tolerance of increased pressures enables operation at higher flow rates, reducing the residence time of the plastic reaction mixture in the mixer, which enables one to avoid the risk of premature setting or of too great a degree of polymerization of the reaction mixture, which occurrences affect the fluidity and homogeneity of the reaction mixture of the plastic material. The reaction mixture leaving the mixer is of a completely homogeneous composition (i.e., both chemically and physically), and is thus totally free from (the susceptibility to produce) striae.
The inventive mixing process and apparatus described infra in detail are suited not only for mixing reaction resins but also obviously for mixing and homogenizing in other systems, e.g., mixing of solvents and adhesives, where the mixture must meet particularly stringent requirements relating to homogeneity. This will always be the case if the film or coating (e.g., of adhesive) must be free from striae in order to ensure freedom from optical distortion.
The stages in the process are illustrated schematically in FIG. 1. The flow-moldable polyurethane resin is produced from components K1 and K2, K1 comprising a polyether obtained by condensing epoxypropane with a triol and having a molecular weight of c. 450 and a content of free OH groups of 10.5 to 12% (by wt.) and K2 comprising a biuret of 1,6-hexanediisocyanate, having a content of free NCO groups of 21 to 22% (by wt.). The viscosity of component K1 at ambient temperature is 300 to 800 centipoise, and that of component K2 is 2,000 to 14,000 cp. To produce the flow-moldable mixture, the following additives are employed: 2,6-di-t-butyl-p-cresol in the amount of 2.3% (by wt.) (based on the amount of K1), as a stabilizer against U.V. radiation, and dibutyltin dilaurate in the amount of 0.05% (based on the amount of K1), as a catalyst. K1 and K2 are mixed together in a weight ratio of about 1:1.
Before components K1 and K2 are combined in the mixing chamber 1, a mixture of the additives (the stabilizer S and the catalyst B, in the indicated ratio) is produced, and this mixture is charged to the mixing apparatus 3 by the dosing pump 2 (shown schematically). Compnent K1 is then charged to mixing apparatus 3 by dosing pump 4. Dosing pumps 2 and 4 are provided with means such that the desired ratio of stabilizer-catalyst mixture to component K1 is maintained with precision. The mixing apparatus 3 may basically be of any type desired, and is not a critical element of the process. Static mixers of the type 10 described in detail infra, of which mixing chamber 1 is an example, have proven suitable for the mixing apparatus 3. Component K1 after mixing with the stabilizer and catalyst is fed from mixing apparatus 3 to the mixing chamber 1.
Component K2 is also fed to mixing chamber 1 in the desired ratio, by dosing pump 8.
Mixing chamber 1 serves simply to combine the reactants. The supply pipes for the two components comprise check valves (not shown) which prevent reversal of the direction of flow in the event of a pressure inversion. The outlet pipe (of mixing chamber 1) is connected to a nozzle 9 which feeds the mixed reactants into the static mixer 10.
Static mixer 10 is illustrated in longitudinal cross section in FIG. 2. It is comprised of a pipe 11 of length 360 mm, provided with flanges 12, in which pipe the mixing elements 13 and 14 are installed, each of which is 24 mm long with diameter 12 mm (corresponding to the inner diameter of piper 11). The mixing elements comprise latch structures disposed generally transversely to the flow direction, each element shifted by a (radial) angle of 90° with respect to the preceding one. Fifteen such elements 13 and 14 in all are disposed alternatingly in the pipe 11. The laths of the mixing elements disposed transversely to the (gross) flow direction cause continuous mixing of the components which are sought to be mixed, by breaking them, i.e., "the flow", up into films and dispersing them (i.e., "the films") over the entire cross section of the pipe.
The Sulzer type SMX static mixer (supplied by Gebrueder Sulzer AG, of Switzerland) and the N-FORM mixer (supplied by Societe Bran & Luebbe, of Hamburg, W. Germany) have proven particularly suitable for this application.
Immediately after passing through the static mixer 10, the reaction mixture is fed to the dynamic mixer 21 illustrated in detail in FIGS. 3-7. FIG. 3 shows the mixer 21 with fixed forward housing piece 22 and entrance pipe 23 through which the fluid reaction mixture passes. Forward housing piece 22 is provided with a cylindrical channel 24 which is connected to entrance pipe 23. Another cylindrical channel 25 branches above channel 24 to a (radially) central chamber 35 in housing piece 22. Part of the reaction mixture passes directly through channel 25 and across the ball bearing 34 which supports the shaft 33, thus assuring continuous rinsing of the bearing and avoiding flow stagnation in the region of the bearing. The casing 26 of the mixer may be rigidly connected to the fowar housing piece 26, e.g., by machine screws. The casing 26 is terminated by a detachable end piece 27 which is provided with an axially running channel 28 and an exit pipe 29 for outflow of the fluid reaction mixture comprised of synthetic material. An inclined branch channel 30 connects the (radially) central cavity 31 to channel 28. Rotating shaft 33 is disposed in cavity 31. In the interior of casing 26 there is disposed an interior coupling ring 32 (part of the magnetic coupling described infra) which is rigidly connected to shaft 33. Said ring is rotatably mounted on ball bearing 34 in cavity 35 of housing piece 22. Permanent magnets 36 are disposed around the periphery of the interior coupling ring and are axially inserted to fit in corresponding cavities of an annular element 37. The permanent magnets 36 are covered on the outside, e.g., by a thin-walled hollow cylinder 38 (FIG. 4) comprised, e.g., of a chemically resistant synthetic material.
The mixing elements 39, which may be in particular mixing crosses, are disposed a certain distance apart on the mixing shaft 33 in the mixing chamber 40. Shaft 33 extends through the entire mixing chamber 40, and is terminated in a journal 41 rotatably mounted on bearings 42 and 43 in the end piece 27. Part of the reaction mixture leaving the mixing chamber passes through bearings 42 and 43 and channel 30 to exit pipe 29.
Fixed mixing bars 44 are mounted in the wall of casing 26 in the axial region of mixing chamber 40. The ends of these bars extend into the mixing chamber 40 between the rotating crosses 39 of shaft 33. Preferably two or four mixing bars are distributed around the periphery of casing 26 at each axial mixing-bar location (FIG. 7).
Exterior to the casing 26 at the axial level of ring 32, a coupling ring 45 is mounted, which rotates on the casing, preferably by the intermediary of a bearing 46. Ring 45 is connected via spur gear 47 to a motor (not shown) which drives said ring. Permanent magnets 48 are housed parallel in cavities interior to the annular surface of ring 45 which surface faces the casing 26, said magnets being distributed around the periphery of said surface. The permanent magnets in exterior ring 45 and in annular element 37 are disposed so that they are always oriented with opposite poles facing. Thus, if the magnets disposed in ring 45 are oriented with south poles facing interiorly, the magnets disposed in element 37 are oriented with north poles facing exteriorly (FIG. 6).
The synthetic fluid reaction mixture passes through entrance pipe 23, channel 24 in forward housing piece 22, and the annular space between interior coupling ring 32 and the wall of casing 26, into mixing chamber 40 disposed downstream of the permanent magnet coupling mechanism. At the same time, part of the reaction mixture flows through channel 25 (and space 35) and directly through ball bearing 34. The reaction mixture is subjected to fluid dynamic treatment (agitation etc.) in the mixing chamber 40, where intensive mixing takes place and stagnant zones are prevented from forming in the shaft coupling region near the bearings and in the mixing chamber itself. The reaction mixture passes out of the mixing chamber 40 through the bearings 42 and 43, and then flows through channel 28 and exit pipe 29. The arrows (other than the arrows clearly associated with cross section lines V--V and VII--VII and unit arrow 21) indicate the flow direction. The flow direction and ratio in the region of the magnetic coupling are shown in particular in FIG. 4. (In operation, a vertical orientation of the mixer is anticipated, with exit pipe 29 at the top.)
It is seen clearly from FIG. 3 that the mixer illustrated is free of sliding seal joints which can heat up during operation and thereby cause a locally excessive rate of polymerization. The synthetic fluid reaction mixture flows quasi-linearly through the mixer without passing across stagnant regions. This feature is important in enabling production of a reaction mixture which is uniformly well-mixed.
When the reaction mixture passes out through exit pipe 29 it has optimal homogeneity. It is admitted through pipe 50 to flow-molding device 51, which may be in the form of a so-called molding head with scraper, of the type disclosed, e.g., in German Pat. No. 2,614,596. Where the reaction mixture is to be employed to produce a sheet or film, the molding substrate 52 employed is advantageously a glass sheet. The reaction mixture is applied to the molding substrate 52 in a layer of uniform thickness. After polymerization of layer 53 with appropriate (external) heating, the finished polyurethane sheet is stripped from the molding substrate 52.
Having now fully described this invention, it will be apparent to one of ordinary skill in the art that many changes and modifications can be made thereto without departing from the spirit or scope of the invention as set forth herein. | A process and apparatus for producing a homogeneous and highly transparent sheet or film from a mixture of a plurality of components which comprises mixing the combined reaction components and depositing the reaction mixture on a molding substrate where the reaction is carried out in a layer thereon, wherein the combined reaction components are mixed, first, in a static mixer and, immediately thereafter, in a dynamic mixer.
The invention can be advantageously applied to the manufacture of polyurethane sheets which can be employed in laminated glass sheets. | 8 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority to German Patent Application No. 102 51 574.3, filed Nov. 6, 2002, the disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
The invention relates to an apparatus provided in a spinning preparation machine, such as a carding machine, a cleaner, or the like, for measuring distances between a sensor and clothing surfaces, where a clothed roll (main carding cylinder) cooperates with clothed flat bars which glide on slide guides by means of flat bar slide elements.
The distances between the clothing of the main carding cylinder and clothings which face same are of substantial significance as concerns machine and fiber technology. The carding result, that is, the cleaning, nep formation and fiber shortening, is to a large measure dependent from the carding clearance, that is, from the distance between the clothing of the main carding cylinder and the clothings of the traveling flats. The guidance of air about the main carding cylinder and the removal of heat are also dependent from the distance between the clothing of the main carding cylinder and the clothed flat bars. The distances are affected by various, partly opposed influences. The wear of facing clothing leads to an increase of the carding clearance which involves an increase of the nep number and a decrease of the fiber shortening. An increase of the rpm of the main carding cylinder, for example, for intensifying the cleaning effect, causes, by virtue of centrifugal forces, an expansion of the main carding cylinder, including its clothing, and thus results in a decrease of the carding clearance. A temperature increase when processing large fiber quantities and certain fiber types, such as chemical fibers, also causes the main carding cylinder to expand, so that for this reason too, the distances decrease. The carding clearance is affected particularly by the machine settings, on the one hand, and by the condition of the clothing, on the other hand. The most important carding clearance of the traveling flats type carding machine is located in the principal carding zone, that is, between the main carding cylinder and the traveling flats assembly. In most cases both clothings which border the working distance are in motion.
In practice, the quality of the flat bar clothing is regularly optically examined by an attendant. A wear results in an increase of the carding clearance. In a known apparatus described in German Patent Document DE-OS 199 23 419, the distance between a sensor and the points of the flat bar clothing is determined. The stationary sensor is associated with the traveling flats and is facing the flat bars as they are guided along their return path.
SUMMARY OF THE INVENTION
It is an object of the invention to improve an apparatus of the type described above for measuring the distances at the clothing of the carding machine.
Embodiments of the invention include an arrangement in a spinning preparation machine. The arrangement has a clothed roll having clothing presenting free ends; flat bar slide elements; clothed flat bars having clothing presenting free ends and cooperating with the clothing of the clothed roll, the flat bars having slide guides which glide on the flat bar slide elements; and a measuring apparatus comprising at least one sensor arranged for detecting a distance between a reference surface and at least one of the free ends of the clothing of the clothed roll and the free ends of the clothing of the clothed flat bars.
The measures according to the invention permit a simple and direct determination of the distance between the clothing points and the slide surface of the flat bar slide elements (for example, flat bar pins). In this manner, on the one hand, a quality monitoring concerning the uniformity of the flat bars may be obtained and, on the other hand, a simpler and more accurate setting of the distance between the points of the flat bar clothing and the main carding cylinder may be effected. It is a particular advantage to determine the wear, that is, the consumption of the flat bar clothing, particularly after a long running period. Upon a change in the carding clearance, the effect of the change of the flat bar clothing is determined directly as concerns wear and also indirectly as concerns the distance change relative to the main carding cylinder, particularly due to the wear of the clothing of the main carding cylinder, the expansion of the main carding cylinder effected by centrifugal forces and temperature change. In this manner an optimal setting of the carding clearance is feasible, namely, related to a desired value. Measuring is possible during operation.
It is a further advantage that the geometrically tallest flat bar is found. Furthermore, an adjustment of the flat bar after the grinding of the flat bar clothing is possible.
Expediently, the height/distance sensor determines the distance “c” between the free ends of the flat bar clothing and the slide surfaces of the flat bar slide elements. In practice slight manufacturing tolerances of the flat bars and the clothing may appear which may be ascertained in this manner. This makes possible a determination of a mid value for the distance “c” for a plurality or for all of the flat bars, thus obtaining a uniform carding clearance. Furthermore, determining the distance “c” yields a magnitude with which the carding clearance “a” may be directly calculated. Advantageously, the height/distance sensor may determine the distance “b” between the free ends of the clothing of the main carding cylinder and the slide guide for the flat bar slide elements. As a result, a further magnitude is made available in a simple manner for directly calculating the carding clearance “a”.
Due to the fact that the slide faces of the flat bar slide elements glide on the slide guide, the slide faces correspond to the slide guide. The distance “a” (carding clearance) between the free ends of the flat bar clothing and the free end of the clothing of the main carding cylinder is preferably determined in accordance with the relationship “a”=“b”−“c”. The determination is effected expediently by computation, for which preferably an electronic regulating and control device may be used. In this manner, at the same time, a predetermined optimal carding clearance may be automatically set by a device which is connected to the electronic control and regulating device. The computed carding clearance may, however, also be outputted to an indicating device, a monitor, a printer or the like. Thus the carding clearance may be set by a control with an inputting device or may be set manually in a mechanical manner.
The invention permits a determination of the important distance between the slide surface of the flat bar heads and the free ends (points) of the flat bar clothing. Further, by the measures according to the invention, an accurate adjustment of the flat bar heads with respect to the clothing points is effected and thus the correct distance between the clothing points and the clothing of the main carding cylinder (carding clearance) is obtained.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is explained below in further detail with the aid of exemplary embodiments shown in the drawings, wherein:
FIG. 1 shows a schematic side view of a carding machine including an apparatus according to the invention;
FIGS. 2 a and 2 b show a side view and section through clothed flat bars, a part of a slide guide and a flexible bend and the distance between the clothing of the flat bars and the clothing of the main carding cylinder;
FIG. 3 shows a front view of a returning flat bar and three apparatuses according to the invention;
FIG. 4 shows a side view of three returning flat bars and a stationary measuring apparatus;
FIG. 5 shows a laser beam of a light section sensor in the zone of a flat bar head;
FIG. 6 shows a top view of a measuring flat bar having two light section sensors;
FIG. 7 shows a laser beam of a light section sensor in the zone of a flat bar head of a measuring flat bar; and
FIG. 8 shows a block diagram of an electronic regulating and control device to which at least a stationary sensor, a moved sensor and a setting device for displacing the slide guides are connected.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIGS. 1 , 2 a and 2 b show a carding machine, for example, a Trützschler high-performance carding machine DK 903 , including a feed roll 1 , a feed table 2 , licker-ins 3 a , 3 b , 3 c , a main carding cylinder 4 , a doffer 5 , a stripping roll 6 , crushing rolls 7 , 8 , a web guiding element 9 , a sliver trumpet 10 , calendar rolls 11 , 12 , traveling flats 13 having clothed flat bars 14 , a coiler can 15 and a sliver coiler 16 . The rotary directions of the rolls are indicated by curved arrows. The working direction is designated at arrow A. Stationary carding elements 33 and 34 face the main carding cylinder clothing 4 a . The apparatus 24 according to the invention is arranged facing the clothing of the returning flat bars 14 ′.
According to FIG. 2 a , a flexible bend 17 a , having a plurality of non-illustrated set screws, is secured to the machine stand, laterally on each side of the carding machine. The flexible bend 17 a has a convex outer surface 17 1 and an underside 17 2 . A slide guide 20 , made, for example, of a low-friction plastic material is arranged above the flexible bend 17 a . The slide guide 20 has a convex outer surface 20 1 and a concave inner surface 20 2 . The concave inner surface 20 2 lies on the convex outer surface 17 1 and may glide thereon in the direction of arrows B, C. A slide guide 20 and a convex outer surface 17 are provided to support each end of the flat bars (shown as 20 a , 20 b , 17 a and 17 b in FIG. 2 b ). Each flat bar 14 which may be structured, for example, in accordance with European Patent Application EP 0 567 747 A1, is formed of a back part 14 a and a carrier body 14 b . The carrier body 14 b has a foot surface, two side surfaces and two upper surfaces. Each flat bar 14 has, at both ends, a respective flat bar head 14 I , 14 II (see FIG. 2 b ) each having two steel pins 14 1 , 14 2 and, respectively, 14 3 , 14 4 which are, with one part, axially affixed to the flat bar. The parts of the steel pins 14 1 , 14 2 projecting beyond the end faces of the carrier body 14 b glide on the convex outer surface 20 1 of the slide guide 20 in the direction of the arrow D.
A clothing strip 18 , having clothing 19 , is mounted on the underface of the carrier body 14 b . The circle circumscribing the points of the flat bar clothing 19 is designated as 21 . The main carding cylinder 4 has on its periphery a main carding cylinder clothing 4 a , such as a saw tooth clothing. The circle circumscribing the points of the main carding cylinder clothing 4 a is designated as 22 . The distance between the circles 21 and 22 is designated by “a” and is, for example, 3/1000″. The distance between the convex outer surface 20 1 and the circle 22 is designated by “b”. The radius of the convex outer surface 20 1 is designated as r 1 , and the radius of the circle 22 is designated as r 2 . The radii r 1 and r 2 are taken from the axis M of the main carding cylinder 4 .
FIG. 3 shows a flat bar 14 ′ whose steel pins 14 1 , 14 2 and 14 3 , 14 4 glide on stationary supports 29 a and 29 b , respectively, during the return travel on that side of the traveling flats 13 (see FIG. 1 ) which is opposite the slide guide 20 . Three light section sensors 24 a , 24 b and 24 c , for example, SICK light section sensors DMH, functioning as height/distance sensors face at a distance the clothing 19 of the flat bar 14 ′. Light sensors 24 a , 24 b , and 24 c produce light beams 25 3 , 25 4 and 25 5 , respectively. The light section sensors are sensors having a large measuring range. The provision of the three sensors 24 a through 24 c allows conclusions to be drawn concerning the wear of the flat bar 14 as viewed over the length l (see FIG. 2 b ).
According to FIGS. 4 and 5 , three flat bars 14 ′, 14 ″, 14 ′″ have clothing 19 ′, 19 ″, 19 ″′, respectively.
Flat bar 14 ″ glides with surfaces 14 ** of the slide pins 14 1 through 14 4 in the direction E over the stationary support 29 a . The measuring surface 24 ′ of the stationary sensor 24 faces at a distance d the points of the clothing 19 ″ of the flat bar 14 ″. The light section sensor 24 generates, in the direction of the flat bar length (see FIG. 5 ), a laser beam 25 which impinges on the slide surfaces 14 * of the slide pins 14 1 through 14 4 as well as on the flat bar clothing 19 ″. As the flat bars 14 pass under the sensor 24 , the height profile shown in FIG. 5 is obtained. For an evaluation, the measured value of the two slide pins 14 3 , 14 4 is deducted from the maximum value which is to be filtered out via the constant pin distance. The height difference c thus obtained is utilized for checking the flat bars 14 (uniformity check) and/or for setting the carding clearance “a”. The distance between the free ends of the flat bar clothing 19 ″ and the slide surfaces 14 * of the flat bars 14 1 through 14 4 is designated as “c”. The distance between the sensor 24 ′ and the slide surfaces 14 * of the flat bars 14 1 through 14 4 is designated as “f”. The distance between the sensor 24 ′ and the free ends of the flat bar clothing 19 ″ is designated as “d”.
As shown in FIG. 6 , the flat bar heads of a measuring flat bar 26 glide on the outer surfaces 20 1 of the slide guides 20 a and 20 b , respectively (see FIGS. 2 a , 2 b ). In the regions of the two ends of the measuring flat bar 26 , respective light section sensors 24 1 and 24 2 as height/distance sensors are arranged between the two pins of the respective flat bar heads. The light section sensors 24 1 and 24 2 generate, in the length direction of the flat bars (axial direction), laser beams 25 1 and 25 2 which impinge on the outer surfaces 20 1 and 20 2 as well as on the surface of the clothing 4 a of the main carding cylinder 4 . As the measuring flat bar 26 passes over the outer surfaces 20 1 , 20 1 and the main carding cylinder clothing 4 a , a height profile is obtained which is evaluated and which yields a height difference “b” (see FIGS. 2 a , 2 b ).
According to FIG. 7 the distance between the sensor 24 1 and the slide surface 20 1 (outer surface) of the slide guide 20 is designated as “g”. The distance between the sensor 24 1 and the points of the main carding cylinder clothing 4 a is designated as “h”. The height difference between “h” and “g” results in “b”. It is noted in this connection that the slide surfaces 14 * of the slide pins 14 1 through 14 4 lie on the outer surfaces 20 1 , 20 1 and glide thereon.
As a result, the distance “a” (carding clearance) is obtained between the free ends of the fat bar clothing 19 and the free ends of the main carding cylinder clothing 4 a by the relationship “a”=“b”−“c”.
In practice at least one of the flat bars 14 ′, 14 ″, 14 ″′ is replaced by the measuring flat bar 26 for the duration of the measuring process. Thus, the measuring flat bar 26 circulates endlessly—like the flat bars 14 —by means of two (non-illustrated) toothed belts on either side of the carding machine.
The measuring flat bar 26 may also be advantageously installed stationarily relative to the clothing 19 of the returning flat bars 14 as shown in FIG. 4 .
According to FIG. 8 an electronic control and regulating device 27 , for example a microcomputer, is provided to which, for example, the stationary sensor 24 ′ and the circulating sensor 24 1 are connected. The carding clearance “a” is calculated from the measuring results yielded by the sensors 24 ′ and 24 1 . The computed carding clearance “a” is compared with a stored (pre-given) carding clearance a′. Further, to the electronic control and regulating device 27 an automatic setting device 28 for the carding clearance “a” is connected which is known, for example, from German Patent Document DE-OS 196 51 894.
It is to be understood that even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and function of the invention, the disclosure is illustrative only, and changes may be made in detail, especially in matters of shape, size and arrangement of parts within the principles of the invention.
The embodiments illustrated and discussed in this specification are intended only to teach those skilled in the art the best way known to the inventors to make and use the invention. Nothing in this specification should be considered as limiting the scope of the invention. All examples presented are representative and non-limiting. The above-described embodiments of the invention may be modified or varied, without departing from the invention, as appreciated by those skilled in the art in light of the above teachings. It is therefore to be understood that the invention may be practiced otherwise than as specifically described. | An arrangement in a spinning preparation machine is provided. The arrangement has a clothed roll having clothing presenting free ends; flat bar slide elements; clothed flat bars having clothing presenting free ends and cooperating with the clothing of the clothed roll, the flat bars having slide guides which glide on the flat bar slide elements; and a measuring apparatus comprising at least one sensor arranged for detecting a distance between a reference surface and at least one of the free ends of the clothing of the clothed roll and the free ends of the clothing of the clothed flat bars. | 3 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to an exposure method for use in photolithography and a mask for use in photolithography. More particularly, the invention relates to a phase-shift mask and an exposure method using the phase-shift mask.
[0003] 2. Description of the Related Art
[0004] To form patterns of semiconductor elements, a photolithography technique is commonly employed. A pattern of a mask is transferred to a photosensitive resin layer provided on a semiconductor substrate by the photolithography technique. The photosensitive resin is also known as “resist.” A resist is classified into two type, i.e., negative type and positive type. The negative-type resist is of the type; any part of which that has been exposed to the light applied through a mask will remain on the semiconductor substrate. The positive-type resist is of the type; any part of which that has been exposed to the light applied through a mask will be removed from the semiconductor substrate.
[0005] In recent years, it has been demanded that an image be formed on a resist layer in higher resolution to provide fine patterns of semiconductor elements. Fine semiconductor element patterns increase integration density of a semiconductor integrated circuit.
[0006] To enhance the resolution of an image formed on a resist, a phase shift exposure method is proposed in 1982. In the phase shift exposure method, the phase difference between light beams applied is utilized to improve the resolution of the image focused on a resist layer. The principle of the phase shift exposure will be described, with reference to FIGS. 1A to 1 D and FIGS. 2A to 2 D.
[0007] In the ordinary exposure, the light applied perpendicularly to a mask 106 passes through the transparent regions 150 and 151 of the mask as illustrated in FIG. 1A. Chromium mask patterns 121 are provided on the mask 106 . The mask 106 has transparent regions 150 and 151 . The light beams passing through the transparent regions 150 and 151 have the same phase. The light beams emanate from the transparent regions 150 and 151 and pass through the projection lens of a reducing projection exposure apparatus. The two beams are then focused on the surface of a resist layer, which is on an image-forming surface.
[0008] The distance between the transparent regions 150 and 151 cannot be reduced to an infinitesimal value, for the following reason. If the distance is extremely short, the two beams passing the regions 150 and 151 overlaps at the image-forming surface as indicated by the broken lines in FIG. 1C. The light beams, which have a same phase, intensify each other at the image-forming surface. As a result, the light-intensity distribution on the surface of the resist has one peak as illustrated in solid line in FIG. 1D. Consequently, the chromium mask patterns 121 are not correctly transferred to the resist layer. Thus, the interval between the transparent regions 150 and 151 cannot be decreased over a certain limit. The limit R of resolution for any image formed on a resist is given as follows:
R=K 1 ×λ/NA (1)
[0009] where K 1 is the constant that depends on the properties of the photosensitive resin, λ is the wavelength of the light applied to the mask 106 , and NA is the numerical aperture of the projection lens that is incorporated in the reducing projection exposure apparatus. Here, the limit R is known as “Reyleigh resolution”.
[0010] In the phase shift exposure, light is applied to a resist layer through a phase shift mask 107 as is illustrated in FIG. 2A. The phase shift mask 107 has transparent regions 152 and 153 . The region 153 is provided with a phase shifter 120 , while the region 152 has no phase shifters. The light beam passing through the transparent region 153 is delayed as it passes through the phase shifter 120 . Hence, the light beam passing through the transparent region 153 differs in phase from the light beam passing through the transparent region 152 . The thickness D that the phase shifter should have to impart a phase difference of 180° to the light beams is given as follows:
D=λ/{ 2×( n− 1)} (2)
[0011] where λ is the wavelength of the light applied to the phase shift mask 107 , and n is the refractive index of the phase shifter 120 . If the two light beams emanating from the transparent region 152 and the transparent region 153 , respectively, have a phase difference of 180°, their parts overlapping at the image-forming surface will cancel out each other. As a result, as shown in FIG. 2C, the intensity of light is nil at one part of the surface of the resist layer. It follows that the light-intensity distribution on the resist has two peaks as shown in FIG. 2D. The chromium patterns 121 can therefore be transferred to the resist with high accuracy. Thus, the use of the phase shift mask 107 can enhance the resolution of an image focused on the surface of a resist.
[0012] Also, the phase shift exposure technique can increase the depth of focus (DOF). The term “depth of focus” means the range of distance over which the focus may be displaced without causing troubles. The reason is discussed comparing the ordinary exposure technique and the phase exposure technique in the following.
[0013] In the ordinary exposure using no phase shifters, the more the image-forming surface deviates from the focal plane, the more the two beam emanating from the transparent regions 150 and 151 overlap each other at the image-forming surface. This means that the resolution will sharply decrease if the image-forming surface of the resist deviates from the focal plane.
[0014] In the phase shift exposure, the two adjacent beams emanating from the transparent regions 152 and 153 have a phase difference of 180°. Their overlapping parts cancel out each other at the image-forming surface of the resist layer. The intensity of light is therefore zero at one part of the image-forming surface. Hence, even if defocusing occurs, that is, even if the focus deviates from the image-forming surface, the dimensional precision of the pattern, transferred to the resist, will be hardly influenced. Thus, the depth of focus can be increased in the phase shift exposure.
[0015] The phase shift exposure technique, however, cannot successfully apply to two-dimensional random patterns. The layout pattern of a semiconductor integrated circuit includes regular patterns and random patterns. Each regular pattern extends in one direction only, whereas each random pattern randomly extends first in one direction, and then in another direction. Here, examples of regular patterns are the bit lines and word lines of a DRAM (Dynamic Random Access Memory). Examples of random patterns are the wires of logic circuits. The phase shift masks are designed in accordance with the basic rule that a phase difference of 180° is imparted to two beams that have passed through two adjacent transparent regions. This basic rule can be easily applied to the regular patterns, but not to two-dimensional random patterns.
[0016] [0016]FIG. 3A is a plan view of a phase shift mask 108 that may be used to form two-dimensional random patterns by means of the conventional phase shift exposure. The phase-shift mask 108 is designed to transfer a pattern on a positive-type resist. The mask 108 has a shield region 111 , a transparent region 113 and a transparent region 114 . The shield region 111 is identical in shape to the pattern that is to be transferred to a resist. Phase shifters 120 are provided on the transparent region 113 . The beam passing through the transparent region 113 is out of phase with respect to the beam passing through the transparent region 114 . In other words, the phase of the beam differs by 180° from that of the beam passing through the transparent region 114 . FIG. 3C is a sectional view of the Levenson-type mask 108 , taken along line C-C in FIG. 3A. As FIG. 3C shows, the mask 108 is composed of a glass substrate 122 . A chromium film 121 is provided on the shield region 111 , and a phase shifter 120 is provided on the transparent region 113 . No phase shifters are provided on the transparent region 114 .
[0017] Light is applied to the positive-type resist through the phase-shift mask 108 . Light-exposed parts of the positive-type resist are developed and resist patterns 117 are formed as shown in FIG. 3B. The shield region 111 shields the part 115 of the positive-type resist from the light. Thus, the part 115 of the resist, which opposes the shield region 111 , is developed as is intended.
[0018] In addition, the part 116 of the resist layer, which opposes the boundaries between the transparent regions 113 and 114 , is developed. The beams passing through the transparent region 113 (having a phase shifter) and the transparent region 114 (having no phase shifters) have the opposite phases. The intensity of light is therefore almost nil at the boundary between the transparent regions 113 and 114 . The part 116 of the resist, which opposes the boundary between the transparent regions 113 and 114 , is also developed. That is, not only the part 115 that should be developed, but also the parts 116 which should not be developed is developed.
[0019] With the conventional phase shift exposure it is difficult to prevent the part 116 of the resist layer from being developed. Hence, the conventional phase-shift mask 108 cannot be used to transfer two-dimensional random patterns to a positive-type resist.
[0020] It will be described now how two-dimensional random patterns are transferred to a negative-type resist by means of the conventional phase shift exposure technique. FIG. 4 is a plan view of a phase-shift mask 109 that is used to transfer two-dimensional random patterns to a negative-type resist. As shown in FIG. 4, the phase-shift mask 109 has a shield region 111 ′, a transparent region 113 ′ and a transparent region 114 ′. A phase shifter is provided on the shield region 111 ′. The transparent region 113 has phase shifters while the transparent region 114 ′ has no phase shifters. The phase shifter imparts a phase different of 180° to the beam that has passed through the transparent region 113 ′, with respect to the beam that has passed through the transparent region 114 ′.
[0021] The transparent region 113 ′ is an auxiliary pattern for enhancing the resolution of the negative-type resist pattern that will be formed at a position corresponding to the transparent region 114 ′. Nonetheless, the transparent region 113 ′ is required to have a width equal to or less than the value equivalent to the resolution limit. It is difficult to form transparent regions having such a small width at high reliability. Hence, the conventional phase shift exposure technique cannot process resists to form two-dimensional random patterns on negative-type resists.
[0022] As described above, the conventional phase shift exposure cannot be applied to transfer two-dimensional random patterns on positive-type resists or negative-type resists.
[0023] It is desired that images be formed on resists at resolution high enough to form two-dimensional random patterns.
[0024] It is also desired that two-dimensional random patterns of high precision be transferred to resists by means of phase shift exposure technique.
SUMMARY OF THE INVENTION
[0025] An object of the present invention is to form high-resolution images on resists in the process of forming two-dimensional random patterns.
[0026] Another object of the invention is to transfer two-dimensional random patterns of high precision to resists by means of phase shift exposure technique.
[0027] In order to achieve an aspect of the present invention, a method of forming a photoresist pattern by a photolithography technique is composed of:
[0028] providing a photoresist layer;
[0029] exposing the photoresist layer to a first pattern-defining light using a first mask; and
[0030] exposing the photoresist layer to a second pattern-defining light using a second mask. The first mask includes a shielding region shielding the first pattern-defining light. The second mask includes a phase-shifting region having a phase shifter edge and a non-phase-shifting region adjacent to the phase-shifting region on the phase shifter edge. A first light portion of the second pattern-defining light passes through the phase-shifting region. A second light portion of the second pattern-defining light passes through the non-phase-shifting region. A first phase of the first light portion differs from a second phase of the second light portion. The first and second masks are aligned such that the phase shifter edge overlaps on the shielding region.
[0031] The shield region may include a line resist shielding portion to form a line resist pattern extending to a first direction. The line shielding portion has a centerline extending to the direction. In this case, it is desirable that the phase shifter edge substantially overlaps on the centerline when the first and second masks are aligned.
[0032] The phase shifter edge may be composed of first and second phase shifter edges parallel to each other and extending to the first direction. In this case, a distance between the first and second phase shifter edges is desirably larger than a width of the line shielding portion in a second direction perpendicular to the first direction.
[0033] The phase-shifting region may be provided with a phase-shifter layer. In this case, a thickness of the phase-shifter layer is desirably determined such that a phase difference between the first phase and the second phase ranges from 175 to 185°.
[0034] Also, the first pattern-defining light has a first intensity and the second pattern-defining light has a second intensity. In this case, the second intensity is desirably larger than the first intensity.
[0035] In order to achieve another aspect of the present invention, A mask set is composed of a first mask and second mask. The first mask includes a shielding region shielding a pattern-defining light exposed to the first mask. The second mask includes a phase-shifting region having a phase shifter edge and a non-phase-shifting region adjacent to the phase-shifting region in the phase shifter edge. A first phase of a first light passing through the phase-shifting region differs from a second phase of a second light passing through the non-phase-shifting region. The phase shifter edge overlaps on the shield region when the first and second masks are aligned.
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] [0036]FIGS. 1A to 1 D are diagrams explaining a conventional exposure technique;
[0037] [0037]FIGS. 2A to 2 D are diagrams for explaining a conventional phase shift exposure technique;
[0038] [0038]FIG. 3A is a plan view of a conventional Levenson-type mask that may be used to form two-dimensional random patterns;
[0039] [0039]FIG. 3B is a diagram showing parts of a positive-type resist which are developed after exposed to light applied through the mask shown in FIG. 3A;
[0040] [0040]FIG. 3C is a sectional view of the conventional phase-shift mask 108 ;
[0041] [0041]FIG. 4 is a plan view of another Levenson-type mask 109 that may be used to transfer two-dimensional random patterns;
[0042] [0042]FIG. 5A is a plan view of a chromium mask 1 (i.e., a photo-mask) used in the first exposure step of the exposure method according to the invention;
[0043] [0043]FIG. 5B is a sectional view of the chromium mask 1 ;
[0044] [0044]FIG. 5C is a plan view of a chromium-less phase shift mask 2 used in the second exposure step of the exposure method according to the invention;
[0045] [0045]FIG. 5D is a sectional view of the chromium-less phase shift mask 2 ;
[0046] [0046]FIG. 6A shows a layout of patterns obtained when the masks 1 and 2 are laid one upon the other;
[0047] [0047]FIG. 6B is a sectional view of the chromium mask 1 ;
[0048] [0048]FIG. 6C is a sectional view of the chromium-less phase shift mask 2 ;
[0049] [0049]FIG. 6D represents the intensity distribution of a laser beam 54 applied to a positive-type resist 56 in the first exposure step;
[0050] [0050]FIG. 6E depicts the intensity distribution of a laser beam 58 applied to a positive-type resist 56 in the second exposure step;
[0051] [0051]FIG. 6F represents half the total distribution of the light beams applied to the positive-type resist 56 in the first and second exposure steps;
[0052] [0052]FIG. 7 shows the intensity distribution of light applied to a resist in the exposure method of the invention and the intensity distribution of light applied to a resist in the conventional exposure method;
[0053] [0053]FIGS. 8A to 8 F are diagrams showing the defocus-dependency of the intensity distribution of light applied to a resist, which is observed in the exposure method according to the invention;
[0054] [0054]FIGS. 9A to 9 F are diagrams showing the defocus-dependency of the intensity distribution of light applied to a resist, which is observed in the conventional exposure method;
[0055] [0055]FIG. 10 is a plan view depicting another type of a chromium mask and another type of a chromium-less phase shift mask;
[0056] [0056]FIG. 11 is a sectional view of a chromium-less phase shift mask 2 ′ designed for printing patterns on substrates; and
[0057] [0057]FIG. 12 shows the reducing projection exposure apparatus that is used to perform the exposure method according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0058] An exposure method according to an embodiment of the present invention will be described below, with reference to the accompanying drawings.
[0059] The exposure method according to the present embodiment includes the first exposure step and the second exposure step. The first exposure step is performed, using a chromium mask 1 shown in FIG. 5A. The second exposure step is performed, using a chromium-less phase shift mask 2 shown in FIG. 5B.
[0060] As shown in FIG. 5A, the chromium mask 1 has a shield region 11 and a first transparent region 12 . The shield region 11 defines a two-dimensional random pattern. The term “two-dimensional random pattern” means a pattern composed of lines irregularly arranged, not composed of lines that extend in vertical direction or horizontal direction, or both. In other words, a two-dimensional random pattern is one in which the interval between the constituent lines and/or the length of each constituent line is not regular in the vertical direction and/or the horizontal direction. The shield region 11 defining a two-dimensional random pattern has vertical lines and horizontal lines, each having a centerline 10 . The shape of the shield 11 is determined based on the design values described in the layout data generated by means of CAD (Computer Aided Design).
[0061] As shown in FIG. 5B, the chromium mask 1 includes a transparent substrate 22 . A shield film 21 is provided on a part of the transparent substrate 22 that corresponds to the shield region 11 . The shield film 21 reflects the light applied to the chromium mask 1 in the exposure process, not allowing the light to pass through the chromium mask 1 . No shield film is provided on the first transparent region 12 . Hence, the first transparent region 12 allows passage of the light.
[0062] As shown in FIG. 5C, the chromium-less phase shift mask 2 has a second transparent region 13 and a third transparent region 14 . In the second transparent region 13 , a phase shifter 20 is formed on the transparent substrate 24 as is illustrated in FIG. 5D. In the third transparent region 14 , no phase shifters are provided on the transparent substrate 24 . The phase shifter 20 shifts the phase of the beam passing through the second transparent region 13 , with respect to the phase of the beam passing through the third transparent region 14 . The phase shifter 20 has such a thickness d that the beam output from it differs in phase by 180° from the beam input to it. The thickness d is defined as follows:
d=λ/{ 2×( n− 1)}. (3)
[0063] The second transparent region 13 has a phase shifter edge 16 . The phase shifter edge 16 is a boundary between the second transparent region 13 and the third transparent region 14 .
[0064] The region near the phase shifter edge 16 functions as a shield section. The beams passing through the second transparent region 13 and third transparent region 14 , respectively, are out of phase with respect to each other. The intensity of light is therefore almost nil at position on a resist layer, where the image of the phase shift edge 16 is formed. The chromium-less phase shift mask 2 substantially has a shield region, though no shield films are provided on it.
[0065] [0065]FIG. 6A shows a layout of patterns obtained when the chromium mask 1 and the chromium-less phase shift mask 2 are laid one upon the other. The phase shifter edge 16 has a part 15 aligning with the centerline 10 of the shield region 11 of the chromium mask 1 . When the masks 1 and 2 are laid one upon the other as shown in FIG. 6A, the centerline 10 of the shield region 11 overlaps the part 15 of the phase shifter edge 16 of the second transparent region 13 shown in FIG. 5B. In FIGS. 5A and 6A, the part 15 of the phase shifter edge 16 is indicated in thick line. The thick line does not mean that the boundary line is thick in part.
[0066] When exposure is carried out using the chromium-less phase shift mask 2 , the part of the resist layer which is near the part on which the phase shifter edge 16 is projected will not be exposed to light. That is, a resist pattern may be formed near the part on which the phase shifter edge 16 is projected. However, no resist patterns will be formed in that part of the resist layer which is exposed to light through the chromium mask 1 in the first exposure step. In the exposure method of this invention, a resist pattern is formed in only a part of the resist layer which is near the position where the phase shifter edge 16 of the second transparent region 12 is projected, and is also covered with the shield region 11 .
[0067] As shown in FIGS. 6A to 6 C, the width of the second transparent region 13 , that is, the distance s between the phase shifter edges 16 , is greater than the width w of the shield region 11 of the chromium mask 1 . The distance s is one between the opposing edges of the second transparent region 13 that defines the phase shifter edges 16 . The fact that the distance s is greater than the width w helps to enhance the resolution of the image focused on the resist, as will be described later.
[0068] The exposure method according to the present embodiment will now be described in detail. At first, the first exposure step is carried out, using the chromium mask 1 shown in FIG. 5A. FIG. 12 illustrates a reducing projection exposure apparatus 50 that is used to perform the exposure method. The apparatus 50 effects the first exposure step. In the first exposure step, the chromium mask 1 is secured to the mask holder 51 of the reducing projection exposure apparatus 50 . The KrF excimer laser 52 provided in the apparatus 50 emits a laser beam 53 . The wavelength of the laser beam 53 is 248 nm. The laser beam 53 is applied at right angles to the chromium mask 1 . As shown in FIG. 6B, the shield film 21 reflects the laser beam 53 thus applied. The laser beam 53 cannot pass through the shield region 11 and passes through the first transparent region 12 only. The laser beam 54 emerging from the first transparent region 12 passes through the projection lens 55 of the reducing projection exposure apparatus. The laser beam 54 is applied to the positive-type resist 56 provided on a semiconductor substrate 57 .
[0069] [0069]FIG. 6D shows the intensity distribution of the laser beam 54 at the position on the positive-type resist 56 , where the line C-C′ is projected as shown in FIG. 6A. In FIG. 6D, the origin, at which x=0, coincides with the position where the centerline 10 of the shield region 11 is projected at the surface of the positive-type resist 56 . That is, the origin coincides with the position where the part 15 of the phase shifter edge 16 is projected at the surface of the positive-type resist 56 . On the surface of the positive-type resist 56 , the width w of the shield film 21 has such a value that a resist pattern may be formed, which is 120 nm (0.12 μm) wide along the x axis, i.e., the direction in which the image of the C-C′ line extends. The NA value, that is, the numerical aperture of the projection lens 55 is 0.68.
[0070] The laser beam 54 applied to the to the positive-type resist 56 in the first exposure step has the intensity distribution illustrated in FIG. 6D. As shown in FIG. 6D, the beam 54 is least intense at a position where x=0. That is, the first dark section 3 is formed near that position where x=0. The broken line 40 in FIG. 6 D represents the lower limit to the intensity of light that the positive-type resist 56 responds to. The resist 56 is dissolved at any part that has been irradiated with a laser beam having intensity higher than the intensity represented by the broken line 40 . The intensity corresponding to the broken line 40 varies with the conditions of the exposure process.
[0071] Then, the second exposure step is performed, using the chromium-less phase shift mask 2 . As shown in FIG. 12, the chromium mask 1 is removed from the mask holder 51 and the chromium-less phase shift mask 2 is secured to the mask holder 51 . A laser beam 53 is applied to the chromium-less phase shift mask 2 , at right angles as in the first exposure step. The laser beam 53 passes through both the second transparent region 13 and the third transparent region 14 as is illustrated in FIG. 6C. As described above, the phase shifter 20 has the thickness d defined by the equation (3). Hence, the phase shifter 20 imparts a phase difference of 180° to the two laser beams emerging from the second transparent region 13 and the third transparent region 14 . The laser beam 58 which passed through the second transparent region 13 and the third transparent region 14 passes through the projection lens 55 and is applied to the positive-type resist 56 .
[0072] The laser beams 58 applied to the resist 56 in the second exposure step have the intensity distribution of FIG. 6E at the position on the positive-type resist 56 , where the line C-C′ is projected as shown in FIG. 6A. In FIG. 6E, the origin (x=0) is identical to the origin of the graph (FIG. 6D) that represents the light-intensity distribution observed in the first exposure step. The phase shifter 20 has such a width that the image of the phase shift edge 16 is projected on the positive-type resist 56 , at a distance of 0.4 μm in the x axis. The incoherence ratio σ, or the incoherence of the beam emitted from the KrF excimer laser 52 , is 0.3. It is desired that the incoherence ratio σ be as small as possible in the second exposure step.
[0073] In the second exposure step, the laser beam 58 applied to the positive-type resist 56 has least intense at two positions, x=0 (μm) and x=0.4 (μm), as shown in FIG. 6E. That is, the beam is most weak at two positions where the image of the phase shift edge 16 is projected on the resist 56 . Two second dark sections 4 1 and 4 2 are formed, respectively, near that position where x=0 (μm) and near the position where x=0.4 (μm).
[0074] The second transparent region 13 and the third transparent region 14 , through which two beams output of phase pass, sharply change the light-intensity distribution at a position which is close to the position where the image of the phase shift edge 16 is projected on the positive-type resist 56 . The intensities of the laser beams 58 much change at the boundary of the second dark sections 4 1 and 4 2 . This means that the widths of both dark sections 4 1 and 4 2 can be decreased.
[0075] [0075]FIG. 6F represents half the total distribution of the light beams applied to the positive-type resist 56 in the first and second exposure steps. As FIG. 6F shows, a third dark section 5 is formed on the positive-type resist 56 . The third dark section 5 is located near a position that corresponds to the origin (x=0) of the graph (FIG. 6F). That is, the third dark section 5 is formed at a position where the first dark section 3 and one of the second dark sections 4 1 overlap each other. Namely, the third dark section 5 is provided at the position where a pattern is to be formed.
[0076] Also, no resist patterns should not be formed at the position where the other second dark section 4 2 is provided. However, no resist patterns will be formed at the position where the other second dark section 4 2 is provided. This is because a light beam having more intense than is represented by the broken line 40 is applied at the position where the other second dark section 4 2 is provided in the first exposure step.
[0077] Thus, the phase shift exposure technique according to the present embodiment can be utilized to form two-dimensional random patterns.
[0078] In the second exposure step, the distance s between the phase shifter edges 16 is desirably greater than the width w of the shield region 11 of the chromium mask 1 . This results in that the phase shifter edges 16 of the phase shifter 20 reliably function as shield sections. The shorter the distance s between the edges 16 , the shorter the distance between the two dark sections formed in the second exposure step. If the distance s is too short, no dark sections will be formed on the positive-type resist 56 . Hence, it is required that the distance s between the phase shifter edges be sufficiently long. The distance s greater than the width w of the shield region 11 enhances the resolution of the image focused on the positive-type resist 56 . In addition, two-dimensional random patterns can be formed in high dimensional precision on the positive-type resist 56 .
[0079] The exposure method according to the present embodiment can form images on the positive-type resist 56 at higher resolution than is possible with the conventional exposure method. FIG. 7 is a magnified representation of that part of FIG. 6F which shows the light-intensity distribution (solid line) at the third dark section 5 , and illustrates the light-intensity distribution (broken lines) observed in the conventional exposure method using a chromium mask 1 only. The exposure method of the invention increases the contrast about twice the value achieved by the conventional exposure method. The word “contrast” used here is concerned with the light applied to the positive-type resist. It means the ratio of the most intense part of the beam to the least intense part thereof in terms of brightness.
[0080] Moreover, the exposure method of the invention can increase the depth of focus more than is possible with the conventional exposure method described above. FIGS. 8A to 8 F are diagrams showing the defocus-dependency of light-intensity distribution, which is observed in the exposure method according to the invention. FIGS. 9 A to 9 F are diagrams illustrating the defocus-dependency of light-intensity distribution, which is observed in the conventional exposure method. “Defocus” here represents a difference in vertical directions from the surface of the resist whose focal position is the image field. As seen from FIGS. 8A to 8 F and FIGS. 9A to 9 F, the depth of focus achieved in the method of the invention is greater than that obtained in the conventional method. Thanks to the great depth of focus, two-dimensional random patterns can be formed on the resist in the exposure method according to the present invention.
[0081] In the exposure method described above, more light is desirably applied to the resist in the second exposure step than in the first exposure step. The light-intensity distribution in the second exposure step using the phase shift mask is sharper than the light-intensity distribution in the first exposure step using no phase shift masks. It is desired that light be applied to a part (x=0) of the resist, where a resist pattern will be formed, mainly in the second exposure step. When more light is applied to the resist in the second exposure step than in the first exposure step, the ratio of light applied in the second exposure step to the light applied in the first exposure is greater. This further enhances the resolution of the image focused at the surface of the resist and ultimately increases the dimensional precision of the two-dimensional random patterns formed on the resist. In the first exposure step, on the other hand, it suffices to apply a smaller amount of light to the second dark section 4 2 of the resist. This is because no pattern needs be formed on the second dark section 4 2 .
[0082] The phase shifter edge 16 provided at the second transparent region 13 of the chromium-less phase shift mask 2 can achieve the object of the present invention, only if the overlapping parts of the chromium mask 1 and the phase shift mask 2 lie over the shield region 11 . A resist pattern is formed on only that part of the resist which is near the image of the phase shift edge 16 of the second transparent region 12 projected on the resist and which is protected by the shield region 11 . It is, however, desired that all centerline 10 of the shield region 11 should align with the phase shifter edge 16 provided at the second transparent region 13 . If the centerline 10 aligns with the phase shifter edge 16 , the least intense point in the distribution of the laser beam applied in the first exposure step coincides with the least intense point in the light distribution of the laser beam applied in the second exposure step. This enhances the resolution of any pattern formed on the resist.
[0083] The chromium mask 1 and chromium-less phase shift mask 2 , shown in FIG. 5A and FIG. 5B, respectively, are nothing more than examples. The chromium mask and chromium-less mask that are shown in FIG. 10 may replace them. FIG. 10 is a plan view depicting the alternative chromium mask and chromium-less phase shift mask, which overlap each other. As shown in FIG. 10, the distance s 3 between the phase shifter edges of the chromium-less phase shift mask is equal to the distance between shield regions. The term “distance between shield regions” means the distance between the centerlines of any two opposing shield regions. Like the chromium-less phase shift mask 2 described above, the chromium-less phase shift mask shown in FIG. 10 has phase shifter edges spaced apart by distances (s 1 , s 2 , s 4 , s 5 ) which are longer than the width of the shield region 11 of the chromium mask.
[0084] Also, the two beams that have passed through the second and third transparent regions 13 and 14 , respectively, are allowed to have a phase difference that deviates a little from the desired value of 180°. The experiments the inventor hereof conducted reveal that the light-intensity distributions of the beams applied to the resist in the first and second exposure steps have a desirable contrast so long as the phase difference falls within the range of 175° to 185°.
[0085] [0085]FIG. 11 shows a chromium-less phase shift mask 2 ′ designed for printing patterns on substrates. The mask 2 ′ may be used in place of the chromium-less phase shift film 2 . The chromium-less phase shift mask 2 ′ has a transparent substrate 24 ′. The transparent substrate 24 ′ has a phase shifter 20 ′ that has been etched to a depth d′. The depth d′ is given as follows:
d′=/{ 2×( n′− 1)}, (3′)
[0086] where n′ is the refractive index of the transparent substrate 24 ′.
[0087] In the exposure method described above, it is possible to use the chromium-less phase shift mask in the first exposure step and the chromium mask in the second exposure step.
[0088] As has been described above, the exposure method according to the present invention comprises the first exposure step and the second exposure step. A photo-mask having a two-dimensional random pattern is used in the first exposure step. A phase shift mask having a phase shift edge pattern is used in the second exposure step. With the exposure method of the invention, it is possible to form two-dimensional random patterns by the use of phase shift exposure technique. The exposure method of the invention can therefore enhance the resolution of images focused on a resist. Moreover, the exposure method of the invention can form, on resists, two-dimensional random patterns of high dimensional precision.
[0089] Although the invention has been described in its preferred form with a certain degree of particularity, it is understood that the present disclosure of the preferred form has been changed in the details of construction and the combination and arrangement of parts may be resorted to without departing from the spirit and scope of the invention as hereinafter claimed. | A mask set has a first mask including a shielding region shielding a first pattern-defining light; a second mask including a phase-shifting region having a phase shifter edge and a non-phase-shifting region adjacent to the phase-shifting region on the phase shifter edge. A first phase of the first light portion passing through the phase-shifting region differs from a second phase of the second light portion. The first and second masks are aligned such that the phase shifter edge overlaps on the shielding region. | 6 |
FIELD OF THE INVENTION
This invention relates to an image scanner, and more particularly to, an image scanner used for reading image data from a manuscript.
BACKGROUND OF THE INVENTION
A flat-bed-type image scanner or copier with which a mechanism of correcting an optical path length in sub-scanning is provided is known, for example, as disclosed in Japanese patent application laid-open No.2-101862(1990). FIG. 1A shows a composition of such conventional image scanner. As shown in FIG. 1A, a reflecting mirror 61 reflects a light reflected on a scanned manuscript 60 in the horizontal direction. Reflecting mirrors 62 and 63, which are integrated with each other, allow the reflected light from the reflecting mirror 61 to be turned in the reverse direction. The reflected light from the reflecting mirror 63 is then transmitted through a focusing lens 64, forming an image on an one-dimensional image sensor 65.
In sub-scanning, the reflecting mirror 61 is parallel moved in the direction as shown by an arrow in FIG. 1A to sequentially scan the manuscript 60. At this time, since the unit composed of the reflecting mirrors 62, 63 is parallel moved by half the distance that the reflecting mirror 61 is parallel moved in the same direction, the optical path length from the scanned manuscript 60 to the one-dimensional image sensor 65 can be constant.
On the other hand, known in a conventional flat-bed-type image scanner or copier are a manner that a unit 66 in which a reflecting mirror, a focusing lens and an one-dimensional image sensor are integrated is, as shown in FIG. 1B, parallel moved to a scanned manuscript 60, and a manner that a unit in which a focusing lens 64 and an one-dimensional image sensor 65 are integrated and to which a light reflected on a scanned manuscript 60 is led through reflecting mirrors 61, 67 and 68 is, as shown in FIG. 1C, parallel roved with the parallel movement of the reflecting mirror 61 to the manuscript 60.
Furthermore, Japanese patent application laid-open No.62-291259(1987) discloses an image scanner in which a reflecting mirror is rotated to scan a manuscript and an one-dimensional image sensor reads the image data and with which a mechanism of correcting an optical path length is provided. In this image scanner, the rotation of the reflecting mirror and the parallel movement of an focusing lens and the one-dimensional image sensor are conducted by using a cam mechanism.
A unit in which the reflecting mirror, focusing lens and one-dimensional image sensor are fixed is pressed against a slide plane of the cam by a spring. The cam is composed of two slide planes, where one is used for the reflecting mirror and the other is used for the unit composed of the focusing lens and the one-dimensional image sensor. The slide planes are designed such that the reflecting mirror is driven by a predetermined angle and the unit of the focusing lens and one-dimensional image sensor is driven by a predetermined distance of parallel movement. Rotating the cam by, for example, a stepping motor, the reflecting mirror and the unit of the focusing lens and one-dimensional image sensor can be simultaneously driven.
Japanese patent application laid-open No.8-7073(1996) discloses another image sensor in which a reflecting mirror is rotated to scan a manuscript and an one-dimensional image sensor reads the image data. However, this image scanner is not provided with an optical path length correcting mechanism by which an optical path length from an one-dimensional image sensor to a reading surface is corrected to be constant. Therefore, the image to be read may have a barrel distortion.
However, in the conventional techniques as shown in FIGS. 1A and 1C, there are problems that the driven units and drive mechanism are complicated and that the entire device becomes thicker since the optical path is turned. Also, in the image scanner shown in FIG. 1B, there are problems that the miniaturization of the driven unit is limited and that, when the driven unit is miniaturized, the optical path length becomes shorter, therefore making the designing of optical system difficult. Furthermore, there is a common problem that the image scanners in FIGS. 1A to 1C require a high torque and a high precision of the drive mechanism.
On the other hand, the optical path length correcting mechanism with the cam as disclosed in Japanese patent application laid-open No.62-291259(1987), since the reflecting mirror and the unit of the focusing lens and one-dimensional image sensor are pressed against the slide plane of the cam by the spring, requires a relatively high torque of a drive means such as a stepping motor. Furthermore, there is a problem that, with the increase in the distance of parallel movement for correcting an optical path length and the increase in the rotation angle of the reflecting mirror, the size of the cam needs to be larger in the two-dimensional directions.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the invention to provide an image scanner in which a torque required of a drive mechanism can be lowered.
It is a further object of the invention to provide an image scanner in which a desired reading resolution can be obtained in a desired range without increasing a precision of drive mechanism.
It is a still further object of the invention to provide an image scanner which can be miniaturized when it is not used.
According to the invention, an image scanner, comprises:
a reflecting mirror for reflecting a light reflected from a scanned manuscript in a predetermined direction;
a sub-scanning means for sequential sub-scanning which parallel moves on a plane which has an acute angle to the surface of the scanned manuscript while keeping the reflecting surface of the reflecting mirror perpendicular to the surface of the scanned manuscript;
a focusing lens which focuses the light reflected from the scanned manuscript which is reflected by the reflecting mirror; and
an one-dimensional image sensor which outputs a manuscript image by conducting a photoelectric conversion of the light reflected by the reflecting mirror which is focused on a light-receiving surface of the one-dimensional image sensor by the focusing lens.
According to another aspect of the invention, an image scanner, comprising:
a first reflecting mirror for reflecting a light reflected from a scanned manuscript in a predetermined direction;
a sub-scanning means for sequential sub-scanning which parallel moves on a plane which has an acute angle to the surface of the scanned manuscript while keeping the reflecting surface of the first reflecting mirror perpendicular to the surface of the scanned manuscript;
a second reflecting mirror for reflecting the light reflected by the first reflecting mirror, wherein the second reflecting mirror is fixed at a position,
a focusing lens which focuses the light reflected by the second reflecting mirror; and
an one-dimensional image sensor which outputs a manuscript image by conducting a photoelectric conversion of the light reflected by the second reflecting mirror which is focused on a light-receiving surface of the one-dimensional image sensor by the focusing lens.
According to a further aspect of the invention, an image scanner, comprising:
a first reflecting mirror for reflecting a light reflected from a scanned manuscript in a predetermined direction;
a sub-scanning means for sequential sub-scanning which parallel moves on a plane which has an acute angle to the surface of the scanned manuscript while keeping the reflecting surface of the first reflecting mirror perpendicular to the surface of the scanned manuscript;
a second reflecting mirror for reflecting the light reflected by the first reflecting mirror, wherein the second reflecting mirror is fixed at a position,
a focusing lens which focuses the light reflected by the second reflecting mirror;
an one-dimensional image sensor which outputs a manuscript image by conducting a photoelectric conversion of the light reflected by the second reflecting mirror which is focused on a light-receiving surface of the one-dimensional image sensor by the focusing lens;
a housing which includes a folding mechanism by which the housing is foldable to accommodate the sub-scanning means, the second reflecting mirror, the focusing lens and the one-dimensional image sensor which are fixed on the housing; and
a drive circuit which drives the sub-scanning means and the one-dimensional image sensor, the drive circuit being fixed on the housing;
wherein, when the image scanner is not used, the sub-scanning means, the second reflecting mirror, the focusing lens, the one-dimensional image sensor and the drive circuit are accommodated with the first reflecting mirror in a space where the first reflecting mirror moves.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be explained in more detail in conjunction with the appended drawings, wherein:
FIGS. 1A to 1C show different compositions of conventional image scanners,
FIG. 2 shows a composition of an image scanner in a first preferred embodiment according to the invention,
FIG. 3 shows the composition of the image scanner in the first embodiment in the case that it is seen from a lateral position
FIG. 4 shows a composition of an image scanner in a second preferred embodiment according to the invention,
FIG. 5 shows the composition of the image scanner in the second embodiment in the case that it is seen from a lateral position, and
FIGS. 6A and 6B show a composition of an image scanner in a third preferred embodiment according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
An image scanner in the first preferred embodiment will be explained in FIG. 2.
As shown in FIG. 2, a reflecting mirror 1 is held by a reflecting mirror perpendicularity holding jig 5 such that a reflecting surface thereof is kept to be perpendicular to the surface of a scanned subscript 7. The reflecting mirror 1, a focusing lens 2 and an one-dimensional image sensor 3 are disposed on a straight line which has an angle θ as to the scanned subscript 7. A guide 4 for reflecting mirror's parallel movement and the reflecting mirror perpendicularity holding jig 5 compose a ball screw, where the reflecting mirror parallel movement guide 4 is a male screw and the reflecting mirror perpendicularity holding jig 5 is a female screw. As a sub-scanning mechanism 6, for example, a stepping motor can be used. The reflecting mirror parallel movement guide 4 has an angle θ to the scanned manuscript 7.
In operation, a light reflected on a reading line 8 of the scanned manuscript 7 is reflected by the reflecting mirror 1, then focused through the focusing lens 2 on the one-dimensional image sensor 3, thereby a partial one-dimensional image as to the reading line 8 being formed via a photoelectric conversion. On the other hand, by rotating the reflecting mirror parallel movement guide 4 that is the ball male screw, the sub-scanning mechanism 6 can be parallel moved on a plane that has the angle θ to the scanned manuscript 7, i.e., in the direction of an arrow A in FIG. 2.
Thus, the reflecting mirror 1 is parallel moved on the plane that has the angle θ to the surface of the scanned manuscript 7 while keeping the reflecting surface perpendicular to the surface of the scanned manuscript 7, thereby the reading line 8 being moved in the direction of an arrow B on the scanned manuscript 7. Accordingly, a partial image of the reading line 8 that moves in the direction of the arrow B is sequentially obtained by the one-dimensional image sensor 3, thereby obtaining a two-dimensional image of the scanned manuscript 7 in which these partial images are synthesized.
FIG. 3 shows the composition of the first embodiment in the case that it is seen from a lateral position. As clearly shown in FIG. 3, the reflecting mirror 1 is parallel moved on the plane that has the angle θ to the scanned manuscript 7. Thereby, the reading line 8 is moved on the scanned manuscript 7, i.e., being sub-scanned. Since the reflecting mirror 1 is parallel moved while keeping the reflecting surface perpendicular to the surface of the scanned manuscript 7, a triangle ABC in FIG. 3, which has three apogees located on the reading line 8, the reflecting surface of the reflecting mirror 1 and the intersecting line of the reflecting mirror parallel movement guide 4 and the surface of the scanned manuscript 7, is formed as an isosceles triangle. Therefore, the optical path length L from the focusing lens 2 to the reading line 8 is represented as:
L=L1+L2=(constant).
On the other hand, if the amount of movement of the reflecting mirror 1 as to the scanned manuscript 7 is x, the amount s of movement of the reading line 8 is, as seen from FIG. 3, given by:
s=2cosθ·x
Then, differentiating the above expression, the next expression is obtained.
ds=2cosθ·dx
where dx represents a positioning resolution capability of the sub-scanning mechanism 6 and ds represents a sub-scanning width per a main scanning. The reading length in the sub-scanning direction is given by:
s.sub.max =2cosθ·L
Accordingly, by varying only the angle θ while keeping the positioning precision of the sub-scanning mechanism 6 as it is, the range of sub-scanning and the resolution can be controlled. Namely,
if θ=60°, then, ds=dx and s max =L,
if θ>60°, then, ds<dx and s max <L, and
if θ<60°, then, ds>dx and s max >L.
Thus, in the first embodiment, in case of θ>60°, the reading of a narrow range with a high resolution can be performed, and, in case of θ<60°, the reading of a wide range with a low resolution can be performed. Meanwhile, θ is in the range of an angle less than 90° and more than 0°.
In the first embodiment, since the constant optical path length from the one-dimensional image sensor 3 to the surface of the scanned manuscript 7 in sub-scanning can be given by the parallel movement of only the reflecting mirror 1, the driven unit can be significantly lightened, thereby allowing the driving mechanism to have a low torque, a low consumed power and a small size.
An image scanner in the second preferred embodiment will be explained in FIG. 4, wherein like parts are indicated by like reference numerals as used in FIG. 2.
In the second embodiment, as a sub-scanning mechanism, a stepping motor 30 and a driving belt 31 are used. Furthermore, a second reflecting mirror 9 is disposed and fixed at a position where a light reflected on the reflecting mirror 1 can be led to the focusing lens 2. The reflecting mirror parallel movement guide 4 is composed of a rail or a shaft along which the reflecting mirror 1 car be parallel moved. The reflecting mirror perpendicularity holding jig 5 is provided with a hole into which the reflecting mirror parallel movement guide 4 can be fitted.
In the second embodiment, since the driving belt 31 is used in the sub-scanning mechanism, the reflecting mirror 1 can be driven at a speed higher than that in the first embodiment, while the increase in resolution is limited to some degree.
In operation, a light reflected on the reading line 8 is reflected on the reflecting mirror 1, further reflected on the reflecting mirror 9. While the reflecting mirror 1 is parallel moved by the stepping motor 30 and driving belt 31, the reflecting mirror 9 is fixed. The light reflected on the reflecting mirror 9 is then focused through the focusing lens 2 on the one-dimensional image sensor 3.
FIG. 5 shows the composition of the second embodiment in the case that it is seen from a lateral position. In the comparison of FIGS. 3 and 5, it will be appreciated that, though a reflecting mirror is added and the position and direction of the focusing lens and one-dimensional image sensor are changed, there is no variation of the optical path length during the parallel movement of the reflecting mirror 1. Thus, also in the second embodiment, since the constant optical path length from the one-dimensional image sensor 3 to the surface of the scanned manuscript 7 in sub-scanning can be given by the parallel movement of only the reflecting mirror 1, the driven unit can be significantly lightened, thereby allowing the driving mechanism to have a low torque, a low consumed power and a small size.
FIGS. 6A and 6B show a composition of the third embodiment, which is obtained by modifying the composition in the second embodiment, in the case that it is seen from a lateral position, wherein FIG. 6A shows a state that it is used and FIG. 6B shows a state that is not used. As shown in FIGS. 6A and 6B, a unit including the focusing lens 2 and one-dimensional image sensor 3 is fixed on a housing 12. Though it is not shown, the reflecting mirror parallel movement guide 4 and stepping motor 30 as explained in the second embodiment are also fixed on the housing 12. A drive circuit 10, which is used for driving the one-dimensional image sensor 3 and stepping motor 30, is also fixed on the housing 12.
The housing 12 can be fixed at a desired angle by using a folding mechanism 11, i.e., the angle θ as explained in the first embodiment can be changed free. When the image scanner is used, as shown in FIG. 6A, it has the composition similar to that in the second embodiment. Here, the reflecting mirror 1 is scanned in the sub-scanning direction as in the second embodiment, thereby a two-dimensional image of the scanned manuscript 7 being obtained by the one-dimensional image sensor 3.
When it is not used, as shown in FIG. 6B, the housing 12 is folded by the folding mechanism 11. In this state, the reflecting mirror 1 is located at an end of the housing 12 and the focusing lens 2, one-dimensional image sensor 3 and drive circuit 10 are accommodated in a space where the reflecting mirror 1 is parallel moved. Thus, in the third embodiment, when the image scanner is not used, the entire thickness can be significantly reduced.
Although the invention has been described with respect to specific embodiment for complete and clear disclosure, the appended claims are not to be thus limited but are to be construed as embodying all modification and alternative constructions that may be occurred to one skilled in the art which fairly fall within the basic teaching here is set forth. | Disclosed is an image scanner, which has: a reflecting mirror for reflecting a light reflected from a scanned manuscript in a predetermined direction; a sub-scanning means for sequential sub-scanning which parallel moves on a plane which has an acute angle to the surface of the scanned manuscript while keeping the reflecting surface of the reflecting mirror perpendicular to the surface of the scanned manuscript; a focusing lens which focuses the light reflected from the scanned manuscript which is reflected by the reflecting mirror; and an one-dimensional image sensor which outputs a manuscript image by conducting a photoelectric conversion of the light reflected by the reflecting mirror which is focused on a light-receiving surface of the one-dimensional image sensor by the focusing lens. | 7 |
FIELD OF THE INVENTION
This invention relates to the field of immunoassays for determining the presence and/or quantifying the amount of lenalidomide and thalidomide in human biological fluids in order to rapidly determine optimal drug concentrations during treatment.
BACKGROUND OF THE INVENTION
Cancer is a term used to describe a group of malignancies that all share the common trait of developing when cells in a part of the body begin to grow out of control. Most cancers form as tumors, but can also manifest in the blood and circulate through other tissues where they grow. Cancer malignancies are most commonly treated with a combination of surgery, chemotherapy, and/or radiation therapy. The type of treatment used to treat a specific cancer depends upon several factors including the type of cancer malignancy and the stage during which it was diagnosed.
The chemotherapeutic agent whose common chemical name is thalidomide has the following formula:
The chemotherapeutic agent whose common chemical name is lenalidomide has the following formula:
Thalidomide possesses immunomodulatory, anti-inflammatory and anti-angiogenic properties. The immunomodulatory and anti-inflammatory properties may be related to suppression of excessive tumor necrosis factor-alpha production through degradation of mRNA encoding the factor (Moreira, J Exp Med, 177(6): 1675-80, 1993). Other immunomodulatory and anti-inflammatory properties of thalidomide may include suppression of macrophage involvement in prostaglandin synthesis, and modulation of interleukin-10 and interleukin-12 production by peripheral blood mononuclear cells. The combination of anti-inflammatory and anti-angiogenic properties makes thalidomide a novel therapeutic agent with significant potential in treating a wide variety of diseases (Teo, Clin Pharmacokinet, 43(5): 311-27, 2004). A number of recent clinical trials have demonstrated therapeutic effect of thalidomide in patients with multiple myeloma, renal carcinoma and glioblastoma multiforme (Singhal, N Engl J Med, 341(21): 1565-71, 1999; Marx, J Neurooncol, 54(1): 31-8, 2001). Currently, thalidomide is approved for treatment of patients with newly diagnosed multiple myeloma and for acute treatment of erythema nodosum leprosum (Package-insert-Thalidomide, Celgene Corp., 2009).
Lenalidomide is a thalidomide derivative with immunomodulatory, anti-proliferative, and anti-angiogenic properties. Lenalidomide exerts direct anti-proliferative effect on multiple myeloma cells by inducing cell cycle arrest and apoptosis (Armoiry, J Clin Pharm Ther, 33(3): 219-26, 2008). Lenalidomide is approved for treatment of patients with multiple myeloma and myelodysplastic syndromes associated with a deletion 5q cytogenetic abnormality (Package-insert-Revlimid, Celgene Corp., 2009).
The mechanisms of action and metabolic pathways of thalidomide and lenalidomide are not fully characterized yet. In vivo, both drugs can undergo non-enzymatic hydrolysis and enzymatic metabolism producing a multitude of metabolites, but none of those compounds were found to be responsible for thalidomide therapeutic effect Lepper, Curr Drug Metab, 7(6): 677-85, 2006).
Thalidomide and lenalidomide exhibit significant variability in plasma concentrations. A phase I study of pharmacokinetic effects of thalidomide in HIV patients has demonstrated a wide range of maximum drug concentration C max (2.8±2.6 mg/L) and half-life time t 1/2 (5.9±2.3 hours) (Wohl, J Infect Dis, 185(9): 1359-63, 2002). Administration of thalidomide to healthy subjects resulted in up to 52% variability in C max and up to 37% variability in to (Package-insert-Thalidomide, Celgene Corp., 2009). A Phase I trial of lenalidomide in patients with central nervous system tumors has revealed up to 78% variability in C max and up to 122% variability in to (Fine, Clin Cancer Res, 13(23): 7101-6, 2007).
Since efficacy of thalidomide and lenalidomide is improved at higher concentration levels and the drugs exhibit wide intra- and inter-patient pharmacokinetic variability monitoring concentrations of these drugs in blood and adjusting to target levels would be of value in increasing efficacy and minimizing toxicity. The degree of intra- and inter-individual pharmacokinetic variability of thalidomide and lenalidomide is impacted by many factors, including:
Age Weight Organ function Drug-drug interaction Genetic regulation Compliance
As a result of this variability, equal doses of the same drug in different individuals can result in dramatically different clinical outcomes. The effectiveness of the same dosage of thalidomide and lenalidomide varies significantly based upon individual drug clearance and the ultimate serum drug concentration in the patient. Therapeutic drug management would provide the clinician with insight on patient variation in drug administration. With therapeutic drug management, drug dosages could be individualized to the patient, and the chances of effectively treating the disorder without the unwanted side effects would be much higher.
Routine therapeutic drug management of thalidomide and lenalidomide would require the availability of simple automated tests adaptable to general laboratory equipment. The use of liquid chromatography (LC) with UV or mass spectroscopy detection to determine the concentration of thalidomide and lenalidomide in human blood and plasma has been described (Tohnya, J Chromatogr B Analyt Technol Biomed Life Sci, 811(2): 135-41, 2004; Chen, J Clin Pharmacol, 47(12): 1466-75, 2007; Teo, J Clin Pharmacol, 39(11): 1162-8, 1999). These methods are labor intensive, requiring liquid-liquid or solid phase extractions, use expensive equipment and are not amenable to routine clinical laboratory use. To date, there are no immunoassays for measuring lenalidomide and/or thalidomide in human biological fluids of patients treated with these chemotherapeutic agents.
As seen from the foregoing, there are no immunoassays for determining the presence and/or quantifying the amount of thalidomide and lenalidomide in human biological fluids. Routine therapeutic drug management of thalidomide and lenalidomide by immunoassays would provide simple automated tests adapted to standard laboratory equipment. However, in order to provide such immunoassays, antibodies specific to thalidomide and lenalidomide must be produced. The derivatives and immunogen used in this assay must impart through these corresponding antibodies produced specific reactivity to thalidomide and lenalidomide.
SUMMARY OF INVENTION
In accordance with this invention, a new class of antibodies have been produced which are substantially reactive to thalidomide and lenalidomide and can be used in the same immunoassay to determine the presence and/or quantify the amount of thalidomide and lenalidomide in patients' samples treated with these chemotherapeutic drugs.
It has been found that by using immunogens which are conjugates of an immunogenic carrier containing polyamine polymer with a compound of the formula:
wherein B is —C(═O)—CH 2 —, —C(═O)—NH—CH 2 —, —C(═O)—O—CH 2 — or —CH 2 —
Y is an organic spacing group; p is an integer from 0 to 1; X is a terminal functional group capable of binding to said polyamine polymer,
antibodies are produced which are specific for lenalidomide as well as mixtures of lenalidomide with thalidomide and are non reactive or non binding with pharmaceutically inactive metabolites of both thalidomide and lenalidomide.
The provision of these antibodies which are selectively reactive with either lenalidomide or a mixture of thalidomide and lenalidomide, allows one to produce an immunoassay which can specifically detect and quantify so as to monitor thalidomide and lenalidomide in the fluid samples of patients being treated with either thalidomide or lenalidomide. Also included within this invention are reagents and kits for said immunoassay.
DETAILED DESCRIPTION
In accordance with this invention, a new class of antibodies is provided which selectively binds to lenalidomide or mixtures of lenalidomide with thalidomide and is not cross reactive with pharmaceutically inactive metabolites of either thalidomide and lenalidomide. It has been discovered that through the use of these derivatives of lenalidomide of formula III as immunogens, this new class of antibodies of this invention is provided. It is through the use of these antibodies that an immunoassay, including reagents and kits for such immunoassay for detecting and/or quantifying thalidomide and lenalidomide in blood, plasma or other body fluid samples has been developed.
In accordance with this invention a new class of reagents is provided which can be used in either of these immunoassays for detecting and/or quantifying thalidomide or lenalidomide in samples. This reagent is a conjugate of a carrier with a ligand having the formula:
wherein B, Y and P are as above and X 2 is a terminal functional group capable of binding to said carrier.
By use of this immunoassay, the presence and amount of thalidomide or lenalidomide in body fluid samples of patients being treated with either therapeutic agent can be detected and/or quantified. In this manner, a patient being treated with thalidomide or lenalidomide can be monitored during therapy and the treatment adjusted in accordance with said monitoring by using antibodies produced by the immunogen of formula III and the conjugate of Formula III-A. By means of this invention one achieves the therapeutic drug management of thalidomide and lenalidomide in patients being treated with either thalidomide or lenalidomide as therapeutic agents. The therapeutic agents to be detected and/or quantified are thalidomide of formula I and lenalidomide of formula II.
The provision of the conjugates of formulae III-A as a reagent in the immunoassay and the immunogen of Formula III conjugated with an immunogenic carrier provides antibodies and reagents which can be utilized in immunoassays to detect and/or quantify the chemotherapeutic agents lenalidomide and thalidomide. These reagents and the antibodies produced in accordance with this invention can be utilized both in immunoassays for detecting and quantifying lenalidomide or thalidomide. In general, patients are treated with one and not both of these chemotherapeutic agents. Therefore, an antibody or reagent which is selectively reactive against both lenalidomide and thalidomide can be utilized in these immunoassays to detect either lenalidomide or thalidomide. This is true, since a patient treated lenalidomide is not generally treated with thalidomide and a patient treated with thalidomide is not generally treated lenalidomide. Therefore, the reagents and antibodies of this invention can be used in either of these two immunoassays to separately detect and/or quantify these two chemotherapeutic agents.
As set forth hereinbefore, the antibodies that can be produced by the immunogen of formula III are selectively reactive with lenalidomide and mixtures of thalidomide with lenalidomide and can be used in either an immunoassay for thalidomide or for lenalidomide. While these antibodies are selectively reactive with both thalidomide and lenalidomide, in order to be used in an immunoassay for thalidomide, the antibody should have a selective reactivity of at least about 10%, preferably at least about 40%, for thalidomide, based upon its combined reactivity with both thalidomide and lenalidomide. In accordance with this invention, antibodies can be produced utilizing the immunogen of formula III having reactivity with thalidomide of at least about 10%, and at most about 50%, based upon their reactivity with both lenalidomide and thalidomide.
On the other hand for utilizing an antibody in an immunoassay for lenalidomide, any of the antibodies produced by the immunogen of formula III having a selective reactivity with lenalidomide or with both lenalidomide and thalidomide can be used. In accordance with this invention antibodies which are selectively reactive with lenalidomide based upon their reactivity with thalidomide and lenalidomide or selectivity reactive with both lenalidomide and thalidomide can be produced by means of the immunogen of formula III. In accordance with this invention an antibody which is selectively reactive with lenalidomide and not thalidomide, i.e., antibodies having 100% selective reactivity with lenalidomide based upon their selective reactivity with both lenalidomide and thalidomide can be produced by use of the immunogen of formula III. The antibodies having substantially 100% selective reactivity with lenalidomide and substantially no selective reactivity with thalidomide are especially preferred for use in the immunoassay for lenalidomide.
The reagents utilized in the assays of this invention are conjugates of a polymeric carrier with the compounds of formula III-A. These conjugates are competitive binding partners with the thalidomide or lenalidomide present in the sample for the binding with the antibodies of this invention. Therefore, the amount of this conjugate reagent which binds to the antibody will be inversely proportional to the amount of thalidomide or lenalidomide in the sample. In accordance with this invention, the assay utilizes any conventional measuring means for detecting and measuring the amount of said conjugate which is bound or unbound to the antibody. Through the use of said means, the amount of the bound or unbound conjugate can be determined. Generally, the amount of thalidomide and lenalidomide in a sample is determined by correlating the measured amount of the bound or unbound conjugate produced by the thalidomide or lenalidomide in the sample with values of the bound or unbound conjugate determined from a standard or calibration curve obtained with samples containing known amounts of thalidomide or lenalidomide, which known amounts are in the range expected for the sample to be tested. These studies for producing calibration curves are determined using the same immunoassay procedure as used for the sample.
The conjugates, as well as the immunogens, are prepared from compounds of the formula III. When in the conjugates or immunogens, the carrier and the polyamine polymer are linked to ligand portions of the compounds of formula III, this ligand portions has the formula:
wherein X′ is —CH 2 — or a functional linking group;
and Y, p and B, are as above
This ligand portion may be linked to one or more active sites on the carrier of the conjugate or the immunogen. Generally these carriers contain polymers, most preferably polyamine polymers having a reactive amino group. In forming the conjugates especially the immunogen, X′ is preferably a functional group which can react with an amino group. However with respect to the reagent used in the immunoassay, X′ can be any functional group which can react with any conventional carrier. When the compound of formula III is used to make immunogens, X′ in the compound of formula III is preferably any functional group capable of binding or linking to a polyamine polymer.
DEFINITIONS
Throughout this description the following definitions are to be understood:
The term “alkylene” designates a divalent saturated straight or branch chain hydrocarbon substituent containing from one to ten carbon atoms
The terms “immunogen” and “immunogenic” refer to substances capable of eliciting, producing, or generating an immune response in an organism.
The term “conjugate” refers to any substance formed from the joining together of two parts. Representative conjugates in accordance with the present invention include those formed by the joining together of a small molecule, such as the compound of formula III or the compound of formula III-A and a large molecule, such as a carrier, preferably carriers which comprise a polyamine polymer, particularly a protein. In the conjugate the small molecule may be joined or linked at one or more active sites on the large molecule. The term conjugate includes the term immunogen. In the conjugates used as reagents the carrier can be any carrier and X can be any functional group which can be linked to a carrier. In the immunogen the carrier is a polyamine polymer and X is any functional group capable of linking to a polyamine polymer.
“Haptens” are partial or incomplete antigens. They are protein-free substances, mostly low molecular weight substances, which are not capable of stimulating antibody formation, but which do react with antibodies. The latter are formed by coupling a hapten to a high molecular weight immunogenic carrier and then injecting this coupled product, i.e., immunogen, into a human or animal subject. The hapten of this invention is lenalidomide (II).
As used herein, a “spacing group” or “spacer” refers to a portion of a chemical structure which connects two or more substructures such as haptens, carriers, immunogens, labels, or tracer through a CH 2 or functional linking group. These spacer groups will be enumerated hereinafter in this application. The atoms of a spacing group and the atoms of a chain within the spacing group are themselves connected by chemical bonds. Among the preferred spacers are straight or branched, saturated or unsaturated, carbon chains. Theses carbon chains may also include one or more heteroatoms within the chain or at termini of the chains. By “heteroatoms” is meant atoms other than carbon which are chosen from the group consisting of oxygen, nitrogen and sulfur. Spacing groups may also include cyclic or aromatic groups as part of the chain or as a substitution on one of the atoms in the chain.
The number of atoms in the spacing group is determined by counting the atoms other than hydrogen. The number of atoms in a chain within a spacing group is determined by counting the number of atoms other than hydrogen along the shortest route between the substructures being connected. A functional linking group may be used to activate, e.g., provide an available functional site on, a hapten or spacing group for synthesizing a conjugate of a hapten with a label or carrier or polyamine polymer.
An “immunogenic carrier,” as the terms are used herein, is an immunogenic substance, commonly a protein, that can join with a hapten, in this case lenalidomide or the lenalidomide derivatives hereinbefore described, thereby enabling these hapten derivatives to induce an immune response and elicit the production of antibodies that can bind specifically with these haptens and to thalidomide. The immunogenic carriers and the linking groups will be enumerated hereinafter in this application. Among the immunogenic carrier substances are included proteins, glycoproteins, complex polyamino-polysaccharides, particles, and nucleic acids that are recognized as foreign and thereby elicit an immunologic response from the host. The polyamino-polysaccharides may be prepared from polysaccharides using any of the conventional means known for this preparation.
Also various protein types may be employed as a poly (amino acid) immunogenic carrier. These types include albumins, serum proteins, lipoproteins, etc. Illustrative proteins include bovine serum albumin (BSA), keyhole limpet hemocyanin (KLH), egg ovalbumin, bovine thyroglobulin (BTG) etc. Alternatively, synthetic poly(amino acids) may be utilized.
Immunogenic carriers can also include polyamino-polysaccharides, which are high molecular weight polymers built up by repeated condensations of monosaccharides. Examples of polysaccharides are starches, glycogen, cellulose, carbohydrate gums such as gum arabic, agar, and so forth. The polysaccharide also contains polyamino acid residues and/or lipid residues.
The immunogenic carrier can also be a poly (nucleic acid) either alone or conjugated to one of the above mentioned poly(amino acids) or polysaccharides.
The immunogenic carrier can also include solid particles. The particles are generally at least about 0.02 microns (μm) and not more than about 100 μm, and usually about 0.05 μm to 10 μm in diameter. The particle can be organic or inorganic, swellable or non-swellable, porous or non-porous, optimally of a density approximating water, generally from about 0.7 to 1.5 g/mL, and composed of material that can be transparent, partially transparent, or opaque. The particles can be biological materials such as cells and microorganisms, including non-limiting examples such as erythrocytes, leukocytes, lymphocytes, hybridomas, Streptococcus, Staphylococcus aureus, E. coli , and viruses. The particles can also be comprised of organic and inorganic polymers, liposomes, latex, phospholipid vesicles, or lipoproteins.
“Poly(amino acid)” or “polypeptide” is a polyamide formed from amino acids. Poly(amino acids) will generally range from about 2,000 molecular weight, having no upper molecular weight limit, normally being less than 10,000,000 and usually not more than about 600,000 daltons. There will usually be different ranges, depending on whether an immunogenic carrier or an enzyme is involved.
A “peptide” is any compound formed by the linkage of two or more amino acids by amide (peptide) bonds, usually a polymer of α-amino acids in which the α-carboxyl group of each amino acid residue is linked to the α-amino group of the next residue in a linear chain. The terms peptide, polypeptide and poly(amino acid) are used synonymously herein to refer to this class of compounds without restriction as to size. The largest members of this class are referred to as proteins.
A “label,” “detector molecule,” or “tracer” is any molecule which produces, or can be induced to produce, a detectable signal. The label can be conjugated to an analyte, immunogen, antibody, or to another molecule such as a receptor or a molecule that can bind to a receptor such as a ligand, particularly a hapten. Non-limiting examples of labels include radioactive isotopes, enzymes, enzyme fragments, enzyme substrates, enzyme inhibitors, coenzymes, catalysts, fluorophores, dyes, chemiluminescers, luminescers, or sensitizers; a non-magnetic or magnetic particle, a solid support, a liposome, a ligand, or a receptor.
The term “antibody” refers to a specific protein binding partner for an antigen and is any substance, or group of substances, which has a specific binding affinity for an antigen to the exclusion of other substances. The generic term antibody subsumes polyclonal antibodies, monoclonal antibodies and antibody fragments.
The term “derivative” refers to a chemical compound or molecule made from a parent compound by one or more chemical reactions.
The term “carrier” refers to solid particles and/or polymeric polymers such as immunogenic polymers such as those mentioned above. Where the carrier is a solid particle, the solid particle may be bound, coated with or otherwise attached to the polymeric material which preferably is a polyamine polymer to provide one or more reactive sites for bonding to the terminal functional group X in the compounds of the formula III.
The term “reagent kit,” or “test kit,” refers to an assembly of materials that are used in performing an assay. The reagents can be provided in packaged combination in the same or in separate containers, depending on their cross-reactivities and stabilities, and in liquid or in lyophilized form. The amounts and proportions of reagents provided in the kit can be selected so as to provide optimum results for a particular application. A reagent kit embodying features of the present invention comprises antibodies specific for the compounds of formula I and formula II. The kit may further comprise ligands of the analyte and calibration and control materials. The reagents may remain in liquid form or may be lyophilized.
The phrase “calibration and control materials” refers to any standard or reference material containing a known amount of a drug to be measured. The concentration of drug is calculated by comparing the results obtained for the unknown specimen with the results obtained for the standard. This is commonly done by constructing a calibration curve.
The term “biological sample” includes, but is not limited to, any quantity of a substance from a living thing or formerly living thing. Such living things include, but are not limited to, humans, mice, monkeys, rats, rabbits, horses, and other animals. Such substances include, but are not limited to, blood, serum, plasma, urine, cells, organs, tissues, bone, bone marrow, lymph, lymph nodes, synovial tissue, chondrocytes, synovial macrophages, endothelial cells, and skin.
Reagents and Immunogens
In constructing an immunoassay, a conjugate of the compound of formula IV is constructed to compete with the compounds of formula I or formula II in the sample for binding sites on the antibodies. In the immunoassay of this invention, the reagents are conjugates of a carrier with the compound of formula IV. In the compound of formula IV the linker spacer constitutes the “—B—(Y)p-X′—” portion of this molecule. The linker X′ and the spacer “—B—(Y)p-”— are conventional in preparing conjugates and immunogens. Any of the conventional spacer-linking groups utilized to prepare conjugates and immunogens for immunoassays can be utilized in the compound of formula IV. Such conventional linkers and spacers are disclosed in U.S. Pat. No. 5,501,987 and U.S. Pat. No. 5,101,015.
Among the preferred spacer groups are included the spacer groups hereinbefore mentioned. Particularly preferred spacing groups are groups such as alkylene containing from 1 to 10 carbon atoms,
wherein m and o are integers from 0 to 6, and n is an integer from 1 to 6 with alkylene being the especially preferred spacing group In these formulae m is 0, n is preferably an integer of from 1-6, most preferably 1 or 2 and o is preferably 0 or 1.
In the compound of formula IV, X′ is —CH 2 — or a functional group linking the spacer to the carrier, preferably to an amine group on a polymeric carrier. The group X′ is the result of the terminal functional group X in the compound of formula III which is capable of binding to a carrier, preferably to an amino group in the polyamine polymer present in the carrier or used as the immunogen. Any terminal functional group capable of binding to a carrier, preferably capable of reacting with an amine can be utilized as the functional group X in the compound of formula III. These terminal functional groups preferably included within X are:
wherein R 3 is hydrogen or taken together with its attached oxygen atom forms a reactive ester and R 4 is oxygen or sulfur. The radical —N═C═R 4 can be an isocyanate or an isothiocyanate. The active esters formed by OR 3 include imidoester, such as N-hydroxysuccinamide, 1-hydroxy benzotriazole and p-nitrophenyl ester. However any active ester which can react with an amine group can be used.
The carboxylic group and the active esters are coupled to the carrier or immunogenic polymer by conventional means. The amine group on the polyamine polymer, such as a protein, produces an amide group which connects the spacer to the polymer, immunogens or carrier and/or conjugates of this invention. On the other hand, carriers can be coated with a polyamine polymer to supply the amino group for linking to the ligand portion.
In the immunogens and conjugates of the present invention, the chemical bonds between the carboxyl group-containing the compound of formula III as a hapten and the amino groups on the polyamine polymer on the carrier or immunogen can be produced using a variety of methods known to one skilled in the art. It is frequently preferable to form amide bonds. Amide bonds are formed by first activating the carboxylic acid moiety of the hapten in the compounds of formula III by reacting the carboxy group with a leaving group reagent (e.g., N-hydroxysuccinimide, 1-hydroxybenzotriazole, o- or p-nitrophenol, or o- or p-nitrophenyl chloroformate). An activating reagent such as dicyclohexylcarbodiimide, diisopropylcarbodiimide and the like can be used. The activated form of the carboxyl group in the hapten of formula III is then reacted with a buffered solution containing the protein carrier. Various methods of conjugating haptens and carriers are also disclosed in U.S. Pat. No. 3,996,344 and U.S. Pat. No. 4,016,146, which are herein incorporated by reference.
Where X is a terminal isocyanate or isothiocyanate radical in the compound of formula III, these radicals when reacted with the free amine of a polyamine polymer produce the conjugate or the immunogen of the hapten of formula IV where X′ is,
In the ligand of formula IV, X′ functionally connects the hapten with the amino group on the polyamine containing carrier or on the immunogenic polypeptide.
Where X, in the compounds of formula III is an aldehyde group these compounds may be connected to the amine group of the polyamine polypeptide or carrier through an amine linkage by reductive amination. Any conventional method of condensing an aldehyde with an amine such as through reductive amination can be used to form this linkage. In this case, X′ in the ligand portions of formula IV is —CH 2 —. Any conventional means of condensing a reactive carbonyl with the amine group can be used in carrying out this condensation reaction.
The compound of formula III, when B is a methylene carbonyl of the formula:
is produced by condensing the amine group in the compound of formula II with an acyl chloride of the formula:
Cl—C(═O)—CH 2 —(Y)p-X V
Any conventional method of reacting a primary amine with an acyl chloride can be used in this condensation procedure. Where Y is lower alkylene and B is the above methylene carbonyl group in the compound of formula III, this compound is produced by treating the compound of formula II with an anhydride of a di carboxylic acid such as glutaric anhydride. Any conventional means of condensing an anhydride with the primary amine group can be used in carrying out this condensation reaction
The compound of formula III when B is —CH 2 — may be produced by reacting the compound of formula I with an alkyl halide of the formula:
Halo CH 2 —(Y)p-X VII
wherein Y, p and X are as above.
Any conventional means of condensing an alkyl halide with a primary amine group can be used in carrying out this condensation reaction.
The compound of formula III where B is —C(═O)—NH—CH 2 may be produced by condensing the compound of formula II with a halide or the formula:
wherein Y, p and X are as above.
utilizing conventional means.
The compound of formula III where B is —C(═O)—O—CH 2 — may be produce by condensing the compound of formula II with a compound of the formula:
where Y, p and X are as above,
utilizing conventional means,
In cases where the compounds of formula V, VII, VIII, and IX contain a reactive amino group as well as a reactive carboxyl group, it is necessary to use an amine or ester protecting group during the reactions to form the compounds of formula III. Typically, the amines are protected by forming the corresponding N-trifluoroacetamide, N-tertbutyloxycarbonyl urethane (N-t-BOC urethane), N-carbobenzyloxy urethane or similar structure. Once the condensation reaction with the structure of formula I has been accomplished, as described above, the amine or the ester protecting group can be removed using reagents that do not otherwise alter the structure of the conjugate. Such reagents and methods are known to one skilled in the art and include weak or strong aqueous or anhydrous acids, weak or strong aqueous or anhydrous bases, hydride-containing reagents such as sodium borohydride or sodium cyanoborohydride and catalytic hydrogenation.
The compound of formula III can be converted into the immunogens and/or the conjugate reagents of this invention by reacting this compound with a carrier, preferably a polyamine polypeptide or a carrier coated with a polyamine polypeptide as described above. The same polypeptide can be utilized as the carrier and as the immunogenic polymer in the immunogen of this invention provided that polyamines or polypeptides are immunologically active. However, to form the conjugates used as reagents in the immunoassay, these polymers need not produce an immunological response as needed for the immunogens. In accordance with this invention, the various functional group represented by X in the compounds of formula III can be conjugated to the carrier by conventional means of attaching a functional group to a carrier. In accordance with a preferred embodiment, in the compounds of formula III, X is a carboxylic acid group or an activated carboxyl group.
Antibodies
The present invention also relates to novel antibodies, particularly monoclonal antibodies, to the compounds of formula I and formula II and mixtures thereof which can be produced by utilizing the aforementioned immunogens. It has been found that these antibodies produced in accordance with this invention are selectively reactive with the compounds of formula I and the compound of formula II and mixtures thereof. These antibodies do not react with non-pharmaceutically inactive metabolites of the compounds of formula I and the compound of formula II which would interfere with immunoassays for either the compound of formula I and the compound of formula II. The ability of the antibodies of this invention not to react with these inactive metabolites makes these antibodies particularly valuable in providing an immunoassay for either the compound of formula I or the compound of formula II.
The present invention relates to these selectively reactive novel antibodies to the compounds of formula I and formula II and mixtures thereof. The antisera of the invention can be conveniently produced by immunizing host animals with the immunogens of this invention. Suitable host animals include rodents, such as, for example, mice, rats, rabbits, guinea pigs and the like, or higher mammals such as goats, sheep, horses and the like. Initial doses, bleedings and booster shots can be given according to accepted protocols for eliciting immune responses in animals. Through periodic bleeding, the blood samples of the immunized mice were observed to develop an immune response against the compounds of formula I and II utilizing conventional immunoassays. These methods provide a convenient way to screen for hosts and antibodies which are producing antisera having the desired activity.
The antibodies having substantially 100% selective reactivity with lenalidomide and substantially no selective reactivity with thalidomide or substantially selective reactivity with both thalidomide and lenalidomide can be produced utilizing the immunogen of formula III and by the screening method disclosed below. This screening method can be used to obtain antibodies which are reactive with both the lenalidomide and thalidomide chemotherapeutic agents, antibodies which are specific and selective to lenalidomide and antibodies having any desired relative reactivity with regard to these chemotherapeutic agents.
In preparing these antibodies, an immunogenic carrier can be conjugated with the immunogen of formula III and used to immunize host animals such as mice, rabbits, sheep or rats. Development of the immune response to the compound of formula III can be monitored by ELISA utilizing microtiter plates coated with a conjugate of BSA and the compound of formula III. Once the immune response has been sufficiently developed the spleen cells of the host animal can be isolated and fused with an immortalized cell line. With respect to producing monoclonal antibodies the fused cells can be plated on 96-well plates and grown in the presence of a selective medium to select hybridoma cells. Hybridoma supernatants and antisera can be assayed for the presence of anti-lenalidomide antibodies by ELISA. Antibodies from wells that gave positive ELISA results can be tested for lenalidomide and thalidomide binding by indirect competitive microtiter plate assay. The IC 50 values of an analyte such as lenalidomide and thalidomide and their metabolites, can be calculated from this assay. The IC 50 (inhibitory concentration at 50%) of an analyte in an assay is the concentration of that analyte in a sample at which the signal in the assay is 50% of the total signal for the assay in the absence of analyte in an inhibition assay.—Selective reactivity of an analyte is calculated from a ratio of the IC 50 's expressed as a %: 100%−[IC 50 -analyte/(IC l 50 -lenalidomide+IC l 50 -thalidomide)]×100. For antibodies having substantially 100% selective reactivity with lenalidomide and substantially no selective reactivity with thalidomide this value will approach 100%. The calculation of the IC 50 is carried out according to the procedure found in The Immunoassay Handbook, pp 108-110, 3 rd edition, edited by D. Wild, published by Elsevier, Amsterdam, 2005. As seen from the above formula, the IC 50 of an analyte is inversely proportional to the reactivity of the analyte. Cells from wells that had desired relative reactivity with both lenalidomide and thalidomide can be obtained by screening and sub-cloning by limiting dilution to isolate individual clones producing monoclonal antibodies having the desired reactivity with thalidomide and lenalidomide
Monoclonal antibodies are produced conveniently by immunizing Balb/c mice according to the schedule followed by injecting the mice with additional immunogen i.p. or i.v. on three successive days starting three days prior to the cell fusion. Other protocols well known in the antibody art may of course be utilized as well. The complete immunization protocol detailed herein provided an optimum protocol for serum antibody response for the antibody to the compounds of formula I and II.
B lymphocytes obtained from the spleen, peripheral blood, lymph nodes or other tissue of the host may be used as the monoclonal antibody producing cell. Most preferred are B lymphocytes obtained from the spleen. Hybridomas capable of generating the desired monoclonal antibodies of the invention are obtained by fusing such B lymphocytes with an immortal cell line, which is a cell line that imparts long term tissue culture stability on the hybrid cell. In the preferred embodiment of the invention the immortal cell may be a lymphoblastoid cell or a plasmacytoma cell such as a myeloma cell. Murine hybridomas which produce lenalidomide and thalidomide monoclonal antibodies are formed by the fusion of mouse myeloma cells and spleen cells from mice immunized with the aforementioned immunogenic conjugates. Chimeric and humanized monoclonal antibodies can be produced by cloning the antibody expressing genes from the hybridoma cells and employing recombinant DNA methods now well known in the art to either join the subsequence of the mouse variable region to human constant regions or to combine human framework regions with complementary determining regions (CDR's) from a donor mouse or rat immunoglobulin. An improved method for carrying out humanization of murine monoclonal antibodies which provides antibodies of enhanced affinities is set forth in International Patent Application WO92/11018.
Polypeptide fragments comprising only a portion of the primary antibody structure may be produced, which fragments possess one or more immunoglobulin activities. These polypeptide fragments may be produced by proteolytic cleavage of intact antibodies by methods well known in the art, or by inserting stop codons at the desired locations in expression vectors containing the antibody genes using site-directed mutageneses to produce Fab fragments or (Fab′) 2 fragments. Single chain antibodies may be produced by joining VL and VH regions with a DNA linker (see Huston et al., Proc. Natl. Acad. Sci. U.S.A., 85:5879-5883 (1988) and Bird et al., Science, 242:423-426 (1988))
The antibodies produced in accordance with this invention can be selectively reactive with the compound of formula II or both the compounds of formula I and the compound of formula II without having any substantial cross-reactivity with the pharmacologically, therapeutically non-active metabolites of the compound of formula I and the compound of formula II. By having no substantial cross-reactivity, it is meant that the antibodies of this invention have cross-reactivity relative to both their reactivity with the compound of formula I and the compound of formula II of less than 10%, preferably less than 5%.
In accordance with this invention antibodies which are selectively reactive with lenalidomide and have no selective reactivity with thalidomide can be produced. By an antibody having selective reactivity for lenalidomide and with no selective reactivity with thalidomide, it is meant that the antibody has at least 95% activity for lenalidomide based upon its reactivity or binding with both thalidomide and lenalidomide. In order to be utilized in a thalidomide immunoassay the antibody should be selectively reactive with both lenalidomide and thalidomide and have a cross-reactivity with the aforementioned pharmacologically, therapeutically non-active metabolites of the compound of formula I and the compound of formula II of less than 10% based upon its reactivity with the both the compounds of formula I and formula II and have a reactivity with thalidomide of at least 10% based upon its reactivity with both thalidomide and lenalidomide. In order to be utilized in a lenalidomide immunoassay, any antibody of this invention which is selectively reactive with lenalidomide or is selectively reactive with both lenalidomide and thalidomide and have a cross-reactivity with the aforementioned pharmacologically, therapeutically non-active metabolites of the compound of formula I and the compound of formula II of less than 10% based upon its reactivity with the both the compounds of formula I and formula II can be used.
Immunoassays
In accordance with this invention, the conjugates and the antibodies generated from the immunogens of the compound of formula III can be utilized as reagents for the determination of the compounds of formula I and formula II in patient samples. This determination is performed by means of an immunoassay. Any immunoassay in which the reagent conjugates formed from the compound of formula III compete with the compound of formula I or formula II in the sample for binding sites on the antibodies generated in accordance with this invention can be utilized to determine the presence of the compound of formula I or formula II in a patient sample. The manner for conducting such an assay for the compound of formula I and formula II in a sample suspected of containing lenalidomide or thalidomide, comprises combining an (a) aqueous medium sample, (b) an antibody to the compound of formula I and formula II generated in accordance with this invention and (c) the conjugates formed from the compound of formula III. The compound of formula I or formula II in the sample can be determined by measuring the inhibition of the binding to the specific antibody of a known amount of the conjugate added to the mixture of the sample and antibody. The result of the inhibition of such binding of the known amount of conjugates by the unknown sample is compared to the results obtained in the same assay by utilizing known standard solutions of the compounds of formula I or formula II. In determining the amount of the compounds of formula I or formula II in an unknown sample, the sample, the conjugates formed from the compounds of formula III and the antibody may be added in any order.
Various means can be utilized to measure the amount of conjugate formed from the compound of formula III bound to the antibody. One method is where binding of the conjugates to the antibody causes a decrease in the rate of rotation of a fluorophore conjugate. The amount of decrease in the rate of rotation of a fluorophore conjugate in the liquid mixture can be detected by the fluorescent polarization technique such as disclosed in U.S. Pat. No. 4,269,511 and U.S. Pat. No. 4,420,568.
On the other hand, the antibody can be coated or absorbed on nanoparticles so that when these particles react with the compounds of formula I or formula II and conjugates formed from the compounds of formula III these nanoparticles form an aggregate. However, when the antibody coated or absorbed on nanoparticles react with thalidomide or lenalidomide in the sample, the thalidomide or lenalidomide from the sample bound to these nanoparticles does not cause aggregation of the antibody nanoparticles. The amount of aggregation or agglutination can be measured in the assay mixture by absorbance.
On the other hand, these assays can be carried out by having either the antibody or the compounds of formula III attached to a solid support such as a microtiter plate or any other conventional solid support including solid particles. Attaching antibodies and proteins to such solid particles is well known in the art. Any conventional method can be utilized for carrying out such attachments. In many cases, in order to aid measurement, labels may be placed upon the antibodies, conjugates or solid particles, such as radioactive labels or enzyme labels, as aids in detecting the amount of the conjugates formed from the compound of formula III which is bound or unbound with the antibody. Other suitable labels include chromophores, fluorophores, etc.
As a matter of convenience, assay components of the present invention can be provided in a kit, a packaged combination with predetermined amounts of new reagents employed in assaying for the compounds of formula I or formula II. These reagents include the antibody of this invention, as well as, the conjugate formed from the compounds of formula III. In carrying out an immunoassay in accordance with this invention the radicals p, X, Y and B in the reagent and the immunogen which forms the antibody used in a given immunoassay can be the same or be a different substituent within the groups defined for each of these radicals. Therefore while the definitions of the radicals p, X, Y, and B are the same for the conjugate reagent and the immunogen, the particular substituent which these radicals represent for the immunogen and the conjugate reagent in a given assay may be different.
In addition to these necessary reagents, additives such as ancillary reagents may be included, for example, stabilizers, buffers and the like. The relative amounts of the various reagents may vary widely to provide for concentrations in solution of the reagents which substantially optimize the sensitivity of the assay. Reagents can be provided in solution or as a dry powder, usually lyophilized, including excipients which on dissolution will provide for a reagent solution having the appropriate concentrations for performing the assay.
EXAMPLES
In the examples, the following abbreviations are used for designating the following:
HATU O-(7-Azabenzotriazol-1-yl)-N,N,N′,N′-tetramethyluronium hexafluorophosphate DIPEA N—N′-Diisopropylethylamine DMF Dimethylformamide TFA Trifluoroacteic acid CH 2 Cl 2 dicholoromethane DMSO Dimethylsulfoxide NHS N-hydroxy succinimide s-NHS sulfo-N-hydroxy succinimide EDC 1-(3-dimethylaminopropyl)-3-ethylcarbodiimide hydrochloride KLH Keyhole Limpet Hemocyanin BSA Bovine serum albumin PBS Phosphate buffered saline NaCl sodium chloride HRP horseradish peroxidase ANS 8-Anilino-1-naphthalenesulfonic acid TMB 3,3′,5,5′-Tetramethylbenzidine TRIS Tris(hydroxymethyl)aminomethane hydrochloride di H 2 O deionized water
The phosphate buffer composition has an aqueous solution containing
15.4 mM Sodium phosphate dibasic (Na 2 HPO 4 ) 4.6 mM Sodium phosphate monobasic (NaH 2 PO 4 ) pH=7.2±0.10
In the examples, Schemes 1-2 below set forth the specific compounds prepared and referred to by numbers in the Examples. The schemes are as follows:
Example 1
Preparation of Carbamoyl Pentantoic Acid Derivative of Lenalidomide Derivative [3] (Scheme 1)
A mixture of lenalidomide [1] (1.0 g, 3.86 mmol) and glutaric anhydride [2] (0.48 g, 4.25 mmol) in anhydrous toluene was heated and refluxed under nitrogen for 3.5 hours. Another portion of glutaric anhydride [2] (0.18 g, 1.53 mmol) was added and the mixture was heated another 2 hours to produce [3]. The mixture was cooled to 0° C., to precipitate [3]. The precipitated solid was filtered, and washed with CH 2 Cl 2 to obtain 1.55 g of crude compound [3]. This crude compound was recrystallized from ethanol (20 mL)/H 2 O (1 mL) to obtain pure [3] (1.30 g, 90%) as a white solid.
Example 2
Preparation of Carbamoyl-Butyrylamino-Methyl Benzoic Acid Derivative of Lenalidomide Derivative [7] (Scheme 2)
The compound [3] produced in example 1 (800 mg, 2.14 mmol) was dissolved in anhydrous DMF (20 mL) under nitrogen, to which was added diisopropylethyl amine (DIPEA) (1.27 mL, 7.27 mmol) and the amine [10] (700 mg, 2.35 mmol) followed by HATU (1.88 g, 4.93 mmol). This reaction mixture was stirred at 25° C. for 24 hours to produce [6]. The contents of the flask were diluted with ethyl acetate. The organic phase (ethyl acetate) was washed with 1 M hydrochloric acid, saturated sodium bicarbonate and water. The ethylacetate layer was then dried over sodium sulfate, which was filtered off. Removal of the ethylacetate solvent provided the crude product [6], which was purified by flash chromatography with 100% EtOAc and 1-2% MeOH/EtOAc to obtain the pure product [6] (680 mg, 57%) as a white solid.
1 H NMR (300 MHz, DMSO-d 6 ): δ 11.03 (s, 1H), 9.82 (s, 1H), 8.46 (t, J=6.0 Hz, 1H), 7.82-7.86 (m, 3H), 7.46-7.52 (m, 2H), 7.35 (d, J=8.3 Hz, 2H), 5.14 (dd, J=5.0, 13.5 Hz, 1H), 4.32-4.38 (m, 4H), 2.86-2.96 (m, 1H), 2.56-2.64 (m, 2H), 2.39 (t, J=7.5 Hz, 2H), 2.25 (t, J=7.5 Hz, 2H), 1.97-2.05 (m, 1H), 1.82-1.92 (m, 2H), 1.53 (s, 9H). APCI] − =561.
This white solid [6] (676 mg, 1.20 mmol) was dissolved in dichloromethane (3 mL). To this solution of compound [6] at 0° C. under N 2 was added TFA (3 mL) to produce [7]. The dichloromethane was removed under reduced pressure and the resulting residue [7] was triturated with ether to isolate the crude acid. This material was recrystallized from aqueous EtOH to obtain pure [7] (507 mg, 83%).
Example 3
General Method for Preparing NHS/s-NHS Activated Drug Derivatives from the Corresponding Acids [3] & [7]
Lenalidomide acid derivative [3] was activated with EDC and NHS to produce the NHS activated ester of lenalidomide [4] for eventual conjugation to proteins (examples 4 and 5a). Lenalidomide acid derivative [7] was activated with EDC and s-NHS to produce the s-NHS activated ester of lenalidomide [8] for eventual conjugation to protein (example 5b).
Example 3a
Preparation of NHS Activated Ester Lenalidomide Carbamoyl Pentantoic Acid Derivative [4]
Lenalidomide derivative [3], example 1, scheme 1, (67.62 mg) was dissolved in 7 mL of DMSO to which was added NHS (59.60 mg) and EDC (93.00 mg). The reaction mixture was stirred for 20 hours at ambient temperature under a nitrogen atmosphere to produce the NHS activated ester of lenalidomide derivative [4]. The reaction mixture was used directly in examples 4 and 5a.
Example 3b
Preparation of s-NHS Activated Ester Lenalidomide Carbamoyl-Butyrylamino-Methyl Benzoic Acid Derivative [8]
Lenalidomide derivative [7], example 2, scheme 2 (16.3 mg) was dissolved in 1.6 mL of DMSO to which was added s-NHS (25.3 mg) and EDC (18.1 mg). The reaction mixture was stirred for 20 hours at ambient temperature under a nitrogen atmosphere to produce the s-NHS activated ester of lenalidomide derivative [8]. The reaction mixture was used directly in example 5b.
Example 4
Preparation of KLH Immunogen with Activated Hapten [4]
A protein solution of KLH was prepared by dissolving 300 mg of KLH in 15 mL of phosphate buffer (50 mM, pH 7.5), followed by addition of 1.5 mL DMSO and 3.50 mL of NHS activated lenalidomide derivative [4] prepared in Example 3a. The reaction mixture of KLH and activated lenalidomide derivative [4] was allowed to stir for 20 hours at room temperature to produce the lenalidomide-KLH conjugate [5]. The lenalidomide-KLH conjugate [5] was then purified by dialysis against 10% DMSO in phosphate buffer (50 mM, pH 7.5) at room temperature. Thereafter lenalidomide-KLH conjugate [5] was dialyzed against phosphate buffer (50 mM, pH 7.5) at room temperature. The last dialysis was performed against phosphate buffer at 4° C. The lenalidomide-KLH conjugate [5] was characterized by ultraviolet-visible spectroscopy (UV/VIS). The conjugate was diluted to a final concentration of 2 mg/mL in phosphate buffer (50 mM, pH 7.5).
Example 5a
Preparation of BSA Conjugate with Activated Hapten [4]
A protein solution of BSA was prepared by dissolving 1 g BSA in phosphate buffer (50 mM, pH 7.5) for a final concentration of 50 mg/mL. DMSO (3.3 mL) was slowly added to the protein solution of BSA while stirring on ice, followed by addition of 0.60 mL of NHS activated lenalidomide derivative [4] prepared in Example 3a. The amount of NHS activated lenalidomide derivative [4] added to the protein solution of BSA was calculated for a 1:1 molar ratio between the derivative of lenalidomide [4] and BSA. The mixture of BSA and activated lenalidomide derivative [4] was allowed to stir for 18 hours at room temperature to produce the conjugate of the activated lenalidomide ester [4] and BSA. This conjugate was then purified by dialysis against 10% DMSO in phosphate buffer (50 mM, pH 7.5) at room temperature. Thereafter lenalidomide-BSA conjugate [5] was dialyzed against phosphate buffer (50 mM, pH 7.5) at room temperature. The last dialysis was performed against phosphate buffer at 4° C. The purified lenalidomide-BSA conjugate [5] was characterized by UV/VIS spectroscopy.
Example 5b
Preparation of BSA Conjugate with Activated Hapten [8]
A protein solution of BSA was prepared by dissolving 0.5 g BSA in phosphate buffer (50 mM, pH 7.5) for a final concentration of 50 mg/mL. s-NHS activated lenalidomide derivative [8] prepared in Example 3b was slowly added to the protein solution of BSA while stirring on ice. The amount of s-NHS activated lenalidomide derivative [8] added to the protein solution of BSA was calculated for a 1:1 molar ratio between the derivative of lenalidomide [8] and BSA. The mixture of BSA and activated lenalidomide derivative [8] was allowed to stir for 18 hours at room temperature to produce the conjugate of the activated lenalidomide ester [8] and BSA. This conjugate was then purified by dialysis against 10% DMSO in phosphate buffer (50 mM, pH 7.5) at room temperature. Thereafter lenalidomide-BSA conjugate [9] was dialyzed against phosphate buffer (50 mM, pH 7.5) at room temperature. The last dialysis was performed against phosphate buffer at 4° C. The purified lenalidomide-BSA conjugate [9] was characterized by UV/VIS spectroscopy.
Example 6a
Preparation of Polyclonal Antibodies to Lenalidomide [3]
Ten female BALB/c mice were immunized i.p. with 100 μg/mouse of lenalidomide-KLH immunogen [5], as prepared in Example 4, emulsified in Complete Freund's adjuvant. The mice were boosted once, four weeks after the initial injection with 100 μg/mouse of the same immunogen emulsified in Incomplete Freund's Adjuvant. Twenty days after the boost, test bleeds containing polyclonal antibodies from each mouse were obtained by orbital bleed. The anti-serum from these test bleeds containing lenalidomide antibodies were evaluated in Examples 8 and 9.
Example 6b
Preparation of Monoclonal Antibodies to Lenalidomide [3]
Mice from Example 6a that were immunized with lenalidomide-KLH conjugate [5] prepared in Example 4 were used to produce monoclonal antibodies. For monoclonal antibodies starting three days before the fusion, the mice were injected i.p. with 400 μg (3 days before fusion), 200 μg (2 days before fusion), and 200 μg (1 day before fusion) of lenalidomide-KLH conjugate [5] in PBS prepared in Example 4. Spleen cells were isolated from the selected mice and fused with 2×10 7 SP2/0 cells with 50% polyethylene glycol 1500 according to the method of Coligan, J. E. et al., eds., Current Protocols in Immunology, 2.5.1-2.5.8, (1992), Wiley & Sons, NY. The fused cells were plated on ten 96-well plates in DMEM/F12 supplemented with 20% FetalClone I, 2% L-glutamine (100 mM) and 2% 50×HAT. Two to three weeks later, the hybridoma supernatant was assayed for the presence of anti-lenalidomide antibodies by ELISA (as in example 8b). Cells from the wells that gave positive ELISA results were expanded to 24 well plates. These monoclonal antibodies were tested for lenalidomide and thalidomide binding by indirect competitive microtiter plate assay as described in example 9. Clones positive by ELISA were subcloned at least once by limiting dilution according to the method disclosed in Coligan, J. E. et al., eds., Current Protocols in Immunology, 2.5.8-2.5.17, (1992), Wiley & Sons, NY.
Example 7a
Microtiter Plate Sensitization Procedure with Lenalidomide-BSA Conjugate [5]
The ELISA method for measuring lenalidomide concentrations was performed in polystyrene microtiter plates (Nunc MaxiSorp F8 Immunomodules) optimized for protein binding and containing 96 wells per plate. Each well was coated with lenalidomide-BSA conjugate [5] (prepared as in Example 5a) by adding 300 μL of lenalidomide-BSA conjugate [5] at 10 μg/mL in 0.05M sodium carbonate, pH 9.6, and incubating for three hours at room temperature. The wells were washed with 0.05M sodium carbonate, pH 9.6 and then were blocked with 375 μL of 5% sucrose, 0.2% sodium caseinate solution for 30 minutes at room temperature. After removal of the post-coat solution the plates were dried at 37° C. overnight.
Example 7b
Microtiter Plate Sensitization Procedure with Lenalidomide-BSA Conjugate [9]
The ELISA method for measuring lenalidomide concentrations was performed in polystyrene microtiter plates (Nunc MaxiSorp F8 Immunomodules) optimized for protein binding and containing 96 wells per plate. Each well was coated with lenalidomide-BSA conjugate [9] (prepared as in Example 5b) by adding 300 μL of lenalidomide-BSA conjugate [9] at 10 μg/mL in 0.05M sodium carbonate, pH 9.6, and incubating for three hours at room temperature. The wells were washed with 0.05M sodium carbonate, pH 9.6 and then were blocked with 375 μL of 5% sucrose, 0.2% sodium caseinate solution for 30 minutes at room temperature. After removal of the post-coat solution the plates were dried at 37° C. overnight.
Example 8a
Antibody Screening Procedure—Titer
This procedure is to find the dilution of antibody to be tested for displacement as in Example 9. The ELISA method for screening lenalidomide antibodies (produced in Example 6) was performed with the microtiter plates that were sensitized with lenalidomide-BSA conjugates prepared in Examples 7a and 7b. The antibody screening assay was performed by diluting the murine serum from test bleeds (as in Example 6a) containing polyclonal lenalidomide antibodies to 1:2,000, 1:6,000, 1:18,000 and 1:54,000 (volume/volume) in phosphate buffered saline containing 0.1% BSA and 0.01% thimerosal. To each well of lenalidomide-BSA sensitized wells (prepared in Examples 7a and 7b) 50 μL phosphate buffered saline containing 0.1% BSA and 0.01% thimerosal and 50 μL of diluted antibody were added and incubated for 10 minutes at room temperature with shaking. During this incubation antibody binds to the lenalidomide-BSA conjugate passively absorbed in the wells (Examples 7a and 7b). The wells of the plates were washed three times with 0.02 M TRIS, 0.9% NaCl, 0.5% Tween-80 and 0.001% thimerosal, pH 7.8 to remove any unbound antibody. To detect the amount of lenalidomide antibody bound to the lenalidomide-BSA conjugate in the wells, 100 μL of a goat anti-mouse antibody—HRP enzyme conjugate (Jackson Immunoresearch) diluted to a specific activity (approximately 1/3000) in PBS with 0.1% BSA, 0.05% ANS, 0.01% thimerosal, capable of binding specifically with murine immunoglobulins and producing a colored product when incubated with a substrate, in this example TMB, were added to each well. After an incubation of 10 minutes at room temperature with shaking, during which the goat anti-mouse antibody—HRP enzyme conjugate binds to lenalidomide antibodies in the wells, the plates were again washed three times to remove unbound goat anti-mouse antibody—HRP enzyme conjugate. To develop a measurable color in the wells washing was followed by the addition of 100 μL of TMB (TMB Substrate, BioFx), the substrate for HRP, to develop color during a 10 minute incubation with shaking at room temperature. Following the incubation for color development, 50 μL of stop solution (1.5% sodium fluoride in di H 2 O) was added to each well to stop the color development and after 20 seconds of shaking the absorbance was determined at 650 nm (Molecular Devices Plate Reader). The amount of antibody in a well was proportional to the absorbance measured and was expressed as the dilution (titer) resulting in an absorbance of 1.5. Titers were determined by graphing antibody dilution of the antibody measured (x-axis) vs. absorbance 650 nm (y-axis) and interpolating the titer at an absorbance of 1.5. The titer which produced absorbance of 1.5 determined the concentration (dilution) of antibody used in the indirect competitive microtiter plate assay described in Example 9.
Example 8b
Antibody Screening Procedure—Monoclonal Screening
The ELISA method for screening lenalidomide monoclonal antibodies (produced in example 8b) was performed with the microtiter plates that were sensitized with lenalidomide-BSA conjugate [9] as described in example 7b. To each well of lenalidomide-BSA sensitized wells (prepared in example 7b) 50 μL phosphate buffered saline containing 0.1% BSA and 0.01% thimerosal and then 50 μL of monoclonal culture supernatant were added and incubated for 10 minutes at room temperature with shaking. During this incubation antibody binds to the lenalidomide-BSA conjugate in the well. The wells of the plates were washed three times with 0.02 M TRIS, 0.9% NaCl, 0.5% Tween-80 and 0.001% thimerosal, pH 7.8 to remove any unbound antibody. To detect the amount of lenalidomide antibody bound to the lenalidomide-BSA conjugate in the wells, 100 μL of a goat anti-mouse antibody—HRP enzyme conjugate (Jackson Immunoresearch) diluted 1/3000 in PBS with 0.1% BSA, 0.05% ANS, 0.01% thimerosal, capable of binding specifically with murine immunoglobulins and producing a colored product when incubated with a substrate, in this example TMB, were added to each well. After an incubation of 10 minutes at room temperature with shaking, during which the goat anti-mouse antibody—HRP enzyme conjugate binds to lenalidomide antibodies in the wells, the plates were again washed three times to remove unbound goat anti-mouse antibody—HRP enzyme conjugate. To develop a measurable color in the wells washing was followed by the addition of 100 μL of TMB (TMB Substrate, BioFx), the substrate for HRP, to develop color during a 10 minute incubation with shaking at room temperature. Following the incubation for color development, 50 μL of stop solution (1.5% sodium fluoride in diH 2 O) was added to each well to stop the color development and after 10 seconds of shaking the absorbance was determined at 650 nm (Molecular Devices Plate Reader). The amount of antibody in a well was proportional to the absorbance measured. Samples with an absorbance of greater than three or more times background were designated as positive. Samples with absorbance above 0.4 or fifty samples with highest absorbance were expanded to 24 well plates, as described in Example 8b.
Example 9
Indirect Competitive Microtiter Plate Immunoassay Procedure Determining IC 50 for Antibodies to Lenalidomide
The ELISA method for determining IC 50 values was performed with the microtiter plates that were sensitized with lenalidomide-BSA conjugate [9] as described in Example 7b. The analytes—lenalidomide and thalidomide were dissolved in DMSO and diluted in diH 2 O over a concentration range of 1 to 100,000 ng/mL. Each of the assays were performed by incubating 50 μL of the analyte solution with 50 μL of one of the antibodies selected from the polyclonal antibodies produced in Example 6a with the immunogen of Example 4 (lenalidomide) and the monoclonal antibody produced in Example 8b (lenalidomide and thalidomide). The assays were all performed by diluting the concentration of the antibodies in each of the wells to the titer determined in Example 8a. During the 10 minute incubation (at room temperature with shaking) there is a competition of antibody binding for the lenalidomide-BSA conjugate in the well (produced in Example 7b) and the analyte in solution. Following this incubation the wells of the plate were washed three times with 0.02 M TRIS, 0.9% NaCl, 0.5% Tween-80 and 0.001% thimerosal, pH 7.8 to remove any material that was not bound. To detect the amount of lenalidomide antibody bound to the lenalidomide-BSA conjugate in the wells (produced in Example 7b), 100 μL of a goat anti-mouse antibody—HRP enzyme conjugate (Jackson Immunoresearch) diluted to a predetermined specific activity (approximately 1/3000) in PBS with 0.1% BSA, 0.05% ANS, 0.01% thimerosal, capable of binding specifically with murine immunoglobulins and producing a colored product when incubated with a substrate, in this example TMB, were added to each well. After an incubation of 10 minutes at room temperature with shaking, during which the goat anti-mouse antibody—HRP enzyme conjugate binds to lenalidomide antibodies in the wells, the plates were again washed three times to remove unbound secondary conjugate. To develop a measurable color in the wells washing was followed by the addition of 100 μL of TMB (TMB Substrate, BioFx), the substrate for HRP, to develop color in a 10 minute incubation with shaking at room temperature. Following the incubation for color development, 50 μL of stop solution (1.5% sodium fluoride in di H 2 O) was added to each well to stop the color development and after 20 seconds of shaking the absorbance was determined at 650 nm (Molecular Devices Plate Reader). The amount of antibody in a well was proportional to the absorbance measured and inversely proportional to the amount of lenalidomide or thalidomide in the sample. The IC 50 's of lenalidomide and thalidomide were determined by constructing dose-response curves with the absorbance in the wells plotted versus analyte concentration in the wells. The absorbance of the color in the wells containing analyte was compared to that with no analyte and a standard curve was generated. The IC 50 value for a given analyte was defined as the concentration of analyte that was required to have 50% of the absorbance of the wells containing no analyte. Results for polyclonal antibodies to lenalidomide are in table I below. Results for monoclonal antibodies to lenalidomide are in table II below.
TABLE I
IC 50 's of lenalidomide and titers of polyclonal antibodies to lenalidomide
(Example 6a) using plates coated with lenalidomide-BSA conjugate [9]
(Example 7b).
Bleed #
Titer
IC 50 , ng/mL
1
51,000
84
2
66,000
59
3
28,000
3,400
4
15,000
2,200
5
111,000
510
6
5,200
810
7
9,300
80
8
9,400
870
9
58,000
570
10
18,000
9
TABLE II
IC 50 's of lenalidomide and thalidomide using monoclonal antibodies
to lenalidomide (Example 6b) using plates coated with lenalidomide-BSA
conjugate [9] (Example 7b).
Monoclonal
antibody
Analyte
% cross-reactivity to
number
Lenalidomide
Thalidomide
Thalidomide
1H12
1
7
<15%
6G1
11
992
<2%
7E4
6
7
<86%
As seen from these tables, the antibodies of this invention are substantially reactive with lenalidomide and thalidomide. | Novel conjugates and immunogens derived from lenalidomide and antibodies generated by these immunogens are useful in immunoassays for the quantification and monitoring of thalidomide and lenalidomide in biological fluids. | 8 |
This application is a divisional of application Ser. No. 10/293,874, entitled “Linear Motor Controller” and filed on Nov. 13, 2002, now U.S. Pat. No. 6,812,597.
FIELD OF INVENTION
This invention relates to a controller for a linear motor used for driving a compressor and in particular but not solely a refrigerator compressor.
SUMMARY OF THE PRIOR ART
Linear compressor motors operate on a moving coil or moving magnet basis and when connected to a piston, as in a compressor, require close control on stroke amplitude since unlike more conventional compressors employing a crank shaft stroke amplitude is not fixed. The application of excess motor power for the conditions of the fluid being compressed may result in the piston colliding with the cylinder head in which it is located.
In International Patent Publication no. WO01/79671 the applicant has disclosed a control system for free piston compressor which limits motor power as a function of property of the refrigerant entering the compressor. However in some free piston refrigeration systems it may be useful to detect an actual piston collision and then to reduce motor power in response. Such a strategy could be used purely to prevent a compressor damage, when excess motor power occurred for any reason or, could be used as a way of ensuring high volumetric efficiency. Specifically in relation to the latter, a compressor could be driven with power set to just less than to cause piston collisions, to ensure the piston operated with minimum head clearance volume. Minimising head clearance volume leads to increased volumetric efficiency.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a linear motor controller which goes someway to achieving the above mentioned desiderata.
Accordingly in one aspect the invention may broadly be said to consist in a free piston gas compressor comprising:
a cylinder,
a piston,
said piston reciprocable within said cylinder,
a reciprocating linear electric motor derivably coupled to said piston having at least one excitation winding,
means for obtaining a measure of the reciprocation time of said piston,
means for detecting any change in said reciprocation time, and
means for adjusting the power input to said excitation winding in response to any detected change in reciprocation time.
Preferably said motor is an electronically commutated permanent magnet DC motor.
Preferably said compressor further comprises back EMF detection means for sampling the back EMF induced in said at least one excitation winding when exciting current is not flowing, and zero crossing means connected to the output of said back EMF detection means and means for determining the time interval between output pulses from said zero crossing detection means to thereby determine the time of each half cycle of said piston.
Preferably two successive half cycles of said piston operation are summed to provide said reciprocation time.
Preferably means for detecting any change in said reciprocation time includes means to detect said reciprocation time from a filtered or smoothed value, to provide a difference valve and if said difference value is above a predetermined threshold for a predetermined period, said means for adjusting the power is configured to reduce the power input to said excitation winding.
In a second aspect the present invention may broadly be said to consist in a method of preventing overshoot of the reciprocating portion of a linear motor comprising the steps:
determining the reciprocation time of said reciprocating portion,
detecting any change in said reciprocation time, and
adjusting the power input to said linear motor in response to any detected reduction in reciprocation time.
Preferably said reciprocating portion comprises the armature of said linear motor.
Preferably said step of determining said reciprocation time includes the step of detecting zero crossings of the current in said linear motor and determining said reciprocation time from the time interval there between.
Preferably said step of detecting any change in said reciprocation time includes the step of deducting said reciprocation time from a filtered or smoothed value, to provide a difference valve and if said difference value is above a predetermined threshold for a predetermined period, reducing the power input to said linear motor.
In a third aspect the present invention may broadly be said to consist in a controller for a linear motor including an reciprocating portion, said controller adapted to implement at least the following steps:
determining the reciprocation time of a reciprocating portion,
detecting any change in said reciprocation time, and
adjusting the power input to said linear motor in response to any detected reduction in reciprocation time.
Preferably a reciprocating portion comprises the armature of a linear motor.
Preferably said step of determining said reciprocation time includes the step of detecting zero crossings of the current in a linear motor and determining said reciprocation time from the time interval there between.
Preferably said step of detecting any change in said reciprocation time includes the step of deducting said reciprocation time from a filtered or smoothed value, to provide a difference valve and if said difference value is above a predetermined threshold for a predetermined period, reducing the power input to said linear motor.
To those skilled in the art to which the invention relates, many changes in construction and widely differing embodiments and applications of the invention will suggest themselves without departing from the scope of the invention as defined in the appended claims. The disclosures and the descriptions herein are purely illustrative and are not intended to be in any sense limiting.
The invention consists in the foregoing and also envisages constructions of which the following gives examples.
BRIEF DESCRIPTION OF THE DRAWINGS
One preferred form of the invention will now be described with reference to the accompanying drawings in which;
FIG. 1 is a cross-section of a linear compressor according to the present invention,
FIG. 2 is a cross-section of the double coil linear motor of the present invention in isolation,
FIG. 3 is a cross-section of a single coil linear motor,
FIG. 4 is a block diagram of the free piston vapour compressor and associated controller of the present invention,
FIG. 5 is a flow diagram showing control processors used by said controller,
FIG. 6 shows a graph of compressor motor back EMF versus time, and
FIG. 7 shows a graph of piston reciprocation period versus time.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention provides a method for controlling a linear motor with a number of improvements over the prior art. Firstly it has a reduced size compared to the conventional linear motor of the type described in U.S. Pat. No. 4,602,174 and thus reduces the cost. This change keeps the efficiency high at low to medium power output at the expense of slightly reduced efficiency at high power output. This is an acceptable compromise for a compressor in a household refrigerator which runs at low to medium power output most of the time and at high power output less than 20% of the time (this occurs during periods of frequent loading and unloading of the refrigerator contents or on very hot days). Secondly it uses a control strategy which allows optimally efficient operation, while negating the need for external sensors, which also reduces size and cost.
While in the following description the present invention is described in relation to a cylindrical linear motor it will be appreciated that this method is equally applicable to linear motors in general and in particular also to flat linear motors see for example our co-pending International Patent Application no. PCT/NZ00/00201 the contents of which are incorporated herein by reference. One skilled in the art would require no special effort to apply the control strategy herein described to any form of linear motor. It will also be appreciated that the present invention will be applicable in any form of compressor. While it is described in relation to a free piston compressor it could equally be used in a diaphragm compressor for example, without any special modifications.
One embodiment of the present invention, shown in FIG. 1 , involves a permanent magnet linear motor connected to a reciprocating free piston compressor. The cylinder 9 is supported by a cylinder spring 14 within the compressor shell 30 . The piston 11 is supported radially by the bearing formed by the cylinder bore plus its spring 13 via the spring mount 25 . The bearings may be lubricated by any one of a number of methods as are known in the art, for example the gas bearing described in our co-pending International Patent Application no. PCT/NZ00/00202, or the oil bearing described in International Patent Publication no. WO00/26536, the contents of both of which are incorporated herein by reference. Equally the present invention is applicable to alternative reciprocation systems. For example while below a compressor is described with a combined gas/mechanical spring system, an entirely mechanical or entirely gas spring system can be used with the present invention.
The reciprocating movement of piston 11 within cylinder 9 draws gas in through a suction tube 12 through a suction port 26 through a suction muffler 20 and through a suction valve port 24 in a valve plate 21 into a compression space 28 . The compressed gas then leaves through a discharge valve port 23 , is silenced in a discharge muffler 19 , and exits through a discharge tube 18 .
The compressor motor comprises a two part stator 5 , 6 and an armature 22 . The force which generates the reciprocating movement of the piston 11 comes from the interaction of two annular radially magnetised permanent magnets 3 , 4 in the armature 22 (attached to the piston 11 by a flange 7 ), and the magnetic field in an air gap 33 (induced by the stator 6 and coils 1 , 2 ).
A two coil embodiment of present invention, shown in FIG. 1 and in isolation in FIG. 2 , has a current flowing in coil 1 , which creates a flux that flows axially along the inside of the stator 6 , radially outward through the end stator tooth 32 , across the air gap 33 , then enters the back iron 5 . Then it flows axially for a short distance 27 before flowing radially inwards across the air gap 33 and back into the centre tooth 34 of the stator 6 . The second coil 2 creates a flux which flows radially in through the centre tooth 34 across the air gap axially for a short distance 29 , and outwards through the air gap 33 into the end tooth 35 . The flux crossing the air gap 33 from tooth 32 induces an axial force on the radially magnetised magnets 3 , 4 provided that the magnetisation of the magnet 3 is of the opposite polarity to the other magnet 4 . It will be appreciated that instead of the back iron 5 it would be equally possible to have another set of coils on the opposite sides of the magnets.
An oscillating current in coils 1 and 2 , not necessarily sinusoidal, creates an oscillating force on the magnets 3 , 4 that will give the magnets and stator substantial relative movement provided the oscillation frequency is close to the natural frequency of the mechanical system. This natural frequency is determined by the stiffness of the springs 13 , 14 and mass of the cylinder 9 and stator 6 . The oscillating force on the magnets 3 , 4 creates a reaction force on the stator parts. Thus the stator 6 must be rigidly attached to the cylinder 9 by adhesive, shrink fit or clamp etc. The back iron is clamped or bonded to the stator mount 17 . The stator mount 17 is rigidly connected to the cylinder 9 .
In a single coil embodiment of the present invention, shown in FIG. 3 , current in coil 109 , creates a flux that flows axially along the inside of the inside stator 110 , radially outward through one tooth 111 , across the magnet gap 112 , then enters the back iron 115 . Then it flows axially for a short distance before flowing radially inwards across the magnet gap 112 and back into the outer tooth 116 . In this motor the entire magnet 122 has the same polarity in its radial magnetisation.
Control Strategy
Experiments have established that a free piston compressor is most efficient when driven at the natural frequency of the compressor piston-spring system. However as well as any deliberately provided metal spring, there is an inherent gas spring, the effective spring constant of which, in the case of a refrigeration compressor, varies as either evaporator or condenser pressure varies. The electronically commutated permanent magnet motor already described, is controlled using techniques including those derived from the applicant's experience in electronically commutated permanent magnet motors as disclosed in International Patent Publication no. WO01/79671 for example, the contents of which are incorporated herein by reference.
When the linear motor is controlled as described in WO01/79671 it is possible that the compressor input power increases to a level where the excursion of the piston ( 11 , FIG. 1 ) results in the collision with the cylinder ( 9 , FIG. 1 ). When this occurs (the first collision 302 ) the piston reciprocation period 300 is reduced compared to the filtered or smoothed value 308 . More importantly because the piston period is made up of two half periods 304 , 306 , between bottom dead centre and top dead centre, the half periods are not symmetrical. The half period moving away from the head 304 is shorter than the half period moving towards the head 306 , although both half periods are reduced in time whenever a piston collision occurs (second collision 310 ). In the preferred embodiment of the present invention the half period times are monitored and when any reduction in the half period times is detected the input power is reduced in response.
It will also be appreciated the present invention is equally applicable to a range of applications. It is desirable in any reciprocating linear motor to limit or control the maximum magnitude of reciprocation. For the present invention to be applied the system requires a restoring force eg: a spring system or gravity, causing reciprocation, and some change in the mechanical or electrical system which causes a change in the electrical reciprocation period when a certain magnitude of reciprocation is reached.
In the preferred embodiment of the present invention, shown in FIG. 4 , back EMF detection is used to detect the electrical period of reciprocation. As already described the current controller 208 receives inputs from the compressor 210 , the back EMF detector 204 and the collision detector 206 . While in the preferred embodiment of the present invention the current controller 208 , the back EMF detector 204 and the collision detector 206 are implemented in software stored in the microprocessor 212 , they could equally be implemented in a single module or in discrete analogue circuitry. The collision detector 206 receives the electrical period data from the back EMF detector 204 allowing it to detect overshoot, or more specifically collision of the piston with the cylinder. The current controller 208 adjusts the maximum current through the duty cycle applied by the drive circuit 200 to the stator winding 202 .
Example waveforms in a linear motor employing the present invention are seen in FIG. 6 . The stator winding voltage is fully positive 400 for a time t on(ex) during the beginning of the expansion stroke. With the voltage removed the current 402 decays to zero over time t off1(ex) , with the stator winding voltage forced fully negative 403 by the current flowing in the windings. For the remainder of the expansion stroke, time t off2(ex) the winding voltage represents the back EMF 404 , and the zero crossing thereof zero velocity of the piston at the end of the expansion stroke. A similar pattern occurs during the compression stroke, rendering a time t off2(comp) relating to the zero crossing of the back EMF 406 during compression, from which the reciprocation time can be calculated.
The process the collision detector 206 uses in the preferred embodiment to detect a collision is seen in FIG. 5 . Using the back EMF zero crossing data successive half period times are stored 504 and a smoothed or filtered value for each half period is calculated 500 , 502 . These averages are summed 506 and the sum is monitored for an abrupt reduction 508 . Because of a signal noise caused for various reasons it is not safe to consider one transient reduction as indicative of a piston collision. Accordingly the variable B is preferably set at five successive cycles. The threshold difference value A is preferably set at 30 microseconds.
When a collision is detected ( 510 , FIG. 5 ), the current controller ( 208 , FIG. 4 ) decreases the current magnitude. The reductions to the current and thus input power to the motor are reduced incrementally. Once the collisions stop, the current value is allowed to slowly increase to its previous value over a period of time. Preferably the period of time is approximately 1 hour. Alternatively the current will remain reduced until the system variables change significantly. In one embodiment where the system in WO01/79671 is used as the main current controller algorithm, such a system change might be monitored by a change in the ordered maximum current. In that case it would be in response to a change in frequency or evaporator temperature. In the preferred embodiment the combination of that algorithm with the present invention providing a supervisory role provides an improved volumetric efficiency over the prior art. | A free piston gas compressor comprising a cylinder, a piston reciprocable within the cylinder and a reciprocating linear electric motor derivably coupled to the piston having at least one excitation winding. A measure of the reciprocation time of the piston is obtained, any change in the reciprocation time is detected and the power input to said excitation winding is adjusted in response to any detected change in reciprocation time. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a divisional of U.S. patent application Ser. No. 13/233,874, filed Sep. 15, 2011, which is incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to fuel cell systems, and more particularly, to systems and methods for steam reforming a hydrocarbon fuel, e.g., for use in a fuel cell stack.
BACKGROUND
Systems that effectively reform hydrocarbon fuels remain an area of interest. Some existing systems have various shortcomings, drawbacks, and disadvantages relative to certain applications. Accordingly, there remains a need for further contributions in this area of technology.
SUMMARY
One embodiment of the present invention is a unique method for operating a fuel cell system. Another embodiment is a unique system for reforming a hydrocarbon fuel. Another embodiment is a unique fuel cell system. Other embodiments include apparatuses, systems, devices, hardware, methods, and combinations for fuel cell systems and steam reforming systems. Further embodiments, forms, features, aspects, benefits, and advantages of the present application will become apparent from the description and figures provided herewith.
BRIEF DESCRIPTION OF THE DRAWINGS
The description herein makes reference to the accompanying drawings wherein like reference numerals refer to like parts throughout the several views, and wherein:
FIG. 1 schematically illustrates some aspects of a non-limiting example of a fuel cell system in accordance with an embodiment of the present invention.
FIG. 2 schematically illustrates some aspects of a non-limiting example of a reformer in accordance with an embodiment of the present invention.
FIG. 3 is an isometric view schematically illustrating some aspects of the non-limiting example of the reformer of FIG. 2 .
FIG. 4 is a non-limiting example of a plot illustrating catalyst performance for a non-limiting example of a steam reforming catalyst in accordance with an embodiment of the present invention in the presence of sulfur in the feed stream and after removal of sulfur from the feed stream in comparison to a conventional steam reforming catalyst under the same conditions.
DETAILED DESCRIPTION
For 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 nonetheless be understood that no limitation of the scope of the invention is intended by the illustration and description of certain embodiments of the invention. In addition, any alterations and/or modifications of the illustrated and/or described embodiment(s) are contemplated as being within the scope of the present invention. Further, any other applications of the principles of the invention, as illustrated and/or described herein, as would normally occur to one skilled in the art to which the invention pertains, are contemplated as being within the scope of the present invention.
Referring to the drawings, and in particular FIG. 1 , a non-limiting example of a fuel cell system 10 in accordance with an embodiment of the present invention is schematically depicted. In one form, fuel cell system 10 is a solid oxide fuel cell system. In other embodiments, fuel cell system 10 may be any other type of fuel cell system, e.g., such as a proton exchange membrane fuel cell system, a molten carbonate fuel cell system, a phosphoric acid fuel cell system, an alkali fuel cell system or any type of fuel cell system configured to operate using a fuel generated by steam reforming a hydrocarbon fuel.
In one form, fuel cell system 10 includes a fuel cell stack 12 and a reformer 14 . In some embodiments, fuel cell system 10 may also include a desulfurization system 16 configured to reduce or eliminate sulfur-containing compounds in hydrocarbon fuels supplied to fuel cell system 10 . In other embodiments, fuel cell system 10 does not include a desulfurization system. Fuel cell system 10 is configured to provide electrical power to an electrical load 18 , e.g., via electrical power lines 20 . In one form, fuel cell stack 12 is a plurality of electrochemical cells (not shown). In various embodiments, any number of electrochemical cells may be used to form fuel cell stack 12 , electrochemical cells may be physically and electrically arranged in any suitable manner. Each electrochemical cell includes (not shown) an anode, a cathode and an electrolyte disposed between the anode and the cathode.
Reformer 14 is in fluid communication with fuel cell stack 12 , in particular, the anodes of fuel cell stack 12 . For embodiments so equipped, desulfurization system 16 is in fluid communication with reformer 14 . In one form, reformer 14 is a steam reformer. In other embodiments, reformer 14 may take one or more other forms in addition to or in place of being a steam reformer. In one form, reformer 14 is configured to receive steam as a constituent of a recycled fuel cell product gas stream, and receives heat for operation from fuel cell 12 electro-chemical reactions. In other embodiments, other sources of steam and/or heat may be employed. In one form, reformer 14 employs a catalytic reactor configured to receive a hydrocarbon fuel and steam, to reform the mixture into a synthesis gas (syngas). In some embodiments, reformer 14 may be an adiabatic steam reformer. In some embodiments, reformer 14 may also be supplied with an oxidant in addition to the steam and hydrocarbon fuel, and may be configured to reform the fuel using both the oxidant and the steam, e.g., may be configured as an autothermal reformer. In other embodiments, reformer 14 may be configured as an adiabatic or endothermic steam reformer. During fuel cell system 10 operation, the syngas is supplied to the anodes of fuel cell stack 12 . In one form, the syngas produced by reformer 14 consists primarily of hydrogen (H 2 ), carbon monoxide (CO), and other reformer by-products, such as water vapor in the form of steam, and other gases, e.g., nitrogen and carbon-dioxide (CO 2 ), methane slip (CH 4 ), as well as trace amounts of higher hydrocarbon slip. In other embodiments, the syngas may have different compositions. The synthesis gas is oxidized in an electro-chemical reaction in the anodes of fuel cell stack 12 with oxygen ions received from the cathodes of fuel cell stack 12 via migration through the electrolytes of fuel cell stack 12 . The electro-chemical reaction creates water vapor and electricity in a form of free electrons on the anodes that are used to power electrical load 18 . The oxygen ions are created via a reduction of the cathode oxidant by the electrons returning from electrical load 18 into cathodes of fuel cell stack 12 .
In one form, the fuel supplied to fuel cell system 10 is natural gas. In a particular form, the fuel is a compressed natural gas (CNG). In other embodiments, other fuels may be employed, in liquid and/or gaseous forms, in addition to or in place of natural gas. For example, in some embodiments, methane and/or liquefied petroleum gas may be employed in addition to or in place of natural gas. In embodiments configured to employ an oxidant in addition to the fuel and steam, the oxidant employed by fuel cell system 10 is air. In other embodiments, other oxidants may be employed, in liquid and/or gaseous forms, in addition to or in place of air.
Referring now to FIGS. 2 and 3 , some aspects of a non-limiting example of reformer 14 in accordance with an embodiment of the present invention are schematically depicted. Reformer 14 includes a catalytic reactor 30 . Catalytic reactor 30 is the active component of reformer 14 that performs the fuel reforming, e.g., as set forth above. In one form, catalytic reactor 30 is a fixed-bed reactor having a catalyst disposed thereon, wherein the catalyst is retained within a reaction zone in a fixed arrangement. In other embodiments, reformer 14 may incorporate other types of reactors in addition to or in place a fixed-bed reactor, and/or may employ more than one type of fixed bed reactor. Other suitable reactors include, for example and without limitation, fluid bed reactors, e.g., wherein the catalyst is in the form of small particles fluidized by the stream of process gas, e.g., the hydrocarbon fuel, steam, and in some embodiments, an oxidant.
Catalytic reactor 30 includes surfaces onto which the catalyst is deposited for use in steam reforming. The catalyst-laden surfaces are configured to expose the catalyst to hydrocarbon fuel and steam during a steam reforming process, e.g., an endothermic steam reforming process, in accordance with embodiments of the present invention. In one form, catalytic reactor 30 is a monolithic structure. In other embodiments, other fixed-bed reactor schemes may be employed, e.g., catalyst pellets retained by a suitable structure. Suitable monolithic structures include, for example and without limitation, refractory oxide monoliths, metallic monoliths, ceramic foams and/or metal foams. In some embodiments, metallic foams and other metallic structures are desirable for use in steam reforming because they offer higher heat transfer rates required to maintain catalyst activity relative to non-metallic structures or foams. In some embodiments, the catalyst may be disposed on the channels of a heat exchanger for driving endothermic steam reforming reactions, including, for example and without limitation, being disposed on a corrugated metal foil, metal mesh and/or porous metal foam. In other embodiments, the catalyst may be disposed or deposited on other structures, e.g., pellets or other structures. In various embodiments, the catalyst may be deposited via one or more means, including, for example and without limitation, washcoat, vapor deposition and/or other techniques for depositing materials onto desired surfaces, including electroless plating and electrolysis.
In one form, catalytic reactor 30 is formed by stacking together a flat sheet 32 and a corrugated sheet 34 , e.g., of metallic foil, and rolling the sheets to form a structure such as that illustrated in FIGS. 2 and 3 , having an axis or centerline 31 . In other embodiments, catalytic reactor 30 may be formed differently, and/or may take one or more other physical forms. In some cases, excess flow area, e.g., flow areas 36 and 38 , may result at some locations, e.g., at the ends of the sheets, e.g., depending upon the size and thickness of the metallic sheet, and depending upon whether the sheets were rolled about a spindle and whether end treatments for the external sheet edges are employed. Any such excess flow areas may be closed by suitable means, e.g., including the use of a filler material. Sheets 32 and 34 form openings 40 , which extend along axis 31 . The size and shape of openings 40 , e.g., formed between the flat and corrugated sheets, may vary with the needs of the application. In one form, catalytic reactor 30 is formed to have openings 40 at a desired size in the range of 200-1200 openings per square inch. In other embodiments, other opening sizes may be employed. It will be understood that the depiction of FIGS. 2 and 3 illustrate an exaggerated opening 40 size for purposes of clarity of illustration. The catalyst is disposed on surfaces within openings 40 , e.g., including surfaces 42 , 44 and 46 of each opening 40 .
In various embodiments, the catalyst may be supported on a suitable carrier. Suitable carriers include, but are not limited to, refractory oxides, such as silica, alumina, titania, zirconia and tungsten oxides and/or mixtures thereof. Other suitable carriers that may be employed in conjunction with or in place of the aforementioned carriers include mixed refractory oxides having at least two cations. Preferred carriers that may be employed alone or in combination with aforementioned carriers include alumina oxides stabilized with oxides, for example and without limitation, baria, ceria, lanthana and magnesia.
The catalyst may be deposited on the carrier by one or more of various techniques, including, for example and without limitation, impregnation, e.g., by contacting the carrier material with a solution of the metals that form the catalyst. In various embodiments, the resulting material may then be dried and calcined. The catalyst may be further activated by heating in hydrogen and/or another reducing gas stream.
It is desirable to provide relatively clean fuel to reformer 14 and fuel cell stack 12 . However, some fuels include substances that have deleterious effects upon the systems that receive and/or employ the fuel. For example, in a fuel cell application, such substances may have deleterious effects on the catalyst in reformer 14 , the anodes of fuel cell stack 12 , and/or other components. Some fuels, such as natural gas and compressed natural gas (CNG), as well as other hydrocarbon fuels, may contain sulfur in one or more forms, e.g., sulfur-containing compounds. For example, some natural gas fuels have a sulfur content in the range of 2-10 parts per million by volume (ppms). Sulfur, e.g., in the form of sulfur-containing compounds, is known to damage certain systems. For example, in a fuel cell system, sulfur-containing compounds may poison the reformer 14 catalyst and/or fuel cell stack 12 , e.g., the anodes of fuel cell stack 12 .
For embodiments employing a desulfurization system, such as desulfurization system 16 , the desulfurization system is configured to remove sulfur (e.g., sulfur-containing compounds) from the fuel. Various embodiments may be configured to remove all or substantially all of the sulfur-containing compounds, or to reduce the content of the sulfur-containing compounds by some amount and/or to some selected level, e.g., an amount or level commensurate with achieving a desired downstream component catalyst life, such as reformer 14 catalyst life and/or fuel cell stack 12 life. For embodiments that do not include a desulfurization system, it is desirable to ensure that the fuel supplied to reformer 14 is sulfur-free or has a low sulfur content, for example and without limitation, approximately 0.05 ppmv or less.
During the operation of fuel cell system 10 , conditions may arise wherein reformer 14 is supplied with a high-sulfur content hydrocarbon fuel, e.g., a hydrocarbon fuel having a sulfur content of 1-10 parts per million by volume or greater, e.g., inadvertently. For example, in embodiments employing desulfurization system 16 , sulfur breakthrough may occur under some circumstances, or desulfurization system 16 may fail, at least partially. As another example, for embodiments that may or may not include desulfurization system 16 , the fuel supplied to fuel cell system 10 may inadvertently include a higher sulfur content than intended. Once the high sulfur content is discovered, remedial action may be taken to reduce the sulfur level. However, the period of time in which reformer 14 is exposed to the high sulfur level may poison the catalyst employed by reformer 14 , which may reduce the efficiency of reformer 14 . Once poisoned, typical catalysts must be cleaned, which may be time consuming, and in some cases, an expensive process. The degree of poisoning that is considered undesirable depends upon, for example, the particular application and the temperature at which the steam reforming is performed. Other factors may also apply.
However, the inventor has determined that a particular catalyst combination is not only less susceptible to sulfur poisoning, but also exhibits the ability to self-clean relatively quickly after being poisoned by sulfur exposure during stream reforming. The catalyst combination proposed by the inventor is a platinum ruthenium catalyst, that is, a catalyst consisting essentially of ruthenium and platinum as the active catalytic materials. In various embodiments, the catalytically active material may be a platinum-ruthenium alloy, or may be formed of separate ruthenium particles and platinum particles dispersed among each other. In one form, the catalyst does not include akali metals or oxides thereof. In other embodiments the catalyst may include alkali metals and/or oxides thereof. The catalyst is configured for tolerance of sulfur-containing fuels, and for self cleaning of sulfur compounds. In one form, the catalyst is configured for self cleaning of sulfur compounds by performing steam reforming using a low-sulfur-content hydrocarbon fuel. In other embodiments, other procedures may be employed to perform self cleaning. The self-cleaning may be achieved by performing steam reforming at a suitable temperature, e.g., in the range of 650° C. to 900° C., and in some embodiments, in the range of 750° C. to 800° C., with a low-sulfur content fuel, e.g., a hydrocarbon fuel having a sulfur content in the range of 0 to about 0.05 ppmv. The platinum and ruthenium compositions of the platinum ruthenium catalyst may vary over a wide range, although a typical composition may be 0.01 to 10 wt % for platinum and 0.5 to 40 wt % for ruthenium, with the balance of material being the catalyst carrier. In some embodiments, the catalytically active materials of the catalyst may include platinum in amounts ranging from 0.01% to 25% by weight, with ruthenium in amounts ranging from approximately 75% to 99.99% by weight. Because of the relatively high cost of platinum, e.g., relative to ruthenium, in some embodiments, it is desirable to minimize the amount of platinum to an amount consistent with the desired level of sulfur resistance, e.g., for the particular application.
Sulfur is known to have a detrimental effect on ruthenium steam reforming catalysts, e.g., compared to some other catalysts, for example and without limitation, platinum/rhodium formulations. In addition, ruthenium catalyst regeneration (self-cleaning after exposure to sulfur in the hydrocarbon feed) is known generally to be slow. Hence, one of ordinary skill in the art would not be expected to employ a ruthenium catalyst for steam reforming in system where the catalyst may be exposed to a sulfur-containing fuel. However, the inventor has determined that the addition of platinum to ruthenium as a steam-reforming catalyst provides surprising and unexpected results, not only reducing the adverse impact of poisoning of the catalyst, but also rendering the catalyst to be self-cleaning in shorter times than catalysts formed of ruthenium alone. The inventor posits that the beneficial effect of alloying platinum as part of a platinum-ruthenium catalyst is greater than that which may be expected from a simple replacement of some of the ruthenium with platinum. It is proposed that one potential explanation for the surprising and unexpected results may be that platinum in close proximity to ruthenium may facilitate the desorption of sulfur species bound to the ruthenium. The platinum content may vary with the needs of the application. It is proposed that increased platinum content yields lower susceptibility of the catalyst and faster catalyst regeneration. However, since platinum is more expensive than ruthenium, in some embodiments, the minimum platinum content necessary to achieve a desired catalyst regeneration (self-cleaning) time for the particular application is employed in particular embodiments. In many embodiments, the ruthenium content of the catalyst will be substantially greater than the platinum content. Example 1, below, illustrates one prophetic example of compositional ranges for a catalyst in accordance with an embodiment of the present invention:
Example 1
1-20 wt-% ruthenium-platinum catalytically active component(s) with a ruthenium/platinum weight ratio>3;
50-90 wt-% alumina; and
5-30 wt-% a metal oxide or oxides selected from Groups IIA-VIIA, the Lanthanides and Actinides (e.g. using the old International Union of Pure and Applied Chemistry (IUPAC) version of the periodic table).
Referring to FIG. 4 , a non-limiting example of a plot 48 illustrating test results of a platinum ruthenium catalyst as compared to a ruthenium catalyst is illustrated. In particular, the example of FIG. 4 illustrates the effect of sulfur poisoning upon methane (CH 4 ) conversion for two catalysts: a ruthenium catalyst; and a non-limiting example of a platinum ruthenium catalyst in accordance with an embodiment of the present invention. The catalytically active material of the ruthenium catalyst consists essentially of ruthenium, and is 6 wt % in an metal-oxide stabilized alumina washcoat. The catalytically active material of the platinum ruthenium catalyst consists essentially of platinum and ruthenium, with a ruthenium content of 5 wt % and a platinum content of 1 wt % (5:1 weight ratio of ruthenium to platinum) in an metal-oxide stabilized alumina washcoat.
Methane steam reforming is an exothermic reaction, and the methane conversion for a set of conditions may be calculated using the equilibrium constant shown below (K CH4 ):
CH 4 +H 2 O CO+3H 2 ΔH°(298K)=206.2 kJ·mole −1
K CH4 =[CO][H 2 ] 3 /([CH 4 ][H 2 O])
The equilibrium methane conversion is affected by the reaction temperature, pressure and the feed composition. Increasing reaction temperatures favors methane conversion while increasing pressure decreases methane conversion. The observed methane conversion will be dependent on the catalyst activity and the process throughput (GHSV).
The feed stream supplied to the catalysts consisted of a hydrocarbon stream in the form of dry natural gas, and steam, yielding 14.2% by volume CH 4 and an H 2 O/CH 4 ratio of 2.8 supplied at 750° C. and 6.4 bar absolute, with a gas hourly space velocity (GHSV) of 20,942/h. Methane conversion (to syngas) was measured in order to determine the performance of the catalysts, with 65% methane conversion determined to be a minimum target activity level. Under the specified process conditions, a methane conversation of 65% corresponds to about 90% of the equilibrium methane conversion. The hydrocarbon feed stream was initially supplied to both catalysts with a sulfur content of below about 0.05 ppmv. At approximately 1 hour, at a point P 1 , sulfur was added to the hydrocarbon feed stream in the form of methyl mercaptan in the amount of 716 parts per billion by volume (ppbv) of the hydrocarbon feed stream, yielding 716 ppbv sulfur content in the hydrocarbon feed stream. Curve 50 represents the performance data associated with the platinum ruthenium catalyst, whereas curve 52 represents the performance data associated with the ruthenium catalyst. From FIG. 4 , it is seen that the initial performance of the platinum ruthenium catalyst was approximately 68% methane conversion immediately prior to the time of the introduction of the sulfur into the feed stream, and the initial performance of the ruthenium catalyst was approximately 66% methane conversion immediately prior to the time of the introduction of the sulfur into the feed stream. Within less than 1 hour after the sulfur was introduced, the ruthenium catalyst performance fell below the performance threshold of 65% methane conversion, as indicated by a point P 2 , and fell below 35% methane conversion at approximately 12-13 hours after the introduction of the sulfur, as indicated by a point P 3 . The performance of the ruthenium catalyst ultimately reached approximately 33% methane conversion prior to the removal of the sulfur from the feed stream. The platinum ruthenium catalyst, on the other hand, remained above the 65% methane conversion threshold until about 20 hours after the introduction of the sulfur, as indicated by a point P 4 , ultimately dropping to approximately 57% methane conversion by the time the sulfur was removed from the feed stream. The sulfur was removed from the feed stream after approximately 40 hours of steam reforming for each of the catalyst configurations, and is indicated by a point P 5 . Removal of the sulfur allowed for self-cleaning of the catalysts in the presence of a low sulfur content feed stream. Approximately 20 hours after the sulfur was removed, indicated by a point P 6 , the performance of the platinum ruthenium catalyst reached the 65% methane conversion threshold, whereas approximately 85 hours was required for the ruthenium catalyst to reach the 65% methane conversion threshold, indicated by a point P 7 . Thus, as seen from FIG. 4 , surprising and unexpected results were obtained by adding a small amount of platinum to a ruthenium catalyst. The surprising and unexpected results included both a reduction in the poisoning of the catalyst due to the presence of sulfur in the feed stream, as well as a reduction in the amount of time required for self-cleaning of the catalyst in the presence of a low sulfur feed stream. As a result, embodiments of the present invention may employ a platinum ruthenium catalyst in a reformer, e.g., for steam reforming, for example, to provide syngas to a fuel cell. A low sulfur hydrocarbon feed stream may be supplied to the reformer, and in the event of an exposure to a high or higher sulfur content hydrocarbon feed stream, poisoning of the catalyst will be reduced, e.g., relative to other catalysts, such as ruthenium catalysts. Further, the recovery time, or time required for self-cleaning, e.g., upon the introduction of a low sulfur content hydrocarbon feed stream or sulfur-free hydrocarbon feed, will be reduced, e.g., relative to other catalysts, such as ruthenium catalysts.
Embodiments of the present invention include a method for operating a fuel cell system, comprising: providing a catalyst consisting essentially of platinum and ruthenium as catalytically active materials, wherein the platinum content is selected based on a desired level of sulfur resistance; and wherein the catalyst is configured for self cleaning of sulfur compounds when performing steam reforming using a low-sulfur-content hydrocarbon fuel; providing a catalytic reactor having surfaces having the catalyst disposed thereon and configured to expose the catalyst to at least a hydrocarbon fuel and steam; reforming a high-sulfur content hydrocarbon fuel with at least steam for a first period of time; reforming the low-sulfur-content hydrocarbon fuel with at least steam for a second period of time; and providing reformed hydrocarbon fuel to a fuel cell stack.
In a refinement, the reforming of the low-sulfur-content hydrocarbon fuel is performed after the reforming of the high-sulfur content hydrocarbon fuel.
In another refinement, the reforming of the low-sulfur-content hydrocarbon fuel is performed both before and after the reforming of the high-sulfur content hydrocarbon fuel.
In yet another refinement, the platinum content is a minimum platinum content consistent with the desired level of sulfur resistance.
In still another refinement, the ruthenium content of the catalytically active materials is selected to be approximately 75% to 99.99% by weight; and wherein the platinum content of the catalytically active materials is selected to be approximately 0.01% to 25% by weight.
In yet still another refinement, the method further comprises providing a carrier for the catalyst.
In a further refinement, the carrier includes a refractory oxide, including at least one of silica, alumina, zirconia and tungsten oxides.
In a yet further refinement, the carrier includes mixed refractory oxides having at least two cations.
In a still further refinement, the alumina oxide is stabilized by at least one of baria, ceria, lanthana and magnesia oxides.
In a yet still further refinement, the method further comprises activating the catalyst by heating the catalyst in hydrogen and/or another reducing gas.
Embodiments of the present invention include a system for steam reforming a hydrocarbon fuel, comprising: a catalytic reactor having surfaces configured for exposure to the hydrocarbon fuel and steam; and a catalyst having catalytically active materials consisting essentially of ruthenium and platinum disposed on the surfaces of the catalytic reactor, wherein the system is configured to steam reform a hydrocarbon fuel.
In a refinement, the ruthenium content of the catalyst is greater than the platinum content of the catalyst.
In another refinement, the catalyst is configured for self cleaning of sulfur compounds when performing steam reforming using a hydrocarbon fuel having little or no sulfur content.
In yet another refinement, the little or no sulfur content is less than about 0.05 parts per million by volume.
In still another refinement, the catalyst is configured for steam reforming with the hydrocarbon fuel having a sulfur content of greater than about 0.1 parts per million by volume for a period of not less than 30 hours; and wherein the catalyst is configured for self cleaning of sulfur compounds when performing steam reforming using a hydrocarbon fuel having little or no sulfur content.
In yet still another refinement, the little or no sulfur content is less than about 0.05 parts per million by volume.
In a further refinement, the sulfur content of greater than 0.1 parts per million by volume is a sulfur content of greater than 0.5 parts per million by volume.
In a yet further refinement, the catalytic reactor includes a tube having an axis, and having a plurality of channels extending parallel to the axis; and wherein the catalyst is disposed in the surfaces of the channels.
In a still further refinement, the number of channels is in the range of 200 to 1200 channels per square inch when viewed in a direction along the axis.
In a yet still further refinement, the catalyst is supported on a carrier that includes alumina oxide.
In an additional refinement, the carrier also includes at least one of baria, ceria, lanthana and magnesia oxides.
In another additional refinement, the catalyst and the carrier do not include alkali metals or oxides thereof.
In yet another additional refinement, the catalyst is configured for self cleaning within a period of 50 hours or less to achieve a methane conversion of greater than 90% of the equilibrium conversion, when using natural gas as a hydrocarbon feed stream.
In still another additional refinement, the catalyst is configured for self cleaning within a period of 40 hours or less to achieve a methane conversion of greater than 90% of the equilibrium conversion.
In yet still another additional refinement, the catalyst is configured for self cleaning within a period of 25 hours or less to achieve a methane conversion of greater than 90% of the equilibrium conversion.
In a further additional refinement, the system further comprises a fuel cell in fluid communication with the catalytic reactor.
In a yet further additional refinement, the catalytic reactor is configured to steam reform the hydrocarbon fuel with or without an oxidant.
Embodiments of the present invention include a fuel cell system, comprising: a fuel cell stack; and a reformer in fluid communication with the fuel cell stack, wherein the reformer includes a catalytic reactor having surfaces configured for exposure to a hydrocarbon fuel and steam; and a catalyst having catalytically active materials consisting essentially of ruthenium and platinum disposed on the surfaces of the catalytic reactor, wherein the reformer is configured to steam reform a hydrocarbon fuel and output reformed fuel to the fuel cell stack.
In a refinement, the reformer is configured to reform a high-sulfur content hydrocarbon fuel with at least steam for a first period of time; and reform a low-sulfur-content hydrocarbon fuel with at least steam for a second period of time.
In another refinement, the catalytic reactor is configured to self-clean sulfur poisoning during the second period of time.
In yet another refinement, the second period of time is less than an amount of time required for a catalyst having a catalytically active material consisting essentially of ruthenium to self-clean.
While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiment(s), but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims, which scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures as permitted under the law. Furthermore it should be understood that while the use of the word preferable, preferably, or preferred in the description above indicates that feature so described may be more desirable, it nonetheless may not be necessary and any embodiment lacking the same may be contemplated as within the scope of the invention, that scope being defined by the claims that follow. In reading the claims it is intended that when words such as “a,” “an,” “at least one” and “at least a portion” are used, there is no intention to limit the claim to only one item unless specifically stated to the contrary in the claim. Further, when the language “at least a portion” and/or “a portion” is used the item may include a portion and/or the entire item unless specifically stated to the contrary. | One embodiment of the present invention is a unique method for operating a fuel cell system. Another embodiment is a unique system for reforming a hydrocarbon fuel. Another embodiment is a unique fuel cell system. Other embodiments include apparatuses, systems, devices, hardware, methods, and combinations for fuel cell systems and steam reforming systems. Further embodiments, forms, features, aspects, benefits, and advantages of the present application will become apparent from the description and figures provided herewith. | 2 |
PRIORITY CLAIM
[0001] This application claims priority from U.S. Provisional Application Ser. No. 60/778,803 filed on Mar. 3, 2006, which is hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a plush delivery vehicle. More specifically, the present invention relates to a plush delivery vehicle for transmission of an electronic transfer device, and kit for containing the same with secondary use as a display item.
[0004] 2. Description of the Related Art
[0005] The related art involves plush children's toys and dolls having a generally cushioning feel and greatly varied construction depending upon an ultimate use of the product.
[0006] In Chun, U.S. Pat. No. 6,446,361, a transformable slipper toy is constructed from plush material. Specifically, a slipper having a sole and a foot covering transform into a toy play character by coupling the sole to the foot covering. The toy character may tale the form of an animal, a human figure, or an imaginary, or abstract character, or other object. The transforming slipper toy may be made of plush material providing a pleasing feel. Conveniently, the sole is coupled to the foot covering using Velcro, buttons or snap fasteners, hooks, a zipper or other means. The sole may be constructed to have a type of pocket for receiving a heel portion of the sole whereby the sole and the foot covering are united. As shown, the foot covering carries a number of decorative appendages for simulating a toy character. The appendages will preferably be made of plush material so that the slipper will have a generally cuddly appearance
[0007] In Sheridan, U.S. Pat. No. 6,256,965, a plush toy bed apparatus is constructed by a method for reproducing a pre-selected subject matter such as a wild animal in a “material comfort object” incorporating a cavity that may be enhanced into an enclave by incorporating pre-selected portions of the subject matter such as a head or legs to add a surround to the cavity, giving preference to reproducing areas of the subject matter with plush material which resembles the color and texture of the subject matter while maintaining easy access to the cavity thereby presenting an exposed surface or comfort panel that is soft, warm and inviting to the user of the object. A child safe pocket may be formed in the object to hold custom designed device. Here there is no capacity to employ the device as a promotional system.
[0008] In Trageser, U.S. Pat. No. 6,176,759, for a push-pull toy having pivoting arms. A toy body is formed as a generally fanciful creature including a tail portion and a head portion. A storage vehicle suitable for receiving and retaining a plush toy figure is positioned as shown in the disclosure. A conventional sound circuit is supported within the interior of the head portion while a rotatable string reel is supported for actuating the sound circuit. A pocket within the body is provided for storing a toy lifesaver or other toy. The four supporting wheels of the push-pull toys body are supported upon respective axels in an offset or eccentric attachment. In addition, the front two wheel each include an offset cam and cam follower which cooperate and pivot an upwardly extending arm. The upwardly extending arm provides pivotal coupling to the forwardly extending arms and imparts pivotal motion thereto in a pleasing manner. Again here, there is no capacity to employ the device as a promotional system, nor the ready adaptability to alternative shapes.
[0009] What is not appreciated by the related art is the need for a plush delivery vehicle for a gift promotional situation, one that is readily adaptable to a variety of shapes and promotional situations.
[0010] What is also not appreciated by the related prior art is the need for an advertising assembly that securely holds a first gift and also serves a secondary role as an additional gift following removal of the first gift.
[0011] Accordingly, there is a need for a plush delivery vehicle that addresses the unmet needs in the related art.
OBJECTS AND SUMMARY OF THE INVENTION
[0012] A goal of the present invention is to provide a plush vehicle for securely retaining an electronic device that responds to at least one of the needs noted above.
[0013] Another goal of the present invention is to provide a delivery vehicle for an electronic delivery card device that enables a secondary use as a display and promotion device for promoting the sale of the electronic device.
[0014] Another goal of the present invention is to provide a delivery vehicle that enables additional use as an ornament, picture frame, decorative hanging, or other consumer device.
[0015] Another goal of the present invention is to provide a gift packaging kit, comprising: a flexible-textile plush exterior layer substantially bounding an inner volume containing a compressible medium and forming a three dimensional configuration; at least one external pocket means on an outer surface of said plush exterior layer for receivably storing a gift item; and said gift item being at least one of an electronic data storage medium (gift card) and an image display device (a photo).
[0016] The present invention relates to a plush delivery vehicle for securely retaining, transporting, and displaying a card-type electronic device as a gift, and a kit for containing the same. The plush delivery vehicle is operable as an additional gift or useful consumer item following transfer and removal of the electronic gift. The plush delivery vehicle may assume a different function for post-sale operation and use, for example as a decorative device, a frame display, and an entertainment device.
[0017] According to an embodiment of the present invention, there is provided a plush delivery vehicle for securely retaining, transporting, and displaying a card-type electronic device as a gift, and kit for containing the same with secondary use of the plush delivery vehicle as an additional gift or other useful consumer item following transfer of the electronic gift. The plush delivery vehicle may assume a different function for after transmission operation as a decorative device, a service device, a display device, and an entertainment device.
[0018] According to another embodiment of the present invention, there is also provided, the use of a plush vehicle for receiving and securely retaining a card-type electronic memory device and use of the same in sales promotion. According to the present business model, a selected sales promoter (a consumer store) will absorb the cost of the plush package to promote gift-card sales which is normally considered to be profitable. The invention is some form of a gift-card vehicle having a preferably soft plush exterior defining and bounding an inner volume containing a compressible medium, wherein the vehicle may be constructed in a wide variety of shapes (animal, star, geometric object, plant shape, mask, etc.). The vehicle including a pocket for receiving an electronic data storage medium a/k/a gift-card and for protecting the same from electromagnetic degradation via separation from other electronic gift cards.
[0019] According to another embodiment of the present invention the plush vehicles may be alternative used as sales promotions or give-away items, wherein a web site or other address is printed on an exterior surface, and a pre-loaded gift card is included in a pocket for promotional spending on the advertised web site or local. In this manner, a business model may self-promote by either giving away the plush vehicles, or selling at a steep discount allowing the customer to employ the remaining electronic cash stored on the gift card on the promoted web site.
[0020] The above, and other objects, features and advantages of the present invention will become apparent from the following description read in conduction with the accompanying drawings, in which like reference numerals designate the same elements.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 refers to a gift card plush folding book pillow ornament device for enclosing a gift card in an inner pocket.
[0022] FIG. 2 refers to a gift card plush gift box ornament-containing a packet member for receiving an electronic transmission device on an outer surface of the plush vehicle.
[0023] FIG. 3 contains a comprehensive disclosure for a gift card plush line directed to a heart-shaped ornament vehicle, and a secondary pocketbook apparatus incorporating the use of the heart-shaped ornament apparatus.
[0024] FIG. 4 refers to a gift card plush item shown as a plush gift box ornament according to one of the embodiments of the present invention.
[0025] FIG. 5 refers to a gift box ornament embodiment as described in FIG. 4 containing an electronic transmission device within a pocket.
[0026] FIG. 6 refers to a gift card plush vehicle wherein a gift box ornament contains a looping device for suspending the same from a support feature.
[0027] FIG. 7 an embodiment is shown describing a plush card gift product shaped as a star ornament, wherein an additional hanging loop is described.
[0028] FIG. 8 refers now to variant plush vehicle design based on FIG. 7 .
[0029] FIG. 9 refers to a measuring tape type ornament for a gift card plush line, wherein the assembly is shaped as a tape measurer additionally containing a gift-card receiving pocket for receipt and transmission of an electronic transfer device.
[0030] FIG. 10 discloses an alternative embodiment of the present invention wherein a mobile/cell phone ornament having an additional cord loop and pocket for receiving an electronic transmission device are disclosed.
[0031] FIG. 11 is an alternative embodiment of the present disclosure and provides an ornament containing an additional hanging loop and a pocket for containing an electronic transmission device such as a gift card.
[0032] FIG. 12 is an alternative embodiment of the present invention wherein an ornamental assembly contains an additional hanging cord loop, and an attached envelope for retaining an electronic transmission device in close proximity to the plush vehicle.
[0033] FIG. 13 is an alternative embodiment of the present invention, and additionally discloses a close-up view of a roundish ornament for review and disclosure thereto.
[0034] FIG. 14 wherein an alternative embodiment of the present invention provides a sneaker-type ornament device having a hanging loop proximate a distal end thereof and a removable foam rubber tread portion along with an electronic gift transfer medium.
[0035] FIG. 15 provides an alternative embodiment of the present invention as a snowflake pillow containing a suspension loop and a rear positioned pocket for receiving an electronic transmission device therein.
[0036] FIG. 16 provides an alternative embodiment of the present invention and notes a suit lapel type ornament as a plush vehicle delivery system containing an additional pocket for receiving an electronic transmission device.
[0037] FIG. 17 provides an alternative embodiment of the present invention as a tree-shaped ornament, containing an additional suspension loop
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0038] Reference will now be made in detail to several embodiments of the invention that are illustrated in the accompanying drawings. Wherever possible, same or similar reference numerals are used in the drawings and the description to refer to the same or like parts or steps. The drawings are in simplified form and are not to precise scale. For purposes of convenience and clarity only, directional terms, such as top, bottom, up, down, over, above, and below may be used with respect to the drawings. These and similar directional terms should not be construed to limit the scope of the invention in any manner. The words “connect,” “couple,” and similar terms with their inflectional morphemes do not necessarily denote direct and immediate connections, but also include connections through mediate elements or devices.
[0039] As used herein the phrase plush is intended to be broadly interpreted, and to those of skill in the art viewing the entire disclosure, will have a broad descriptive meaning incorporating a soft or squeezable capacity and not necessarily a soft-to-the-touch outer surface. Plush vehicles are commonly made of an exterior or outer boundary layer formed from a furry or compressible textile fabrics like terry cloth or velvet that are soft-to-the-touch and are easy to grab and pleasing to hold yet retain an outer shape reasonable well when filled with a compressible medium such as cushioning or stuffing.
[0040] However, as used herein a plush vehicle may also include an outer boundary layer of non-textile flexible materials such as vinyl film, Mylar, neoprene and neoprene like materials including elastomeric films, amorphous-strand thin-film products such as housing-wrap and mailing envelopes or combinations of any of the above.
[0041] Each type of plush construction may also include semi-rigid or rigid portions enabling the outer covering to assume various functions and shapes adapted to a customer advertising need; for example as a gift box, as a gift shoe or sneaker, a bar-code label box region, and as a gift tape measuring tool while retaining a squeezable capacity (deflection in response to force and return to near initial-net form or initial-net form). In each case a flexible outer layer bounds an inner compressible medium. The inner compressible medium may be air, foam, cloth, gel, neoprene, textile goods, and any other type of packing and stuffing material readily available to the consuming public. The pocket or region for retaining and securely retaining
[0042] On an exterior surface, the semi-rigid or rigid portions may be a belt loop snap of the type commonly found on tape-measurers, a hanging member, a pocket container ridge, a picture-frame member, an applied decoration, a brand-name marking or label member, zipper, a light emitting device such as an LED, an attachment point for an additional garment member, a picture-frame-stand member, or any other semi-rigid or rigid member useful to those of skill in the art attempting to carry out the goals discussed herein that may be stitched, applied, or fixed in position relative to the external layer of the plush vehicle. On interior regions the semi-rigid or rigid portions may be structurally supportive, or create a form that receives the inner compressible medium and is enwrapped by the outer boundary layer. Where alternative embodiments also include an RFID product identification tag, a vibration-generation unit for entertainment, a sound recording mechanism, or other advertising or marketing aids, these may be retained on the interior regions of the plush vehicle.
[0043] In brief summary, the concept is the use of a plush vehicle for receiving and securely retaining a card-type electronic memory or an electronic transmission device. The store will absorb the cost of the package to promote gift-card sales—typically a high profit margin business.
[0044] The invention is some form of a gift-card vehicle having a preferably plush exterior or outer boundary layer defining and bounding an inner volume containing a compressible medium, wherein the vehicle may be constructed in a wide variety of shapes (animal, star, geometric object, plant shape, mask, etc.). The vehicle including a pocket or other storage system or engagement function for receiving and securely storing an electronic data storage medium a/k/a gift-card. For example, a storage system may be a pocket, or series of rigid clips for compressing and securely retaining the gift-card, or a Velcro attachment point for bonding with a co-Velcro unit affixed to the gift-card.
[0045] As noted above, the preferably soft plush exterior being any common type of plush medium, from looped cotton terry to synthetic fur or vinyl film, along a definable plush fineness scale. The inner compressible medium having a certain average modulus of elasticity when contained (for example, air has a module of elasticity of approximately 1.0 when retained in a balloon). The pocket optionally includes a viewing window and a gift-card engagement function for securing the electronic recording medium (electronic gift card).
[0046] Optional details for the plush vehicle include: (1) a vibration feature, (2) a hanger device enabling secondary use as a decoration; (3) a “write-on area” for addressing to a gift recipient or to print or secure an item bar code—constructed from a smoother textile or smooth film material for accepting a printing medium or an add-on sticker for writing, (4) combination with an RFID tracking and quick-check-out device for theft prevention and to speed sales transfer, (5) an openable “inner pocket” for storing an additional or second gift, (6) the later use of the viewing window as a picture frame or the inclusion of specially designed exterior window regions allowing later use of the plush vehicle as a soft picture frame; and (7) an internal power source+sound recording and generation system to record a gift-message “Happy Birthday” perhaps upon removal of the gift card.
[0047] Referring now to FIG. 1 , a plurality of views are provide and disclose a plush delivery vehicle or simply a plush vehicle 1 includes an outer boundary layer 2 (here a vinyl leather) enclosing an inner compressible medium (not shown). A loop 3 projects away from plush vehicle 1 to enable hanging plush vehicle 1 from an external support. A bounded pocket region 4 is shaped to receive and electronic transmission device 5 , here shown as a representative electronic gift card for transferring store credit or a preserved cash value.
[0048] Here, a hinge region 6 enables opposing sides of plush vehicle 1 to fold relative to hinge region 6 and tie strings 7 allowing a user to secure both sides together for ready transport and a pleasing outer appearance. An external labeling or branding region 8 allows users to either write a message or provide a particular brand, as shown a brand is provided.
[0049] As can be noted from the side view, plush vehicle 1 is approximately ½″ deep in a central region and outer boundary layer 2 bounds inner compressible medium.
[0050] Referring now to FIG. 2 , a variety of views are provided and disclose a plush delivery vehicle or a plush vehicle 1 A including an outer boundary layer 2 A (here a velour fabric) enclosing an inner compressible medium (not shown). A loop 3 A within a ribbon member 6 A projects away from plush vehicle 1 A to aid in hanging plush vehicle 1 A from an external support. A bounded pocket region 4 A is shaped to receive and securely retain an electronic transmission device 5 A, shown here as an electronic gift card.
[0051] Here a brand label region 8 A is positioned on bounded pocket region 4 A and allows a user to hand-write or label a particular brand with a sellers mark. Without departing from the scope of the present invention. Here plush vehicle 1 A is shown as a plush gift-box to be appealing to consumers, but nothing herein shall require such a shape, and the present principal of invention is represented thoughout the disclosure as adaptable to a wide variety of promotional shapes, depending upon a user's demand.
[0052] Referring now to FIG. 3 , a variety of views are provided and disclose a plush delivery vehicle 1 B including an outer boundary layer 2 B (ere a patterned or plain satin textile) enclosing a compressible medium (not shown). A loop 3 B is provided near a top center of tie heart-shape device, and projects away from plush vehicle 1 B to aid in displaying and supporting the device (prior to sale or during later use as an ornament). A bounded pocket region 4 B is shaped to receive and securely retain an electronic transmission device 5 B, shown here as an electronic gift card.
[0053] A brand label or message region 8 B allows a user or initial manufactured to identify their brand or create a message to an intended gift recipient. Also shown here is an accessory bag 6 B that may be created to match plush vehicle 1 B.
[0054] Referring now to FIG. 4 , a plush delivery vehicle 1 C includes an outer boundary layer 2 C (here a satin textile) encloses a compressible medium (not shown). A loop 3 C associated with a ribbon 7 C projects upwardly away from vehicle 1 C to aid in later use—post purchase. A bounded pocket region 4 C, here shown as a separable plastic sleeve is affixed to plush vehicle by a tie-member (not shown). Pocket region 4 C is shaped to receive and securely retain an electronic transmission device 5 C, shown again as an electric gift card.
[0055] In contrast to the above embodiments a branding or labeling region 8 C is provided on ribbon 7 C or on the electronic medium 5 C itself.
[0056] Referring now to FIG. 5 , a plush delivery vehicle 1 D includes an outer boundary layer 2 D (shown here as a velvet) encloses a compressible medium (not shown). A loop 3 D, associated with ribbon 7 D projects upwardly away from vehicle 1 D to aid in later support and re-use post purchase.
[0057] A bounded pocket region 4 D, here attached to an exterior of plush vehicle 1 D, and is shaped to receive and securely retain an electronic transmission device 5 D, noted as an electronic gift card.
[0058] Referring now to FIG. 6 , a plush delivery vehicle 1 E includes an outer boundary layer 2 E (shown here as a velvet) encloses a compressible medium (not shown). A loop 3 E, associated with ribbon 7 E projects upwardly away from vehicle 1 E to aid in later support and re-use post purchase.
[0059] A bounded pocket region 4 E, here attached to an exterior of plush vehicle 1 E, and is shaped to receive and securely retain an electronic transmission device 5 E, noted as an electronic gift card. A brand or logo region 5 E may be alternatively used as a writing surface and is smooth for easy resale.
[0060] Referring now to FIG. 7 , a plush delivery vehicle 1 F includes an outer boundary layer 2 F (here red satin), and encloses a compressible medium (not shown). A loop 3 F, associated with ribbon element 7 F projects upwardly away from the from plush vehicle 1 F for use as an aid in promoting purchase.
[0061] A bounded pocket region 4 F, here attached via a string to ribbon element 7 F, to securely receive and retain an electronic transmission device 5 F, noted as an electronic gift card. A brand or logo region 8 F may be alternatively used as a writing surface and is smooth for easy resale.
[0062] Referring now to FIG. 8 , a plush delivery vehicle 1 G includes an outer boundary layer 2 G there red satin), and encloses a compressible medium (not shown). A loop 3 G projects upwardly away from the from plush vehicle 1 G for use as an aid in promoting purchase.
[0063] A bounded pocket region 4 G, is shaped to securely receive and retain an electronic transmission device 5 G, noted as an electronic gift card. A brand or logo region 8 G may be alternatively used as a writing surface and is smooth for easy resale.
[0064] Referring now to FIG. 9 , a plurality of views show an alternative variation of a plush delivery vehicle 1 H includes an outer boundary layer 2 H (here a shiny vinyl), and encloses a compressible medium (not shown). A loop 3 H projects away from plush vehicle 1 H for use as an aid in promoting purchase and hanging and displaying the product. Here, loop 3 H mimics the measuring-tape pull-tab.
[0065] A bounded pocket region 4 H, is shaped to securely receive and retain an electronic transmission device 5 H, noted as an electronic gift card. A brand or logo region 5 H may be alternatively used as a writing surface and is smooth for easy resale. A rigid button member 7 H mimics the operation tab on a tape measurer and promotes a pleasing exterior.
[0066] Referring now to FIG. 10 , a plurality of views show an alternative variation of a plush delivery vehicle 1 I including an outer boundary layer 2 I (here a shiny lame fabric), and encloses a compressible medium (not shown). A loop 3 I projects away from plush vehicle 1 I for use as an aid in promoting purchase and hanging and displaying the product. Here, loop 3 I mimics the measuring-tape pull-tab.
[0067] A bounded pocket region 4 H, is shaped to securely receive and retain an electronic transmission device 5 I (not shown within pocket region 4 H), noted as an electronic gift card. A brand or logo region 8 I may be alternatively used as a writing surface and is smooth (in this embodiment) for easy resale. A plurality of rigid button members 9 I mimic the buttons on a cellular phone, as does printing on outer boundary layer 2 I.
[0068] Referring now to FIG. 11 , a single view shows an alternative variation of a plush delivery vehicle 1 J including an outer boundary layer 2 J (here a red lame fabric with top cap being a silver lame), and encloses a compressible medium (not shown). A loop 3 J projects away from plush vehicle 1 J for use as an aid in promoting purchase and hanging and displaying the product. Here, loop 3 J mimics the hanging loop on a holiday ornament.
[0069] A bounded pocket region 4 J, is shaped to securely receive and retain an electronic transmission device 5 J (not shown within pocket region 4 H), noted as an electronic gift card. A brand or logo region 8 J may be alternatively used as a writing surface and is smooth (in this embodiment) for easy reuse. Here, an additional cap member 9 J is also formed of outer boundary layer material (here a silver or alternative color lame).
[0070] Referring now to FIG. 12 , several views provide an alternative variation of a plush delivery vehicle 1 K including an outer boundary layer 2 K (here a colored and patterned textile or vinyl), and encloses a compressible medium (not shown). A loop 3 K projects away from plush vehicle 1 K for use as an aid in promoting purchase and hanging and displaying the product. As earlier, loop 3 K mimics the hanging loop on a holiday ornament.
[0071] A separate bounded pocket region 4 K, is shaped to securely receive and retain an electronic transmission device 5 K, noted as an electronic gift card. A brand or logo region 8 K may be alternatively used as a writing surface and is pre-printed (in this embodiment) for brand marking purposes. Here, an additional cap member 9 K is also formed of outer boundary layer material and includes a ribbon member 7 K.
[0072] Referring now to FIG. 13 , several views of an alternative variation of a plush delivery vehicle 1 L including an outer boundary layer 2 L (here a colored and patterned lame or vinyl), and encloses a compressible medium (not shown). A loop 3 L projects away from plush vehicle 1 L for use as an aid in promoting purchase and hanging and displaying the product. As earlier, loop 3 L mimics the hanging loop on a holiday ornament.
[0073] A separate bounded pocket region 4 L, is shaped to securely receive and retain an electronic transmission device 5 L, noted as an electronic gift card. A brand or logo region 8 L may be alternatively used as a writing surface and is pre-printed (in this embodiment) for brand marking purposes. Here, an additional cap member 9 L is also formed of outer boundary layer material.
[0074] Referring now to FIG. 14 , a plurality of views of construction steps for an alternative variation of a plush delivery vehicle 1 M including an outer boundary layer 2 M (here a colored and patterned lame or vinyl), and encloses a compressible medium (not shown). A loop 3 M projects away from plush vehicle 1 M and mimics a sneaker pull-tab for use as an aid in promoting purchase and hanging and displaying the product on a point of purchase display rack similar to the related sneaker product.
[0075] A separate bounded pocket region 4 M, is shaped to securely receive and retain an electronic transmission device 5 M, noted as an electronic gift card. A brand or logo region 8 M may be alternatively used as a writing surface and is pre-printed (in this embodiment) for brand marling purposes. Here, an additional foam rubber tread-mimic member 9 M is also formed on outer boundary layer material to further the impression of the plush vehicle as related to the product promoted.
[0076] As should be additionally noted, loop 3 M and other areas of plush vehicle 1 M includes external webbing 7 M, employed in a manner and affixed to outer boundary layer 2 M to aid the mimic-quality of the plush vehicle as a sneaker.
[0077] Referring now to FIG. 15 , a plurality of views for an alternative variation of a plush delivery vehicle 1 N including an outer boundary layer 2 N (here a colored silver glitter fabric), and encloses a compressible medium (not shown). A loop 3 N projects away from plush vehicle 1 N and mimics a hanging tab for a holiday ornament as an aid in promoting purchase and hanging and displaying the product on a point of purchase display rack similar to the related sneaker product.
[0078] A separate bounded pocket region 4 N, is shaped to securely receive and retain an electronic transmission device 5 N, noted as an electronic gift card. A brand or logo region 8 N may be alternatively used as a writing surface and is left blank (in this embodiment) for purchaser entry of a gift recipient. Here, an additional ribbon 7 N is provided proximate loop 3 N to aid the impression of a glittery plush vehicle 1 N.
[0079] Referring now to FIG. 16 , a plurality of views for a plush delivery vehicle 1 P including an outer boundary layer 2 P (here a black satin material and a dark gray flannel material), and encloses a compressible medium (not shown). A loop 3 P projects away from plush vehicle 1 P and mimics a bow-tie portion for use as an aid in promoting purchase and hanging and displaying the product on a point of purchase display region.
[0080] A separate bounded pocket region 4 P, is shaped to securely receive and retain an electronic transmission device 5 P, noted as an electronic gift card. Here, an additional region of exterior layer 2 P is shaped as a suit lapel to aid the impression of the product. Similarly a rigid or semi-rigid button member 7 P is affixed to exterior or outer boundary layer 2 P.
[0081] As should be additionally noted, loop 3 P and other areas of plush vehicle 1 P and outer boundary layer 2 P may include ornamental stitching 8 P or physical adornment without departing from the scope and spirit of the present invention.
[0082] Referring now to FIG. 17 , a plurality of views of construction steps for an alternative variation of a plush delivery vehicle 1 Q including an outer boundary layer 2 Q (here a colored and patterned lame or vinyl), and encloses a compressible medium (not shown). A top lop 3 Q projects away from plush vehicle 1 Q and mimics a holiday tree ornament as an aid in promoting purchase and hanging and displaying the product on a point of purchase display rack similar to the related product. Obviously, this also enables the product to assume a secondary role as an ornament post-purchase.
[0083] A separate bounded pocket region 4 Q, is shaped to securely receive and retain an electronic transmission device 5 Q, noted as an electronic gift card. A brand or logo region 8 Q may be alternatively used as a writing surface and may be pre-printed for brand marling purposes. Here, an additional element, namely a plurality of rigid or semi-rigid plastic buttons 9 Q are also formed on outer boundary layer material 2 Q to further the impression of the plush vehicle as related to the product promoted.
[0084] As should be additionally noted, an external ribbon member 7 Q may be used to enhance the overall product.
[0085] In the claims, means- or step-plus-function clauses are intended to cover the structures described or suggested herein as performing the recited function and not only structural equivalents but also equivalent structures. Thus, for example, although a nail, a screw, and a bolt may not be structural equivalents in that a nail relies on friction between a wooden part and a cylindrical surface, a screw's helical surface positively engages the wooden part, and a bolt's head and nut compress opposite sides of a wooden part, in the environment of fastening wooden parts, a nail, a screw, and a bolt may be readily understood by those skilled in the art as equivalent structures.
[0086] Having described at least one of the preferred embodiments of the present invention with reference to the accompanying drawings, it is to be understood that the invention is not limited to those precise embodiments, and that various changes, modifications, and adaptations may be effected therein by one skilled in the art without departing from the scope or spirit of the invention as defined in the appended claims. | The present invention relates to a plush delivery vehicle for securely retailing, transporting, and displaying a card-type electronic device as a gift, and a kit for containing the same. The plush delivery vehicle is operable as an additional gift or useful consumer item following transfer and removal of the electronic gift. The plush delivery vehicle may assume a different function for post-sale operation and use, for example as a decorative device, a frame display, and an entertainment device. | 1 |
BACKGROUND OF THE INVENTION
The present invention is directed to electronic garage door openers and, more particularly, to a safety beam bracket and method of assembly for an electronic garage door safety beam.
In order to prevent the closing of a garage door upon an obstruction, it is known in the art to pass a sensor beam across the garage door opening. Usually, the sensor beam is oriented in a direction generally parallel to the garage floor. Passage of the beam across the garage door opening is monitored, and when the beam is broken, an electronic garage door controller either stops the electric motor moving the door or reverses the direction of the motor to move the door back upward.
It is desirable to have the beam mounted within approximately one foot of the garage floor so that small children and pets in danger of being hit by the door will break the beam. It is also desirable to have the beam mounted some distance off of the garage floor to prevent the path from being obstructed by contaminants such as moisture, dirt and road salt. In some areas, the height of the beam is mandated by legislation to be a particular distance off of the garage floor.
Commonly, brackets are used to hold both the beam transmitter and the beam receiver. Installation of the brackets to be at a proper height is often a difficult and time consuming process. Likewise, attachment of the beam transmitter and the beam receiver to the brackets and alignment of the beam transmitter and the beam receiver is often a time and labor intensive process. There is a need for a an improved safety beam mounting system to reduce the difficulty and time needed for installation of a garage door opener safety beam system.
SUMMARY OF THE INVENTION
A mounting system for the safety beam units of a garage door opener according to an exemplary embodiment of the present invention has two brackets. Each bracket has a base with a circular opening, and a support. The supports of both brackets are adjustably coupleable to each other. The mounting system also has a beam unit housing with a cylindrical mounting base fittable through the circular opening in the base of at least one of the brackets. A spring is coupled to the cylindrical mounting base. The spring has at least one end extending beyond a side of the cylindrical mounting base. The beam unit housing is held in position by the spring end extending into contact with the base of least one bracket.
In an embodiment, the spring is a leaf spring, the spring is coupled to a center of the cylindrical mounting base, and the spring has two pointed ends extending into contact with the base of at least one bracket. The base has a plurality of detents; and the spring end is held in at least one of the detents. The base of at least one bracket also has at least one receiving gap in communication with the circular opening. The end of the spring is insertable through the receiving gap. Additionally, the base of at least one bracket has a plurality of mounting holes.
The support of each bracket has a notch and a retaining clip. The retaining clip of each support is insertable into the notch of the other support. The two supports are coupled to each other by a fastener. Additionally, the support of each bracket has a plurality of measuring guide markers. In an embodiment, each of the brackets is made from a single piece of resilient metal folded to form the base and the support, and the fold has a plurality of gussets.
BRIEF DESCRIPTION OF THE DRAWINGS
Other features and advantages of the present invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a perspective view of an interior of a garage showing a garage door and an electronic garage door opening system;
FIG. 2 is a perspective view of a mounting system where the beam emitter/sensor is unattached to the brackets according to an exemplary embodiment of the present invention;
FIG. 3 is a perspective view of a mounting system where the beam emitter/sensor is attached to the inside of the brackets according to an exemplary embodiment of the present invention;
FIG. 4 is a perspective view of a mounting system where the beam emitter/sensor is attached to the outside of the brackets and according to an exemplary embodiment of the present invention;
FIG. 5 is a perspective view of a beam emitter/receiver housing according to an exemplary embodiment of the present invention.
DETAILED DESCRIPTION
A mounting system according to an exemplary embodiment of the present invention is adapted for achieving simple, inexpensive mounting of a safety beam emitter and a safety beam receiver.
As shown in FIG. 1, a garage door opener system 10 has a garage door opener 12 coupled to a garage door 14 . An exemplary garage door 14 is sectional and is mounted for travel on a pair of rails 16 , 18 . The garage door opener has a drive unit 20 coupled to a chain 22 . The chain 22 extends along a T-rail 24 mounted from the drive unit 20 and extending longitudinally to a point above the garage door. The T-rail has laterally extending flanges. A drive assembly 25 is releasably coupled to the chain 22 . The chain 22 is driven by the drive unit, and the drive assembly 25 is driven along the T-rail 24 by the chain 22 . A linkage arm 26 is coupled to the drive assembly 25 and to the garage door 14 . As the drive assembly 25 is driven along the T-rail 24 , the arm 26 causes the garage door 14 to be raised or lowered. A switch 27 activates the drive unit 20 . A safety beam emitter 28 and a safety beam receiver 29 are electrically coupled to the drive unit 20 and may stop the drive unit 20 to prevent the garage door 14 from closing on an obstruction.
As shown in FIG. 2, the mounting system has a mount 32 and a safety beam emitter/receiver housing 34 . The safety beam emitter 28 and the safety beam receiver 29 are each enveloped in a separate housing 34 , and each housing 34 fits into a separate mount 32 . Typically, a first mount and a safety beam emitter are placed on one side of a garage door opening. A second mount and a safety beam receiver are placed on an opposite side of the garage door opening.
Each mount 32 contains two brackets 38 , 40 . The two brackets 38 , 40 are identical and fit together to form the mount 32 . Each bracket has a base 42 and a support 44 oriented perpendicular to the base 42 . The two brackets 38 , 40 are assembled so that one base is mountable against a surface and the other base is used to mount the beam emitter/receiver housing 34 .
The base 42 has a circular opening 46 . The circular opening 46 has two receiving gaps 48 , 50 located on opposite sides of the circular opening 46 . The base 42 also has two mounting holes 52 , 54 for attachment to a surface, such as a floor or a wall. Additionally, the base 42 has two sets of detents 56 positioned adjacent to portions of the circular opening on a first side, and second sets of detents 58 positioned adjacent to portions of the circular opening on a second side.
The support 44 has an oblong notch 60 extending along a portion of its length. At an end of the notch 60 farthest from the base 42 , the support 44 has a retaining clip 62 that extends through the notch 60 . The retaining clip 62 is formed by two tabs. The two tabs are oriented to have an external width approximately equal to the width of the notch 60 . Along the length of the support 44 are indented measurement markings 64 .
In an exemplary embodiment of the present invention, a bracket is made from a single piece of material. In an embodiment, the bracket is made from a strip of suitable metal such as aluminum, steel, or stainless steel. The strip is stamped on a first side with the measurement markings 64 for the support and with the first sets of detents 56 on the first side of the base. The strip is stamped on a second side with the ,second set of detents 58 for the second side of the base. The strip is also stamped on the second side to create the retaining clip 62 .
The circular opening 46 , two receiving gaps 48 , 50 , mounting holes 52 , 54 and notch 60 are punched out of the strip. The strip is bent to form the base and the support. The corner of the bend is stamped to form two gussets 66 , 68 . In an alternative embodiment, the bracket is made of plastic. The plastic is molded to obtain the desired features. In another embodiment, the bracket is made by coupling a base to a support.
As shown in FIGS. 2 to 4 , the mount 32 is assembled by facing the brackets 38 , 40 in opposite directions with the bases pointing away from each other. The two supports are lined up so that the two notches are superimposed. Each retaining clip is placed in the notch of the other bracket. The retaining clips maintain alignment of the supports. Although the retaining clips can slide along the length of the notch, the width of the retaining clips prevent the notches from being rotated relative to each other. The supports are moveable to obtain a desired length between the two bases. An exact measurement of the distance between the two bases may be achieved by lining up an end of one support with the measurement markings 64 on the other support.
Once the proper distance between the two bases has been achieved, a fastener 70 is placed through both notches and secured. In an embodiment, the fastener is a nut and bolt. In an additional embodiment, a lock washer is placed on the bolt prior to the nut, to prevent vibration from loosening the nut. One of the bases 42 is attached to a desired surface, and the other base is available for attachment of the beam emitter/receiver housing 36 .
As shown in FIG. 5, the beam emitter/receiver housing 34 has a body 72 and a raised cylindrical mounting base 74 . The diameter of the cylindrical mounting base 74 corresponds to the diameter of the circular opening 46 in the base of each bracket. The circular opening 46 fits over the mounting base 74 with little play. In an embodiment of the present invention, the housing 34 and the cylindrical mounting base 74 are a unitary piece made of molded plastic.
A spring clip 76 is coupled to an outer surface of the cylindrical mounting base 54 using a fastener 78 . In an embodiment, the fastener 78 coupling the spring clip to the mounting base is a screw. The spring clip 76 extends beyond the outer diameter of the mounting base 74 . The ends of the spring clip 76 are pointed flanges 80 , pointing toward the body 72 of the beam emitter/receiver housing 34 . In an exemplary embodiment of the present invention, the spring clip 76 is a leaf spring made of a resilient metal, such as steel or stainless steel.
To couple the beam emitter/receiver housing 34 to the mount 32 , the housing 34 is rotated until the spring clip 76 is aligned with the two receiving gaps 48 , 50 on the base. The spring clip 76 and the mounting base 74 are inserted into the receiving gaps 48 , 50 and the circular opening 46 respectively. Once inserted, the housing 34 is rotated so that the spring clip 76 cannot fit back through the receiving gaps 48 , 50 . The housing 34 is rotated so that the pointed flanges 80 pass over the detents located on the base until the housing 34 is at a desired orientation within the mount 32 . Once at the desired orientation, the resting of one of the pointed flanges 80 in a detent holds the beam housing 34 in the desired orientation.
The mount may be attached to different surfaces in different orientations. For example, as shown in FIG. 3, the mount may be attached to a vertical surface, such as a garage wall. Alternatively, as shown in FIG. 4, the mount may be attached to a horizontal surface such as a garage floor.
The beam emitter/receiver housing 34 may be coupled to the mount in different orientations. For example, as shown in FIG. 3, the housing 34 may be attached in an inside orientation. In an inside orientation, the housing 34 is inserted into the circular opening 46 of the base 42 from the side of the base closest to the mounting surface. Alternatively, as shown in FIG. 4, the housing 34 may be attached in an outside orientation. In the outside orientation, the housing 34 is inserted into the circular opening 46 of the base from the side of the base facing away from the mounting surface.
Although references have been made in the foregoing description to an exemplary embodiment, persons of ordinary skill in the art of designing garage door openers will recognize that insubstantial modifications, alterations, and substitutions can be made to the exemplary embodiment described without departing from the invention as claimed in the accompanying claims. | A mounting system for the safety beam units of a garage door opener, the mounting system having two brackets, each bracket having a base with a circular opening and a support, the supports of both brackets being adjustably coupleable together. The mounting system also has a beam unit housing with a cylindrical mounting base fittable through the circular opening in the base of at least one of the brackets. A spring is coupled to the cylindrical mounting base, the spring having at least one end extending beyond a side of the cylindrical mounting base. The beam unit housing being held in position by the at least one spring end extending into contact with the base of least one bracket. | 5 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the invention
[0002] This invention relates to a finishing device for floors made of hardenable material, in particular concrete or mortar, which device comprises a frame, at least one rotating tool connected thereto and provided with at least two arms upon each of which a blade is fixed, and a driving mechanism, provided on the frame, for driving the tool.
[0003] 2. Discussion of the Related Art
[0004] Such finishing devices are applied for processing particles, such as quartz particles, into poured and still soft hardenable material, for leveling the hardenable material previous to the complete hardening thereof, or for polishing the material during hardening.
[0005] In known finishing devices of this kind, a beam is attached to the upper side of each blade, mostly riveted into place, and the blade is fixed to an arm of the tool by means of screws or bolts which are screwed through the arm into the beam.
[0006] In order to replace or exchange a blade, the screws or bolts must be completely screwed off the beam, which is time-consuming.
[0007] Mostly, three openings are provided in the beam, of which only two are used for fixation to an arm, whereby these openings can be different, depending on whether the arm is short or long.
[0008] Especially in the case of a short arm, there are openings which remain free and into which cement and other dirt may penetrate.
[0009] For a short arm, in fact, bolts are screwed into the central and one of the two outer openings. Into the third opening, cement or other dirt may penetrate, such that, when one wants to attach the blade to the arm in another position, to wit in the position in which said third opening of the beam is situated the most outward, it will become difficult to screw a bolt into this dirty third opening and, therefore, the fixation of the beam at the arm is difficult or impossible.
[0010] Moreover, the position of the beam, and therefore also of the blade, is fixed in respect to the arm.
[0011] For finishing the borders, mostly another finishing device is used than for finishing the central surfaces, and up to now, two different finishing devices are used to this end.
SUMMARY OF THE INVENTION
[0012] The invention aims at a finishing device for floors made of hardenable material which does not have these disadvantages and whereby the blades can be replaced or exchanged in a fast and simple manner and the blades can be fixed in an adjustable manner in respect to the arms, such that it is also possible to provide different types of blades in the same tool and the position of the blades can be chosen such that it is possible to perform the finishing very close to the walls, such that a special border-finishing device no longer is necessary.
[0013] According to the invention, this aim is achieved in that the blade is fixed to an arm of the tool by means of a connection with at least two parts which can be adjusted in respect to each other in the longitudinal direction of the arm, the first part of which is mounted on the blade and the second part is connected to the arm by means of connecting means and can be fixedly clamped onto this first part.
[0014] Preferably, the first part of the connection is an open-box profile extending parallel to the arm, whereas the second part is situated with at least a portion within the open-box profile.
[0015] An open-box profile is a profile with a C-shaped cross-section which is open at both extremities.
[0016] In a form of embodiment, the second part can be clamped onto the first part by means of the connecting means by which the second part is connected to the arm.
[0017] These connecting means may comprise at least one screw or bolt which protrudes through the arm and is screwed into said second part, or may comprise at least one bolt which extends through the arm and through the second part and onto which a nut is screwed.
[0018] The second part may be a beam fitting, with a play and in a movable manner, into the open-box profile, whereby, thus, parts of the open-box profile can be clamped between the beam and the arm by the connecting means.
[0019] In another form of embodiment, this second part is formed by a portion of the connecting means themselves, and these connecting means consist, for example, of at least one bolt with a nut, whereby the bolt extends through the arm and through the slot into the open-box profile and either the head of the bolt, or the nut is situated within the open-box profile and forms the aforementioned second part.
[0020] In the last case, this second part can be clamped on the first in that parts of the open-box profile are clamped between the beam and the head of the bolt, the nut, respectively, by screwing the nut onto the bolt.
[0021] The invention also relates to a blade obviously destined for being used in the finishing device according to the invention described in the aforegoing and which is characterized in that a hollow profile, in particular an open-box profile, is attached thereupon.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] With the intention of better showing the characteristics of the invention, hereafter, as an example without any limiting character, a preferred form of embodiment of a finishing device and a blade used therewith according to the invention are represented, with reference to the accompanying drawings, wherein:
[0023] [0023]FIG. 1 represents a perspective view of a finishing device according to the invention;
[0024] [0024]FIG. 2 represents a portion of a tool from the finishing device of FIG. 1, drawn with the parts in exploded view;
[0025] [0025]FIG. 3, at a larger scale, represents a cross-section according to line III-III in FIG. 2, but with the parts in mounted condition;
[0026] [0026]FIG. 4 represents a side view of an extremity of an arm with blade of the finishing device of the preceding figures;
[0027] [0027]FIG. 5 represents a cross-section analogous to that of FIG. 3, however, relating to another form of embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0028] As represented in FIG. 1, the finishing device according to the invention substantially consists of a frame 1 , one or more, in the example two, rotating tools 2 provided thereupon, and a driving mechanism 3 for synchronously driving said tools 2 .
[0029] The driving mechanism 3 consists of a driving motor 4 driving a pump 5 with a variable flow rate which forms part of a hydraulic circuit 6 in which a liquid reservoir 7 is provided as well as a hydromotor 8 which drives the two tools 2 by means of two reduction boxes 9 , each having a vertical shaft and coupled to each other by means of a mechanical universal coupling.
[0030] The liquid reservoir 7 is fixed to the frame 1 which below comprises a bordering 10 .
[0031] Each tool 2 substantially consists of a hub 11 , four radial arms 12 positioned in cross-shape, and on each arm 12 a blade 13 which is connected to the arm 12 by means of connection 14 in a continuously adjustable manner. The hub 11 is fixed at the shaft of a reduction box 9 .
[0032] As represented in FIG. 2, each arm 12 is attached to the hub 11 adjustable around its longitudinal direction, as it fits with a round extremity in a tubular portion 11 A of the hub 11 .
[0033] This arm 12 is retained in this portion 11 A by means of a bolt 15 which protrudes through this portion into a groove 15 A in the arm 12 .
[0034] A ring 16 , which, by means of a bolt 17 and a locking nut 18 screwed thereupon, can be locked against a hexagonal portion of the arm 12 , is provided with an arm 19 situated next to the tubular portion 11 A.
[0035] By means of this arm 19 , the arm 12 can be adjusted around its longitudinal axis and, therefore, the angle of the blade 13 attached thereto can be adjusted by means of a mechanism, not represented in the figures and provided between the hub 11 and the reduction box on the shaft of this latter.
[0036] A bolt 21 which is screwed through this arm 19 and can be locked by means of a locking nut 20 allows for a fine adjustment of the aforementioned angle.
[0037] Between the ring 16 and the tubular portion 11 A, an O-ring 22 is provided around arm 12 in order to prevent dirt from penetrating into the portion 11 A.
[0038] The portion of the arm 12 which is turned away from the hub 11 is hexagonal.
[0039] The connection 14 substantially consists of an open-box profile 23 which is attached to the upper side of the blade 13 , for example, welded thereto, and a beam 24 fitting with a play into the open-box profile 23 and being connected to the arm 12 by means of fixation means, to wit two screws or bolts 25 .
[0040] These bolts 25 loosely extend through openings 26 through the hexagonal extremity of the arm 12 and are screwed into openings 27 , provided with screw thread, in the beam 24 .
[0041] The open-box profile 23 in fact is a profile, open at the extremities, with a C-shaped cross-section or, in other words, a rectangular or square tubular profile, in the upper side of which, over the entire length, there is a slot 28 in the center through which the bolts 25 may pass loosely.
[0042] Next to the outermost-situated extremity of the beam 24 , this beam is passed by one or more, in the represented example, three, openings 29 , 30 and 31 directed perpendicular to the arm 12 and parallel to the blade 13 .
[0043] A lockable pin 32 , which is wider than the beam 24 , can be put through one of the openings 29 , 30 or 31 in order to allow a fast adjustment of preferred positions of the blade 13 , as will be explained in the following.
[0044] Connecting a blade 13 and an arm 12 takes place as follows:
[0045] If necessary, the bolts 25 , with which the beam 24 is fixed to the arm 12 , are unscrewed, without completely releasing the beam 24 .
[0046] The open-box profile 23 , which is fixed onto the blade 13 , is slid over the beam 24 , whereby the hexagonal portion of the arm 12 remains outside the open-box profile 23 and the two bolts 25 with a portion thereof extend through the slot 28 .
[0047] The blade 13 is placed in radial direction into the desired position, after which the bolts 25 are screwed in as far as possible.
[0048] As a result thereof, the portions of the open-box profile 23 which are situated at opposite sides of the slot 28 are clamped between the beam 24 and the arm 12 , as a result of which the blade 13 is fixed to the arm 12 .
[0049] The beam 24 which is clamped against the open-box profile 23 reduces or prevents the bending of this open-box profile 23 .
[0050] In this manner, the position of the blade 13 is continuously adjustable in radial direction, within limits.
[0051] So, the blades 13 of one or both tools 2 can be adjusted such that they can finish a surface close to the upright walls. As a result of this, the necessary manual finishing along the walls is reduced.
[0052] Then, a usual finishing device can be used a as an edge-finishing device, such that no separate device is necessary for finishing the borders.
[0053] The fixation of the blade 13 on the arm 12 can be performed rapidly, in consideration of the fact that the bolts 25 only have to be screwed in by several turns in order to fixedly clamp the open-box profile 23 .
[0054] The loosening of the blade 13 from the arm 12 can also be performed in a rapid manner. It suffices to unscrew the bolts 25 a little and to shift the open-box profile 23 off the beam 24 .
[0055] In this manner, a blade 13 , for example, for the normal polishing finish of a surface, can be replaced by another blade 13 A, for example, for a pre-processing, or a blade 13 B.
[0056] When a blade 13 is worn out, it is thrown away together with the open-box profile 23 . The mostly longer and heavier and therefore also more expensive beam 24 remains with the arm 12 and, therefore, with the device.
[0057] Polishing blades, such as the represented blade 13 , mostly can be used double-sided, such that, when the side situated foremost in turning direction is worn, the blade 13 can be turned over 180° and can be fixed to the arm 12 again, with the other edge to the front.
[0058] Although a blade 13 is continuously adjustable in respect to the arm 12 , the openings 29 , 30 and 31 determine three standard positions thereof.
[0059] To this end, the open-box profile 23 is slid over the beam 24 in such a manner that the extremity of the beam 24 protrudes, such that the opening 29 , 30 or 31 corresponding to the desired standard position is situated out of the open-box profile 23 , after which the pin 32 is put through said opening and the open-box profile 23 is moved back up to against the extremities of the pin 32 which protrude from the beam 24 and therefore form a stop, and finally the bolts 25 are tightened.
[0060] In FIG. 4, a portion of an arm 12 is represented to which a blade 13 in such standard position is attached. The pin 32 is provided, for example, through the central opening 30 .
[0061] It is obvious that a stop, such as a pin 32 , is not really necessary for the determination of standard positions.
[0062] Instead of one or more openings 29 , 30 and 31 and a pin 32 , one or more marks can be provided on the beam 24 , such that the user can see how far one has to shift the open-box profile 23 over the beam 24 .
[0063] Instead of being welded to the blade 13 , the open-box profile 23 can be attached thereto by means of rivets or similar. Of course, the play in the vertical direction of the beam 24 in the open-box profile 23 must be sufficiently large in order to allow the presence of the heads of these rivets or similar on the bottom of the open-box profile 23 .
[0064] The connecting means connecting the beam 24 to an arm 12 do not necessarily have to be screws or bolts screwed into this beam 24 .
[0065] In a variant, these connecting means can be bolts which do not only fit loosely through the arm 12 , but also fit loosely through the beam 24 and onto which nuts are screwed. Due to the open-box profile 23 , the turning of the nut can be prevented, and preferably it is also prevented that the nut can be screwed completely off the bolt.
[0066] The clamping of the beam 24 in respect to the open-box profile 23 by means of these connecting means then takes place by means of screwing-in or turning the bolt in respect to the nut.
[0067] The second part of the connection 14 does not necessarily have to be a beam 24 . The beam 24 can be replaced by one portion of the connecting means themselves.
[0068] These connecting means can be formed by bolts 33 onto which nuts 34 are screwed, as represented in FIG. 5.
[0069] The bolts 33 extend loosely through the arm 12 and through the slot 28 and are situated with their head 33 A, which forms the movable and clampable second part 24 of the connection 14 , in the open-box profile 23 .
[0070] This head 33 A is sufficiently large and preferably of such a shape that a rotation thereof in the open-box profile 23 is restricted or impossible.
[0071] It is obvious that by the tightening of the nut 34 which is situated on top of the arm 12 , the open-box profile 23 and the arm 12 are drawn towards each other and that, thus, the portions of the open-box profile 23 situated between the head 33 A and the arm 12 are fixedly clamped.
[0072] By tightening the nuts 34 on both bolts 33 , thus the bolts 33 and the arm 12 are fixedly clamped on the open-box profile 23 .
[0073] By unscrewing the bolts 33 , the open-box profile 23 can be adjusted in its longitudinal direction in respect to the arm 12 .
[0074] In particular, this form of embodiment can be applied with finishing devices with long arms 12 .
[0075] In the last-mentioned form of embodiment, the bolts 33 can be reversed such that their head 33 A is situated at the upper side of the arm 12 and the nuts 34 are situated in the open-box profile 23 and have such a shape that they are prevented from turning, but keep their clamping function during the tightening of the bolts 33 .
[0076] The number of arms 12 does not necessarily have to be four. For example, there may be three, five or six arms 12 per tool 2 .
[0077] The invention is in no way limited to the form of embodiment described heretofore and represented in the figures, however, such finishing device can be realized in different variants without leaving the scope of the invention. | The invention relates to a finishing device for floors made of hardenable material which comprises a frame, at least one rotating tool ( 2 ) connected thereto and provided with at least two arms ( 12 ) upon each of which a blade ( 13 ) is fixed, and a driving mechanism, provided on the frame, for driving the tool ( 2 ). The blade ( 13 ) is fixed to an arm ( 12 ) of the tool ( 2 ) by means of a connection ( 14 ) with at least two parts ( 23,24 ) which can be adjusted in respect to each other in the longitudinal direction of the arm ( 12 ), the first part ( 23 ) of which is mounted on the blade ( 13 ) and the second part (24) is connected to the arm ( 12 ) by means of connecting means ( 25, 33 - 34 ) and can be fixedly clamped onto this first part ( 23 ). | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present invention claims priority under 35 U.S.C. § 119 from U.S. Provisional Patent Application No. 60/261,396 titled “Integral Rain Gutter” filed Jan. 12, 2001, the full disclosures of which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to a roof structure, and more particularly, to a roof structure having an integral rain gutter.
It is generally known to provide for a roof support located along a central peak of pitched roofs for small storage and utility buildings or sheds having shallow-pitched roof panels. Such roof supports typically span the length of the roof and provide structural support at the joint between sloped roof panels which abut along the roof peak. The roof support may typically include a separate cover portion to cover the joint and reduce exposure of the joint and shed interior to snow, rain and other weather elements. Roof supports of this type are typically made from lightweight materials and assembled from multiple components manufactured by a thermoplastic molding or extrusion process.
However, such molded and/or extruded thermoplastic roof support assemblies have several disadvantages including roof sagging and concomitant water leakage. Such sagging and leakage is typically due to the relatively low rigidity and the temperature and time dependent creep of the thermoplastic roof support material. These disadvantages have required manufacturers to attempt to develop roof supports that are more rigid, thereby preventing roof sagging and subsequent water leakage. For example, roof supports are now designed to include separate steel rods that are inserted within the extruded roof support to provide more rigidity to the roof support and limit deflection and creep of the roof supports.
Despite such improvements, roofs continue to sag and extruded roof supports continue to deflect, allowing water leakage at the joint. To overcome the water leakage problem, manufacturers began providing a rain gutter in combination with the roof support to capture and divert any water that penetrates the cover and joint along the roof peak to reduce leakage inside the building. Traditionally, rain gutters snap-on to the roof panels under the joint of the roof peak, and any water that creeps along the surface of the roof panels or enters the joint will be directed to the rain gutter for subsequent disposal. Although the addition of rain gutters help to prevent water leakage inside the building, it provides another piece of equipment to manufacture and does not alleviate the problems and disadvantages associated with roof sagging and roof support deflection. As a result, manufacturers have provided columns or other vertical supports within the building to bolster the roof support, resulting in the additional expense associated with several manufacturing processes and assembly operations.
Accordingly, there exists a need for a roof support that provides more rigidity and which can also accommodate water leakage. Therefore, it is an objective of the present invention to provide a roof support with integral gutter. Another objective of the roof support with integral gutter of the present invention is to provide a roof support having higher strength and rigidity, which will limit roof support deflection and roof sag. A related objective of the roof support with integral gutter is that it should not require additional components, such as steel rods, to provide rigidity to the roof support.
Another objective of the roof support with integral gutter of the present invention is to provide a roof support with a panel joint cover and a gutter that are unitarily formed with the roof support by a single manufacturing process, thereby eliminating the necessity to separately manufacture each individual part, and reducing manufacturing costs.
Additionally, an objective of the roof support with an integral gutter is that it should be manufactured by a process that is easy to implement, is versatile, and produces a higher strength product to prevent roof sag that results in subsequent water leakage. Finally, it is an objective of the roof support with integral rain gutter that it provide all of the aforesaid objectives and advantages without incurring any substantial relative disadvantage.
SUMMARY OF THE INVENTION
The present invention relates to a roof support with an integral gutter including a roof support, a panel joint cover, and a gutter for a small storage or utility building or shed having a shallow-pitched roof. In particular, the roof support with integral gutter includes a support web, an exposure surface perpendicularly bisecting the support web, and a collector perpendicularly bisecting the support web opposite the exposure surface.
The exposure surface acts as the panel joint cover and is designed to fit over abutting roof panels to protect a joint formed therebetween from environmental conditions. The exposure surface also acts as the first barrier to water leakage inside the building. The exposure surface may have a negative angle with respect to the support web to correspond to the angle of the abutting roof panels to provide a seal between the roof panels and roof support, and to maintain continuity between the roof panels and the roof support.
The collector includes a distal edge angled from the plane of the lower portion of the collector to provide a channel between the distal edge and the support web, forming the integral gutter. The distal edge of the collector is angled away from the lower surface between about 90° and 175°, with a length great enough to provide the collector with a depth sufficient to direct a substantial volume of liquid along the collector. With the collector, any water or other moisture which penetrates the joint and the exposure surface will seep into the collector and be directed to a drain or away from the building.
The roof support with integral gutter may be used in combination with at least one roof panel having an exterior surface and an interior surface opposite the exterior surface. When two roof panels are used, the roof structure divides and supports each roof panel. Each roof panel abuts the support web, with a portion of the roof panel fitting between the exposure surface and the collector of the roof support. This permits the exposure surface to extend over the exterior surfaces of the roof panels and cover the joint formed between the roof panels. The roof panels are supported by the distal edges of the collector, which are closely adjacent to the interior surfaces of the roof panels. Each roof panel may also include a drip edge that extends longitudinally along the interior surface parallel to the support web of the roof support and intermediate the distal edge and the support web over the collector. The drip edge acts to disrupt the cohesive bond between the moisture and the roof panel surface so that the moisture drips from the interior surface at this point. The collector extends beyond the drip edge to capture any moisture that falls from the roof panel when the roof panel is situated intermediate the exposure surface and the collector.
In part, the present invention is a method of making a roof support. The method includes introducing fibers to a resin bath to form a fiber-resin combination, contouring the fiber-resin combination in the shape of a roof support and curing the resin-fiber combination. The roof support may be contoured to include a support web, an exposure surface and a collector. The roof support may then be cut to desired specifications.
This invention overcomes the problems and disadvantages associated with the related art by providing a roof support with integral gutter. The roof support with integral gutter has increased strength and rigidity to limit roof support deflection and roof sag. Further, the roof support with integral gutter of the present invention does not require additional components, such as steel rods, to provide the strength and rigidity to the roof support.
The roof support with integral gutter also provides a roof support with a panel joint cover and a gutter integrally formed with the roof support. This is accomplished by a single manufacturing process, and reduces parts inventory and manufacturing costs.
Also, the roof support with integral gutter of the present invention is manufactured by a process that is easy, versatile, and produces a high strength product. This results in a roof support that prevents roof sag and water seepage through and/or near the joint between roof panels. As is shown and described, the roof support with integral gutter of the present invention has one or more of these or other advantageous features, and achieves all of the aforesaid advantages and objectives without incurring any substantial relative disadvantage.
The above brief description sets forth rather broadly the more important features of the present invention so that the detailed description that follows may be better understood, and so that the present contributions to the art may be better appreciated. Throughout this application, the text refers to various embodiments of the present article of manufacture and/or related methods. The various embodiments described are meant to provide a variety of illustrative examples and should not be construed as descriptions of alternative species. Rather it should be noted that the descriptions of various embodiments provided herein may be of overlapping scope. The embodiments discussed herein are merely illustrative and the invention is not limited in its application to the details of the construction and the arrangements set forth in the following description and/or illustrated in the drawings. The present invention is capable of other embodiments and of being practiced and carried out in various ways, as will be appreciated by those skilled in the art. Also, it is to be understood that the phraseology and terminology employed herein are for description and not limitation, are not meant to limit the scope of the present invention.
DESCRIPTION OF THE FIGURES
FIG. 1 is a perspective view of a building having shallow pitch roof panels and a roof support according to the preferred embodiment.
FIG. 2 is a top plan view of the roof according to the preferred embodiment.
FIG. 3 is a cross sectional view of the roof support along section A—A of FIG. 2 according to the preferred embodiment.
FIG. 4 is a perspective view of the roof support according to the preferred embodiment.
FIG. 5 is a cross sectional view of the roof support according to the preferred embodiment.
FIG. 6 is a cross sectional view of the roof support according to an alternative embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1 , a small storage or utility building 10 having a shallow-pitched roof 12 is shown according to the preferred embodiment. An example of a building and roof of this type are described in U.S. patent application Ser. No. 09/086,061 titled “Modular Panel Construction System,” filed on May 27, 1998, the disclosure of which is incorporated herein by reference. The shallow pitched-roof 12 includes roof panels 14 that are supported along a central peak line 15 of shallow-pitched roof 12 by roof support 20 (not shown in this view).
FIG. 2 displays the shallow-pitched roof 12 more clearly. The shallow-pitched roof 12 includes two roof panels 14 separated by a centrally positioned roof support 20 that divides the roof 12 . The roof support 20 spans the length of building 10 and is supported on either end by the end wall structure 18 of building 10 (shown in FIG. 1 ). Although a roof having two roof panels is shown and described, it would be apparent to one skilled in the art to construct a roof using a single roof panel.
FIG. 3 more clearly displays the roof panel 14 and roof support 20 relationship. Roof panels 14 are positioned in a continuously abutting relationship along both lateral sides of a support web portion 22 of roof support 20 . Roof panels 14 have an exterior surface 17 and an interior surface 19 . Roof panels 14 are configured with a longitudinal drip edge 16 (e.g. slot, groove, indent, lip, etc.) that extends along the interior surface 19 of the roof panel 14 parallel to the longitudinal axis of the roof support 20 . Drip edge 16 provides a discontinuity in the interior panel surface that allows any leaking moisture adhering to roof panel 14 to drip off the panel into the roof support 20 and prevents moisture from migrating laterally beyond the roof support 20 .
Roof support 20 includes an exposure surface 24 (e.g., panel joint cover, flaps, shields, protector, etc.) extending along the entire length of roof support 20 . Exposure surface 24 projects laterally outward from an upper end of support web 22 and is intended to overlap roof panels 14 on both lateral sides of support web 22 to shield the joint created between the abutting roof panels 14 and support web 22 from rain and other elements of the weather.
Roof support 20 also includes a collector 50 (e.g., tray, channel, pan, trough, etc.) extending along the entire length of roof support 20 . Collector 50 projects laterally outward from a lower end of support web 22 and extends beneath a portion of each roof panel 14 , slightly beyond the drip edges 16 . Collector 50 is configured to capture water that penetrates the joint created between the abutting roof panels 14 and support web 22 and divert the water to a drain (not shown) or away from the interior of the building.
Referring to FIGS. 4 and 5 , roof support 20 is shown according to a preferred embodiment. Roof support 20 is desirably formed using a thermoset pultrusion process where reinforcing filaments are passed from a fiber delivery system (e.g., reels, spindles, etc.) and pulled through a resin impregnation bath. The resin-embedded fibers are then pulled through preform fixtures (e.g., one or more dies), which contour and align the fiber-resin combination into the roof support shape that will be subsequently described. The contoured fiber-resin combination then passes through a heated fixture or die (not shown) to cure (i.e., “cross-link”) the resin. Upon curing, roof support 20 is extracted from the heated die and cut into the lengths that correspond to use in buildings 10 or other structures. Although pultrusion is preferred, other types of methods may be used to form the roof support including extrusion, rollform, weldment, or a combination thereof.
According to a particularly preferred embodiment, roof support 20 has a length of approximately 64 in, and all subsequently described dimensions correspond to a length of approximately 64 in; however the length can be modified to suit a wide variety of building sizes and the subsequently described dimensions may be adjusted accordingly to maintain acceptable deflection levels under a particular set of loading conditions. In a preferred embodiment, the fiber filaments and resin combination have a modulus of elasticity (E) of at least about 2,500,000 pounds per square in (PSI). In the particularly preferred embodiment, the fiber filaments are glass fibers and the resin is a thermoset polyester resin, the combination having a modulus of elasticity (E) of approximately 2,700,000 to 3,300,000 PSI. However, other fibers and resins known in the art may be used, including graphite, polyethylene, vinyl esters, epoxy resins and combinations thereof. The fiber-resin combination may also be cured by other methods known by those skilled in the art, including chemical curing. In further alternative embodiments, roof support 20 may be fabricated with an extrusion process from thermoplastic materials or composites thereof.
Referring further to FIGS. 4 and 5 , roof support 20 is formed with a uniform cross-section along its entire length that is symmetrical and generally “I-beam” shaped, and includes a centrally located vertical support web 22 . Integrally formed with the support web 22 is the exposure surface 24 , which generally perpendicularly bisects the support web 22 . Support web 22 is also integral with the collector 50 , which also generally perpendicularly bisects the support web 22 . In a preferred embodiment, the roof support 20 has a moment of inertia of between about 2.9 in 4 and 3.3 in 4 . In a particularly preferred embodiment, the roof support 20 has a moment of inertia of approximately 3.180 in 4 , and the support web 22 has a thickness of approximately 0.080 in and a height of approximately 4.222 in. However, the roof support may have a wide range of moment of inertia, and the support web a wide range of thickness and height to meet desired specifications. Further, the support web may be shaped differently when used in combination with a single roof panel to support the roof panel and prevent roof sag.
The exposure surface 24 has flanges 30 (e.g., arms, flaps, etc.) projecting outward in opposing lateral directions from an upper end of support web 22 , the underside of flanges 30 having rounded fillets 40 at the juncture with support web 22 , although squared fillets would be suitable as well. The outwardly projecting flanges 30 have a shallow negative slope corresponding to the pitch of roof panels 14 to improve the sealing performance of the exposure surface 24 against roof panels 14 . The shallow negative slope may be any angle from and including horizontal, which is suitable for providing a tight fit with the pitch of roof panels 14 . Flanges 30 may be formed along their length with arcuate projections 36 (e.g., ridges, channels, tracks, etc.) extending parallel to the longitudinal axis of roof support 20 and configured to interface with any corresponding projections 42 on the upper surface of roof panels 14 for improved position retention and sealing performance of roof support 20 (shown most clearly in FIG. 3 ). In a particularly preferred embodiment, exposure surface 24 has an overall width of approximately 3.750 in and a thickness of approximately 0.080 in, although this may vary depending on desired specifications. Further, exposure surface 24 of roof support 20 and the exterior surface 17 of roof panels 14 have a relative clearance of approximately 0.015 in. Again, the relative clearance between the exposure surface 24 and the exterior surface 17 may vary widely to account for desired specifications.
Referring further to FIGS. 4 and 5 , collector 50 is shown according to the preferred embodiment. Collector 50 has flanges 52 (e.g., legs, channels, troughs, etc.) projecting horizontally outward in opposing lateral directions from a lower end of support web 22 with each flange 52 having a distal end. The top side of flanges 52 have rounded fillets 40 at the juncture with support web 22 , but the fillets 40 may also be squared. Flanges 52 are formed along the length of their distal ends with an angularly upward projecting lip 56 extending parallel to the longitudinal axis of roof support 20 and configured to interface with a interior surface 19 of roof panels 14 . The angular portion of lip 56 has an angle from the top surface of flange 52 of about 90° to 175°, and more preferably about 125° to 145°. The angular portion of lip 56 may include a smooth transition to a horizontal portion 58 and then to a partial return bend end portion 60 . Horizontal portion 58 is configured to project slightly beyond drip edge 16 of roof panels 14 to support roof panels 14 and ensure that all moisture that drips from drip edge 16 is captured in collector 50 . The depth of collector 50 is determined by the vertical distance between the top surfaces of flanges 52 and horizontal portions 58 of distal ends, and the depth is greater than the maximum expected deflection of roof support 20 under the intended loading conditions to ensure that collected moisture flows to the ends of roof support 20 . In a particularly preferred embodiment, collector 50 has an overall width of approximately 3.500 in and a thickness of approximately 0.080 in, and the transition to horizontal portion 58 occurs at a distance of approximately 1.360 in from the centerline of support web 22 , with horizontal portion 58 raised above the top side of flanges 52 to provide a collector depth of approximately 0.335 in. In alternative embodiments, the overall width of collector 50 may be increased or decreased any desired amount provided that horizontal portion 58 extends beyond drip edge 16 , and the thickness of collector 50 may be any dimension suitable for providing a support and collector function.
Referring to FIG. 6 , a roof support 120 is shown according to an alternative embodiment. Roof support 120 is formed with a uniform cross section along its entire length that is symmetrical and generally “I-beam” shaped, having a centrally located vertical support web 122 that generally perpendicularly bisects, and is integrally formed with, the exposure surface 124 and the collector 150 . The support web 122 has a thickness of approximately 0.075 in and a height of approximately 3.977 in, which may be either increased or decreased depending on load requirements.
The exposure surface 124 has flanges 130 (e.g., arms, flaps, etc.) projecting outward in opposing lateral directions from an upper end of support web 122 . The outwardly projecting flanges 130 have a shallow negative slope corresponding to the pitch of roof panels 14 . The shallow negative slope may have any angle from and including to horizontal provide a tight fit with the pitch of roof panels 14 . Flanges 130 may be formed along their length with arcuate projections 136 extending parallel to the longitudinal axis of roof support 120 and configured to interface with corresponding projections 42 on the exterior surface 17 of roof panels 14 . The exposure surface 124 has an overall width of approximately 3.750 in and a thickness of approximately 0.075 in, which may be either increased or decreased depending on requirements.
The collector 150 also has flanges 152 projecting horizontally outward in opposing lateral directions from a lower end of support web 122 . Flanges 152 are formed along their distal ends with an upward projecting lip 156 that extends parallel to the longitudinal axis of roof support 120 .
It is also important to note that the construction and arrangement of the elements of the roof support as shown in the preferred and other exemplary embodiments is illustrative only. Although only a few embodiments of the present inventions have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited in the claims. For example, the roof support may be fabricated by aluminum extrusion, plastic extrusion or molding, metal roll forming, formed and welded metal assembly, etc. or a composite thereof and the dimensions may be tailored according to the width spanned by the roof support and the intended loading requirements. Accordingly, all such modifications are intended to be included within the scope of the present invention as defined in the appended claims. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. In the claims, any means-plus-function clause is intended to cover the structures described herein as performing the recited function and not only structural equivalents but also equivalent structures. Other substitutions, modifications, changes and omissions may be made in the design, operating conditions and arrangement of the preferred and other exemplary embodiments without departing from the spirit of the present inventions as expressed in the appended claims. | A roof support with an integral gutter including a roof support, a panel joint cover, and a gutter for a small storage or utility building or shed having a shallow-pitched roof. In particular, the roof support with integral gutter includes a support web, an exposure surface perpendicularly bisecting the support web, and a collector perpendicularly bisecting the support web opposite the exposure surface. The roof support with integral gutter is made by the pultrusion process, which eliminates the need for additional and separate components to provide rigidity and strength to the roof support. | 4 |
TECHNICAL FIELD
[0001] The present invention relates to normal detection method using distance detectors, a normal detection device, and a machining machine provided with a normal detection function.
BACKGROUND ART
[0002] In machining, it is important to perform machining according to design drawings and according to machining setting. For that purpose, it is required to precisely find out machining positions, machining directions, and machining amounts with respect to workpieces.
[0003] For example, in a structure in which a number of component parts are mechanically coupled together by mechanical coupling parts, such as rivets and fasteners, as in an airframe of an aircraft, it is necessary to perform drilling, which allows the mechanical coupling parts to pass through the respective component parts, with precise machining positions, machining directions, and machining amounts.
[0004] When a main wing that is one component part of the aircraft, and a skeleton part or the like are mechanically coupled together by a mechanical coupling part or the like, a protrusion may be formed on the surface of the main wing as the mechanical coupling part protrudes from the surface of the main wing, or a recess may be formed in the surface of the main wing as an attachment hole of the mechanical coupling part becomes deep. The protrusion and recess on the surface of the main wing influence the aerodynamic performance of an airplane. Hence, drilling, which allows a mechanical coupling part to pass through the main wing that is a workpiece, is performed with a precise machining position, a precise machining direction, and a precise machining amount so that the protrusion and the recess are minimized. Here, the machining direction is mainly an angle orthogonal to a workpiece, and it is necessary to obtain the normal vector on a surface to be machined.
CITATION LIST
Patent Literature
[0005] [PTL 1] Japanese Unexamined Patent Application Publication No. 61-269002
[0006] [PTL 2] Japanese Unexamined Patent Application Publication No. 8-71823
SUMMARY OF INVENTION
Technical Problem
[0007] PTL 1 discloses a normal detection method that obtains the normal vector on the surface to be machined, and PTL 2 discloses a machining machine provided with a normal detection function.
[0008] The normal detection method of PTL 1 is a method of obtaining the normal vector on a measured surface of a measurement subject by two opposed contact sensors among a plurality of contact sensors radially installed on a tip surface of an inner tube at one end coming into contact with the measurement subject and two opposed contact sensors installed on two protruding opposed tip surfaces of the outer tube at one end coming into contact with the measurement subject, in a movable normal detection jig in which the inner tube and the outer tube are coaxially fitted to each other and the outer tube is rotatable in a circumferential direction and movable in an axial direction with respect to the inner tube.
[0009] This is a method of determining whether the axial direction of the normal detection jig is the same as the normal vector on the measured surface. That is, the axial direction of the normal detection jig should be sought such that the two opposed contact sensors of the inner tube detect the measurement subject and the two contact sensors installed at the tip of the outer tube detect the measurement subject. Hence, the operation for allowing the axial direction of the normal detection jig to coincide with the normal vector on the measured surface will take a substantial time. Additionally, in the normal detection method of PTL 1, it is difficult to automatically control the posture of the normal detection jig.
[0010] The machining machine provided with a normal detection function of PTL 2 is a drilling machine provided with a machining jig in which two non-contact sensors are provided at one end and a motor-driven height adjustment mechanism is provided at the other end. The two non-contact sensors are arranged so as to become symmetrical with respect to the drilling tool, and the height adjustment mechanism is arranged so as to line up with the two non-contact sensors and the machining tool. By performing adjustment using the height adjustment mechanism so that measurement distances obtained by the two non-contact sensors become equal to each other, the angle of the machining machine to the surface to be machined is made right-angled.
[0011] This is a device that detects perpendicularity with respect to one direction in which the two non-contact sensors and the height adjustment mechanism are lined up. Hence, since the perpendicularity to a direction different from the one direction cannot be detected, it is insufficient for obtaining the normal vector on the surface to be machined with high precision.
[0012] The invention has been made in view of the above problems, and an object thereof is to calculate a normal vector on a measured surface with high precision from measurement distances obtained by distance detectors so that it is not necessary to search for the normal vector on the measured surface.
Solution to Problem
[0013] A normal detection method related to a first aspect of the invention to solve the above problems measures a plurality of distances to a measurement subject using one or a plurality of distance detectors, and obtains a normal vector on a measured surface of the measurement subject from the obtained measurement results. A plurality of measurement points on the measured surface at a plurality of measurement positions are represented by three-dimensional coordinates from the plurality of measurement positions where the distance detectors measure the distances to the measurement subject, and a plurality of measurement results obtained by the distance detectors at the plurality of measurement positions, a straight line connecting, on three-dimensional axes, a first measurement point measured at an arbitrary first measurement position among the plurality of measurement positions by the distance detector and a second measurement point measured at a second measurement position different from the first measurement position is defined as a first vector, a straight line connecting, on three-dimensional axes, the first measurement point and a third measurement point measured at a third measurement position different from the first measurement position and the second measurement position is defined as a second vector, and a normal vector on the measured surface is obtained by determining an outer product of the first vector and the second vector.
[0014] In the normal detection method according to a second aspect of the invention to solve the above problems, the first measurement position, the second measurement position, and the third measurement position are selected so that the area of a triangle made with three points of the first measurement position, the second measurement position, and the third measurement position becomes the largest.
[0015] In the normal detection method according to a third aspect of the invention to solve the above problems, the distance detectors are radially arranged in eight places including the first measurement position, the second measurement position, and the third measurement position.
[0016] In the normal detection method according to a fourth aspect of the invention to solve the above problems, non-contact sensors are used as the distance detectors.
[0017] A normal detection device related to a fifth aspect of the invention to solve the above problems includes one or a plurality of distance detectors that measure a distance to a measurement subject; and arithmetic means for representing a plurality of measurement points on the measured surface at a plurality of measurement positions by three-dimensional coordinates from the plurality of measurement positions where the distance detectors measure distances to the measurement subject, and a plurality of measurement results obtained by the distance detectors at the plurality of measurement positions, defining, as a first vector, a straight line connecting, on three-dimensional axes, a first measurement point measured at an arbitrary first measurement position among the plurality of measurement positions by the distance detector and a second measurement point measured at a second measurement position different from the first measurement position, defining, as a second vector, a straight line connecting, on three-dimensional axes, the first measurement point and a third measurement point measured at a third measurement position different from the first measurement position and the second measurement position, calculating a normal vector on the measured surface by an outer product of the first vector and the second vector, and calculating a machining vector passing through a setting point of a machining place using the calculated normal vector.
[0018] A machining machine provided with a normal detection function according to a sixth aspect of the invention to solve the above problems includes the normal detection device according to the fifth aspect of the invention, and three-dimensional posture control means for three-dimensionally controlling the posture of the normal detection device and a machining tool to be the machining vector calculated by the arithmetic means.
Advantageous Effects of Invention
[0019] According to the normal detection method related to the first invention, since the normal vector is calculated from the first vector and the second vector that are not parallel to each other and are different from each other, the normal vector can be obtained with high precision. Additionally, since the normal vector on the measured surface can be calculated from the measurement distances obtained by the distance detectors, when the normal detection method related to the invention is applied to a machining machine or the like, it is easy to automatically control the posture of a machining tool or the like of the machining machine, and it is possible to shorten the working hours, which are taken for controlling the posture of the machining tool or the like of the machining machine so that the machining direction or the like of the machining machine coincides with the normal vector on the measured surface.
[0020] According to the normal detection method related to the second invention, the first measurement position, the second measurement position, and the third measurement position are selected so that the area of the triangle made at the three points of the first measurement position, the second measurement position, and the third measurement position becomes the largest, and the first measurement position, the second measurement position, and the third measurement position are spaced apart from each other. Thus, the precision of the normal vector, which is calculated from the measurement distances at the first measurement position, the second measurement position, and the third measurement position obtained by the distance detectors, is improved.
[0021] According to the normal detection method related to the third invention, simultaneous measurements are allowed in eight places by using the eight distance detectors that are radially installed. As a result, even when some distance detectors cannot perform effective measurement due to holes, end surfaces, or the like, the normal vector can be obtained from the measurement distances obtained by the other distance detectors that can perform effective measurement.
[0022] According to the normal detection method related to the fourth invention, since the operation for bringing contact sensors into contact with a measurement subject is eliminated by using the non-contact sensors as the distance detectors, the working hours for obtaining the normal vector on the measured surface can be shortened.
[0023] According to the normal detection device related to the fifth invention, since the normal vector is calculated from the first vector and the second vector that are not parallel and are different, the normal vector can be obtained with high precision. Additionally, since the normal vector on the measured surface can be calculated from the measurement distances obtained by the distance detectors, when the normal detection device related to the invention is applied to a machining machine or the like, it is easy to automatically control the posture of a machining tool or the like of the machining machine, and it is possible to shorten the working hours, which are taken for controlling the posture of the machining tool or the like of the machining machine so that the machining direction or the like of the machining machine coincides with the normal vector on the measured surface.
[0024] According to the machining machine provided with a normal detection function related to the sixth invention, the normal vector on the measured surface is calculated by the normal detection device related to the fifth invention, and the posture of the machining tool is controlled in conformity with the calculated normal vector by the three-dimensional posture control means. Thus, the machining tool can be precisely and rapidly made to coincide with the normal vector, and machining in a precise normal direction can be processed.
BRIEF DESCRIPTION OF DRAWINGS
[0025] FIG. 1 is a conceptual diagram showing measurement using distance detectors related to Example 1.
[0026] FIG. 2 is a plan view (as seen from a direction of arrow II in FIG. 3 ) showing the arrangement of the distance detectors in a machining jig related to Example 1.
[0027] FIG. 3 is a side view as seen from a direction of arrow III of FIG. 2 .
[0028] FIG. 4 is a plan view (as seen from a direction of arrow IV in FIG. 5 ) showing the machining jig related to Example 1 to which a parallel jig is attached.
[0029] FIG. 5 is a side view as seen from a direction of arrow V of FIG. 4 .
[0030] FIG. 6 is a plan view (as seen from a direction of arrow VI in FIG. 7 ) showing the machining jig related to Example 1 to which an inclined jig is attached.
[0031] FIG. 7 is a side view as seen from a direction of arrow VII of FIG. 6 .
[0032] FIG. 8A is a schematic view showing an example of the selection of forming a triangle with a largest area, in the arrangement of the distance detectors in the machining jig related to Example 1.
[0033] FIG. 8B is a schematic view showing an example of the selection of forming a triangle with a second largest area, in the arrangement of the distance detectors in the machining jig related to Example 1.
[0034] FIG. 8C is a schematic view showing an example of the selection of forming a triangle with a third largest area, in the arrangement of the distance detectors in the machining jig related to Example 1.
[0035] FIG. 8D is a schematic view showing an example of the selection of forming a triangle with a fourth largest area, in the arrangement of the distance detectors in the machining jig related to Example 1.
[0036] FIG. 8E is a schematic view showing an example of the selection of forming a triangle with a fifth largest area, in the arrangement of the distance detectors in the machining jig related to Example 1.
DESCRIPTION OF EMBODIMENTS
[0037] Hereinafter, examples of a normal detection method related to the invention will be described in detail with reference to the attached drawings. Of course, it is obvious that the invention is not limited to the following examples but various changes can be made without departing from the concept of the invention.
Example 1
[0038] A normal detection method related to Example 1 of the invention will be described with reference to FIGS. 1 to 8 .
[0039] In the present example, a machining jig 10 including a normal detection mechanism is attached to a machining machine (not shown) so as to allow machining from a normal direction on a measured surface 21 of a measurement subject 20 that is a workpiece.
[0040] As shown in FIGS. 1 and 2 , the machining jig 10 includes non-contact sensors 30 that measure a distance to the measurement subject 20 , arithmetic means (not shown) for calculating a normal vector Vn and a machining vector Vm on the measured surface 21 from a measurement distance L obtained by the non-contact sensors 30 , and three-dimensional posture control means (not shown) for three-dimensionally controlling the posture of the machining jig 10 to be in a direction calculated by the arithmetic means, together with the machining machine (not shown). In the machining jig 10 of the present example, eight non-contact sensors 30 a , 30 b , 30 c , 30 d , 30 e , 30 f , 30 g , and 30 h are radially installed on a machining-side tip surface 11 of the machining jig 10 .
[0041] Additionally, the machining jig 10 includes a machining-side tip hole 12 through which a parallel jig 40 ( FIGS. 4 and 5 ) performing Z-direction correction in the non-contact sensors 30 a to 30 h installed in the machining jig 10 and an inclined jig 50 ( FIGS. 6 and 7 ) that performing X-direction and Y-direction correction in the non-contact sensors 30 a to 30 h installed in the machining jig 10 are attachable and detachable. Here, the Z direction is a measurement direction of the non-contact sensors 30 a to 30 h , the X direction is an arbitrary direction orthogonal to the Z direction, and the Y-direction is a direction orthogonal to the Z direction and the X direction. In addition, the machining-side tip hole 12 is also used as a hole that allows a machining part of the machining machine (not shown) to pass therethrough during machining.
[0042] The parallel jig 40 is a jig that performs the Z-direction correction in the non-contact sensors 30 a to 30 h , and as shown in FIGS. 4 and 5 , has an attachment cylindrical portion 41 to be fitted to the machining-side tip hole 12 of the machining jig 10 , and a Z-direction correction surface 42 that performs the Z-direction correction in the non-contact sensors 30 a to 30 h . If the attachment cylindrical portion 41 of the parallel jig 40 is inserted into the machining-side tip hole 12 of the machining jig 10 and the parallel jig 40 is fixed to the machining jig 10 , the Z-direction correction surface 42 perpendicularly intersects the Z direction that is a direction parallel to the machining-side tip surface 11 of the machining jig 10 , that is, the measurement direction of the non-contact sensors 30 a to 30 h , and is located at an arbitrary distance δz from the machining-side tip surface 11 of the machining jig 10 . In addition, since the Z-direction correction in the eight non-contact sensors 30 a to 30 h is performed, the Z-direction correction surface 42 is broad to such a degree that the eight non-contact sensors 30 a to 30 h can measure a distance to the Z-direction correction surface 42 .
[0043] The inclined jig 50 is a jig that performs the X-direction and Y-direction correction in the non-contact sensors 30 a to 30 h , and as shown in FIGS. 6 and 7 , has an attachment cylindrical portion 51 to be fitted to the machining-side tip hole 12 of the machining jig 10 , and an XY-direction correction surface 52 that performs the Z-direction correction in the non-contact sensors 30 a to 30 h . If the attachment cylindrical portion 51 is inserted into the machining-side tip hole 12 and the inclined jig 50 is fixed to the machining jig 10 , the XY-direction correction surface 52 forms an arbitrary angle θ with respect to the machining-side tip surface 11 of the machining jig 10 , and a central portion 53 of the XY-direction correction surface 52 is located at an arbitrary distance δxy from the machining-side tip surface 11 of the machining jig 10 . In addition, since the XY-direction correction in the eight non-contact sensors 30 a to 30 h is performed, the XY-direction correction surface 52 is broad to such a degree that the eight non-contact sensors 30 a to 30 h can measure a distance to the XY-direction correction surface 52 .
[0044] The XY-direction correction surface 52 can be attached so as to be parallel to the X direction by providing a protrusion (not shown) on an outer wall surface of the attachment cylindrical portion 51 of the inclined jig 50 , providing a first recess (not shown) in an inner wall surface of the machining-side tip hole 12 of the machining jig 10 and allowing the protrusion of the attachment cylindrical portion 51 of the inclined jig 50 and the first recess of the machining-side tip hole 12 of the machining jig 10 to engage with each other, and the XY-direction correction surface 52 can be attached so as to become parallel to the Y direction by providing a second recess (not shown) at a position rotated by 90° from the first recess in the circumferential direction in the inner wall surface of the machining-side tip hole 12 of the machining jig 10 and by allowing the protrusion of the attachment cylindrical portion 51 of the inclined jig 50 and the second recess of the machining-side tip hole 12 of the machining jig 10 to engage with each other.
[0045] First, the Z-direction correction in the non-contact sensors 30 a to 30 h installed in the machining jig 10 , using the machining jig 10 and the parallel jig 40 , will be described with reference to FIG. 5 .
[0046] The parallel jig 40 is attached to the machining jig 10 , and the distance to the Z-direction correction surface 42 of the parallel jig 40 is measured by the eight non-contact sensors 30 a to 30 h . The parallel jig 40 and the Z-direction correction surface 42 are formed so that the Z-direction correction surface 42 of the parallel jig 40 has the arbitrary distance 6 z from the machining-side tip surface 11 of the machining jig 10 , and are assembled to the machining jig 10 . Hence, the Z-direction correction in the eight non-contact sensors 30 a to 30 h can be performed by comparison with measurement distances Lza to Lzh to the Z-direction correction surface 42 obtained by the non-contact sensors 30 a to 30 h . That is, the installation positions of the eight non-contact sensors 30 a to 30 h in the Z direction with respect to the machining jig 10 can be precisely found out, relative errors caused by the assembling or the like of the eight non-contact sensors 30 a to 30 h to the machining jig 10 can be corrected for, and Z-direction distance measurement using the non-contact sensors 30 a to 30 h can be precisely performed.
[0047] Next, the X-direction correction in the non-contact sensors 30 a to 30 h installed in the machining jig 10 , using the machining jig 10 and the inclined jig 50 , will be described with reference to FIG. 7 .
[0048] The inclined jig 50 is attached to the machining jig 10 so that the XY-direction correction surface 52 becomes parallel to the Y direction, and the distance to the XY-direction correction surface 52 of the inclined jig 50 is measured by the eight non-contact sensors 30 a to 30 h . The inclined jig 50 and the XY-direction correction surface 52 are formed so that the XY-direction correction surface 52 has the arbitrary angle θ with respect to the machining-side tip surface 11 of the machining jig 10 and the central portion of the XY-direction correction surface has the arbitrary distance 6 xy from the machining-side tip surface 11 of the machining jig 10 , and are assembled to the machining jig 10 . Hence, the X-direction correction in the eight non-contact sensors 30 a to 30 h can be performed by calculation from measurement distances Lxa to Lxh obtained by the non-contact sensors 30 a to 30 h . That is, the installation positions Xa to Xh of the eight non-contact sensors 30 a to 30 h in the X direction with respect to the machining jig 10 can be precisely found out, relative errors caused by the assembling or the like of the eight non-contact sensors 30 a to 30 h to the machining jig 10 can be corrected for, and X-direction distance measurement using the non-contact sensors 30 a to 30 h can be precisely performed.
[0049] Next, the Y-direction correction in the non-contact sensors 30 a to 30 h installed in the machining jig 10 , using the machining jig 10 and the inclined jig 50 , will be described with reference to FIG. 7 .
[0050] The inclined jig 50 is attached to the machining jig 10 so that the XY-direction correction surface 52 becomes parallel to the X direction, and the distance to the XY-direction correction surface 52 of the inclined jig 50 is measured by the eight non-contact sensors 30 a to 30 h . The inclined jig 50 is formed so that the XY-direction correction surface 52 has the arbitrary angle θ and the central portion of the XY-direction correction surface has the arbitrary distance xy from the machining-side tip surface 11 of the machining jig 10 , and is assembled to the machining jig 10 . Hence, the Y-direction correction in the eight non-contact sensors 30 a to 30 h can be performed by calculation from measurement distances Lya to Lyh obtained by the non-contact sensors 30 a to 30 h . That is, the installation positions Ya to Yh of the eight non-contact sensors 30 a to 30 h in the Y direction with respect to the machining jig 10 can be precisely found out, relative errors caused by the assembling or the like of the eight non-contact sensors 30 a to 30 h to the machining jig 10 can be corrected for, and Y-direction distance measurement using the non-contact sensors 30 a to 30 h can be precisely performed.
[0051] Next, the normal detection method of obtaining the normal vector Vn on the measured surface 21 , using the machining jig 10 , will be described with reference to FIG. 1 .
[0052] The normal vector Vn is obtained by selecting three non-contact sensors from the eight non-contact sensors 30 a to 30 h installed in the machining jig 10 , and performing calculation from measurement distances La, Ld, and Lf obtained by non-contact sensors 30 a , 30 d , and 30 f of a selected combination to be described below, and installation positions (a first measurement position, a second measurement position, and a third measurement position) Pa (Xa, Ya), Pd (Xd, Yd), and Pf (Xf, Yf) of the non-contact sensors 30 a , 30 d , and 30 f of the selected combination.
[0053] Measurement distances La to Lh to the measurement subject 20 is measured using the eight non-contact sensors 30 a to 30 h installed in the machining jig 10 . In the eight non-contact sensors 30 a to 30 h installed in the machining jig 10 , the number of combinations of selecting three non-contact sensors is fifty six ways, and is five ways if being classified according to the areas of triangles made by the respective combinations.
[0054] For example, the number of combinations of obtaining triangles with a largest area is eight ways of selecting the non-contact sensors 30 a , 30 d , and 30 f , or the like, the number of combination of obtaining triangles with a second largest area is eight ways of selecting the non-contact sensors 30 a , 30 c , and 30 g , or the like, the number of combinations of obtaining triangles with a third largest area is sixteen ways of selecting the non-contact sensors 30 a , 30 b , and 30 f , or the like, the number of combinations of obtaining triangles with a fourth largest area is sixteen ways of selecting the non-contact sensors 30 a , 30 b , and 30 g , or the like, and the number of combinations of obtaining triangles with a smallest area is eight ways of selecting the non-contact sensors 30 a , 30 b , and 30 h , or the like.
[0055] All the measurement distances La to Lh to the measurement subject 20 measured by the eight non-contact sensors 30 a to 30 h are not necessarily effective. That is, a hole is made at measurement points Qa to Qh of the measurement subject 20 or the measurement points Qa to Qh deviate from an end portion of the measurement subject 20 . However, the measurement distances La to Lh that are measurement results by all the non-contact sensors 30 a to 30 h are not necessarily obtained, and it is sufficient if a required number of effective measurement distances La to Lh are valid. When a required number of effective measurement distances La to Lh are not value, the required number of effective measurement distances La to Lh are valid by slightly translating the machining jig 10 and performing measurement using the non-contact sensors 30 a to 30 h.
[0056] The non-contact sensors 30 a to 30 h to be used for the calculation of the normal detection are selected so that the area made by three non-contact sensors 30 selected from the non-contact sensors 30 a to 30 h by which the measurement distances La to Lh that are effective measurement results are obtained becomes the largest.
[0057] Measurement points (a first measurement point, a second measurement point, and a third measurement point) Qa, Qd, and Qf on the measured surface 21 to be measured by the non-contact sensors 30 a , 30 d , and 30 f of the selected combination are represented by three-dimensional coordinates from the installation positions Pa (Xa, Ya), Pd (Xd, Yd), and Pf (Xf, Yf) of the non-contact sensors 30 a , 30 d , and 30 f in XY directions, and the measurement distances La, Ld, and Lf obtained by the non-contact sensors 30 a , 30 d , and 30 f.
[0058] Measurement point Qa: (Xa, Ya, Za)
[0059] Measurement point Qd: (Xd, Yd, Zd)
[0060] Measurement point Of: (Xf, Yf, Zf)
[0061] A vector (first vector) Vad connecting the measurement point Qa and the measurement point Qd measured by two arbitrary non-contact sensors 30 a and 30 d among the non-contact sensors 30 a , 30 d , and 30 f of the selected combination, and a vector (second vector) Vaf connecting the measurement point Qa and measurement point Qf measured by two arbitrary non-contact sensors 30 a and 30 f among the non-contact sensors 30 a , 30 d , and 30 f of the selected combination are calculated on the basis of the three-dimensional coordinates.
[0000]
Vad
=
s
(
Xd
-
Xa
Yd
-
Ya
Zd
-
Za
)
+
(
Xa
Ya
Za
)
Vaf
=
t
(
Xf
-
Xa
Yf
-
Ya
Zf
-
Za
)
+
(
Xa
Ya
Za
)
[
Formula
1
]
[0062] Here, s and t are arbitrary real numbers.
[0063] The vector Vn that is an outer product of the vector Vad and the vector Vaf is calculated. The vector Vn is a direction vector orthogonal to the vector Vad and the vector Vaf, and represents a normal vector on the measured surface 21 .
[0000]
Vn
=
Vaf
×
Vad
=
u
(
(
Yf
-
Ya
)
(
Zd
-
Za
)
-
(
Yd
-
Ya
)
(
Zf
-
Za
)
(
Zf
-
Za
)
(
Xd
-
Xa
)
-
(
Zd
-
Za
)
(
Xf
-
Xa
)
(
Xf
-
Xa
)
(
Yd
-
Ya
)
-
(
Xd
-
Xa
)
(
Yf
-
Ya
)
)
+
(
Xa
Ya
Za
)
[
Formula
2
]
[0064] Here, u is an arbitrary real number.
[0065] The machining vector Vm passing through a set point Rm (Xm, Ym, Zm) of a machining place is calculated from the calculated normal vector Vn.
[0000]
Vm
=
v
(
(
Yf
-
Ya
)
(
Zd
-
Za
)
-
(
Yd
-
Ya
)
(
Zf
-
Za
)
(
Zf
-
Za
)
(
Xd
-
Xa
)
-
(
Zd
-
Za
)
(
Xf
-
Xa
)
(
Xf
-
Xa
)
(
Yd
-
Ya
)
-
(
Xd
-
Xa
)
(
Yf
-
Ya
)
)
+
(
Xm
Ym
Zm
)
[
Formula
3
]
[0066] Here, v is an arbitrary real number.
[0067] The posture of the machining jig 10 is controlled by three-dimensional posture control means so that the central axis of the machining jig 10 coincides with the obtained machining vector Vm. At this time, the measurement distances La, Ld, and Lf obtained by the opposed non-contact sensors 30 a , 30 d , and 30 f become the same value.
[0068] By virtue of the above-described normal detection method and three-dimensional posture control, the normal vector Vn on the measured surface 21 can be obtained with high precision, the orientation of the machining jig 10 and the orientation of a machining tool of the machining machine (not shown) can be made to coincide with the calculated normal vector Vn, and machining in a precise normal direction can be performed.
[0069] Additionally, the normal vector Vn on the measured surface 21 can also be obtained with higher precision not only by calculating the normal vector Vn from the measurement distances La, Ld, and Lf obtained by the non-contact sensors 30 a , 30 d , and 30 f of the selected combination and the installation positions Pa (Xa, Ya), Pd (Xd, Yd), and Pf (Xf, Yf) of the non-contact sensors 30 a , 30 d , and 30 f of the selected combination, but also, for example, by calculating a normal vector V′n from the measurement distances Lb, Le, and Lg obtained by the non-contact sensors 30 b , 30 e , and 30 g and the installation positions Pb (Xb, Yb), Pe (Xe, Ye), and Pg (Xg, Yg) of the non-contact sensors 30 b , 30 e , and 30 g of the selected combination, and taking the average of the plurality of normal vectors Vn and V′n.
[0070] In addition, by repeating the operation of the normal detection method and three-dimensional posture control of the present example, the normal vector Vn on the measured surface 21 can be obtained with higher precision, and the machining jig 10 and the machining tool of the machining machine (not shown) can be made to coincide with the normal vector Vn that is calculated with higher precision.
[0071] Since the normal detection is influenced by the measurement distances La to Lh obtained by the non-contact sensors 30 a to 30 h , precise measurement using the non-contact sensors 30 a to 30 h is required. Hence, in the present example, the X-direction, Y-direction, and Z-direction corrections of the eight non-contact sensors 30 a to 30 h attached to the machining jig 10 are performed. Of course, if precise measurement and installation using the non-contact sensors 30 are allowed in advance, the X-direction, Y-direction, and Z-direction corrections as in the present example are unnecessary.
[0072] In the present example, the eight non-contact sensors 30 a to 30 h are radially installed as distance detectors to perform the normal detection, but the invention is not limited to this. For example, by making the non-contact sensors 30 movable, the normal vector Vn may be calculated from a plurality of measurement results measured at a plurality of measurement positions by one non-contact sensor 30 or the normal vector Vn may be calculated from measurement results using contact sensors as the distance detectors.
[0073] Additionally, in the present example, the normal vector Vn is obtained using the machining jig 10 including the normal detection mechanism, but the invention is not limited to this. For example, the normal detection may be performed without using the machining jig 10 by providing the machining machine with the distance detectors, the arithmetic means, and the three-dimensional posture control means.
INDUSTRIAL APPLICABILITY
[0074] The normal detection method related to the invention can detect a normal vector on a target surface in a short time with high precision, and is very useful for the drilling that performs drilling in an aircraft main wing or the like.
REFERENCE SIGNS LIST
[0000]
10 : MACHINING JIG
11 : MACHINING-SIDE TIP SURFACE
12 : MACHINING-SIDE TIP HOLE
20 : MEASUREMENT SUBJECT
21 : MEASURED SURFACE
30 : NON-CONTACT SENSOR
40 : PARALLEL JIG
41 : ATTACHMENT CYLINDRICAL PORTION
42 : Z-DIRECTION CORRECTION SURFACE
50 : INCLINED JIG
51 : ATTACHMENT CYLINDRICAL PORTION
52 : XY-DIRECTION CORRECTION SURFACE
53 : CENTRAL PORTION | A normal detection method for measuring the distance to a measurement subject using one or more distance detectors, and obtaining a normal vector (Vn) on the measured surface of the measurement subject from the obtained measurement result (L), wherein: within a three-dimensional space, the straight line linking a first measurement point (Qa) measured at a first measurement position (Pa) using the distance detector and a second measurement point (Qd) measured at a second measurement position (Pd) different from the first measurement position (Pa) is set as a first vector (Vad); the straight line linking the first measurement point (Qa) and a third measurement point (Qf) measured at a third measurement position (Pf) different from the first measurement position (Pa) and the second measurement position (Pd) as a second vector (Vaf); and a normal vector (Vn) on the measured surface is obtained by determining the vector product of the first vector (Vad) and the second vector (Vaf). | 6 |
CLAIM OF PRIORITY
[0001] This application claims the priority of U.S. Ser. No. 62/118,777 filed on Feb. 20, 2015, the contents of which are fully incorporated herein by reference.
FIELD OF THE EMBODIMENTS
[0002] The invention and its embodiments relate to medical devices, namely an elastic band ligator. In particular, the present invention and its embodiments relate to an improved elastic band ligator for use in the treatment of hemorrhoids.
BACKGROUND OF THE EMBODIMENTS
[0003] Hemorrhoids are one of the most common issues in America today. Studies indicate that by the age of 50, 50% of Americans have been diagnosed with hemorrhoids. Hemorrhoids are clusters of swollen blood vessels that begin to swell into the alimentary canal of humans. At first hemorrhoids can easily go undetected, but if left alone can turn into the source of serious pain. Worse, if left unattended for a long enough period of time, hemorrhoids will begin to prolapse.
[0004] That is, untreated hemorrhoids will descend through the alimentary canal and extend through one's anus. Additionally, there exist “external” hemorrhoids which form not inside the alimentary canal, but around one's anus.
[0005] There are a number of different methods to treat and/or remove hemorrhoids, however, one such method, ligation, has gained popularity. Over the years, ligation is the act of closing off the blood vessels in the swollen hemorrhoid tissue. Over time, due to the lack of blood flow, the ligated hemorrhoid will eventually wither and fall off, painlessly. Ligation has been performed as early as 460 BC, however since then a number of apparatuses and methods have been developed to perform this task. That said, the prior art leaves a number of areas to be improved upon. For example, the devices taught by the prior art are notoriously difficult to operate with gloves on which is a prerequisite to ligating hemorrhoids. Further, the devices of the prior art are incapable of ligating hemorrhoids placed in the more remote areas of the alimentary canal.
[0006] Thus, there is a need for an elastic band ligation device that is easy to operate while wearing medical gloves, that also provides the ability to ligate the hard-to-reach places in a patient's alimentary canal. The present invention and its embodiments meet and exceed these objectives.
[0007] Review of related technology:
[0008] U.S. Pat. No. 5,741,273 pertains to an elastic band ligation device for that treatment of hemorrhoids. The device permits a doctor to band hemorrhoidal tissue without the help of an assistant and does not have to be attached to an aspirator. The device has the capability of suctioning tissue into a tubular member before banding. The device also has a plastic inner tubular member retains a stretched elastic band over a front end of an inner tubular member which extends for a sufficient length for insertion into the rectum of a patient. A plunger in the tubular member may be slid backwards to draw a suction in the tubular member to draw tissue in through the front end. A plastic outer pusher sleeve fits over the tubular member and is adapted to push the elastic band off the front end of the tubular member to capture the hemorrhoidal tissue drawn into the tubular member.
[0009] U.S. Patent Publication 2014/0121679 pertains to an elastic band ligation device for treating hemorrhoids and treatment method are provided. The device includes an inner tubular member for retaining an elastic band over the front end and the entire device is insertable into the rectum of a patient. The device is equipped with a plunger which generates suction for drawing hemorrhoidal tissue into the inner tubular member through the front end. A plastic outer tubular pusher sleeve has an arced configuration corresponding to the arcuate inner tubular member to provide a limited friction fit over the inner tubular member. The pusher sleeve is equipped with a thumb pusher to allow the outer tubular pusher sleeve to be pushed towards the front end of the inner tubular member and release the elastic band from the front end of the inner tubular member to engage hemorrhoidal tissue extending through the opening in the inner tubular member.
[0010] Various devices are known in the art. However, their structure and means of operation are substantially different from the present invention. Such devices fail to provide a device that can be easily operated through medical gloves and that provide a tool that can be used on a wider array of hemorrhoidal tissue. Further, the prior art teaches devices that are difficult to release suction with, provide for a poor fit within a patients rectum, and are so large that significant discomfort is caused in a patient being treated. At least one embodiment of this invention is presented in the drawings below and will be described in more detail herein.
SUMMARY OF THE EMBODIMENTS
[0011] The present invention provides for a medical device, comprising: an inner tube, having a wall and a flat tip, wherein said flat tip is comprised of an edge that is perpendicular to the walls of said inner tube; a pusher, complementarily shaped to said inner tube; and a receiving port, wherein said receiving port is configured to removably attach to a device capable of generating suction. Preferably, this device capable of generating suction is a luer lock syringe, and preferably said inner tube is embowed. In one embodiment, said pusher is permanently affixed to said inner tube and comes equipped with a plurality of protrusions. In some embodiments, the present invention is equipped with a reloader comprising: a conical frustum, an indentation, an a cylinder with at least one recessed flange.
[0012] In a preferred embodiment, the present invention is an elastic band ligation device, comprising: a curved inner tube, having a distal end, a proximate end, and a primary recessed flange located at said distal end; a pusher, wherein: said pusher is complementarily shaped to said curved inner tube, said pusher has a limited friction fit with the curved inner tube, said pusher is equipped with at least one protruding portion, and said pusher is equipped with a secondary recessed flange; and a receiving member, having an outer chamber, a receiving port located within said outer chamber, and a rear flange attached to said outer chamber, wherein said receiving port is configured to removably attach to a device capable of generating suction. In a preferred embodiment said pusher is capable of being extended at least 1 millimeter beyond the distal end of the inner rigid member.
[0013] In yet another embodiment, the present invention consists of a kit, comprising: a medical device, comprising: an inner tube, having a wall and a flat tip, wherein said flat tip is comprised of an edge that is perpendicular to the walls of said inner tube; a pusher, complementarily shaped to said inner tube; and a receiving port, wherein said receiving port is configured to removably couple to a device capable of generating suction; at least one elastic band; and a reloader, comprising: a bottom lip, a conical frustum section, a recessed flange, and a fitted opening, wherein said fitted opening is configured to receive the distal end of the curved inner tube.
[0014] Additionally, the present invention may be comprised of an inner tube, having a wall and a flat tip, wherein said flat tip is comprised of an edge that is perpendicular to the walls of said inner tube; a pusher, complementarily shaped to said inner tube; and a receiving port, wherein said receiving port is configured to removably attach to a syringe, preferably a luer lock syringe. In a preferred embodiment, this inner tube is embowed to allow for greater access to a patient's alimentary canal.
[0015] In yet another preferred embodiment, the inner tube and receiving port of the present invention are a single, unitary piece. This is intended to allow for the simplification of the manufacture of the present invention. In many embodiments, said pusher is engaged via a limited friction fit with the inner tube. This pusher may be equipped with a plurality of protrusions as well. In yet another preferred embodiment, the pusher is sized to extend at least one millimeter beyond the tip of the inner tube when extended.
[0016] The present invention also contemplates an elastic band reloader that works in conjunction with the medical device of the present invention. In a preferred embodiment, this reloader is comprised of a recessed flange, intended to be preloaded with an elastic band, a conical frustum section to allow for easy loading of the elastic band onto the medical device, and an indentation sized to receive the tip of the medical device of the present invention.
[0017] In general, the present invention succeeds in conferring the following, and other not mentioned, benefits and objectives.
[0018] The present invention has the benefit of the primary elastic band being preloaded on the device. This has the benefit of removing the difficult step found in the prior art, where an elastic band had to be manually loaded onto the ligator; something that is difficult while wearing medical gloves. Further, the embowed nature of the inner tube of the present invention allows for both easier insertion by the operator, and provides for increased comfort for the patient. Moreover, the inner tube of the present invention is significantly smaller than similar components found in the prior art, and said inner tube is equipped with a rounded flat tip, both of which provide for further increased comfort in a patient. Additionally, in a preferred embodiment, the present invention is entirely preassembled, providing for a sturdier product than that was is taught by the prior art.
[0019] It is an object of the present invention to provide a means for treating hemorrhoids.
[0020] It is an object of the present invention to provide a medical device.
[0021] It is an object of the present invention to provide an improved medical device for ligating hemorrhoids.
[0022] It is an object of the present invention to provide a medical device that is inexpensive and easy to use.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 is a front view of an embodiment of the present invention, wherein the present invention is removably attached to a standard luer lock syringe.
[0024] FIG. 2 is a front view of an embodiment of the invention, highlighting the removable nature of the present invention.
[0025] FIG. 3 is a perspective view of an embodiment of the invention.
[0026] FIG. 4 is a perspective view of an embodiment of the present invention, wherein the medical device of the present invention is interfacing with the reloader of the present invention.
[0027] FIG. 5 is a top view of an embodiment of the present invention, illustrating the reloading mechanism.
[0028] FIG. 6 is an illustration of the present invention in use is provided.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0029] The preferred embodiments of the present invention will now be described with reference to the drawings. Identical elements in the various figures are identified with the same reference numerals.
[0030] Reference will now be made in detail to each embodiment of the present invention. Such embodiments are provided by way of explanation of the present invention, which is not intended to be limited thereto. In fact, those of ordinary skill in the art may appreciate upon reading the present specification and viewing the present drawings that various modifications and variations can be made thereto.
[0031] Referring to FIG. 1 , a front view of an embodiment of the present invention is provided, wherein the present invention is removably attached to a standard luer lock syringe. Here, medical device 100 is shown. It is comprised of inner tube 101 , which may be permanently affixed to pusher 106 . Inner tube 101 is equipped with primary recessed flange 105 . Primary recessed flange 105 is intended to, when loaded, house at least one elastic band (not pictured). In a preferred embodiment, to account for a failed deployment of an elastic band from the primary recessed flange 105 , the present invention is equipped with secondary recessed flange 107 .
[0032] Secondary recessed flange may be equipped with an elastic band such that it can be easily slid down pusher 106 onto primary recessed flange 105 . This mechanism provides the additional benefit that it may be done easily while wearing medical gloves; something that is essential when hemorrhoid ligation is performed. In a preferred embodiment, medical device 100 is equipped with rear flange 102 . This makes handling the present invention easier. Another feature of this particular embodiment is flat tip 111 . Flat tip 111 allows for the consistent deployment of any elastic bands from primary recessed flange 105 . The inclusion of flat tip 111 is particularly important when inner tube 101 is embowed. This is because the embowment of inner tube 101 allows for medical device 100 to reach previously unreachable areas of a patient's alimentary canal. In a preferred embodiment, medical device 100 operates by interfacing with a device that is capable of generating suction 115 . Preferably, device capable of generating suction 115 is a luer lock syringe. Note that pusher 106 will engage with clicking stop point 118 such that it was informed the operator of the present invention that pusher 106 is in a position that provides for immediate deployment of at least one elastic band 117 (see FIG. 4 or 6 ). This is achieved by allowing pusher 106 to engage in a limited friction fit with inner tube 101 . This feature has the benefit of preventing misfires, as well as allowing the operator to be certain of medical device's 100 position before deploying at least one elastic band 117 . In an alternative embodiment, pusher 106 is equipped with bumps to allow for a tactile feel, increasing the dexterity in which medical device 100 may be operated with.
[0033] In one embodiment, once medical device 100 has interfaced with device capable of generating suction 115 , it is equipped with an elastic band. Note that at least one elastic band may be comprised of latex, or a non-latex material. Medical device 100 is subsequently inserted into a patient's anus into the patient's alimentary canal. It should be noted that medical device 100 is suitable for treating external hemorrhoids, however, this description of use is for treatment of internal hemorrhoids. Once inserted into the patients alimentary canal, flat tip 111 is placed in close proximity to said hemorrhoid and device capable of generating suction 115 will generate suction, resulting in said hemorrhoid being drawn into inner tube 101 . Once the hemorrhoid has been drawn into inner tube 101 , pusher 106 is engaged and pushed beyond flat tip 111 . This motion results in the loaded elastic band being wrapped around the base of said hemorrhoid. This placement of the elastic band will result in the hemorrhoid eventually falling off.
[0034] Referring to FIG. 2 , a front view of an embodiment of the invention is shown, highlighting the removable nature of the present invention. Specifically, viewing port 112 and receiving port 103 are highlighted. Receiving port 103 is the aspect of the invention that interfaces with device capable of generating suction 115 . When interfaced, these two components create a seal sufficient to support a vacuum capable of drawing a hemorrhoid within inner tube 101 . Viewing port 112 is a feature of the present invention so that a user attempting to interface receiving port 103 with device that is capable of generating suction 115 may have a visual aid. Outer chamber 116 exists to help preserve the seal between receiving port 103 and device capable of generating suction 115 . However, without the inclusion of viewing port 112 , outer chamber 116 would inhibit the ease of interfacing between receiving port 103 and device capable of generating suction 115 . This increases the efficiency of use of the present invention.
[0035] Also present in this figure are flat tip 111 , primary recessed flange 105 , inner tube 101 , pusher 106 , protrusions 114 .
[0036] To use an alternative embodiment of the present invention, first device capable of generating suction 115 , here a luer lock syringe, is screwed into receiving port 103 . This provides for a seal between receiving port 103 and the luer lock syringe, allowing a vacuum to be generated near flat tip 111 . Next, elastic band reloader 108 is accessed. If an elastic band is not present in cylinder with at least one recessed flange 109 , an elastic band should be placed there. Then, elastic band reloader is used to load an elastic band onto primary recessed flange 105 . Then, the luer lock syringe is engaged to draw the hemorrhoid inside of inner tube 101 . From there, pusher 106 is used to slide the elastic band over the hemorrhoid.
[0037] FIG. 3 shows a perspective view of an embodiment of the invention. FIG. 3 highlights the relationship between inner tube 101 and pusher 106 . Specifically, FIG. 3 shows that in a preferred embodiment, pusher 106 is shaped such that it creates a limited friction fit with inner tube 101 . Protrusions 114 are also shown in FIG. 3 . Protrusions 114 serve the purpose of providing a plurality of surfaces for a user to engage pusher 106 with. This is particularly beneficial in embodiments where inner tube 101 is embowed due to the fact that when in use, medical device 100 will likely be rotated after being inserted into a patient's alimentary canal. The embowment of inner tube 101 is also beneficial because it allows for a better fit around the patient's hemorrhoid, increasing the likelihood of success of the elastic band ligation. Having a plurality of protrusions will enable a user of medical device 100 to track the movement of the embowed inner tube 101 , as well as provide ample surfaces to engage pusher 106 with. It should be noted that in a preferred embodiment, the position of protrusions 114 should not obstruct viewing port 112 , and should not scrape against outer chamber 116 .
[0038] Referring to FIG. 4 , a perspective view of an embodiment of the present invention is provided, wherein the medical device of the present invention is interfacing with the reloader of the present invention. Medical device 100 interfaces with elastic band reloader 108 by having flat tip 111 inserted into indentation 113 . It is not imperative that any kind of seal be maintained at this junction, merely that the fit is tight enough that at least one elastic band 117 may be easily loaded onto primary recessed flange 105 (not shown) by sliding down conical frustum 110 . The elasticity of at least one elastic band 117 will hold at least one elastic band 117 to inner tube 101 (not shown) when loaded. In a preferred embodiment, at least one elastic band 117 is preloaded onto cylinder with at least one recessed flange 109 . In another preferred embodiment, elastic band loader 108 is shaped such that it may be used to load elastic bands onto secondary recessed flange 107 . There, pusher 106 would interface with indentation 113 , again forming a seal such that at least one elastic band 117 may slide down conical frustum 110 , as well as pusher 106 down to secondary recessed flange 107 (not shown). Also of note here is the relationship between receiving port 103 and viewing port 112 . In one embodiment, viewing port 112 is sized such that the entirety of receiving port 103 is visible through viewing port 112 .
[0039] In a preferred embodiment, secondary recessed flange 107 and elastic band reloader 108 are preloaded with elastic bands. In an alternative embodiment, secondary recessed flange 107 and primary recessed flange 105 are both preloaded with elastic bands. Preferably, these bands will be located on secondary recessed flange 107 and cylinder with at least one recessed flange 109 . There, flat tip 111 is inserted into indentation 113 . This creates a substantially flush surface between conical frustum 110 and inner tube 101 , providing for an easy means to load the elastic band onto primary recessed flange 105 .
[0040] Regarding FIG. 5 , a top view of an embodiment of the present invention is shown, illustrating the reloading mechanism. Here, the fact that more than one of the at least one elastic band 117 may be loaded onto cylinder with at least one recessed flange 109 , and that primary recessed flange 105 is also capable of receiving more than one of the at least one elastic band 117 . In an alternative embodiment, secondary recessed flange 107 is also capable of receiving more than one of the at least one elastic band 117 .
[0041] Referring to FIG. 6 , an illustration of the present invention in use is provided. The process illustrated here involved places flat tip 111 in close proximity to a hemorrhoid to be treated. Device capable of generating suction 115 then generates suction, drawing the hemorrhoid within inner tube 101 . Pusher 106 is subsequently engaged resulting in at least one elastic band 117 being wrapped around said hemorrhoid. The suction is then turned off and medical device 100 is removed from the patient. This view illustrates the benefit of protrusions 114 , as it gives a number of different surfaces to begin the deployment of at least one elastic band 117 .
[0042] When introducing elements of the present disclosure or the embodiment(s) thereof, the articles “a,” “an,” and “the” are intended to mean that there are one or more of the elements. Similarly, the adjective “another,” when used to introduce an element, is intended to mean one or more elements. The terms “including” and “having” are intended to be inclusive such that there may be additional elements other than the listed elements.
[0043] While the disclosure refers to exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the disclosure. In addition, many modifications will be appreciated by those skilled in the art to adapt a particular instrument, situation or material to the teachings of the disclosure without departing from the spirit thereof. Therefore, it is intended that the disclosure not be limited to the particular embodiments disclosed. | The application provides for an elastic band application ligation device. The following medical device medical device features an embowed inner tube, having a wall and a flat tip, a pusher which is complementarily shaped to said inner tube; and a receiving port, which is configured to removably attach to a device capable of generating suction. Preferably, this device capable of generating suction will be a disposable luer lock syringe. | 0 |
TECHNICAL FIELD
[0001] The present invention relates to an art of a ship maneuvering device.
BACKGROUND ART
[0002] Conventionally, a ship is known having an inboard motor (inboard engine, outboard drive) in which a pair of left and right engines are arranged inside a hull and power is transmitted to a pair of left and right outdrive devices arranged outside the hull. The outdrive devices are propulsion devices rotating screw propellers so as to propel the hull, and are rudder devices rotated concerning a traveling direction of the hull so as to make the hull turn.
[0003] Such outdrive devices are rotated with hydraulic steering actuators provided in the outdrive devices (for example, see the Patent Literature 1). Then, a rotation angle of each of the outdrive devices, that is, a steering angle is grasped based on detection results of an angle detection sensor and the like provided in a linkage mechanism constituting the outdrive device.
[0004] The ship has an operation means setting a traveling direction of the ship. The ship is controlled with a control device so as to travel to the direction set with the operation means.
PRIOR ART REFERENCE
Patent Literature
[0005] Patent Literature 1: the Japanese Patent Laid Open Gazette Hei. 1-285486
DISCLOSURE OF INVENTION
Problems to be Solved by the Invention
[0006] The operation means has an oblique sailing component determination unit and a turning component determination unit. Conventionally, when the oblique sailing component determination unit and the turning component determination unit are operated simultaneously, priority is not set and action of the hull is unnatural, whereby smooth maneuvering cannot be performed.
[0007] In consideration of the above problems, the purpose of the present invention is to provide a ship maneuvering device that can increase operation sensitivity and enables smooth operation when simultaneously operating the oblique sailing component determination unit and the turning component determination unit of an operation means.
Means for Solving the Problems
[0008] The problems to be solved by the present invention have been described above, and subsequently, the means of solving the problems will be described below.
[0009] According to the present invention, a ship maneuvering device includes a pair of left and right engines, rotation speed changing actuators independently changing engine rotation speeds of the pair of left and right engines, a pair of left and right outdrive devices respectively connected to the pair of left and right engines and rotating screw propellers so as to propel a hull, forward/reverse switching clutches disposed between the engines and the screw propellers, a pair of left and right steering actuators respectively independently rotating the pair of left and right outdrive devices laterally within a predetermined angle range, an operation means setting a traveling direction of a ship, an operation amount detection means detecting the operation amount of the operation means, and a control device controlling the rotation speed changing actuators, the forward/reverse switching clutches, and the steering actuators so as to travel to a direction set by the operation means. The control device calculates oblique sailing component propulsion power vectors for oblique sailing of the left and right outdrive devices and turning component propulsion power vectors for the turning from the operation amount of the operation means, and composes the oblique sailing component propulsion power vectors and the turning component propulsion power vectors of the left and right outdrive devices so as to calculates composition vectors, thereby calculating propulsion powers and directions of the left and right outdrive devices.
[0010] According to the present invention, when directions of the composition vector is within a range over a predetermined angle range of the outdrive device, the outdrive device is controlled so as to be made a predetermined limiting angle mode and the engine rotation speed is reduced to a set rotation speed.
[0011] According to the present invention, when the direction of the composition vector is within a range over a predetermined angle range of the outdrive device, a rotation angle of the outdrive device is fixed at a state of a predetermined limiting angle.
[0012] According to the present invention, when a direction of the composition vector is within a range over a predetermined angle range of the outdrive device, the engine rotation speed of the engine is reduced following reduction of a minor angle between the direction of the composition vector and a lateral direction of the hull.
Effect of the Invention
[0013] The present invention brings the following effects.
[0014] According to the present invention, in comparison with the case of calculating the propulsion powers and the directions of the left and right outdrive devices based on only the oblique sailing component propulsion power vectors and subsequently calculating the propulsion powers and the directions of the left and right outdrive devices based on only the turning component propulsion power vectors, by calculating the composition vectors based on the oblique sailing component propulsion power vectors and the turning component propulsion power vectors, smooth operation is obtained and operability is improved. Since the oblique sailing component propulsion power and the turning component propulsion power can be controlled independently, the components do not interfere with each other, whereby a turning moment generated at the time of the turning operation has always the same characteristics regardless of the input of the oblique sailing operation. Accordingly, in the ship having this control, accuracy of correction of the turning direction is improved.
[0015] According to the present invention, even if the direction of the composition vector is over the predetermined angle range of the outdrive device, the steering of the outdrive device can be corrected.
[0016] According to the present invention, when the direction of the composition vector is over the predetermined angle range of the outdrive devices, frequent change of the rotation angle and frequent switching of forward/reverse rotation of the outdrive device is prevented.
[0017] According to the present invention, when the direction of the composition vector is over the predetermined angle range of the outdrive devices, the switching of forward/reverse rotation of the outdrive devices can be performed smoothly.
BRIEF DESCRIPTION OF DRAWINGS
[0018] FIG. 1 is a drawing of a ship according to an embodiment of the present invention.
[0019] FIG. 2 is a left side view partially in section of an outdrive device according to the embodiment of the present invention.
[0020] FIG. 3 is a right side view partially in section of the outdrive device according to the embodiment of the present invention.
[0021] FIG. 4 is a drawing of an operation device.
[0022] FIG. 5 is a block diagram of a control device.
[0023] FIG. 6 is a flow chart of a calculation method of propulsion powers and directions of left and right outdrive devices.
[0024] FIG. 7(A) is a drawing of oblique sailing component propulsion power vectors of the outdrive devices. FIG. 7(B) is a drawing of turning component propulsion power vectors of the outdrive devices. FIG. 7(C) is a drawing of composition vectors of the outdrive devices.
[0025] FIG. 8 is a plan view of a rotation angle of the outdrive device.
[0026] FIG. 9 is a graph of relation of the angle of the composition vector and the rotation angle of the outdrive device.
[0027] FIG. 10 is a plan view of the rotation angle of the outdrive device.
[0028] FIG. 11 is a graph of relation of the rotation angle of the outdrive device and a reduction rate of an engine rotation speed.
DESCRIPTION OF NOTATIONS
[0029] 1 ship maneuvering device
[0030] 2 hull
[0031] 3 A and 3 B engines
[0032] 4 A and 4 B rotation speed changing actuators
[0033] 10 A and 10 B outdrive devices
[0034] 15 A and 15 B screw propellers
[0035] 16 A and 16 B forward/reverse switching clutches
[0036] 17 A and 17 B hydraulic steering actuators
[0037] 21 joystick (operation means)
[0038] 31 control device
[0039] 39 operation amount detection sensor (operation amount detection means)
[0040] T Atrans and T Btrans oblique sailing component propulsion power vectors
[0041] T Arot and T Brot turning component propulsion power vectors
[0042] T A and T B composition vectors
[0043] β angles of composition vectors
[0044] θ A and θ B rotation angles of outdrive devices
DETAILED DESCRIPTION OF THE INVENTION
[0045] Firstly, an explanation will be given on a ship maneuvering device according to an embodiment of the present invention.
[0046] As shown in FIGS. 1 , 2 and 3 , a ship maneuvering device 1 has a pair of left and right engines 3 A and 3 B, rotation speed changing actuators 4 A and 4 B independently changing engine rotation speeds N A and N B of the pair of left and right engines 3 A and 3 B, a pair of left and right outdrive devices 10 A and 10 B respectively connected to the pair of left and right engines 3 A and 3 B and rotating screw propellers 15 A and 15 B so as to propel a hull 2 , forward/reverse switching clutches 16 A and 16 B disposed between the engines 3 A and 3 B and the screw propellers 15 A and 15 B, a pair of left and right hydraulic steering actuators 17 A and 17 B respectively independently rotating the pair of left and right outdrive devices 10 A and 10 B laterally, electromagnetic valves 17 Aa and 17 Ba controlling hydraulic pressure in the hydraulic steering actuators 17 A and 17 B, a joystick 21 , accelerator levers 22 A and 22 B and an operation wheel 23 as operation means setting a traveling direction of the ship, an operation amount detection sensor 39 (see FIG. 5 ) as an operation amount detection means detecting an operation amount of the joystick 21 , operation amount detection sensor 43 A and 43 B (see FIG. 5 ) as operation amount detection means detecting operation amounts of the accelerator levers 22 A and 22 B, an operation amount detection sensor 44 (see FIG. 5 ) as an operation amount detection means detecting an operation amount of the operation wheel 23 , and a control device 31 (see FIG. 5 ) controlling the rotation speed changing actuators 4 A and 4 B, the forward/reverse switching clutches 16 A and 16 B, the hydraulic steering actuators 17 A and 17 B and the electromagnetic valves 17 Aa and 17 Ba so as to travel to a direction set by the joystick 21 , the accelerator levers 22 A and 22 B and the operation wheel 23 .
[0047] The engines 3 A and 3 B are arranged in a rear portion of the hull 2 as a pair laterally, and are connected to the outdrive devices 10 A and 10 B arranged outside the ship. The engines 3 A and 3 B have output shafts 41 A and 41 B for outputting rotation power.
[0048] The rotation speed changing actuators 4 A and 4 B are means controlling the engine rotation power, and changes a fuel injection amount of a fuel injection device and the like so as to control engine rotation speeds of the engines 3 A and 3 B.
[0049] The outdrive devices 10 A and 10 B are propulsion devices rotating the screw propellers 15 A and 15 B so as to propel the hull 2 , and are provided outside the rear portion of the hull 2 as a pair laterally. The pair of left and right outdrive devices 10 A and 10 B are respectively connected to the pair of left and right engines 3 A and 3 B. The outdrive devices 10 A and 10 B are rudder devices which are rotated concerning the traveling direction of the hull 2 so as to make the hull 2 turn. The outdrive devices 10 A and 10 B mainly include input shafts 11 A and 11 B, the forward/reverse switching clutches 16 A and 16 B, drive shafts 13 A and 13 B, final output shaft 14 A and 14 B, and the rotating screw propellers 15 A and 15 B.
[0050] The input shafts 11 A and 11 B transmit rotation power. In detail, the input shafts 11 A and 11 B transmit rotation power of the engines 3 A and 3 B, transmitted from the output shafts 41 A and 41 B of the engines 3 A and 3 B via universal joints 5 A and 5 B, to the forward/reverse switching clutches 16 A and 16 B. One of ends of each of the input shafts 11 A and 11 B is connected to corresponding one of the universal joints 5 A and 5 B attached to the output shafts 41 A and 41 B of the engines 3 A and 3 B, and the other end thereof is connected to corresponding one of the forward/reverse switching clutches 16 A and 16 B.
[0051] The forward/reverse switching clutches 16 A and 16 B are arranged between the engines 3 A and 3 B and the rotating screw propellers 15 A and 15 B, and switch rotation direction of the rotation power. In detail, the forward/reverse switching clutches 16 A and 16 B are rotation direction switching devices which switch the rotation power of the engines 3 A and 3 B, transmitted via the input shafts 11 A and 11 B and the like, to forward or reverse direction. The forward/reverse switching clutches 16 A and 16 B have forward bevel gears and reverse bevel gears which are connected to inner drums having disc plates, and pressure plates of outer drums connected to the input shafts 11 A and 11 B is pressed against the disc plates of the forward bevel gears or the reverse bevel gears so as to switch the rotation direction.
[0052] The drive shafts 13 A and 13 B transmit the rotation power. In detail, the drive shafts 13 A and 13 B are rotation shafts which transmit the rotation power of the engines 3 A and 3 B, transmitted via the forward/reverse switching clutches 16 A and 16 B and the like, to the final output shaft 14 A and 14 B. A bevel gear provided at one of ends of each of the drive shafts 13 A and 13 B is meshed with the forward bevel gear and the reverse bevel gear provided on corresponding one of the forward/reverse switching clutches 16 A and 16 B, and a bevel gear provided at the other end is meshed with a bevel gear provided on corresponding one of the final output shaft 14 A and 14 B.
[0053] The final output shaft 14 A and 14 B transmit the rotation power. In detail, the final output shaft 14 A and 14 B are rotation shafts which transmit the rotation power of the engines 3 A and 3 B, transmitted via the drive shafts 13 A and 13 B and the like, to the screw propellers 15 A and 15 B. As mentioned above, the bevel gear provided at one of ends of each of the final output shaft 14 A and 14 B is meshed with the bevel gear of corresponding one of the drive shafts 13 A and 13 B, and the other end is attached thereto with corresponding one of the screw propellers 15 A and 15 B.
[0054] The screw propellers 15 A and 15 B are rotated so as to generate propulsion power. In detail, the screw propellers 15 A and 15 B are driven by the rotation power of the engines 3 A and 3 B transmitted via the final output shaft 14 A and 14 B and the like so that a plurality of blades arranged around the rotation shafts paddle surrounding water, whereby the propulsion power is generated.
[0055] The hydraulic steering actuators 17 A and 17 B are hydraulic devices which drive steering arms 18 A and 18 B so as to rotate the outdrive devices 10 A and 10 B. The hydraulic steering actuators 17 A and 17 B are provided therein with the electromagnetic valves 17 Aa and 17 Ba for controlling hydraulic pressure, and the electromagnetic valves 17 Aa and 17 Ba are connected to the control device 31 .
[0056] The hydraulic steering actuators 17 A and 17 B are so-called single rod type hydraulic actuators. However, the hydraulic steering actuators 17 A and 17 B may alternatively be double rod type.
[0057] The joystick 21 as the operation means is a device determining the traveling direction of the ship, and is provided near an operator's seat of the hull 2 . A plane operation surface of the joystick 21 is an oblique sailing component determination part 21 a, and a torsion operation surface thereof is a turning component determination part 21 b.
[0058] The joystick 21 can be moved free within the operation surface parallel to an X-Y plane shown in FIG. 4 , and a center of the operation surface is used as a neutral starting point. Longitudinal and lateral directions in the operation surface correspond to the traveling direction, and an inclination amount of the joystick 21 corresponds to a target hull speed. The target hull speed is increased corresponding to increase of the inclination amount of the joystick 21 .
[0059] The torsion operation surface is provided with the joystick 21 , and by twisting the joystick 21 concerning a Z axis extended substantially perpendicularly to the plane operation surface as a turning axis, a turning speed can be changed. A torsion amount of the joystick 21 corresponds to a target turning speed. A maximum target lateral turning speed is set at fixed turning angle positions of the joystick 21 .
[0060] The accelerator levers 22 A and 22 B as the operation means are devices determining the target hull speed of the ship, and are provided near the operator's seat of the hull 2 . The two accelerator levers 22 A and 22 B are provided so as to correspond respectively to the left and right engines 3 A and 3 B. The rotation speed of the engine 3 A is changed by operating the accelerator lever 22 A, and the rotation speed of the engine 3 B is changed by operating the accelerator lever 22 B.
[0061] The operation wheel 23 as the operation means is a device determining the traveling direction of the ship, and is provided near the operator's seat of the hull 2 . The traveling direction is changed widely following increase of a rotation amount of the operation wheel 23 .
[0062] A correction control start switch 42 (see FIG. 5 ) is a switch for starting correction control of turning action of the hull 2 .
[0063] The correction control start switch 42 is provided near the joystick 21 and is connected to the control device 31 .
[0064] Next, an explanation will be given on various kinds of detection means referring to FIG. 5 .
[0065] Rotation speed detection sensors 35 A and 35 B as rotation speed detection means are means for detecting engine rotation speeds N A and N B of the engines 3 A and 3 B and are provided in the engines 3 A and 3 B.
[0066] An elevation angle sensor 36 as an elevation angle detection means is a means for detecting an elevation angle a of the hull 2 . The elevation angle indicates inclination of the hull in the water concerning a flow.
[0067] A hull speed sensor 37 as a hull speed detection means is a means for detecting a hull speed V, and is an electromagnetic log, a Doppler sonar or a GPS for example.
[0068] Lateral rotation angle detection sensors 38 A and 38 B as lateral rotation angle detection means are means for detecting lateral rotation angles θ A and θ B of the outdrive devices 10 A and 10 B. The lateral rotation angle detection sensors 38 A and 38 B are provided near the hydraulic steering actuators 17 A and 17 B, and detect the lateral rotation angles θ A and θ B of the outdrive devices 10 A and 10 B based on the drive amounts of the hydraulic steering actuators 17 A and 17 B.
[0069] The operation amount detection sensor 39 as the operation amount detection means is a sensor for detecting the operation amount in the plane operation surface and the operation amount in the torsion operation surface of the joystick 21 . The operation amount detection sensor 39 detects an inclination angle and an inclination direction of the joystick 21 . The operation amount detection sensor 39 detects the torsion amount of the joystick 21 .
[0070] The operation amount detection sensors 43 A and 43 B as the operation amount detection means are sensors for detecting the operation amounts of the accelerator levers 22 A and 22 B. The operation amount detection sensors 43 A and 43 B detect inclination angles of the accelerator levers 22 A and 22 B.
[0071] The operation amount detection sensor 44 as the operation amount detection means is a sensor for detecting the operation amount of the operation wheel 23 . The operation amount detection sensor 44 detects the rotation amount of the operation wheel 23 .
[0072] Outdrive device rotation speed detection sensors 40 A and 40 B as rotation speed detection means of the outdrive devices 10 A and 10 B are sensors for detecting rotation speeds of the screw propellers 15 A and 15 B of the outdrive devices 10 A and 10 B, and are provided at middle portions of the final output shaft 14 A and 14 B. The outdrive device rotation speed detection sensors 40 A and 40 B detect outdrive device rotation speeds ND A and ND B .
[0073] The control device 31 controls the rotation speed changing actuators 4 A and 4 B, the forward/reverse switching clutches 16 A and 16 B and the hydraulic steering actuators 17 A and 17 B so that the ship travels to the direction set by the joystick 21 . The control device 31 is connected respectively to the rotation speed changing actuators 4 A and 4 B, the forward/reverse switching clutches 16 A and 16 B, the hydraulic steering actuators 17 A and 17 B, the electromagnetic valves 17 Aa and 17 Ba, the joystick 21 , the accelerator levers 22 A and 22 B, the operation wheel 23 , the rotation speed detection sensors 35 A and 35 B, the elevation angle sensor 36 , the hull speed sensor 37 , the lateral rotation angle detection sensors 38 A and 38 B, the operation amount detection sensor 39 , the operation amount detection sensors 43 A and 43 B, the operation amount detection sensor 44 , and the outdrive device rotation speed detection sensors 40 A and 40 B. The control device 31 includes a calculation means 32 having a CPU (central processing unit) and a storage means 33 such as a ROM, a RAM or a HDD.
[0074] Next, an explanation will be given on a method for calculating the propulsion powers and directions of the left and right outdrive devices 10 A and 10 B with the control device 31 referring to FIG. 6 .
[0075] Firstly, an operation amount of the joystick 21 is detected (step S 10 ), and based on the operation amount of the joystick 21 , oblique sailing component propulsion power vectors T Atrans and T Btrans for the oblique sailing and turning component propulsion power vectors T Arot and T Brot for the turning of the left and right outdrive devices 10 A and 10 B are calculated respectively (step S 20 ).
[0076] The operation amount of the joystick 21 is the inclination angle, the inclination direction and a torsion amount of the joystick 21 , and detected with the operation amount detection sensor 39 . Then, based on the operation amounts, the control device 31 calculates the oblique sailing component propulsion power vectors T Atrans and T Btrans for the oblique sailing and the turning component propulsion power vectors T Arot and T Brot for the turning of the left and right outdrive devices 10 A and 10 B. The oblique sailing component propulsion power vectors T Atrans and T Btrans of the left and right outdrive devices 10 A and 10 B are calculated as shown in FIG. 7(A) . The turning component propulsion power vectors T Arot and T Brot of the left and right outdrive devices 10 A and 10 B are calculated as shown in FIG. 7(B) .
[0077] Next, the oblique sailing component propulsion power vectors T Atrans and T Btrans and the turning component propulsion power vectors T Arot and T Brot of the left and right outdrive devices 10 A and 10 B are composed respectively so as to calculate the propulsion powers and the directions of the left and right outdrive devices 10 A and 10 B (step S 30 ).
[0078] As shown in FIG. 7(C) , vectors T A and T B are calculated by composing the oblique sailing component propulsion power vectors T Atrans and T Btrans and the turning component propulsion power vectors T Arot and T Brot of the left and right outdrive devices 10 A and 10 B calculated at the step S 20 .
[0079] Next, based on norms of the composited vectors T A and T B , the control device 31 calculates a rotation speed N of each of the left and right engines 3 A and 3 B (step S 40 ), the forward/reverse switching clutches 16 A and 16 B are switched, and the left and right engines 3 A and 3 B are driven. Based on the directions of the composited vectors T A and T B , the lateral rotation angles θ A and θ B of the outdrive devices 10 A and 10 B are calculated respectively (step S 50 ), and the hydraulic steering actuators 17 A and 17 B are driven.
[0080] Next, an explanation will be given on a process of restriction of the lateral rotation angles of the pair of left and right outdrive devices 10 A and 10 B at the calculation of the rotation angles θ A and θ B at the step S 50 . Since the same process is performed concerning the pair of left and right outdrive devices 10 A and 10 B, the process of restriction of the lateral rotation angle of the one outdrive device 10 A is described.
[0081] When the angle (direction) β of the composition vectors T A is over a predetermined angle range of the outdrive device 10 A at the step S 50 in the flow chart, the outdrive device 10 A is controlled so as to be at a predetermined limiting angle mode.
[0082] Herein, the predetermined angle range is a range shown with slashes in FIG. 8 , and is an angle range in which the outdrive device 10 A can be rotated. Since the hydraulic steering actuator 17 A is constructed by a hydraulic cylinder and its rotation range is limited, the predetermined angle range is provided. When the predetermined angle range is referred to as θ 1 , a limiting angle is referred to as α, and the rear side is regarded as 0°, the relation thereof is −α<θ 1 ≦α. Since the rotation of the engine 3 A can be switched between forward and reverse rotations with the forward/reverse switching clutch 16 A, centering on the front side, in other words,) 180° (−180°), the lateral angle is −180°<θ 1 ≦180°−(−α), 180°−α<θ 1 ≦180°. For example, when α is 30°, the predetermined angle range is −180°<θ 1 ≦−150°, −30°<θ 1 ≦30°, 150°<θ 1 ≦180°.
[0083] Next, an explanation will be given on the limiting angle mode.
[0084] In the limiting angle mode, for obtaining smooth action following the operation of the joystick 21 , the driving is performed with reduced propulsion power. Namely, the engine rotation speed N A is reduced to a set rotation speed N set . In the limiting angle mode, the rotation angle θ A of the outdrive device 10 A is fixed at a state of a predetermined limiting angle. Concretely, by the angle (direction) β of the composition vectors T A determined with the control device 31 , the lateral rotation angle θ A of the outdrive device 10 A is determined. As shown in FIG. 9 , in the case in which an X axis indicates the angle β of the composition vector T A and a Y axis indicates the lateral rotation angle θ A of the outdrive device 10 A, when the angle β of the composition vector T A is within a range of −180°−(−α)<β≦−90°, the lateral rotation angle θ A of the outdrive device 10 A is −180°−(−α). When the angle β of the composition vector T A is within a range of −90°<β≦−α, the lateral rotation angle θ A of the outdrive device 10 A is (−α). When the angle β of the composition vector T A is within a range of α<β≦90°, the lateral rotation angle θ A of the outdrive device 10 A is α. When the angle β of the composition vector T A is within a range of 90°<β≦180°−α, the lateral rotation angle θ A of the outdrive device 10 A is 180°−α.
[0085] As shown in FIG. 9 , in the limiting angle mode, a play tolerance (hysteresis) is set so as to prevent frequent change of the rotation angle θ A of the outdrive device 10 A.
[0086] In the case in which the angle β of the composition vector T A is within a range of −180°−(−α)<β≦−90°, when the angle β of the composition vector T A is larger than −90°+γ, the rotation angle θ A of the outdrive device 10 A is (−α). In the case in which the angle β of the composition vector T A is within a range of −90°<β≦−α, when the angle β of the composition vector T A is not more than −90°−γ, the rotation angle θ A of the outdrive device 10 A is −180°−(−α).
[0087] In the case in which the angle β of the composition vector T A is within a range of α<β≦90°, when the angle β of the composition vector T A is larger than 90°+γ, the rotation angle θ A of the outdrive device 10 A is 180°−α. In the case in which the angle β of the composition vector T A is within a range of 90°<β≦180°−α, when the direction of the composition vector T A is not more than 90°−γ, the rotation angle θ A of the outdrive device 10 A is α.
[0088] In the limiting angle mode, the engine rotation speed N A of the engine 3 A may alternatively be reduced following reduction of a minor angle between the direction of the composition vector T A and the lateral direction of the hull 2 . Following the reduction of the angle between the direction of the composition vector T A and the lateral direction of the hull (90° and −90°), that is, following approach of the angle β of the composition vector T A to 90° or −90°, the engine rotation speed N A of the engine 3 A is reduced.
[0089] As shown in FIGS. 10 and 11 , in the limiting angle mode, by increasing a rotation reduction rate of the engine 3 A, the engine rotation speed N A is reduced.
[0090] An area shown with slashes in FIG. 10 is a rotation speed reduction area in which the engine rotation speed N A is reduced gradually, and a colored area is a reduction rate 100% area in which the reduction rate of the engine rotation speed N A is 100%.
[0091] Concretely, as shown in FIG. 11 , within a range larger than −180°−(−α) and not more than Φ1, the reduction rate is increased following the increase of the angle β of the composition vector T A , and at Φ1, the reduction rate is 100%, that is, the engine rotation speed N A is a low idling rotation speed.
[0092] When the angle β of the composition vector T A is larger than Φ1 and not more than Φ2, the reduction rate is maintained at 100%.
[0093] When the angle β of the composition vector T A is larger than Φ2 and not more than −α, the reduction rate is reduced following the increase of the angle β. At −α, the reduction rate is 0%, that is, the engine rotation speed N A is the engine rotation speed calculated at the step S 40 .
[0094] Herein, Φ1 and Φ2 are angles are linearly symmetrical with −90°. For example, when Φ1 is −100°, Φ2 is −80°.
[0095] When the angle β of the composition vector T A is larger than α and not more than Φ3, the reduction rate is increased following the increase of the angle β. At Φ3, the reduction rate is 100%, that is, the engine rotation speed N A is the low idling rotation speed.
[0096] When the angle β of the composition vector T A is larger than Φ3 and not more than Φ4, the reduction rate is maintained at 100%.
[0097] When the angle β of the composition vector T A is larger than Φ4 and not more than 180°−α, the reduction rate is reduced following the increase of the angle β. At 180°−α, the reduction rate is 0%, that is, the engine rotation speed N A is the engine rotation speed calculated at the step S 40 .
[0098] Herein, Φ3 and Φ4 are angles are linearly symmetrical with 90°. For example, when Φ3 is 80°, Φ4 is 100°.
[0099] Φ1, Φ2, Φ3 and Φ4 can be changed within the ranges of −180°−(−α)≦Φ1<−90°, −90°≦Φ2<−α, α≦Φ3<90°, and 90°≦Φ4<180°−α.
[0100] As mentioned above, the ship maneuvering device 1 has the pair of left and right engines 3 A and 3 B, the rotation speed changing actuators 4 A and 4 B independently changing engine rotation speeds N of the pair of left and right engines 3 A and 3 B, the pair of left and right outdrive devices 10 A and 10 B respectively connected to the pair of left and right engines 3 A and 3 B and rotating the screw propellers 15 A and 15 B so as to propel the hull 2 , the forward/reverse switching clutches 16 A and 16 B disposed between the engines 3 A and 3 B and the screw propellers 15 A and 15 B, the pair of left and right hydraulic steering actuators 17 A and 17 B respectively independently rotating the pair of left and right outdrive devices 10 A and 10 B laterally, the joystick 21 setting the traveling direction of the ship, the operation amount detection sensor 39 detecting the operation amount of the joystick 21 , and the control device 31 controlling the rotation speed changing actuators 4 A and 4 B, the forward/reverse switching clutches 16 A and 16 B, and the hydraulic steering actuators 17 A and 17 B so as to travel to a direction set by the joystick 21 . From the operation amount of the joystick 21 , the control device 31 calculates the oblique sailing component propulsion power vectors T Atrans and T Btrans for the oblique sailing of the left and right outdrive devices 10 A and 10 B and the turning component propulsion power vectors T Arot and T Brot for the turning, and composes the oblique sailing component propulsion power vectors T Atrans and T Btrans and the turning component propulsion power vectors T Arot and T Brot of the left and right outdrive devices 10 A and 10 B so as to calculates the composition vectors T A and T B , thereby calculating the propulsion powers and the directions of the left and right outdrive devices 10 A and 10 B.
[0101] According to the construction, in comparison with the case of calculating the propulsion powers and the directions of the left and right outdrive devices 10 A and 10 B based on only the oblique sailing component propulsion power vectors T Atrans and T Btrans and subsequently calculating the propulsion powers and the directions of the left and right outdrive devices 10 A and 10 B based on only the turning component propulsion power vectors T Arot and T Brot , by calculating the composition vectors T A and T B based on the oblique sailing component propulsion power vectors T Atrans and T Btrans and the turning component propulsion power vectors T Arot and T Brot , the final propulsion powers and the final directions can be calculated, whereby smooth operation is obtained without setting priority and operability is improved.
[0102] When the angle β of the composition vector T A (T B ) is over the predetermined angle range of the outdrive devices 10 A and 10 B, the outdrive devices 10 A and 10 B are controlled so as to be made the predetermined limiting angle mode and the engine rotation speed N A (N B ) is reduced to the set rotation speed N set .
[0103] According to the construction, even if the angle β of the composition vector T A (T B ) is over the predetermined angle range of the outdrive device 10 A ( 10 B), the steering of the outdrive devices 10 A ( 10 B) can be corrected.
[0104] When the angle β of the composition vector T A (T B ) is over the predetermined angle range of the outdrive device 10 A ( 10 B), the rotation angle θ A (θ B ) of the outdrive device 10 A ( 10 B) is fixed at the state of the predetermined limiting angle.
[0105] According to the construction, when the angle of the composition vector T A (T B ) is over the predetermined angle range of the outdrive devices 10 A ( 10 B), frequent change of the rotation angle and frequent switching of forward/reverse rotation of the outdrive device 10 A ( 10 B) is prevented.
[0106] When the angle β of the composition vector T A (T B ) is over the predetermined angle range of the outdrive device 10 A ( 10 B), the engine rotation speed N A (N B ) of the engine 3 A ( 3 B) is reduced following the reduction of the minor angle between the direction β of the composition vector T A (T B ) and the lateral direction of the hull.
[0107] According to the construction, when the angle β of the composition vector T A (T B ) is over the predetermined angle range of the outdrive devices 10 A ( 10 B), the switching of forward/reverse rotation of the outdrive devices 10 A ( 10 B) can be performed smoothly.
INDUSTRIAL APPLICABILITY
[0108] The present invention can be used for a ship having an inboard motor in which a pair of left and right engines are arranged inside a hull and power is transmitted to a pair of left and right outdrive devices arranged outside the hull. | Provided is a ship maneuvering device that can increase operation sensitivity and enables smooth operation when simultaneously operating the rotation component determination unit and the oblique sailing component determination unit of an operation means. In the ship maneuvering device 1, a control device 31 computes a rotation component propulsion vector Trot for rotation and an oblique sailing component propulsion vector T trans for oblique sailing for left and right out-drive units 10 A, 10 B from the amount of operation of a joystick 21, calculates the combined torque T by combining the rotation component propulsion vector T rot and the oblique sailing component propulsion vector T trans for each of the left and right out-drive units 10 A, 10 B, and computes the propulsion and orientation for each of the left and right out-drive units 10 A, 10 B. | 1 |
FIELD OF THE INVENTION
[0001] The present invention relates to the substituted 3,7-diazabicyclo[3.3.1]nonane (commonly known as bispidine) carboxamides based molecules as antithrombotic (anti-platelet agents) agents. The present invention also relates to the use of these moieties as inhibitors of collagen induced platelet adhesion and aggregation mediated through collagen receptors. Further, the present invention also relates this class of compound exhibiting anti-platelet efficacy through dual mechanism inhibited both collagen as well as U46619 (thromboxane receptor agonist) induced platelet aggregation. The present invention further relates to the process and preparation of substituted 3,7-diazabicyclo[3.3.1]nonane (commonly known as bispidine) carboxamides based molecules.
BACKGROUND OF THE INVENTION
[0002] The curiosity in the designing of cyclic diamine scaffold stems from the finding of nipecotamide analogs as platelet aggregation inhibitors induced by ADP (Lasslo A et. al., Med. Prog. Technol. 1986; 11: 109; Folie B J et. al., Blood, 1989; 72: 1393), collagen (Lasslo A et. al., Am. Soc. Art. Int. Organs 1983; 6: 47), thrombin (Petrusewicz J et. al., Biochim. Biophys. Acta 1989; 983: 161), epinephrine (Gollamudi R et. al., Thromb. Haemostas. 1993; 69: 1322) and the stable TxA2 mimetic in vitro (Gollamudi R et. al., Thromb. Res. 1993; 69: 361).
[0003] Amides of N-substituted pyroglutamic acids have been reported as moderate inhibitor of thrombin (Dikshit et al, 2001 Indian Patent 1206/DEL/2001) and have shown anti-thrombotic activity in mice model of thrombosis. Watson et al used the amides of piperidine and the more lipophilic bispidine unit to prepare N-substituted pyrrolidine analogues (Fig. A) as potent, selective factor Xa inhibitor with good anticoagulant activity (Nigel S Watson et. al., Bioorganic & Medicinal Chemistry Letters 2006; 16: 3784-3788). Further, N-acetylated bispidine derived compounds (Fig. B) were found to be useful in the treatment of cardiac arrhythmias (U.S. Pat. No. 6,887,881 BI). Moreover, many amino acid and peptidyl derivatives having 3 or 4-aminomethyl-1-amidinopiperidine were reported as potential antithrombotics (U.S. Pat. No. 6,255,301).
[0000]
[0004] With the recognition that a high frequency of treatment failures occur with single anti-platelet therapy, there has been a strong push for the routine use of more intensive anti-platelet therapy that includes Aspirin and Clopidogrel. However, individuals receiving the therapy reportedly suffer from bleeding risk, thereby prompting a reevaluation of antithrombotic regimens that can maximize efficacy without increasing the risk of bleeding. A great deal of insight has been gained into the contribution of collagen, thromboxane A 2 (TxA 2 ) and their respective receptors and signaling mechanism in promoting platelet adhesion, activation and subsequent thrombus growth and stability. Hence, targeting against the synergy between collagen and TxA 2 mediated platelet activation pathway could prove to be novel and very useful in terms of improving the outcome of high intensity antithrombotic therapy.
[0005] Considering the structural features of nipecotamides and the highly promising activity of pyroglutamic acid derived amides synthesized in our laboratory, the proposed work focuses to introduce rigidity in the nipecotamide by incorporating them in bicyclic diamine framework, and to put various acyl, alkyl and aryl residues at the 3 rd and 7 th nitrogens of bispidine. Further, we also proposed bispidine acylated with some protected, hydrophobic amino acids, expecting enhanced activity. Confirmationally rigid systems such as bispidines can provide required orientation to the molecules so that it could easily arrange itself to interact with the enzyme and prevent the hydrophobic collapse.
OBJECT OF THE INVENTION
[0006] The main object of the present invention is to provide 3,7-diazabicyclo[3.3.1]nonane carboxamides of general formula 1 and process for preparation thereof.
[0007] Another object of the present invention is to provide compounds of formula 1, having significant anti-thrombotic activity both in vivo and in vitro.
[0008] Further object of the invention is to relate this class of compound of formula 1, exhibiting anti-platelet efficacy through dual mechanism inhibiting both collagen as well as U46619 (thromboxane receptor agonist) induced platelet aggregation.
SUMMARY OF THE INVENTION
[0009] Accordingly, the present invention provides a compound of general formula 1;
[0000]
wherein, R′ is;
[0000]
wherein R is selected from alkyl, acyl, tosyl, tert-butyloxycarbonyl, araalkyl or substituted araalkyl groups; R″ is selected preferably from halogen, cyano, lower alkyl, aryl, substituted aryl and tosyl groups; R 1 is selected from hydrogen and lower alkyl groups; R 2 is selected from lower alkyl and aryl groups; R 3 is selected from tert-butyloxycarbonyl and bezyloxycarbonyl groups; n=0,1
[0012] In an embodiment of the present invention, the representative compounds of general formula 1 comprising;
1. tert-butyl 7-(1-Benzyl-5-oxo-pyrrolidine-2-carbonyl)-3,7-diaza-bicyclo[3.3.1]nonane-3-carboxylate, (1a) 2. tert-butyl 7-[1-(2-Bromo-benzyl)-5-oxo-pyrrolidine-2-carbonyl]-3,7-diaza-bicyclo[3.3.1]nonane-3-carboxylate, (1b) 3. 1-Benzyl-5-(7-benzyl-3,7-diaza-bicyclo[3.3.1]nonane-3-carbonyl)-pyrrolidin-2-one, (1c) 4. (5S)-5-(7-Benzyl-3,7-diaza-bicyclo[3.3.1]nonane-3-carbonyl)-1-(2-bromo-benzyl)-pyrrolidin-2-one, (1d) 5. tert-butyl 7-[1-(4-Methyl-benzyl)-5-oxo-pyrrolidine-2-carbonyl]-3,7-diaza-bicyclo[3.3.1]nonane-3-carboxylate, (1e) 6. (5S)-5-(7-Benzyl-3,7-diaza-bicyclo[3.3.1]nonane-3-carbonyl)-1-(4-methyl-benzyl)-pyrrolidin-2-one, (1j) 7. (5 S)-5-(7-benzyl-3,7-diazabicyclo[3.3.1]nonane-3-carbonyl)-1-(2,6-dichlorobenzyl) pyrrolidin-2-one, (1g) 8. (5S)-5-(7-benzyl-3,7-diazabicyclo[3.3.1]nonane-3-carbonyl)-1-(4-chlorobenzyl)pyrrolidin-2-one, (1h) 9. (5 S)-5-(7-benzyl-3,7-diazabicyclo[3.3.1]nonane-3-carbon yl)-1-tosylpyrrolidin-2-one, (1i) 10. tert-butyl 7-((S)-1-(4-cyanobenzyl)-5-oxopyrrolidine-2-carbonyl)-3,7-diazabicyclo[3.3.1]nonane-3-carboxylate, (1j) 11. tert-butyl 7-((S)-1-(4-chlorobenzyl)-5-oxopyrrolidine-2-carbonyl)-3,7-diazabicyclo[3.3.1]nonane-3-carboxylate, (1k) 12. tert-butyl 7-((S)-1-(2,6-dichlorobenzyl)-5-oxopyrrolidine-2-carbonyl)-3,7-diazabicyclo[3.3.1]nonane-3-carboxylate, (1l) 13. tert-butyl 7-((S)-1-(4-methoxybenzyl)-5-oxopyrrolidine-2-carbonyl)-3,7-diazabicyclo[3.3.1]nonane-3-carboxylate, (1m) 14. tert-butyl 7-((S)-1-(naphthalen-1-ylmethyl)-5-oxopyrrolidine-2-carbonyl)-3,7-diazabicyclo [3.3.1]nonane-3-carboxylate, (1n) 15. (5S)-5-(7-benzyl-3,7-diazabicyclo[3.3.1]nonane-3-carbonyl)-1-(4-bromobenzyl)pyrrolidin-2-one; (1o) 16. (5S)-5-(7-benzyl-3,7-diazabicyclo[3.3.1]nonane-3-carbonyl)-1-(4-methoxybenzyl)pyrrolidin-2-one, (1p) 17. (5 S)-5-(7-Benzoyl-3,7-diaza-bicyclo[3.3.1]nonane-3-carbonyl)-1-(2-bromo-benzyl)-pyrrolidin-2-one, (1q) 18. 1-(2-Bromo-benzyl)-5-[7-(toluene-4-sulphonyl)-3,7-diaza-bicyclo[3.3.1]nonane-3-carbonyl]-pyrrolidin-2-one, (1r) 19. (5S)-5-(7-benzyl-3,7-diazabicyclo[3.3.1]nonane-3-carbonyl)-1-tosylpyrrolidin-2-one, (1s) 20. (5S)-5-(7-Benzoyl-3,7-diaza-bicyclo[3.3.1]nonane-3-carbonyl)-1-(4-methyl-benzyl)-pyrrolidin-2-one, (1t) 21 (5 S)-5-(7-(2-bromobenzyl)-3,7-diazabicyclo[3.3.1]nonane-3-carbonyl)-1-(4-methylbenzyl) pyrrolidin-2-one, (1u) 22. (5S)-5-(7-(4-bromobenzyl)-3,7-diazabicyclo[3.3.1]nonane-3-carbonyl)-1-(4-methylbenzyl) pyrrolidin-2-one, (1v) 23. (5S)-5-(7-(4-chlorobenzyl)-3,7-diazabicyclo[3.3.1]nonane-3-carbonyl)-1-(4-methylbenzyl) pyrrolidin-2-one, (1w) 24. benzyl (2S)-1-(7-benzyl-3,7-diazabicyclo[3.3.1]nonan-3-yl)-3-methyl-1-oxobutan-2-yl carbamate, (1x) 25. benzyl (2S)-1-(7-benzyl-3,7-diazabicyclo[3.3.1]nonan-3-yl)-4-methyl-1-oxopentan-2-yl carbamate, (1y) 26. benzyl (2S)-1-(7-benzyl-3,7-diazabicyclo[3.3.1]nonan-3-yl)-1-oxo-3-phenylpropan-2-yl carbamate, (1z)
[0039] In still another embodiment of the present invention, the compounds of generals formula 1 are useful as anti-thrombotic agents (antiplatelets agents) via collagen-epinephrine induced pulmonary thromboembolism in mice (in vivo) and collagen induced platelet aggregation in human platelets (in vitro).
[0040] In yet another embodiment of the present invention, the % protection of compounds of general formula 1, by collagen plus epinephrine induced pulmonary thromboembolism in mice (in vivo) varies from 25 to 60% at 30 μM concentration.
[0041] In still another embodiment of the present invention a process for preparation compound of general formula 1
[0000]
wherein, R′ is;
[0000]
[0000] wherein R is selected from alkyl, acyl, tosyl, tert-butyloxycarbonyl, araalkyl or substituted araalkyl groups; R″ is selected preferably from halogen, cyano, lower alkyl, aryl, substituted aryl, and tosyl groups; R 1 is selected from hydrogen and lower alkyl groups; R 2 is selected from lower alkyl and aryl groups; R 3 is selected from tert-butyloxycarbonyl and bezyloxycarbonyl groups; n=0,1, comprising the steps of:
i) reacting a first compound with a second compound to obtain a reaction mass comprising compound of general formula 1 and more particularly, one or more of compound of formula 1a to 1p and 1x to 1z, wherein the first compound being selected from
(a) a compound of general formula
[0000]
[0000] or
(b) a compound of general formula
[0000]
[0000] and
the second compound being selected from a group comprising of (a) a compound of general formula
[0000]
[0000] or (b) a compounds of general formula
[0000]
[0000] wherein, R″ is selected preferably from halogen, cyano, lower alkyl, aryl, substituted aryl, and tosyl groups; R 1 is selected from hydrogen and lower alkyl groups; R 2 is selected from lower alkyl and aryl groups; R 3 is selected from tert-butyloxycarbonyl and bezyloxycarbonyl groups; n=0,1; with the proviso that the compound of general formula 2 is reaction with compounds of general formula 4 and 5, both; and the compound of general formula 3 is reacting with compound of general formula 4 only,
ii) if the reaction mass thus obtained in step (i) comprises one or more compound of formula 1a, 1b, 1e, 1j to 1n, then, deprotecting a Boc-Group in the reaction mass with TFA at a temperature ranging between 0° C. to 15° C. for a period in the range of 4 to 5 hours followed by N-acylation at temperature ranging between 0° C. to 25° C. in solvent selected from DCM or THF followed by N-benzylation at temperature ranging between 50 to 60° C. for a period in the range of 4 to 5 hours in acetone to obtain a reaction mass comprising deprotected compound of formula 1q to 1w and converting the deprotected compound of formula 1q to 1w thus obtained to N-benzylation, benzoylation, tosylation to provide protected compound 1q to 1w; wherein: a) the compounds of formula 1a to 1p include:
[0000]
with R″ is selected from halogen, cyano, lower alkyl, aryl, substituted aryl, tosyl and naphthyl groups; R is selected from alkyl, aryl, tert-butyloxycarbonyl or substituted araalkyl groups;
b) the compounds of formula 1x to 1z include:
[0000]
with R is selected from alkyl, tert-butyloxycarbonyl, araalkyl or substituted araalkyl groups; R 1 is selected from hydrogen and lower alkyl groups; R 2 is selected from lower alkyl and aryl groups; R 3 is selected from tert-butyloxycarbonyl and bezyloxycarbonyl groups; n=0,1; and
c) the compounds of formula 1q to 1w include:
[0000]
with R is selected from acyl, tosyl, or substituted araalkyl groups; X is selected preferably from halogen, and lower alkyl groups.
[0056] In yet another embodiment of the present invention, the reaction of step (i) takes place in the presence of a coupling agent selected from the group consisting of dicyclohexylcarbodiimide, benzotriazole-1-yl-oxy-tris-pyrrolidino-phosphonium hexafluorophophate, isobutyl chloroformate-TEA/DIPEA, oxalyl chloride-TEA/DIPEA or an activating agent 1-hydroxy benzotrizole at a temperature ranging between −20° C. to 0° C. for a period in the range of 30 to 45 min, followed by stirring at temperature range from 25-30° C. for a period ranging from 2-3 hours in aprotic solvents selected from DCM, THF and dioxane.
[0057] In yet another embodiment of the present invention, N-benzylation in step (ii) of the process for the preparation of general formula 1, is carried in dry acetone in presence of anhydrous potassium carbonate (K 2 CO 3 ) followed by the addition of substituted benzyl bromide by refluxing at a temperature ranging 50-60° C. for 2-3 hours.
[0058] In still another embodiment of the present invention, benzoylation in step (ii) of the process for the preparation of general formula 1, is carried in dry dichloromethane using benzoyl chloride in presence of triethylamine or diisopropylethyl amine at a temperature ranging from 0-5° C. for 30-60 minutes.
[0059] In yet another embodiment of the present invention, tosylation in step (ii) of the process for the preparation of general formula 1, is carried in dry dichloromethane using toluenesulphonyl chloride in presence of triethylamine or diisopropylethyl amine at a temperature ranging from 0-5° C. for 30-60 minutes.
[0060] In still another embodiment of the present invention the pharmaceutically acceptable salt of compounds 1 (c-d), 1 (f-i), 1 (o-p), 1(u-z) is selected from a group consisting of selected from a group consisting of hydrochloride and tartrate salts.
[0061] In yet another embodiment of the present invention the % aggregation of compounds by collagen induced platelet aggregation in human platelets (in vitro) varies from 03.00±3.00 to 86.00±3.41% at 30 μM concentration. The compound 1d was the most potent among these groups exhibiting a percentage inhibition of aggregation of 86.000±3.41 induced by collagen.
[0062] In still another embodiment of the present invention, the Compounds 1d, 1g, 1h, 1o, 1u, 1v and 1w exhibited highly promising anti-platelet efficacy inhibited collagen, in vitro varies from 57.00±11.00 to 86.00±3.41% and Compound 1d was the most potent among these groups and exhibited a percent inhibition of aggregation of 86.00±3.41, induced by collagen.
[0063] In yet another embodiment of the present invention, the compounds 1d, 1g, 1h, 1u, 1v and 1w exhibited dose dependent anti-platelet efficacy through dual mechanism inhibited both collagen inhibited both collagen as well as U46619 (thromboxane receptor agonist) induced platelet aggregation and varies from 52±03 to 85±03.
[0064] In still another embodiment of the present invention, Compound 1d was evaluated for its antithrombotic efficacy in ferric chloride induced arterial thrombosis model in mice and after 4 hr of its oral administration, prolonged the time to occlusion of carotid artery by 2.2 fold (control, 9.5±0.4 min vs 1d, 19.2±0.9 min), while the standard drug Clopidogrel increased the TTO upto 23±0.9 min. Therefore, the efficacy elicited in this model substantiates the anti-thrombotic potential of this compound.
[0065] In yet another embodiment of the present invention, the action of compound 1d is platelet specific, since its presence did not alter the coagulability of blood as assessed by TT, PT and aPTT in human plasma.
BRIEF DESCRIPTION OF THE DRAWINGS
[0066] Scheme 1: Coupling reactions involving N-substituted pyroglutamic acid
[0067] Scheme 2: Coupling reactions involving N-protected hydrophobic amino acids.
[0068] Scheme 3: Modifications of bispidine ring.
[0069] Table 1. In vivo (% protection; inducer, collagen plus epinephrine) and in vitro (% inhibition of aggregation; inducer, collagen) activity of bispidine derivatives of N-substituted pyroglutamic acid, 1(a-w).
[0070] Table 2. In vivo (% protection; inducer, collagen plus epinephrine) and in vitro (% inhibition of aggregation; inducer, collagen) activity of bispidine derivatives of N-protected amino acids, 1(x-z).
[0071] FIG. 1 : Effect of compound 1d against (a) collagen induced aggregation in human platelets (in vitro), (b) U46619 induced platelet aggregation, (c) ADP, TRAP, Ristocetin, CRP-XL and arachidonic acid induced platelet aggregation in human, platelets. Results are expressed as Mean±SEM (n=3). Bars in graph (a) and (b) represents percent inhibition (Mean±SEM) offered by compound 1 d against human platelet aggregation induced by collagen and U46619 respectively. Bars in graph (c) represents percent platelet aggregation (Mean±SEM) induced by ADP, TRAP, Ristocetin, CRP-XL and arachidonic acid in presence of vehicle/compound 1d.
[0072] FIG. 2 : Effect of compound 1d on Tail bleeding time in mice after (a) 1 hr (b) 4 hr of oral administration. Results are expressed as Mean±SEM (n=5, 10 animals/group/experiment).
[0073] FIG. 3 : Effect of compound 1d on total time to occlusion (TTO) in ferric chloride induced arterial thrombosis in mice (n=6).
ABBREVIATIONS
[0000]
ADP: Adenosine Diphosphate, TxA2: Thromboxane A2, LiHMDS: Lithium bis(trimethylsilyl)amide, Boc: tert-butyloxycarbonyl, TFA: Triflouroacetic acid, DCC: Dicyclohexyldicarbodiimide, DCM: Dichloromethane, HOBt: 1-Hydroxybenzotriazole, TEA: Triethylamine, TDW: triple distilled water, CPD: citrate-phosphate-dextrose, PRP: Platelet-rich plasma, ACD: Acid Citrate Dextrose, HEPES: 4-(2-hydroxyethyl)-1-piperazineethanesulfonic acid, EGTA: ethylene glycol tetraacetic acid, BSA: bovine serum albumin, TRAP: thrombin receptor activating peptide; TTO: total time to occlusion; CRP: collagen-related peptide; TT: thrombin time; PT: prothrombin time; aPTT: Activated Partial Thromboplastin Time; COX: cyclooxygenase; DIPEA: N,N-Diisopropylethylamine; PyBOP: benzotriazol-1-yl-oxytripyrrolidinophosphonium hexafluorophosphate
DETAILED DESCRIPTION OF THE INVENTION
[0075] The present invention provides N-substituted pyroglutamic acids and substituted/protected amino acids condensed with substituted bispidines and a process for the preparation of the said compounds of general formula 1, respectively, useful in antithrombotic activity.
[0000]
Wherein, R′ is;
[0000]
[0077] Wherein R is selected from alkyl, acyl, tosyl, tert-butyloxycarbonyl or substituted araalkyl groups; R″ is selected preferably from halogen, cyano, lower alkyl, aryl, substituted aryl and tosyl groups; R 1 is selected from hydrogen and lower alkyl groups; R 2 is selected from lower alkyl and aryl groups; R 3 is selected from tert-butyloxycarbonyl and bezyloxycarbonyl groups; n=0,1.
[0078] The compounds synthesized were tested for antiplatelet activities. A number of these compounds showed protection against collagen-epinephrine induced pulmonary thromboembolism in mice, in vivo and Inhibition of collagen as well as U46619 induced platelet aggregation (in vitro) in human platelets.
[0079] Accordingly, the present invention provides a process for the preparation of general formula 1, wherein the process steps comprising of intermediates 2, 3, 4 and 5 and were prepared by the reported procedures,
[0000]
[0080] R″ is selected preferably from halogen, cyano, lower alkyl, aryl, substituted aryl and tosyl groups; R 1 is selected from hydrogen and lower alkyl groups; R 2 is selected from lower alkyl and aryl groups; R 3 is selected from tert-butyloxycarbonyl and bezyloxycarbonyl groups; n=0,1.
Further process steps comprising; i) Reacting compound of formula 2 with compound of formula 4 or 5 in an aprotic solvent selected form a group consisting of dichloromethane, tetrahydrofuran, dioxane in presence of a coupling reagent selected from the group consisting of dicyclohexylcarbodiimide, benzotriazole-1-yl-oxy-tris-pyrrolidino-phosphonium hexafluorophophate, OR an activating agent 1-hydroxy benzotrizole or isobutyl chloroformate at −20° C., followed by stirring at 30° C. for a period of 3 hrs followed by purification using chromatography (silica gel 60-120 mesh) to produce compound of formula 1 (Scheme1).
In an embodiment of the invention wherein the compound of formula 2 is reacted with oxalyl chloride at 0° C. to obtain the acid chloride followed by reaction with compound of formula 4 or 5 in presence of triethylamine (TEA) in dichloromethane at 25° C. for a period ranging from 2h to 3 h to obtain the compound of formula 1 (Scheme1). In another embodiment of the invention wherein the compound of formula 2 is reacted with compound of formula 4 or 5 in presence of a coupling reagent dicyclohexylcarbodiimide (DCC) and 1-hydroxybenzotrizole (HOBt) in dichloromethane at −5° C. for a period of 3h to get compound of formula 1 (Scheme1). In a further embodiment of the invention wherein the compound of formula 2 is reacted with compound of formula 4 or 5 in the presence of diisopropylethylamine (DIPEA), and benzotriazole-1-yl-oxy-tris-pyrrolidino-phosphoniumhexafluorophophate, (PyBOP), in dichloromethane at 0° C. for 3h followed by stirring at 0° C. for 1h and then at 27° C. for 2h to obtain compound of formula 1 (Scheme1). In still another embodiment of the invention wherein the compound of formula 2 is reacted with compound of formula 4 or 5 in presence of TEA, and isobutyl chlorormate, in THF at −20° C., for 2h followed by stirring at 0° C. for 1h and then at 25° C. for 2h to obtain compound of formula 1 (Scheme1).
[0000]
wherein R is selected from alkyl, tert-butyloxycarbonyl or substituted araalkyl groups; R″ is selected from halogen, cyano, lower alkyl, alkoxy substituted aryl groups.
ii) Synthesis of amino acid derivatives of substituted bispidines, 1(x-z) by reacting compound of formula 3 with compound of formula 4 or 5 as illustrated as in the case of Scheme-1 to obtain compound of general formula. (Scheme-2)
[0000]
wherein R is selected from alkyl, tert-butyloxycarbonyl or substituted araalkyl groups; R 1 is selected from hydrogen and lower alkyl groups; R 2 is selected from lower alkyl and aryl groups; R 3 is selected from tert-butyloxycarbonyl and bezyloxycarbonyl groups; n=0,1.
iii) Synthesis of 3-(N)-acyl, sulfonyl and substituted benzyl analogs of the compound 1 by modifying the bispidine portion to obtain compounds of general formula 1(q-w). (Scheme 3).
[0000]
wherein R 1 is selected from substituted acyl, tosyl, groups or substituted benzyl groups; X is selected from halogen, cyano, lower alkyl or alkoxy groups.
EXAMPLES
The Following Examples are Given by Way of Illustrating the Present Invention and should not be Construed to Limit the Scope of the Present Invention
Example 1
General Synthesis of (2S)—N-arylalkyl pyroglutamic acid, (2)
[0092]
[0093] A solution of Methyl pyroglutamate, 7 (2.0 gm, 1 eq, 13.9 mmol) and THF (100 ml, freshly distilled over benzophenone ketyl radical) was taken in a three necked RBF fitted with rubber septa, N 2 inlet and cooled to −20° C. LiHMDS (14 ml, 1.2 eq, 16.7 mmol) was added through a syringe to that solution and allowed to stir for 1 h. Benzylbromide (2.85 g, 1.1 eq, 15.4 mmol) was added and stirring was continued for 4h from 0° C. to 25° C. The reaction was quenched by addition of 1N HCl (10 ml) and extracted with ethyl acetate (3×25 ml). The organic layer was washed with brine (2×25 ml), dried over Na 2 SO 4 and concentrated under reduced pressure to give an oily ester, 8. This ester was then dissolved in methanol (10 ml) and cooled to 0° C. 20% sodium carbonate solution was then added to the reaction mixture portion wise. The reaction mixture was then stirred 25° C. for 5 hours. Methanol was then distilled off and the reduced reaction mixture was then extracted with ether (1×25 ml). The mixture was acidified with conc.HCl and extracted with ethyl acetate (3×30 ml). The organic layer was dried and concentrated.
[0094] Yield: 40%; M.P.: 86-88° C.; [α] D 27° C. : +33.96 (c=0.10; Methanol); IR (Neat): 3758, 3452, 2962, 1969, 1663, 1453, 1422, 1281, 1024, 801 cm −1 ; 1 H NMR (CDCl 3 , 200 MHz): □□2.05-2.18 (m, 1H, 3-H a ); 2.20-2.27 (m, 1H, 3-H b ); 2.32 (s, 3H, —CH 3 ); 2.50-2.60 (m, 2H, 4-H); 3.88-3.92 (d, 1H, —NCHPh); 4.02-4.04 (m, 1H, 2-H); 5.09-5.17 (d, 1H, —NCHPh); 7.12 (s, 5H, Ph-H); 13 C NMR (CDCl 3 , 200 MHz): 14.57, 21.52, 23.26, 30.10, 45.83, 59.01, 61.00, 128.95, 129.92, 132.62, 138.11, 174.74, 176.90; FAB MS (m/z): 234 (M+H) +
Example 2
4-Oxo-piperidine-1-carboxylic acid tert-butyl ester, (10)
[0095]
[0096] A solution of piperidin-4-one, 9 (5.0g, 1 eq, 0.032 mol) in THF was cooled to 0° C. and 20% aqueous solution of sodium bicarbonate (100 ml.) was added portion wise to the stirring reaction mixture. A solution of di-tert-butyl-dicarbonate (6.984g, 1 eq, 0.032 mol) in THF was added drop wise to the stirring reaction mixture at 0° C. and continued to stir at 25° C. for 3 to 4 hours. The reaction mixture was extracted with ethyl acetate. The organic layer was washed with brine The combined organics were dried with anhydrous Na 2 SO 4 , concentrated to obtain pale yellow oily liquid which turned to pale white solid (6.4g). The residue was purified by column chromatography on silica gel (n-hexane/ethyl acetate=4/1) to obtain pure compound (5.671 g).
[0097] Yield: 87.44%; MP: 63° C.; IR (KBr): 2979.1, 2938.9, 2868.1, 1686.1, 1424.6, 1366.2, 1318.1, 1242.3, 1166.7, 1115.1 cm −1 ; 1 H NMR (300 MHz, CDCl 3 , ppm): δ 3.73 (t, 2H, CH 2 NC(O)); 2.45 (t, 2H, CH 2 C(O)); 1.50 (s, 9H, CMe 3 ); 13 C NMR (50 MHz, CDCl 3 , ppm): δ 207 (C═O), 154 (Boc C═O), 80.5 (CMe 3 ), 43.0 (CH 2 NC(O)), 41.1 (CH 2 ), 28.3 (CH 3 ).
Example 3
7-Benzyl-9-oxo-3,7-diaza-bicyclo[3.3.1]nonane-3-carboxylic acid tert-butyl ester, (11)
[0098]
[0099] A solution of 4-Oxo-piperidine-1-carboxylic acid tert-butyl ester, 10 (4.0g, 1 eq, 0.020 mol), acetic acid (1.145 ml, 1 eq, 0.020 mol) and benzylamine (2.229 ml, 1.1 eq, 0.0204 mol) in methanol was added drop wise to the stirring suspension of paraformaldehyde (1.2g, 2 eq, 0.04 mol) in methanol (40 ml) at 65° C. and allowed to heat at reflux for 1 hr. After 1 hr., it was allowed to cool and a second portion of paraformaldehyde (1.2g, 2 eq, 0.04 mol) was added and reaction mixture was heated at reflux for 4 hrs this time. After being cooled to 25° C., the solvent was evaporated under reduced pressure. The residue was dissolved in diethyl ether and washed with 1M KOH. The organic layer was washed with brine. The combined organics were dried with anhydrous Na 2 SO 4 concentrated to obtain pale yellow sticky material (6.426g). The crude product was purified by column chromatography on silica gel (n-hexane/ethyl acetate=9/1) to obtain pure product (3.678 g).
[0100] Yield=55.45%; MP: 78° C.; IR (KBr): 3015.2, 2929.9, 2864.8, 2806.0, 1730.8, 1688.4, 1424.7, 1232.1, 1168.0 cm −1 ; 1 H NMR (300 MHz, CDCl 3 , ppm): δ 7.23-7.26 (m, 5H, Ph-H); 4.61-4.57 (brd, J=12 Hz, 1H, C(O)NCH); 4.45-4.41 (brd, J=12 Hz, 1H, C(O)NCH); 3.54-3.52 (d, J=6 Hz, 2H, CH 2 Ph); 3.40-3.32 (m, 2H, 2×C(O)NCH); 3.32-3.19 (m, 2H, 2×NCH); 2.75-2.66 (d, 1H, 2×NCH), 2.46-2.44 (m, 2H, 2×CH), 1.55 (s, 9H, CMe 3 ); 13 C NMR (50 MHz, CDCl 3 , ppm) δ213.56 (bridge C═O), 154.78 (Boc C═O), 137.45 (ipso Ph), 128.77 (Ph), 128.33 (Ph), 127.26 (Ph), 80.09 (CMe 3 ), 61.84 (CH 2 Ph), 50.49 (C(O)NCH), 47.59 (2×CH), 28.59 (CH 3 ).
Example 4
7-Benzyl-3,7-diaza-bicyclo[3.3.1]nonane-3-carboxylic acid tert-butyl ester, (12)
[0101]
[0102] To a mixture of 4-Oxo-piperidine-1-carboxylic acid tert-butyl ester (2g, 1 eq, 6.1 mmol) hydrazine monohydrate (0.33 g, 1.1 eq, 6.6 mmol) and diethylene glycol (27.83 ml) was added. At 60° C., powdered KOH (2.504g) was added to the reaction mixture and again heated at 160° C. for 8 hrs. Then the mixture was cooled and water (40 ml) was added and allowed to stir. The reaction mixture was extracted with dichloromethane and combined organics were dried with anhydrous Na 2 SO 4 concentrated to obtain oily residue (2.331g). The crude product was purified by column chromatography on silica gel (n-hexane/ethyl acetate=9/1) to obtain pure product.
[0103] Yield=57.54%; IR (Neat): 3016.3, 2922.7, 1672.4, 1427.3, 1217.4, 1174.6 cm −1 ; 1 H NMR (300 MHz, CDCl 3 , ppm) δ7.36-7.23 (m, 5H, Ph-H); 4.19-4.13 (br d, J=18 Hz, 1H, CONCH); 4.03-3.99 (br d, J=12 Hz, 1H, CONCH); 3.48-3.44 (d, J=12 Hz, 1H, CH 2A Ph); 3.34-3.30 (d, J=12 Hz, 1H, CH 2B Ph); 3.13-3.09 (m, 2H, 2×CONH); 3.03-2.98 (br d, J=15 Hz, 1H, NCH); 2.92-2.89 (br d, J=9 Hz, 1H, NCH); 2.25-2.17 (m, 2H, 2×NCH); 1.89 (br s, 1H, CH); 1.81 (br s, 1H, CH); 1.68 (m, 2H, bridge CH 2 ); 1.54 (s, 9H, CMe 3 ); 13 C NMR (50 MHz, CDCl 3 , ppm) δ155.15 (C═O), 128.68 (Ph), 128.10 (Ph), 126.68 (Ph), 78.83 (CMe 3 ), 63.49 (CH 2 Ph), 58.77 (NCH 2 ), 48.43 (CON C H 2 ), 47.65 (CON C H 2 ), 37.63 (bridge-CH 2 ), 31.10 (2×CH), 28.72 (CH 3 ); MS (ESI): 317.3 (M+H) +
Example 5
3-Benzyl-3,7-diaza-bicyclo[3.3.1]nonane, (4)
[0104]
[0105] Trifluoro acetic acid (TFA) (2.25 ml, 5 eq, 0.03 mol) was injected to the stirring suspension of compound 12 (2.0g, 1 eq, 0.006 mol) in DCM at 0° C. and allowed to stir at 25° C. (25-35° C.). Then reaction mixture was made alkaline by adding 20% aq. solution of Na 2 CO 3 and resulting mixture was extracted with dichloromethane (3×50 ml) and organics were washed with brine. The combined organics were dried with anhydrous Sodium sulphate and concentrated to obtain yellow oily liquid (1.641g).
[0106] Yield: 90%; IR(Neat): 3451.4, 2924.6, 1610.0, 1450.4 cm −1 ; 1 H NMR (300 MHz, CDCl 3 , ppm): δ7.37-7.27 (m, 5H, Ph-H); 3.49-3.41 (m, 4H, C H 2 Ph, 2×NCH); 3.31-3.27 (d, J=12 Hz, 2H, 2×NCH); 3.19-3.11 (m, 2H, 2×NCH); 2.49-2.45 (d, J=12 Hz, 2H, 2×NCH); 2.12-2.07 (m, 2H, 2×CH); 1.93-1.89 (d, J=12 Hz, 1H, bridge CH); 1.79-1.75 (d, J=12 Hz, 1H, bridge CH); MS (ESI): m/z=217 (M+H) +
Example 6
3,7-Diaza-bicyclo[3.3.1]nonane-3-carboxylic acid tert-butyl ester, (5)
[0107]
[0108] Palladium hydroxide (0.5g), (Pearlman's catalyst), was added portion wise to a suspension of compound 12 (1.102g, 0.0367 mol) in methanol (25 ml) in steel parr. The reaction mixture was hydrogenated at 55° C. and 150 psi for about 17 hrs. Then it was allowed to cool and filtered over sintered funnel with the aid of vacuum and concentrated to get pale yellow solid.
[0109] Yield=93.33%; MP: 75° C.; IR (KBr): 2979.2, 2919.7, 2858.5, 1679.6, 1402.4, 1240.4, 1172.31131.9 cm −1 ; 1H NMR (300 MHz, CDCl 3 , ppm): δ4.13-4.09 (brd, J=12 Hz, 2H, 2×CONCH); 3.14-3.10 (m, 3H, 2×CONCH, NCH); 3.01-2.96 (brd, J=15 Hz, 1H, NCH); 2.25 (s, 2H, 2×NH); 1.92-1.88 (d, J=12 Hz, 1H, CH); 1.80-1.76 (d, J=12 Hz, 1H, CH); 1.67 (s, bridge CH 2 ); 1.48 (s, 9H, CMe 3 ); 13 C NMR (50 MHz, CDCl 3 , ppm): δ155.49 (C═O), 79.78 (CMe 3 ), 51.50 (NCH 2 ), 48.94 (C(O)NCH 2 ), 31.39 (CH), 28.52 (CMe 3 ), 28.15 (CMe 3 ); MS (ESI): 227.1481 (M+H) +
Example 7
7-(1-Benzyl-5-oxo-pyrrolidine-2-carbonyl)-3,7-diaza-bicyclo[3.3.1]nonane-3-carboxylic acid tert-butyl ester, (1a)
[0110]
[0111] DCC (308 mg, 1.2 eq, 1.495 mmol) dissolved in DCM (5 ml) was added to the stirring reaction mixture containing N-benzyl pyroglutamic acid, 3 (273 mg, 1 eq, 1.25 mmol) and HOBt (252.58 mg, 1.5 eq, 1.86 mmol) dissolved in dry DCM (10 ml) at 0° C. and continued to stir for 15 minutes at same temperature. Then N-Boc bispidine, 5 (281.82 mg, 1 eq, 1.25 mmol) dissolved in dry DCM (5 ml) was added drop wise to the stirring reaction mixture and continued to stir for about 2-3 hrs. The reaction mixture was then brought to 25° C. and concentrated. The concentrated mass was then dissolved in diethyl ether and washed successively with dilute citric acid (1×20 ml), dilute NaHCO 3 (1×20 ml), brine and then extracted with ethyl acetate (3×20 ml). The combined organics were dried with anhydrous Na 2 SO 4 and concentrated to obtain sticky oily product (534 mg).
[0112] Yield=59.17%; [α] D 27° C. =−15.1890 (Methanol, c=0.3160); IR (Neat): 3017.0, 2366.7, 2337.8, 1678.9, 1432.0, 1217.9 cm −1 ; 1 H NMR (300 MHz, CDCl 3 , ppm): δ 7.36-7.14 (m, 5H, Ph-H); 5.15-5.10 (brd, J=15 Hz, 1H, PhCH A ); 4.59-4.54 (brd, J=12 Hz, 1H, NC 2′ H A ); 4.09-4.06 (m, 2H, NC 2 H, PhCH B ); 3.81-3.76 (br d, J=15 Hz, 1H, NC 8′ H A ); 3.51-3.47 (d, J=12 Hz, 1H, NC 2′ H B ); 3.08-2.86 (m, 4H, PhCH B′ , NC 8′ H B , NC 4′ H A , C 6′ H 2 ); 2.51-2.40 (m, 2H, C 4 H A , C 4′ H B ); 2.26-2.16 (m, 1H, C 4 H B ); 2.16-1.89 (m, 4H, C 3 H 2 , C 3′ H, C 7′ H); 1.70 (s, 2H, C 9′ H 2 ); 1.41 (s, 9H, CMe 3 ); 13 C NMR (50 MHz, CDCl 3 , ppm): δ 176.16 (COOH), 174.85 (C═O), 135.40 (Ph), 128.84 (Ph), 128.53 (Ph), 127.95 (Ph), 49.48 (NCH), 49.00 (NCH 2 ), 45.36 (NC 2′ , NC 8′ ), 29.99 (C 9′ ), 34.49 (bridge CH 2 ), 28.35 (C 3′ ), 27.70 (C 7′ ), 27.32 (CMe 3 ), 22.88 (CH 2 ); MS (ESI): m/z=427.9 (M + )
Example 8
7-[1-(2-Bromo-benzyl)-5-oxo-pyrrolidine-2-carbonyl]-3,7-diaza-bicyclo[3.3.1]nonane-3-carboxylic acid tert-butyl ester, (1b)
[0113]
[0114] The compound was prepared from N-(2-bromobenzylpyroglutamic acid using DCC (249.08 mg, 1.2 eq, 1.207 mmol) containing and HOBt (203.91 mg, 1.5 eq, 1.509 mmol) dissolved in dry DCM (10 ml) followed by the addition of N-Boc bispidine, 5 (227.51 mg, 1 eq, 1.006 mmol) dissolved in dry DCM.
[0115] Yield: 49.64%; MP: 138° C.; [α] D 27° C. : 3.7608 (Methanol, c=0.2180); IR (KBr): 3458.8, 2927.9, 1679.6, 1434.4, 1241.5, 1172.5, 1134.3 cm −1 ; 1 H NMR (300 MHz, CDCl 3 , ppm): δ 7.5-7.1 (m, 4H, Ph-H); 5.1-5.0 (d, 1H, PhCH A ); 4.5 (d, 1H, NC 2′ H A ); 4.1-4.0 (m, 2H, NC 2 H, PhCH B ); 3.5 (d, 1H, NC 8′ H B ); 3.1-2.8 (m, 4H, NC 2′ H B , NC 8′ H B , NC 4′ H, NC 6′ H A ); 2.4-2.3 (m, 3H, C 4 H A , NC 4′ H, NC 6′ H B ); 2.2-2.0 (m, 2H, C 4 H B , C 3 H A ); 1.9 (m, 1H, C 3 H B ); 1.8 (m, 2H, C 3′ H, C 7′ H); 1.7 (s, 2H, C 9′ H 2 ); 1.4 (s, 9H, CMe 3 ); 13 C NMR (50 MHz, CDCl 3 , ppm): δ135.84 (Ph), 132.75 (Ph), 131.39 (Ph), 129.38 (Ph), 127.76 (Ph), 124.13 (Ph), 79.73 ( C Me 3 ), 56.85 (C C H 3 ), 49.59 (COONCH), 46.51 (NCH), 45.30 (OCONCH), 34.64 (bridge CH 2 ), 28.32 (CH), 28.13 (CH), 27.70 (CMe 3 ), 27.29 (CMe 3 ), 22.82 (CMe 3 ); MS(ESI): m/z: 528.0 (M+Na) +
Example 9
1-Benzyl-5-(7-benzyl-3,7-diaza-bicyclo[3.3.1]nonane-3-carbonyl)-pyrrolidin-2-one, (1c)
[0116] Step 1: N-benzylpyroglutamic acid (329 mg, 1 eq, 1.369 mmol) dissolved in dry DCM (15 ml) was cooled to 0° C. and oxalyl chloride (0.191 ml, 1.5 eq, 2.053 mmol) was added drop wise to the stirring reaction mixture at same temperature and allowed to stir overnight at 25° C. The reaction mixture was concentrated to evaporate DCM.
[0000]
[0117] Step 2: N-benzyl bispidine (349.18 mg, 1 eq 1.617 mmol) dissolved in dry DCM (10 ml) was cooled to 0° C. and triethyl amine (0.471 ml, 2.3 eq, 3.3803 mmol) was added drop wise to the stirring reaction mixture. Then concentrated mass from step-1 dissolved in dry DCM was added drop wise at same temperature and continued to stir for 2-3 hrs.
[0118] Yield=30.32%; [α] D 27° C. =+3.44 (Methanol, c=0.2120); MP: 144° C.; IR (KBr): 3424.2, 3010.2, 2924.5, 1680.5, 1642.6, 1449.8, 1218.9 cm −1 ; 1 H NMR (300 MHz, CDCl 3 , ppm): δ 7.29-7.22 (m, 10H, 2×Ph); 5.23-5.18 (m, 1H, PhCH A ); 4.60-4.45 (m, 1H, NC 2′ H A ); 4.17-4.15 (m, 1H, NC 2 H); 3.85-3.79 (m, 1H, PhCH B ); 3.50-3.45 (m, 2H, PhCH A′ , NC ′ H A ); 3.26-3.22 (m, 1H, PhCH B′ ); 3.08-2.99 (m, 3H, NC 2′ H B , NC 8′ H B , NC 4′ H A ); 2.85 (m, 1H, NC 6′ H A ); 2.57 (m, 1H, C 4 H A ); 2.38-2.33 (m, 1H, C 4′ H B , NC 6′ H B ); 2.10-2.06 (m, 2H, C 4 H B , C 3 H A ); 1.97 (m, 1H, C 3 H B ); 1.88 (m, 2H, C 3′ H, C 7′ H); 1.70 (s, 2H, C 9′ H 2 ); 13 C NMR (50 MHz, CDCl 3 , ppm): δ175.67 (C═O), 168.41 (C═O), 128.64 (Ph), 128.54 (Ph), 128.35 (Ph), 128.07 (Ph), 127.58 (Ph), 127.05 (Ph), 63.52 (NCH 2 Ph), 59.35 (C 6′ ), 58.38 (C 4′ ), 56.54 (NCH 2 ), 46.44 ( ), 45.40 (NC 2′ ), 31.04 (bridge CH 2 ), 29.98 (C 4 ), 29.19 (C 3′ ), 28.54 (C 7′ ), 21.56 (CH 2 ); MS (ESI): m/z=418.2 (M+H) +
Example 10
5-(7-Benzyl-3,7-diaza-bicyclo[3.3.1]nonane-3-carbonyl)-1-(2-bromo-benzyl)-pyrrolidin-2-one (1d)
[0119]
[0120] Step 1: N-2-bromobenzylpyroglutamic acid (300 mg, 1 eq, 1.006 mmol) dissolved in dry DCM (10 ml) was cooled to 0° C. and oxalyl chloride (0.127 ml, 1.5 eq, 1.509 mmol) was added drop wise to the stirring reaction mixture at same temperature and allowed to stir overnight at 25° C. (25-35° C.).
[0121] Step 2: N-benzyl bispidine dissolved (239.02 mg, 1 eq 1.1066 mmol) in dry DCM (10 ml) was cooled to 0° C. and triethylamine (0.322 ml, 2.3 eq 2.314 mmol) was added drop wise to the stirring reaction mixture. Then concentrated mass from step-1 dissolved in dry DCM was added drop wise at same temperature and continued to stir for 2-3 hrs.
[0122] Yield=54.04%; MP: 131° C.; [α] D 27° C. : +25.5130 (Methanol, c=0.2040); IR (KBr): 3464.8, 3354.4, 2911.5, 2802.9, 1690.2, 1638.9, 1442.4, 1342.4, 1285.8, 1254.6 cm −1 ; 1 H NMR (300 MHz, CDCl 3 , ppm): δ 7.29-7.22 (m, 9H, 2×Ph); 5.14-5.09 (m, 1H, PhCH A ); 4.57-4.53 (d, J=12 Hz, 1H, NC 2′ H A ); 4.21-4.09 (m, 2H, NC 2 H, PhCH B ); 3.50-3.43 (m, 2H, PhCH A , NC 8′ H A ); 3.25-3.16 (m, 2H, PhCH B′ , NC 2′ H B ); 3.0-2.84 (m, 3H, NC 8′ H B , NC 4′ H A , C 6′ H A ); 2.61-2.49 (m, 1H, C 4 H A ); 2.35-2.27 (m, 2H, NC 4′ H B , C 6′ H B ); 2.05-1.93 (m, 1H, C 3 H B ); 1.89 (m, 2H, C 3′ H, C 7′ H); 1.68 (s, 2H, C 9′ H 2 );
[0123] 13 C NMR (50 MHz, CDCl 3 , ppm): δ 175.72 (C═O), 168.34 (C═O), 137.90 (Ph), 136.149 (Ph), 132.84 (Ph), 128.61 (Ph), 128.33 (Ph), 127.77 (Ph), 127.01 (Ph), 124.43 (Ph), 115.35 (Ph), 63.83 (NCH 2 Ph), 59.73 (NCH 2 ), 58.56 (NCH), 56.97 (CH 2 Ph), 49.29 (NCH 2 ), 45.67 (COCH 2 ), 34.64 (bridge CH 2 ), 31.33 (CH), 29.20 (CH), 21.96 (CH 2 ); MS (ESI): m/z=496.2 (M+H) +
Example 11
7-[1-(4-Methyl-benzyl)-5-oxo-pyrrolidine-2-carbonyl]-3,7-diaza-bicyclo[3.3.1]nonane-3-carboxylic acid tert-butyl ester, (1e)
[0124]
[0125] Compound 5 (305.53 mg, 1 eq, 1.350 mmol) dissolved in dry DCM (10 ml) was added to N-(4-methylbenzyl)pyroglutamic acid (314 mg, 1 eq, 1.350 mmol) dissolved in dry DCM (5 ml). Then DIPEA (0.470 ml, 2 eq, 2.76 mmol) was added drop wise to the stirring reaction mixture at 0° C. under nitrogen atmosphere. Then PyBOP (702.52 mg, 1 eq, 1.350 mmol) dissolved in dry DCM was added drop wise to the stirring reaction mixture at same temperature and continued to stir for about 3 hrs. The reaction mixture was washed successively with 20% citric acid (1×20 ml), 20% NaHCO 3 (1×20 ml) and brine. The combined organics were dried with anhydrous Na 2 SO 4 and concentrated to get the sticky oily product. Then it was purified by column chromatography on silica gel to obtain pure product.
[0126] Yield: 50.91%; [α] D 27° C. : −16.7970 (Methanol, c=0.0980); IR (Neat): 3412.3, 2925.2, 1667.9, 1423.3, 1364.3, 1245.4, 1172.5, 1135.0 cm −1 ; 1 H NMR (300 MHz, CDCl 3 , ppm): δ 7.28-7.04 (m, 4H, Ph); 5.13-5.08 (d, J=15 Hz, PhCH A ); 4.61-4.56 (m, 1H, NC 2′ H A ); 4.15-4.07 (m, 1H, NC 2 H); 3.76-3.71 (d, J=15 Hz, 1H, PhCH B ); 3.54-3.50 (d, J=12 Hz, 1H, NC 8′ H A ); 3.04-2.94 (m, 4H, NC 2′ H B , NC 8′ H B , NC 4′ H A , NC 6′ H A ); 2.34 (s, 1H, CH 3 ); 2.22-2.00 (m, 6H, C 4 H A , C 6′ H B , C 4′ H B , C 4 H B , C 3 H 2 ); 1.91-1.90 (m, 2H, C 3′ H, C 7′ H); 1.80 (s, 2H, C 9′ H 2 ); 1.42 (s, 9H, CMe 3 ); 13 C NMR (50 MHz, CDCl 3 , ppm): δ 175.68 (C═O), 168.33 (C═O), 137.29 (Ph), 129.28 (Ph), 128.58 (Ph), 49.52 (NCH 2 ), 45.03 (NCH 2 ), 34.64 (bridge CH 2 ), 30.04 (CH 2 ), 28.35 (CMe 3 ), 27.74 (CH 3 ), 27.35 (CH 3 ), 22.81 (CH 3 ), 21.08 (PhCMe 3 ); MS (ESI): m/z=441.9 (M + )
Example 12
5-(7-Benzyl-3,7-diaza-bicyclo[3.3.1]nonane-3-carbonyl)-1-(4-methyl-benzyl)-pyrrolidin-2-one (1f)
[0127]
[0128] DCC (335.69 mg, 1 eq, 1.36 mmol) dissolved in dry DCM (5 ml) was added to the stirring reaction mixture containing N-(4-methyl benzyl) pyroglutamic acid (316.30 mg, 1 eq, 1.356 mmol) and HOBt (274.85 mg, 1.2 eq 1.627 mmol) dissolved in dry DCM (10 ml) at 0° C. and continued to stir for 15 minutes at same temperature. Then N-benzyl bispidine (293 mg, 1 eq, 1.356 mmol) dissolved in dry DCM (5 ml) was added drop wise to the stirring reaction mixture and continued to stir for about 2-3 hrs. The reaction mixture was then brought to 25° C. and concentrated. The concentrated mass was then dissolved in diethyl ether and washed successively with 20% citric acid (1×20 ml), 20% NaHCO 3 (1×20 ml), brine and then extracted with ethyl acetate (3×20 ml). The combined organics were dried with anhydrous Na 2 SO 4 and concentrated to obtain sticky oily product which get solidified later. Then it was purified by column chromatography on silica gel (DCM: Methanol=7:3) to obtain pure product.
[0129] Yield=59.13%; MP: 133° C.; [α] D 27° C. : +0.9200 (Methanol, c=0.1260); IR (KBr): 3445.7, 2362.3, 1637.4, 1466.5, 1219.1 cm −1 ; 1 H NMR (300 MHz, CDCl 3 , ppm): δ 7.30-7.07 (m, 9H, 2×Ph); 5.18-5.14 (br d, J=12 Hz, 1H, PhCH A ); 4.59-4.45 (m, 1H, NC 2′ H A ); 4.17-4.15 (m, 1H, NC 2 H); 3.79-3.74 (m, 1H, PhCH B ); 3.51-3.47 (m, 2H, PhCH A′ , NC 8′ H A ); 3.27-3.10 (m, 1H, PhCH B′ ); 3.02-2.86 (m, 4H, NC 2′ H B , NC 8′ H B , NC 4′ H A , NC 6′ H A ), 2.55 (m, 2H, C 4 H A ), 2.33 (s, 3H, CH 3 ); 2.33 (m, 2H, NC 4′ H B , NC 6 H B ); 2.09-2.06 (m, 2H, C 4 H B , C 3 H A ); 1.97 (m, 1H, C 3 H B ); 1.89 (m, 2H, C 3′ H, C 7 H); 1.70 (s, 2H, C 9′ H 2 ); MS (ESI): m/z=432.2 (M+1) +
Example 13
(5S)-5-(7-benzyl-3,7-diazabicyclo[3.3.1]nonane-3-carbonyl)-1-(2,6-dichlorobenzyl)pyrrolidin-2-one (1g)
[0130]
[0131] The compound was prepared from N-(2,6-dichlorobenzyl) pyroglutamic acid as described in the case of 1f
[0132] Yield=76%; MP: 50-55° C.; [α] D =+51.6304 (Chloroform, c=0.10);
[0133] 1 H NMR (300 MHz, CDCl 3 , ppm); δ7.35-7.24 (m, 8H, 2×Ph), 5.31-5.26 (d, 1H, PhCH A ), 4.60-4.56 (d, 1H, C(O)NC 2′ H A ), 4.46-4.41 (d, 1H, PhCH B ), 4.05-4.02 (dd, 1H, NC 2 H), 3.50-3.46 (m, 2H, PhCH A′ , NC 8′ H A ), 3.28-3.24 (m, 2H, PhCH B , C(O)NC 4′ H A ), 3.05-3.01 (m, 1H, C(O)NC 2′ H B ), 2.90-2.87 (m, 2H, C(O)NC 8′ H B , NC 6′ H A ), 2.56 (m, 1H, C 4 H A ), 2.36 (m, 2H, C 4′ H B , NC 6′ H B ), 2.11-2.01 (m, 2H, C 4 H B , C 3 H A ), 1.99-1.97 (m, 1H, C 3 H B ), 1.93 (m, 2H, C 3′ H, C 7′ H), 1.73 (bs, 2H, C 9′ H 2 ); 13 C NMR (50 MHz, CDCl 3 , ppm) δ175.10 (CON(CH 3 ) 2 ), 168.25 (C═O), 151.52, 137.89, 129.57 (Ph), 128.58 (Ph), 128.45 (Ph), 128.33 (Ph), 127.26 (Ph), 127.01 (Ph), 63.54 (NCH 2 Ph), 59.53 (C 6′ ), 58.47 (C 4′ ), 56.20 (NCH 2 ), 46.45 (NC 2′ ), 31.08 (bridge CH 2 ), 29.62 (C 4 ), 29.30 (C 3′ ), 28.55 (C 7′ ), 21.81 (CH 2 ); IR (KBr): 3639.2, 3400, 2955, 2800, 1690, 1645, 1439, 1362, 1228, 1154, 1119 cm −1 ; MS (ESI): m/z=486.3 (M+).
Example 14
(5S)-5-(7-benzyl)-3,7-diazabicyclo[3.3.1]nonane-3-carbonyl)-1-(4-chlorobenzyl)pyrrolidin-2-one (1h)
[0134]
[0135] The compound was prepared from N-(4-chlorobenzyl)pyroglutamic acid as described in the case of 1f
[0136] Yield=67%; 1 H NMR (300 MHz, CDCl 3 , ppm) δ7.45-7.04 (m, 8H, Ph-H) 5.20-5.05 (d, 1H, PhCH A ), 4.61-4.56 (d, 1H, C(O)NC 2′ H A ), 4.20-4.12 (dd, 1H, NC 2 H), 3.83-3.71 (d, 1H, PhCH B ), 3.52-3.41 (m, 2H, PhCH A′ , NC 8′ H A ), 3.19-3.15 (m, 2H, PhCH B′ , C(O)NC 4′ H A ), 2.95 (m, 2H, C(O)NC 2 , H B , NC 8′ H B ), 2.65 (m, 1H, NC 6′ H A ), 2.15-1.88 (m, 4H, C 4′ H B , NC 6′ H B C 4 H B , C 3 H A ), 1.83-1.79 (m, 1H, C 3 H B ), 1.74 (m, 2H, C 3′ H, C 7′ H, bs, 2H, C 9′ H 2 ); 13 C NMR (50 MHz, CDCl 3 , ppm); 175.33, 168.44, 137.22, 136.79, 133.38, 131.46, 130.16, 129.28, 128.54, 127.89, 120.79, 62.72, 59.36, 58.16, 49.20, 46.33, 45.04, 31.05, 29.96, 29.68, 29.40, 29.19, 28.48, 21.10; IR (KBr): 3870,3777, 3588, 3526, 2924, 2276, 1680, 1451, 1220 cm −1
Example 15
(5S)-5-(7-benzyl-3,7-diazabicyclo[3.3.1]nonane-3-carbonyl)-1-tosylpyrrolidin-2-one, (1i)
[0137]
[0138] The compound was prepared from p-toluene sulphonic acid as described in the case of 1f
[0139] Yield=83%; 1 H NMR (300 MHz, CDCl 3 , ppm) δ7.81-7.79 (d, 2H, SO 2 Ph) 7.31-7.21 (m, 7H, SO 2 Ph, Ph), 4.84-4.81 (d, 1H, C(O)NC 2′ H A ), 3.86-3.82 (d, 1H, PhCH A′ ), 3.56-3.32 (m, 4H, PhCH B′ , C(O)NC 4′ H A , NC 8′ H A , NC 2 H), 3.01-2.89 (m, 3H, C(O)NC 2′ H B , C(O)NC 8′ H B , NC 6′ H A ), 2.43 (s, 3H, CH 3 ), 0.2.34-2.31 (d, 1H, C 3 H A ), 2.17-1.69 (m, 10H, C 4′ H B , NC 6′ H B , C 3′ H, C 7′ H, C 3 H B , C 4 H, C 5 H, C 9′ H 2 ); 13 C NMR (200 MHz, CDCl 3 , ppm) δ175.61, 168.19, 163.33, 139.25, 129.83, 128.77, 128.62, 128.33, 127.05, 63.53, 59.34, 58.36, 56.57, 49.22, 46.46, 31.91, 29.79, 29.14, 22.67, 21.58, 14.08; IR (KBr): 3783, 3448, 3374, 2923, 2361, 2135, 1817, 1640, 1446, 1337, 1224, 1098 cm −1 ; MS (ESI): m/z=468.3 (M + )
Example 16
tert-butyl-7-((S)-1-(4-cyanobenzyl)-5-oxopyrrolidine-2-carbonyl)3,7diazabicyclo[3.3.1]nonane-3-carboxylate, (1j)
[0140]
[0000] The compound was prepared from N-(4-cyanobenzyl)pyroglutamic acid as described in the case of 1f
[0141] Yield=53%; MP: 160-165° C.; 1 H NMR (300 MHz, CDC 3 , ppm) δ7.64-7.61 (m, 2H, Ph), 7.28 (m, 2H, Ph) 5.17-5.12 (d, 1H, PhCH A ), 4.59-4.55 (d, 1H, C(O)NC 2′ H A ), 4.12-3.92 (d, 1H, PhCH B ), 3.87 (d, 1H, NC 2 H), 3.12 (m, 1H, PhCH A′ ,), 3.10-3.01 (m, 2H, PhCH B′ , C(O)NC 4′ H A ), 2.60-2.51 (m, 1H, C(O)NC 2′ H B ), 2.40-2.50 (m, 2H, C(O)NC 8′ H B , NC 6′ H A ), 2.12 (m, 1H, C 4 H A ), 2.10-1.90 (m, 2H, C 4′ H B , NC 6′ H B , NC 8′ H A ), 1.90-1.82 (m, 2H, C 4 H B , C 3 H A ), 1.99-1.97 (bs, 4H, C 3 H B , C 3′ H, C 7′ H, C 9′ H 2 ), 1.43 (s, 9H, (CH 3 ) 3 ); 13 C NMR (50 MHz, CDCl 3 , ppm) δ175.87 (CON(CH 3 ) 2 ), 169.33 (C═O), 154.89 (Ph), 142.20 (Ph), 132.46 (Ph), 128.87 (Ph), 127.58 (Ph), 111.52 (Ph), 79.93 (NCH 2 Ph), 56.99 (C 6′ ), 49.56 (C 4′ ), 46.54 (NCH 2 ), 45.20 (NC 2′ ), 30.27 (bridge CH 2 ), 29.69 (C 4 ), 29.52 (C 3′ ), 28.56 (C 7′ ), 28.38 (CH 2 ) 27.74, 27.32, 23.09; IR (KBr): 3896, 3744, 3700, 3576, 3456, 2924, 2859, 2361, 2228, 1679, 1418 cm −1 ; MS (ESI): m/z=452.5 (M + )
Example 17
tert-butyl 7-((S)-1-(4-chlorobenzyl)-5-oxopyrrolidine-2-carbonyl)-3,7-diazabicyclo [3.3.1]nonane-3-carboxylate, (1k)
[0142]
[0143] The compound was prepared from N-(4-chlorobenzyl)pyroglutamic acid as described in the case of 1f
[0144] Yield=77%; 1 H NMR (300 MHz, CDCl 3 , ppm) δ7.30-7.28 (m, 2H, Ph), 7.27-7.12 (m, 2H, Ph) 5.11-5.04 (d, 1H, PhCH A ), 4.59-4.54 (d, 1H, C(O)NC 2′ H A ), 4.20-4.00 (d, 1H, PhCH B , NC 8′ H A ), 3.79 (d, 1H, NC 2 H), 3.56 (m, 1H, PhCH A′ ,), 3.09-3.04 (m, 2H, PhCH B , C(O)NC 4′ H A ), 2.99-2.96 (m, 1H, C(O)NC 2′ H B ), 2.91-2.86 (m, 2H, C(O)NC 8′ H B , NC 6′ H A ), 2.50-2.48 (m, 1H, C 4 H A ), 2.44-2.43 (m, 2H, C 4′ H B , NC 6′ H B ,), 2.41-2.40 (m, 2H, C 4 H B , C 3 H A ), 1.94 (bs, 2H, C 3 H B , C 3 ′H,) 1.81 (bs, 2H, C 7 H, C 9′ H 2 ), 1.41 (s, 9H, (CH 3 ) 3 );
[0145] 13 C NMR (50 MHz, CDCl 3 , ppm); 175.57, 169.53, 154.93, 134.94, 133.46, 129.87, 128.78, 79.58, 56.5, 56.49, 56.47, 49.54, 44.70, 29.81, 28.35, 27.74, 22.92; IR(KBr): 3869, 3759, 3496, 3010, 2926, 2860, 1679, 1423 cm −1 ; MS(ESI): m/z=461.9 (M + )
Example 18
tert-butyl 7-((S)-1-(2,6-dichlorobenzyl)-5-oxopyrrolidine-2-carbonyl)-3,7-diazabicyclo [3.3.1]nonane-3-carboxylate, (1l)
[0146]
[0147] The compound was prepared from N-(2,6-dichlorobenzyl)pyroglutamic acid as described in the case of 1f
[0148] Yield=63%; MP: 160-165° C.; 1 H NMR (300 MHz, CDCl 3 , ppm) δ7.64-7.61 (m, 2H, Ph), 7.28 (m, 2H, Ph) 5.17-5.12 (d, 1H, PhCH A ), 4.59-4.55 (d, 1H, C(O)NC 2′ H A ), 4.12-3.92 (d, 1H, PhCH B ), 3.87 (d, 1H, NC 2 H), 3.12 (m, 1H, PhCH A′ ,), 3.10-3.01 (m, 2H, PhCH B′ , C(O)NC 4′ H A ), 2.60-2.51 (m, 1H, C(O)NC 2′ H B ), 2.40-2.50 (m, 2-1, C(O)NC 8′ H B , NC 6′ H A ), 2.12 (m, 1H, C 4 H A ), 2.10-1.90 (m, 2H, C 4′ H B , NC 6 H B , NC 8′ H A ), 1.90-1.82 (m, 2H, C 4 H B , C 3 H A ), 1.99-1.97 (bs, 4H, C 3 H B , C 3′ H, C 7′ H, C 9′ H 2 ), 1.43 (s, 9H, (CH 3 ) 3 ); 13 C NMR (50 MHz, CDCl 3 , ppm) δ175.87 (CON(CH 3 ) 2 ), 169.33 (C═O), 154.89 (Ph), 142.20 (Ph), 132.46 (Ph), 128.87 (Ph), 127.58 (Ph), 111.52 (Ph), 79.93 (NCH 2 Ph), 56.99 (C 6′ ), 49.56 (C 4′ ), 46.54 (NCH 2 ), 45.20 (NC 2′ ), 30.27 (bridge CH 2 ), 29.69 (C 4 ), 29.52 (C 3′ ), 28.56 (C 7′ ), 28.38 (CH 2 ) 27.74, 27.32, 23.09; IR (KBr): 3896, 3744, 3700, 3576, 3456, 2924, 2859, 2361, 2228, 1679, 1418 cm −1 ;
Example 19
tert-butyl-7-((S)-1-(4-methoxybenzyl)-5-oxopyrrolidine-2-carbonyl)-3,7-diazabicyclo[3.3.1]nonane-3-carboxylate, (1m)
[0149]
[0150] The compound was prepared from N-(4-methoxybenzyl)pyroglutamic acid described in the case of 1f
[0151] Yield=54%; 1 H NMR (300 MHz, CDCl 3 , ppm) δ7.28-7.23 (m, 2H, Ph), 6.83-6.72 (m, 2H, Ph), 5.14-5.10 (d, 1H, PhCH A ), 4.61-4.56 (d, 1H, C(O)NC 2′ H A ), 4.20-4.04 (d, 2H, PhCH B , NC 2 H), 3.85-3.75 (s, 3H, OCH 3 ), 3.74-3.71 (m, 1H, PhCH A′ ,), 3.60-3.48 (m, 1H, PhCH B′ ,), 3.04-3.00 (m, 2H, C(O)NC 2′ H B , C(O)NC 4′ H A ), 2.94-2.88 (m, 1H, C(O)NC 8′ H B , NC 8′ H A ), 2.49-2.55 (m, 2H, C 4 H A , NC 6′ H A ), 2.31-2.25 (m, 2H, C 4′ H B , NC 6′ Ha), 2.20 (m, 2H, C 4 H B , C 3 H A ), 1.80 (bs, 4H, C 3 H B , C 3′ H, C 7′ H, C 9′ H 2 ), 1.42 (s, 9H, (CH 3 ) 3 );
[0152] 13 C NMR (50 MHz, CDCl 3 , ppm) 172.17, 169.73, 159.90, 139.16, 137.77, 129.58, 120.78, 114.11, 114.03, 113.96, 113.22, 113.05, 79.74, 55.21, 55.18, 49.49, 45.31, 33.76, 29.63, 28.32, 22.81, 14.07; IR (KBr): 3900, 3565, 3366, 3013, 2926, 2856, 2196, 1679, 1434, 1363, 1219 cm −1 ; MS (ESI): m/z=457.5 (M + )
Example 20
tert-butyl-7-((S)-1-(naphthalen-1-ylmethyl)-5-oxopyrrolidine-2-carbonyl)-3,7-diazabicyclo [3.3.1]nonane-3-carboxylate, (1n)
[0153] The compound was prepared from N-(1-naphthyl)pyroglutamic acid as described in the case of 1f
[0000]
[0154] Yield=77%; 1 H NMR (300 MHz, CDCl 3 , ppm) δ8.05-7.37 (m, 7H, Naphthyl), 5.62-5.67 (d, 1H, PhCH A ), 5.04-4.97 (d, 1H, PhCH B ), 4.62-4.52 (d, 1H, C(O)NC 2′ H A ), 4.11-4.07 (m, 1H, NC 2 H, NC 8′ H A ), 3.77-3.76 (m, 1H, PhCH A′ ), 3.24-3.20 (m, 1H, PhCH B′ ), 3.01-2.91 (m, 3H, C(O)NC 4′ H A , C(O)NC 8′ H B , C(O)NC 2′ H B ), 2.66-2.42 (m, 3H, NC 6′ H A 1H, C 4 H A , C 4′ H B ), 2.39 (m, 1H, NC 6′ H B ), 2.07-2.03 (m, 5H, C 4 H B , C 3 H A , C 3 H B , C 3′ H, C 7′ H), 1.70 (bs, 2H, C 9′ H 2 ), 1.42 (s, 9H, (CH 3 ) 3 ); IR (KBr): 3947, 3675, 3484, 3421, 3287, 2923, 2853, 2361, 1674, 1452, 1365 cm −1 ; MS (ESI): m/z=447.5 (M + )
Example 21
(5S)-5-(7-(4-benzyl)-3,7-diazabicyclo[3.3.1]nonane-3-carbonyl)-1-(4-bromobenzyl)pyrrolidin-2-one, (1o)
[0155]
[0156] The compound was prepared from N-(4-bromobenzyl)pyroglutamic acid as described in the case of 1f
[0157] Yield=65%; 1 H NMR (300 MHz, CDCl 3 , ppm) δ7.45-7.04 (m, 8H, Ph-H) 5.20-5.15 (d, 1H, PhCH A ), 4.61-4.56 (d, 1H, C(O)NC 2′ H A ), 4.20-4.12 (dd, 1H, NC 2 H), 3.83-3.71 (d, 1H, PhCH B ), 3.52-3.41 (m, 2H, PhCH A′ , NC 8′ H A ), 3.19-3.15 (m, 2H, PhCH B′ , C(O)NC 4′ H A ), 2.95 (m, 2H, C(O)NC 2′ H B , NC 8′ H B ), 2.65 (m, 1H, NC 6′ H A ), 2.15-1.88 (m, 4H, C 4′ H B , NC 6′ H B , C 4 H B , C 3 H A ), 1.83-1.79 (m, 1H, C 3 H B ), 1.74 (m, 2H, C 3′ H, C 7′ H, bs, 2H, C 9′ H 2 );
[0158] 13 C NMR (50 MHz, CDCl 3 , ppm); 175.33, 168.44, 137.22, 136.79, 133.38, 131.46, 130.16, 129.28, 128.54, 127.89, 120.79, 62.72, 59.36, 58.16, 49.20, 46.33, 45.04, 31.05, 29.96, 29.68, 29.40, 29.19, 28.48, 21.10; IR (KBr): 3870,3777, 3588, 3526, 2924, 2276, 1680, 1451, 1220 cm −1 ; MS (ESI): m/z=510.3 (M + )
Example 22
(5S)-5-(7-benzyl)-3,7-diazabicyclo[3.3.1]nonane-3-carbonyl)-1-(4-methoxybenzyl) pyrrolidin-2-one, (1p)
[0159]
[0160] The compound was prepared from N-(4-methoxybenzyl)pyroglutamic acid as described in the case of 1f
[0161] Yield=75%; 1 H NMR (300 MHz, CDCl 3 , ppm) δ7.55-7.08 (m, 8H, Ph-H) 5.19-5.16 (d, 1H, PhCH A ), 4.59-4.55 (d, 1H, C(O)NC 2′ H A ), 4.22-4.09 (dd, 1H, NC 2 H), 3.83-3.70 (d, 1H, PhCH B ), 3.74 (s, 3H, OCH 3 ), 3.50-3.39 (m, 2H, PhCH A′ , NC 8′ H A ), 3.20-3.16 (m, 2H, PhCH B′ , C(O)NC 4′ H A ), 2.95 (m, 2H, C(O)NC 2′ H B , NC 8′ H B ), 2.64 (m, 1H, NC 6′ H A ), 2.17-1.87 (m, 4H, C 4′ H B , NC 6′ H B C 4 H B , C 3 H A ), 1.83-1.79 (m, 1H, C 3 H B ), 1.76-1.57 (m, 2H, C 3′ H, C 7 H, bs, 2H, C 9′ H 2 ); 13 CNMR (50 MHz, CDCl 3 , ppm); 175.30, 167.45, 137.22, 138.79, 134.38, 131.40, 131.16, 130.28, 128.55, 127.80, 121.79, 62.62, 59.26, 58.21, 49.20, 46.42, 45.00, 31.17, 30.22, 29.68, 29.42, 29.20, 28.50, 21.12; IR (KBr): 3872, 3775, 3584, 3540, 2934, 2277, 1668, 1453, 1222 cm −1 ;
Example 23
5-(7-Benzoyl-3,7-diaza-bicyclo[3.3.1]nonane-3-carbonyl)-1-(2-bromo-benzyl)-pyrrolidin-2-one, (1q)
[0162]
[0163] Step-1: 1b (1.5 g, 1.0 eq., 4.39 mmoles) was weighed and dissolved in dry DCM (10 ml). To the stirred solution at a temperature of 0° C., TFA (1.641 ml, 5.0 eq., 2.196 mmoles) was injected slowly and allowed to stir for 1 hour. The resulting mixture was extracted with DCM. It was washed with water and brine. Organic layer was collected and the combined fractions were dried over anhydrous sodium sulphate and concentrated to get yellow oily liquid (1.2 g).
[0164] Step-2: Benzoyl chloride (0.104 ml, 1.2 eq, 0.741 mmol) was added drop wise to the stirring solution of crude mass in DCM from step-1 (250 mg, 1 eq, 0.617 mmol) and triethylamine (0.198 ml, 2.3 eq, 1.42 mmol) in dry dichloromethane at 0° C. and allowed to stir for half hour. The reaction mixture was washed with 1N HCl (1×25 ml), 20% NaHCO 3 (1×25 ml). The combined organics were washed with anhydrous sodium sulphate and concentrated to obtain yellow oily liquid. The crude product was purified by column chromatography on silica (Chloroform: Methanol, 8:2) to obtain the pure product
[0165] Yield: 88%; MP: 85° C.; [α] D 27° C. : +13.73 (Methanol, c=0.1000); IR (KBr): 3404.0, 2929.5, 2365.0, 1629.8, 1429.4, 1351.7, 1246.7, 1085.7 cm −1 ; 1 H NMR (300 MHz, CDCl 3 , ppm) δ7.57-7.17 (m, 9H, 2×Ph); 5.15-5.10 (br d, J=15 Hz, 1H, PhCH A ); 4.80-4.75 (br d, J=15 Hz, 1H, NC 2′ H A ); 4.62-4.57 (br d, J=15 Hz, 1H, PhCH B ); 4.22-4.11 (m, 1H, NC 2 H); 3.88-3.83 (d, J=15 Hz, 1H, NC 8′ H A ); 3.71-3.66 (d, J=15 Hz, 1H, NC 2′ H B ); 3.24-3.12 (m, 3H, NC 8′ H B , NC 4′ H A , NC 6′ H A ); 2.90-2.86 (d, J=12 Hz, NC 6′ H B ); 2.52-2.49 (m, 1H, C 4 H A ); 2.44-2.40 (m, 1H, C 4′ H B ); 2.34-2.24 (m, 1H, C 4 H B ); 2.22-2.07 (m, 1H, C 3 H A ); 1.95-1.91 (m, 3H, C 3 H B , C 3′ H, C 7′ H); 1.83 (m, 2H, C 9′ H 2 ); 13 C NMR (75 MHz, CDCl 3 , ppm) δ175.83 (C═O), 171.35 (N 1′ CO), 170.21 (N 5′ CO), 135.87 (Ph), 132.80 (Ph), 131.37 (Ph), 129.43 (Ph), 128.74 (Ph), 127.84 (Ph), 126.70 (Ph), 124.14 (Ph), 56.95 (NC 2 ), 52.47 (NC 2′ ), 49.53 (NC 8′ ), 46.56 (NC 6′ ), 46.08 (NC 4′ ), 45.30 (NCH 2 ), 30.85 (Bridge CH 2 ) 29.87 (C 3 ), 27.66 (C 3′ , C 7′ ), 23.39 (C 4 ); MS (ESI): m/z=512 (M+3) +
Example 24
1-(2-Bromo-benzyl)-5-[7-(toluene-4-sulphonyl)-3,7-diaza-bicyclo[3.3.1]nonane-3-carbonyl]-pyrrolidin-2-one, (1r)
[0166]
[0167] p-Toluene sulphonyl chloride (0.140g, 1.2 eq, 0.739 mmol) was added drop wise to the stirring solution of Boc de-protected product of 1b (250 mg, 1 eq, 0.616) and TEA (0.197 ml, 2.3 eq, 1.41 mmol) in dry DCM at 0° C. and allowed to stir for half hour. The reaction mixture was washed with 1N HCl (1×25 ml), 20% NaHCO 3 (1×25 ml). The combined organics were washed with anhydrous sodium sulphate and concentrated to obtain yellow oily liquid.
[0168] Yield=85%; [α] D 27° C. : −2.8263 (Methanol, c=0.1000); MP: 203-205° C.; IR (KBr): 3451.8, 1638.4 cm −1 ; 1 H NMR (300 MHz, CDCl 3 , ppm): δ 7.58-7.15 (m, 8H, 2×Ph); 5.13-5.08 (d, J=15 Hz, 1H, PhCH A ); 4.66-4.62 (d, J=12 Hz, 1H, NC 2′ H A ); 4.27-4.23 (m, 1H, NC 2 H); 4.15-4.10 (d, J=15 Hz, 1H, PhCH B ); 3.793.76 (d, J=9 Hz, 2H, NC 8′ H A , NC 2′ H B ); 3.66-3.62 (d, J=12 Hz, 1H, NC 4′ H A ); 3.20-3.15 (m, 1H, NC 8′ H B ); 2.96-2.91 (m, 1H, NC 6′ H A ); 2.71-2.62 (m, 1H, NC 4 H A ); 2.47-2.43 (m, 6H, NC 4′ H B , NC 6′ H B , C 4 H B , CH 3 ); 2.34-2.31 (m, 2H, C 3 H 2 ); 2.28-2.05 (C 3′ H, C 7′ H); 1.98 ppm (m, 2H, C 9′ H 2 ); 13 C NMR (75 MHz, CDCl 3 , ppm): δ 176.05 (C═O), 169.32 (C═O), 143.74 (Ph), 135.97 (Ph), 132.80 (Ph), 131.50 (Ph), 131.12 (Ph), 129.67 (Ph), 129.33 (Ph), 127.79 (Ph), 127.75 (Ph), 124.06 (Ph), 56.80 (NC 2 ), 50.59 (NC 8′ ), 48.65 (NC 2′ ), 46.13 (NC 6′ ), 45.38 (NCH 2 ), 29.74 (Bridge CH 2 ), 27.73 (NC 4′ ), 27.28 (C 3′ , C 4′ ) 22.57 (CH 3 ), 21.51 ppm (C 4 ); MS (ESI): m/z: 562.0 (M+1) +
Example 25
5-(7-Benzoyl-3,7-diaza-bicyclo[3.3.1]nonane-3-carbonyl)-1-(4-methyl-benzyl)-pyrrolidin-2-one, (1s)
[0169] Benzoyl chloride (0.123 g, 1.2 eq, 0.880 mmol) was added drop wise to the stirring solution of Boc deprotected product of 1e (250 mg, 1 eq, 0.733 mmol) and TEA (0.235 ml, 2.3 eq, 1.68 mmol) in dry DCM at 0° C. and allowed to stir for half hour. The reaction mixture was washed with 1N HCl (1×25 ml) 20% NaHCO 3 (1×25 ml). The combined organics were washed with anhydrous sodium sulphate and concentrated to obtain yellow oily liquid.
[0000]
[0170] Yield=89.2%; [α] D 27° C. : +2.1583 (Methanol, c=0.1000); IR (Neat): 3420.3, 2958.5, 1678.4, 1632.11, 1438.3, 1220.2 cm −1 ; 1 H NMR (300 MHz, CDCl 3 , ppm): δ7.42-7.00 (m, 9H, 2×Ph); 5.15-5.04 (m, 1H, PhCH A ); 4.81-4.55 (m, 1H, NC 2′ H A ); 4.16 (m, 1H, NC 2 H); 3.89-3.77 (m, 1H, NC 8′ H A ); 3.67-33.64 (m, 1H, PhCH B ); 3.33-3.19 (m, 2H, NC 2′ H B , NC 8′ H B ); 3.04-3.02 (m, 1H, NC 4′ H A ); 2.93-2.89 (m, 7H, C 4 H A , NC 6′ H B , C 4 H B , C 4′ H B , CH 3 ); 2.22-2.18 (m, 2H, C 3 H 2 ); 1.95-1.81 (m, 2H, C 3′ H, C 7′ H); 1.27-1.26 (m, 2H, C 9 H 2 ); 13 C NMR (75 MHz, CDCl 3 , ppm): δ 175.83 (C═O), 171.28 (C═O), 170.20 (NC 5′ O), 137.4 (ipso Ph), 136.08 (Ph), 136.00 (Ph), 129.40 (Ph), 129.22 (Ph), 128.87 (Ph), 128.72 (Ph), 128.65 (Ph), 128.56 (Ph), 128.20 (Ph), 127.22 (Ph), 126.76 (Ph), 57.49 (NC 2 ), 49.47 (NCH 2 ), 46.49 (NC 4′ ), 46.16 (NC 6′ ), 45.92 (NC 2′ ), 45.13 (NC 8′ ), 34.27 (Bridge CH 2 ), 30.40 (C 4 ), 27.61 (C 3′ ), 23.40 (C 7′ ), 21.29 (C 3 ), 21.17 (CH 3 ); MS (ESI): m/z=446.1 (M+H) +
Example 26
1-(4-Methyl-benzyl)-5-[7-(toluene-4-sulphonyl)-3,7-diaza-bicyclo[3.3.1]nonane-3-carbonyl]-pyrrolidin-2-one, (1t)
[0171]
[0172] The compound was prepared by the addition of p-toluene sulphonyl chloride (0.167g, 1.2 eq, 0.880 mmol) to the stirring solution Boc de-protected product of 1e (250 mg, 1 eq, 0.733 mmol) and TEA (0.235 ml, 2.3 eq, 1.68 mmol) in dry DCM.
[0173] Yield=91.5%; [α] D 27° C. : −0.9313 (Methanol, c=0.1000); IR (Neat): 3449.8, 2953.7, 1641.5, 1443.2, 1220.9 cm −1 ; 1 H NMR (300 MHz, CDCl 3 , ppm): δ 7.60-7.00 (m, 8H, 2×Ph), 5.20-5.03 (m, 1H, PhCH A ), 4.68-4.65 (m, 1H, NC 2′ H A ), 4.24-4.23 (m, 1H, NC 2 H), 3.94-3.64 (m, 3H, PhCH B , NC 2′ H B , NC 8′ H A ), 3.13-2.97 (m, 2H, NC 8′ H B , NC 4′ H A ), 2.77-2.76 (m, 1H, NC 6′ H B ), 2.72-2.66 (m, 3H, C 4 H A , NC 6′ H B , C 4′ H B ), 2.45-2.07 (m, 5H, C 4 H A , C 3 H 2 , CH 3 ), 1.92 (m, 2H, C 3′ H), 1.66 (m, 1H, C 7′ H), 1.28-1.25 (m, 2H, C 9′ H 2 ); 13 C NMR (50 MHz, CDCl 3 , ppm): δ 151.53 (Ph), 135.80 (Ph), 129.68 (Ph), 129.22 (Ph), 128.51 (Ph), 128.25 (Ph), 128.65 (Ph), 128.56 (Ph), 128.20 (Ph), 127.22 (Ph), 126.76 (Ph), 46.10 (NCH 2 ), 45.01 (NC 2 ), 34.20 (Bridge CH 2 ), 34.23 (NC 4′ ), 30.34 (NC 6′ ), 27.80 (C 3′ ), 27.36 (C 7′ ), 22.64 (CH 3 ), 21.53 (CH 3 ), 21.20 (C 3 ); MS (ESI): m/z: 496.0 (M+H) +
Example 27
(5S)-5-(2-bromobenzyl-3,7-diazabicyclo[3.3.1]nonane-3-carbonyl)-1-(4-methylbenzyl)pyrrolidin-2-one, (1u)
[0174]
[0175] (5S)-5-(3,7-diazabicyclo[3.3.1]nonane-3-carbonyl)-1-(4-methylbenzyl)pyrrolidin-2-one (250 mg, 1.0 eq., 0.76 mmol) was weighed and taken in round bottom flask, dissolved in dry acetone (2 ml). 2 g of anhydrous potassium carbonate (K 2 CO 3 ) was added. 2-bromobenzyl bromide (182.4 mg, 1.5 eq., 1.14 mmol) was added to the reaction mixture and refluxed in an oil bath at 50-60° C. for 2 hours with stirring. The reaction was monitored for completion by TLC. After the completion of reaction, reaction mixture was filtered to remove K 2 CO 3 and concentrated in vacuum. The desired product was isolated from the crude reaction mixture by column chromatography.
[0176] Yield=64%; MP: 85-90° C.; 1 H NMR (300 MHz, CDCl 3 , ppm) δ7.29 (m, 9H, 2×Ph), 5.18-5.14 (d, 1H, PhCH A ), 4.94-4.90 (m, 1H, C(O)NC 2′ H A ), 4.61-4.56 (d, 1H, PhCH B ), 4.14 (m, 1H, NC 2 H), 3.85-3.80 (m, 2H, PhCH A′ , NC 8′ H A ), 3.51-3.47 (m, 2H, PhCH B′ , C(O)NC 4′ H A ), 3.29-3.15 (m, 2H, C(O)NC 2′ H B , C(O)NC 8′ H B ,), 3.04-2.89 (m, 1H, NC 6′ H A ), 2.57 (m, 1H, C 4 H A ), 2.37 (m, 2H, C 4′ H B , NC 6′ H B ), 2.09-2.08 (m, 2H, C 4 H B , C 3 H A ), 1.98 (m, 1H, C 3 H B ), 1.93 (m, 2H, C 3′ H, C 7′ H), 1.72 (bs, 2H, C 9′ H 2 ); 13 C NMR (50 MHz, CDCl 3 , ppm) δ181.36, 180.12, 169.59, 143.12, 129.42, 128.74, 128.17, 127.64, 114.05, 63.58, 59.23, 58.80, 49.77, 48.27, 46.64, 30.88, 29.83, 29.68, 29.33, 21.52; IR (KBr): 3444, 2925, 2857, 2372, 2338, 2141, 1638, 1447, 1355, 1225, 1093 cm −1 ; MS (ESI): m/z=452.3 (M + )
Example 28
(5S)-5-(7-(4-bromobenzyl)-3,7-diaza bicyclo[3.3.1]nonane-3-carbonyl)-1-(4-methylbenzyl)pyrrolidin-2-one, (1v)
[0177] Please refer the example 1u (4-bromobenzyl bromide used here)
[0000]
[0178] Yield=67%; 1 H NMR (300 MHz, CDCl 3 , ppm) δ7.45-7.04 (m, 8H, Ph-H) 5.20-5.15 (d, 1H, PhCH A ), 4.61-4.56 (d, 1H, C(O)NC 2′ H A ), 4.20-4.12 (dd, 1H, NC 2 H), 3.83-3.71 (d, 1H, PhCH B ), 3.52-3.41 (m, 2H, PhCH A′ , NC 8′ H A ), 3.19-3.15 (m, 2H, PhCH B , C(O)NC 4′ H A ), 2.95 (m, 2H, C(O)NC 2′ H B , NC 8′ H B ), 2.65 (m, 1H, NC 6′ H A ), 2.15-1.88 (m, 4H, C 4′ H B , NC 6′ H B , C 4 H B , C 3 H A ), 1.83-1.79 (m, 1H, C 3 H B ), 1.74 (m, 2H, C 3′ H, C 7′ H, bs, 2H, C 9′ H 2 )
[0179] 13 C NMR (50 MHz, CDCl 3 , ppm) 180.33, 173.40, 142.20, 138.34, 137.69, 134.78, 134.30, 133.53, 132.90, 67.65, 64.34, 63.14, 61.36, 59.96, 54.18, 51.32, 50.03, 36.06, 34.68, 34.17, 26.47; IR (KBr): 3891, 3806, 3708, 3625, 3585, 3446, 2924, 2411, 1676, 1452, 1363, 1221, 1091 cm −1 ; MS (ESI): m/z=510.4 (M + )
Example 29
(5S)-5-(7-(4-chlorobenzyl)-3,7-diazabicyclo[3.3.1]nonane-3-carbonyl)-1-(4-methylbenzyl)pyrrolidin-2-one, (1w)
[0180]
[0181] Please refer the example 1u (4-chlorobenzyl chloride used here)
[0182] Yield=62%; 1 H NMR (300 MHz, CDCl 3 , ppm) δ: 7.52-7.49 (m, 1H) 7.35-7.28 (m, 2H), 7.11-7.00 (m, 4H) 6.85-6.82 (d, 1H) 5.18-5.13 (d, 1H, PhCH A ), 4.64-4.59 (d, 1H, C(O)NC 2′ H A ), 4.16-4.12 (dd, 1H, NC 2 H), 3.79-3.74 (d, 1H, PhCH B ), 3.60-3.41 (m, 2H, PhCH A′ , NC 8′ H A ), 3.16-3.00 (m, 2H, PhCH B′ , C(O)NC 4′ H A ), 2.91-2.88 (m, 1H, C(O)NC 2′ H B ), 1.98-1.97 (m, 2H, C(O)NC 8′ H B , NC 6′ H A ), 1.95-1.93 (m, 2H, C 4′ H B , NC 6′ H B ), 1.85 (m, 2H, C 4 H B , C 3 H A ), 1.44-1.43 (m, 1H, C 3 H B ), 1.28 (m, 2H, C 3′ H, C 7′ H, bs, 2H, C 9′ H 2 ); 13 C NMR (50 MHz, CDCl 3 , ppm) 175.50, 168.55, 137.20, 136.98, 133.44, 132.65, 129.27, 128.54, 62.45, 59.62, 58.58, 56.41, 54.93, 49.15, 46.36, 45.04, 29.90, 29.90, 29.26, 28.51, 21.10; IR (KBr): 3869, 3441, 3013, 2365, 1679, 1515, 1450, 1218 cm −1 ; MS (ESI): m/z=466.01 (M + )
Example 30
Benzyl(2S)-1-(7-benzyl-3,7-diazabicyclo[3.3.1]nonan-3-yl)-3-methyl-1-oxobutan-2-yl carbamate, (1x)
[0183]
[0184] Cbz protected L-Valine (530 mg, 1.00 eq., 2.10 mmol) was weighed and taken in a round bottom flask, dissolved in dry DCM (10 ml). At 0° C., HOBt (427 mg, 1.5 eq., 3.10 mmol) was added and allowed to stir for 15 mins. Further 519 mg of DCC (1.2 eq., 2.50 mmol) dissolved in dry DCM was injected slowly to the reaction mixture in a moisture free condition. After 15 minutes 499 mg of N-benzyl bispidine (1.1 eq., 2.32 mmol) dissolved in dry DCM was added slowly to the reaction mixture and allowed to stir for 1-2 hours at 25° C. The reaction was monitored for completion by TLC. After the completion of reaction the reaction mixture was filtered to remove the DCU formed during the reaction ant the washed with 1 N HCl and Sodium bicarbonate solution to remove the excess of unreacted base and acid respectively. The organic layer was collected and evaporated to get the crude product which was purified by column chromatography to obtain the pure product (456 mg) as yellow oily liquid.
[0185] Yield=67%; 1 H NMR (300 MHz, CDCl 3 , ppm) δ7.37-7.26 (m, 10H, Ph-H) 5.91-5.87 (d, 1H, NH), 5.11-5.05 (d, 3H, C(O)OCH 2 , NHCHC(O)) 4.72-4.65 (d, 1H, C(O)NC 2′ H A ), 4.25-4.20 (d, 1H, CH(CH 3 ) 2 ) 4.12-4.08 (d, 1H, CONC 8′ H B ), 3.51-3.46 (d, 2H, NCH A′ Ph, NCH B′ Ph), 3.33 (d, 2H, CHCH A Ph, CHCH B Ph), 3.28-3.02 (m, 3H, CH 3 ), 2.90 (d, 3H, CH 3′ ), 2.35-2.25 (m, 2H, 2×NC 6 H), 2.11-2.98 (m, 4H, C(O)NC 4′ H A , C(O)NC 4′ H B , NC 8′ H A , NC 8′ H B ), 1.87-1.63 (m, 4H, C 1 ′H, C 5 ′H, bridge CH 2 ); 13 C NMR (200 MHz, CDCl 3 , ppm) δ166.51, 156.59, 139.26, 136.42, 128.95, 128.47, 128.37, 128.22, 128.13, 127.99, 66.77, 66.75, 66.73, 63.49, 58.53, 55.56, 50.49, 46.98, 29.70, 22.69, 20.12, 14.12; IR (KBr): 3932, 3780, 3744, 3704, 3666, 3606, 3559, 3483, 3436, 3191, 3093, 2936, 2844, 2383, 2344, 2274, 1634, 1451, 1222, 1107, 1022 cm −1 ; MS (ESI): m/z=450.3 (M+)
Example 31
Benzyl(2S)-1-(7-benzyl-3,7-diazabicyclo[3.3.1]nonan-3-yl)-1-oxo-3-phenylpropan-2-yl carbamate (1y)
[0186]
[0187] Cbz protected L-Phenyalanine (580 mg, 1.00 eq., 1.93 mmol) was weighed and taken in a round bottom flask, dissolved in dry DCM (10 ml). At 0° C., HOBt (393 mg, 1.5 eq., 2.90 mmol) was added and allowed to stir for 15 mins. Further 477 mg of DCC (1.2 eq., 2.31 mmol) dissolved in dry DCM was injected slowly to the reaction mixture in a moisture free condition. After 15 min., 459 mg of N-benzyl bispidine (1.1 eq., 2.12 mmol) dissolved in dry DCM was added slowly to the reaction mixture and allowed to stir for 1-2 hours at 25° C. The reaction was monitored for completion by TLC. After the completion of reaction the reaction mixture was filtered to remove the DCU formed during the reaction ant the washed with 1 N HCl and Sodium bicarbonate solution to remove the excess of unreacted base and acid respectively. The organic layer was collected and evaporated to get the crude product which was purified by column chromatography to obtain the pure product (510 mg) as yellow oily liquid.
[0188] Yield=53%; 1 H NMR (300 MHz, CDCl 3 , ppm) δ7.31-7.16 (m, 15H, Ph-H) 6.06-6.03 (d, 1H, NH), 5.13-5.03 (dd, 3H, C(O)OCH 2 , NHCHC(O)) 4.63-4.59 (d, 1H; C(O)NC 2′ H A ), 3.75-3.71 (d, 1H, CONC 8′ H B ), 3.29-3.27 (d, 1H, NCH A′ Ph), 3.06-3.04 (d, 1H, NCH B′ Ph), 2.81-2.77 (CHCH A Ph), 2.59-2.54 (d, 1H, CHCH B Ph), 2.92-2.77 (m, 4H, C(O)NC 4′ H A , C(O)NC 4′ H B , NC 8′ H A , NC 8′ H B ), 2.19-2.16 (m, 2H, 2×NC 6 H), 2.02 (bs, 1H, C 1 ′H), 1.87 (bs, 1H, C 5′ H), 1.69 (m, 2H, bridge CH 2 ); 13 C NMR (200 MHz, CDCl 3 , ppm) 169.33, 155.58, 138.40, 136.99, 129.68, 129.40, 128.94, 128.45, 128.45, 128.22, 126.82, 77.79, 76.52, 66.65, 63.45, 59.29, 58.39, 51.90, 49.84, 46.51, 39.84, 31.61, 29.23, 28.43; IR (KBr): 3865, 3755, 3439, 3295, 1634, 1507, 1453, 1219, 1145, 1049 cm −1 ; MS (ESI): m/z=498.3 (M + )
Example 32
Benzyl(2S)-1-(7-benzyl-3,7-diazabicyclo[3.3.1]nonan-3-yl)-4-methyl-1-oxopentan-2-ylcarbamate (1z)
[0189]
[0190] Cbz protected L-Leucine (530 mg, 1.00 eq., 1.93 mmol) was weighed and taken in a round bottom flask, dissolved in dry DCM (10 ml). At 0° C.; HOBt (405 mg, 1.5 eq., 2.90 mmol) was added and allowed to stir for 15 mins. Further 469 mg of DCC (1.2 eq., 2.21 mmol) dissolved in dry DCM was injected slowly to the reaction mixture in a moisture free condition. After 15 mins 452 mg of N-benzyl bispidine (1.1 eq., 2.02 mmol) dissolved in dry DCM was added slowly to the reaction mixture and allowed to stir for 1-2 hours at 25° C. The reaction was monitored for completion by TLC. After the completion of reaction the reaction mixture was filtered to remove the DCU formed during the reaction ant the washed with 1 N HCl and Sodium bicarbonate solution to remove the excess of unreacted base and acid respectively. The organic layer was collected and evaporated to get the crude product which was purified by column chromatography to obtain the pure product (482 mg) as yellow oily liquid.
[0191] Yield=63%; 1 H NMR (300 MHz, CDCl 3 , ppm) δ7.36 (m, 10H, Ph-H) 5.93-5.90 (d, 1H, NH), 5.72-5.69 (d, 1H, NHCHC(O)), 5.11-5.05 (d, 2H, C(O)OCH 2 ,), 4.95-4.89 (d, 3H, C(O)NC 2′ H A , NHCHCH 2 ), 4.74-4.72 (d, 1H, CH(CH 3 ) 2 ), 4.64-4.60 (d, 2H, NCH A′ Ph, NCH B′ Ph), 4.39-4.34 (d, 1H, CONC 8′ H B ), 4.04-3.99 (d, 1H, CHCH A Ph), 3.84-3.80 (d, 1H, CHCH B Ph), 3.52-3.48 (m, 3H, CH 3 ), 3.23-3.19 (m, 2H, 2×NC 6 H), 2.94 (d, 3H, CH 3′ ), 2.93-2.81 (m, 4H, C(O)NC 4′ H A , C(O)NC 4′ H B , NC 8′ H A , NC 8′ H B ), 2.41-2.38 (d, 1H, C 1′ H), 2.33-2.29 (d, 1H, C 5′ H), 2.11 (m, 2H, bridge CH 2 ); 13 C NMR (200 MHz, CDCl 3 , ppm) 171.17, 156.40, 137.88, 136.61, 128.43, 128.37, 128.25, 127.92, 126.91, 63.52, 59.59, 58.14, 49.98, 46.66, 42.68, 30.73, 29.70, 29.47, 28.93, 24.66, 24.54, 23.79, 23.47, 22.16, 21.84; IR (KBr): 3842, 3756, 3016, 2925, 1711, 1629, 1508, 1453, 1335, 1218, 1118, 1048 cm −1 ; MS (ESI): m/z=464.3 (M + )
Evaluation of Anti-Thrombotic Activity of Compounds
In Vivo/Ex Vivo Studies
[0192] The animals, male Swiss albino mice (20-25g), were obtained from the National Laboratory Animal Centre of CSIR-Central Drug Research Institute, Lucknow. All the animal experiments were subjected to Institutional Animal Ethical Committee (IAEC) guidelines and were conducted according to the guidelines of Experimental Animal Care issued by the Committee for Purpose of Control and Supervision of Experiments on Animals (CPCSEA). The animals were housed in polypropylene cages and maintained on standard chow diet and water ad libitum and on 12 hr/12 hr light-dark cycle at temperature: 25±2° C., humidity: 45-55% and ventilation: 10-12 exchanges/hr.
Collagen-Epinephrine Induced Pulmonary Thromboembolism
[0193] To assess the antithrombotic efficacy of compounds, mice were grouped into vehicle, aspirin and compound treated groups, and each group included ten animals. Pulmonary thromboembolism was induced by injecting a mixture of collagen (150 μg/ml) and adrenaline (50 μg/ml) into the tail vein to achieve final doses of collagen (1.5 mg/kg) and adrenaline (0.5 mg/kg) to induce hind limb paralysis or death. 11, 12 Number of test animals killed or paralyzed were evaluated (death/paralysis were employed as endpoint to evaluate antithrombotic agents). The percent protection was calculated by taking the ratio of number of test animals killed or paralyzed to that of total tested animals. Results have been reported as percentage protection, which represents protection against collagen and epinephrine induced thromboembolism and expressed as;
[0000] Percent Protection=[1−( P test /P control )]×100
[0000] Where, P test is the number of animals paralyzed/dead in test compound-treated group, and P control is the total number of animals paralyzed/dead in vehicle treated group. The percent protection refers to the number of animals in compound treated group that were prevented from paralysis/death.
Results:
[0194] After 1 hour of dosing by oral route, 14 compounds showed ˜40-60% protection against collagen plus epinephrine induced pulmonary thromboembolism in mice at 30 μM/kg concentration (in vivo), while the standard antithrombotic drug Aspirin displayed only 40% protection at a dose of 170 μM/kg, which is sufficient enough to cause bleeding complications (Table 1).
Bleeding Time
[0195] Bleeding time in mice was evaluated by the method of Dejana et al. ( Thromb Res. 1979; 15:191-7) The tail 2 mm from tip of mice was incised and the blood oozed was soaked on a filter paper, which was monitored at an interval of 10-15 sec till the bleeding stops. The time elapsed from the tip incision to the stoppage of bleeding was determined as the bleeding time. The preferred compound, aspirin (170 μM/kg), Clopidogrel (70 μM/kg) or vehicle was given orally 60 min prior to the tail incision in a group of 5 mice each.
Results:
[0196] The compound 1d after 1 hr of dosing (by oral route) had a mild effect on bleeding tendency in mice when compared against aspirin and clopidogrel and hence, indicates that the compound escapes the adverse events of bleeding risk in comparison to existing anti-platelet agents, at least in preclinical models. However, after 4 hours (p.o.), the compound 1d (30 μM/kg) displayed upto 60% of protection in collagen-epinephrine induced pulmonary thromboembolism ii mice which was higher than that observed in standard drug Aspirin treated mice (40%). This indicates that the bioavailability and efficacy of compound 1d is increased after 4 hours of oral dosing. The bleeding tendency in 1d treated mice was also increased after 4 hrs (8.4 min) but the prolongation was comparable to that of standard drug Aspirin (8.2 min), and less than Clopidogrel (9.8 min). This suggests that the compound 1d displays a remarkable antithrombotic efficacy much better than the existing anti-platelet drugs, with a moderate alteration in bleeding tendency. ( FIG. 2 )
FeCl 3 Induced Thrombosis
[0197] Male Swiss albino mice were anesthetized byurethane (1.25 g/kg, i.p.). The carotid artery was carefully dissected and a pulsed Doppler Probe (LDF 100C, BioPac, USA) was placed around it to record the blood flow velocity and patency of the blood vessels. The carotid artery thrombosis was induced by FeCl 3 as follows: a square (1×0.5 mm) of Whatman Chromatography paper was immersed in 10% FeCl 3 solution for 5 min and placed on the carotid artery as described earlier. (Kurz K D, et al., Thromb Res 1990; 60(4):269-80; Surin W R et al J Pharmacol Toxicol Methods. 2010; 61(3):287-91) Thrombosis was monitored as the reduction in carotid artery blood flow. The time at which the blood-flow velocity was decreased to zero was recorded as the time to occlusion (TTO) of the carotid artery. When the blood flow velocity did not occlude within 120 minutes the time to thrombotic occlusion was assigned a value of >120 minutes.
Results:
[0198] FeCl 3 induced thrombosis is one of the widely used animal model for screening of anti-thrombotic agents. The model involves application of FeCl 3 on the adventitial layer of artery to induce vascular injury. FeCl 3 induces the generation of reactive oxygen species that leads to endothelial denudation resulting in platelet adhesion and formation of occlusive platelet rich thrombi. The compound 1d was further evaluated for its antithrombotic efficacy in ferric chloride induced arterial thrombosis model in mice. The compound 1d after 4 hr of its oral administration, prolonged the time to occlusion of carotid artery by 2.2 fold (control 9.5±0.4 min vs 1d 19.2±0.9 min). The standard drug Clopidogrel increased the TTO upto 23±0.9 min. Therefore, the efficacy elicited in this model substantiates the anti-thrombotic potential of this compound (Figure-3).
In Vitro Studies
[0199] From human subjects blood was collected in citrate-phosphate-dextrose (CPD) (1:7) from healthy volunteers (age between 18-60 years) after prior consent. A detailed medical history and physical examination was carried out before phlebotomy. The donors were free from heart, lung, kidney disease, cancer, epilepsy, diabetes, tuberculosis, abnormal bleeding tendency, allergic disease, sexually transmitted diseases, jaundice, malaria, typhoid and thyroid or any other endocrine disorder. Donors were free from any prior medication for last 72 hours.
Platelet Aggregation Measurements
[0200] A turbidimetric method was applied to measure platelet aggregation, using a four channel-Aggregometer (Model 700, Chronolog-corp, Havertown, USA. (Armida P T et al., Thrombosis Research. 1995; 78:107-15, Jain M, Surin W R et al Chem Biol Drug Des. 2012.) Fresh blood was drawn by venipuncture from consenting healthy human volunteers in citrate-phosphate-dextrose. Platelet-rich plasma (PRP) was obtained by centrifugation at 108 g for 20 minutes at 25° C. (Beckman TJ6, USA). Platelet rich plasma (1×10 8 platelets/ml, 0.45 ml) was pre-warmed to 37° C. for 2 min, then incubated with compound (3-300 μM) or an isovolumetric solvent control (0.5% DMSO) for 5 min before addition of the agonists (i.e., 1 μg/ml Collagen, 5 μM ADP, 25 μM TRAP, 1.5 mg/ml Ristocetin, Arachidonic Acid, collagen related peptide CRP-XL). The reaction was allowed to proceed for at least 5 min, and the extent of aggregation was expressed in percent aggregation by Aggrolink software. (Jain M, Surin W R et al Chem Biol Drug Des. 2012)
Results:
[0201] All the molecules were further tested (30 μM, in vitro) for their inhibitory effect on human platelet aggregation induced by various agonists (in vitro). The compounds 1d, 1g, 1h, 1o, 1u, 1v and 1w exhibited significant inhibition against collagen induced platelet aggregation (TABLE 1). Compound 1d, 1g, 1h, 1u, 1v and 1w is exhibiting dose dependent anti-platelet efficacy through dual mechanism inhibited both collagen as well as U46619 (thromboxane receptor agonist) induced platelet aggregation. Compound 1d was the most potent among these groups and exhibited a percent inhibition of 86±3.41% against collagen. The compound 1d, even up to 300 μM, did not exhibit any significant effect against ADP, thrombin mimetic SFLLRN (TRAP), GPVI agonist collagen related peptide (CRP-XL) and GP 1b-IX-V agonist Ristocetin induced platelet aggregation. However, the compound at 30 μM displayed a significant inhibition of platelet aggregation induced by thromboxane A 2 analog U46619 (75.5±6%). The compound 1d did not exhibit any inhibition of COX pathway via arachidonic acid induced platelet aggregation at 30 μM, but at higher concentration (300 μM and 500 μM) the compound 1d attenuated platelet aggregation upto 50%. These findings indicate that the compound 1d might exhibit its anti-platelet efficacy through dual mechanism, and hence requires further confirmation regarding its mechanism of action. Since aspirin is already proven clinically for its inhibitory effect on the production of thromboxane A2 by inhibiting cyclooxygenase, hence these compounds having a relatively potent TP-receptor as well as collagen receptor antagonistic activity could be very useful as therapeutic antithrombotic agents. Moreover, the action of compound 1d is platelet specific, since its presence did not altered the coagulability of blood as assessed by TT, PT and aPTT in human plasma. ( FIG. 1 )
[0000]
TABLE 1
In vivo (% protection; inducer, collagen + epinephrine) and in vitro
(% inhibition of aggregation; inducer, collagen) activity of bispidine
derivatives of N-substituted pyroglutamic acid, 1(a-w).
No.
Compound
R
R”
Protection (%) *
Inhibition (%) #,δ
1
1a
Boc
Phenyl
40
06.00 ± 14.00
2
1b
Boc
2-Bromophenyl
50
Ns
3
1c
Benzyl
Phenyl
30
44.00 ± 13.00
4
1d
Benzyl
2-Bromophenyl
40
86.00 ± 3.41
5
1e
Boc
4-Methylphenyl
40
25.00 ± 9.00
6
1f
Benzyl
4-Methylphenyl
25
07.00 ± 7.00
7
1g
Benzyl
2,6-Dichlorophenyl
40
68.00 ± 6.00
8
1h
Benzyl
4-Chlorophenyl
30
52.00 ± 8.00
9
1i
Benzyl
Tosyl
30
29.00 ± 1.00
10
1j
Boc
4-Cyanophenyl
55
11.00 ± 3.00
11
1k
Boc
4-Chlorophenyl
30
06.00 ± 11.00
12
1l
Boc
2,6-dichlorophenyl
30
03.00 ± 3.00
13
1m
Boc
4-Methoxyphenyl
45
10.00 ± 3.00
14
1n
Boc
1-Naphthyl
30
11.00 ± 4.00
15
1o
Benzyl
4-Bromophenyl
40
57.00 ± 11.00
16
1p
Benzyl
4-Methoxyphenyl
30
10.00 ± 4.00
17
1q
Benzoyl
2-Bromophenyl
60
25.60 ± 3.55
18
1r
Tosyl
2-Bromophenyl
55
16.80 ± 5.66
19
1s
Benzoyl
4-Methylphenyl
40
20.50 ± 7.50
20
1t
Tosyl
4-Methylphenyl
40
37.50 ± 10.50
21
1u
2-Bromobenzyl
4-Methylphenyl
30
67.00 ± 10.00
22
1v
4-Bromobenzyl
4-Methylphenyl
50
61.00 ± 8.00
23
1w
2-Chlorobenzyl
4-Methylphenyl
35
67.00 ± 8.00
Aspirin
40 (at 170 μm)
—
DMSO
25.31 ± 2.59
* Collagen-epinephrine induced pulmonary thromboembolism in mice (in vivo)
# Inhibition of collagen induced platelet aggregation in human platelets (in vitro)
δ Compound concentration used = 30 μM; n = 3; ns, not significant
[0202] Carboxamides of substituted or protected amino acids with substituted bispidines were also prepared 1(x-z) and they exhibited low profile antiplatelet efficacy both in vitro and in vivo (Table-2).
[0000]
TABLE 2
In vivo (% protection; inducer, collagen + epinephrine) in vitro (% inhibition of
aggregation; inducer, collagen) activity of bispidine derivatives of N-protected amino acids, 1(x-z)
Protection
Inhibition
No.
Compound
R
R 1
R 2
R 3
n
(%)*
(%) # δ
1
1x
Benzyl
methyl
methyl
Bezyloxycarbonyl
0
20
18.00 ± 04
2
1y
Benzyl
H
phenyl
Bezyloxycarbonyl
0
55
22.00 ± 5.00
3
1z
Benzyl
H
methyl
Bezyloxycarbonyl
1
40
12.00 ± 10.00
Aspirin
40 (at
170 μm)
*Collagen-epinephrine induced pulmonary thromboembolism in mice (in vivo)
# Inhibition of collagen induced platelet aggregation in human platelets (in vitro)
δ Compound concentration used = 30 μM; n = 3; ns, not significant
Advantages of the Invention
[0000]
1. Both starting materials L-glutamic acid and 4-piperidone hydrochloride and reaction reagents are economically cheap, easily accessible and non-hazardous in nature.
2. All the products were isolated in moderately good yield (ranging 50 to 90%).
3. All the final products are very much stable even at room temperature.
4. The compounds exhibited tremendous inhibition of % platelet aggregation induced by collagen induced aggregation in human platelets (in vitro) varies from 03.00±3.00 to 86.00±3.41% at 30 μM concentration out of them seven compounds exhibited highly promising anti-platelet efficacy inhibited collagen, in vitro varies from 57.00±11.00 to 86.00±3.41%
5. Moreover, five compound exhibited dose dependent anti-platelet efficacy through dual mechanism inhibited both collagen as well as U46619 (thromboxane receptor agonist) induced platelet aggregation and varies from 52±03 to 85±03. | The present invention relates to the 3,7-diazabicyclo[3.3.1]nonane carboxamides and process for preparation thereof. The present invention further relates to the compounds of general formula 1 possessing anti-thrombotic (anti-platelet) activities. The invention also relates to use of these moieties as inhibitors of collagen induced platelet adhesion and aggregation mediated through collagen receptors both in vitro and in vivo. Further, invention also relates these class of compounds exhibiting anti-platelet efficacy through dual mechanism inhibited both collagen as well as U46619 (thromboxane receptor agonist) induced platelet aggregation.
wherein, R′ is;
wherein R is selected from alkyl, acyl, tosyl, tert-butyloxycarbonyl, araalkyl or substituted araalkyl groups; R″ is selected preferably from halogen, cyano, lower alkyl, aryl, substituted aryl, and tosyl groups; R1 is selected from hydrogen and lower alkyl groups; R2 is selected from lower alkyl and aryl groups; R3 is selected from tert-butyloxycarbonyl and bezyloxycarbonyl groups; n=0,1. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 12/688,339 ('339 application) filed Jan. 15, 2010, the entirety of which is incorporated herein by reference. The '339 application is a continuation to U.S. patent application Ser. No. 12/055,963 ('963 application), filed Mar. 26, 2008 the entirety of which is incorporated herein by reference. The '963 application claims the benefit of the following provisional applications, each of which is incorporated herein by reference in its entirety: U.S. Provisional Patent Application 60/908,383 filed Mar. 27, 2007; and U.S. Provisional Patent Application 60/908,666, filed Mar. 28, 2007.
[0002] The '963 application is a continuation-in-part of co-pending United States patent application entitled WIRELESS NON-RADIATIVE ENERGY TRANSFER filed on Jul. 5, 2006 and having Ser. No. 11/481,077 ('077 application), the entirety of which is incorporated herein by reference. The '077 application claims the benefit of provisional application Ser. No. 60/698,442 filed Jul. 12, 2005 ('442 application), the entirety of which is incorporated herein by reference.
[0003] The '963 application, pursuant to U.S.C. §120 and U.S.C. §363, is a continuation-in-part of International Application No. PCT/US2007/070892, filed Jun. 11, 2007, which is incorporated herein by reference in its entirety, and which claims priority to the following provisional applications, each of which is incorporated herein by reference in its entirety: U.S. Provisional Patent Application 60/908,383 filed Mar. 27, 2007; and U.S. Provisional Patent Application 60/908,666, filed Mar. 28, 2007.
STATEMENT REGARDING GOVERNMENT FUNDING
[0004] This invention was made with government support awarded by the National Science Foundation under Grant No. DMR 02-13282. The government has certain rights in this invention.
BACKGROUND
[0005] The disclosure relates to wireless energy transfer. Wireless energy transfer may for example, be useful in such applications as providing power to autonomous electrical or electronic devices.
[0006] Radiative modes of omni-directional antennas (which work very well for information transfer) are not suitable for such energy transfer, because a vast majority of energy is wasted into free space. Directed radiation modes, using lasers or highly-directional antennas, can be efficiently used for energy transfer, even for long distances (transfer distance L TRANS >>L DEV , where L DEV is the characteristic size of the device and/or the source), but require existence of an uninterruptible line-of-sight and a complicated tracking system in the case of mobile objects. Some transfer schemes rely on induction, but are typically restricted to very close-range (L TRANS <<L DEV ) or low power (˜mW) energy transfers.
[0007] The rapid development of autonomous electronics of recent years (e.g. laptops, cell-phones, house-hold robots, that all typically rely on chemical energy storage) has led to an increased need for wireless energy transfer.
SUMMARY
[0008] The inventors have realized that resonant objects with coupled resonant modes having localized evanescent field patterns may be used for non-radiative wireless energy transfer. Resonant objects tend to couple, while interacting weakly with other off-resonant environmental objects. Typically, using the techniques described below, as the coupling increases, so does the transfer efficiency. In some embodiments, using the below techniques, the energy-transfer rate can be larger than the energy-loss rate. Accordingly, efficient wireless energy-exchange can be achieved between the resonant objects, while suffering only modest transfer and dissipation of energy into other off-resonant objects. The nearly-omnidirectional but stationary (non-lossy) nature of the near field makes this mechanism suitable for mobile wireless receivers. Various embodiments therefore have a variety of possible applications including for example, placing a source (e.g. one connected to the wired electricity network) on the ceiling of a factory room, while devices (robots, vehicles, computers, or similar) are roaming freely within the room. Other applications include power supplies for electric-engine buses and/or hybrid cars and medical implantable devices.
[0009] In some embodiments, resonant modes are so-called magnetic resonances, for which most of the energy surrounding the resonant objects is stored in the magnetic field; i.e. there is very little electric field outside of the resonant objects. Since most everyday materials (including animals, plants and humans) are non-magnetic, their interaction with magnetic fields is minimal. This is important both for safety and also to reduce interaction with the extraneous environmental objects.
[0010] In one aspect, an apparatus is disclosed for use in wireless energy transfer, which includes a first resonator structure configured to transfer energy with a second resonator structure over a distance D greater than a characteristic size L 2 of the second resonator structure. In some embodiments, D is also greater than one or more of: a characteristic size L 1 of the first resonator structure, a characteristic thickness T 1 of the first resonator structure, and a characteristic width W 1 of the first resonator structure. The energy transfer is mediated by evanescent-tail coupling of a resonant field of the first resonator structure and a resonant field of the second resonator structure. The apparatus may include any of the following features alone or in combination.
[0011] In some embodiments, the first resonator structure is configured to transfer energy to the second resonator structure. In some embodiments, the first resonator structure is configured to receive energy from the second resonator structure. In some embodiments, the apparatus includes the second resonator structure.
[0012] In some embodiments, the first resonator structure has a resonant angular frequency ω 1 , a Q-factor Q 1 , and a resonance width Γ 1 , the second resonator structure has a resonant angular frequency ω 2 , a Q-factor Q 2 , and a resonance width Γ 2 , and the energy transfer has a rate κ. In some embodiments, the absolute value of the difference of the angular frequencies ω 1 and ω 2 is smaller than the broader of the resonant widths Γ 1 and Γ 2 .
[0013] In some embodiments Q 1 >100 and Q 2 >100, Q 1 >300 and Q 2 >300, Q 1 >500 and Q 2 >500, or Q 1 >1000 and Q 2 >1000. In some embodiments, Q 1 >100 or Q 2 >100, Q 1 >300 or Q 2 >300, Q 1 >500 or Q 2 >500, or Q 1 >1000 or Q 2 >1000.
[0014] In some embodiments, the coupling to loss ratio
[0000]
κ
Γ
1
Γ
2
>
0.5
,
κ
Γ
1
Γ
2
>
1
,
κ
Γ
1
Γ
2
>
2
,
or
κ
Γ
1
Γ
2
>
5.
[0000] In some such embodiments, D/L 2 may be as large as 2, as large as 3, as large as 5, as large as 7, or as large as 10.
[0015] In some embodiments, Q 1 >1000 and Q 2 >1000, and the coupling to loss ratio
[0000]
κ
Γ
1
Γ
2
>
10
,
κ
Γ
1
Γ
2
>
25
,
or
κ
Γ
1
Γ
2
>
40.
[0000] In some such embodiments, D/L 2 may be as large as 2, as large as 3, as large as 5, as large as 7, as large as 10.
[0016] In some embodiments, Q κ =ω/2κ is less than about 50, less than about 200, less than about 500, or less than about 1000. In some such embodiments, D/L 2 is as large as 2, as large as 3, as large as 5, as large as 7, or as large as 10.
[0017] In some embodiments, the quantity κ/√{square root over (Γ 1 Γ 2 )} is maximized at an angular frequency {tilde over (ω)} with a frequency width {tilde over (Γ)} around the maximum, and the absolute value of the difference of the angular frequencies ω 1 and {tilde over (ω)} is smaller than the width {tilde over (Γ)}, and the absolute value of the difference of the angular frequencies ω 2 and {tilde over (ω)} is smaller than the width {tilde over (Γ)}.
[0018] In some embodiments, the energy transfer operates with an efficiency η work greater than about 1%, greater than about 10%, greater than about 30%, greater than about 50%, or greater than about 80%.
[0019] In some embodiments, the energy transfer operates with a radiation loss η rad less that about 10%. In some such embodiments the coupling to loss ratio
[0000]
κ
Γ
1
Γ
2
≥
0.1
.
[0020] In some embodiments, the energy transfer operates with a radiation loss η rad less that about 1%. In some such embodiments, the coupling to loss ratio
[0000]
κ
Γ
1
Γ
2
≥
1.
[0021] In some embodiments, in the presence of a human at distance of more than 3 cm from the surface of either resonant object, the energy transfer operates with a loss to the human η h of less than about 1%. In some such embodiments the coupling to loss ratio
[0000]
κ
Γ
1
Γ
2
≥
1.
[0022] In some embodiments, in the presence of a human at distance of more than 10 cm from the surface of either resonant object, the energy transfer operates with a loss to the human η h of less than about 0.2%. In some such embodiments the coupling to loss ratio
[0000]
κ
Γ
1
Γ
2
≥
1.
[0023] In some embodiments, during operation, a device coupled to the first or second resonator structure with a coupling rate Γ work receives a usable power P work from the resonator structure.
[0024] In some embodiments, P work is greater than about 0.01 Watt, greater than about 0.1 Watt, greater than about 1 Watt, or greater than about 10 Watt.
[0025] In some embodiments, if the device is coupled to the first resonator, then
[0000] ½≦[(Γ work /Γ 1 ) 2 −1]/(κ/√{square root over (Γ 1 Γ 2 )}) 2 ≦2, or
¼≦[(Γ work /Γ 1 ) 2 −1]/(κ/√{square root over (Γ 1 Γ 2 )}) 2 ≦4, or
⅛≦[(Γ work /Γ 1 ) 2 −1]/(κ/√{square root over (Γ 1 Γ 2 )}) 2 ≦8, and, if the device is coupled to the second resonator, then ½≦[(Γ work /Γ 2 ) 2 −1]/(κ/√{square root over (Γ 1 Γ 2 )}) 2 ≦2, or
¼≦[(Γ work /Γ 2 ) 2 −1]/(κ/√{square root over (Γ 1 Γ 2 )}) 2 ≦4, or
⅛≦[(Γ work /Γ 2 ) 2 −1]/(κ/√{square root over (Γ 1 Γ 2 )}) 2 ≦8.
[0026] In some embodiments, the device includes an electrical or electronic device. In some embodiments, the device includes a robot (e.g. a conventional robot or a nano-robot). In some embodiments, the device includes a mobile electronic device (e.g. a telephone, or a cell-phone, or a computer, or a laptop computer, or a personal digital assistant (PDA)). In some embodiments, the device includes an electronic device that receives information wirelessly (e.g. a wireless keyboard, or a wireless mouse, or a wireless computer screen, or a wireless television screen). In some embodiments, the device includes a medical device configured to be implanted in a patient (e.g. an artificial organ, or implant configured to deliver medicine). In some embodiments, the device includes a sensor. In some embodiments, the device includes a vehicle (e.g. a transportation vehicle, or an autonomous vehicle).
[0027] In some embodiments, the apparatus further includes the device.
[0028] In some embodiments, during operation, a power supply coupled to the first or second resonator structure with a coupling rate Γ supply drives the resonator structure at a frequency f and supplies power P total . In some embodiments, the absolute value of the difference of the angular frequencies ω=2πf and ω 1 is smaller than the resonant width Γ 1 , and the absolute value of the difference of the angular frequencies ω=2πf and ω 2 is smaller than the resonant width Γ 2 . In some embodiments, f is about the optimum efficiency frequency.
[0029] In some embodiments, if the power supply is coupled to the first resonator, then ½≦[(Γ supply /Γ 1 ) 2 −1]/(κ/√{square root over (Γ 1 Γ 2 )}) 2 ≦2, or
[0000] ¼≦[(Γ supply /Γ 1 ) 2 −1]/(κ/√{square root over (Γ 1 Γ 2 )}) 2 ≦4, or
⅛≦[(Γ supply /Γ 1 ) 2 −1]/(κ/√{square root over (Γ 1 Γ 2 )}) 2 ≦8, and, if the power supply is coupled to the second resonator, then ½≦[(Γ supply /Γ 2 ) 2 −1]/(κ/√{square root over (Γ 1 Γ 2 )}) 2 ≦2, or
¼≦[(Γ supply /Γ 2 ) 2 −1]/(κ/√{square root over (Γ 1 Γ 2 )}) 2 ≦4, or
⅛≦[(Γ supply /Γ 2 ) 2 −1]/(κ/√{square root over (Γ 1 Γ 2 )}) 2 ≦8.
[0030] In some embodiments, the apparatus further includes the power source.
[0031] In some embodiments, the resonant fields are electromagnetic. In some embodiments, f is about 50 GHz or less, about 1 GHz or less, about 100 MHz or less, about 10 MHz or less, about 1 MHz or less, about 100 KHz or less, or about 10 kHz or less. In some embodiments, f is about 50 GHz or greater, about 1 GHz or greater, about 100 MHz or greater, about 10 MHz or greater, about 1 MHz or greater, about 100 kHz or greater, or about 10 kHz or greater. In some embodiments, f is within one of the frequency bands specially assigned for industrial, scientific and medical (ISM) equipment.
[0032] In some embodiments, the resonant fields are primarily magnetic in the area outside of the resonant objects. In some such embodiments, the ratio of the average electric field energy to average magnetic filed energy at a distance D p from the closest resonant object is less than 0.01, or less than 0.1. In some embodiments, L R is the characteristic size of the closest resonant object and D p /L R is less than 1.5, 3, 5, 7, or 10.
[0033] In some embodiments, the resonant fields are acoustic. In some embodiments, one or more of the resonant fields include a whispering gallery mode of one of the resonant structures.
[0034] In some embodiments, one of the first and second resonator structures includes a self resonant coil of conducting wire, conducting Litz wire, or conducting ribbon. In some embodiments, both of the first and second resonator structures include self resonant coils of conducting wire, conducting Litz wire, or conducting ribbon. In some embodiments, both of the first and second resonator structures include self resonant coils of conducting wire or conducting Litz wire or conducting ribbon, and Q 1 >300 and Q 2 >300.
[0035] In some embodiments, one or more of the self resonant conductive wire coils include a wire of length/and cross section radius a wound into a helical coil of radius r, height h and number of turns N. In some embodiments, N=√{square root over (l 2 −h 2 )}/2πr.
[0036] In some embodiments, for each resonant structure r is about 30 cm, h is about 20 cm, a is about 3 mm and N is about 5.25, and, during operation, a power source coupled to the first or second resonator structure drives the resonator structure at a frequency f. In some embodiments, f is about 10.6 MHz. In some such embodiments, the coupling to loss ratio
[0000]
κ
Γ
1
Γ
2
≥
40
,
κ
Γ
1
Γ
2
≥
15
,
or
κ
Γ
1
Γ
2
≥
5
,
or
κ
Γ
1
Γ
2
≥
1.
[0000] In some such embodiments D/L R is as large as about 2, 3, 5, or 8.
[0037] In some embodiments, for each resonant structure r is about 30 cm, h is about 20 cm, a is about 1 cm and N is about 4, and, during operation, a power source coupled to the first or second resonator structure drives the resonator structure at a frequency f. In some embodiments, f is about 13.4 MHz. In some such embodiments, the coupling to loss ratio
[0000]
κ
Γ
1
Γ
2
≥
70
,
κ
Γ
1
Γ
2
≥
19
,
or
κ
Γ
1
Γ
2
≥
8
,
or
κ
Γ
1
Γ
2
≥
3.
[0000] In some such embodiments D/L R is as large as about 3, 5, 7, or 10.
[0038] In some embodiments, for each resonant structure r is about 10 cm, h is about 3 cm, a is about 2 mm and N is about 6, and, during operation, a power source coupled to the first or second resonator structure drives the resonator structure at a frequency f. In some embodiments, f is about 21.4 MHz. In some such embodiments, the coupling to loss ratio
[0000]
κ
Γ
1
Γ
2
≥
59
,
κ
Γ
1
Γ
2
≥
15
,
or
κ
Γ
1
Γ
2
≥
6
,
or
κ
Γ
1
Γ
2
≥
2.
[0000] In some such embodiments D/L R is as large as about 3, 5, 7, or 10.
[0039] In some embodiments, one of the first and second resonator structures includes a capacitively loaded loop or coil of conducting wire, conducting Litz wire, or conducting ribbon. In some embodiments, both of the first and second resonator structures include capacitively loaded loops or coils of conducting wire, conducting Litz wire, or conducting ribbon. In some embodiments, both of the first and second resonator structures include capacitively loaded loops or coils of conducting wire or conducting Litz wire or conducting ribbon, and Q 1 >300 and Q 2 >300.
[0040] In some embodiments, the characteristic size L R of the resonator structure receiving energy from the other resonator structure is less than about 1 cm and the width of the conducting wire or Litz wire or ribbon of said object is less than about 1 mm, and, during operation, a power source coupled to the first or second resonator structure drives the resonator structure at a frequency f. In some embodiments, f is about 380 MHz. In some such embodiments, the coupling to loss ratio
[0000]
κ
Γ
1
Γ
2
≥
14.9
,
κ
Γ
1
Γ
2
≥
3.2
,
κ
Γ
1
Γ
2
≥
1.2
,
or
κ
Γ
1
Γ
2
≥
0.4
.
[0000] In some such embodiments, D/L R is as large as about 3, about 5, about 7, or about 10.
[0041] In some embodiments, the characteristic size of the resonator structure receiving energy from the other resonator structure L R is less than about 10 cm and the width of the conducting wire or Litz wire or ribbon of said object is less than about 1 cm, and, during operation, a power source coupled to the first or second resonator structure drives the resonator structure at a frequency f. In some embodiments, f is about 43 MHz. In some such embodiments, the coupling to loss ratio
[0000]
κ
Γ
1
Γ
2
≥
15.9
,
κ
Γ
1
Γ
2
≥
4.3
,
κ
Γ
1
Γ
2
≥
1.8
,
or
κ
Γ
1
Γ
2
≥
0.7
.
[0000] In some such embodiments, D/L R is as large as about 3, about 5, about 7, or about 10.
[0042] In some embodiments, the characteristic size L R of the resonator structure receiving energy from the other resonator structure is less than about 30 cm and the width of the conducting wire or Litz wire or ribbon of said object is less than about 5 cm, and, during operation, a power source coupled to the first or second resonator structure drives the resonator structure at a frequency f. In some such embodiments, f is about 9 MHz. In some such embodiments, the coupling to loss ratio
[0000]
κ
Γ
1
Γ
2
≥
67.4
,
κ
Γ
1
Γ
2
≥
17.8
,
κ
Γ
1
Γ
2
≥
7.1
,
or
κ
Γ
1
Γ
2
≥
2.7
.
[0000] In some such embodiments, D/L R is as large as about 3, about 5, about 7, or about 10.
[0043] In some embodiments, the characteristic size of the resonator structure receiving energy from the other resonator structure L R is less than about 30 cm and the width of the conducting wire or Litz wire or ribbon of said object is less than about 5 mm, and, during operation, a power source coupled to the first or second resonator structure drives the resonator structure at a frequency f. In some embodiments, f is about 17 MHz. In some such embodiments, the coupling to loss ratio
[0000]
κ
Γ
1
Γ
2
≥
6.3
,
κ
Γ
1
Γ
2
≥
1.3
,
κ
Γ
1
Γ
2
≥
0.5
.
,
or
κ
Γ
1
Γ
2
≥
0.2
.
[0000] In some such embodiments, D/L R is as large as about 3, about 5, about 7, or about 10.
[0044] In some embodiments, the characteristic size L R of the resonator structure receiving energy from the other resonator structure is less than about 1 m, and the width of the conducting wire or Litz wire or ribbon of said object is less than about 1 cm, and, during operation, a power source coupled to the first or second resonator structure drives the resonator structure at a frequency f. In some embodiments, f is about 5 MHz. In some such embodiments, the coupling to loss ratio
[0000]
κ
Γ
1
Γ
2
≥
6.8
,
κ
Γ
1
Γ
2
≥
1.4
,
κ
Γ
1
Γ
2
≥
0.5
,
κ
Γ
1
Γ
2
≥
0.2
.
[0000] In some such embodiments, D/L R is as large as about 3, about 5, about 7, or about 10.
[0045] In some embodiments, during operation, one of the resonator structures receives a usable power P w from the other resonator structure, an electrical current I s flows in the resonator structure which is transferring energy to the other resonant structure, and the ratio
[0000]
I
s
P
w
[0000] is less than about 5 Amps/√{square root over (Watts)} or less than about 2 Amps/√{square root over (Watts)}. In some embodiments, during operation, one of the resonator structures receives a usable power P w from the other resonator structure, a voltage difference V s appears across the capacitive element of the first resonator structure, and the ratio
[0000]
V
s
P
w
[0000] is less than about 2000 Volts/√{square root over (Watts)} or less than about 4000 Volts/√{square root over (Watts)}.
[0046] In some embodiments, one of the first and second resonator structures includes a inductively loaded rod of conducting wire or conducting Litz wire or conducting ribbon. In some embodiments, both of the first and second resonator structures include inductively loaded rods of conducting wire or conducting Litz wire or conducting ribbon. In some embodiments, both of the first and second resonator structures include inductively loaded rods of conducting wire or conducting Litz wire or conducting ribbon, and Q 1 >300 and Q 2 >300.
[0047] In some embodiments, the characteristic size of the resonator structure receiving energy from the other resonator structure L R is less than about 10 cm and the width of the conducting wire or Litz wire or ribbon of said object is less than about 1 cm, and, during operation, a power source coupled to the first or second resonator structure drives the resonator structure at a frequency f. In some embodiments, f is about 14 MHz. In some such embodiments, the coupling to loss ratio
[0000]
κ
Γ
1
Γ
2
≥
32
,
κ
Γ
1
Γ
2
≥
5.8
,
κ
Γ
1
Γ
2
≥
2
,
or
κ
Γ
1
Γ
2
≥
0.6
.
[0000] In some such embodiments, D/L R is as large as about 3, about 5, about 7, or about 10.
[0048] In some embodiments, the characteristic size L R of the resonator structure receiving energy from the other resonator structure is less than about 30 cm and the width of the conducting wire or Litz wire or ribbon of said object is less than about 5 cm, and, during operation, a power source coupled to the first or second resonator structure drives the resonator structure at a frequency f. In some such embodiments, f is about 2.5 MHz. In some such embodiments, the coupling to loss ratio
[0000]
κ
Γ
1
Γ
2
≥
105
κ
Γ
1
Γ
2
≥
19
,
κ
Γ
1
Γ
2
≥
6.6
,
or
κ
Γ
1
Γ
2
≥
2.2
.
[0000] In some such embodiments, D/L R is as large as about 3, about 5, about 7, or about 10.
[0049] In some embodiments, one of the first and second resonator structures includes a dielectric disk. In some embodiments, both of the first and second resonator structures include dielectric disks. In some embodiments, both of the first and second resonator structures include dielectric disks, and Q 1 >300 and Q 2 >300.
[0050] In some embodiments, the characteristic size of the resonator structure receiving energy from the other resonator structure is L R and the real part of the permittivity of said resonator structure ∈ is less than about 150. In some such embodiments, the coupling to loss ratio
[0000]
κ
Γ
1
Γ
2
≥
42.4
κ
Γ
1
Γ
2
≥
6.5
,
κ
Γ
1
Γ
2
≥
2.3
,
κ
Γ
1
Γ
2
≥
0.5
.
[0000] In some such embodiments, D/L R is as large as about 3, about 5, about 7, or about 10.
[0051] In some embodiments, the characteristic size of the resonator structure receiving energy from the other resonator structure is L R and the real part of the permittivity of said resonator structure ∈ is less than about 65. In some such embodiments, the coupling to loss ratio
[0000]
κ
Γ
1
Γ
2
≥
30.9
,
κ
Γ
1
Γ
2
≥
2.3
,
or
κ
Γ
1
Γ
2
≥
0.5
.
[0000] In some such embodiments, D/L R is as large as about 3, about 5, about 7.
[0052] In some embodiments, at least one of the first and second resonator structures includes one of: a dielectric material, a metallic material, a metallodielectric object, a plasmonic material, a plasmonodielectric object, a superconducting material.
[0053] In some embodiments, at least one of the resonators has a quality factor greater than about 5000, or greater than about 10000.
[0054] In some embodiments, the apparatus also includes a third resonator structure configured to transfer energy with one or more of the first and second resonator structures, where the energy transfer between the third resonator structure and the one or more of the first and second resonator structures is mediated by evanescent-tail coupling of the resonant field of the one or more of the first and second resonator structures and a resonant field of the third resonator structure.
[0055] In some embodiments, the third resonator structure is configured to transfer energy to one or more of the first and second resonator structures.
[0056] In some embodiments, the first resonator structure is configured to receive energy from one or more of the first and second resonator structures.
[0057] In some embodiments, the first resonator structure is configured to receive energy from one of the first and second resonator structures and transfer energy to the other one of the first and second resonator structures.
[0058] Some embodiments include a mechanism for, during operation, maintaining the resonant frequency of one or more of the resonant objects. In some embodiments, the feedback mechanism comprises an oscillator with a fixed frequency and is configured to adjust the resonant frequency of the one or more resonant objects to be about equal to the fixed frequency. In some embodiments, the feedback mechanism is configured to monitor an efficiency of the energy transfer, and adjust the resonant frequency of the one or more resonant objects to maximize the efficiency.
[0059] In another aspect, a method of wireless energy transfer is disclosed, which method includes providing a first resonator structure and transferring energy with a second resonator structure over a distance D greater than a characteristic size L 2 of the second resonator structure. In some embodiments, D is also greater than one or more of: a characteristic size L 1 of the first resonator structure, a characteristic thickness T 1 of the first resonator structure, and a characteristic width W 1 of the first resonator structure. The energy transfer is mediated by evanescent-tail coupling of a resonant field of the first resonator structure and a resonant field of the second resonator structure.
[0060] In some embodiments, the first resonator structure is configured to transfer energy to the second resonator structure. In some embodiments, the first resonator structure is configured to receive energy from the second resonator structure.
[0061] In some embodiments, the first resonator structure has a resonant angular frequency ω 1 , a Q-factor Q 1 , and a resonance width Γ 1 , the second resonator structure has a resonant angular frequency ω 2 , a Q-factor Q 2 , and a resonance width Γ 2 , and the energy transfer has a rate κ. In some embodiments, the absolute value of the difference of the angular frequencies ω 1 and ω 2 is smaller than the broader of the resonant widths Γ 1 and Γ 2 .
[0062] In some embodiments, the coupling to loss ratio
[0000]
κ
Γ
1
Γ
2
>
0.5
,
κ
Γ
1
Γ
2
>
1
,
κ
Γ
1
Γ
2
>
2
,
or
κ
Γ
1
Γ
2
>
5.
[0000] In some such embodiments, D/L 2 may be as large as 2, as large as 3, as large as 5, as large as 7, or as large as 10.
[0063] In another aspect, an apparatus is disclosed for use in wireless information transfer which includes a first resonator structure configured to transfer information by transferring energy with a second resonator structure over a distance D greater than a characteristic size L 2 of the second resonator structure. In some embodiments, D is also greater than one or more of: a characteristic size L 1 of the first resonator structure, a characteristic thickness T 1 of the first resonator structure, and a characteristic width W 1 of the first resonator structure. The energy transfer is mediated by evanescent-tail coupling of a resonant field of the first resonator structure and a resonant field of the second resonator structure.
[0064] In some embodiments, the first resonator structure is configured to transfer energy to the second resonator structure. In some embodiments, the first resonator structure is configured to receive energy from the second resonator structure. In some embodiments the apparatus includes, the second resonator structure.
[0065] In some embodiments, the first resonator structure has a resonant angular frequency ω 1 , a Q-factor Q 1 , and a resonance width Γ 1 , the second resonator structure has a resonant angular frequency ω 2 , a Q-factor Q 2 , and a resonance width Γ 2 , and the energy transfer has a rate κ. In some embodiments, the absolute value of the difference of the angular frequencies ω 1 and ω 2 is smaller than the broader of the resonant widths Γ 1 and Γ 2 .
[0066] In some embodiments, the coupling to loss ratio
[0000]
κ
Γ
1
Γ
2
>
0.5
,
κ
Γ
1
Γ
2
>
1
,
κ
Γ
1
Γ
2
>
2
,
or
κ
Γ
1
Γ
2
>
5.
[0000] In some such embodiments, D/L 2 may be as large as 2, as large as 3, as large as 5, as large as 7, or as large as 10.
[0067] In another aspect, a method of wireless information transfer is disclosed, which method includes providing a first resonator structure and transferring information by transferring energy with a second resonator structure over a distance D greater than a characteristic size L 2 of the second resonator structure. In some embodiments, D is also greater than one or more of: a characteristic size L 1 of the first resonator structure, a characteristic thickness T 1 of the first resonator structure, and a characteristic width W 1 of the first resonator structure. The energy transfer is mediated by evanescent-tail coupling of a resonant field of the first resonator structure and a resonant field of the second resonator structure.
[0068] In some embodiments, the first resonator structure is configured to transfer energy to the second resonator structure. In some embodiments, the first resonator structure is configured to receive energy from the second resonator structure.
[0069] In some embodiments, the first resonator structure has a resonant angular frequency ω 1 , a Q-factor Q 1 , and a resonance width Γ 1 , the second resonator structure has a resonant angular frequency ω 2 , a Q-factor Q 2 , and a resonance width Γ 2 , and the energy transfer has a rate κ. In some embodiments, the absolute value of the difference of the angular frequencies ω 1 and ω 2 is smaller than the broader of the resonant widths Γ 1 and Γ 2 .
[0070] In some embodiments, the coupling to loss ratio
[0000]
κ
Γ
1
Γ
2
>
0.5
,
κ
Γ
1
Γ
2
>
1
,
κ
Γ
1
Γ
2
>
2
,
or
κ
Γ
1
Γ
2
>
5.
[0000] In some such embodiments, D/L 2 may be as large as 2, as large as 3, as large as 5, as large as 7, or as large as 10.
[0071] It is to be understood that the characteristic size of an object is equal to the radius of the smallest sphere which can fit around the entire object. The characteristic thickness of an object is, when placed on a flat surface in any arbitrary configuration, the smallest possible height of the highest point of the object above a flat surface. The characteristic width of an object is the radius of the smallest possible circle that the object can pass through while traveling in a straight line. For example, the characteristic width of a cylindrical object is the radius of the cylinder.
[0072] The distance D over which the energy transfer between two resonant objects occurs is the distance between the respective centers of the smallest spheres which can fit around the entirety of each object. However, when considering the distance between a human and a resonant object, the distance is to be measured from the outer surface of the human to the outer surface of the sphere.
[0073] As described in detail below, non-radiative energy transfer refers to energy transfer effected primarily through the localized near field, and, at most, secondarily through the radiative portion of the field.
[0074] It is to be understood that an evanescent tail of a resonant object is the decaying non-radiative portion of a resonant field localized at the object. The decay may take any functional form including, for example, an exponential decay or power law decay.
[0075] The optimum efficiency frequency of a wireless energy transfer system is the frequency at which the figure of merit
[0000]
κ
Γ
1
Γ
2
[0000] is maximized, all other factors held constant.
[0076] The resonant width (Γ) refers to the width of an object's resonance due to object's intrinsic losses (e.g. loss to absorption, radiation, etc.).
[0077] It is to be understood that a Q-factor (Q) is a factor that compares the time constant for decay of an oscillating system's amplitude to its oscillation period. For a given resonator mode with angular frequency ω and resonant width Γ, the Q-factor Q=ω/2Γ.
[0078] The energy transfer rate (κ) refers to the rate of energy transfer from one resonator to another. In the coupled mode description described below it is the coupling constant between the resonators.
[0079] It is to be understood that Q κ =ω/2κ.
[0080] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. In case of conflict with publications, patent applications, patents, and other references mentioned incorporated herein by reference, the present specification, including definitions, will control.
[0081] Various embodiments may include any of the above features, alone or in combination. Other features, objects, and advantages of the disclosure will be apparent from the following detailed description.
[0082] Other features, objects, and advantages of the disclosure will be apparent from the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0083] FIG. 1 shows a schematic of a wireless energy transfer scheme.
[0084] FIG. 2 shows an example of a self-resonant conducting-wire coil.
[0085] FIG. 3 shows a wireless energy transfer scheme featuring two self-resonant conducting-wire coils
[0086] FIG. 4 shows an example of a capacitively loaded conducting-wire coil, and illustrates the surrounding field.
[0087] FIG. 5 shows a wireless energy transfer scheme featuring two capacitively loaded conducting-wire coils, and illustrates the surrounding field.
[0088] FIG. 6 shows an example of a resonant dielectric disk, and illustrates the surrounding field.
[0089] FIG. 7 shows a wireless energy transfer scheme featuring two resonant dielectric disks, and illustrates the surrounding field.
[0090] FIGS. 8 a and 8 b show schematics for frequency control mechanisms.
[0091] FIGS. 9 a through 9 c illustrate a wireless energy transfer scheme in the presence of various extraneous objects.
[0092] FIG. 10 illustrates a circuit model for wireless energy transfer.
[0093] FIG. 11 illustrates the efficiency of a wireless energy transfer scheme.
[0094] FIG. 12 illustrates parametric dependences of a wireless energy transfer scheme. The figure shows efficiency, total (loaded) device Q, and source and device currents, voltages and radiated powers, normalized to 1 Watt of output working power, as functions of frequency for a particular choice of source and device loop dimensions, wp and N s and different choices of N d =1, 2, 3, 4, 5, 6, 10.
[0095] FIG. 13 plots the parametric dependences of a wireless energy transfer scheme. Efficiency, total (loaded device Q, and source and device currents, voltages and radiated powers (normalized to 1 Watt of output working power) as functions of frequency and wp for a particular choice of source and device loop dimensions, and number of turns Ns and Nd.
[0096] FIG. 14 is a schematic of an experimental system demonstrating wireless energy transfer.
[0097] FIGS. 15-17 . Plot experiment results for the system shown schematically in FIG. 14 .
[0098] FIG. 15 shows a comparison of experimental and theoretical values for κ as a function of the separation between the source and device coils.
[0099] FIG. 16 shows a comparison of experimental and theoretical values for the parameter κ/Γ as a function of the separation between the two coils. The theory values are obtained by using the theoretically obtained κ and the experimentally measured Γ. The shaded area represents the spread in the theoretical κ/Γ due to the ˜5% uncertainty in Q.
DETAILED DESCRIPTION
[0100] FIG. 1 shows a schematic that generally describes one embodiment of the invention, in which energy is transferred wirelessly between two resonant objects.
[0101] Referring to FIG. 1 , energy is transferred, over a distance D, between a resonant source object having a characteristic size L 1 and a resonant device object of characteristic size L 2 . Both objects are resonant objects. The source object is connected to a power supply (not shown), and the device object is connected to a power consuming device (e.g. a load resistor, not shown). Energy is provided by the power supply to the source object, transferred wirelessly and non-radiatively from the source object to the device object, and consumed by the power consuming device. The wireless non-radiative energy transfer is performed using the field (e.g. the electromagnetic field or acoustic field) of the system of two resonant objects. For simplicity, in the following we will assume that field is the electromagnetic field.
[0102] It is to be understood that while two resonant objects are shown in the embodiment of FIG. 1 , and in many of the examples below, other embodiments may feature 3 or more resonant objects. For example, in some embodiments a single source object can transfer energy to multiple device objects. In some embodiments energy may be transferred from a first device to a second, and then from the second device to the third, and so forth.
[0103] Initially, we present a theoretical framework for understanding non-radiative wireless energy transfer. Note however that it is to be understood that the scope of the invention is not bound by theory.
[0104] Coupled Mode Theory
[0105] An appropriate analytical framework for modeling the resonant energy-exchange between two resonant objects 1 and 2 is that of “coupled-mode theory” (CMT). The field of the system of two resonant objects 1 and 2 is approximated by F(r,t)≈a 1 (t)F 1 (r)+a 2 (t)F 2 (r), where F 1,2 (r) are the eigenmodes of 1 and 2 alone, normalized to unity energy, and the field amplitudes a 1,2 (t) are defined so that |a 1,2 (t)| 2 is equal to the energy stored inside the objects 1 and 2 respectively. Then, the field amplitudes can be shown to satisfy, to lowest order:
[0000]
a
1
t
=
-
i
(
ω
1
-
i
Γ
1
)
a
1
+
i
κ
a
2
a
2
t
=
-
i
(
ω
2
-
i
Γ
2
)
a
2
+
i
κ
a
1
,
(
1
)
[0000] where ω 1,2 are the individual angular eigenfrequencies of the eigenmodes, Γ 1,2 are the resonance widths due to the objects' intrinsic (absorption, radiation etc.) losses, and κ is the coupling coefficient. Eqs. (1) show that at exact resonance (ω 1 =ω 2 and Γ 1 =Γ 2 ), the eigenmodes of the combined system are split by 2κ; the energy exchange between the two objects takes place in time ˜π/2κ and is nearly perfect, apart for losses, which are minimal when the coupling rate is much faster than all loss rates (κ Γ 1,2 ). The coupling to loss ratio κ/√{square root over (Γ 1 Γ 2 )} serves as a figure-of-merit in evaluating a system used for wireless energy-transfer, along with the distance over which this ratio can be achieved. The regime κ/√{square root over (Γ 1 Γ 2 )}>>1 is called “strong-coupling” regime.
[0106] In some embodiments, the energy-transfer application preferably uses resonant modes of high Q=ω/2Γ, corresponding to low (i.e. slow) intrinsic-loss rates Γ. This condition may be satisfied where the coupling is implemented using, not the lossy radiative far-field, but the evanescent (non-lossy) stationary near-field.
[0107] To implement an energy-transfer scheme, usually finite objects, namely ones that are topologically surrounded everywhere by air, are more appropriate. Unfortunately, objects of finite extent cannot support electromagnetic states that are exponentially decaying in all directions in air, since, from Maxwell's Equations in free space: {right arrow over (k)} 2 =ω 2 /c 2 where {right arrow over (k)} is the wave vector, ω the angular frequency, and c the speed of light. Because of this, one can show that they cannot support states of infinite Q. However, very long-lived (so-called “high-Q”) states can be found, whose tails display the needed exponential or exponential-like decay away from the resonant object over long enough distances before they turn oscillatory (radiative). The limiting surface, where this change in the field behavior happens, is called the “radiation caustic”, and, for the wireless energy-transfer scheme to be based on the near field rather than the far/radiation field, the distance between the coupled objects must be such that one lies within the radiation caustic of the other.
[0108] Furthermore, in some embodiments, small Q κ =ω/2κ corresponding to strong (i.e. fast) coupling rate κ is preferred over distances larger than the characteristic sizes of the objects. Therefore, since the extent of the near-field into the area surrounding a finite-sized resonant object is set typically by the wavelength, in some embodiments, this mid-range non-radiative coupling can be achieved using resonant objects of subwavelength size, and thus significantly longer evanescent field-tails. As will be seen in examples later on, such subwavelength resonances can often be accompanied with a high Q, so this will typically be the appropriate choice for the possibly-mobile resonant device-object. Note, though, that in some embodiments, the resonant source-object will be immobile and thus less restricted in its allowed geometry and size, which can be therefore chosen large enough that the near-field extent is not limited by the wavelength. Objects of nearly infinite extent, such as dielectric waveguides, can support guided modes whose evanescent tails are decaying exponentially in the direction away from the object, slowly if tuned close to cutoff, and can have nearly infinite Q.
[0109] In the following, we describe several examples of systems suitable for energy transfer of the type described above. We will demonstrate how to compute the CMT parameters ω 1,2 , Q 1,2 and Q κ described above and how to choose these parameters for particular embodiments in order to produce a desirable figure-of-merit κ/√{square root over (Γ 1 Γ 2 )}=√{square root over (Q 1 Q 2 )}/Q κ . In particular, this figure of merit is typically maximized when ω 1,2 are tuned to a particular angular frequency {tilde over (ω)}, thus, if {tilde over (Γ)} is half the angular-frequency width for which √{square root over (Q 1 Q 2 )}/Q κ is above half its maximum value at {tilde over (ω)}, the angular eigenfrequencies ω 1,2 should typically be tuned to be close to {tilde over (ω)} to within the width {tilde over (Γ)}.
[0110] In addition, as described below, Q 1,2 can sometimes be limited not from intrinsic loss mechanisms but from external perturbations. In those cases, producing a desirable figure-of-merit translates to reducing Q κ (i.e. increasing the coupling). Accordingly we will demonstrate how, for particular embodiments, to reduce Q κ .
[0111] Self-Resonant Conducting Coils
[0112] In some embodiments, one or more of the resonant objects are self-resonant conducting coils. Referring to FIG. 2 , a conducting wire of length l and cross-sectional radius a is wound into a helical coil of radius r and height h (namely with N=√{square root over (l 2 −h 2 )}/2πr number of turns), surrounded by air. As described below, the wire has distributed inductance and distributed capacitance, and therefore it supports a resonant mode of angular frequency ω. The nature of the resonance lies in the periodic exchange of energy from the electric field within the capacitance of the coil, due to the charge distribution ρ(x) across it, to the magnetic field in free space, due to the current distribution j(x) in the wire. In particular, the charge conservation equation ∇·j=iωρ implies that: (i) this periodic exchange is accompanied by a π/2 phase-shift between the current and the charge density profiles, namely the energy U contained in the coil is at certain points in time completely due to the current and at other points in time completely due to the charge, and (ii) if ρ l (x) and I(x) are respectively the linear charge and current densities in the wire, where x runs along the wire,
[0000]
q
o
=
1
2
∫
x
ρ
l
(
x
)
[0000] is the maximum amount of positive charge accumulated in one side of the coil (where an equal amount of negative charge always also accumulates in the other side to make the system neutral) and I o =max{|I(x)|} is the maximum positive value of the linear current distribution, then I o =ωq o . Then, one can define an effective total inductance L and an effective total capacitance C of the coil through the amount of energy U inside its resonant mode:
[0000]
U
≡
1
2
I
o
2
L
⇒
L
=
μ
o
4
π
I
o
2
∫
∫
x
x
′
j
(
x
)
·
j
(
x
′
)
x
-
x
′
,
(
2
)
U
≡
1
2
q
o
2
1
C
⇒
1
C
=
1
4
π
ɛ
o
q
o
2
∫
∫
x
x
′
ρ
(
x
)
·
ρ
(
x
′
)
x
-
x
′
,
(
3
)
[0000] where μ o and ∈ o are the magnetic permeability and electric permittivity of free space. With these definitions, the resonant angular frequency and the effective impedance are given by the common formulas ω=1/√{square root over (LC)} and Z=√{square root over (L/C)} respectively.
[0113] Losses in this resonant system consist of ohmic (material absorption) loss inside the wire and radiative loss into free space. One can again define a total absorption resistance R abs from the amount of power absorbed inside the wire and a total radiation resistance R rad from the amount of power radiated due to electric- and magnetic-dipole radiation:
[0000]
P
abs
≡
1
2
I
o
2
R
abs
⇒
R
abs
≈
ζ
c
1
2
π
a
·
I
rms
2
I
o
2
(
4
)
P
rad
≡
1
2
I
o
2
R
rad
⇒
R
rad
≈
ζ
o
6
π
[
(
ω
p
c
)
2
+
(
ω
m
c
)
4
]
,
(
5
)
[0000] where c=1/√{square root over (μ o ∈ o )} and ζ o =√{square root over (μ o /∈ o )} are the light velocity and light impedance in free space, the impedance ζ c is ζ c =1/σδ=√{square root over (μ o ω/2σ)} with σ the conductivity of the conductor and δ the skin depth at the frequency ω,
[0000]
I
rms
2
=
1
l
∫
x
I
(
x
)
2
,
[0000] p=∫dx rρ l (x) is the electric-dipole moment of the coil and
[0000]
m
=
1
2
∫
x
r
×
j
(
x
)
[0000] is the magnetic-dipole moment of the coil. For the radiation resistance formula Eq. (5), the assumption of operation in the quasi-static regime (h, r<<λ=2πc/ω) has been used, which is the desired regime of a subwavelength resonance. With these definitions, the absorption and radiation quality factors of the resonance are given by Q abs =Z/R abs and Q rad =Z/R rad respectively.
[0114] From Eq. (2)-(5) it follows that to determine the resonance parameters one simply needs to know the current distribution j in the resonant coil. Solving Maxwell's equations to rigorously find the current distribution of the resonant electromagnetic eigenmode of a conducting-wire coil is more involved than, for example, of a standard LC circuit, and we can find no exact solutions in the literature for coils of finite length, making an exact solution difficult. One could in principle write down an elaborate transmission-line-like model, and solve it by brute force. We instead present a model that is (as described below) in good agreement (˜5%) with experiment. Observing that the finite extent of the conductor forming each coil imposes the boundary condition that the current has to be zero at the ends of the coil, since no current can leave the wire, we assume that the resonant mode of each coil is well approximated by a sinusoidal current profile along the length of the conducting wire. We shall be interested in the lowest mode, so if we denote by x the coordinate along the conductor, such that it runs from −l/2 to +l/2, then the current amplitude profile would have the form I(x)=I o cos(πx/l), where we have assumed that the current does not vary significantly along the wire circumference for a particular x, a valid assumption provided a<<r. It immediately follows from the continuity equation for charge that the linear charge density profile should be of the form ρ l (x)=ρ o sin(πx/l), and thus q o =∫ 0 l/2 dxρ o |sin(πx/l)|=ρ o l/π. Using these sinusoidal profiles we find the so-called “self-inductance” L s and “self-capacitance” C s of the coil by computing numerically the integrals Eq. (2) and (3); the associated frequency and effective impedance are ω s and Z s respectively. The “self-resistances” R s are given analytically by Eq. (4) and (5) using
[0000]
using
I
rms
2
=
1
l
∫
-
l
/
2
1
/
l
x
I
o
cos
(
π
x
/
l
)
2
=
1
2
I
o
2
,
p
=
q
o
(
2
π
h
)
2
+
(
4
N
cos
(
π
N
)
(
4
N
2
-
1
)
π
r
)
2
and
m
=
I
o
(
2
π
N
π
r
2
)
2
+
(
cos
(
π
N
)
(
12
N
2
-
1
)
-
sin
(
π
N
)
π
N
(
4
N
2
-
1
)
(
16
N
4
-
8
N
2
+
1
)
π
hr
)
2
,
(
5
)
[0000] and therefore the associated Q s factors may be calculated.
[0115] The results for two particular embodiments of resonant coils with subwavelength modes of λ s /r≧70 (i.e. those highly suitable for near-field coupling and well within the quasi-static limit) are presented in Table 1. Numerical results are shown for the wavelength and absorption, radiation and total loss rates, for the two different cases of subwavelength-coil resonant modes. Note that, for conducting material, copper (σ=5.998·10̂−7 S/m) was used. It can be seen that expected quality factors at microwave frequencies are Q s abs ≧1000 and Q s rad ≧5000.
[0000]
TABLE 1
single coil
λ s /r
f (MHz)
Q s rad
Q s abs
Q s = ω s /2Γ s
r = 30 cm, h = 20 cm,
74.7
13.39
4164
8170
2758
a = 1 cm, N = 4
r = 10 cm, h = 3 cm,
140
21.38
43919
3968
3639
a = 2 mm, N = 6
[0116] Referring to FIG. 3 , in some embodiments, energy is transferred between two self-resonant conducting-wire coils. The electric and magnetic fields are used to couple the different resonant conducting-wire coils at a distance D between their centers. Usually, the electric coupling highly dominates over the magnetic coupling in the system under consideration for coils with h>>2r and, oppositely, the magnetic coupling highly dominates over the electric coupling for coils with h<<2r. Defining the charge and current distributions of two coils 1,2 respectively as ρ 1,2 (x) and j 1,2 (x), total charges and peak currents respectively as q 1,2 and I 1,2 , and capacitances and inductances respectively as C 1,2 and L 1,2 , which are the analogs of ρ(x), j(x), q o , I o , C and L for the single-coil case and are therefore well defined, we can define their mutual capacitance and inductance through the total energy:
[0000]
U
≡
U
1
+
U
2
+
1
2
(
q
1
*
q
2
+
q
2
*
q
1
)
/
M
C
+
1
2
(
I
1
*
I
2
+
I
2
*
I
1
)
M
L
⇒
1
M
C
=
1
4
π
ɛ
o
q
1
q
2
∫
∫
x
x
′
ρ
1
(
x
)
·
ρ
2
(
x
′
)
x
-
x
′
u
,
M
L
=
μ
o
4
π
I
1
I
2
∫
∫
x
x
′
j
1
(
x
)
·
j
2
(
x
′
)
x
-
x
′
u
,
(
6
)
[0000] where
[0000]
U
1
=
1
2
q
1
2
/
C
1
=
1
2
I
1
2
L
1
,
U
2
=
1
2
q
2
2
/
C
2
=
1
2
I
2
2
L
2
[0000] and the retardation factor of u=exp (iω|x−x′|/c) inside the integral can been ignored in the quasi-static regime D<<λ of interest, where each coil is within the near field of the other. With this definition, the coupling coefficient is given by κ=ω√{square root over (C 1 C 2 )}/2M C +ωM L /2√{square root over (L 1 L 2 )} Q κ −1 =(M C /√{square root over (C 1 C 2 )}) −1 +(√{square root over (L 1 L 2 )}/M L ) −1 .
[0117] Therefore, to calculate the coupling rate between two self-resonant coils, again the current profiles are needed and, by using again the assumed sinusoidal current profiles, we compute numerically from Eq. (6) the mutual capacitance M C,s and inductance M L,s between two self-resonant coils at a distance D between their centers, and thus Q κ,s is also determined.
[0000]
TABLE 2
pair of coils
D/r
Q = ω/2Γ
Q κ = ω/2κ
κ/Γ
r = 30 cm, h = 20 cm,
3
2758
38.9
70.9
a = 1 cm, N = 4
5
2758
139.4
19.8
λ/r ≈ 75
7
2758
333.0
8.3
Q s abs ≈ 8170, Q s rad ≈ 4164
10
2758
818.9
3.4
r = 10 cm, h = 3 cm,
3
3639
61.4
59.3
a = 2 mm, N = 6
5
3639
232.5
15.7
λ/r ≈ 140
7
3639
587.5
6.2
Q s abs ≈ 3968, Q s rad ≈ 43919
10
3639
1580
2.3
[0118] Referring to Table 2, relevant parameters are shown for exemplary embodiments featuring pairs or identical self resonant coils. Numerical results are presented for the average wavelength and loss rates of the two normal modes (individual values not shown), and also the coupling rate and figure-of-merit as a function of the coupling distance D, for the two cases of modes presented in Table 1. It can be seen that for medium distances D/r=10−3 the expected coupling-to-loss ratios are in the range κ/Γ˜2-70.
[0119] Capacitively-Loaded Conducting Loops or Coils
[0120] In some embodiments, one or more of the resonant objects are capacitively-loaded conducting loops or coils. Referring to FIG. 4 a helical coil with N turns of conducting wire, as described above, is connected to a pair of conducting parallel plates of area A spaced by distance d via a dielectric material of relative permittivity ∈, and everything is surrounded by air (as shown, N=1 and h=0). The plates have a capacitance C p =∈ o ∈A/d, which is added to the distributed capacitance of the coil and thus modifies its resonance. Note however, that the presence of the loading capacitor modifies significantly the current distribution inside the wire and therefore the total effective inductance L and total effective capacitance C of the coil are different respectively from L s and C s , which are calculated for a self-resonant coil of the same geometry using a sinusoidal current profile. Since some charge is accumulated at the plates of the external loading capacitor, the charge distribution ρ inside the wire is reduced, so C<C s , and thus, from the charge conservation equation, the current distribution j flattens out, so L>L s . The resonant frequency for this system is ω=1/√{square root over (L(C+C p ))}<ω s =1/√{square root over (L s C s )}, and I(x)→I o cos(πx/l) C→C s ω→ω s , as C p →0.
[0121] In general, the desired CMT parameters can be found for this system, but again a very complicated solution of Maxwell's Equations is required. Instead, we will analyze only a special case, where a reasonable guess for the current distribution can be made. When C p >>C s >C, then ω≈1/√{square root over (LC p )}<<ω s and Z≈√{square root over (L/C p )}<<Z s , while all the charge is on the plates of the loading capacitor and thus the current distribution is constant along the wire. This allows us now to compute numerically L from Eq. (2). In the case h=0 and N integer, the integral in Eq. (2) can actually be computed analytically, giving the formula L=μ o r[ln(8r/a)−2]N 2 . Explicit analytical formulas are again available for R from Eq. (4) and (5), since I rms =I o , |p|≈0 and |m|=I o Nπr 2 (namely only the magnetic-dipole term is contributing to radiation), so we can determine also Q abs =ωL/R abs and Q rad =ωL/R rad . At the end of the calculations, the validity of the assumption of constant current profile is confirmed by checking that indeed the condition C p >>C s ω<<ω s is satisfied. To satisfy this condition, one could use a large external capacitance, however, this would usually shift the operational frequency lower than the optimal frequency, which we will determine shortly; instead, in typical embodiments, one often prefers coils with very small self-capacitance C s to begin with, which usually holds, for the types of coils under consideration, when N=1, so that the self-capacitance comes from the charge distribution across the single turn, which is almost always very small, or when N>1 and h>>2Na, so that the dominant self-capacitance comes from the charge distribution across adjacent turns, which is small if the separation between adjacent turns is large.
[0122] The external loading capacitance C p provides the freedom to tune the resonant frequency (for example by tuning A or d). Then, for the particular simple case h=0, for which we have analytical formulas, the total Q=ωL/(R abs +R rad ) becomes highest at the optimal frequency
[0000]
ω
~
=
[
c
4
π
ɛ
o
2
σ
·
1
aNr
3
]
2
7
,
(
7
)
[0000] reaching the value
[0000]
Q
~
=
6
7
π
(
2
π
2
η
o
σ
a
2
N
2
r
)
3
7
·
[
ln
(
8
r
a
)
-
2
]
.
(
8
)
[0123] At lower frequencies it is dominated by ohmic loss and at higher frequencies by radiation. Note, however, that the formulas above are accurate as long as {tilde over (ω)}<<ω s and, as explained above, this holds almost always when N=1, and is usually less accurate when N>1, since h=0 usually implies a large self-capacitance. A coil with large h can be used, if the self-capacitance needs to be reduced compared to the external capacitance, but then the formulas for L and {tilde over (ω)}, {tilde over (Q)} are again less accurate. Similar qualitative behavior is expected, but a more complicated theoretical model is needed for making quantitative predictions in that case.
[0124] The results of the above analysis for two embodiments of subwavelength modes of λ/r≧70 (namely highly suitable for near-field coupling and well within the quasi-static limit) of coils with N=1 and h=0 at the optimal frequency Eq. (7) are presented in Table 3. To confirm the validity of constant-current assumption and the resulting analytical formulas, mode-solving calculations were also performed using another completely independent method: computational 3D finite-element frequency-domain (FEFD) simulations (which solve Maxwell's Equations in frequency domain exactly apart for spatial discretization) were conducted, in which the boundaries of the conductor were modeled using a complex impedance ζ c =√{square root over (μ o ω/2σ)} boundary condition, valid as long as ζ c /ζ o <<1 (<10 −5 for copper in the microwave). Table 3 shows Numerical FEFD (and in parentheses analytical) results for the wavelength and absorption, radiation and total loss rates, for two different cases of subwavelength-loop resonant modes. Note that for conducting material copper (σ=5.998·10 7 S/m) was used. (The specific parameters of the plot in FIG. 4 are highlighted with bold in the table.) The two methods (analytical and computational) are in very good agreement and show that, in some embodiments, the optimal frequency is in the low-MHz microwave range and the expected quality factors are Q abs ≧1000 and Q rad ≧10000.
[0000]
TABLE 3
single coil
λ/r
f (MHz)
Q rad
Q abs
Q = ω/2Γ
r = 30 cm, a = 2 cm
111.4 (112.4)
8.976 (8.897)
29546 (30512)
4886 (5117)
4193 (4381)
ε = 10, A = 138 cm
2
, d = 4 mm
r = 10 cm, a = 2 mm
69.7 (70.4)
43.04 (42.61)
10702 (10727)
1545 (1604)
1350 (1395)
ε = 10, A = 3.14 cm 2 , d = 1 mm
[0125] Referring to FIG. 5 , in some embodiments, energy is transferred between two capacitively-loaded coils. For the rate of energy transfer between two capacitively-loaded coils 1 and 2 at distance D between their centers, the mutual inductance M L can be evaluated numerically from Eq. (6) by using constant current distributions in the case ω<<ω s . In the case h=0, the coupling is only magnetic and again we have an analytical formula, which, in the quasi-static limit r<<D<<λ and for the relative orientation shown in FIG. 4 , is M L ≈πμ o /2·(r 1 r 2 ) 2 N 1 N 2 /D 3 , which means that Q κ ∝(D/√{square root over (r 1 r 2 )}) 3 is independent of the frequency ω and the number of turns N 1 , N 2 . Consequently, the resultant coupling figure-of-merit of interest is
[0000]
κ
Γ
1
Γ
2
=
Q
1
Q
2
Q
κ
≈
(
r
1
r
2
D
)
3
·
π
2
η
o
r
1
r
2
λ
·
N
1
N
2
∏
j
=
1
,
2
(
πη
o
λσ
·
r
j
a
j
N
j
+
8
3
π
5
η
o
(
r
j
λ
)
4
N
j
2
)
1
2
,
(
9
)
[0000] which again is more accurate for N 1 =N 2 =1.
[0126] From Eq. (9) it can be seen that the optimal frequency {tilde over (ω)}, where the figure-of-merit is maximized to the value is that where √{square root over (Q 1 Q 2 )} is maximized, since Q κ does not depend on frequency (at least for the distances D<<λ of interest for which the quasi-static approximation is still valid). Therefore, the optimal frequency is independent of the distance D between the two coils and lies between the two frequencies where the single-coil Q 1 and Q 2 peak. For same coils, it is given by Eq. (7) and then the figure-of-merit Eq. (9) becomes
[0000]
(
κ
Γ
)
~
=
Q
~
Q
κ
≈
(
r
D
)
3
·
3
7
(
2
π
2
η
0
σ
a
2
N
2
r
)
3
7
.
(
10
)
[0000] Typically, one should tune the capacitively-loaded conducting loops or coils, so that their angular eigenfrequencies are close to {tilde over (ω)} within {tilde over (Γ)}, which is half the angular frequency width for which √{square root over (Q 1 Q 2 )}/Q κ > /2.
[0127] Referring to Table 4, numerical FEFD and, in parentheses, analytical results based on the above are shown for two systems each composed of a matched pair of the loaded coils described in Table 3. The average wavelength and loss rates are shown along with the coupling rate and coupling to loss ratio figure-of-merit κ/Γ as a function of the coupling distance D, for the two cases. Note that the average numerical Γ rad shown are again slightly different from the single-loop value of FIG. 3 , analytical results for Γ rad are not shown but the single-loop value is used. (The specific parameters corresponding to the plot in FIG. 5 are highlighted with bold in the table.) Again we chose N=1 to make the constant-current assumption a good one and computed M L numerically from Eq. (6). Indeed the accuracy can be confirmed by their agreement with the computational FEFD mode-solver simulations, which give i through the frequency splitting (=2κ) of the two normal modes of the combined system. The results show that for medium distances D/r=10−3 the expected coupling-to-loss ratios are in the range κ/Γ˜0.5-50.
[0000]
TABLE 4
pair of coils
D/r
Q rad
Q = ω/2Γ
Q κ = ω/2κ
κ/Γ
r = 30 cm, a = 2 cm
3
30729
4216
62.6 (63.7)
67.4 (68.7)
ε = 10, A = 138 cm
2
, d = 4 mm
5
29577
4194
235 (248)
17.8 (17.6)
λ/r ≈ 112
7
29128
4185
589 (646)
7.1 (6.8)
Q abs ≈ 4886
10
28833
4177
1539 (1828)
2.7 (2.4)
r = 10 cm, a = 2 mm
3
10955
1355
85.4 (91.3)
15.9 (15.3)
ε = 10, A = 3.14 cm 2 , d = 1 mm
5
10740
1351
313 (356)
4.32 (3.92)
λ/r ≈ 70
7
10759
1351
754 (925)
1.79 (1.51)
Q abs ≈ 1646
10
10756
1351
1895 (2617)
0.71 (0.53)
[0128] Optimization of √{square root over (Q 1 Q 2 )}/Q κ
[0129] In some embodiments, the results above can be used to increase or optimize the performance of a wireless energy transfer system which employs capacitively-loaded coils. For example, the scaling of Eq. (10) with the different system parameters one sees that to maximize the system figure-of-merit κ/Γ one can, for example:
Decrease the resistivity of the conducting material. This can be achieved, for example, by using good conductors (such as copper or silver) and/or lowering the temperature. At very low temperatures one could use also superconducting materials to achieve extremely good performance. Increase the wire radius a. In typical embodiments, this action is limited by physical size considerations. The purpose of this action is mainly to reduce the resistive losses in the wire by increasing the cross-sectional area through which the electric current is flowing, so one could alternatively use also a Litz wire or a ribbon instead of a circular wire. For fixed desired distance D of energy transfer, increase the radius of the loop r. In typical embodiments, this action is limited by physical size considerations. For fixed desired distance vs. loop-size ratio D/r, decrease the radius of the loop r. In typical embodiments, this action is limited by physical size considerations. Increase the number of turns N. (Even though Eq. (10) is expected to be less accurate for N>1, qualitatively it still provides a good indication that we expect an improvement in the coupling-to-loss ratio with increased N.) In typical embodiments, this action is limited by physical size and possible voltage considerations, as will be discussed in following sections. Adjust the alignment and orientation between the two coils. The figure-of-merit is optimized when both cylindrical coils have exactly the same axis of cylindrical symmetry (namely they are “facing” each other). In some embodiments, particular mutual coil angles and orientations that lead to zero mutual inductance (such as the orientation where the axes of the two coils are perpendicular) should be avoided. Finally, note that the height of the coil h is another available design parameter, which has an impact to the performance similar to that of its radius r, and thus the design rules are similar.
[0137] The above analysis technique can be used to design systems with desired parameters. For example, as listed below, the above described techniques can be used to determine the cross sectional radius a of the wire which one should use when designing as system two same single-turn loops with a given radius in order to achieve a specific performance in terms of κ/Γ at a given D/r between them, when the material is copper (σ= 5 . 998 · 10 7 S/m):
[0000] D/r= 5, κ/Γ≧10, r= 30cm a≧ 9mm
[0000] D/r= 5, κ/Γ≧10, r= 5cm a≧ 3.7mm
[0000] D/r= 5, κ/Γ≧20, r= 30cm a≧ 20mm
[0000] D/r= 5, κ/Γ≧20, r= 5cm a≧ 8.3mm
[0000] D/r= 10, κ/Γ≧1, r= 30cm a≧ 7mm
[0000] D/r= 10, κ/Γ≧1, r= 5cm a≧ 2.8mm
[0000] D/r= 10, κ/Γ≧3, r= 30cm a≧ 25mm
[0000] D/r= 10, κ/Γ≧3, r= 5cm a≧ 10mm
[0138] Similar analysis can be done for the case of two dissimilar loops. For example, in some embodiments, the device under consideration is very specific (e.g. a laptop or a cell phone), so the dimensions of the device object (r d ,h d ,a d ,N d ) are very restricted. However, in some such embodiments, the restrictions on the source object (r s ,h s ,a s ,N s ) are much less, since the source can, for example, be placed under the floor or on the ceiling. In such cases, the desired distance is often well defined, based on the application (e.g. D ˜1 m for charging a laptop on a table wirelessly from the floor). Listed below are examples (simplified to the case N s =N d =1 and h s =h d =0) of how one can vary the dimensions of the source object to achieve the desired system performance in terms of κ/√{square root over (Γ s Γ d )}, when the material is again copper (σ=5.998·10 7 S/m):
[0000] D= 1.5m, κ/√{square root over (Γ s Γ d )}≧15, r d =30cm, a d =6mm r s =1.158m, a s ≧5mm
[0000] D= 1.5m, κ/√{square root over (Γ s Γ d )}≧30, r d =30cm, a d =6mm r s =1.15m, a s ≧33mm
[0000] D= 1.5m, κ/√{square root over (Γ s Γ d )}≧1, r d =5cm, a d =4mm r s =1.119m, a s ≧7mm
[0000] D= 1.5m, κ/√{square root over (Γ s Γ d )}≧2, r d =5cm, a d =4mm r s =1.119m, a s ≧52mm
[0000] D= 2m, κ/√{square root over (Γ s Γ d )}≧10, r d =30cm, a d =6mm r s =1.518m, a s ≧7mm
[0000] D= 2m, κ/√{square root over (Γ s Γ d )}≧20, r d =30cm, a d =6mm r s =1.514m, a s ≧50mm
[0000] D= 2m, κ/√{square root over (Γ s Γ d )}≧0.5, r d =5cm, a d =4mm r s =1.491m, a s ≧5mm
[0000] D= 2m, κ/√{square root over (Γ s Γ d )}≧1, r d =5cm, a d =4mm r s =1.491m, a s ≧36mm
[0139] Optimization of Q κ
[0140] As will be described below, in some embodiments the quality factor Q of the resonant objects is limited from external perturbations and thus varying the coil parameters cannot lead to improvement in Q. In such cases, one may opt to increase the coupling to loss ratio figure-of-merit by decreasing Q κ (i.e. increasing the coupling). The coupling does not depend on the frequency and the number of turns. Therefore, the remaining degrees of freedom are:
Increase the wire radii a 1 and a 2 . In typical embodiments, this action is limited by physical size considerations. For fixed desired distance D of energy transfer, increase the radii of the coils r 1 and r 2 . In typical embodiments, this action is limited by physical size considerations. For fixed desired distance vs. coil-sizes ratio D/√{square root over (r 1 r 2 )}, only the weak (logarithmic) dependence of the inductance remains, which suggests that one should decrease the radii of the coils r 1 and r 2 . In typical embodiments, this action is limited by physical size considerations. Adjust the alignment and orientation between the two coils. In typical embodiments, the coupling is optimized when both cylindrical coils have exactly the same axis of cylindrical symmetry (namely they are “facing” each other). Particular mutual coil angles and orientations that lead to zero mutual inductance (such as the orientation where the axes of the two coils are perpendicular) should obviously be avoided. Finally, note that the heights of the coils h 1 and h 2 are other available design parameters, which have an impact to the coupling similar to that of their radii r 1 and r 2 , and thus the design rules are similar.
[0146] Further practical considerations apart from efficiency, e.g. physical size limitations, will be discussed in detail below.
[0147] It is also important to appreciate the difference between the above described resonant-coupling inductive scheme and the well-known non-resonant inductive scheme for energy transfer. Using CMT it is easy to show that, keeping the geometry and the energy stored at the source fixed, the resonant inductive mechanism allows for ˜Q 2 (˜10 6 ) times more power delivered for work at the device than the traditional non-resonant mechanism. This is why only close-range contact-less medium-power (˜W) transfer is possible with the latter, while with resonance either close-range but large-power (˜kW) transfer is allowed or, as currently proposed, if one also ensures operation in the strongly-coupled regime, medium-range and medium-power transfer is possible. Capacitively-loaded conducting loops are currently used as resonant antennas (for example in cell phones), but those operate in the far-field regime with D/r I, r/λ˜I, and the radiation Q's are intentionally designed to be small to make the antenna efficient, so they are not appropriate for energy transfer.
[0148] Inductively-Loaded Conducting Rods
[0149] A straight conducting rod of length 2h and cross-sectional radius a has distributed capacitance and distributed inductance, and therefore it supports a resonant mode of angular frequency ω. Using the same procedure as in the case of self-resonant coils, one can define an effective total inductance L and an effective total capacitance C of the rod through formulas (2) and (3). With these definitions, the resonant angular frequency and the effective impedance are given again by the common formulas ω=1/√{square root over (LC)} and Z=√{square root over (L/C)} respectively. To calculate the total inductance and capacitance, one can assume again a sinusoidal current profile along the length of the conducting wire. When interested in the lowest mode, if we denote by x the coordinate along the conductor, such that it runs from −h to +h, then the current amplitude profile would have the form I(x)=I o cos(πx/2h), since it has to be zero at the open ends of the rod. This is the well-known half-wavelength electric dipole resonant mode.
[0150] In some embodiments, one or more of the resonant objects are inductively-loaded conducting rods. A straight conducting rod of length 2h and cross-sectional radius a, as in the previous paragraph, is cut into two equal pieces of length h, which are connected via a coil wrapped around a magnetic material of relative permeability μ, and everything is surrounded by air. The coil has an inductance L c , which is added to the distributed inductance of the rod and thus modifies its resonance. Note however, that the presence of the center-loading inductor modifies significantly the current distribution inside the wire and therefore the total effective inductance L and total effective capacitance C of the rod are different respectively from L s and C s , which are calculated for a self-resonant rod of the same total length using a sinusoidal current profile, as in the previous paragraph. Since some current is running inside the coil of the external loading inductor, the current distribution j inside the rod is reduced, so L<L s , and thus, from the charge conservation equation, the linear charge distribution ρ 1 flattens out towards the center (being positive in one side of the rod and negative in the other side of the rod, changing abruptly through the inductor), so C>C s . The resonant frequency for this system is ω=1/√{square root over ((L+L c )C)}<ω s =1/√{square root over (L s C s )}, and I(x)→I o cos(πx/2h) L→L s ω→ω s , as L c →0.
[0151] In general, the desired CMT parameters can be found for this system, but again a very complicated solution of Maxwell's Equations is required. Instead, we will analyze only a special case, where a reasonable guess for the current distribution can be made. When L c >>L s >L, then ω≈1/√{square root over (L c C)}<<ω s and Z≈√{square root over (L c /C)}>>Z s , while the current distribution is triangular along the rod (with maximum at the center-loading inductor and zero at the ends) and thus the charge distribution is positive constant on one half of the rod and equally negative constant on the other side of the rod. This allows us now to compute numerically C from Eq. (3). In this case, the integral in Eq. (3) can actually be computed analytically, giving the formula 1/C=1/(π∈ o h)[ln(h/a)−1]. Explicit analytical formulas are again available for R from Eq. (4) and (5), since I rms =I o , |p|=q o h and |m|=0 (namely only the electric-dipole term is contributing to radiation), so we can determine also Q abs =1/ωCR abs and Q rad =1/ωCR rad . At the end of the calculations, the validity of the assumption of triangular current profile is confirmed by checking that indeed the condition L c >>L s ω<<ω s is satisfied. This condition is relatively easily satisfied, since typically a conducting rod has very small self-inductance L s to begin with.
[0152] Another important loss factor in this case is the resistive loss inside the coil of the external loading inductor L c and it depends on the particular design of the inductor. In some embodiments, the inductor is made of a Brooks coil, which is the coil geometry which, for fixed wire length, demonstrates the highest inductance and thus quality factor. The Brooks coil geometry has N Bc turns of conducting wire of cross-sectional radius a Bc wrapped around a cylindrically symmetric coil former, which forms a coil with a square cross-section of side r Bc , where the inner side of the square is also at radius r Bc (and thus the outer side of the square is at radius 2r Bc ), therefore N Bc ≈(r Bc /2a Bc ) 2 . The inductance of the coil is then L c =2.0285μ o r Bc N Bc 2 ≈2.0285μ o r Bc 5 /8a Bc 4 and its resistance
[0000]
R
c
≈
1
σ
l
Bc
π
a
Bc
2
1
+
μ
o
ωσ
2
(
a
Bc
2
)
2
,
[0000] where the total wire length is l Bc ≈2π(3r Bc /2)N Bc ≈3πr Bc 3 /4a Bc 2 and we have used an approximate square-root law for the transition of the resistance from the dc to the ac limit as the skin depth varies with frequency.
[0153] The external loading inductance L c provides the freedom to tune the resonant frequency. (For example, for a Brooks coil with a fixed size r Bc , the resonant frequency can be reduced by increasing the number of turns N Bc by decreasing the wire cross-sectional radius a Bc . Then the desired resonant angular frequency ω=1/√{square root over (L c C)} is achieved for a Bc ≈(2.0285μ o r Bc 5 ω 2 C) 1/4 and the resulting coil quality factor is Q c ≈0.169μ o σr Bc 2 ω/√{square root over (1+ω 2 μ o σ√{square root over (2.0285μ o (r Bc /4) 5 C)})}). Then, for the particular simple case L c >>L s , for which we have analytical formulas, the total Q=1/ωC(R c +R abs +R rad ) becomes highest at some optimal frequency {tilde over (ω)}, reaching the value {tilde over (Q)}, both determined by the loading-inductor specific design. (For example, for the Brooks-coil procedure described above, at the optimal frequency {tilde over (Q)}≈Q c ≈0.8(μ o σ 2 r Bc 3 /C) 1/4 ) At lower frequencies it is dominated by ohmic loss inside the inductor coil and at higher frequencies by radiation. Note, again, that the above formulas are accurate as long as {tilde over (ω)}<<ω s and, as explained above, this is easy to design for by using a large inductance.
[0154] The results of the above analysis for two embodiments, using Brooks coils, of subwavelength modes of λ/h≧200 (namely highly suitable for near-field coupling and well within the quasi-static limit) at the optimal frequency {tilde over (ω)} are presented in Table 5. Table 5 shows in parentheses (for similarity to previous tables) analytical results for the wavelength and absorption, radiation and total loss rates, for two different cases of subwavelength-loop resonant modes. Note that for conducting material copper (σ=5.998·10 7 S/m) was used. The results show that, in some embodiments, the optimal frequency is in the low-MHz microwave range and the expected quality factors are Q abs ≧1000 and Q rad ≧100000.
[0000]
TABLE 5
Q = ω/
single rod
λ/h
f (MHz)
Q rad
Q abs
2Γ
h = 30 cm,
(403.8)
(2.477)
(2.72 * 10 6 )
(7400)
(7380)
a = 2 cm μ = 1,
r Bc = 2 cm,
a Bc = 0.88 mm,
N Bc = 129
h = 10 cm,
(214.2)
(14.010)
(6.92 * 10 5 )
(3908)
(3886)
a = 2 mm μ = 1,
r Bc = 5 mm,
a Bc = 0.25 mm,
[0155] In some embodiments, energy is transferred between two inductively-loaded rods. For the rate of energy transfer between two inductively-loaded rods 1 and 2 at distance D between their centers, the mutual capacitance M c can be evaluated numerically from Eq. (6) by using triangular current distributions in the case ω<<ω s . In this case, the coupling is only electric and again we have an analytical formula, which, in the quasi-static limit h<<D<<λ and for the relative orientation such that the two rods are aligned on the same axis, is 1/M C ≈1/2π∈ o ·(h 1 h 2 ) 2 /D 3 , which means that Q κ ∝(D/√{square root over (h 1 h 2 )}) 3 is independent of the frequency ω. Consequently, one can get the resultant coupling figure-of-merit of interest
[0000]
κ
Γ
1
Γ
2
=
Q
1
Q
2
Q
κ
.
[0000] It can be seen that the optimal frequency {tilde over (ω)}, where the figure-of-merit is maximized to the value is that where √{square root over (Q 1 Q 2 )} is maximized, since Q κ does not depend on frequency (at least for the distances D<<λ of interest for which the quasi-static approximation is still valid). Therefore, the optimal frequency is independent of the distance D between the two rods and lies between the two frequencies where the single-rod Q 1 and Q 2 peak. Typically, one should tune the inductively-loaded conducting rods, so that their angular eigenfrequencies are close to {tilde over (ω)} within {tilde over (Γ)}, which is half the angular frequency width for which √{square root over (Q 1 Q 2 )}/Q κ > /2.
[0156] Referring to Table 6, in parentheses (for similarity to previous tables) analytical results based on the above are shown for two systems each composed of a matched pair of the loaded rods described in Table 5. The average wavelength and loss rates are shown along with the coupling rate and coupling to loss ratio figure-of-merit κ/Γ as a function of the coupling distance D, for the two cases. Note that for Γ rad the single-rod value is used. Again we chose L c >>L s to make the triangular-current assumption a good one and computed M C numerically from Eq. (6). The results show that for medium distances D/h=10−3 the expected coupling-to-loss ratios are in the range κ/Γ˜0.5-100.
[0000]
TABLE 6
pair of rods
D/h
Q κ = ω/2κ
κ/Γ
h = 30 cm, a = 2 cm
3
(70.3)
(105.0)
μ = 1, r Bc = 2 cm, a Bc = 0.88 mm,
5
(389)
(19.0)
N Bc = 129
λ/h ≈ 404
7
(1115)
(6.62)
Q ≈ 7380
10
(3321)
(2.22)
h = 10 cm, a = 2 mm
3
(120)
(32.4)
μ = 1, r Bc = 5 mm, a Bc = 0.25 mm,
5
(664)
(5.85)
N Bc = 103
λ/h ≈ 214
7
(1900)
(2.05)
Q ≈ 3886
10
(5656)
(0.69)
[0157] Dielectric Disks
[0158] In some embodiments, one or more of the resonant objects are dielectric objects, such as disks. Consider a two dimensional dielectric disk object, as shown in FIG. 6 , of radius r and relative permittivity ∈ surrounded by air that supports high-Q “whispering-gallery” resonant modes. The loss mechanisms for the energy stored inside such a resonant system are radiation into free space and absorption inside the disk material. High-Q rad and long-tailed subwavelength resonances can be achieved when the dielectric permittivity ∈ is large and the azimuthal field variations are slow (namely of small principal number m). Material absorption is related to the material loss tangent:
[0000] Q abs ˜Re{∈}/Im{∈}. Mode-solving calculations for this type of disk resonances were performed using two independent methods: numerically, 2D finite-difference frequency-domain (FDFD) simulations (which solve Maxwell's Equations in frequency domain exactly apart for spatial discretization) were conducted with a resolution of 30pts/r; analytically, standard separation of variables (SV) in polar coordinates was used.
[0000]
TABLE 7
single disk
λ/r
Q abs
Q rad
Q
Re{ε} = 147.7, m = 2
20.01 (20.00)
10103 (10075)
1988 (1992)
1661 (1663)
Re{ε} = 65.6, m = 3
9.952 (9.950)
10098 (10087)
9078 (9168)
4780 (4802)
[0159] The results for two TE-polarized dielectric-disk subwavelength modes of λ/r≧10 are presented in Table 7. Table 7 shows numerical FDFD (and in parentheses analytical SV) results for the wavelength and absorption, radiation and total loss rates, for two different cases of subwavelength-disk resonant modes. Note that disk-material loss-tangent Im{∈}/Re{∈}=10 −4 was used. (The specific parameters corresponding to the plot in FIG. 6 . are highlighted with bold in the table.) The two methods have excellent agreement and imply that for a properly designed resonant low-loss-dielectric object values of Q rad ≧2000 and Q abs ˜10000 are achievable. Note that for the 3D case the computational complexity would be immensely increased, while the physics would not be significantly different. For example, a spherical object of ∈=147.7 has a whispering gallery mode with m=2, Qrad=13962, and λ/r=17.
[0160] The required values of ∈, shown in Table 7, might at first seem unrealistically large. However, not only are there in the microwave regime (appropriate for approximately meter-range coupling applications) many materials that have both reasonably high enough dielectric constants and low losses (e.g. Titania, Barium tetratitanate, Lithium tantalite etc.), but also c could signify instead the effective index of other known subwavelength surface-wave systems, such as surface modes on surfaces of metallic materials or plasmonic (metal-like, negative-∈) materials or metallo-dielectric photonic crystals or plasmono-dielectric photonic crystals.
[0161] To calculate now the achievable rate of energy transfer between two disks 1 and 2, as shown in FIG. 7 we place them at distance D between their centers. Numerically, the FDFD mode-solver simulations give κ through the frequency splitting (=2κ) of the normal modes of the combined system, which are even and odd superpositions of the initial single-disk modes; analytically, using the expressions for the separation-of-variables eigenfields E 1,2 (r) CMT gives κ through κ=ω 1 /2·∫d 3 r∈ 2 (r)E* 2 (r)E 1 (r)/∫d 3 r∈(r)|E 1 (r)| 2 where ∈ j (r) and ∈(r) are the dielectric functions that describe only the disk j (minus the constant ∈ o background) and the whole space respectively. Then, for medium distances D/r=10−3 and for non-radiative coupling such that D<2r c , where r c =mλ/2π is the radius of the radiation caustic, the two methods agree very well, and we finally find, as shown in Table 8, coupling-to-loss ratios in the range κ/Γ˜1-50. Thus, for the analyzed embodiments, the achieved figure-of-merit values are large enough to be useful for typical applications, as discussed below.
[0000]
TABLE 8
two disks
D/r
Q rad
Q = ω/2Γ
ω/2κ
κ/Γ
Re{ε} = 147.7,
3
2478
1989
46.9 (47.5)
42.4 (35.0)
m = 2 λ/r ≈ 20
5
2411
1946
298.0 (298.0)
6.5 (5.6)
Q abs ≈ 10093
7
2196
1804
769.7 (770.2)
2.3 (2.2)
10
2017
1681
1714 (1601)
0.98 (1.04)
Re{ε} = 65.6,
3
7972
4455
144 (140)
30.9 (34.3)
m = 3 λ/r ≈ 10
5
9240
4324
2242 (2083)
2.2 (2.3)
Q abs ≈ 10096
7
9187
4810
7485 (7417)
0.64 (0.65)
[0162] Note that even though particular embodiments are presented and analyzed above as examples of systems that use resonant electromagnetic coupling for wireless energy transfer, those of self-resonant conducting coils, capacitively-loaded resonant conducting coils and resonant dielectric disks, any system that supports an electromagnetic mode with its electromagnetic energy extending much further than its size can be used for transferring energy. For example, there can be many abstract geometries with distributed capacitances and inductances that support the desired kind of resonances. In any one of these geometries, one can choose certain parameters to increase and/or optimize √{square root over (Q 1 Q 2 )}/Q κ or, if the Q's are limited by external factors, to increase and/or optimize for Q κ .
[0163] System Sensitivity to Extraneous Objects
[0164] In general, the overall performance of particular embodiment of the resonance-based wireless energy-transfer scheme depends strongly on the robustness of the resonant objects' resonances. Therefore, it is desirable to analyze the resonant objects' sensitivity to the near presence of random non-resonant extraneous objects. One appropriate analytical model is that of “perturbation theory” (PT), which suggests that in the presence of an extraneous object e the field amplitude a 1 (t) inside the resonant object 1 satisfies, to first order:
[0000]
a
1
t
=
-
(
ω
1
-
Γ
1
)
a
1
+
(
κ
11
-
e
+
Γ
1
-
e
)
a
1
(
11
)
[0000] where again ω 1 is the frequency and Γ 1 the intrinsic (absorption, radiation etc.) loss rate, while κ 11-e is the frequency shift induced onto 1 due to the presence of e and Γ 1-e is the extrinsic due to e (absorption inside e, scattering from e etc.) loss rate. The first-order PT model is valid only for small perturbations. Nevertheless, the parameters κ 11-e , Γ 1-e are well defined, even outside that regime, if a 1 is taken to be the amplitude of the exact perturbed mode. Note also that interference effects between the radiation field of the initial resonant-object mode and the field scattered off the extraneous object can for strong scattering (e.g. off metallic objects) result in total radiation-Γ 1-e 's that are smaller than the initial radiation-Γ 1 (namely Γ 1-e is negative).
[0165] The frequency shift is a problem that can be “fixed” by applying to one or more resonant objects a feedback mechanism that corrects its frequency. For example, referring to FIG. 8 a , in some embodiments each resonant object is provided with an oscillator at fixed frequency and a monitor which determines the frequency of the object. Both the oscillator and the monitor are coupled to a frequency adjuster which can adjust the frequency of the resonant object by, for example, adjusting the geometric properties of the object (e.g. the height of a self-resonant coil, the capacitor plate spacing of a capacitively-loaded loop or coil, the dimensions of the inductor of an inductively-loaded rod, the shape of a dielectric disc, etc.) or changing the position of a non-resonant object in the vicinity of the resonant object. The frequency adjuster determines the difference between the fixed frequency and the object frequency and acts to bring the object frequency into alignment with the fixed frequency. This technique assures that all resonant objects operate at the same fixed frequency, even in the presence of extraneous objects.
[0166] As another example, referring to FIG. 8 b , in some embodiments, during energy transfer from a source object to a device object, the device object provides energy to a load, and an efficiency monitor measures the efficiency of the transfer. A frequency adjuster coupled to the load and the efficiency monitor acts to adjust the frequency of the object to maximize the transfer efficiency.
[0167] In various embodiments, other frequency adjusting schemes may be used which rely on information exchange between the resonant objects. For example, the frequency of a source object can be monitored and transmitted to a device object, which is in turn synched to this frequency using frequency adjusters as described above. In other embodiments the frequency of a single clock may be transmitted to multiple devices, and each device then synched to that frequency.
[0168] Unlike the frequency shift, the extrinsic loss can be detrimental to the functionality of the energy-transfer scheme, because it is difficult to remedy, so the total loss rate Γ 1[e] =Γ 1 +Γ 1-e (and the corresponding figure-of-merit κ [e] /√{square root over (Γ 1[e] Γ 2[e] )}, where κ [e] the perturbed coupling rate) should be quantified.
[0169] Capacitively-Loaded Conducting Loops or Coils
[0170] In embodiments using primarily magnetic resonances, the influence of extraneous objects on the resonances is nearly absent. The reason is that, in the quasi-static regime of operation (r<<λ) that we are considering, the near field in the air region surrounding the resonator is predominantly magnetic (e.g. for coils with h<<2r most of the electric field is localized within the self-capacitance of the coil or the externally loading capacitor), therefore extraneous non-conducting objects e that could interact with this field and act as a perturbation to the resonance are those having significant magnetic properties (magnetic permeability Re{μ}>1 or magnetic loss Im{μ}>0). Since almost all every-day non-conducting materials are non-magnetic but just dielectric, they respond to magnetic fields in the same way as free space, and thus will not disturb the resonance of the resonator. Extraneous conducting materials can however lead to some extrinsic losses due to the eddy currents induced on their surface.
[0171] As noted above, an extremely important implication of this fact relates to safety considerations for human beings. Humans are also non-magnetic and can sustain strong magnetic fields without undergoing any risk. A typical example, where magnetic fields B˜1T are safely used on humans, is the Magnetic Resonance Imaging (MRI) technique for medical testing. In contrast, the magnetic near-field required in typical embodiments in order to provide a few Watts of power to devices is only B˜10 −4 T, which is actually comparable to the magnitude of the Earth's magnetic field. Since, as explained above, a strong electric near-field is also not present and the radiation produced from this non-radiative scheme is minimal, it is reasonable to expect that our proposed energy-transfer method should be safe for living organisms.
[0172] One can, for example, estimate the degree to which the resonant system of a capacitively-loaded conducting-wire coil has mostly magnetic energy stored in the space surrounding it. If one ignores the fringing electric field from the capacitor, the electric and magnetic energy densities in the space surrounding the coil come just from the electric and magnetic field produced by the current in the wire; note that in the far field, these two energy densities must be equal, as is always the case for radiative fields. By using the results for the fields produced by a subwavelength (r<<λ) current loop (magnetic dipole) with h=0, we can calculate the ratio of electric to magnetic energy densities, as a function of distance D p from the center of the loop (in the limit r<<D p ) and the angle θ with respect to the loop axis:
[0000]
u
e
(
x
)
u
m
(
x
)
=
ɛ
o
E
(
x
)
2
μ
o
H
(
x
)
2
=
(
1
+
1
x
2
)
sin
2
θ
(
1
x
2
+
1
x
4
)
4
cos
2
θ
+
(
1
-
1
x
2
+
1
x
4
)
sin
2
θ
;
x
=
2
π
D
p
λ
⇒
∯
S
p
u
e
(
x
)
S
∯
S
p
u
m
(
x
)
S
=
1
+
1
x
2
1
+
1
x
2
+
3
x
4
;
x
=
2
π
D
p
λ
,
(
12
)
[0000] where the second line is the ratio of averages over all angles by integrating the electric and magnetic energy densities over the surface of a sphere of radius D p . From Eq. (12) it is obvious that indeed for all angles in the near field (x<<1) the magnetic energy density is dominant, while in the far field (x>>1) they are equal as they should be. Also, the preferred positioning of the loop is such that objects which may interfere with its resonance lie close to its axis (θ=0), where there is no electric field. For example, using the systems described in Table 4, we can estimate from Eq. (12) that for the loop of r=30 cm at a distance D p =10r=3 m the ratio of average electric to average magnetic energy density would be ˜12% and at D p =3r=90 cm it would be ˜1%, and for the loop of r=10 cm at a distance D p =10r=1 m the ratio would be ˜33% and at D p =3r=30 cm it would be ˜2.5%. At closer distances this ratio is even smaller and thus the energy is predominantly magnetic in the near field, while in the radiative far field, where they are necessarily of the same order (ratio→1), both are very small, because the fields have significantly decayed, as capacitively-loaded coil systems are designed to radiate very little. Therefore, this is the criterion that qualifies this class of resonant system as a magnetic resonant system.
[0173] To provide an estimate of the effect of extraneous objects on the resonance of a capacitively-loaded loop including the capacitor fringing electric field, we use the perturbation theory formula, stated earlier, Γ 1- e abs =ω 1 /4·∫d 3 r Im{∈ e (r)}|E 1 (r)| 2 /U with the computational FEFD results for the field of an example like the one shown in the plot of FIG. 5 and with a rectangular object of dimensions 30 cm×30 cm×1.5 m and permittivity ∈=49+16i (consistent with human muscles) residing between the loops and almost standing on top of one capacitor (˜3 cm away from it) and find Q c-h abs ˜10 5 and for ˜10 cm away Q c-h abs ˜5·10 5 . Thus, for ordinary distances (˜1 m) and placements (not immediately on top of the capacitor) or for most ordinary extraneous objects e of much smaller loss-tangent, we conclude that it is indeed fair to say that Q c-e abs →∞. The only perturbation that is expected to affect these resonances is a close proximity of large metallic structures.
[0174] Self-resonant coils are more sensitive than capacitively-loaded coils, since for the former the electric field extends over a much larger region in space (the entire coil) rather than for the latter (just inside the capacitor). On the other hand, self-resonant coils are simple to make and can withstand much larger voltages than most lumped capacitors.
[0175] In general, different embodiments of resonant systems have different degree of sensitivity to external perturbations, and the resonant system of choice depends on the particular application at hand, and how important matters of sensitivity or safety are for that application. For example, for a medical implantable device (such as a wirelessly powered artificial heart) the electric field extent must be minimized to the highest degree possible to protect the tissue surrounding the device. In such cases where sensitivity to external objects or safety is important, one should design the resonant systems so that the ratio of electric to magnetic energy density u e /u m is reduced or minimized at most of the desired (according to the application) points in the surrounding space.
[0176] Dielectric Disks
[0177] In embodiments using resonances that are not primarily magnetic, the influence of extraneous objects may be of concern. For example, for dielectric disks, small, low-index, low-material-loss or far-away stray objects will induce small scattering and absorption. In such cases of small perturbations these extrinsic loss mechanisms can be quantified using respectively the analytical first-order perturbation theory formulas All perturbations
[0000] Γ 1- e rad =ω 1 ∫d 3 rRe{∈ e ( r )}| E 1 ( r )| 2 /U
[0000] and
[0000] Γ 1- e abs =ω 1 /4·∫ d 3 rIm{∈ e ( r )}| E 1 ( r )| 2 /U
[0000] where U=1/2∫d 3 r∈(r)|E 1 (r)| 2 is the total resonant electromagnetic energy of the unperturbed mode. As one can see, both of these losses depend on the square of the resonant electric field tails E 1 at the site of the extraneous object. In contrast, the coupling rate from object 1 to another resonant object 2 is, as stated earlier,
[0000] κ=ω 1 /2·∫ d 3 r∈ 2 ( r ) E* 2 ( r ) E 1 ( r )/∫ d 3 r∈ ( r )| E 1 ( r )| 2
[0000] and depends linearly on the field tails E 1 of 1 inside 2. This difference in scaling gives us confidence that, for, for example, exponentially small field tails, coupling to other resonant objects should be much faster than all extrinsic loss rates (κ>>Γ 1-e ), at least for small perturbations, and thus the energy-transfer scheme is expected to be sturdy for this class of resonant dielectric disks. However, we also want to examine certain possible situations where extraneous objects cause perturbations too strong to analyze using the above first-order perturbation theory approach. For example, we place a dielectric disk c close to another off-resonance object of large Re{∈}, Im{∈} and of same size but different shape (such as a human being h), as shown in FIG. 9 a , and a roughened surface of large extent but of small Re{∈}, Im{∈} (such as a wall w), as shown in FIG. 9 b . For distances D h/w/r =10 −3 between the disk-center and the “human”-center or “wall”, the numerical FDFD simulation results presented in FIGS. 9 a and 9 b suggest that, the disk resonance seems to be fairly robust, since it is not detrimentally disturbed by the presence of extraneous objects, with the exception of the very close proximity of high-loss objects. To examine the influence of large perturbations on an entire energy-transfer system we consider two resonant disks in the close presence of both a “human” and a “wall”. Comparing FIG. 7 to FIG. 9 c , the numerical FDFD simulations show that the system performance deteriorates from κ/Γ c ˜1-50 to κ[hw]/Γ c[hw] ˜0.5-10 i.e. only by acceptably small amounts.
[0178] Inductively-loaded conducting rods may also be more sensitive than capacitively-loaded coils, since they rely on the electric field to achieve the coupling.
[0179] System Efficiency
[0180] In general, another important factor for any energy transfer scheme is the transfer efficiency. Consider again the combined system of a resonant source s and device d in the presence of a set of extraneous objects e. The efficiency of this resonance-based energy-transfer scheme may be determined, when energy is being drained from the device at rate Γ work for use into operational work. The coupled-mode-theory equation for the device field-amplitude is
[0000]
a
d
t
=
-
(
ω
-
Γ
d
[
e
]
)
a
d
+
κ
[
e
]
a
s
-
Γ
work
a
d
,
(
13
)
[0000] where Γ d[e] =Γ d[e] rad +Γ d[e] abs =Γ d[e] rad +(Γ d abs +Γ d-e abs ) is the net perturbed-device loss rate, and similarly we define Γ s[e] for the perturbed-source. Different temporal schemes can be used to extract power from the device (e.g. steady-state continuous-wave drainage, instantaneous drainage at periodic times and so on) and their efficiencies exhibit different dependence on the combined system parameters. For simplicity, we assume steady state, such that the field amplitude inside the source is maintained constant, namely a s (t)=A s e −iωt , so then the field amplitude inside the device is a d (t)=A d e −iωt with A d /A s =iκ [e] /(Γ d[e] +Γ work ). The various time-averaged powers of interest are then: the useful extracted power is P work =2Γ work |A d | 2 , the radiated (including scattered) power is P rad =2Γ s[e] rad |A s | 2 +2Γ d[e] rad |A d | 2 , the power absorbed at the source/device is P s/d =2Γ s/d abs |A s/d | 2 , and at the extraneous objects P e =2Γ s-e abs |A s | 2 +2Γ d-e abs |A d | 2 . From energy conservation, the total time-averaged power entering the system is P total =P work +P rad +P s +P d +P e . Note that the reactive powers, which are usually present in a system and circulate stored energy around it, cancel at resonance (which can be proven for example in electromagnetism from Poynting's Theorem) and do not influence the power-balance calculations. The working efficiency is then:
[0000]
η
work
≡
P
work
P
total
=
1
1
+
Γ
d
[
e
]
Γ
work
·
[
1
+
1
fom
[
e
]
2
(
1
+
Γ
work
Γ
d
[
e
]
)
2
]
,
(
14
)
[0000] where fom [e] =κ [e] /√{square root over (Γ s[e] Γ d[e] )} is the distance-dependent figure-of-merit of the perturbed resonant energy-exchange system. To derive Eq. (14), we have assumed that the rate Γ supply , at which the power supply is feeding energy to the resonant source, is Γ supply =Γ s[e] +κ 2 /(Γ d[e] +Γ work ), such that there are zero reflections of the fed power P total back into the power supply.
EXAMPLE
Capacitively-Loaded Conducting Loops
[0181] Referring to FIG. 10 , to rederive and express this formula (14) in terms of the parameters which are more directly accessible from particular resonant objects, e.g. the capacitively-loaded conducting loops, one can consider the following circuit-model of the system, where the inductances L s , L d represent the source and device loops respectively, R s , R d their respective losses, and C s , C d are the required corresponding capacitances to achieve for both resonance at frequency ω. A voltage generator V g is considered to be connected to the source and a work (load) resistance R ω to the device. The mutual inductance is denoted by M.
[0182] Then from the source circuit at resonance (ωL s =1/ωC s ):
[0000]
V
g
=
I
s
R
s
-
jω
MI
d
⇒
1
2
V
g
*
I
s
=
1
2
I
s
2
R
s
+
1
2
jω
MI
d
*
I
s
,
[0000] and from the device circuit at resonance (ωL d =1/ωC d ):
[0000] 0= I d ( R d +R ω )− jωMI s jMI s =I d ( R d +R ω )
[0000] So by substituting the second to the first:
[0000]
1
2
V
g
*
I
s
=
1
2
I
s
2
R
s
+
1
2
I
d
2
(
R
d
+
R
w
)
.
[0000] Now we take the real part (time-averaged powers) to find the efficiency:
[0000]
P
g
≡
Re
{
1
2
V
g
*
I
s
}
=
P
s
+
P
d
+
P
w
⇒
η
work
≡
P
w
P
tot
=
R
w
I
s
I
d
2
·
R
s
+
R
d
+
R
w
.
Namely,
[0183]
η
work
=
R
w
(
R
d
+
R
w
)
2
(
ω
M
)
2
·
R
s
+
R
d
+
R
w
,
[0000] which with Γ work =R ω /2L d , Γ d =R d /2L d , Γ s =R s /2L s , and κ=ωM/2√{square root over (L s L d )}, becomes the general Eq. (14). [End of Example]
[0184] From Eq. (14) one can find that the efficiency is optimized in terms of the chosen work-drainage rate, when this is chosen to be Γ work /Γ d[e] =Γ supply /Γ s[e] =√{square root over (1+fom [e] 2 )}>1. Then η work is a function of the fom [e] parameter only as shown in FIG. 11 with a solid black line. One can see that the efficiency of the system is η>17% for fom [e] >1, large enough for practical applications. Thus, the efficiency can be further increased towards 100% by optimizing fom [e] as described above. The ratio of conversion into radiation loss depends also on the other system parameters, and is plotted in FIG. 5 for the conducting loops with values for their parameters within the ranges determined earlier.
[0185] For example, consider the capacitively-loaded coil embodiments described in Table 4, with coupling distance D/r=7, a “human” extraneous object at distance D h from the source, and that P work =10 W must be delivered to the load. Then, we have (based on FIG. 11 ) Q s[h] rad =Q d[h] rad ˜10 4 , Q s abs =Q d abs ˜10 3 , Q κ ˜500, and Q d-h abs →∞, Q s-h abs ˜10 5 at D h ˜3 cm, and Q s-h abs ˜5·10 5 at D h ˜10 cm. Therefore fom [h] ˜2, so we find η≈38%, P rad ≈1.5 W, P s ≈11 W, P d ≈4 W, and most importantly η h ≈0.4%, P h =0.1 W at D h ˜3 cm and η h ≈0.1%, P h =0.02 W at D h ˜10 cm.
[0186] Overall System Performance
[0187] In many cases, the dimensions of the resonant objects will be set by the particular application at hand. For example, when this application is powering a laptop or a cell-phone, the device resonant object cannot have dimensions larger that those of the laptop or cell-phone respectively. In particular, for a system of two loops of specified dimensions, in terms of loop radii r s,d and wire radii a s,d , the independent parameters left to adjust for the system optimization are: the number of turns N s,d , the frequency f, the work-extraction rate (load resistance) Γ work and the power-supply feeding rate Γ supply .
[0188] In general, in various embodiments, the primary dependent variable that one wants to increase or optimize is the overall efficiency η. However, other important variables need to be taken into consideration upon system design. For example, in embodiments featuring capacitively-loaded coils, the design may be constrained by, for example, the currents flowing inside the wires I s,d and the voltages across the capacitors V s,d . These limitations can be important because for ˜Watt power applications the values for these parameters can be too large for the wires or the capacitors respectively to handle. Furthermore, the total loaded Q tot =ωL d /(R d +R w ) of the device is a quantity that should be preferably small, because to match the source and device resonant frequencies to within their Q's, when those are very large, can be challenging experimentally and more sensitive to slight variations. Lastly, the radiated powers P rad,s,d should be minimized for safety concerns, even though, in general, for a magnetic, non-radiative scheme they are already typically small.
[0189] In the following, we examine then the effects of each one of the independent variables on the dependent ones. We define a new variable wp to express the work-drainage rate for some particular value of fom [e] through
[0000]
Γ
work
/
Γ
d
[
e
]
=
1
+
wp
·
fom
[
e
]
2
.
[0000] Then, in some embodiments, values which impact the choice of this rate are: Γ work /Γ d[e] =1 wp=0 to minimize the required energy stored in the source (and therefore I s and V s ),
[0000]
Γ
work
/
Γ
d
[
e
]
=
1
+
wp
·
fom
[
e
]
2
>
1
⇔
wp
=
1
[0000] to increase the efficiency, as seen earlier, or Γ work /Γ d[e] >>1 wp>>1 to decrease the required energy stored in the device (and therefore I d and V d ) and to decrease or minimize Q tot =ωL d /(R d +R w )=ω/[2(Γ d +Γ work )]. Similar is the impact of the choice of the power supply feeding rate Γ supply , with the roles of the source and the device reversed.
[0190] Increasing N s and N d increases κ/√{square root over (Γ s Γ d )} and thus efficiency significantly, as seen before, and also decreases the currents I s and I d , because the inductance of the loops increases, and thus the energy
[0000]
U
s
,
d
=
1
2
L
s
,
d
I
s
,
d
2
[0000] required for given output power P work can be achieved with smaller currents. However, increasing N d increases Q tot , P rad,d and the voltage across the device capacitance V d , which unfortunately ends up being, in typical embodiments one of the greatest limiting factors of the system. To explain this, note that it is the electric field that really induces breakdown of the capacitor material (e.g. 3 kV/mm for air) and not the voltage, and that for the desired (close to the optimal) operational frequency, the increased inductance L d implies reduced required capacitance C d , which could be achieved in principle, for a capacitively-loaded device coil by increasing the spacing of the device capacitor plates d d and for a self-resonant coil by increasing through h d the spacing of adjacent turns, resulting in an electric field (≈V d /d d for the former case) that actually decreases with N d ; however, one cannot in reality increase d d or h d too much, because then the undesired capacitance fringing electric fields would become very large and/or the size of the coil might become too large; and, in any case, for certain applications extremely high voltages are not desired. A similar increasing behavior is observed for the source P rad,s and V s upon increasing N s . As a conclusion, the number of turns N s and N d have to be chosen the largest possible (for efficiency) that allow for reasonable voltages, fringing electric fields and physical sizes.
[0191] With respect to frequency, again, there is an optimal one for efficiency, and Q tot is approximately maximum, close to that optimal frequency. For lower frequencies the currents get worse (larger) but the voltages and radiated powers get better (smaller). Usually, one should pick either the optimal frequency or somewhat lower.
[0192] One way to decide on an operating regime for the system is based on a graphical method. In FIG. 12 , for two loops of
[0000] r s =25 cm, r d =15 cm, h s =h d =0, a s =a d =3 mm and distance D=2 m between them, we plot all the above dependent variables (currents, voltages and radiated powers normalized to 1 Watt of output power) in terms of frequency and N d , given some choice for wp and N s . The Figure depicts all of the dependencies explained above. We can also make a contour plot of the dependent variables as functions of both frequency and wp but for both N s and N d fixed. The results are shown in FIG. 13 for the same loop dimensions and distance. For example, a reasonable choice of parameters for the system of two loops with the dimensions given above are: N s =2, N d =6, f=10 MHz and wp=10, which gives the following performance characteristics: η work =20.6%, Q tot =1264, I s =7.2 A, I d =1.4 A, V s =2.55 kV, V d =2.30 kV, P rad,s =0.15 W, P rad,d =0.006 W. Note that the results in FIGS. 12 and 13 , and the just above calculated performance characteristics are made using the analytical formulas provided above, so they are expected to be less accurate for large values of N s , N d , still they give a good estimate of the scalings and the orders of magnitude.
[0193] Finally, one could additionally optimize for the source dimensions, since usually only the device dimensions are limited, as discussed earlier. Namely, one can add r s and a s in the set of independent variables and optimize with respect to these too for all the dependent variables of the problem (we saw how to do this only for efficiency earlier). Such an optimization would lead to improved results.
[0194] Experimental Results
[0195] An experimental realization of an embodiment of the above described scheme for wireless energy transfer consists of two self-resonant coils of the type described above, one of which (the source coil) is coupled inductively to an oscillating circuit, and the second (the device coil) is coupled inductively to a resistive load, as shown schematically in FIG. 14 . Referring to FIG. 14 , A is a single copper loop of radius 25 cm that is part of the driving circuit, which outputs a sine wave with frequency 9.9 MHz. s and d are respectively the source and device coils referred to in the text. B is a loop of wire attached to the load (“light-bulb”). The various κ's represent direct couplings between the objects. The angle between coil d and the loop A is adjusted so that their direct coupling is zero, while coils s and d are aligned coaxially. The direct coupling between B and A and between B and s is negligible.
[0196] The parameters for the two identical helical coils built for the experimental validation of the power transfer scheme were h=20 cm, a=3 mm, r=30 cm, N=5.25. Both coils are made of copper. Due to imperfections in the construction, the spacing between loops of the helix is not uniform, and we have encapsulated the uncertainty about their uniformity by attributing a 10% (2 cm) uncertainty to h. The expected resonant frequency given these dimensions is f 0 =10.56±0.3 MHz, which is about 5% off from the measured resonance at around 9.90 MHz.
[0197] The theoretical Q for the loops is estimated to be ˜2500 (assuming perfect copper of resistivity ρ=1/σ=1.7×10 −8 Ωm) but the measured value is 950±50. We believe the discrepancy is mostly due to the effect of the layer of poorly conducting copper oxide on the surface of the copper wire, to which the current is confined by the short skin depth (˜20 μm) at this frequency. We have therefore used the experimentally observed Q (and Γ 1 =Γ 2 =Γ=ω/(2Q) derived from it) in all subsequent computations.
[0198] The coupling coefficient κ can be found experimentally by placing the two self-resonant coils (fine-tuned, by slightly adjusting h, to the same resonant frequency when isolated) a distance D apart and measuring the splitting in the frequencies of the two resonant modes in the transmission spectrum. According to coupled-mode theory, the splitting in the transmission spectrum should be Δω=2√{square root over (κ 2 −Γ 2 )}. The comparison between experimental and theoretical results as a function of distance when the two the coils are aligned coaxially is shown in FIG. 15 .
[0199] FIG. 16 shows a comparison of experimental and theoretical values for the parameter κ/Γ as a function of the separation between the two coils. The theory values are obtained by using the theoretically obtained ic and the experimentally measured Γ. The shaded area represents the spread in the theoretical κ/Γ due to the ˜5% uncertainty in Q.
[0200] As noted above, the maximum theoretical efficiency depends only on the parameter κ/√{square root over (Γ 1 Γ 2 )}=κ/Γ, plotted as a function of distance in FIG. 17 . The coupling to loss ratio κ/Γ is greater than 1 even for D=2.4 m (eight times the radius of the coils), thus the sytem is in the strongly-coupled regime throughout the entire range of distances probed.
[0201] The power supply circuit was a standard Colpitts oscillator coupled inductively to the source coil by means of a single loop of copper wire 25 cm in radius (see FIG. 14 ). The load consisted of a previously calibrated light-bulb, and was attached to its own loop of insulated wire, which was in turn placed in proximity of the device coil and inductively coupled to it. Thus, by varying the distance between the light-bulb and the device coil, the parameter Γ work /Γ was adjusted so that it matched its optimal value, given theoretically by √{square root over (1+κ 2 /(Γ 1 Γ 2 ))}. Because of its inductive nature, the loop connected to the light-bulb added a small reactive component to Γ work which was compensated for by slightly retuning the coil. The work extracted was determined by adjusting the power going into the Colpitts oscillator until the light-bulb at the load was at its full nominal brightness.
[0202] In order to isolate the efficiency of the transfer taking place specifically between the source coil and the load, we measured the current at the mid-point of each of the self-resonant coils with a current-probe (which was not found to lower the Q of the coils noticeably.) This gave a measurement of the current parameters I 1 and I 2 defined above. The power dissipated in each coil was then computed from P 1,2 =ΓL|I 1,2 | 2 , and the efficiency was directly obtained from η=P work /(P 1 +P 2 +P work ). To ensure that the experimental setup was well described by a two-object coupled-mode theory model, we positioned the device coil such that its direct coupling to the copper loop attached to the Colpitts oscillator was zero. The experimental results are shown in FIG. 17 , along with the theoretical prediction for maximum efficiency, given by Eq. (14).
[0203] Using this embodiment, we were able to transfer significant amounts of power using this setup, fully lighting up a 60 W light-bulb from distances more than 2 m away, for example. As an additional test, we also measured the total power going into the driving circuit. The efficiency of the wireless transfer itself was hard to estimate in this way, however, as the efficiency of the Colpitts oscillator itself is not precisely known, although it is expected to be far from 100%. Nevertheless, this gave an overly conservative lower bound on the efficiency. When transferring 60 W to the load over a distance of 2 m, for example, the power flowing into the driving circuit was 400 W. This yields an overall wall-to-load efficiency of ˜15%, which is reasonable given the expected ˜40% efficiency for the wireless power transfer at that distance and the low efficiency of the driving circuit.
[0204] From the theoretical treatment above, we see that in typical embodiments it is important that the coils be on resonance for the power transfer to be practical. We found experimentally that the power transmitted to the load dropped sharply as one of the coils was detuned from resonance. For a fractional detuning Δf/f 0 of a few times the inverse loaded Q, the induced current in the device coil was indistinguishable from noise.
[0205] The power transfer was not found to be visibly affected as humans and various everyday objects, such as metallic and wooden furniture, as well as electronic devices large and small, were placed between the two coils, even when they drastically obstructed the line of sight between source and device. External objects were found to have an effect only when they were closer than 10 cm from either one of the coils. While some materials (such as aluminum foil, styrofoam and humans) mostly just shifted the resonant frequency, which could in principle be easily corrected with a feedback circuit of the type described earlier, others (cardboard, wood, and PVC) lowered Q when placed closer than a few centimeters from the coil, thereby lowering the efficiency of the transfer.
[0206] We believe that this method of power transfer should be safe for humans. When transferring 60 W (more than enough to power a laptop computer) across 2 m, we estimated that the magnitude of the magnetic field generated is much weaker than the Earth's magnetic field for all distances except for less than about 1 cm away from the wires in the coil, an indication of the safety of the scheme even after long-term use. The power radiated for these parameters was ˜5 W, which is roughly an order of magnitude higher than cell phones but could be drastically reduced, as discussed below.
[0207] Although the two coils are currently of identical dimensions, it is possible to make the device coil small enough to fit into portable devices without decreasing the efficiency. One could, for instance, maintain the product of the characteristic sizes of the source and device coils constant.
[0208] These experiments demonstrated experimentally a system for power transfer over medium range distances, and found that the experimental results match theory well in multiple independent and mutually consistent tests.
[0209] We believe that the efficiency of the scheme and the distances covered could be appreciably improved by silver-plating the coils, which should increase their Q, or by working with more elaborate geometries for the resonant objects. Nevertheless, the performance characteristics of the system presented here are already at levels where they could be useful in practical applications.
[0210] Applications
[0211] In conclusion, we have described several embodiments of a resonance-based scheme for wireless non-radiative energy transfer. Although our consideration has been for a static geometry (namely κ and Γ e were independent of time), all the results can be applied directly for the dynamic geometries of mobile objects, since the energy-transfer time κ −1 (˜1 μs-1 ms for microwave applications) is much shorter than any timescale associated with motions of macroscopic objects. Analyses of very simple implementation geometries provide encouraging performance characteristics and further improvement is expected with serious design optimization. Thus the proposed mechanism is promising for many modern applications.
[0212] For example, in the macroscopic world, this scheme could potentially be used to deliver power to for example, robots and/or computers in a factory room, or electric buses on a highway. In some embodiments source-object could be an elongated “pipe” running above the highway, or along the ceiling.
[0213] Some embodiments of the wireless transfer scheme can provide energy to power or charge devices that are difficult or impossible to reach using wires or other techniques. For example some embodiments may provide power to implanted medical devices (e.g. artificial hearts, pacemakers, medicine delivery pumps, etc.) or buried underground sensors.
[0214] In the microscopic world, where much smaller wavelengths would be used and smaller powers are needed, one could use it to implement optical inter-connects for CMOS electronics, or to transfer energy to autonomous nano-objects (e.g. MEMS or nano-robots) without worrying much about the relative alignment between the sources and the devices. Furthermore, the range of applicability could be extended to acoustic systems, where the source and device are connected via a common condensed-matter object.
[0215] In some embodiments, the techniques described above can provide non-radiative wireless transfer of information using the localized near fields of resonant object. Such schemes provide increased security because no information is radiated into the far-field, and are well suited for mid-range communication of highly sensitive information.
[0216] A number of embodiments of the invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. | Described herein are embodiments of an electronic system that includes a substrate, having a plurality of power consuming elements thereon, said power consuming elements arranged in a fixed geometry on said substrate, and at least a plurality of said power consuming elements including at least one high-Q wireless power receiving element, that wirelessly receives power that is sent thereto from at least one high-Q wireless power source element, and uses said power which is wirelessly received, to power said power consuming elements, wherein at least one of said power consuming elements receives power separately from at least another of said power consuming elements, and wherein each of said power consuming elements operates substantially simultaneously, and wherein at least one of said power consuming elements has an output connected to another of said power consuming elements. | 7 |
FIELD OF THE INVENTION
This invention relates generally to the surface treatment of metallic filaments, and particularly metal-plated semimetallic and polymeric fibers. More particularly, the invention relates to surface treating metallic filaments, e.g., metal-plated carbon fibers to afford properties which enhance the fibers as weaving materials and for producing reinforced composites with thermosetting polymeric materials having superior properties.
DESCRIPTION OF THE PRIOR ART
It has been known for some time that metallic filaments, e.g., filaments of metals, and metal coated nonmetals and semimetals such as carbon, boron, silicon carbon, polyesters, polyamides, and the like in the form of filaments, fibers, mats, cloths and chopped strands are extremely desirable and beneficial, for example, in reinforcing organic polymeric materials.
Weaving, braiding or knitting are used to form the filaments into cloth or fabric-like articles, particularly when strength or substance is to be provided in a matrix comprised of the metallic filaments and a polymeric material such as an epoxy, bismaleimide, polyimide, polyether ether ketone, polyetherimide, nylon, a polyester, a phenolic, or a polyolefin such as polypropylene. Sheets of such composites form structural members in aircraft, automobiles, marine equipment and other applications.
Recently, it has been recognized that the properties of the high strength nonmetal or semimetallic filaments such as carbon, or polymeric filaments such as aramid filaments can be enhanced by deposition of metal such as nickel and silver in thin surface coatings. These metallic filaments have the same application as uncoated carbon or polymer filaments but enjoy improved properties such as increased strength in plastic matrixes and electrical conductivity. This makes them especially useful, for example as components in aircraft where lightning strike protection is essential.
Several processes now exist for the production of metallic filaments, e.g., vacuum deposition, ion discharge coating, electroless metal deposition and electrodeposition.
Regardless of the process by which the filaments are obtained or coated with metal, the resulting products are somewhat characterized by a lack of ease with respect to weaving them into fabric-like articles and some difficulty with blending them with organic materials. It is believed that these difficulties are due in part to the fineness of the material and a tendency for fuzz to develop. Additionally, these difficulties are also believed to be due in part to the surface characteristics of the fibers and possibly the presence of random tow material extending from the fiber surface.
In commonly assigned copending application, U.S. Ser. No. 507,602, filed June 24, 1983, incorporated herein by reference, it is disclosed that passing the metallic filaments through a sizing medium, e.g., 0.1 to 2.5 percent of a silane and then heating to dry and set the sizing material on the filaments is a valuable technique to overcome such shortcomings. Moreover, if the process also includes passing the filaments through a medium comprising 15 to 40 percent of poly(vinyl acetate) a desirable bulk density increase is noted, which appears to enhance the ability of the filaments to blend with thermoplastics. However, this large amount of poly(vinyl acetate) tends to cause problems in weaving and knitting and requires "working" of the treated fibers, which are usually in yarns and tows comprising thousands of individual fibers. Working involves passing the yarns or tows through fingers or eyelets, and the like, to sharply change their direction and while this flexibilizes the coating and makes the fibers more amenable to braiding, it is uneconomical and breakage is a serious problem.
It has now been discovered that reducing substantially the amount of poly(vinyl acetate) while maintaining the silane at the same level employed in the process of the said copending application reduces the tendency to break, and renders the filaments uniquely suitable for fabricating into unidirectional tapes, non-woven, woven cloths and fabrics and knitted articles. A most surprising effect in result is also found when the properties of thermoset composites reinforced with the sized fibers of this invention are compared with those of the pending application. Whereas the thermoplastic composites with low poly(vinyl acetate) level treatment may be difficult to blend, thermoset composites according to this invention have enhanced short beam shear strengths both dry and after wet conditioning in comparison with those prepared according to the said Ser. No. 507,602. This discovery makes fibers surface treated according to the present invention uniquely suited for use in high performance aerospace vehicles.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a process by which metallic filaments, especially metal-coated filaments, can be provided with the properties desirable and necessary for weaving the metal-coated fibers into fabric or mat-like articles.
It is a further object of the invention to provide metallic, filaments with enhanced flexibility.
It is another and further object of the invention to provide metal-coated high strength fibers with a minimum of random fibrils extending outwardly from the basic fiber.
It is yet another object of the invention to provide metallized filaments with a metal oxide surface layer which is subsequently surface treated to enhance weaving, knitting and the like.
It is another object of the invention to provide composites, e.g., laminates, comprising metallized filaments surface treated and/or oxidizing and an organic polymeric matrix, the composites having superior properties, especially short beam shear strength, both dry and after wet conditioning.
The process of the present invention is characterized by delivery of metallic filaments to a medium or combination of media comprising a surface treating agent, e.g., a silane, preferably an aminosilane, in combination with a poly(vinyl acetate). The amounts of silane, preferably aminosilane, and poly(vinyl acetae) should be judiciously selected. In general, they each will comprise from about 0.1 to about 2.5 percent by weight of the medium, preferably from about 0.2 to about 1.2 percent by weight, and especially preferably each will comprise about 0.8 percent by weight. If higher amounts are used, e.g., the 15 percent disclosed in Ser. No. 507,602, physical properties in thermoset composites will be markedly lower. Further processing of the material is also contemplated by passage of the material through dispersants, fluxes, and/or an external lubricant and sizing agent, e.g., polyethylene emulsion, combined with, or after discharge from the surface treating bath. The entire process is conveniently referred to as surface treating. During an intermediate step or after the sizing steps are complete, the fibers can be dried and, preferably, heated, to set the materials on the fibers. Among its features, the present invention also contemplates a process to surface oxidize metallic filaments under controlled conditions in combination with the surface treatment employed herein.
The apparatus used to facilitate the process to surface treat the metallic filaments is typically comprised of one or more tanks, each of which contains idler rollers disposed near the bottom and driven contact rollers above. The tank or tanks have the capacity to maintain emulsions or solutions of surface treating material, i.e., aminosilane and poly(vinyl acetate). Guide rollers are also provided at the entry of each tank. Air-drying means, or means in the form of heating ovens, heated rolls, and the like are provided to dry and set the material after each step or steps, and a driven capstan roller can be provided to afford the principal motive force for the passage of the metal-coated filaments through the bath. Surface oxidation, if desired, is carried out conveniently by way of illustration, in a medium, such as a steam bath, or in a bath of dichromating solution, during which the metal surface reacts with air or an obvious equivalent.
DESCRIPTION OF THE DRAWING
The invention will be more readily understood by reference to the drawing, which is a cross-sectional elevational schematic view of the process of the invention and a suitable apparatus for surface treating and/or surface-oxidizing metallic filaments, e.g., metal-coated high strength fibers.
DETAILED DESCRIPTION OF THE INVENTION
The process of the present invention is directed to providing the surface of metallic filaments and similar articles with properties desirable for weaving and the like, and for producing composites of the product having enhanced physical properties. The process, in essence, provides metallized filaments, e.g., fibers, with a surface comprising a layer of materials that impart various properties to them, such as lubricity and bulk, and enhanced compatibility with plastics, and improved resistance to moisture, e.g., when mixed with polymers.
For convenience, the following discussion will deal with metal-coated fibers, although it is to be understood that metallic filaments can be processed also.
As best seen, in the drawing, a suitable apparatus consists of pay-out reels 2, surface treating sections 4, heating assemblies 6, and a capstan 8. Heated rollers can be substituted for the heating towers 6. As will be explained later, section 4 can comprise a single tank and one or more heating assemblies 6 can be used. Air drying can also be used, but this slows down the overall process. Furthermore, means 32 for providing an oxidized surface, such as low pressure steam boxes, can also be included.
As seen in the drawing, in one embodiment the surface treating section 4 is further comprised of a first tank 10, a second tank 12, and a third tank 14, all of which are adapted to contain surface treating media solutions and to facilitate the continuous flow of metal-coated fibers therethrough. Each tank 10, 12 and 14 is provided with idler rollers 16 and 18 disposed near the bottom of the tank. Rollers 16 and 18 are cylindrical and guide roller 22 is flat bottom, to facilitate tow spread and uniform surface treating.
Each tank is arranged with driven contact rollers 20 and 22 located above the tank in general alignment with the idler rollers 16 and 18. Guide rollers 22 are also located at the entry of each tank.
The optional heating section 6 consists of means for heating the sized metal-coated fiber to dry and set the surface treating solutions or emulsions to the metal-coated carbon fiber. As has been indicated, each tank can be followed by an independent heating section 6.
The drive for the assembly is provided by a motor 24, which transmits drive directly to the capstan 8 and a chain gear assembly comprised of chains 26 and 27, from which the power is transmitted from the capstan gear 30 to the contact roller 20.
In one way of carrying out the present invention, a plurality of metal-coated fibers 36, preferably nickel-coated carbon or nickel-coated aramid, e.g., DuPont KEVLAR 49, fibers is threaded, from the pay-out reels 2 through optional steam boxes 32, over the guide rollers 22 and around the contact rollers 20 under the idler rollers 16 and 18 through one or more of the tanks in one or more sections 4 and preferably through one or more heating sections 6 to the capstan 8. The capstan is then driven by the motor 24, and the process of surface treatment begins. The metal-coated surface-oxidized fibers are drawn through tank 10, which is filled with the surface treating agents such as an aminosilane solution and a poly(vinyl acetate) emulsion. After passage through the tank 10, the metal-coated fiber is essentially provided with a treated surface that has been coupled to the metal oxide surface of the coated fiber. Thereafter, the fiber 36 can be delivered to the tank 12, which contains more of the surface treating agents. Optionally, tank 10 can contain one and tank 12 the other agent. Thereafter, and optionally, the fibers 36 are delivered to tank 14, in which a lubricating agent, e.g., polyethylene solution or emulsion is provided to afford lubricity for the fibers. Alternatively, this can be combined in a single tank with the other surface treating agents.
The surface treated fibers 28 are then either air dried, or preferably delivered to the oven section 6, or to a heated roller (not shown) wherein drying and setting occur and the heated dried fibers 28 are optionally forwarded to a second section 4 and drying section 6 and, finally wound on the capstan roll 8. Although dual stages are shown, for flexibility, depending on the circumstances, only a single stage may be used.
With respect to the silane component, this will typically comprise a surface-reactive coupling silane. Silanes have the general formula Y-R-Si-X 3 wherein X represents a hydrolyzable group, e.g., alkoxy; Y is a functional organic group such as methacryloxy, epoxy, etc., and R typically is a small aliphatic linkage, -(CH 2 ) n -, that serves to attach the functional organic group to silicon (Si) in a stable position. Illustratively, available silanes are: vinyltriethoxysilane, vinyl-tris(beta-methoxyethoxy) silane, gamma-methacryloxypropyltrimethoxy silane, beta-(3,4-epoxycyclohexyl) ethyltrimethoxysilane, gamma-glycidoxypropyltrimethoxysilane, gamma-aminopropyltriethoxysilane, n-beta(aminoethyl) gamma-aminopropyltriethoxysilane, gammauriedopropyltriethoxysilane, gamma-chloropropyltrimethoxysilane, gamma-mercaptopropyltrimethoxysilane, and the like. The aminosilanes are preferred. All can be used in conventional amounts and in the usual media, as supplied, or diluted with water or an organic solvent, or even as a dry concentrate, e.g., in a fluidized bed.
In practice, it has been found that aminosilane solutions of between 0.1 and 2.5 parts of gamma-amino propyltriethoxysilane such as Dow-Corning Z-6020, or gamma-glycidoxypropyltrimethoxysilane such as Dow-Corning Z-6040, per 100 parts of water adjusted to a pH of between 3.5 and 9, e.g., by acetic acid., are particularly suitable for coupling aminosilanes to nickel- or silver-coated carbon or aramid fibers. Practice has taught that the residence time of the fiber in the solution should be at least sufficient to generate a surface having coupled surface treatment. This will usually be about 0.5 seconds, but the time can be longer, e.g., at least about 5 seconds, depending on downstream residence time requirements.
Practice has taught that a polyvinyl acetate solution of about 0.1 to about 2.5 parts of polyvinyl acetate homopolymer (Borden's Polyco 2113, 55% solids) per 100 parts of water provides a particularly suitable solution for surface characteristics to the metal plated fibers. The residence time for the fiber in the polyvinyl acetate medium should also be at least sufficient to generate the desired surface, preferably at least about 0.5 seconds.
Lubricity can be imparted by optional slip agents or lubricants comprising organic materials conventionally used. Preferably, molecular films will be formed between the sized fibers and surfaces against which they are moved, e.g., loom guides. Such a characteristic reduces tendency to hang-up and abrade. Illustrative lubricants are fatty alcohols, fatty acid esters, glycerol partial esters, polyesters, fatty acid amides, e.g., oleamide, metal soaps, fatty acids, e.g., stearic acid and polyolefins, especially polyethylenes, which are preferred. These can be used in the form of solutions and emulsions.
A polyethylene emulsion of 10 parts of polyethylene (Bercen, Inc.'s Bersize S-200, 50% solids) in 100 parts by weight of water provides a particularly desirable solution to afford lubricity to the fibers. Fiber residence times sufficient to generate a lubricated surface are used. Time of at least about 5 seconds in the polyethylene medium has been found to be desirable.
The method for producing an oxidized surface on the metal-coated filament comprises in general exposing the outer surface to an oxidizing medium. The metal surface, of course, will be one capable of oxidation. Chemical or atmospheric techniques, and the like, can be employed, e.g., with nickel, tin, copper, brass, and the like, and the use of heat is recommended because the rate of production of the surface oxide coating is enhanced. It is convenient to use air or an oxygen-containing gas as the medium for oxidation and to use steam as a source of heat. It is especially convenient to use a dichromating bath as a medium for oxidation. Sufficient time is provided to produce the metal oxide coating, preferably a uniform, thin, coating. In a continuous process, using steam and air, only a fraction of a second is preferred, e.g., about 0.5 seconds, although less or more time can be allowed. For best results, the filaments are dried prior to being surface treated.
If the surface treated and/or oxidized metallic filaments are woven, knitted or laid up onto the mats, laminates can be obtained. Testing has shown that composites made from unidirectional tapes of 75 parts of surface treated fibers according to this invention with 25 parts, by weight, of epoxy resin and curing, are about 200% better in terms of short beam shear strength at room temperature, and at elevated moist temperature, than those made with unsized fibers.
The fibers surface treated and/or surface oxidized in accordance with the process of the present invention also have been woven into fabric patterns. It has been observed that the fuzz typically extending randomly from the metal-coated fiber do not interfere with the weaving after the sizing has occurred. Further, the woven material can be formed into a fabric pattern very easily by virtue of the lubricity that inheres in the surface treated material. Conversely, surface treated nickel-coated carbon, graphite, or other high strength fiber, has been found to have excellent lubricity and lacks abrasiveness, facilitating weaving. Also surface treated fibers avoid random fibers extending from the fibers which can cause an accumulation of fuzzy materials which interfere considerably with any weaving pattern by depositing on guides in the machines, etc.
Further, the surface treated materials can act as water displacement agents which reduce the tendency of composites made from the coated fibers to delaminate after being put into a plastic matrix, and exposed to moisture.
Practice has taught that a carbon fiber coated with nickel and treated with steam, e.g., distilled water steam, or a dichromating solution, preferably, will provide a nickel oxide surface, dense and adherent of 15-50 angstroms thick, particularly compatible with aminosilane, and this is very useful to produce composites with polymers having desirable characteristics.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Unidirectional tapes were made by passing tows of nickel plated graphite filaments through a surface treating bath comprising a water based solution/emulsion gamma-aminopropyl triethoxy silane and poly(vinyl acetate) at pH 9 in the amounts specified hereinafter, air-drying, and winding on a mandrel to produce one layer thick, 52 tow bundles wide (Ca, 2 inches) tapes. The tapes are painted on the mandrel with a commercial thermosettable epoxy resin composition (CYCOM® 985, American Cyanamid Company). The impregnated tapes are carefully removed from the mandrel by slitting and laid up in a mold for compressing into test bars from which pieces to measure short beam shear strength (0.56 in.×0.25 in.×0.08 in.) can be cut for testing according to ASTM D2344.
Wet testing is carried out on samples that have been immersed in boiling dionized water for 48 hours.
The compositions used and the results obtained are set forth in Table 1.
TABLE 1______________________________________SURFACE TREATED NICKEL COATEDGRAPHITE/EPOXY COMPOSITES EXAMPLE 1 2 3 4 1A*______________________________________Composition (parts by weight)Epoxy resin/hardener/catalyst.sup.c 75 75 75 75 75Nickel Coated Graphite Fibers 25 -- -- -- --Surface Treated With 0.2%silane.sup.a /0.2% poly(vinylacetate).sup.bSurface treated with 0.4% -- 25 -- -- --silane.sup.a /0.4% poly(vinylacetate).sup.bSurface treated with 0.8% -- -- 25 -- --silane.sup.a /0.8% poly(vinylacetate).sup.bSurface treated with 1.2% -- -- -- 25 --silane.sup.a /1.2% poly(vinylacetate).sup.bSurface treated with 0.8% -- -- -- -- 25silane.sup.a /15% poly(vinylacetate).sup.bPropertiesShort beam shear strengthDry, lb./in..sup.2 × 10.sup.3 14.5 13.5 13.2 13.4 4.8Wet, lb./in..sup.2 × 10.sup.3 6.3 7.3 6.9 6.4 2.0______________________________________ *Control .sup.a Gamma-aminopropyltriethoxy silane .sup.b Bordon Chemical Co. Polyco ® 2113 .sup.c CYCOM ® 985, American Cyanamid Company
The results demonstrate that composites of nickel coated graphite surface treated according to this invention have substantial advantages in physical properties in comparison with those made according to the current state of the art.
The invention may be varied in ways which will suggest themselves to those skilled in this art in light of the above, detailed description. For example, instead of a nickel coated graphite filament, a nickel coated polyaramide filament can be used. All such obvious variations are within the full intended scope of the appended claims. | Metallic filaments, esp., metal-coated fibers, are surface treated by a combination of silane and poly (vinyl acetate) and exhibit improved processability when used in the form of filaments, yarns or tows in knitting and weaving machines, and produce composites with thermosetting organic polymers, having enhanced physical properties. | 3 |
This application is a continuation of application Ser. No. 07/999,546 filed Dec. 31, 1992, which is a continuation of application Ser. No. 07/560,195 filed Jul. 31, 1990 both abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a recording method and apparatus to record image on a recording medium.
Here, the recording apparatus includes those taking such form as, for example, facsimile, electronic typewriter, copying machine, printer, etc.
2. Related Background Art
Hereunder are explained the thermal transfer recording method and apparatus as the example of the recording method and apparatus, with reference to actual examples.
Generally speaking, a thermal transfer printer executes image recording by using an ink sheet obtained by coating hot-melt (or hot-sublimating etc.) ink on a base film, selectively heating such ink sheet with a thermal head according to the image signal and transferring the molten (or sublimated etc.) ink on the recording sheet. Generally speaking, the ink of such ink sheet is completely transferred to the recording sheet by one image recording (the so-called one-time sheet) and therefore it has been necessary to convey such ink sheet, after termination of recording for one character or one line, for a distance corresponding to the length of such recording so that an unused part of the ink sheet is brought to the position of the succeeding recording with certainly. As a result, the amount of ink sheet consumed increases and the running cost of thermal transfer printer tends to be higher than that of the ordinary heat-sensitive printer which records on the heat sensitive sheet.
In order to solve such problems, a thermal transfer printer wherein the recording sheet and ink sheet are conveyed at different speed has been proposed as observed in U.S. Pat. No. 4,456,392, Japanese Laid-Open Patent Applications Nos. 58-201686 and 62-58917. As described in these references, the ink sheet which enables image recording for plural number (n) of times (the so-called multi-print ink sheet) has been known and when such ink sheet is used, it is possible, in the continuous recording of recording length L, to record by making the conveying length of the ink sheet at the termination of recording of the image during recording of the image smaller than the length L(L/n:n>1). In this way, the efficiency of use of the ink sheet becomes n times larger than conventional case and savings of running costs of thermal transfer printer can be expected. Hereunder, such a recording system is called multi-print system.
In recording systems that execute recording with a head, there is a trend when a dark dot (the dot for recording) is recorded next to a white dot (the dot not for recording), the heat generating apparatus corresponding to the dot cools off and the printed dot becomes pale in shade.
History control may be exercised as a solution of such problem. However in the case of history control, energizing of the recording head for recording one line must be conducted dividedly for a plural number of times. Besides, the data corresponding to each of thus divided energizations must be transferred, and as a result, the circuit becomes complicated.
SUMMARY OF THE INVENTION
An objective of the present invention is to provide a recording method and apparatus which provides a recorded image having improved quality.
Another objective of the present invention is to provide a thermal transfer recording method and apparatus which enables reduction of ink sheet consumption.
Still another objective of the present invention is to provide a thermal transfer recording method and apparatus which enables the reduction of running costs.
Still another objective of the present invention is to provide a thermal transfer recording method and apparatus which enables to reproduction of an image of favorable quality being free from weakness of concentration (or fading) of independent black pixels, by a simple composition.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is the drawing that illustrate the connection of control unit and recording unit of an embodiment of the present invention.
FIG. 2 is a block diagram showing the outline of construction of the facsimile apparatus of the aforesaid embodiment.
FIG. 3A is a side sectional view showing the structural unit of the facsimile of the aforesaid embodiment.
FIG. 3B is an external diagonal view of the facsimile.
FIG. 4 is a drawing depicting the conveying system of ink sheet and recording sheet.
FIG. 5 is a flow chart showing processing steps of the CPU 113 of the aforesaid embodiment.
FIG. 6 is a flow chart showing the processing steps of the action of the recording control unit (UPi) of the aforesaid embodiment.
FIG. 7 is a drawing showing the timing of action of CPU 113 and the recording control unit.
FIGS. 8A and 8B are drawings that explain the method of producing inverted data.
FIG. 9 is a drawing showing the state of the recording sheet and ink sheet at the time of recording according to the present embodiment, and
FIG. 10 is a sectional view of the multi-ink sheet used in the present embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereunder is explained in detail a preferred embodiment of the present invention with reference to the attached drawings.
The explanation shall be made taking a facsimile apparatus as the example of recording apparatus.
The embodiment to be explained hereunder concerns an apparatus which functions in such a way that prior to the ordinary recording of image by recording means the recording means is driven with an amount of energy smaller than that used in the ordinary recording, utilizing the inverted data of the image used in the preceding recording.
Explanation of facsimile (FIGS. 1-4)!.
FIGS. 1-4 are drawings that show the example where a thermal transfer printer using an embodiment of the present invention is incorporated in a facsimile. FIG. 1 is the drawing that shows the electric connections of the control unit 101 and recording unit 102 of facsimile; FIG. 2 is the block diagram that shows the outline of the composition of the facsimile; FIG. 3A is the side sectional view of facsimile; FIG. 3B is the external diagonal view of the aforesaid facsimile and FIG. 4 is the drawing showing the conveying mechanism of the recording sheet and ink sheet.
In reference to FIG. 2, the outline of the composition of facsimile is now explained.
In FIG. 2, 100 is the reading unit to read the manuscript and output the digital image signal to the control unit 101 which is provided with the motor to convey the manuscript, and CCD image sensor, etc. Next the composition of this control unit 101 is explained. 110 is the line memory to store each line of the image data, which stores, at the time of transmission or copying of the manuscript, the image data of one line sent from the reading unit 100 and at the time of receiving of image data, it stores the decoded image data for one line received.
An image is formed when the stored data are output at recording unit 102. 111 is the encoding/decoding unit which encodes the image information to be transmitted by MH encoding and decodes the received encoded image data to convert the data into image data. 112 is the buffer memory that stores the encoded image data to be transmitted or received. The sections of the control unit 101 are individually controlled, for example by microprocessor CPU 113 etc. The control unit 101 is provided, other than CPU 113, with ROM 114 which memorizes the control program of CPU 113 and various other data and RAM 115 which temporarily preserves various data as the work area of CPU 113.
102 is the recording unit which is provided with a thermal line head and which executes recording of image on the recording sheet by thermal transfer recording method. Its composition shall be stated in detail with reference to FIG. 3. 103 is the operating unit which includes the keys to instruct various functions such as start of transmission, telephone number input keys etc; 103a is the switch that selects the kind of ink sheet 14 to be used, and also indicates that the multi-print ink sheet is mounted when switch 103a is turned ON and the ordinary ink sheet (the so-called one-time ink sheet) is mounted when it is OFF. 104 is usually installed adjacent to the operating unit. 103 is the indicating unit that indicates the state of various functions and the apparatus. 105 is the power source that supplies power to the entire apparatus. 106 is the modem (modulator/demodulator); 107 is the net control unit (NCU) and 108 is the telephone set.
Next, with reference to FIG. 3, the composition of the recording unit 102 is explained in detail. The parts corresponding to those of FIG. 2 are indicated with the same numbers.
In FIG. 3, 10 is the rolled sheet composed of the recording sheet 11, which is an ordinary sheet, rolled around the core 10a. This rolled sheet 10 is housed in the apparatus in such a way that it can rotate freely so that it can feed the recording sheet 11 to the thermal head 13 according to the rotation of platen roller 12 in the direction of arrow. 10b is the rolled sheet mounting unit on which rolled sheet 10 is mounted in a way allowing ON and OFF mounting and demounting. 12 is the platen roller which conveys the recording sheet 11 in the direction of arrow b and presses the ink sheet 14 and recording sheet 11 between the roller and the heat generating member 132 of thermal head 13. The recording sheet 11 on which the image is recorded by heating of thermal head 13 is conveyed toward the exhaust rollers 16 (16a and 16b) by the further rotation of platen roller 12 and when image recording for one page terminates, it is cut to single page lengths by the gearing of the cutter 15 (15a and 15b) and is then discharged.
17 is the ink sheet feed roll on which ink sheet 14 is coiled; 18 is the ink sheet winding roll which is driven by the ink sheet conveying motor to be described later and which winds the ink sheet 14 in the direction of arrow a. This ink sheet feed roll 17 and ink sheet wind up roll 18 are mounted on the ink sheet mounting unit 70 in the main body of the apparatus in such a way that it can be mounted on and off. 19 is the sensor to detect the remaining amount of the ink sheet 14 and the conveying speed of ink sheet 14. 20 is the ink sheet sensor to detect the presence or absence of ink sheet 14; 21 is the spring which presses the thermal head 13 against the platen roller 12 along with recording sheet 11 or ink sheet 14. 22 is the recording sheet sensor which detects whether the recording sheet is present or not.
Next the composition of reading unit 100 is explained.
In FIG. 3, 30 is the light source to irradiate the manuscript 32, the light reflected by the manuscript 32 being input into CCD sensor 31 via the optical system (mirror 50, 51 and lens 52) to be converted into electric signal. Manuscript 32 is conveyed by the conveying roller 53, 54, 55 and 56 which are driven by the manuscript conveying motor (not shown), in correspondence with the speed of reading manuscript 32. 57 is the table to hold the manuscript; plural sheets 32 placed on such table 57 are separated sheet by sheet by the coordinated motion of conveying roller 54 and pressure separating piece 58 while being guided by slider 57a, and each sheet of the manuscript is conveyed to the reading unit 100 and after reading discharged into the tray 77.
41 is the control baseboard which constitutes the recording control unit in the main section of the control unit 101 and recording unit 102, and various control signals are output from this control baseboard 41 to each part of the apparatus. 106 is the modem baseboard unit and 107 is the NCU baseboard unit.
FIG. 4 is the drawing to showing the details of the conveying system of the ink sheet 14 and recording sheet 11.
In FIG. 4, 24 is the motor for conveying recording sheets which drives and rotates the platen roller 12 and conveys the recording sheet 11 in the direction of arrow b which is in the direction opposite to the direction of arrow a. 25 is the motor for conveying ink sheets which conveys the ink sheet 14 in the direction of arrow a by capstan roller 71 and pinch roller 72. Further, 26 and 27 are transmission gears that transmit the rotation of the motor for conveying recording sheets to platen roller 12, while 73 and 74 are transmission gears that to transmit the rotation of the motor for conveying ink sheets to capstan roller 71. 75 is a sliding clutch unit.
Here, by setting the gears ratio of gear 74 and 75 in such way that the length of ink sheet 14 wound up by the winding roll 18 according to the rotation of gear 75a becomes somewhat longer than the length of the ink sheet conveyed by the capstan roller 71, so that the ink sheet 14 conveyed by capstan roller 71 is wound up on the wind-up roll 18 with certainty. The amount corresponding to the difference between the amount of ink sheet 14 wound on the wind-up roll 18 and the amount delivered from the capstan roller 71 is absorbed by the sliding clutch unit 75. In this way it is possible to reduce fluctuations in conveying speed (amount) of ink sheet 14 caused by fluctuations of winding diameters of wind-up roll 18.
As stated above, by reversing the conveying direction of recording sheet 11 and ink sheet 14, the direction in which the image is recorded on the recording sheet 11 in longitudinal direction (direction of arrow a) agrees with the conveying direction of ink sheet 14. When the conveying speed of recording sheet 11 is Vp and Vp=-n·V I (V I is the conveying speed of ink sheet 14 and "11--11" indicates that the conveying direction of recording sheet 11 is opposite to the conveying direction of ink sheet 14), the relative speed Vp I of recording sheet 11 and ink sheet 14 as against the thermal head 13 is,
Vp.sub.I =V.sub.p -V.sub.I =(1+1/n) Vp
and it is known therefrom that such relative speed Vp I is larger than Vp or the relative speed of the two in the conventional system (the relative speed in the conventional system is VP I =Vp-V I =Vp-Vp/n =(1-1/n) Vp).
Beside the above there is such method as to convey the ink sheet 14 for l/m line for every (n/m) line (m is an integral number and n>m) in the direction of an arrow a for recording of image of n line by thermal head 13 or such method as to convey ink sheet 14 at the same speed as the recording sheet 11 but in the direction opposite to the direction of its motion during recording and prior to the recording of predetermined amount, the ink sheet is rewound for the length of L·(n-1)/n (where n>1) for recording of the length L. In either of the above cases, the relative speed of recording while keeping the ink sheet 14 standstill becomes Vp and the recording speed while keeping the ink sheet 14 moving becomes 2 Vp.
FIG. 1 indicates the connection of control unit 101 and recording unit 102 of the facsimile of the present embodiment, wherein the parts corresponding to those in the other drawings are given the same numbers.
The recording unit 102 of the present embodiment is provided with the recording control unit 201 (hereafter simply called UPi) which controls the entirety of recording unit 102. It reduces the work load of recording and processing of the control unit 101 (MPU 113 etc.) which is the core of the present apparatus. UPi201 is composed of the microprocessors which link the subsystem to MPU 113. Communication of various commands given by control unit 101 to various commands of UPi201 and output of various status information from UPi201 to control unit 101 are executed through the data line 202.
Thermal head 13 of the present embodiment is a line head (being provided with heat generating apparatus for the entire recording width). The thermal head 13 is provided with the serial recording data for one line supplied by control section 101 (to be delivered through data line 200), shift register 130 to input the shift clock 43, latch circuit 131 to latch the data of shift register 130 and heat generating apparatus 132 composed of head generating resistance for one line. Latch signal 44 can also be output from Upi201. Heat generating resistance 132 is driven by being divided into m pieces of blocks represented by 132-1˜132-m. 133 is a temperature sensor attached to the thermal head 13 and it detects the temperature of thermal head 13. Output signal 42 of temperature sensor 133 is A/D converted in UPi201 and input into CPU 113 in the control unit 101. Thereby CPU 113 detects the temperature of thermal head 13 and according to the detected temperature, it changes the instruction of pulse width of strobe signal 47 or instructs a change of driving voltage of thermal head 13 so that the energy impressed on the thermal head 13 is changed according to the characteristics of ink sheet 14. 116 is the programmable timer on which programmed time is set and it starts counting time when time counting is instructed. At each instructed time point, it outputs interrupt/signal, time-out signal etc.
It may be so arranged that the kind (characteristics) of ink sheet 14 is instructed by the manual operation of switch 103a of operating unit 103 stated above or automatically judged by detecting the mark printed on the ink sheet 14. Alternatively it may be so arranged that the kind of ink sheet 14 is automatically judged by detecting the mark, notch or projection provided to the cartridge. 46 is the driving circuit that outputs the strobe signal 47 to drive the thermal head 13 block by block by feeding the driving signal of thermal head 13 from UPi201. This driving circuit 46 can change the energy impressed on the thermal head 13 by changing the voltage output on the source line 45 which feeds current to the heat generating apparatus 132 of thermal head 13 according to the instruction of UPi201. 36 is the driving circuit to cause gearing operation of cutter 13 and it controls the cutter driving motor etc. 39 is the sheet exhaust motor to drive the sheet exhaust roller 16. 35, 31 and 32 are the driver circuits to drive and rotate the corresponding sheet exhaust motor 39, recording sheet conveying motor 24 and ink sheet conveying motor 25. The sheet exhaust motor 39, recording sheet conveying motor 24 and ink sheet conveying motor 25 are all stepping motors in this embodiment but they are not limited thereto. For example DC motors may also be used instead.
Explanation of recording action (FIGS. 1˜8)!
The aforesaid composition eliminates the lack or fading of darkness which occurs when the dot is white (no recording i.e., the corresponding heat generating apparatus does not heat up) in the recording of the immediately preceding line while the dot is black in the present recording (recording is made i.e., the corresponding heat generating apparatus is energized). Such lack of darkness is caused by cooling of ink sheet 14 (including the heat generating resistance 132). Therefore in the present embodiment, the ink sheet is preheated to the appropriate temperature (the temperature at which ink melts) where the heat generating resistance 132 does not actually conduct recording based on the line recorded in the immediately preceding recording. To be more specific, the heat generating resistance which recorded a white dot in the immediately preceding recording is energized for preheating.
The heat generating resistance which recorded a black dot in the recording of the immediately preceding line and the ink sheet contacting such resistance are not preheated as they are considered to be at a sufficiently high temperature.
It is known therefrom that what is necessary here is to invert the line data used in the preceding recording and based on such inverted data, preheat the heat generating resistor. However, a dot should not actually be recorded by such preheating and therefore the strobe width is narrowed so that the energy should be reduced to the level below those supplied for ordinary line recording. In the present embodiment, the heating time of the thermal head for recording is set at 0.6 ms per block and that for preheating is set at around 0.2˜0.3 ms.
Inverted data and main recording data are all output by the control unit 101 but inverted data can be prepared easily, if they are transferred via the inverter. It may also be produced by using software. Therefore, the detailed explanation of such method shall be omitted here.
The explanation goes back a little but there exist "W Busy (Write busy)" line and "DT Busy (Data Transfer busy)" line in the status control line which are output by UPi201 to the control unit 101 and they are so arranged that their signals are output at the control unit 101 when the corresponding flag is set during its processing by UPi201. Based on these two status signals, the control unit 101 determines the timing of transfer of inverted data and main recording data. In between the control unit and UPi201 exists a line to deliver the print command to instruct recording of one line.
The signal "DT Busy" indicates that when this signal is ON, the shift register 130 is still occupied and therefore transfer of succeeding data is prohibited. When "W Busy" is ON, it means that recording of one line of main recording data is proceeding and latching of main recording data of the succeeding line is impossible.
The outline of the performance of CPU 113 and UPi201 in the control unit 101 based on the aforesaid principle is explained in reference to the timing chart of FIG. 7.
First CPU 113 transfers the inverted data of the line recorded immediately preceding to the shift register 130 via line 200 while synchronizing such data with shift clock 43. Thereafter by outputting the latch signal, it causes the latch circuit 131 to latch the inverted data stored in shift register 130. After having it latched, it transfers the main recording data by the same procedure, because the shift register 130 is in an empty state. When transfer of the main recording data terminates, print command of UPi201 is given.
When UPi201 receives this print command, it turns ON "DT Busy" and "W Busy" to prevent the delivery of the succeeding data. Thereafter, based on the inverted data supplied by the latch circuit 131 to heat generating resistance 132, each block is energized for time t 0 for preheating. When such preheating is over, latch signal 44 is emitted to latch the data of shift register 130 (main recording data) at latch circuit 131 and "DT Busy" is turned OFF (thereby CPU 113 transfers the inverted data of the recorded line). Then the aforesaid UPi201 conveys the recording sheet 11 for one line in preparation for main recording and conveys the ink sheet by 1/n line. Then based on the main recording data latched at the latch circuit 131, each block is energized for time t 1 (>t 0 ) which is the energizing time for ordinary recording to perform line recording. Then "W Busy" is turned OFF to get ready for accepting the delivery of the succeeding main recording data. The above steps are repeated one after another.
When the main recording data are the data at the head line of the page, the line immediately before that is regarded to be entirely white dots and thus black data are transferred to recording unit 102. Next the procedure of processing action of CPU113 of the aforesaid control unit 101 are explained in reference to the flow chart of FIG. 5. The control program to execute such processing is memorized in ROM 114 of control unit 101.
The processing starts when the image data for one line to be recorded are stored in the line memory 110 and the system becomes ready for starting recording action and mounting of multi-ink sheet 14 is judged by switch 103a etc. at the control unit 101.
At step S1, whether the transfer of data for one page has terminated or not is judged. When transfer of data for one page is terminated, a command to that effect is output at the recording unit 102.
When the judgment of step S1 is "NO", it proceeds to step S2 and outputs serially the inverted data of the line data recorded immediately prior to it to the shift register 130. When transfer of one line ends, it checks "W Busy" line of status signal of UPi201 at step S3 and waits until "W Busy" becomes OFF. When it becomes OFF, the processing proceeds to step S4 and the inverted data of shift register 103 is latched by the latch circuit 131. Thereafter the processing proceeds to step S5 and the main recording data are transferred to shift register 130. When it judges in step S6 that the transfer has finished, the processing proceeds to step S7 and it waits until "W Busy" turns OFF.
Then the processing proceeds to step S8 and the print command is given out to recording unit 102.
It then proceeds to step S9 and waits until "DT Busy" turns OFF. At steps S3, S7 and S9, while it is waiting until each signal turns OFF, CPU 113 can execute such processing as, for example, decoding of received image, or taking in of image data from reading unit 100.
Steps of processing action of UPi201 in the recording unit 102 are explained with reference to the flow chart of FIG. 6.
First in Step 21, judgment is made whether print command has been received or not.
When it is judged that the command has been received, processing proceeds to step S22 and "DT Busy" and "W Busy" are both turned ON. At step 23, preheating is conducted by energizing the apparatuses which had received the signal "1" from latch circuit 131 of each block of heat generating resistance 132, for the duration of time t 0 . Preheating is continued until preheating is judged to be complete for all blocks in step S24.
When preheating terminates, latch signal 44 is output and the main recording data are latched at the latch circuit 131. Thereby the shift register 130 becomes empty and therefore "DT Busy" is turned OFF to enable acceptance of inverted data (step S26). At step S27 driver circuits 48 and 49 are driven to convey recording sheet 11 for one line and ink sheet 14 for 1/n line. At step S28, the selected block of heat generating resistance 132 is energized for time t 1 (>t 0 ) to execute actual recording.
At step S29, processing made in step S28 is continued until it is judged that all blocks have been energized. When recording of one line is over, "W Busy" is turned OFF at step S30 to inform the control unit 101 that recording of the succeeding line is now possible.
On the other hand, at step S21, when it is so judged that the command other than the print command (page renewal command) has been received, processing proceeds from step S31 to step S32.
First at step S32, recording sheet 11 is conveyed in the direction of sheet exhaust rollers 16a and 16b for predetermined amount. At step S33, cutters 15a and 15b are driven for gearing and cut recording sheet 11 in page lengths. Then at step S34, recording sheet conveying motor 24 is driven in the reverse direction and returns the recording sheet 11 for the distance corresponding to the space between the thermal head 11 and cutter 15.
As aforesaid, according to the present embodiment, heat generating apparatuses of heat generating resistance which were white dots are preheated immediately prior to main recording and therefore there is no change to cause the shade of the black dot become weak.
Sticking of recording sheet 11 and ink sheet 14 which often occurs with thermal transfer apparatus, is eased reduced by preheating as practiced in the present embodiment.
As for the method of preparation of inverted data, as shown in FIG. 8A, at copy mode or at the time of G2 signal reception, raw data may be used and exclusive OR may be taken with the command for inversion at 1 byte unit or FFH (H indicates the hexadecimal number).
At the time of ordinary signal reception, Run Length data are used. In the case of 2 byte unit and B4 thermal head is used, the data length is shown by the lower 12 bits and black or white is determined by the upper most one bit (see FIG. 8B). Therefore at the time of inversion, the upper most bit is inverted and decoded.
Explanation of recording principle (FIG. 9)!
FIG. 9 shows the state of image recording when an image is recorded by inverting the direction of conveying of recording sheet 11 and ink sheet 14 using the device of the present embodiment.
At shown in the drawing, recording sheet 11 and ink sheet 14 are sandwiched between the platen roller 12 and thermal head 13 and thermal head 13 is pressed against the platen roller 12 by the spring 21 with a preset pressure. Here the recording sheet 11 is conveyed in the direction of arrow b by the rotation of platen roller 12 at speed Vp. On the other hand, ink sheet 14 is conveyed in the direction of arrow a at speed V I by the rotation of motor 25 for conveying of ink sheet.
When the heat generating resistance 132 of thermal head 13 is heated by being energized by power source 105, the part 91 indicated by diagonal lines of ink sheet 14 is heated.
Here 14a is the base film of ink sheet 14 and 14b is the ink layer of ink sheet 14. By energizing the heat generating resistance 132, the ink of the heated ink layer 91 melts and the part indicated by 92 is transferred to recording sheet 11. The part of transferred ink layer 92 corresponds to about 1/n of the entire ink layer.
At the time of transfer, it is necessary to apply a shearing force to ink at the border 93 of ink layer 146 and transfer the part indicated by 92 to the recording sheet 11. However, such shearing force varies according to the temperature of ink layer, and the higher the temperature of the ink layer, the smaller need be the shearing force. Therefore when the heating time of ink sheet 14 is shortened, the shearing force in the ink layer becomes large and therefore when the relative speed of ink sheet 14 and recording sheet 11 is made sufficiently large, it is possible to peel off the ink layer to be transferred from ink sheet 14.
Explanation of ink sheet (FIG. 10)!
FIG. 10 shows a sectional view of the ink sheet to be used for multi-print of the present embodiment. It is composed of 4 layers.
The second layer is the base film which supports the ink sheet 14. In the case of multi-print, since heat energy is repeatedly applied to the same spot, aromatic polyamide film or condenser sheet which have high heat resistance, are suitable but conventional polyester film will also do it is used as a medium. The thinner these films, the better will be the quality of prints but in view of the requirement of strength, the thickness of 3-8 μm is preferred.
The third layer is an ink layer which contains the amount of ink sufficient for making n times of transfer print on the recording sheet. This ink layer is mainly composed of EVA or other resins used for adhesive, carbon black or nigrosine dyes used for coloring, carnauba wax or paraffin wax used for binder etc. so that it withstands n times of use on the same spot. The preferred amount of coating is 4-8 g/m 2 but it may be freely selected because the frequency of print and darkness of printed color vary according to the amount of coating.
The fourth layer is the part not printed, which is the top-coating layer and prevents transfer by pressure of the ink of the third layer on the recording sheet and it is composed of transparent wax etc. By the effect of this layer, only the transparent fourth layer is transferred by pressure and the staining of the recording sheet is prevented. The first layer is a heat resistant coating to protect the second layer base film. It is suitable for the multi-print system wherein thermal energy could be impressed for n lines on the same spot (when black information continues) but whether to use it or not is the choice of the user.
It is effective particularly for a base film with relatively low heat resistance such as polyester film.
The composition of ink sheet 14 is not limited to the present embodiment and, for example, it may be composed of the base layer and the ink holding porous layer to contain ink provided at the side of the base layer or it may be so constructed that a heat resistant ink layer having a fine porous net structure is provided on the base film and ink is impregnated into such ink layer.
The material of construction of the base film may be the film composed of polyamide, polyethylene, polyester, PVC, triacetyl cellulose, nylon, etc. A heat resistant coating layer is not necessarily required but when used, it may be made of, for example, silicone resin, epoxy resin, fluororesin, etholocellulose, etc.
An example of an ink sheet having sublimating property may be the one obtained by coating coloring layer composed of spacer granules comprising guanamine resin and fluororesin and dyestuff on the base film made of polyethylene telephthalate, polyethylene naphthalate, aromatic polyamide film etc.
Heating systems introduced in the aforesaid embodiment are not limited to the thermal head system but may be for example, an electrification system or laser transfer system.
In this embodiment, explanation was made for the case using a thermal line head but it is not limited thereto, and the so-called serial type thermal transfer printer may be used. In the present embodiment explanation was made for the case of multi-print system and it is not limited thereto but the present invention may be applied to the ordinary thermal transfer recording system where the so-called one-time ink sheet is used.
In the aforesaid embodiment, explanation was made for the case when the present invention is applied to a facsimile and it is not limited thereto but, for example, it may be applied to a thermal transfer printer, word processor, typewriter or copying machine.
The recording medium is not limited to recording sheets but it may be for example cloth, plastic sheet, etc. as far as it accepts transfer of ink. The ink sheet is not limited to the rolled sheet as shown in the embodiment but it may be the so-called ink sheet cassette type wherein an ink sheet is housed in a box which may be mounted on and off the main body of the recording apparatus and the box as a whole is mounted on and off the recording apparatus.
In the aforesaid embodiment, explanation was made on thermal head as an example of recording means but the present invention is not limited thereto. For example, an ink jet head wherein recording is made on the recording medium by jetting out the ink may be used (for example ink jet printer). Such ink jet head, generally speaking, is provided with a fine liquid discharge hole (orifice), liquid channel, energy action unit provided at a part of the liquid channel and energy generating means provided at the energy action unit to generate energy and form liquid drops to work on the liquid. The energy generating means to generate such energy may be such means that an electromagnetic wave source such as laser is irradiated and energy is absorbed by the liquid to generate heat and thus generated heat causes the liquid drop to jump out and be discharged or alternatively such means as to heat the liquid by electric heat converter and thereby cause the delivery of the liquid. Among them, what is particularly profitable is the bubble jet head wherein the driving signal is impressed on the thermoelectric converter rapid temperature increase, such increase going beyond the boiling point and thermal energy is generated by the thermoelectric converter, thereby causing membrane boiling at the working plane of the head to form air bubbles in the ink and by the growth of such air bubbles, ink is delivered through the delivery hole. With such a bubble jet head, the ink discharge holes may be arranged at high density and it is profitable for conducting recording at high resolution.
As explained above, according to the present embodiment, prior to recording of the line being attended, heat generating resistance 132 is preheated by the inverted data of the line recorded immediately before and thereby such trouble as the loss of darkness of the independent black dot is avoided and a favorable image can be reproduced.
In the foregoing example, explanation was made dividedly on the control unit 101 as the main control unit, recording control unit 201 as the sub-control unit but they may be of course be realized by one microprocessor.
As explained above, according to the present invention, the recording method and apparatus producing the image of improved quality are provided. | Thermal transfer recording apparatus for recording image on the recording medium by transferring ink of the ink sheet on the recording medium characterized by being provided with the ink sheet conveying means, the recording medium conveying means, recording means to record the image on the recording medium by being driven in accordance with the image data and working on the ink sheet and control means to drive the recording means with the energy smaller than that used at the time of ordinary recording utilizing the inverted data of the image data used in the preceding recording, the apparatus providing such advantage as the improvement of image quality, saving of consumption of ink sheet and saving of running cost, etc. | 1 |
[0001] The present application relates to the use of a homogenizing valve used in piston-gap high-pressure technology for preparing a nanosuspension of a solid pharmaceutical active principle. The invention also relates to a method using said valve.
TECHNICAL FIELD
[0002] High-pressure homogenization (HPH) technology is used in galenics to obtain nanosuspensions of particles of a solid pharmaceutical active principle that exhibits very low solubility in water. The particles are characterized by a mean diameter d 50 <500 nm and are stabilized by at least one stabilizer/surfactant, So-called “piston-gap” high-pressure technology (which uses a valve) which forms the subject of the present invention was developed by R. H. Müller and is described in U.S. Pat. No. 5,858,410, EP 1964605 and in the articles “Dissocubes®—a novel formulation for poorly soluble and poorly available drugs” Müller, p. 135 from the book “Modified-release drug delivery technology”, 2002, isbn 0-8247-0869-5 or J. Pharm. Pharmaco. 2004, 56, 827-840. This technology is also described in Chapter 9.2 of the book “Emulsions and nanosuspensions for the formulation of poorly soluble drugs” Medpharm, 1998, isbn 3-88763-069-6.
TECHNICAL PROBLEM
[0003] The problem addressed is that of being able to have a piston-gap high-pressure homogenization technology that can be used to prepare nanosuspensions without any contamination from grinding residue and which uses robust tooling capable of operating at a high flow rate and which demands the lowest possible amount of maintenance. The Applicant company has discovered that this problem can be solved by using sintered or hot-pressed silicon nitride as the material from which to make the valve piston, the valve seat and possibly the impact ring or the exterior surface of said elements.
PRIOR ART
[0004] JP 1028282 describes sintered ceramics (Si 3 N 4 , SiC, Si 5 AlON 7 , etc.) that have good mechanical and erosion-resistance properties.
[0005] WO 2007/148237 describes a valve for a piston-gap type homogenizer.
[0006] WO 2005/097308 describes a piston-gap homogenizer of which one of the elements (“plunger 5 ”), which is not a valve, is made of silicon nitride Si 3 N 4 .
[0007] EP 1964605 describes a piston-gap homogenizer of which one of the elements ( 12 c ) is made of carbide (WC—Co, WC—TiC—Co, WC—TiC—Ta(Nb)C—Co, etc.).
BRIEF DESCRIPTION OF THE INVENTION
[0008] The invention relates to the use of a homogenizing valve consisting of a valve piston, of an impact ring and of a valve seat for the preparation of a nanosuspension of a solid pharmaceutical active principle using piston-gap high-pressure technology, characterized in that the material from which (i) the valve seat, partially, completely or the exterior surface thereof, (ii) the valve piston, completely or the exterior surface thereof (iii) and possibly the impact ring, completely or the exterior surface thereof, are made comprises, by way of predominant component, sintered or hot-pressed silicon nitride.
[0009] The invention also relates to a method of preparing a nanosuspension of a solid pharmaceutical active principle using piston-gap high-pressure homogenization technology, involving:
pumping a dispersion of the active principle in a liquid phase to which at least one stabilizer/surfactant has been added; compressing said dispersion to a pressure ranging from 100 to 2000 bar; expanding said dispersion through a homogenization valve consisting of a valve piston, of an impact ring and of a valve seat, characterized in that the material from which (i) the valve seat, partially, completely or the exterior surface thereof, (ii) the valve piston, completely or the exterior surface thereof (iii) and possibly the impact ring, completely or the exterior surface thereof comprises, by way of predominant component, sintered or hot-pressed silicon nitride.
FIGURES
[0013] FIG. 1 : a diagram of a high-pressure homogenizing valve and the dispersion flow (inlet, outlet).
[0014] FIG. 2 : a drawing of the silicon nitride homogenizing valve according to one of the embodiments of the invention used in the examples. The indicated dimensions are given in millimeters and illustrate one embodiment of the valve according to the invention.
DETAILED DESCRIPTION
Definitions
[0000]
nanosuspension: suspension of nanoparticles;
nanoparticles: particles of a solid compound with a mean diameter d50 (determined by laser scattering) of <1000 nm;
[0017] Because this is piston-gap high-pressure technology, it can be used to prepare a nanosuspension from a dispersion of a solid pharmaceutical active principle in a liquid phase, the initial mean diameter d50 of which is higher than the mean diameter d50 of the nanosuspension. The liquid phase generally consists of pure water although pharmaceutically acceptable solvents such as ethanol for example may also be added. The initial mean diameter d50 is preferably <25 μm in order to avoid blocking the gap between the valve seat and the valve piston. The stability of the nanosuspension is ensured using at least one stabilizer/surfactant which will be chosen according to the pharmaceutical active principle and according to the particle size of the nanosuspension.
[0018] Piston-gap high-pressure technology involves using a piston pump to impose a high pressure (of the order of 100 to 2000 bar) on the dispersion, then expanding the dispersion through a homogenizing valve (described later on). The principle of reducing the size is based firstly on the density of energy generated by the inter-particle impacts and by collision between the particles and the valve piston and with the impact ring and, secondly, on the energy generated by cavitation and by turbulence. Cavitation is caused by the rapid expansion of the liquid which causes microbubbles of vapor to form. Devices that employ this technology are marketed for example by the company APV Gaulin GmbH.
[0019] The homogenizing valve consists of 3 elements: a valve piston ( 1 ), a valve seat ( 2 ) and an impact ring ( 3 ) (see FIG. 1 ). It has been found that the technical problems described hereinabove can be solved if (i) the valve seat ( 2 ) is made partly, completely or the exterior surface thereof, from the silicon-nitride-based material described hereinafter and if, (ii) the valve piston ( 1 ) is made completely or the exterior surface thereof, from said material. This silicon-nitride-based material is strong enough to allow the preparation of the nanosuspension for a long period of time and without the need to dismantle the homogenizing valve in order to change one of the elements thereof. The impact ring ( 3 ) or the exterior surface thereof may also be made of a similar material.
[0020] According to one of the alternative forms of the invention, it is possible for just the external surface of the valve piston ( 1 ) and/or of the valve seat ( 2 ), and/or possibly of the impact ring ( 3 ) to be made of said silicon-nitride-based material, the core of said elements for its part being made of some other material that does not have the same impact-resistant and abrasion-resistant mechanical properties. For example:
E1—the exterior surface of the valve piston and the exterior surface of the valve seat are made of said silicon-nitride-based material; E2—the valve piston is made completely from said silicon-nitride-based material and the exterior surface of the valve seat is made from said silicon-nitride-based material; E3—the exterior surface of the valve piston is made from said silicon-nitride-based material and the valve seat is made completely from said silicon-nitride-based material.
[0024] For these three embodiments E1. E2, E3 above, the ring or the exterior surface thereof may be made of said silicon-nitride-based material or from some other material (as illustrated in the examples: tungsten carbide, etc.).
[0025] As far as the valve seat is concerned, this may actually be made completely from the silicon-nitride-based material described below. It is also possible for just one of the parts of the valve seat to be made of said material. Notably and for example, the internal part ( 6 c , 6 d ) of the valve seat is made of said silicon-nitride-based material, and the external part ( 6 a , 6 b ) of the valve seat is made of some other material that does not have the same impact-resistant and abrasion-resistant mechanical properties. This other material may notably be based on stainless steel (on steels made of an alloy of iron, chromium, nickel and other ores that afford it a certain degree of corrosion resistance). For this embodiment, the surface of the valve piston is made of a silicon-nitride-based material or preferably the valve piston is made completely of the silicon-nitride-based material. For this same embodiment, the ring may be made of said silicon-nitride-based material or of some other material (as illustrated in the examples: tungsten carbide, etc.).
[0026] In practice the starting point is to prepare, in the liquid phase, a dispersion of the solid pharmaceutical active principle, the initial mean diameter d50 of which is preferably <25 μm. At least one stabilizer/surfactant is added to this dispersion. The dispersion is then pumped to the high-pressure homogenizer and compressed to a pressure ranging from 100 to 2000 bar, and is then expanded through the homogenizing valve described above. The compression is performed by a piston pump. A recirculation loop allows the dispersion to be recirculated through the homogenizing valve several times, if necessary.
[0027] In terms of the silicon-nitride-based material, this by way of predominant component contains sintered silicon nitride (or SSN) or hot-pressed silicon nitride (or HPSN which stands for high-pressure silicon nitride). For preference, the material contains over 75% (by weight), advantageously over 80%, preferably over 85% sintered or hot-pressed silicon nitride. It may contain other components the function of which is to enhance the mechanical properties of the silicon nitride or to be sintering agents, for example Al 2 O 3 , Y 2 O 3 , TiO 2 , Nd 2 O 3 . The material preferably contains, by weight, from 80 to 90% sintered or hot-pressed silicon nitride and from 0 to 20% of component(s) chosen from Al 2 O 3 , Y 2 O 3 , TiO 2 or Nd 2 O 3 .
[0028] One example of a silicon-nitride-based material that can be used is KERSIT® 301 which is a hot-pressed silicon nitride developed by C.T.Desrnarquest (from the Saint Gobain group) and of which the composition by weight and properties are as follows: Si 3 N 4 : 88.5%; Al 2 O 3 , Y 2 O 3 , Nd 2 O 3 , TiO 2 : 11.5%; density>3.25; bending strength>800 MPa; hardness: 1450 Hv; toughness: 7 MPa·m 1/2 ),
EXAMPLES
[0029] Three valves made of 3 different materials were tested:
one valve made of zirconium oxide (supplied by Niro-Soavi); one valve made of tungsten carbide coated with titanium nitride (supplied by Niro-Soavi); one valve made of silicon nitride manufactured in the KERSIT® 301 grade described above, and depicted in FIG. 2 .
[0033] Use was made of two Niro-Soavi homogenizers: NS2006 (35 l/h, 1500 bar) and NS3024 (300 l/h, 1500 bar). Each of the valves is made up of a valve seat ( 2 ), a valve piston (or impact head) (1) and an impact ring ( 3 ) (see FIG. 1 ). The dimensions and relative configuration of each of the valves are described in Table I.
[0034] Regarding the valve of FIG. 2 , the valve piston ( 4 ) is made of silicon nitride. The stationary impact ring ( 5 ) is made of tungsten carbide ( 5 a , 5 b ), the valve seat ( 6 ) is made of stainless steel ( 6 a , 6 b ) and of silicon nitride ( 6 c , 6 d ).
[0000]
TABLE I
valve made of
valve made
tungsten carbide
of zirco-
and coated with
valve made of
nium oxide
titanium nitride
silicon nitride
geometric shape of
straight tube
straight tube
convergent-
valve seat
followed by
followed by
divergent as
divergent
divergent
per FIG. 2
inlet diameter D 0
7.98
5
9
[mm]
inside diameter of
11
10.9
11
divergent D 1 [mm]
outside diameter of
12
12.1
12
divergent D 2 [mm]
inside diameter of
12.48
12.4
12.35
impact ring D a [mm]
[0035] Tests were first of all carried out at a pressure of 1400 bar and at a flow rate of 35 l/h using a 20 wt % aqueous suspension of a solid active principle (AVE1625) containing 1.2 wt % of stabilizer (PVP/SDS:60/40% w/w) (Table II). The AVE1625 is N-[1-[bis(4-chlorophenyl)methyl]azetidin-3-yl]-N-(3,5-difluorophenyl)methanesulfonamide having the CAS No. 358970-97-5,
[0000]
TABLE II
valve made of
tungsten carbide
zirconium
coated with titanium
oxide
nitride
silicon nitride
ref.
VRT 769
VRT 770
VRT 783
run time [h]
12.1
3.75
15.65
observations
breakage of
erosion of valve seat
nothing to report
impact ring
and drop in pressure
[0036] These tests show that the valve made of silicon nitride is very resistant and does not become damaged during preparation of the nanosuspension.
[0037] Following these tests, the silicon nitride valve was kept and used in various tests on the NS2006 without the mechanical properties being impaired, as can be seen from the results of Table III.
[0000]
TABLE III
working
working
pressure
flow rate
run time
test reference
[bar]
[l/h]
[hours]
VRT778
1400
44.65
7.2
VRT779
600
62.43
6.0
VRT780
800
57.99
6.25
VRT781
1000
52.86
6.5
VRT782
1200
48.60
6.5
VRT783
1400
44.65
15.65
VRT784
1400
44.65
6.5
VRT787
1400
44.48
6.55
VRT 789
1400
42.90
5.28
VRT792
1400
42.73
6.5
VRT796
1400
42.80
2.05
VRT797
1400
41.29
5
VRT798
1400
40.68
6.08
VRT799
1400
40.91
6.02
total
92.08
[0038] For all the tests in Table III, the valve withstood the test and no drop in pressure was noted, a pressure drop being a sign that the magnitude of the gap through which the dispersion must past has increased, and therefore a sign that the valve is impaired. The total number of hours for which the valve was run without any change in valve is therefore at least 92.08 h.
[0039] Tests were also conducted on a larger scale (1400 bar, at a flow rate 300 l/h, using NS3024). With the valve made of zirconium oxide the test was stopped on 3 occasions because the valve broke after around 5 hours of running in each instance. The valve made of silicon nitride which had already run for 92.08 h ran for a further 10 h without any particular problem. Moreover, it displayed a better grinding efficiency than the valve made of zirconium oxide.
CONCLUSIONS
[0040] The study demonstrates very good mechanical integrity (no erosion over a long period of time) of the valve made of silicon nitride by comparison with the valves made of zirconium oxide and of tungsten carbide coated with titanium nitride, and did so on two scales (35 and 300 l/h). Moreover, the valve demonstrated greater grinding efficiency by comparison with the valve made of zirconium oxide.
[0041] A valve made of silicon nitride, more particularly of the KERSIT® 301 or equivalent material, can therefore be used advantageously in “piston-gap” HPH technology for the preparation of pharmaceutical formulations containing an active principle in a state of nanoparticles dispersed in water and stabilized by at least one stabilizer, the nanoparticles having a mean diameter smaller than 1000 nm and more generally of between 1000 nm and 20 nm. | The invention relates to the use of a homogenisation valve that comprises a flap gate ( 1 ), an impact ring ( 3 ) and a seat in order to prepare, using high-pressure valve technology, a nanosuspension of a solid pharmaceutically active principle, characterized in that the material constituting the flap gate, the seat and optionally the impact ring and/or the outer surface of at least one of said elements includes sintered or hot-pressed silicon nitride as the main component. The invention also relates to a method for preparing a nanosuspension of a solid pharmaceutically active principle using the high-pressure valve homogenization technology. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present PCT application claims priority benefit of the U.S. provisional application for patent Ser. No. 61/176,936 filed on 10 May 2009 under 35 U.S.C. 119(e). The contents of this related provisional application are incorporated herein by reference for all purposes.
FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER LISTING APPENDIX
[0003] Not applicable.
COPYRIGHT NOTICE
[0004] A portion of the disclosure of this patent document contains material that is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or patent disclosure as it appears in the Patent and Trademark Office, patent file or records, but otherwise reserves all copyright rights whatsoever.
FIELD OF THE INVENTION
[0005] The present invention relates generally to the field of inspection and more specifically to a system for collecting and managing alloy verification information.
BACKGROUND OF THE INVENTION
[0006] Proper alloy inspection and verification in piping systems, such as, but not limited to, refineries, and other types of mechanical systems helps prevent catastrophic failure due to the use of incorrect materials in the components of the system. Alloy verification identifies and analyzes all of the critical alloy components, or locations, in a system such as, but not limited to, pipes, valves, fittings, and welds for accuracy and documents the results of this analysis. The verification process also verifies that all of the locations of a system are analyzed.
[0007] Current alloy inspection and verification approaches are often tedious. One current approach is to manually create hand written results of the analysis on drawings of the system. Depending on the complexity of the system, there may be hundreds of locations to analyze per drawing in this approach and multiple copies of each drawing may be required in order to handle the large amount of data collected. The preparation needed for this approach is time consuming including gathering drawings, verifying that drawings are up to date, tagging locations on drawings, etc. In some current approaches, the results may be compiled in a spreadsheet. However, these approaches still require a large amount of preparation time and drawings for gathering the data. These current approaches also make it difficult to efficiently utilize existing data and documentation and to generally ensure that all critical components of the system are analyzed. It is therefore an objective of the present invention to provide means to better manage the alloy verification process by more efficiently organizing analysis data.
[0008] A prior art system for collecting and managing alloy verification data exists. This system assigns locations and groups of locations to barcodes that link these locations to a database of critical components on a PC. Once the analysis data, along with the barcode labels, is downloaded to the PC, an application on the PC generates a report of the accuracy of the components being verified. However, this system still requires a great deal of preparation including updating and tagging existing drawings and generating barcode labels. This system also requires the use of an existing database of general mechanical integrity data. Furthermore, reports cannot be generated until the field data is returned to a PC on which the reporting application and the previously mentioned database is installed. This means that if any locations are missed during field-testing, return trips to the field are required.
[0009] In view of the foregoing, there is a need for improved techniques for providing a management system for alloy verification data that requires a small amount of preparation and can provide reports in the field.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The present invention is illustrated by way of example, and not by way of limitation, in the figures of the accompanying drawings and in which like reference numerals refer to similar elements and in which:
[0011] FIG. 1 is a flow chart illustrating an exemplary process for collecting and managing alloy verification information, in accordance with an embodiment of the present invention;
[0012] FIG. 2 illustrates an exemplary PMI mode selection menu, in accordance with an embodiment of the present invention;
[0013] FIG. 3 illustrates an exemplary map selection menu, in accordance with an embodiment of the present invention;
[0014] FIG. 4 illustrates an exemplary piping map, in accordance with an embodiment of the present invention;
[0015] FIG. 5 illustrates an exemplary PSV Map, in accordance with an embodiment of the present invention;
[0016] FIG. 6 illustrates an exemplary Pressure Vessel Map created in Pressure vessel PMI mode utilizing a vessel photo that was taken with an integrated, accessible, or connected digital camera, in accordance with an embodiment of the present invention;
[0017] FIG. 7 illustrates an exemplary Pressure Vessel Map utilizing a generic vessel drawing preloaded for the specific vessel type, in accordance with an embodiment of the present invention; and
[0018] FIG. 8 illustrates a typical computer system that, when appropriately configured or designed, can serve as a computer system in which the invention may be embodied.
[0019] Unless otherwise indicated illustrations in the figures are not necessarily drawn to scale.
SUMMARY OF THE INVENTION
[0020] To achieve the forgoing and other objects and in accordance with the purpose of the invention, a system, method and computer program product for collecting and managing alloy verification information is presented.
[0021] In one embodiment a system includes means for analyzing alloy composition of parts in a mechanical system, means for storing a representation of the mechanical system and an item type listing with parts and specifications for the parts, means for displaying at least part of the representation comprising a group of parts to validate, means for selecting a location of a part on the displayed representation for analysis and means for linking analysis data from the analyzing means and specifications of the part to the selected location of the displayed representation, thereby transforming the representation to a representation comprising at least the analysis data and the specifications. Other various embodiments further include means for selecting an item type of the selected location and linking to the selected location for determining analysis requirements, means for coding locations on the displayed representation for simplifying location of specific parts, means for indicating on the displayed representation a mismatch between analysis data and specifications, means for archiving the representation and linked location data, means for generating reports, means for capturing a representation of the mechanical system and means for drawing a representation of the mechanical system.
[0022] In another embodiment a method includes steps for providing an alloy analyzer for analyzing composition of parts in a mechanical system, steps for providing a computing device at least comprising computer readable memory and a display, steps for storing a representation of the mechanical system and an item type listing with parts and specifications for the parts, steps for displaying at least part of the representation comprising a group of parts to validate, steps for selecting a location of a part on the displayed representation for analysis, and steps for linking analysis data from the alloy analyzer and specifications of the part to the selected location of the displayed representation, thereby transforming the representation to a representation comprising at least the analysis data and the specifications. Other various embodiments further include steps for selecting an item type of the selected location and linking to the selected location for determining analysis requirements, steps for coding locations on the displayed representation for simplifying location of specific parts, steps for indicating on the displayed representation a mismatch between analysis data and specifications, steps for archiving the representation and linked location data, steps for generating reports, steps for capturing a representation of the mechanical system and steps for drawing a representation of the mechanical system.
[0023] In another embodiment a computer program product residing on or being distributed across one or more computer readable mediums having a plurality of instructions stored thereon which, when executed by one or more associated processors, cause the one or more processors to store a representation of a mechanical system and an item type listing with parts and specifications for the parts. At least part of the representation comprising a group of parts to validate is displayed. A location of a part on the displayed representation is selected for analysis. An item type of the selected location is selected and linked to the selected location for determining analysis requirements. Analysis data from an alloy analyzer and specifications of the part is linked to the selected location of the displayed representation. A mismatch between analysis data and specifications is indicated on the displayed representation, thereby transforming the representation to a representation comprising at least the analysis data and the specifications. Other various embodiments further include instructions causing the one or more processors to capture a representation of the mechanical system, enable drawing a representation of the mechanical system and code locations on the displayed representation for simplifying location of specific parts.
[0024] Other features, advantages, and objects of the present invention will become more apparent and be more readily understood from the following detailed description, which should be read in conjunction with the accompanying drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] The present invention is best understood by reference to the detailed figures and description set forth herein.
[0026] Embodiments of the invention are discussed below with reference to the Figures. However, those skilled in the art will readily appreciate that the detailed description given herein with respect to these figures is for explanatory purposes as the invention extends beyond these limited embodiments. For example, it should be appreciated that those skilled in the art will, in light of the teachings of the present invention, recognize a multiplicity of alternate and suitable approaches, depending upon the needs of the particular application, to implement the functionality of any given detail described herein, beyond the particular implementation choices in the following embodiments described and shown. That is, there are numerous modifications and variations of the invention that are too numerous to be listed but that all fit within the scope of the invention. Also, singular words should be read as plural and vice versa and masculine as feminine and vice versa, where appropriate, and alternative embodiments do not necessarily imply that the two are mutually exclusive.
[0027] The present invention will now be described in detail with reference to embodiments thereof as illustrated in the accompanying drawings.
[0028] Detailed descriptions of the preferred embodiments are provided herein. It is to be understood, however, that the present invention may be embodied in various forms. Therefore, specific details disclosed herein are not to be interpreted as limiting, but rather as a basis for the claims and as a representative basis for teaching one skilled in the art to employ the present invention in virtually any appropriately detailed system, structure or manner.
[0029] Preferred embodiments of the present invention provide a process to identify locations requiring alloy verification and to link associated alloy information during the alloy verification process. Preferred embodiments improve manageability of alloy verification projects by effectively organizing the resulting data so that the comprehensiveness of the study can easily be determined. Preferred embodiments also improve the consistency and quality of alloy validation projects for systems or groups of items requiring analysis by generally ensuring that standardized formats are developed, agreed to and utilized.
[0030] Preferred embodiments of the present invention also provide a system for collecting and managing alloy verification information comprising an alloy analyzer with a programmable interface, a digital representation or map of the group of items for alloy verification, and a customized application on the alloy analyzer that identifies and links locations on the map to alloy analysis data during the alloy verification activity. Preferred embodiments provide an alloy analyzer with a CPU or other computer controlled and programmable interface that supports functions to control the analyzer as well as provide capabilities such as, but not limited to, locating files, selecting locations on a touch screen or other digitizing method, recording specific data on a location, etc. The device according to preferred embodiments supports user input capabilities such as, but not limited to, keyboards, touch screens, barcode scanning, Bluetooth interfaces, digital cameras, and various other common PC or Pocket PC functions. The analyzer in preferred embodiments also includes data storage capabilities to contain digitized system representations, markups, alloy analysis data, reference databases, or other relevant information for the alloy verification project. Preferred embodiments of the present invention also comprise a customized application or software package that runs on the alloy analyzer to expand typical alloy analyzer analysis capabilities to include, without limitation, support for specifying alloy verification locations on a digitized representation and then associating or linking the correct alloy analysis data with the location.
[0031] A digitized representation, such as, but not limited to, a CAD drawing, a photo, a scanned sketch, etc. of the system or group of items requiring alloy verification, is utilized during the alloy verification process. In preferred embodiments this digitized representation can be generated or obtained prior to actual alloy verification activity or during the alloy verification activities. Formats of digitized orientation maps obtained prior to the alloy verification process include, without limitation, digitized CAD or hand sketched ISOs or orientation drawings, previously taken photographs, exported inspection ISOs from common mechanical integrity applications, part or component illustrations from manufacturers, or other illustrations of parts, locations or other items comprising a whole system. Common formats of digitized orientations or maps created during the field gathering process include, without limitation, electronic sketches or CAD drawings, photographs from alloy analyzer integrated or accessible digital cameras, portable or available scanners, and other methods of creating digitized orientation illustrations. Additional sources of digitized orientation illustrations include, without limitation, custom applications typically utilized on larger PC computers, tablets, or laptops where illustrations are reviewed and locations or systems for alloy verification are identified and listings of locations created prior to the alloy verification activities managed on the analyzer.
[0032] FIG. 1 is a flow chart illustrating an exemplary process for collecting and managing alloy verification information, in accordance with an embodiment of the present invention. In the present embodiment, the process comprises the primary steps of selecting the proper Positive Material Identification (PMI) mode, selecting or creating a digitized orientation map, selecting locations for alloy validation on the map, entering/verifying relevant details, and then performing the actual alloy analysis and linking collected alloy verification data to the identified location. Additional steps of reporting on inspection results are conducted at completion of the project, or may be conducted at intermediate stages of completion.
[0033] In the present embodiment, the verification process begins at step 111 where the proper PMI mode is selected on an alloy analyzer to provide the correct reference information for the types of items requiring alloy verification. Examples of possible PMI modes include, but are not limited to, piping, pressure vessel, PSV, manufactured components, and others. Reference information includes items necessary to efficiently conduct the alloy verification such as, but not limited to, default maps for specific items or groups of items, listings of typical or required analysis for specific types of items or groups, and other information that is specific to a particular type of item or component requiring alloy verification. A table of items that comprise multiple parts are defined and pre-loaded on the analyzer for the different categories of items in each particular PMI mode, so that consistent organization of all items and individual parts can be obtained during the data collection stage. This listing of items is grouped by category, which can be from 1 to 5 or more categories for grouping the alloy analysis results in a systematic way on the analyzer and in subsequent reports. The grouping by category is also intended to simplify the location of items on a map when several items are available in the listing for a specific alloy verification mode or project type, such as, but not limited to, piping, pressure vessel, PSV, or other types of systems potentially benefiting or requiring alloy verification. This item type listing is necessary prior to locating any items on the digitized illustration or map and is downloaded to the alloy analyzer prior to the verification process in step 101 .
[0034] For each system or group of items identified as requiring alloy verification, a map or digitized representation is created or selected. This map can be optionally downloaded to the analyzer prior to the actual alloy verification activities in step 103 , or this map can be created during the alloy verification activity. This digitized representation can be in the format of a photograph, sketch or other illustration that provides the orientation of the items requiring analysis. Being able to create the map during the verification process in the present embodiment greatly reduces the amount of preparation needed to be done prior to the process. Referring to FIG. 1 to obtain a map or digitized representation, the user of the alloy analyzer may choose to capture a photo of the system for a group of items to validate using a camera on the alloy analyzer in step 113 , to select a preloaded map on the analyzer in step 115 , or sketch or make a CAD drawing of a map on the analyzer in step 117 . Once the digitized illustration or map is created or located from preloaded items on the analyzer, it is made immediately available for the locating of individual items or locations for analysis.
[0035] The data collection stage comprises three data collection steps including selecting a location in step 119 , entering/verifying relevant data in step 121 , and then collecting alloy analysis data and linking the alloy verification data that is collected to the selected location in step 123 . In step 119 , the locations for alloy analysis may be selected on the alloy analyzer using a touch screen, joystick, or other digitizing method which enables the user to identify an exact location on the map or digitized illustration for later reference to the alloy analysis to be performed. Depending on the map type being used, some locations could already be predefined and thus only require verification of locations and then performing analysis/linking data to each of the locations. Maps of this type could include manufacturers illustrations, standardized cad drawings, or any previously completed PMI illustrations with locations defined during the previous project or prior to the field data collection. Map types that require manual identification of locations for analysis include photos, Cad drawings, or sketches created during the data collection process, or stored pre-loaded maps that have not had locations pre-defined. As part of the selection process, additional alloy data about the location, process, item type, or other relevant details are added or verified and linked to the location in step 121 . For each location, the type of item is selected and associated with the location to determine alloy analysis requirements such as, but not limited to, redundant shot requirements or multiple pieces that make up the item or location. In the present embodiment, since locations are linked on the analyzer after these steps, each location is color coded according to type of item, location or other value added criteria to facilitate simplifying location of specific items on the digitized illustration or map that is now loaded on the analyzer. The color-coding used in the present embodiment enables the user to easily locate all locations for analysis, which is sometimes difficult due to the small screen size of typical alloy analyzers. Once location data is entered, the actual alloy analysis is performed in agreement with the details entered in the previous steps while shot accuracy is verified by the technician in step 123 . Problem locations or items that do not match specified or required material can also be easily highlighted with a color change or other emphasis on the analyzer such as, but not limited to, bold font or flashing for additional validation analysis while still in the field before moving on to the next step. This data is then linked to the location in step 123 , and the process returns to step 119 to select another location or to reselect a problem location when necessary. When all items or locations requiring alloy verification are selected, marked, analyzed, linked, and verified, the process returns to step 113 , 115 or 117 where the next group or system is chosen and a corresponding digitized illustration selected or created.
[0036] Once alloy verification data is collected and linked for all items, groups, or systems, or at intermediate stages of the project, the data is downloaded for archival and reporting purposes in step 125 . In the present embodiment, reports are verified and completed on the analyzer using filters for verification of all locations by type or point or location. Reports can be viewed on the analyzer in the field while data is being collected or as a final report on the completion of data collection. The marked up digitized illustrations of locations or systems are printed, and corresponding alloy analysis details are provided in tabular or other report format. Since locations are linked on the analyzer with relevant alloy analysis data, the locations are color coded in the digitized illustration according to type of alloy verification item or location, to facilitate simplifying location of specific items on the digitized illustration or map. Problem locations or items that did not match specified or required material can also be easily highlighted in the digitized illustration on the analyzer in a discrepancy report for additional validation analysis before archiving or reporting. This report may be emailed from the analyzer while in the field or downloaded in the office for distribution. In step 127 the modified maps and linked verification data are archived. The final remediated reports can be stored on local networks or linked to document management or mechanical integrity applications for documentation purposes. This information is organized by system or equipment circuit, where the safe status of a system can easily be referenced and verified from the map reports and associated material analysis summaries. The detailed analyzer data files can also be stored onto optical, tape, magnetic or other storage media for long term archival purpose in a way that the analyzer can be reloaded for retesting of the same system or circuit due to maintenance replacement of components that once again require analysis. This archiving also allows for the creation of a standardized library of typical systems or groups of items requiring alloy analysis that can be used as is or copied and modified to best fit the actual new systems requiring alloy verification.
[0037] FIGS. 2 through 7 illustrate various different exemplary menus and maps from an alloy analyzer, in accordance with an embodiment of the present invention. FIG. 2 illustrates an exemplary PMI mode selection menu, in accordance with an embodiment of the present invention. In the present embodiment, the PMI selection menu is where the type of PMI project or activity is selected in order to provide access to the proper related information such as, but not limited to, proper manufacturer standards, predefined maps, categorized listings and templates, or examples for use as item group maps for identifying locations. A PMI Select button 201 brings up the choices of alloy verification projects and the associated item type libraries as project buttons 203 .
[0038] FIG. 3 illustrates an exemplary map selection menu, in accordance with an embodiment of the present invention. In the present embodiment, the map selection menu is where the digitized illustration of the items to be analyzed is loaded prior to conducting the alloy verification activities. The type of PMI verification project with type of equipment and associated item type library is indicated by a PMI box 301 . Selecting a map button 303 brings up the map selection menu. Various selection buttons in the map selection menu enable the user to choose between different methods for obtaining a map. A linked camera button 305 enables the user to choose a map from a camera that is directly linked to or accessible to the analyzer. An upload button 307 enables the user to select the map from digitized illustration files from a thumb drive or other storage device. A library drawing button 309 enables the user to select the map from CAD, ISO or manufacturing drawings stored on the analyzer by type of PMI project and then by equipment type. A library photo button 311 enables the user to choose the map from standard photos, manufacturer photos or other typical photos of equipment by PMI project then by equipment type. A sketch button 313 opens a CAD or drawing application on the analyzer in which the user may create a drawing or illustration as needed during the verification process. A copy map button 315 provides a method of browsing and making a copy of a previously created map as is or for modification to fit the current group of items for verification. A continue previous button 317 enables the user to retrieve a previous started or completed map to continue a project. Continue previous button 317 may also be used to open a map generated from an application prior to the alloy verification work.
[0039] FIG. 4 illustrates an exemplary piping map, in accordance with an embodiment of the present invention. In the present embodiment, the piping map is selected in the analyzer application preloaded from an existing Inspection Isometric Drawing, illustrating fitting locations that are located, matching, and non-matching on the drawing. The type of PMI verification project with type of equipment and associated item type library is indicated by a PMI box 401 , and a map box 403 shows what portion of the system or group is being verified along with a sequence number if more than one sequence is required. Map box 403 may be double clicked to load another map. Subcategory buttons 405 enable the user to select different item types or subcategories from pre-populated item listings. The item associated with the selected category is highlighted on the map, and only selected item type locations are shown on the map. Selecting an ALL button 407 shows all item types. A locate button 409 activates a locate mode to identify and enter relevant information for each location and item type. Once locations are defined, an analyze button 411 may be selected to perform alloy analysis on a selected item. An item is located on the map by selecting an item type category from subcategory buttons 405 then touching a location on the map. The type of item is then selected from the list and additional information may be entered or verified. Colored buttons of various shapes and sizes are created and placed on the map for each item location identified. For example, without limitation, in the present embodiment, a location with missing alloy analysis data 413 is highlighted with a red shaded box, and a location with non-matching alloy analysis 415 is highlighted with a yellow box. A location with complete alloy analysis data 417 with a proper match to the specified material has no highlighting.
[0040] FIG. 5 illustrates an exemplary PSV Map, in accordance with an embodiment of the present invention. In the present embodiment, the PSV map is selected in the analyzer application preloaded from manufacturer-supplied illustrations. The map comprises a PMI box 501 , a map box 503 , subcategory buttons 405 , an ALL button 507 , a locate button 509 , and an analyze button 511 , similarly to the map illustrated by way of example in FIG. 4 . Map box 503 shows the name of the manufacturer drawing for the selected PSV. The map illustrates color-coded locations by item type category, and other functionality. The illustration illustrates some of the functionality of the PMI PSV Mode Alloy Analysis application. The functionality of the PSV mode is the same as the Piping mode in FIG. 4 , except that the groups of components and available components in each group are named to correspond to a PSV.
[0041] FIG. 6 illustrates an exemplary Pressure Vessel Map created in Pressure Vessel PMI mode utilizing a vessel photo that was taken with an integrated, accessible, or connected digital camera, in accordance with an embodiment of the present invention. The photo can also be selected in the analyzer application from preloaded manufacturer or generic supplied illustrations or previously obtained photographs of the actual vessel. The map comprises a PMI box 601 , a map box 603 , subcategory buttons 605 , an ALL button 607 , a locate button 609 , and an analyze button 611 , similarly to the maps illustrated by way of example in FIGS. 4 and 5 . Map box 603 shows the name of the field acquired photo. This photomap illustrates color-coded locations by item type category, and other functionality. The illustration describes some of the functionality of the PMI Pressure Vessel Mode Alloy Analysis application. The functionality of the Pressure Vessel Mode is the same as the Piping mode in FIG. 4 , except that the groups of components and available components in each group are named to correspond to a vessel.
[0042] FIG. 7 illustrates an exemplary Pressure Vessel Map utilizing a generic vessel drawing preloaded for the specific vessel type, in accordance with an embodiment of the present invention. The map comprises a PMI box 701 , a map box 703 , subcategory buttons 705 , an ALL button 707 , a locate button 709 , and an analyze button 711 , similarly to the maps illustrated by way of example in FIGS. 4 , 5 and 6 . Map box 703 shows the name of the preloaded manufacturer drawing for the selected pressure vessel. The map illustrates color-coded locations by item type category, and other functionality.
[0043] Those skilled in the art will readily recognize, in accordance with the teachings of the present invention, that any of the foregoing steps and/or system modules may be suitably replaced, reordered, removed and additional steps and/or system modules may be inserted depending upon the needs of the particular application, and that the systems of the foregoing embodiments may be implemented using any of a wide variety of suitable processes and system modules, and is not limited to any particular computer hardware, software, middleware, firmware, microcode and the like. For any method steps described in the present application that can be carried out on a computing machine, a typical computer system can, when appropriately configured or designed, serve as a computer system in which those aspects of the invention may be embodied.
[0044] FIG. 8 illustrates a typical computer system that, when appropriately configured or designed, can serve as a computer system in which the invention may be embodied. The computer system 800 includes any number of processors 802 (also referred to as central processing units, or CPUs) that are coupled to storage devices including primary storage 806 (typically a random access memory, or RAM), primary storage 804 (typically a read only memory, or ROM). CPU 802 may be of various types including microcontrollers (e.g., with embedded RAM/ROM) and microprocessors such as programmable devices (e.g., RISC or SISC based, or CPLDs and FPGAs) and unprogrammable devices such as gate array ASICs or general purpose microprocessors. As is well known in the art, primary storage 804 acts to transfer data and instructions uni-directionally to the CPU and primary storage 806 is used typically to transfer data and instructions in a bi-directional manner. Both of these primary storage devices may include any suitable computer-readable media such as those described above. A mass storage device 808 may also be coupled bi-directionally to CPU 802 and provides additional data storage capacity and may include any of the computer-readable media described above. Mass storage device 808 may be used to store programs, data and the like and is typically a secondary storage medium such as a hard disk. It will be appreciated that the information retained within the mass storage device 808 , may, in appropriate cases, be incorporated in standard fashion as part of primary storage 806 as virtual memory. A specific mass storage device such as a CD-ROM 814 may also pass data uni-directionally to the CPU.
[0045] CPU 802 may also be coupled to an interface 810 that connects to one or more input/output devices such as such as video monitors, track balls, mice, keyboards, microphones, touch-sensitive displays, transducer card readers, magnetic or paper tape readers, tablets, styluses, voice or handwriting recognizers, or other well-known input devices such as, of course, other computers. Finally, CPU 802 optionally may be coupled to an external device such as a database or a computer or telecommunications or internet network using an external connection as shown generally at 812 , which may be implemented as a hardwired or wireless communications link using suitable conventional technologies. With such a connection, it is contemplated that the CPU might receive information from the network, or might output information to the network in the course of performing the method steps described in the teachings of the present invention.
[0046] It will be further apparent to those skilled in the art that at least a portion of the novel method steps and/or system components of the present invention may be practiced and/or located in location(s) possibly outside the jurisdiction of the United States of America (USA), whereby it will be accordingly readily recognized that at least a subset of the novel method steps and/or system components in the foregoing embodiments must be practiced within the jurisdiction of the USA for the benefit of an entity therein or to achieve an object of the present invention. Thus, some alternate embodiments of the present invention may be configured to comprise a smaller subset of the foregoing novel means for and/or steps described that the applications designer will selectively decide, depending upon the practical considerations of the particular implementation, to carry out and/or locate within the jurisdiction of the USA. For any claims construction of the following claims that are construed under 35 USC §112 (6) it is intended that the corresponding means for and/or steps for carrying out the claimed function also include those embodiments, and equivalents, as contemplated above that implement at least some novel aspects and objects of the present invention in the jurisdiction of the USA.
[0047] Having fully described at least one embodiment of the present invention, other equivalent or alternative methods of providing a process and system for collecting and managing alloy verification information according to the present invention will be apparent to those skilled in the art. The invention is thus to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the following claims.
[0048] Claim elements and steps herein have been numbered and/or lettered solely as an aid in readability and understanding. As such, the numbering and lettering in itself is not intended to and should not be taken to indicate the ordering of elements and/or steps in the claims. | A system, method and computer program product include storing a representation of a mechanical system and an item type listing with parts and specifications for the parts. At least part of the representation comprising a group of parts to validate is displayed. A location of a part on the displayed representation is selected for analysis. An item type of the selected location is selected and linked to the selected location for determining analysis requirements. Analysis data from an alloy analyzer and specifications of the part is linked to the selected location of the displayed representation. On the displayed representation, a mismatch between analysis data and specifications is indicated, thereby transforming the representation to a representation comprising at least the analysis data and the specifications. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to liquid crystal displays used in television receivers and display sections of electronic apparatus and, more particularly, to a liquid crystal display in which a polymeric material included in a liquid crystal material is polymerized to impart a pre-tilt angle to the liquid crystal material.
2. Description of the Related Art
There is a recent trend toward larger display screens in the field of liquid crystal displays having a liquid crystal display panel for the use of such displays as display sections of television receivers. For this reason, higher display quality is required for liquid crystal displays. However, it is difficult to achieve characteristics required for a display section of a television receiver using a liquid crystal display employing the TN (Twisted Nematic) method which has been the main stream of the field because of the narrow viewing angle resulting from the method. Under the circumstance, techniques other than the TN method are currently being put in use in order to achieve the property of a wide viewing angle. One of such techniques is referred to as MVA (Multi-domain Vertical Alignment) method. In an MVA type liquid crystal display, liquid crystal molecules in a liquid crystal layer sealed between two substrates combined in a face-to-face relationship are aligned perpendicular to the substrates, and the alignment of the liquid crystal molecules is regulated by protrusions formed on the substrates or slits, provided on a transparent electrode (ITO).
It is known in general that when the vertical alignment method in which liquid crystal molecules are aligned perpendicular to substrates, optical characteristics measured in a direction oblique to a direction normal to the display screen are different from optical characteristics in the normal direction. FIG. 11 is a graph showing characteristics of luminance relative to input gradations (gradation/luminance characteristics) of a vertical alignment type liquid crystal display. The abscissa axis represents input gradations (in gray scale), and the ordinate axis represents luminance (T/Twhite) normalized with reference to the luminance of display of white (TWhite). The curve in a solid line in the figure indicates gradation/luminance characteristics in a direction perpendicular to the display screen (hereinafter referred to as a square direction), and the curve connecting black triangular symbols in the figure indicates gradation/luminance characteristics in a direction at an azimuth angle of 90° and a polar angle of 60° to the display screen (hereinafter referred to as an oblique direction). An azimuth angle is an angle measured counterclockwise with reference to the direction to the right of the display screen. A polar angle is an angle to a line that is vertical to the center of the display screen.
As shown in FIG. 11 , gradation/luminance characteristics in a direction oblique to the direction of a polarization axis significantly deviate from gradation/luminance characteristic in the square direction. For example, luminance in the oblique direction is higher than luminance in the square direction in the range of gradations from 0 to 210, whereas luminance in the oblique direction is lower than luminance in the square direction in the range of gradations from 210 to 255 or higher. As a result, when the screen is viewed in the oblique direction, there are small differences in luminance between input gradations, and the color of an image appears more whitish compared to a view of the same in the square direction.
A known solution to this problem is a liquid crystal display having a pixel structure including a pixel electrode electrically connected to a source electrode of a thin film transistor (TFT) for a pixel and another pixel electrode that is separated from the pixel electrode and insulated from the source electrode. In such a liquid crystal display, an electrostatic capacitance is formed by the pixel electrode insulated from the source electrode, the source electrode, and an insulation film sandwiched between the two electrodes. The pixel electrode insulated from the source electrode is driven by the electrostatic capacitance.
FIG. 12 shows a configuration of one pixel of a liquid crystal display having the pixel structure including two separated pixel electrodes. As shown in FIG. 12 , a gate bus line 106 and a plurality of drain bus lines 108 are formed on a glass substrate 103 , the drain bus lines extending across the gate bus line 106 with an insulation film (not shown) interposed between them. A TFT 110 is disposed in the vicinity of an intersection between the gate bus line 106 and a drain bus line 108 , a TFT being formed at each pixel. A part of the gate bus line 106 serves as a gate electrode 110 c of the TFT 110 . An active semiconductor layer and a channel protection film (both of which are not shown) of the TFT 110 are formed above the gate bus line 106 with an insulation film interposed. A drain electrode 110 a along with an n-type impurity semiconductor layer (not shown) underlying the same and a source electrode 110 b along with an n-type impurity semiconductor layer (not shown) underlying the same are formed on the channel protection film of the TFT 110 above the gate electrode 110 c , the electrodes facing each other across a predetermined gap.
A storage capacitor bus line 114 is formed to extend in parallel with the gate bus line 106 across a pixel region which is defined by the gate bus line 106 and the drain bus lines 108 . A storage capacitor electrode (intermediate electrode) 116 is formed at each pixel above the storage capacitor bus line 114 with an insulation film interposed between them. The storage capacitor electrode 116 is electrically connected to the source electrode 110 b of the TFT 110 through a connection electrode 111 . A storage capacitor Cs is formed by the storage capacitor bus line 114 , the storage capacitor electrode 116 , and the insulation film sandwiched between them.
The pixel region defined by the gate bus line 106 and the drain bus lines 108 is divided into a sub-pixel 120 and a sub-pixel 122 . For example, the sub-pixel 120 , which has a trapezoidal shape, is disposed on the left side of a central part of the pixel region, and the sub-pixel 122 is disposed in upper part and lower parts of the pixel region and on the right side of the central part excluding the area of the sub-pixel 120 . Referring to the disposition of the sub-pixels 120 and 122 in the pixel region, they are substantially line symmetric about the storage capacitor bus line 114 . A pixel electrode 121 is formed at the sub-pixel 120 , and a pixel electrode 123 , which is separate from the pixel electrode 121 , is formed at the sub-pixel 122 . Both of the pixel electrodes 121 and 123 are constituted by a transparent conductive film such as an ITO. The pixel electrode 121 is electrically connected to the storage capacitor electrode 116 and the source electrode 110 b of the TFT 110 through a contact hole 118 which is an opening in a protective film (not shown). The pixel electrode 123 has a region which overlaps the connection electrode 111 with a protective film and an insulation film interposed between them. In that region, an electrostatic capacitance Cc is formed by the connection electrode 111 , the pixel electrode 123 , and the protective film sandwiched between the electrodes 111 and 123 .
A common electrode, which is not shown, is formed on an opposite glass substrate (not shown) provided opposite to the glass substrate 103 . A linear protrusion 112 a as an alignment regulating structure for regulating the direction of alignment of the liquid crystal is formed so as to protrude from the opposite glass substrate in a position opposite to the connecting electrode 111 diagonally extending in the figure. A linear protrusion 112 b is formed so as to protrude from the opposite glass substrate in a position in which it is substantially line symmetric with the liner protrusion 112 a about the storage capacitor bus line 114 . Further, a V-shaped linear protrusion 112 c is formed such that it is disposed above the pixel electrode 121 on the left side of the central part of the pixel region. The linear protrusion 112 c is substantially line symmetric about the storage capacitor bus line 114 .
At the sub-pixel 120 , a liquid crystal capacitance Clc 1 is formed by pixel electrode 121 , the common electrode, and the liquid crystal sandwiched between those electrodes. At the sub-pixel 122 , a liquid crystal capacitance Clc 2 is formed by the pixel electrode 123 , the common electrode, and the liquid crystal sandwiched between those electrodes. The liquid crystal capacitance Clc 2 and the electrostatic capacitance Cc are connected in series between the glass substrate 103 and the opposite glass substrate.
When the TFT 110 is turned on, the source electrode 110 b and the connection electrode 111 bear the same potential as a gradation voltage V D applied to a drain bus line 108 , and the pixel electrode 121 in electrical connection with them also bears the same potential as the gradation voltage V D . A voltage originating from a potential difference applied between the pixel electrode 121 and the common electrode is applied to the liquid crystal capacitance Clc 1 . For example, when the voltage applied to the common electrode is 0 V, the voltage applied to the liquid crystal capacitance Clc 1 is equal to the gradation voltage V D (=V D −0V). On the other hand, the pixel electrode 123 , which is electrically insulated, is applied with a voltage that is obtained by dividing the gradation voltage V D based on the ratio between the liquid crystal capacitance Clc 2 and the electrostatic capacitance Cc. The voltage applied to the pixel electrode 123 (represented by V 1 ) can be expressed as follows.
V 1 =V D ×{Cc /( Clc 2+ Cc )} (1)
As apparent from the above, there is a difference between thresholds of the pixel electrode 121 which is electrically connected to the source electrode 110 b and the pixel electrode 123 which is insulated from the same. Consequently, gradation/luminance characteristics in an oblique direction are significantly improved. As shown in FIG. 11 , the curve representing gradation/luminance characteristics in a square direction bulges downward. On the contrary, the curve indicating gradation/luminance characteristics in an oblique direction of an MVA type display in the related art is a mixture of a range in which the curve greatly bulges upward (the range of gradations from 0 to about 210) and a range in which the curve bulges downward (the range of gradations from about 210 to 255). Therefore, missing or spreading gradations can be generated depending on gradation data to be displayed, which results in variation of the color of an image. In the case of a liquid crystal display having the pixel structure shown in FIG. 12 , a curve indicating gradation/luminance characteristics of the apparatus in a direction oblique thereto will include substantially no upward or downward bulge, and the apparatus will have significantly high gradation characteristics.
Patent Document 1: JP-A-2003-149647
A liquid crystal display having the pixel structure shown in FIG. 12 can provide improved gradation/luminance characteristics in an oblique direction. However, as indicated by Expression 1, the voltage V 1 applied to the liquid crystal capacitance Clc 2 of the sub-pixel 122 decreases below the gradation voltage V D . Therefore, the absolute value of the luminance in an oblique direction of the liquid crystal display is smaller than that of a liquid crystal display without such a pixel structure. Further, since a pixel region of the liquid crystal display is divided into two regions, the disposition of the linear protrusions (bank-like structures) and slits in the pixel electrodes (gaps in the pixel electrodes 121 and 123 ) become complicated. A problem consequently arises in that the aperture ratio is substantially reduced to reduce luminance.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a liquid crystal display in which gradation/luminance characteristics in an oblique direction are improved and in which reduction in luminance is suppressed.
The above-described object is achieved by a liquid crystal display, characterized in that it includes a substrate, an opposite substrate provided opposite to the substrate, a liquid crystal composition including a liquid crystal material, and a polymer obtained by polymerizing a polymeric material by light or heat and sealed between the substrate and the opposite substrate, an alignment regulating structure for regulating the direction of alignment of the liquid crystal material, a gate bus line formed on the substrate, a drain bus line formed across the gate bus line with an insulation film interposed between them, a pixel transistor having a gate electrode electrically connected to the gate bus line, a drain electrode electrically connected to the drain bus line, and a source electrode provided above the gate electrode and opposite to the drain electrode with a predetermined gap left between them, and a pixel region having a first sub-pixel formed with a first pixel electrode electrically connected to the source electrode through a connection electrode and a second sub-pixel formed with a second pixel electrode which sandwiches an insulation film between itself and the connection electrode to form a predetermined electric capacitance and which is separated from the first pixel electrode.
The present invention makes it possible to provide a liquid crystal display in which gradation/luminance characteristics in an oblique direction are improved and in which reduction in luminance is suppressed.
BRIEF DESCRIPTION OF THE INVENTION
FIG. 1 shows a schematic configuration of a liquid crystal display according to a first embodiment of the invention;
FIGS. 2A and 2B show a configuration of one pixel of the liquid crystal display according to the first embodiment of the invention;
FIGS. 3A and 3B are enlarged views of a second sub-pixel 22 of the liquid crystal display according to the first embodiment of the invention;
FIGS. 4A to 4C are illustrations for explaining a height h of a linear protrusion 12 of the liquid crystal display according to the first embodiment of the invention;
FIG. 5 shows gradation/luminance characteristics of the liquid crystal display according to the first embodiment of the invention;
FIG. 6 shows a configuration of one pixel of a liquid crystal display according to a second embodiment of the invention;
FIG. 7 shows a configuration of one pixel of a modification of the liquid crystal display according to the second embodiment of the invention;
FIGS. 8A and 8B show a section of a pixel region of the modification of the liquid crystal display according to the second embodiment of the invention;
FIG. 9 show a configuration of one pixel of another modification of the liquid crystal display according to the second embodiment of the invention;
FIGS. 10A and 10B show a configuration of one pixel of a liquid crystal display according to a third embodiment of the invention;
FIG. 11 shows gradation/luminance characteristics of a liquid crystal display according to the related art; and
FIG. 12 shows a configuration of one pixel of the liquid crystal display according to the related art.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
First Embodiment
A liquid crystal display according to a first embodiment of the invention will be described with reference to FIGS. 1 to 5 . First, a configuration of the liquid crystal display of the present embodiment will be described with reference to FIG. 1 . As shown in FIG. 1 , for example, the liquid crystal display which is an MVA type display, has a liquid crystal display panel constructed by combining a TFT substrate 2 having such as a pixel electrode and a TFT formed at each pixel region thereof and an opposite substrate 4 having such as a CF layer formed thereon in a face-to-face relationship and sealing a liquid crystal material having negative dielectric constant anisotropy between the substrate. Vertical alignment films for aligning liquid crystal molecules in the liquid crystal material in, for example, a direction perpendicular to substrate surfaces are formed on surfaces of the substrates 2 and 4 facing each other.
A gate bus line driving circuit 80 loaded with a driver IC for driving a plurality of gate bus lines and a drain bus line driving circuit 82 loaded with a driver IC for driving a plurality of drain bus lines are provided on the TFT substrate 2 . The driving circuits 80 and 82 output scan signals and data signals to predetermined gate bus lines and drain bus lines based on predetermined signals output by a control circuit 84 .
A polarizer 87 is applied to a surface of the TFT substrate 2 that is opposite to the surface thereof on which the elements are formed. A backlight unit 88 constituted by, for example, a linear primary light source and a planar light guide plate is disposed on a side of the polarizer 87 that is opposite to the side thereof facing the TFT substrate 2 . A polarizer 86 is applied to a surface of the opposite substrate 4 that is opposite to the surface thereof on which a resin CF layer is formed.
FIGS. 2A and 2B show a configuration of one pixel of the liquid crystal display of the present embodiment. FIG. 2A shows a configuration of one of a plurality of pixels formed like a matrix as viewed in a direction normal to a glass substrate 3 . FIG. 2B is a view of a section taken along the line A-A indicated by a chain line in FIG. 2A . As shown in FIG. 2B , the liquid crystal display has the TFT substrate 2 and the opposite substrate 4 provided opposite to each other, and a liquid crystal composition 30 sealed between the substrates 2 and 4 . The liquid crystal composition 30 includes a liquid crystal material which is aligned substantially perpendicularly to substrate surfaces when no voltage is applied and which has negative dielectric constant anisotropy and a polymer which is provided as a result of polymerization of a polymeric material (a monomer or oligomer) by light or heat. For example, the liquid crystal composition 30 includes 0.3% diacrylate monomer by weight as the polymeric material. Although not shown, an alignment film having vertically aligning properties is formed on each of surfaces of the TFT substrate 2 and the opposite substrate 4 facing each other.
As shown in FIGS. 2A and 2B , the TFT substrate 2 has a gate bus line 6 formed on a glass substrate 3 and a plurality of drain bus lines 8 formed so as to extend across the gate bus line 6 with an insulation film 26 interposed between them. A TFT (a pixel transistor) 10 is disposed in the vicinity of an intersection between the gate bus line 6 and a drain bus line 8 , a TFT being formed at each pixel.
The TFT 10 has a gate electrode 10 c which is electrically connected to the gate bus line 6 , a drain electrode 10 a which is electrically connected to a drain bus line 8 , and a source electrode 10 b which is disposed above the gate electrode 10 c so as to face the drain electrode 10 a with a predetermined gap left between them. A part of the gate bus line 6 serves as the gate electrode 10 c of the TFT 10 . An active semiconductor layer and a channel protection film (both of which are not shown) of the TFT 10 are formed above the gate bus line 6 with the insulation film 26 interposed. The drain electrode 10 a along with an n-type impurity semiconductor layer (not shown) underlying the same and the source electrode 10 b along with an n-type impurity semiconductor layer (not shown) underlying the same are formed on a channel protection film of the TFT 10 above the gate electrode 10 c , the electrodes facing each other across a predetermined gap.
A storage capacitor bus line 14 is formed to extend in parallel with the gate bus line 6 across a pixel region which is defined by the gate bus line 6 and the drain bus lines 8 . A connection electrode 11 , which is electrically connected to the source electrode 10 b , is formed substantially in the middle of the pixel region across the storage capacitor bus line 14 so as to extend in parallel with the drain bus lines 8 . The drain electrode 10 a , the source electrode 10 b , and the connection electrode are formed in the same layer as the drain bus lines 8 . A storage capacitor electrode (intermediate electrode) 16 is formed at each pixel above the storage capacitor bus line 14 with an insulation film 26 interposed between them. The storage capacitor electrode 16 is electrically connected to the source electrode 10 b of the TFT 10 through the connection electrode 11 . A storage capacitor Cs is formed by the storage capacitor bus line 14 , the storage capacitor electrode 16 , and the insulation film 26 sandwiched between them.
The pixel region defined by the gate bus line 6 and the drain bus lines 8 is divided into a first sub-pixel 20 and two second sub-pixels 22 and 24 which are disposed side by side in the extending direction of the drain bus lines 8 . The first sub-pixel 20 has a first pixel electrode 21 formed in a substantially square shape. The first pixel electrode 21 is constituted by a transparent conductive film such as an ITO. The first pixel electrode 21 is electrically connected to the connection electrode 11 , storage capacitor electrode 16 and the source electrode 10 b of the TFT 10 through a contact hole 18 which is an opening in a protective film 27 formed above the pixel region.
The second sub-pixel 22 has a second pixel electrode 23 formed in a substantially square shape. The second sub-pixel 24 has a second pixel electrode 25 formed in a substantially square shape. The second pixel electrodes 23 and 25 are constituted by a transparent conductive film such as an ITO. The second pixel electrodes 23 and 25 are formed separately from the first pixel electrode 21 and are in therefore a floating state. A control capacitance (a predetermined electrical capacitance) Cc 1 is formed by the second pixel electrode 23 , the connection electrode 11 , and the protective film (insulation film) 27 sandwiched between the electrodes 11 and 23 . Similarly, a control capacitance (a predetermined electrical capacitance) Cc 1 ′ is formed by the second pixel electrode 25 , the connection electrode 11 , and the protective film (insulation film) 27 sandwiched between the electrodes 11 and 25 . The second pixel electrodes 23 and 25 are disposed side by side in the extending direction of the drain bus lines 8 so as to sandwich the first pixel electrode 21 .
The opposite substrate 4 includes a common electrode 28 constituted by a transparent conductive film formed on a glass substrate 5 . The opposite substrate 4 includes a linear protrusion (bank-like structure) 12 which is formed to protrude from the glass substrate 5 and which serves as an alignment regulating structure for regulating the direction of alignment of liquid crystal molecules 32 in the liquid crystal material. The linear protrusion 12 is formed with a height h of about 0.7 μm. As shown in FIG. 2 A, the linear protrusion 12 has a trunk portion 12 a , a first branch portion 12 b , and second branch portions 12 c and 12 d . The trunk portion 12 a extends substantially in the middle of the pixel region substantially in parallel with the drain bus lines 8 , and the portion is formed across the first and the second sub-pixels 20 , 22 , and 24 . The first branch portion 12 b is formed in the region of the first sub-pixel 20 so as to extend substantially orthogonally to the trunk portion 12 a . The second branch portions 12 c and 12 d are formed in the regions of the sub-pixels 22 and 24 , respectively, so as to extend substantially orthogonally to the trunk portion 12 a . The trunk portion 12 a is disposed opposite to the position where the connection electrode 11 is formed. The trunk portion 12 a is formed so as to overlap the connection electrode 11 when viewed in a direction normal to the glass substrate 3 .
The first and the second branch portions 12 b , 12 c , and 12 d are formed so as to extend substantially in parallel with the gate bus line 6 across the drain bus lines 8 adjacent to each other. The first branch portion 12 b provided in the region of the first sub-pixel 20 is formed so as to overlap the storage capacitor bus line 14 when viewed in the direction normal to the glass substrate 3 . Any reduction in the aperture ratio can be prevented by disposing the trunk portion 12 a and the first branch portion 12 b in the pixel region in such a manner.
The first sub-pixel 20 is divided at the trunk portion 12 a , the first branch portion 12 b , and a peripheral part of the first pixel electrode 21 to provide four divisions 20 a , 20 b , 20 c , and 20 d . Similarly, when viewed in the direction normal to the glass substrate 3 , the second sub-pixel 22 is divided at the trunk portion 12 a , the second branch portion 12 c , and a peripheral part of the second pixel electrode 23 to provide four divisions 22 a , 22 b , 22 c , and 22 d . Similarly, when viewed in the direction normal to the glass substrate 3 , the second sub-pixel 24 is divided at the trunk portion 12 a , the second branch portion 12 d , and a peripheral part of the second pixel electrode 25 to provide four divisions 24 a , 24 b , 24 c , and 24 d.
When a voltage is applied between the first and the second pixel electrodes 21 , 23 and 25 and the common electrode 28 , the electric field applied to the liquid crystal composition 30 is distorted by the peripheral parts of the first and the second pixel electrodes 21 , 23 , and 25 and the linear protrusion 12 . The distortion of the electric field regulates the alignment of the liquid crystal molecules 32 in the vicinity of the peripheral parts of the first and the second pixel electrodes 21 , 23 , and 25 and the linear protrusion 12 . As a result, the liquid crystal molecules 32 are tilted in a different direction in each of the divisions 20 a to 20 d , the divisions 22 a to 22 d , and the divisions 24 a to 24 d . For example, in the section shown in FIG. 2B , the liquid crystal molecules 32 are tilted clockwise from the direction perpendicular to the TFT substrate 2 in the division 22 a and are tilted counterclockwise in the division 22 b . As thus described, the use of the MVA method allows the viewing angle characteristics of the liquid crystal display of the present embodiment to be improved.
At the first sub-pixel 20 , a liquid crystal capacitance Clc 1 is formed by the first pixel electrode 21 , the common electrode 28 , and the liquid crystal composition 30 sandwiched between the electrodes 21 and 28 . At the second sub-pixel 22 , a liquid crystal capacitance Clc 2 is formed by the second pixel electrode 23 , the common electrode 28 , and the liquid crystal composition 30 sandwiched between the electrodes 23 and 28 . The liquid crystal capacitance Clc 2 is connected to the control capacitance Cc 1 in series between the glass substrate 3 and the glass substrate 5 . Similarly, at the second sub-pixel 24 , a liquid crystal capacitance Clc 2 ′ is formed by the second pixel electrode 25 , the common electrode 28 , and the liquid crystal composition 30 sandwiched between the electrodes 25 and 28 . The liquid crystal capacitance Clc 2 ′ is connected to a control capacitance Cc 1 ′ in series between the glass substrate 3 and the glass substrate 5 .
When the TFT 10 is turned on, the source electrode 10 b and the connection electrode 11 bear the same potential as a gradation voltage V D applied to a drain bus line 8 , and the first pixel electrode 21 in electrical connection with them also bears the same potential as the gradation voltage V D . A voltage originating from a potential difference applied between the first pixel electrode 21 and the common electrode 28 is applied to the liquid crystal capacitance Clc 1 . For example, when the voltage applied to the common electrode 28 is 0 V, the voltage applied to the liquid crystal capacitance Clc 1 is equal to the gradation voltage V D (=V D −0V). On the other hand, a voltage obtained by capacitance-dividing the gradation voltage V D based on the ratio between the liquid crystal capacitance Clc 2 and the control capacitance Cc 1 is applied to the second pixel electrode 23 which is capacitively coupled to the connection electrode 11 . The voltage applied to the second pixel electrode 23 (represented by V) can be expressed as follows.
V=V D ×{Cc 1/( Clc 2+ Cc 1)} (2)
Similarly, a voltage obtained by capacitance-dividing the gradation voltage V D based on the ratio between the liquid crystal capacitance Clc 2 ′ and the control capacitance Cc 1 ′ is applied to the second pixel electrode 25 . The voltage applied to the second pixel electrode 25 (represented by V′) can be expressed as follows.
V′=V D ×{Cc 1′/( Clc 2′+ Cc 1′)} (3)
Since one pixel region can be driven by different voltages as thus described, the gradation/luminance characteristics of the liquid crystal display in an oblique direction can be improved. While the voltages V and V′ applied to the second pixel electrodes 23 and 25 may have the same value, three different gradation/luminance characteristics can be provided in the single pixel region at the same time when they are different voltage values. The viewing angle characteristics of the liquid crystal display can be further improved.
A method of manufacturing the liquid crystal display will now be described with reference to FIGS. 1 to 3B . FIGS. 3A and 3B are enlarged views of the second sub-pixel 22 taken in the direction normal to the glass substrate 3 . FIG. 3A shows a state of the same before the monomer is polymerized. FIG. 3B shows a state of the same after the monomer is polymerized. As shown in FIG. 2B , the alignment films (vertical alignment films) are printed and baked on the surfaces of the TFT substrate 2 and the opposite substrate 4 facing to each other. The substrates 2 and 4 are combined by applying a seal material to the periphery of one of the substrates. The liquid crystal composition 30 is then injected between the substrates which are thereafter cut and chamfered to obtain a liquid crystal display panel.
When a voltage is applied between the substrates 2 and 4 after the liquid crystal composition 30 is injected, as shown in FIG. 3A , the liquid crystal molecules 32 begin declining in a direction perpendicular to the linear protrusion 12 or the periphery of the second pixel electrode 23 . The periphery of the second pixel electrode 23 intersects with each of the trunk portion 12 a and the second branch portion 12 c at an angle of about 90°. The liquid crystal molecules 32 declining in respective directions collide with each other in the middle of the second sub-pixel 22 and finally settle at an angle of substantially 45° to the linear protrusion 12 or the periphery of the second pixel electrode 23 as shown in FIG. 3B .
When irradiated with ultraviolet light in this state, the diacrylate monomer mixed in the liquid crystal composition 30 is polymerized to fix the direction of alignment of the liquid crystal molecules 32 . When a voltage is applied between the substrates 2 and 4 after the monomer is polymerized (after the irradiation with ultraviolet light), the liquid crystal molecules 32 immediately incline in a direction substantially at an angle of 45° to the linear protrusion 12 or the periphery of the second pixel electrode 23 .
Next, polarizers 86 and 87 (see FIG. 1 ) are applied to outer surfaces of the substrates 2 and 4 , respectively, on a crossed Nicols basis such that their polarization axes will be parallel or perpendicular to the linear protrusion 12 or the periphery of the second pixel electrode 23 . Next, as shown in FIG. 1 , the gate bus line driving circuit 80 , the drain bus line driving circuit 82 , and the control circuit 84 are mounted on the liquid crystal display panel. The backlight unit 88 is then disposed on a side of the polarizer 87 that is opposite to the side thereof facing the TFT substrate 2 . Thus, a normally black liquid crystal display is completed.
As shown in FIG. 3B , the second sub pixel 22 has four divisions 22 a , 22 b , 22 c , and 22 d . The liquid crystal molecules 32 are tilted in different directions in the divisions 22 a , 22 b , 22 c , and 22 d , respectively. The liquid crystal molecules 32 in the division 22 b are tilted substantially in parallel with a direction which is at a counterclockwise rotation of about 45° from the second branch portion 12 c , the intersection between the trunk portion 12 a and the second branch portion 12 c being the axis of rotation. The liquid crystal molecules 32 in the division 22 a are tilted substantially in parallel with a direction which is a rotation of about 135° in the same direction. The liquid crystal molecules 32 in the division 22 c are tilted substantially in parallel with a direction which is a rotation of about 225° in the same direction. The liquid crystal molecules 32 in the division 22 d are tilted substantially in parallel with a direction which is at a rotation of about 315° in the same direction. Although not shown, the liquid crystal molecules 32 in the divisions 20 a to 20 d of the first sub-pixel 20 and the divisions 24 a to 24 d of the second sub-pixel 24 are also tilted in the same directions as in the divisions 22 a to 22 d of the second sub-pixel 22 , respectively. As a result, the liquid crystal display can be provided with the property of a wide viewing angle.
A description will now be made on the height h of the linear protrusion 12 with reference to FIGS. 4A to 4C . FIGS. 4A to 4C show the second sub-pixel 22 in a state in which the height h of the linear protrusion 12 is not an optimum value. FIG. 4A is an enlarged view of the second sub-pixel 22 taken in the direction normal to the glass substrate 3 . FIG. 4B shows a section of the second sub-pixel 22 . FIG. 4C shows a state of display of the second sub-pixel 22 photographed using a camera with a microscope. The connection electrode 11 is omitted in FIGS. 4A and 4B for easier understanding.
As shown in FIG. 4A , the trunk portion 12 a of the linear protrusion 12 is formed in the vicinity of a drain bus line 8 in parallel with the same. The second branch portion 12 c is substantially orthogonal to the trunk portion 12 a and is formed on the peripheral part of the second pixel electrode 23 which is opposite to the peripheral part of the electrode in the vicinity of the gate bus line 6 . When the linear protrusion 12 is formed with a height h of 0.35 μm which is smaller than the optimum height h of 0.7 μm, a force for regulating the alignment of the liquid crystal molecules 32 provided by an electric field at the linear protrusion 12 is smaller then an alignment regulating force provided by an electric field at the periphery of the second pixel region 23 . As a result, when a voltage is applied between the substrates 2 and 4 , some of the liquid crystal molecules 32 inline in a direction that is opposite to the direction in which the molecules are supposed to incline (the tilting direction of the five liquid crystal molecules 32 shown on the right side of FIG. 4B ) as shown in the ellipse in a broken line in FIG. 4B . Thus, the alignment of the liquid crystal molecules 32 is disturbed.
When the linear protrusion 12 is formed with a height h of 1.4 μm which is greater than the optimum height h of 0.7 μm, the force for regulating the alignment of the liquid crystal molecules 32 provided by the electric field at the linear protrusion 12 is greater than the alignment regulating force provided by the electric field at the periphery of the second pixel region 23 . As a result, the liquid crystal molecules 32 in the vicinity of the linear protrusion 12 cannot be tilted in a direction at an angle of 45° to the linear protrusion 12 as shown in the ellipses in broken lines in FIG. 4A . Thus, as shown in FIG. 4C , the second sub-pixel 22 has dark parts 34 which do not transmit light at the periphery thereof. Dark parts 34 are also generated because of a reduction in transmittance at the peripheral parts of the second pixel electrode 23 on the side thereof where the linear protrusion 12 is not formed. The display characteristics of the liquid crystal display are thus degraded both when the height h of the linear protrusion 12 is too great and when it is too small. Studies made by the present inventors have revealed that the optimum height h of the linear protrusion 12 is about 0.7 μm. The linear protrusion 12 of the liquid crystal display of the present embodiment is formed with a height of 0.7 μm.
As described above, one pixel region of the liquid crystal display can be driven by different voltages. In the liquid crystal display of the present embodiment, the capacitance values of the capacitances Clc 1 , Clc 2 , Cc 1 , Clc 2 ′, and Cc 1 ′ are set such that a threshold difference of 1 V is generated between the first sub-pixel 20 and the second sub-pixels 22 and 24 . The ratio of the area of the first sub-pixel 20 to the area of the second sub-pixels 22 and 24 is set at 4:6. The threshold difference and the area ratio are not limited to those values, and the gradation/luminance characteristics of the liquid crystal display can be set as desired by changing those values.
FIG. 5 is a graph showing the characteristics of luminance relative to input gradations (gradation/luminance characteristics) of the vertical alignment type liquid crystal display of the present embodiment. The abscissa axis represents input gradations (in gray scale), and the ordinate axis represents luminance (T/Twhite) normalized with reference to the luminance of display of white (TWhite). The curve in a solid line in the figure indicates gradation/luminance characteristics of the liquid crystal display of the present embodiment obtained in a direction square to the same. The curve connecting black square symbols in the figure indicates gradation/luminance characteristics of the liquid crystal display of the present embodiment obtained in a direction oblique to the same. The curve connecting black triangular symbols in the figure indicates gradation/luminance characteristics of a liquid crystal display according to the related art obtained in a direction oblique to the same.
As shown in FIG. 5 , the gradation/luminance characteristics of the liquid crystal display of the present embodiment in the oblique direction are significantly higher than the gradation/luminance characteristics in the related art. Referring to the gradation/luminance characteristics in the square direction, the luminance monotonously becomes higher as the input gradation becomes greater, and the curve indicating such characteristics opens upward. Referring to the gradation/luminance characteristics in the oblique direction in the related art, the luminance in the oblique direction is higher than the luminance in the square direction for gradations in the range from 0 to about 210, but the luminance in the oblique direction is lower than the luminance in the square direction for gradations of about 210 or more. The curve indicating such characteristics is a mixture of a part in which the curve greatly bulges upward and a part in which the curve bulges downward. As a result, when the display screen of the liquid crystal display according to the related art is viewed in the oblique direction, differences in luminance between input gradations are small. Thus, some gradations can be missed or spread, which can result in, for example, a change of a color of an image into a whitish color.
On the contrary, referring to the gradation/luminance characteristics of the liquid crystal display of the present embodiment in the direction oblique thereto, the luminance is higher than that the luminance in the square direction for all gradations. Unlike the curve indicating gradation/luminance characteristics according to the related art, the curve indicating such characteristics does not include a part in which the curve greatly bulges upward and a part in which the curve bulges downward. Therefore, there is no missing gradation or spreading gradation on the display screen of the liquid crystal display when viewed in a direction oblique thereto, and it is possible to prevent the color of an image from changing into a whitish color.
As shown in FIGS. 2A and 2B , the storage capacitor Cs of the liquid crystal display in the present embodiment is provided only at the first sub-pixel 20 having the first pixel electrode 21 electrically connected to the source electrode 10 b through the connection electrode 11 . The storage capacitor bus line 14 forming the storage capacitor Cs is disposed so as to extend substantially in the middle of the pixel region substantially in parallel with the gate bus line 6 . The storage capacitor Cs is formed in the region where the storage capacitor bus line 14 and the storage capacitor electrode 16 overlap. The storage capacitor electrode 16 and the connection electrode 11 may be formed integrally with each other and may be formed in a cross-like shape when viewed in the direction normal to the glass substrate 3 .
When a storage capacitor bus line is provided in parallel with the gate bus line 6 in each of the regions of the second sub-pixels 22 and 24 having the second pixel electrodes 23 and 25 capacitively coupled to the connection electrode 11 , a part of a light-transmitting area of the pixel region is obscured. The transmittance of the liquid crystal display is consequently reduced. For this reason, no storage capacitor bus line is provided in the regions of the liquid crystal display of the present embodiment where the second sub-pixels 22 and 24 are formed. For example, a storage capacitor electrode formed integrally with the connection electrode 11 may be provided in the regions where the second sub-pixels 22 and 24 are formed, and a storage capacitor bus line may be disposed opposite to the storage capacitor electrode to form a storage capacitor between them, although the transmittance of the liquid crystal display is slightly reduced.
As described above, in the liquid crystal display of the present embodiment, the first sub-pixel 20 and the second sub-pixels 22 and 24 , which can be driven by voltages different from one and the same gradation voltage V D , are provided in a single pixel region. The liquid crystal display can therefore be provided with improved gradation/luminance characteristics in a direction oblique thereto. Further, the pixel region has a simple structure in which each of the first and the second sub-pixels 20 , 22 , and 24 having a square shape is divided by the linear protrusion 12 into four divisions in the form of a matrix. Therefore, the first and the second sub-pixels 20 , 22 , and 24 can be easily disposed, and the ratio of the area of the first and the second sub-pixels 21 , 23 , and 25 to the area of the pixel region can be made greater than the ratio of the area of the pixel electrodes 121 and 123 of the liquid crystal display according to the related art. As a result, the aperture ratio of the liquid crystal display of the present embodiment can be made higher than that of a liquid crystal display according to the related art to achieve higher luminance of the display screen.
Second Embodiment
A liquid crystal display according to a second embodiment of the invention will now be described with reference to FIGS. 6 to 9 . The general configuration of the liquid crystal display of the present embodiment will not be described because it is similar to that of the liquid crystal display of the first embodiment. FIG. 6 shows a configuration of one of a plurality of pixels in the form of a matrix of the liquid crystal display of the present embodiment as viewed in a direction normal to a glass substrate 3 . As shown in FIG. 6 , the liquid crystal display of the present embodiment is characterized in that it includes a first pixel electrode 21 having a slit portion 21 b formed in a direction substantially in parallel with the declining direction of a liquid crystal material and second pixel electrodes 23 and 25 having respective slit portions 23 b and 25 b providing the same effect as the slit portion 21 b at the periphery thereof.
The first pixel electrode 21 includes a solid portion 21 a disposed in the middle thereof and the slit portion 21 b which is disposed around the solid portion 21 a and which is formed like comb teeth. The slit portion 21 b has a plurality of linear electrode parts 21 c extending from the solid portion 21 a and cut-out parts 21 d formed between adjoining linear electrode parts 21 c . The linear electrode parts 21 c extend in four different directions in divisions 20 a to 20 d of the pixel, respectively. In FIG. 6 , the linear electrode parts 21 c in the division 20 a extend upward and to the left, and the linear electrode parts 21 c in the division 20 b extend upward and to the right. The linear electrode parts 21 c in the division 20 c extend downward and to the left, and the linear electrode parts 21 c in the division 20 d extend downward and to the right. The liquid crystal molecules are tilted in parallel with the extending directions of the linear electrode parts 21 c and toward the solid portion 21 a . Thus, the alignment of the liquid crystal composition is divided in four directions in the first sub-pixel 20 .
Similarly, the second pixel electrode 23 includes a solid portion 23 a disposed in the middle thereof and the slit portion 23 b which is disposed around the solid portion 23 a and which is formed like comb teeth. The slit portion 23 b has a plurality of linear electrode parts 23 c extending from the solid portion 23 a and cut-out parts 23 d formed between adjoining linear electrode parts 23 c . Similarly, the second pixel electrode 25 includes a solid portion 25 a disposed in the middle thereof and the slit portion 25 b which is disposed around the solid portion 25 a and which is formed like comb teeth. The slit portion 25 b has a plurality of linear electrode parts 25 c extending from the solid portion 25 a and cut-out parts 25 d formed between adjoining linear electrode parts 25 c . The liquid crystal molecules are tilted in parallel with the extending directions of the linear electrode parts 23 c and 25 c and toward the solid portions 23 a and 25 a . Thus, the alignment of the liquid crystal composition is divided in four directions in each of the second sub-pixels 22 and 24 .
In the liquid crystal display of the first embodiment, the divisions 20 a to 20 d , 22 a to 22 d , and 24 a to 24 d are defined by the linear protrusions 12 and the peripheries of the first and the second pixel electrodes 21 , 23 , and 25 . Since electric lines of force are sharply bent in the vicinity of the peripheries of the first and the second pixel electrodes 21 , 23 , and 25 , a strong force acts to incline the liquid crystal molecules in directions at an angle of 90° to the extending directions of the peripheries. Therefore, the liquid crystal molecules cannot be directed at an angle of 45° to the extending directions of the peripheries, and the first and the second sub-pixels 20 , 22 , and 24 will have arcuate regions where transmittance is low (see FIG. 4C ). The arcuate shapes have greater areas to reduce the transmittance of the liquid crystal display, the longer the peripheries of the first and the second pixel electrodes 21 , 23 , and 25 .
In the liquid crystal display of the first embodiment, the liquid crystal composition 30 including a liquid crystal material and a polymer is used to prevent the generation of such arcuate regions. In the liquid crystal display of the present embodiment, as shown in FIG. 6 , the first and the second pixel electrodes 21 , 23 , and 25 are formed with the respective slit portions 21 b , 23 b , and 25 b to enhance an alignment regulating force for aligning the liquid crystal molecules in the directions at 45° to the extending directions of the peripheries. The slit portions 21 b , 23 b , and 25 b are formed at a pitch P of 7 μm. The cut-out parts 21 d , 23 d , and 25 d are formed with a width d of 3 μm and a length L of 7 μm. When the length L of the cut-out parts 21 d , 23 d , and 25 d is too great, the width d can fluctuate due to slight fluctuations in processing of the parts. The liquid crystal display panel may consequently have minute luminance irregularities which can reduce display quality. For this reason, it is desirable to set the area of the slit portions 21 b , 23 b , and 25 b within a range below one half of the total area of the first and the second pixel electrodes 21 , 23 , and 25 . The cut-out parts 21 d , 23 d , and 25 d are preferably formed to have a width d in the range from 2 μm to 5 μm, inclusive, and a length L in the range from 3 μm to 10 μm, inclusive.
In the liquid crystal display of the present embodiment, since the first and the second pixel electrodes 21 , 23 , and 25 are formed with the slit portions 21 b , 23 b , and 25 b , substantially no arcuate region of low transmittance is generated. As a result, the transmittance of the liquid crystal display of the present embodiment is 15% higher than that of the liquid crystal display of the first embodiment, and higher luminance is therefore achieved on the display screen of the same.
The force for regulating the alignment of liquid crystal molecules is enhanced by the slit portions 21 b , 23 b , and 25 b . The liquid crystal display therefore remains advantageous even when a point-like protrusion is provided, for example, at each of intersections between the trunk portion 12 a and the first and the second branch portions 12 b , 12 c , and 12 d instead of the linear protrusion 12 .
A modification of the liquid crystal display of the present embodiment will now be described with reference to FIGS. 7 to 8B . FIG. 7 shows a configuration of one pixel of a liquid crystal display according to the present modification as viewed in a direction normal to the glass substrate 3 . The liquid crystal display of the present modification is characterized in that the slit portions 21 b , 23 b , and 25 b are formed at least in a part of the peripheries of the first and the second pixel electrodes 21 , 23 , and 25 . As shown in FIG. 7 , in the liquid crystal display of the present modification, the slit portions 21 b , 23 b , and 25 b are formed only at the peripheries of the first and the second pixel electrodes 21 , 23 , and 25 in the vicinity of the gate bus line 6 and the drain bus lines 8 . The slit portions 21 b , 23 b , and 25 b are not formed at the peripheral regions where the first pixel electrode 21 adjoins the second pixel electrodes 23 and 25 .
FIGS. 8A and 8B show a section of the pixel region. FIG. 8A shows a state in which a relatively large gap is provided between the first and the second pixel electrodes 21 and 23 . FIG. 8B shows a state in which a relatively small gap is provided between the first and the second pixel electrodes 21 and 23 . FIGS. 8A and 8B omit the linear protrusion 12 , the liquid crystal molecules 32 and the like for easier understanding. As shown in FIGS. 8A and 8B , electric lines of force indicated by broken lines in the figure are more weakly bent, the smaller the gap between the first and the second pixel electrodes 21 and 23 . As a result, the force for inclining the liquid crystal molecules in a direction at 90° to the extending directions of the peripheries of the first and the second pixel electrodes 21 and 23 becomes small. Therefore, it is easier to finally direct the liquid crystal molecules at 45° to the extending directions of the first and the second pixel electrodes 21 and 23 , the smaller the gap between the first and the second pixel electrodes 21 and 23 . Thus, substantially no arcuate dark part will be generated at the first and the second sub-pixels 20 , 22 , and 24 .
In the liquid crystal display of the present modification, the gaps that the first pixel electrode 21 forms with the second pixel electrodes 23 and 25 are 4 μm. Thus, the slit portions 21 b , 23 b , and 25 b are not required at the peripheral regions where the first pixel electrode 21 adjoins the second pixel electrodes 23 and 25 , which reduces the risk of generation of luminance irregularities attributable to slight process fluctuations. Therefore, the liquid crystal display of the present modification provides the same advantage as that of the liquid crystal display of the embodiment.
Another modification of the liquid crystal display of the present embodiment will now be described with reference to FIG. 9 . FIG. 9 shows a configuration of one pixel of a liquid crystal display according to the present modification as viewed in a direction normal to the glass substrate 3 . The liquid crystal display of the present modification is characterized in that the slit portions 21 b , 23 b , and 25 b are formed in at least a part of the periphery of at least either the first pixel electrode 21 or the second pixel electrodes 23 and 25 . As shown in FIG. 9 , in the liquid crystal display of the present modification, the slit portions 23 b and 25 b are formed only at the peripheries of the second pixel electrodes 23 and 25 in the vicinity of the gate bus line 6 . Therefore, the slit portion 21 b is not formed at the first pixel electrode 21 .
In the liquid crystal display of the present modification, the gaps between the first and the second pixel electrodes 21 , 23 , and 25 are formed smaller than the gaps in the above-described modification. Further, in the liquid crystal display of the present modification, the gaps between the first and the second pixel electrodes 21 , 23 , and 25 and the drain bus lines 8 are formed smaller than those gaps in the above-described modification. Thus, a conductive material is disposed close to the peripheries of the first and second pixel electrodes 21 , 23 , and 25 . When diacrylate monomer is polymerized, the voltages at the first pixel electrode 21 and the drain bus lines 8 are made substantially equal to each other. Thus, electric lines of force extending from the peripheries of the first and the second pixel electrodes 21 , 23 , and 25 toward the common electrode 28 are more weakly bent except in the peripheral regions of the second pixel electrodes 23 and 25 adjacent to the drain bus line 6 (see FIGS. 8A and 8B ). It is therefore easier to direct the liquid crystal molecules at 45° to the extending directions of the first and the second pixel electrodes 21 , 23 , and 25 , and the generation of arcuate dark parts can be prevented at the first and the second sub-pixels 20 , 22 , and 24 .
Third Embodiment
A liquid crystal display according to a third embodiment of the invention will now be described with reference to FIGS. 10A and 10B . The general configuration of the liquid crystal display of the present embodiment will not be described because it is similar to that of the liquid crystal display of the first embodiment. FIGS. 10A and 10B show a configuration of one pixel of the liquid crystal display of the present embodiment. FIG. 10A shows a configuration of one of a plurality of pixels in the form of a matrix as viewed in a direction normal to a glass substrate 3 . FIG. 10B shows a section taken along the imaginary line A-A shown in FIG. 10A . As shown in FIGS. 10A and 10B , the liquid crystal display of the present embodiment is characterized in that it include a linear protrusion (an alignment regulating structure) 12 formed by patterning a transparent dielectric body provided under first and second pixel electrodes 21 , 23 , and 25 such that it protrudes from a glass substrate 3 rather than an opposite substrate 4 .
In the case of the liquid crystal displays in the first and the second embodiments, the linear protrusion 12 formed on the opposite substrate 4 must be located in the middle of the pixel region in advance in consideration to possible miss-registration between the TFT substrate 2 and the opposite substrate 4 . For example, when the linear protrusion 12 is disposed directly above a peripheral part of the second pixel electrode 23 as shown in FIGS. 4A and 4B , the top of the linear protrusion 12 must be located on the right side of the peripheral part of the second pixel electrode 23 . When the top of the linear protrusion 12 is located on the left side of the peripheral part of the second pixel electrode 23 , the result is the same as a state in which the linear protrusion 12 is formed with a small height h, and the alignment of the liquid crystal molecules are therefore disturbed. However, when the linear protrusion 12 is formed in the middle of the pixel region, the aperture ratio of the liquid crystal display will be substantially reduced.
Under the circumstance, in the liquid crystal display of the present embodiment, the linear protrusion 12 is formed on the TFT substrate 2 as shown in FIGS. 10A and 10B . The first and the second pixel electrodes 21 , 23 , and 25 are formed in an overlapping relationship so as to cover at least the top of the linear protrusion 12 . As shown in FIG. 10B , the slope of the surface of the second pixel electrode 23 on a trunk portion 12 a of the linear protrusion 12 is leveled by an alignment film 36 . Therefore, an angle θ 1 defined by a line normal to the surface of the alignment film 36 and a line normal to the opposite substrate 4 in FIG. 10B is smaller than an angle θ 2 defined by the direction of an electric line of force a penetrating through the surface of the alignment film 36 and the line normal to the opposite substrate 4 . As a result, when a voltage is applied between the substrates 2 and 4 , the direction of alignment of liquid crystal molecules 32 is different from the direction of the electric line of force α, and the liquid crystal molecules 32 incline toward the trunk portion 12 a of the linear protrusion 12 . In the section shown in FIG. 10B , the liquid crystal molecules 32 are tilted from the direction perpendicular to the TFT substrate 2 clockwise in a division 22 a and are tiled counterclockwise in a division 22 b . Since the liquid crystal molecules 32 can be tilted in a different direction in each of the divisions 22 a and 22 b as thus described, the liquid crystal display of the present embodiment can provide the same advantage as that of the liquid crystal displays of the above embodiments. | The invention relates to liquid crystal displays used in television receivers and display sections of electronic apparatus and, more particularly, to a liquid crystal display in which a polymeric material included in a liquid crystal material is polymerized to impart a pre-tilt angle to the liquid crystal material. The invention provides a liquid crystal display in which gradation/luminance characteristics in an oblique direction are improved and in which reduction in luminance is suppressed. The liquid crystal display includes a TFT substrate and an opposite substrate provided opposite to each other and a liquid crystal composition including a liquid crystal material and a polymer sealed between the substrates. A pixel region of the liquid crystal display has a first sub-pixel formed with a first pixel electrode electrically connected to a source electrode of a TFT through a connection electrode and two second sub-pixels formed with two second pixel electrodes which sandwich an insulation film with the connection electrode to form a control capacitance and which are separated from the first pixel electrode. | 6 |
BACKGROUND
[0001] 1. Field of Invention
[0002] The invention relates generally to equipment for controlling the production of wellbore fluid. More specifically, the invention relates to a module removable from a production tree and having passages that register with passages in the production tree.
[0003] 2. Description of Prior Art
[0004] Wellheads used in the production of hydrocarbons extracted from subterranean formations typically comprise a wellhead assembly attached at the upper end of a wellbore formed into a hydrocarbon producing formation. An annular wellhead housing typically makes up the outermost member where wellhead assemblies connect to a wellbore. A production tree usually connects to the upper end of a wellhead assembly for controlling flow in and out of the wellbore and allowing access into the wellbore. Support hangers are generally included within the wellhead housing for suspending production tubing and casing into the wellbore. The casing lines the wellbore, thereby isolating the wellbore from the surrounding formation. The tubing typically lies concentric within the casing and provides a conduit therein for producing the hydrocarbons entrained within the formation.
[0005] Production trees typically include flow lines that connect with other lines outside of the wellhead assembly for porting fluid produced from the wellbore to a location for processing the fluid. Production trees also usually contain passages that also connect to a line is external to the production tree. Typically the passages are used for accessing annuli between concentric wellbore tubulars. The passages are also often used to provide a return path for fluid injected within a tubular (e.g. tubing or casing) that exits the bottom end of the tubular and flows up the wellbore in an annulus around the tubular. Generally, valves regulate flow through the lines and passages, which are included inline with the lines and passages. Thus removing the production tree for service or other reasons usually requires a separate step of disconnecting the lines and passages internal to the tree from the lines and passages external to the tree.
SUMMARY OF THE INVENTION
[0006] Disclosed herein is an example of a wellhead assembly having a production module removably mountable on a production tree and a method of wellbore operations. An example embodiment of a wellhead assembly includes a tubular wellhead housing with a tubing hanger landed within, where the lower end of the tubing hanger is attachable to a tubing string. A production module is included having a mounting bore that extends through the production module; a flow passage projects from the mounting bore through the production module. A production tree is included that selectively inserts into the mounting bore, the production tree mounts on an upper end of the wellhead housing. The production tree includes an axial bore that registers with a bore axially through the tubing hanger. A port is included in the production tree that intersects the axial bore and also intersects an outer surface of the production tree. When the production tree inserts into the mounting bore and the production module lands on the production tree, the port registers with the flow passage. A production spool may optionally be included that couples to the production tree, and where the production spool registers with a production line in the production module when the production module is landed on the production tree. In an example, the port is above the upper end of the tubing hanger. Optionally, the port includes a production port for the flow of production fluid. In an example embodiment, the port has an auxiliary line in communication with an axial passage in the tubing hanger that communicates with an annular space between the tubing hanger and the wellhead housing. In an optional embodiment, the wellhead assembly further includes a selectively removable actuator disposed on the production module for actuating a valve disposed in the production module.
[0007] Also included herein is a method of wellbore operations. In an example embodiment the method includes providing a production module that has an axial mounting bore and a passage that intersects the mounting bore. The production module is positioned on a production tree that mounts on a wellbore and that has a port intersecting an outer surface of the production tree. The method further includes inserting the production tree into the mounting bore to register the passage with the port thereby landing the production module on the production tree. Optionally, the method also includes coupling a production spool having a production stab with the production tree so that the production stab registers with a production flow line formed in the production module when the production module is landed on the production tree. In an alternative, the method further includes producing fluid from a wellbore in communication with the production tree and removing the production module from the production tree. In an example, closing a single valve in the production tree isolates the production module from communication with the wellbore. In an example embodiment, a production spool couples with a well flow jumper and the production spool includes a production stab; where the production spool is supported by being coupled with the production tree, and the production stab registers with a production flow line formed in the production module when the production module is landed on the production tree, so that when the production module is removed from the production tree, the production spool remains coupled with the well flow jumper. Optionally, the production tree mounts on a wellhead housing in which a tubing hanger is landed. An actuator may be coupled with the production tree that mechanically couples with a valve provided with the production module, the method can further include operating the valve with the actuator. Fluids may optionally be produced from the wellbore through the production module and actuators mounted on the production module can be removed.
[0008] Also disclosed herein is an example embodiment of a wellhead assembly, that in an example embodiment includes a tubular wellhead housing, a tubing hanger landed in the wellhead housing with a lower end attachable to a tubing string, and a production module. The production module includes an axial mounting bore and a flow passage projecting from the mounting bore. A production tree is included that selectively inserts into the mounting bore; the production tree mounts on an upper end of the wellhead housing. An axial bore in the production tree registers with a tubing hanger bore, where the tubing hanger bore is axially formed through the tubing hanger. Also included is a production passage in the production tree extending between the axial bore and an outer surface of the production tree. A production line is provided in the production module with an entrance that selectively couples with the production passage when the production module is landed onto the production tree. A production stab selectively communicates with an exit of the production line fluid, so that when the production module is landed on the production tree, the production passage is in fluid communication with a production fluid jumper that is connectable to an exit of the production stab. An auxiliary passage may optionally be included in the production module. In an example embodiment, the auxiliary passage engages an auxiliary stab when the production module is landed on the production tree for communicating the auxiliary passage with a tubing annulus.
BRIEF DESCRIPTION OF DRAWINGS
[0009] Some of the features and benefits of the present invention having been stated, others will become apparent as the description proceeds when taken in conjunction with the accompanying drawings, in which:
[0010] FIG. 1 is a side sectional view of a production module coupled onto a production tree in accordance with the present invention.
[0011] FIG. 2 is a side perspective view of an example of engaging the production module and production tree of FIG. 1 .
[0012] FIG. 3 is a side perspective view of an alternate embodiment of the production module and production tree of FIG. 1 in accordance with the present invention.
[0013] FIG. 4 is a side perspective view of an example of recovering a production module from a subsea production tree in accordance with the present invention.
[0014] While the invention will be described in connection with the preferred embodiments, it will be understood that it is not intended to limit the invention to that embodiment. On the contrary, it is intended to cover all alternatives, modifications, and equivalents, as may be included within the spirit and scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION OF INVENTION
[0015] The method and system of the present disclosure will now be described more fully hereinafter with reference to the accompanying drawings in which embodiments are shown. The method and system of the present disclosure may be in many different forms and should not be construed as limited to the illustrated embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey its scope to those skilled in the art. Like numbers refer to like elements throughout.
[0016] It is to be further understood that the scope of the present disclosure is not limited to the exact details of construction, operation, exact materials, or embodiments shown and described, as modifications and equivalents will be apparent to one skilled in the art. In the drawings and specification, there have been disclosed illustrative embodiments and, although specific terms are employed, they are used in a generic and descriptive sense only and not for the purpose of limitation. Accordingly, the improvements herein described are therefore to be limited only by the scope of the appended claims.
[0017] Shown in FIG. 1 is a side sectional view of an example embodiment of a wellhead assembly 20 that includes a wellhead housing 22 with its lower end mounted on a surface 23 above a formation. In the example of FIG. 1 , the surface 23 may be a sea floor. An annular casing hanger 24 is landed within the wellhead housing 22 and shown having a string of casing 26 connected on its lower end that depends downward into a wellbore. FIG. 1 further illustrates a tubing hanger 28 shown landed on an inner surface of the wellhead housing 22 and above the upper end of the casing hanger 24 . A tubing string 30 attaches to a lower end of the tubing hanger 28 and projects downward concentrically within the casing hanger 24 and casing 26 . An annulus 32 is defined between the tubing 30 , wellhead housing 22 , casing hanger 24 , and casing 26 .
[0018] Mounted on an upper end of the wellhead housing 22 is a production tree 34 that is attached to the wellhead housing 22 by a clamp 36 . Landed on the production tree 34 is a production module 38 that is shown having a bore 40 axially formed through the production module 38 and in which the upper end of the production tree 34 is inserted. Within the production module 38 is an auxiliary line 42 shown extending laterally outward from the bore 40 and intersected by another auxiliary line 44 . The production module 38 is positioned on the production tree 34 so that auxiliary line 42 registers with a vent line 46 shown formed axially through the production tree 34 . A valve 48 within the vent line 46 is provided that may be used for regulating or controlling flow through the vent line 46 . Similarly, within the auxiliary lines 42 , 44 are valves 50 , 52 for controlling flow through the auxiliary lines 42 , 44 . An axial passage 54 extends through the tubing hanger 28 , thereby providing fluid communication from the tubing annulus 32 and into the vent 46 . Thus, communication to the tubing annulus 32 may be obtained via the auxiliary lines 42 , 44 and selective control of the valves 48 , 50 , 52 .
[0019] Also shown formed through the production nodule 38 and intersecting the bore 40 is a production line 56 that registers with a production port 58 when the production module 38 is landed on the production tree 34 . A valve 60 is shown disposed within the production port 58 for controlling flow or communication through the production port 58 . A bypass line 62 intersects the production line 56 within the production module 38 . Valves 64 , 66 respectively provided in the production line 56 and bypass line 62 may be actuated for selectively diverting flow through the production line 56 or bypass line 62 . Also provided in the bypass line 62 is a choke 68 that restricts the cross-sectional area in the bypass line 62 for reducing pressure of the fluid flowing through the bypass line 62 into a pressure more manageable for production of fluid from the wellbore.
[0020] Still referring to FIG. 1 , an annular production stab 70 is shown providing coupling between the tubing hanger 28 and lower end of the production tree 34 for providing seamless flow from within the wellbore and up to the production port 58 . The tubing 30 , tubing hanger 28 , production stab 70 , and inner bore of the production tree 34 are substantially coaxial and define a main production bore 71 through the wellhead assembly 20 . A production main valve 72 is shown set in the main production bore 71 in the portion within the production tree 34 . The production main valve 72 may be selectively opened or closed to regulate communication to the wellbore through the main production bore 71 . Proximate the upper end of the production tree 34 is a swab valve 74 also set within the main production bore 71 and that may be opened or closed to allow access to within the main bore 71 from the upper end of the production tree 34 .
[0021] An optional sensor 76 is shown coupled on an outer surface of the production module 38 and in communication with the production tree 34 . A lateral passage 80 formed through the production module 38 provides a path for the line 78 . Similarly, an actuator 82 is shown mounted on the production module 38 and coupled to a control line 84 that is set within a passage 86 . The passage 86 enables path for the control line 84 to connect to actuators or devices within the production tree 34 and/or production module 38 .
[0022] Referring now to FIG. 2 , a side perspective view is shown of an example embodiment of landing the production module 38 of FIG. 1 onto the production tree 34 . In this example, a bridle assembly 88 is coupled onto an upper end of the production module 38 and suspended by a line 90 . By lowering the production module 38 and aligning the bore 40 in the production module 38 with the upper end of the production tree 34 , the production tree 34 is inserted into the bore 40 as the production module 38 is lowered thereon. As the bore 40 extends through the production module 38 , access to the main production bore 71 in the production tree 34 is unimpeded by the production bore 38 .
[0023] An alternate embodiment of the wellhead assembly 20 A is shown in a side perspective view in FIG. 3 wherein the production module 38 A is set on the production tree 34 . In the example of FIG. 3 , a production spool stab 92 is shown as part of a production spool 94 . The production spool 94 is supported by a coupling 95 attaching the production spool 94 to the production tree 34 . Valves 96 , 98 are shown disposed within the production spool 98 for selectively controlling flow to lines 100 , 102 that attach to the production spool 94 . The lines 100 , 102 may provide a pathway for fluids produced from the wellbore to production facilities (not shown) that process or refine the produced fluids. In the example of FIG. 3 , the production line 56 A has an exit shown intersecting a lower end of the production module 38 A. When the production module 38 A is landed on the production tree 34 the production spool stab 92 inserts into the exit of the production line 56 A. As such, fluid communication between the production spool 92 and main bore 71 is established via the production port 58 and production flow line 56 A through the production spool stab 92 .
[0024] Also optionally provided in the example of FIG. 3 is an optional choke actuator 104 shown mounted to the production tree via coupling 105 . Mechanical linkages 106 , 108 extend from the choke actuator 104 to valves 64 , 66 for regulating flow through the production flow line 56 A and/or bypass line 62 in the production module 38 A. Thus, by orienting the production module 38 A as it lands on the production tree 34 , communication can be established between the production flow line 56 A and production spool stab 92 , as well as automatic coupling of the choke actuator 104 and mechanical linkages 106 , 108 for controlling flow through the production flow line 56 A.
[0025] Referring now to FIG. 4 , in an example of operation the production module 38 is shown being removed from the production tree 34 , such as for maintenance or other reasons. An advantage of the example shown is that the connectivity to the jumper flow lines 100 , 102 may be maintained as the module 38 is removed from the production tree 34 . In this example, only the production main valve 72 is required to be closed in order to isolate flow from the wellbore for allowing removal of the production module 38 . Similar to the production spool 94 is an auxiliary spool 110 mounted to the production tree 34 and having an auxiliary stab 112 for automatic coupling with auxiliary line 42 A as the production module 38 is landed onto the production tree 34 . Further, in the example of FIG. 4 , a work boat 114 is used for raising and lowering the line 94 removal and/or landing of the production module 38 .
[0026] The present invention described herein, therefore, is well adapted to carry out the objects and attain the ends and advantages mentioned, as well as others inherent therein. While a presently preferred embodiment of the invention has been given for purposes of disclosure, numerous changes exist in the details of procedures for accomplishing the desired results. These and other similar modifications will readily suggest themselves to those skilled in the art, and are intended to be encompassed within the spirit of the present invention disclosed herein and the scope of the appended claims. | A wellhead assembly having a production module that includes valves, modules, and passages and mounts onto a production tree. As the production module lands onto the production tree, flow passages in the production tree register with corresponding flow passages in the module. A production spool has an exit connected to a production flow jumper. The production spool can be supported by coupling to the production tree and has a stab that connects to a production flow passage when the production module is landed on the production tree. The production module can be removed from the production tree without disturbing the connection between the production spool and the production flow jumper. | 4 |
FIELD OF THE INVENTION
This invention pertains to light addressable flat panel display devices. More specifically, the present invention is directed to a light addressable electrochromic display panel.
BACKGROUND OF THE INVENTION
Electrochromic materials are substances which change color under electrical stimulation. Electrochromic material is one color in its reduced state and another color in its oxidized state. Most electrochromic materials change color through a redox reaction that is driven by electric current flowing across an electrolyte --electrochrome interface.
Representative reaction mechanisms for redox electrochromic materials include those for Prussian Blue (ferric ferrocyanide), V. D. Neff, J. Electrochem. Soc., 125, 886 (1978), lutetium diphthalocyanine [Margie M. Nicholson, Ind. Eng. Chem. Prod. Res. Dev. 21, 261 (1982)]; viologens [B. Reichman, Fu-Ren F. Fan, and A.J. Bard, J. Electrochem. Soc., 127, 333 (1980)], tungsten oxides [B. Reichman and A.J. Bard, J. Electrochem. Soc., 126, 583 (1979)], and others.
Several authors have mentioned possible display applications for electronically addressable systems involving electrochromic material on a conductive substrate [Margie M. Nicholson, Ind. Eng. Chem. Prod. Res. Dev. 21, 261 (1982)]; e.g., electronically addressable electrochromic displays using tungsten oxides have been suggested for timepieces, according to some researchers (Id. at 265). The major problem with fabrication of these displays, however, was the complexity of matrix addressing systems necessary to achieve the flexibility required for a plurality of displays.
The photoelectrochromic effect of semiconductor--metallic ion solution interfaces was observed by researchers [T. Inoue, A. Fujishima and K. Honda, Chem. Lett., 11, 1197 (1978)]. In these metallic ion systems, the metals are deposited on the semiconductor electrode from the solution by a redox mechanism under a proper electrical bias by irradiation at an energy level above the bandgap of the semiconductor. The radiation creates charge carriers in the semiconductor that drive the redox reaction at the interface. When the bias on the electrode is reversed, the redox reaction is reversed and the metal returns to solution. Thus, the semiconductor electrode undergoes a photoelectrochromic effect because the precipitated metal covering the electrode appears as a change in the color of the electrode.
A similar photoelectrochromic effect was observed for a viologen solution semiconductor interface (B. Reichman, Fu-Ren F. Fan, and A. J. Bard, J. Electrochem. Soc., 127, 333 (1980). Using a p-GaAs electrode in a solution of heptyl viologen and bromide ions, the deposition of heptyl viologen bromide on the electrode through a redox reaction driven by photo generated charge carriers caused a color change to appear on the electrode. The author suggested that this photoelectrochromic system might have display applications if a laser raster system could be developed to control and drive the color changes. It was also suggested that electrochromic viologen polymer films formed on a p-type semiconductor electrode could be used in photoelectrochromic displays in a like manner to the viologen solution system [H. D. Abruna and A. J. Bard, J. Am. Chem. Soc., 103, 6398 (1981)]. However, these polymer films degraded quickly and were limited to use on p-type semiconductors. Further, a suitable matrix addressing system has not, so far as is known, been developed.
SUMMARY OF THE INVENTION
Going beyond those technologies, the present invention is directed to a device for creating a photoelectrochromic display with an electrochromic material united to an n-type semiconductor electrode. In accordance with the present invention, an immobilized film of electrochromic solid is formed on a translucent semiconductor electrode. The electrochromic solid is thereby adapted into a light addressable display panel which overcomes the problems of stability, durability and addressing common to the prior art. The user of the present invention may write on the panel using a light pen or other light source. The image made by the user remains on the panel until the user switches the electrical bias of the panel to an opposite state causing the image to erase.
The light addressable display panel of the present invention includes a translucent semiconductor electrode with an electrochromic solid formed in a thin film on one surface of the semiconductor, an electrolyte suitable for interacting with the electrochromic solid, and a counter-electrode in contact with the electrolyte, and a switched biasing circuit to selectively provide biasing voltage between the electrode and counter electrode. Switching between the semiconductor electrode and the counter electrode is provided to selectively bias the semiconductor electrode to a positive, negative or open circuit state relative to the counter-electrode which places the panel in the write, erase or neutral, i.e., hold, mode respectively. The particular arrangement of these components as described herein provide a display panel having superior display characteristics which may be readily adapted to perform a number of display functions.
Further flexibility of the display characteristics is obtained in another embodiment of the present invention which uses a light addressable panel constructed of translucent materials over an electrically addressable electrochromic panel. In this arrangement, the background color for the display panel which overlays the translucent light addressable panel is controlled by the electrically addressable panel and images are formed on the front light addressable panel in response to a light pen or other concentrated light source directed by the user.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of a first display according to the present invention, with the thickness of the layers greatly exaggerated and showing the control circuits schematically.
FIG. 2 is a cross-sectional view of an alternate display according to the present invention, again with the thickness of the layers greatly exaggerated.
FIG. 3 is a cross-sectional view of yet another alternate display device according to the present invention, showing the arrangement of the electrodes in columns and rows, again with the thickness of the layers greatly exaggerated.
FIG. 4 is a schematic drawing showing the configuration of the matrix address system with the strips on the front panel shown in solid lines and the strips on the back panel shown in dashed lines.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In the drawings, the letter D designates generally a photoelectrochromic display according to the present invention. Display D includes a display face 65 that may be written on using a concentrated light source R, such as a fiber optic laser pen. Images formed by the user on the display D may be stored on the display face 65 or erased in response to a single control switch.
Referring to FIG. 1, display D includes a translucent front panel 10 which defines the display face 65. Translucent panel 10 may be formed of glass, quartz, or synthetic resins. Translucent panel 10 is mounted to enclosure 70. Enclosure 70 includes an insulating back panel 5, and defines an interior cavity 75 between panel 10 and insulating panel 5. Enclosure 70 and the panel 5 may be formed of any suitable chemically inert insulation material, such as glass or synthetic resins, strong enough to provide structural support for the display D.
A semiconductor electrode S, which includes a conductive layer 15 and semiconductive layer 20 formed on the conductive layer 15, is mounted within enclosure 70 spaced below and parallel to panel 10 (FIG. 1). Semiconductive layer 20 may be either n-type or p-type, but in the preferred embodiment, layer 20 is formed of n-type semiconductor materials which provide superior display characteristics and are more easily applied to electrode S. In this configuration, when light at an energy level above the band gap energy of the semiconductive layer 20 emitted from a light source R passes through translucent panel 10 charge carriers are generated in the semiconductor electrode S causing the photoelectrochromic effect described below.
It has been discovered that using a semiconductive layer 20 formed of n-type titanium dioxide provides superior display results. A superior electrode S is formed by coating a titanium or tin oxide conductive layer 15 with titanium dioxide. Preferably, semiconductor electrode S is in the form of a panel that covers the entire display face 65 inside the translucent front panel 10.
In the preferred embodiment of electrode S (FIG. 1), a translucent conductive layer 15 is formed on the posterior surface 80 of translucent front panel 10. Similarly, a translucent semiconductive layer 20 is formed on the posterior surface 81 of conductive layer 15. For example, a glass front panel 10 having a conductive layer 15 formed of a translucent thin film of tin dioxide on its posterior surface 80 has been found to provide excellent display characteristics. Glass having one surface coated with tin dioxide and suitable for this purpose is commercially available through Corning Glass Co. A titanium dioxide semiconductive layer 20 may be formed on the tin dioxide surface of the coated glass by vacuum deposition or other known processes.
Alternatively semiconductor electrode S may be formed on a quartz translucent front panel 10 having a titanium metal conductive layer 15, and a titanium dioxide semiconductive layer 20. In this embodiment titanium is vacuum deposited in a thin film on the inside surface 80 of quartz translucent front panel 10. Thereafter, the titanium coated quartz is heated in pure oxygen to form a titanium dioxide film 20 on the exposed surface of the titanium layer 15. The titanium and titanium dioxide layers thus formed are thin and translucent yet thick enough to provide efficient generation of charge carriers in response to radiation striking semiconductor electrode S.
In the preferred embodiment, a solid electrochromic film 25 is formed on the posterior surface 83 of semiconductive layer 20. A suitable electrochrome for use as a electrochromic film 25 for the titanium dioxide, or other n-type semiconductive layer 20 is ferric ferrocyanide commonly referred in the industry as Prussian Blue. A film of Prussian Blue is deposited on the titanium dioxide semiconductive layer 20 by placing the titanium dioxide semiconductor electrode S in a solution of 0.02 M FeCl 3 plus 0.02 M [Fe(CN) 6 ] 3- for two minutes while maintaining a constant cathodic current density across the semiconductive layer 20 of approximately forty (40) microamperes per square centimeter.
An electrolyte E suitable for chemically interacting with the electrochomic film 25 is contained within cavity 75 in contact with electrochromic film 25. For electrodes formed with Prussian Blue electrochromic film, electrolyte E contains potassium ions. An electrolyte E consisting of a 1.0 molar potassium chloride solution in water at pH 4.0 has been found to provide excellent results. The electrolyte E may be partially immobilized by encasing it within a polymer or other porous structure. Only a very thin layer of electrolyte E is necessary to provide the desired electrolytic effect.
A counter-electrode C is also mounted within enclosure 70 and in contact with the electrolyte E. An electric (ionic) current path is thus provided from semiconductor electrode S through electrolyte E to counter-electrode C. The counter-electrode means C, as shown in FIG. 1, may be a thin layer of conductive material, such as tin dioxide, titanium, or platinum, formed on the insulating back panel 5.
A switch B and wire leads 55, 60, provide an external electric current path between counter-electrode C and semiconductor electrode S and provided for selectively biasing the semiconductor electrode S to a positive (anodic) state, a negative (cathodic) state, or to an open current state with respect to the counter-electrode C. By operation of the switch B, the user is able to switch the display device D to a light writing state, an image erasing state, or to an image preserving state.
The light writing state for the preferred n-type semiconductive layer 20 occurs when the semiconductor electrode S is biased in the positive state. When a p-type semiconductive layer 25 is used, the light writing state is the negative bias state. For clarity, only n-type biasing is described herein.
Under positive bias, minority charge carriers, or holes, will be generated in the space charge region of the semiconductor electrode S when light at an energy level above the band gap of the semiconductive layer 20 strikes the semiconductor electrode S. These minority charge carriers flow into the electrochromic film 25 and drive the electrochromic reaction. The generated electric current flows from electrode S through the electrolyte E to the counter-electrode C and switch B to complete a circuit. For a Prussian Blue electrochromic film 25, the light generated charge carriers will change the white reduced form of Prussian Blue to the oxidized (blue) form. In the preferred embodiment, the positive bias voltage is approximately 0.5 volts, but the magnitude of the required bias may vary considerably depending on the electrolyte E used, the thickness of the electrochromic film 25, the speed with which the user wishes the color change to occur, the concentration of dopants in the semiconductive layer 20, and other factors.
In the positive bias or light writing state, for the n-type display D, the electrochromic reaction will not occur in the absence of light generated charge carriers. Thus, the user may control the image formed on the display device D by controlling the location at which light strikes the semiconductor layer 25. For the titanium dioxide system described above, light in the near ultraviolet range is necessary to generate charge carriers. Thus, by using image forming masks with a Xenon lamp or a fiber optic laser pen with an nitrogen pulse laser, the user may write on the display device D to form a desired image.
For a n-type device, the image erase state occurs when the semiconductor electrode S is under negative bias. In the negative bias state, the majority charge carriers or electrons are driven through the electrochromic film 25 and drive the electrochromic reaction in an opposite direction without requiring light. For Prussian Blue, the electrochromic film 25 will be changed from the oxidized (blue) state to the reduced (white) state under negative bias. Any image formed in the light writing state by oxidizing the white form to the blue form of Prussian Blue will be erased. Again, the magnitude of the negative bias should be around 0.5 volts, but can be varied according to the desires of the user. Of course, for a p-type display device D, the image erase state requires a positive bias.
The image preservation state occurs in either n-type or p-type displays D when the switch B is switched to an open circuit state, thus preventing electric current flow through the display D. The electrochromic reaction cannot proceed in either the oxidation or reduction directions unless current can flow. Thus, when the switch B is switched to an open circuit, the image on display D will be preserved for long periods, almost indefinitely subject to any leakage current that may occur if the display D is not properly insulated or sealed.
Another, more versatile embodiment of the present invention is illustrated in FIG. 2 and designated D'. For ease of reference common elements of display D' (FIG. 2) and display device D (FIG. 2) are designated with the same numbers.
Display D' includes a color background panel 30 having an electrochromic layer 40 formed on its anterior surface (that facing user). Since Prussian Blue in a thin film is translucent in the reduced white form, when Prussian Blue electrochromic film 25 is in the white reduced form, and semiconductor electrode S is translucent the user can discern objects, such as background color panel 30 behind the electrochromic film 25. Electrochromic layer 40 on panel 30 enables the user to control the color of the background panel 30. Background panel 30 may be constructed of a conductive panel 35, such as tin dioxide on glass, with an electrochromic layer 40 formed on the anterior surface of conductive panel 35 facing the translucent front panel 10. An auxiliary electrode 85 is placed in contact with the electrolyte E' in order to provide independent control of the background panel 30 from the semiconductor electrode S'. Switch B' is connected to auxiliary electrode 85 through wire 90, and controls the bias of the background panel 30 with respect to the auxiliary electrode 85 in a like manner as described for the semiconductor electrode S' above. As is appreciated in the art, the current flow across the background panel will drive the electrochromic reaction in the absence of light in either direction depending on the direction of current flow.
A plurality of the displays D of FIG. 1 or the displays D' of FIG. 2 reduced in size may be used in conjunction arranged in a matrix (not shown) in order to provide improved control of the image formation. When arranged in a matrix, each separate display device D may be independently controlled via a switch B. Further, electronic or computer controlled switching systems (not shown) may be employed to coordinate the operation of a large number of displays D arranged in a matrix.
Referring now to FIG. 3, another embodiment of the display D is illustrated and designated D". In this embodiment, a plurality of semiconductor electrodes S" are provided on translucent front panel 10 in the form of a plurality of spaced parallel semiconductor electrode strips 90 (FIG. 4). Each of the semiconductor electrode strips 90 is formed generally in the same manner and with similar materials as semiconductor S described above. Semiconductor electrodes S" can be easily manufactured in strips 90 using masking techniques known in the art. Each of the semiconductor electrode strips 90 is electrically independent of the others. Elements in FIG. 3 that are common to FIGS. 1 and 2 are designated with the same number as in FIG. 1 and 2.
Referring now to FIG. 3, counter-electrode C" is mounted adjacent to insulating back panel 5 and includes a plurality of spaced parallel conductor strips 95 extending transversely with respect to the semiconductor electrode strips 90 (see FIG. 4). Each of conductor strips 95 is electrically independent of the others. Further, each conductor strip is coated with a thin electrochromic layer 100.
For the desired flexibility of operation, spaced parallel auxiliary electrode strips 105 of conductive material are formed between the semiconductor electrode strips 90 on the translucent front panel. Again, each auxiliary electrode strip 105 is electrically independent of the others.
Display D" (FIG. 3) is constructed such that the electrolyte E" is contained in a very thin cavity 75. The thickness of which has been greatly exaggerated in the drawings for clarity. Control 120 operates each semiconductor electrode strip 90, each conductor strip 95 and each auxiliary electrode strip 105 independently for electrically biasing each of them positively, negatively, or to an open circuit with respect to any one of them, thus forming a matrix-type address system.
Referring now to FIG. 4, the application of voltages to a semiconductor electrode 90 and a particular transverse conductive strip 95a will cause activation of the segment of the semiconductor electrode 90a at the point 110 where the transverse conductive strip 95a crosses close to the semiconductor electrode 90a (FIG. 4). Likewise, the electrochromic layer 100 on the conductive strip 95 will be activated by applying appropriate bias with respect to a particular auxiliary electrode 105a in the area near the point (not shown) where the conductive strip 95 and the electrode 105a cross.
Control 120 includes a current recorder (not shown separately) which detects the amount of charge flow through display D" with respect to each conductor strip 95 of the counter-electrode C" and each auxiliary electrode 105. Because the reduction reaction which erases images on the display D" creates current flow proportional to the amount of electrochrome reduced, the user is able to record the current at each cross point 110 (FIG. 4) proportional to the extent of electrochromic reaction at each cross point 110 and store the data received in a computer. In this manner, the image formed on the display face 65 can be recalled.
The current generated during the activation of a given semiconductor electrode S" will indicate the amount of electrochromic reaction occuring near the cross point 110 of the conductive strip 95 with the activated semiconductor electrode S". By sequentially activating each of the semiconductor electrode S" in the image erase state while only one conductive strip 95 of the counter-electrode C" is activated, then repeating the process for each conductive strip 95, control 120 records the reaction occuring at each cross point 110. Thus, the image erased from the display face 65 of display D" can be stored in memory.
Display D of the present invention provides a flat panel that the user may write on with a light pen or other light source and erase repeatedly which has useful application to educational instruction or as in a visual aid in presentations. A variable color background may be provided and display D may be made interactive with a microcomputere for example to provide recall of erased images and programmable image forming as well as light writing. It should be appreciated that the electrochromic materials used can be of a variety of colors and forms. Further, the semiconductor electrodes may be manufactured with a wide range of band gap energies allowing for use of a variety of light sources for writing purposes.
The foregoing disclosure and description of the invention are illustrative and explanatory thereof, and various changes in the size, shape and materials, as well as in the details of the illustrated construction may be made without departing from the spirit of the invention. | A solid electrochromic film is used on a semiconductor electrode in a display device permitting the user to write on the display using a light pen. Additional elements, including arrangement of the semiconductor electrodes transversely with respect to counter-electrodes, or providing an electrochromic film on the counter-electrodes, further enhance the versatility of the display device. | 6 |
BACKGROUND
As the complexity of computer systems has increased, the operating system executing in the computer systems have also become more sophisticated. Specifically, operating systems have been augmented to include resource management utilities. Resource management utilities enable system users to control how processes executing on the computer system use the available system resources (e.g., central processing units (CPUs), physical memory, bandwidth, etc.).
The resource management utilities provide a number of different resource management control mechanisms to control system resource allocation for processes, such as CPU shares allocation, physical memory control, system resource partitioning, etc. Each of the aforementioned resource management control mechanisms may be applied independently and individually to each application (or service (i.e., group of related applications) executing on the computer system. Alternatively, each of the aforementioned resource management control mechanisms may be applied to one or more applications in combination. The resource management control mechanisms described above may be generically categorized into three distinct types: constraint mechanisms, scheduling mechanisms, and partitioning mechanisms.
Constraint mechanisms allow a system user (e.g., a system administrator) or an application developer to set bounds on the consumption of a specific system resource for an application or one or more processes within an application. Once the bounds on resource consumption are specified, the system user and/or application developer may readily and easily model system resource consumption scenarios. Further, the bounds on resource consumption may also be used to control ill-behaved applications that would otherwise compromise computer system performance or availability through unregulated system resource requests.
Scheduling mechanisms allow a system to make a sequence of system resource allocation decisions at specific time intervals. The decision about how to allocate a particular system resource is typically based on a predictable algorithm. In some instances, the scheduling algorithm might guarantee that all applications have some access to the system resource. Scheduling mechanisms enable improved utilization of an under committed system resource, while providing controlled allocations in a critically committed or overcommitted system resource utilization scenario.
Partitioning mechanisms allow a system user to bind a particular application (or one or more sub-processes within the application) to a subset of available system resources. This binding guarantees that a known amount of system resources is always available to the application (or one or more sub-processes within the application).
Operating systems providing the above-mentioned resource management control mechanisms typically provide a resource management utility and/or an application programming interface (API) for each of the mechanisms. Further, each of the resource management utilities/APIs provides a number of different options for the system user to select and configure. In general, the resource management utilities/APIs are not tightly coupled together. In addition, as the operating system evolves, different versions of the resource management utilities/APIs become available that have different options and functionality. Accordingly, in order for a system user to take advantage of the aforementioned mechanisms, the system user typically requires a thorough understanding of the different types of resource management control mechanisms as well as the relationship/interaction between the various resource management control mechanisms.
SUMMARY
In general, in one aspect, the invention relates to a method for managing system resources, comprising creating a container, wherein creating the container comprises allocating a first portion of a first resource to the container, associating the container with a resource pool, wherein the resource pool is associated with the first resource, determining whether the first portion of the first resource is valid, and activating the container if the first portion of the first resource is valid.
In general, in one aspect, the invention relates to a resource management system, comprising a first resource and a second resource, a first resource pool, wherein the resource pool is allocated a portion of the first resource and a portion of the second resource, a first container residing in the first resource pool, wherein the first container comprises a requirements specification for the first resource for the first container and a requirements specification for the second resource for the first container, and a management interface configured to verify the requirements specification for the first resource with the allocated portion of the first resource, and verify the requirements specification for the second resource with the allocated portion of the second resource.
In general, in one aspect, the invention relates to a network system having a plurality of nodes, including a first resource and a second resource, a first resource pool, wherein the resource pool is allocated a portion of the first resource and a portion of the second resource, a first container residing in the first resource pool, wherein the first container comprises a requirements specification for the first resource for the first container and a requirements specification for the second resource for the first container, and a management interface configured to verify the requirements specification for the first resource with the allocated portion of the first resource, and verify the requirements specification for the second resource with the allocated portion of the second resource, wherein the first resource is located on any one of the plurality of nodes, wherein the second resource is located on any one of the plurality of nodes, wherein the first resource pool is located on any one of the plurality of nodes, wherein the container is located on any one of the plurality of nodes, wherein the management interface executes on any one of the plurality of nodes.
Other aspects of the invention will be apparent from the following description and the appended claims.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 shows a system architecture in accordance with one embodiment of the invention.
FIG. 2 shows a view of a container level in accordance with one embodiment of the system.
FIG. 3 shows a view of a resource pool in accordance with one embodiment of the invention.
FIG. 4 shows a flow chart in accordance with one embodiment of the invention.
FIG. 5 shows a computer system in accordance with one embodiment of the invention.
DETAILED DESCRIPTION
Exemplary embodiments of the invention will be described with reference to the accompanying drawings. Like items in the drawings are shown with the same reference numbers.
In one or more embodiments of the invention, numerous specific details are set forth in order to provide a more thorough understanding of the invention. However, it will be apparent to one of ordinary skill in the art that the invention may be practiced without these specific details. In other instances, well-known features have not been described in detail to avoid obscuring the invention.
In general, embodiments of the invention provide a method and apparatus for system resource management. One or more embodiments of the invention provide a simple model that helps manage the complexity of the resource management control mechanisms and their different resource management utilities/APIs for system users. In one embodiment of the invention, a system user may create a container and define the system resources allocated to the particular container. Applications (and services) may then be executed within the container and their performance/system resource usage may be controlled and monitored.
FIG. 1 shows a system architecture in accordance with one embodiment of the invention. The system includes hardware ( 100 ) (e.g., CPUs, physical memory, network interface cards, etc.) and an operating system ( 102 ) executing on the hardware ( 100 ). The operating system ( 102 ) includes a number of management utilities (i.e., Management Utility A ( 104 A), Management Utility B ( 104 B), Management Utility C ( 104 C)). The management utilities ( 105 ) (i.e., Management Utility A ( 104 A), Management Utility B ( 104 B), Management Utility C ( 104 C)) typically provide resource management control mechanisms (e.g., constraint mechanisms, scheduling mechanisms, partitioning mechanisms, etc.) to manage system resources (e.g., CPUs, physical memory, bandwidth, etc.).
In one embodiment of the invention, a container level ( 106 ) interfaces with the management utilities (i.e., Management Utility A ( 104 A), Management Utility B ( 104 B), Management Utility C ( 104 C)). The container level ( 106 ) typically includes one or more containers. The container level ( 106 ) is described in FIGS. 2 and 3 . The container level ( 106 ) interfaces with a management interface ( 108 ). The management interface ( 108 ) provides a system user an interface to specify how resources are to be allocated within a given container in the container level ( 106 ). In one embodiment of the invention, the management interface ( 108 ) includes a graphical user interface to allow the system user to specify the system resource allocation.
In one embodiment of the invention, the management interface ( 108 ) may include functionality to define a container, create a resource pool (as shown in FIG. 2 ), deploy the container in a particular resource pool, activate the container, modify the container (e.g., modify the resources allocated to the container), deactivate the container, and delete the container.
As noted above, the management interface includes functionality to modify the container definition for one or more containers. In one embodiment of the invention, this functionality is extended to allow a system user to change the container definition for deployed containers that have the same container definition. The aforementioned functionality is hereafter referred to as a “Schedule Change” functionality.
In one embodiment of the invention, the Schedule Change Job functionality is implemented in the following manner. Initially, a system user creates a job on selected deployed containers that have the same container definition. Once the job is created it may be executed immediately or at a scheduled time. The changes specified in the job will be applied to those selected containers. In one embodiment of the invention, the job is specific to a container, and may include a list of hosts on which the containers are deployed, a resource specification for one or more system resources, and a schedule to run the job.
Consider the following example, in an enterprise environment, a container called Web Service, which is created for all Web Service related processes, is deployed on a system located in San Francisco and on another system in New York City. During the business hours (peak time), the Web Service containers require 4 CPUs and 2 GB of physical memory to handle all requests. In the evening, the Web Service containers only require 1 CPU and 512 MB of physical memory.
In this scenario, the system administrator could create the following two jobs to change the container definition for the Web Service Container. Specifically, Job 1 would set the CPU specification to 4 CPUs, the physical memory cap to 2 GB, and would be scheduled to execute at the beginning of business hours in the respective geographic locations. Job 2 would set the CPU specification to 1 CPU, the physical memory cap to 512 MB, and would be scheduled to execute at the end of business hours in the respective geographic locations.
Further, the management interface ( 108 ) may include functionality to track system resource usage for a given container and graphically display the system resource usage of the particular container to the system user. In one embodiment of the invention, the management resource interface ( 108 ) may also include functionality to export a container's system resource usage in a format (e.g., comma separated variable format) that may be imported into a word/accounting information processing tool. In addition, the management interface ( 108 ) may include functionality to determine whether a particular container or application/service running in the container is using more system resources than are allocated to the particular container and to notify/alert the system user if this situations exists. For example, the system user may be alerted via an e-mail message.
In one embodiment of the invention, the management interface includes functionality to identify, monitor, and measure the performance of two or more instances of a container (i.e., distinct containers having the same container definition (described below)) executing on different systems on a network.
Further, the management interface ( 108 ) may include functionality to convert the system resource allocations specified by the system user for the containers into commands that are understood by the management utilities ( 105 ) (i.e., Management Utility A ( 104 A), Management Utility B ( 104 B), Management Utility C ( 104 C)). Further, the management interface ( 108 ) interfaces with a database ( 110 ). In one embodiment of the invention, the management interface ( 108 ) includes functionality to discover the system resources that are available on the particular computer system and store this information in the database ( 110 ).
In one embodiment of the invention, the database ( 110 ) stores the container definitions (i.e., what system resources are allocated to the particular container, etc.) Further, the database ( 110 ) stores information about the system resources that are available on the computer system. In addition, the database ( 110 ) may include functionality to store the system resource usage per container.
FIG. 2 shows a detailed view of a container level in accordance with one embodiment of the system. The container level ( 106 ) is partitioned into resource pools (e.g., Resource Pool A ( 120 ) and Resource Pool B ( 122 )). In one embodiment of the invention, the resource pools (e.g., Resource Pool A ( 120 ) and Resource Pool B ( 122 )) provide a persistent configuration mechanism for processor set configuration, and optionally, scheduling class assignment (e.g., Fair Share Scheduling (FSS), Time Share Scheduling (TSS), etc.). Accordingly, each resource pool (e.g., Resource Pool A ( 120 ) and Resource Pool B ( 122 )) is associated with a processor set (e.g., typically 2″ CPUs where n is a whole number).
In one embodiment of the invention, the following information may be stored in the database ( 110 in FIG. 1 ) or an alternate location, for each resource pool: resource pool name, number of CPUs in the resource pool, the processor set associated with the resource pool, the scheduling class assignment for the resource pool, etc. In one embodiment of the invention, the following information may be stored in the database ( 110 in FIG. 1 ), or an alternate location, for each processor set: processor set name, processor set ID, number of CPUs in processor set, minimum size of processor set, maximum size of processor set, etc.
Residing in each resource pool (e.g., Resource Pool A ( 120 ) and Resource Pool B ( 122 )) is one or more containers. For example, Container A ( 124 ) and Container B ( 126 ) reside in resource pool A ( 120 ), while Container C ( 128 ), Container D ( 130 ), Container E ( 132 ), Container F ( 134 ), and Container G ( 136 ) reside in Resource Pool B ( 122 ). In one embodiment of the invention, each container may be described as a multi-dimensional system resource space in which an application (or service) may be executed. The size of the container is typically determined by the amount of each system resource allocated to the container (e.g., the number of CPUs allocated, the amount of physical memory allocated, the amount of network bandwidth, etc).
Though not shown in FIG. 2 , applications (or services) executing in a container correspond to one or more processes. In one embodiment of the invention, all processes executing in a container are associated with the same ID (e.g., a project ID). The ID may be used to track system resource usage for each container and also to enforce constraints on system resource usage.
In one embodiment of the invention, the following information may be stored in the database ( 110 ), or an alternate location, for each container: container ID, container name, project ID, description (e.g., brief description of the properties of the container or the textual description used to identify the container, etc.), name of associated resource pool, minimum number of CPUs required for container activation, the minimum and/or maximum upload (i.e., outgoing) bandwidth required, the minimum download bandwidth required, maximum physical memory allocated to the container, etc. In addition, the following information may be stored in the database, or an alternate location, for each container: real time CPU usage, CPU usage in percentage of total system, real time virtual memory usage, access control lists (ACL), and expressions.
In one embodiment of the invention, an ACL may be used to specify which users may be allowed to join the container and execute applications (or services) within the container. Further, the ACL may also specify groups of users that may join the container and execute applications (or services) within the container. In one embodiment, expressions correspond to regular expressions that may be used to determine whether a particular process may be moved into the container.
FIG. 3 shows a detailed view of a resource pool in accordance with one embodiment of the invention. Allocated Resource A ( 146 ), Allocated Resource B ( 148 ), and Allocated Resource C ( 150 ) are allocated to Resource Pool A ( 120 ). In one embodiment of the invention, Allocated Resource A ( 146 ), Allocated Resource B ( 148 ), and Allocated Resource C ( 150 ) correspond to CPU, physical memory, and bandwidth, respectively. Further, each of the allocated resources (e.g., Allocated Resource A ( 146 ), Allocated Resource B ( 148 ), and Allocated Resource C ( 150 )) may individually correspond to the entire system resource available on the computer system or only a portion thereof.
The allocated resources (e.g., Allocated Resource A ( 146 ), Allocated Resource B ( 148 ), and Allocated Resource C ( 150 )) are further sub-divided by the containers (i.e., Container A ( 124 ) and Container B ( 126 )). Specifically, when a container is created, a container definition ( 140 , 142 ) is specified. The container definition ( 140 , 142 ) defines the resource requirements for each of the resources on a per container basis. For example, Container A ( 124 ) includes a container definition ( 140 ) that defines Resource A Requirements for Container A ( 140 A), Resource B Requirements for Container A ( 140 B), and Resource C Requirements for Container A ( 140 C). Further, Container B ( 126 ) includes a container definition ( 142 ) that defines Resource A Requirements for Container B ( 142 A), Resource B Requirements for Container B ( 142 B), and Resource C Requirements for Container B ( 142 C). In one embodiment of the invention, prior to placing a container in a given resource pool, the management interface ( 108 ) (or a related process) verifies whether the resource pool has sufficient resources to support the container.
In one embodiment of the invention, the minimum CPUs required for a given container is specified as the number of CPUs. For example, the system user may specify that 0.5 CPUs are required by the container, where 0.5 CPUs corresponds to 50% of a given CPU resource. Note that by specifying the number of CPUs required by the container, the management interface may readily validate the allocation by obtaining the total number of CPUs available in the computer system (which is calculated from the total number of CPUs in the computer system less the number of CPUs reserved by other containers). This approach provides an efficient way to avoid over-booking (or over-allocation) of CPUs within the computer system. In one embodiment of the invention, physical memory and bandwidth required by the container are specified and validated in the same manner as CPUs.
In one embodiment of the invention, to aid in defining resource requirements for a particular container, the number of CPUs, available size of physical memory, and available bandwidth are calculated and displayed to the system user when the container is created. The aforementioned information may aid the system user in entering appropriate resource requirements. In one embodiment of the invention, the container definition may be modified at any time after the container is created.
Though not shown in FIG. 3 , in one embodiment of the invention, each resource pool (e.g., Resource Pool A ( 120 )) may include a default container. The default container corresponds to a container that may use all the system resources allocated to the corresponding resource pool in which the default container resides. Typically, the default container is used when a non-default container in the resource pool is deactivated but an application (or service) is still executing in the non-default container. In this scenario, the application (or service) executing in the non-default container is transferred to the default container to continue execution.
FIG. 4 shows a flow chart showing a method in accordance with one embodiment of the invention. Initially, system resources are discovered (Step 100 ). In one embodiment of the invention, the discovered system resources (including corresponding properties such as number, size, location, etc.) are stored in a database. One or more resource pools are subsequently created (Step 102 ). Creating the resource pool typically includes associating a processor set and, optionally, a scheduling class assignment with the resource pool. Once the resource pool has been created, system resources may also be allocated to the resource pool (e.g., CPUs, physical memory, bandwidth, etc.) (Step 104 ).
Once the resource pool has been created and system resources have been allocated to the resource pool, one or more containers may be created (Step 106 ). In one embodiment of the invention, creating the container includes generating a container definition in which individual system resource requirements are specified. In one embodiment of the invention, the container is created and resource requirements are specified using a container template.
Once the containers have been created and the resource requirements specified, the containers are placed within a resource pool (i.e., a container is deployed) (Step 108 ). Prior to activating the container in the resource pool, the resource requirements for the container are validated to determine whether the resource pool in which the container is deployed contains the necessary resources to support the container (Step 110 ). If the resource requirements for the container are valid, the container is activated in the resource pool (Step 112 ). Once a container has been activated, the system users (or groups) as defined by the ACL specified for the container may execute applications (or services) within the container.
Alternatively, the resource requirements are modified and the container is re-validated until the resource pool can support the container (not shown). The container may also be deployed in another resource pool that includes sufficient system resources. Those skilled in the art will appreciate that the aforementioned steps do not necessarily need to be performed in the order shown in FIG. 4 .
In one embodiment of the invention, the system resources used by a container are not allowed to exceed the resource requirements specified in the container definition. Alternatively, if all the resources allocated to a particular resource pool in which the container is executing are not being used, then an application (or service) executing within the container may use additional resources not specified in the corresponding container definition up to the resources available in the corresponding resource pool. In one embodiment of the invention, a physical memory cap daemon is used to enforce physical memory usage of applications (or services) executing in a container.
Those skilled in the art will appreciate that while the containers have been described with respect to three resources (i.e., CPU, physical memory, and bandwidth), the invention may be applied to other system resources as well. Thus, the container definition for each container may specify more than the three aforementioned system resources.
The invention may be implemented on virtually any type of computer regardless of the platform being used. For example, as shown in FIG. 5 , a networked computer system ( 200 ) includes a processor ( 202 ), associated memory ( 204 ), a storage device ( 206 ), and numerous other elements and functionalities typical of today's computers (not shown). The networked computer ( 200 ) may also include input means, such as a keyboard ( 208 ) and a mouse ( 210 ), and output means, such as a monitor ( 212 ). The networked computer system ( 200 ) is connected to a local area network (LAN) or a wide area network (e.g., the Internet) (not shown) via a network interface connection (not shown). Those skilled in the art will appreciate that these input and output means may take other forms. Further, those skilled in the art will appreciate that one or more elements of the aforementioned computer ( 200 ) may be located at a remote location and connected to the other elements over a network. Further, the invention may be implemented on a distributed system having a plurality of nodes, where each portion of the invention (i.e., the helper action, the instrumented application, the tracing framework, etc.) may be located on a different node within the distributed system. In one embodiment of the invention, the node corresponds to a computer system. Alternatively, the node may correspond to a processor with associated physical memory.
By introducing a container model, only single type of resource management control mechanism (i.e., partitioning) is exposed to the system users. Thus, a single system may be partitioned into a single or multiple resource pools, and each resource pool may be further partitioned into a single or multiple containers. Internally, the management interface still uses the aforementioned resource management control mechanisms via the management utilities/APIs to achieve the optimal system resource management. Embodiments of the invention provide a method and apparatus to allow a system user to allocate system resources without requiring the system user to understand the individual management utilities/APIs.
While the invention has been described with respect to a limited number of embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments can be devised which do not depart from the scope of the invention as disclosed herein. Accordingly, the scope of the invention should be limited only by the attached claims. | A method for managing system resources including creating a container, wherein creating the container comprises allocating a first portion of a first resource to the container, associating the container with a resource pool, wherein the resource pool is associated with the first resource, determining whether the first portion of the first resource is valid, and activating the container if the first portion of the first resource is valid. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not Applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable.
BACKGROUND
[0003] The present invention relates generally to valve actuators. More specifically, the present invention relates to override and backup systems for subsea valve actuators. Still more specifically, the present invention relates to override systems for subsea valve applications.
[0004] Increasing performance demands for subsea hydrocarbon production systems have led to a demand for high performance control systems to operate subsea pressure control equipment, such as valves and chokes. Hydraulic actuators are used to operate many of the pressure control equipment used subsea. Pressurized hydraulic fluid may be supplied to the hydraulic actuators by a direct hydraulic control system or an electrohydraulic control system. Direct hydraulic control systems provides pressurized hydraulic fluid directly from the surface to the subsea valve actuators. Electrohydraulic control systems utilize electrical signals transmitted to an electrically actuated valve manifold that controls the flow of hydraulic fluid to the hydraulic actuators of the pressure control equipment.
[0005] The performance of both direct hydraulic and electrohydraulic control systems is affected by a number of factors, including the water depth in which the components operate, the distance from the platform controlling the operation, and a variety of other constraints. Thus, as water depth and field size increases, the limits of hydraulic control systems become an increasing issue. Further, even when the use of a hydraulic control system is technically feasible, the cost of the system may preclude its use in a smaller or marginal field.
[0006] In order to provide an alternative to hydraulic control systems, full electrical control systems, including electric actuators, have been developed. Instead of relying on pressurized hydraulic fluid to actuate the pressure control components, electrical actuators are supplied with an electric current. The reliance on electric current can allow for improved response times, especially over long distances and in deep water.
[0007] Even with electrical control systems and actuators, many operators still desire some sort of system that allows for operation of the actuators in the case of failure of the electric actuator or interruption in the supply of electrical current. In certain applications, an operator may want to be able to override the electrical control system and operate a valve, or some other components, via remote operation or direct intervention, such as with a remotely operated vehicle (ROV).
[0008] Thus, there remains a need to develop methods and apparatus for allowing operation of subsea actuators that overcome some of the foregoing difficulties while providing more advantageous overall results.
SUMMARY OF THE PREFERRED EMBODIMENTS
[0009] The embodiments of the present invention are directed toward methods and apparatus for a valve system comprising a closure member that is linearly translatable within a valve body. A fail safe assembly is connected to the valve body and a first rod member that is connected to the closure member. A linear actuator is movably connected to the fail safe assembly and is operable to move the first rod member by moving the linear actuator relative to the valve body. A mechanical override system is connected to the linear actuator and is operable to move the linear actuator relative to the valve body.
[0010] Thus, the present invention comprises a combination of features and advantages that enable it to overcome various problems of prior devices. The various characteristics described above, as well as other features, will be readily apparent to those skilled in the art upon reading the following detailed description of the preferred embodiments of the invention, and by referring to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] For a more detailed description of the preferred embodiment of the present invention, reference will now be made to the accompanying drawings, wherein:
[0012] FIG. 1 is a partial sectional view of a valve actuator with an override system constructed in accordance with embodiments of the invention;
[0013] FIG. 2 is a partial sectional view of an override system constructed in accordance with embodiments of the invention;
[0014] FIG. 3 is a partial sectional view of a valve actuator with an override system constructed in accordance with embodiments of the invention;
[0015] FIG. 4 is a partial sectional view of a valve actuator with an override system constructed in accordance with embodiments of the invention; and
[0016] FIG. 5 is a partial sectional view of a valve actuator with an override system constructed in accordance with embodiments of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] Referring now to FIG. 1 , valve system 10 comprises valve body 12 , closure member 14 , linear actuator 16 , fail safe assembly 18 , and mechanical override system 32 . First end 20 of fail safe assembly 18 is connected to valve body 12 . Rod 22 of fail safe assembly 18 is coupled to closure member 14 . Linear actuator 16 is connected to second end 24 of fail safe assembly 18 by a mechanical override system 32 . Referring now to FIG. 2 , fail safe assembly 18 comprises cylindrical body 26 , piston 28 , and spring 30 . Piston 28 forms receptacle 40 and closely engages the inner surface of body 26 . Rod 22 is connected to one end of piston 28 . Spring 30 is disposed between first end 20 and piston 28 so as to bias the piston toward second end 24 .
[0018] Piston 28 operates in a pressure-balanced mode where the hydraulic fluid moves across the piston through annular gap 34 between the piston and body 26 . In certain embodiments, piston 28 may also comprise additional fluid passageways 35 that allow fluid to flow through the piston. Annular gap 34 and fluid passageways 35 may be sized so as to restrict the flow of fluid across piston 28 and thus limit the speed at which the piston may travel.
[0019] Referring now to FIG. 3 , receptacle 40 receives a portion of linear actuator 16 that is connected to override assembly 18 by mechanical override system 32 . FIG. 3 shows valve assembly 10 in a retracted position where piston 28 is positioned toward second end 24 and spring 30 is expanded. To shift closure member 14 , linear actuator 16 is activated and rod 46 extends from the actuator, as shown in FIG. 4 .
[0020] FIG. 4 shows valve assembly 10 in an extended position where piston 28 is positioned toward first end 20 and spring 30 is collapsed. Piston 28 is moved toward first end 20 by the operation of actuator 16 . Actuator 16 extends rod 46 that bears against rod 22 that is connected to piston 28 . The movement of piston 28 toward first end 20 compresses spring 30 . As actuator 16 retracts rod 46 , spring 30 pushes piston 28 toward second end 24 and the initial position as shown in FIG. 3 .
[0021] Thus, piston 28 and spring 30 operates as a fail-safe device where spring 30 pushes piston 28 toward second end 24 unless rod 46 is extended from linear actuator 16 . Rod 46 of actuator 16 may also be coupled to piston 28 such that the piston can be used to control the speed at which rod 46 retracts.
[0022] Mechanical override system 32 maintains the position of actuator 16 relative to valve body 12 so that the extension of rod 46 places closure member 14 in the proper position. Mechanical override system 32 also allows actuator 16 to be moved relative to valve body 12 so as to move closure member 14 when rod 46 can not be extended due to component malfunction or other failure. Mechanical override system 32 may comprise a gear system, screw drive, or other mechanically activated translation mechanism that can move actuator 16 with sufficient force to compress spring 30 and shift closure member 14 within valve body 12 Mechanical override system 32 may also comprise an ROV interface that allows the mechanical override system to be operated by an ROV.
[0023] Referring now to FIG. 5 , one embodiment of mechanical override system 32 comprises retainer 50 , split ring 52 , base 54 , gear assembly 56 , threaded rod 58 , guide rod 60 , and drive rod 62 . Base 54 is fixably coupled to the end of body 26 . Split ring 52 engages linear actuator 16 and is held in place by retainer 50 that is slidably mounted to threaded rod 58 and guide rod 60 . Gear assembly comprises drive gear 64 that is mounted to drive rod 60 and traveling gear 66 that engages threaded rod 58 . Drive rod 62 has an ROV interface 68 that allows an ROV to rotate the rod and operate the mechanical override system.
[0024] As drive rod 62 is rotated, drive gear 64 rotates traveling gear 66 . The rotation of traveling gear 66 causes it to move along threaded rod 58 , pushing retainer 50 toward base 54 . As retainer 50 moves, linear actuator 16 is moved toward valve body 12 , compressing spring 30 and moving closure member 14 within the valve body to the fully actuated position of FIG. 5 . Gear assembly 56 may preferably be a self-locking system that will maintain the position of linear actuator 16 until drive rod 62 is rotated in the opposite direction.
[0025] Thus, valve system 10 can be actuated in a first mode (as shown in FIG. 4 ), where linear actuator 16 extends rod 46 so as to move piston 28 toward first end 20 of fail safe assembly 18 . In the first mode, the position of linear actuator 16 relative to valve body 12 is maintained by override system 32 . Valve system 10 can also be actuated in a second mode (as shown in FIG. 5 ), where linear actuator 16 is moved relative to valve body 12 by mechanical override system 32 . The movement of linear actuator 16 moves piston 28 toward first end 20 of fail safe assembly 18 .
[0026] Mechanical override system may utilize any of a number of mechanical systems to move the linear actuator and shift the position of the closure member. For example, a mechanical override system may use a geared or threaded system that transforms rotational motion into linear translation of the actuator. Other mechanical override systems may comprise external hydraulic rams or other type devices to push the linear actuator.
[0027] While preferred embodiments of this invention have been shown and described, modifications thereof can be made by one skilled in the art without departing from the scope or teaching of this invention. The embodiments described herein are exemplary only and are not limiting. Many variations and modifications of the system and apparatus are possible and are within the scope of the invention. For example, the relative dimensions of various parts, the materials from which the various parts are made, and other parameters can be varied, so long as the mechanical override apparatus retain the advantages discussed herein. Accordingly, the scope of protection is not limited to the embodiments described herein, but is only limited by the claims that follow, the scope of which shall include all equivalents of the subject matter of the claims. | A valve system comprising a closure member that is linearly translatable within a valve body. A fail safe assembly is connected to the valve body and a first rod member that is connected to the closure member. A linear actuator is movably connected to the fail safe assembly and is operable to move the first rod member. A mechanical override system is connected to the linear actuator and is operable to move the linear actuator relative to the valve body. | 4 |
RELATED APPLICATIONS
[0001] This present application is related to a provisional application serial No. 60/435,836 filed on Dec. 19, 2002, entitled “Method and Apparatus for Protection of Wildlife from Contact with Power Phase Cutout Mechanism”, by Lynch, currently pending, for which the priority date for this application is hereby claimed.
FIELD OF THE INVENTION
[0002] This invention relates generally to protection of wildlife environments; and specifically to a prevention of electrocution or shock resulting from contact with power cutout or disconnect mechanisms.
BACKGROUND OF THE INVENTION
[0003] An increasingly sensitive environmental issue is that of preventing injury to wildlife that may occur as a result of contact with energized electrical distribution components. Modernly, electrical distribution systems rarely provided any type of electrical barrier between energized components and other objects. For instance, electrical conductors that carry electrical power from power-pole to power-pole are typically devoid of any type of insulation. In the general sense, this is quite acceptable since electrical injury typically requires a complete circuit path phase to ground or phase to phase. Hence, a small bird may land on an electrical conductor without any adverse effects. This is because the small bird contacts only one electrical conductor and the current flowing through the conductor cannot find a “path to ground”.
[0004] It is only when a living creature, including man or beast, contacts an exposed electrical conductor or other energized component and electrical current can find a path to ground that severe injury can occur. This type of unfortunate incident is more likely to occur where exposed electrical conductors are in close proximity to a grounded object or to another conductor or component that is carrying an opposite phase of a particular circuit.
[0005] In one example, a conductor, which is typically electrically isolated from a power pole by means of an insulator, can be contacted by a lineman or wildlife that has climbed the power pole. In such case, the living creature is in close enough proximity to ground by virtue of being in contact with the power pole that the slightest contact with an exposed electrical conductor or other energized component may prove fatal. Larger birds, such as raptors, are often killed when they land on or attempt to land on an exposed electrical conductor near a power-pole or on the power-pole itself. When landing on the conductor near a power-pole, a larger bird can touch the power-pole with a wing and provide a path to ground. A large bird may also short two opposite phases together. This results in a short circuit where electrical current flows through the body of the unfortunate bird from one phase to the other.
[0006] Modern electrical distribution techniques employ various types of components to affect the delivery of electrical power to residential, commercial and industrial customers. In order to effectively manage the delivery of power, one component used in today's power delivery schema is a power interruption device known as a “cutout”. Various forms of cutouts exist and most follow the general form of that described by Biller in U.S. Pat. No. 4,414,527. The modern cutout comprises an insulator that may be mounted onto a power pole or other support structure. The insulator (reference No. 14 in the referenced patent) supports an upper and lower contact assembly. The contact assemblies hold a fuse holder assembly that completes an electrical circuit between the two contact assemblies. Thus the opposing upper and lower contact assemblies form a “fuse receptacle” capable of receiving a fuse holder assembly.
[0007] Each contact assembly further comprises a conductor connector. The conductor connectors are used for connecting the cutout to a tap-point comprising the power distribution system on one end and for connecting the cutout to an electrical load. Typically, a cutout is installed between an energized electrical conductor that carries electrical power from power-pole to power-pole and a step-down transformer. In one application, a cutout is generally mounted on the power pole just below a cross-member that is used to support the inter-pole conductors. The step-down transformer, which is also usually mounted proximate to the cutout, typically receives electrical power from the electrical conductor and reduces the electrical power to a lower voltage level suitable for distribution to an end customer.
[0008] The entire cutout assembly poses a threat not only to wildlife, but also to lineworkers. This is because the upper and lower contact assemblies are not insulated. Lineworkers accept the risk of working with high-voltage electrical power as one of many occupational hazards that are encountered on the job and with foreknowledge of the hazard avoid contacting an energized cutout. Raptors and other large birds often use power-poles, their associated supporting member and components for perching and hunting. Many times, raptors and other large birds return to the power-pole with prey that they intend to consume. Because of the usual manner in which a cutout is mounted, slightly below the power-pole's cross-member, a larger bird can use the cutout as a shelf; ideal for helping manipulate their quarry during consumption. As soon as the raptor contacts the non-insulated, energized cutout assembly it can be severely injured or killed. Other animals, e.g. squirrels, can suffer the same fate as raptors and other large birds.
SUMMARY OF THE INVENTION
[0009] The present invention comprises a method for protecting wildlife from potential electrocution and electrical shock through inadvertent contact with an energized cutout. Generally, a cutout is mounted on a power pole and is used as a fusing circuit between a high-voltage power tap on a distribution system and a transformer. However, the scope of the present invention is not intended to be limited to this one example application.
[0010] A cutout typically comprises an upper connector and contact assembly that is held in opposition to a lower connector and contact assembly by an insulator. The insulator holds the upper and lower contact assemblies in opposition to each other so as to form a fuse receptacle. The present invention provides for a method for protecting wildlife by shrouding the upper connector, the upper contact assembly and a volume of space proximate to the upper end of the fuse receptacle formed by the two contact assemblies. The volume protected by the shroud is made large enough to accommodate not only the upper end of a fuse holder assembly, but also a pull-ring integral to a fuse holder assembly. Such a ring may be used to facilitate the removal of the fuse holder assembly from the fuse receptacle. Even though shrouds are provided, the present method requires that the dielectric integrity of the insulator is to be maintained while the shroud is disposed in an operational position. According to one alternative method, the dielectric integrity of the insulator is maintained by not electrically bridging any of one or more skirts typically integral to the insulator.
[0011] Accordingly, shrouding of a cutout may be accomplished by positioning a shroud over an upper conductor that may be attached to the upper connector. The shroud may then be drawn over the upper end of the cutout assembly. This may be done while the conductor is energized. Once in position, the shroud is held in place by a pin that penetrates two sides of the shroud and is positioned beneath the upper contact assembly.
[0012] Alternative methods of the present invention provide for shrouding the upper conductor that is used to connect the upper contact assembly to a tap-point in a power distribution system. In one illustrative variation of the present method, the lower connector, the lower contact assembly and a volume surrounding the lower end of the fuse receptacle are also shrouded.
[0013] The present invention further comprises a cutout cover assembly. According to one example embodiment, a cutout cover assembly comprises a first shroud section, a second shroud section and a third shroud section. Generally, the first shroud section blends into the second shroud section. In like manner, the second shroud section blends into the third shroud section. Each shroud section comprises walls and a top surface.
[0014] The walls of the first shroud section are used to envelope a portion of the perimeter of an insulator and a top surface is supported by the upper edge of this wall. The second shroud section continues with two opposing walls that stem from the two ends of the wall surrounding the insulator and which straddle the upper contact assembly. The third shroud section again continues with two opposing walls in order to envelope a volume of space in proximity to the upper end of the fuse receptacle and, according to one embodiment, slope outward and down away from the upper contact assembly to form a funnel-shape.
[0015] The second shroud section, according to one alternative embodiment, further comprises pin holes placed in the two opposing walls and a further placed below either the upper contact assembly or the hook assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The foregoing aspects are better understood from the following detailed description of one embodiment of the invention with reference to the drawings, in which:
[0017] [0017]FIG. 1 is a pictorial representation of an electrical cutout assembly;
[0018] [0018]FIGS. 2 and 3 are, respectively, a pictorial diagram that depicts the position of a shroud when it is installed on a cutout and a flow diagram that depicts one illustrative variation of the present method;
[0019] [0019]FIG. 3A is a pictorial representation of an insulator that illustrates application of a method for maintaining the dielectric integrity of the insulator;
[0020] [0020]FIG. 4 is a pictorial diagram that depicts one illustrative method according to the present invention for shrouding the upper portion of a cutout;
[0021] [0021]FIG. 5 is a pictorial diagram that depicts one example method for securing a shroud unit installed on a cutout;
[0022] [0022]FIG. 6 is a pictorial diagram that depicts one alternative method for securing a shroud unit once it is installed on a cutout;
[0023] [0023]FIGS. 7 and 8 are pictorial representations that depict one example of a derivative method of the present invention for shrouding a conductor;
[0024] [0024]FIG. 9 is a pictorial diagram that depicts one example embodiment of a cutout cover according to the present invention; and
[0025] [0025]FIGS. 10 and 11 are, respectively, a perspective and profile pictorial diagrams that depict one alternative method for shrouding a lower contact assembly of a cutout.
DETAILED DESCRIPTION OF THE INVENTION
[0026] [0026]FIG. 1 is a pictorial representation of an electrical cutout assembly. Electrical power distribution systems disseminate electrical power through a distribution grid. When power is delivered from the distribution grid, it is normally received at a very high voltage. The high-voltage power is generally transformed to a lower voltage by a transformer before it is delivered to a power consumer such as a home or a business. It should be noted that these two classes of power consumers are cited as example users of a typical power distribution system and are not intended to limit the scope of the present invention.
[0027] It is not uncommon for a distribution system to distribute electrical power at voltage levels; as high as 69,000 volts and more. A cutout 10 comprises an insulator 15 which is used to support an upper contact assembly 25 . The upper contact assembly usually includes an upper connector 20 . The insulator 15 is used to provide electrical isolation between the upper contact assembly 25 and a mounting bracket 50 and a lower contact assembly 60 .
[0028] The cutout 10 is typically installed between a tap-point on a distribution system and a transformer that receives high-voltage distribution power. The transformer converts the received power to a lower voltage level suitable for delivery to a consumer. The cutout 10 is generally mounted on a power pole by means of the mounting bracket 50 . The upper connector 20 is used to connect an electrical wire 55 to the upper contact assembly 25 . The other end of the electrical wire 55 is generally connected to a high-voltage tap-point provided by the power distribution system.
[0029] The cutout 10 further comprises a lower contact assembly 60 . The lower contact assembly is generally supported by an opposing end of the insulator 15 . The upper and lower contact assemblies ( 25 , 60 ) generally form a fuse receptacle capable of receiving a fuse holder assembly 35 . Generally, the lower contact assembly 60 further comprises a lower connector 65 that may be used to electrically connect the lower contact assembly 60 to a transformer used to step-down power to a lower voltage suitable for delivery to a consumer.
[0030] The fuse holder assembly 35 typically provides a pull-ring 40 . The upper contact assembly 25 further comprises a hook assembly 30 . The hook assembly 30 may be used as an attachment point for a “load-breaking” tool. The load-breaking tool may be attached to the hook assembly 30 and the pull-ring 40 in order to facilitate removal of the fuse holder assembly 35 from the fuse receptacle formed by the upper and lower contact assemblies ( 25 , 60 ). The operation of the load-breaking tool as described herein is well-known and further discussion of its operation and interaction with the hook assembly 30 , the fuse holder assembly 35 and its integral pull-ring 40 is not needed to teach those skilled in the art of electrical power distribution.
[0031] In most instances, the fuse holder assembly 35 comprises a fuse. The pull-ring 40 included in the fuse holder assembly 35 is generally not insulated. The upper 25 and lower 60 contact assemblies are also not insulated. Neither is the electrical wire 55 that connects the upper contact assembly 25 to the high-voltage tap-point. In most instances, installation of the cutout 10 is effected toward the top most portion of a power pole such that it may pose an electrocution hazard to wildlife that may come in contact with the electrically exposed upper 25 and lower 60 contact assemblies.
[0032] [0032]FIGS. 2 and 3 are, respectively, a pictorial diagram that depicts the position of a shroud when it is installed on a cutout and a flow diagram that depicts one illustrative variation of the present method. When the cutout 10 is mounted onto a power pole 80 by means of the mounting bracket 50 , it is the upper contact assembly 25 and its associated connection wire 55 that pose the greatest threat to wildlife. Accordingly, the method of the present invention provides for shrouding the upper connector (step 90 ), shrouding the upper contact assembly (step 95 ) and shrouding the upper portion of the fuse receptacle (step 100 ) formed by the upper and lower contact assemblies ( 25 , 60 ). In one variation of the present method, shrouding of the upper contact assembly comprises an additional step of shrouding the hook assembly 30 . According to yet another variation of the present method, shrouding of the fuse receptacle comprises shrouding of a volume capable of receiving the upper end of a fuse holder assembly 35 and its associated pull-ring 40 . In yet another alternative example method, the dielectric integrity of the insulator 15 is maintained (step 107 ). According to one alternative method, the dielectric integrity of the insulator is maintained by avoiding bridging of skirts 305 included in the insulator 15 .
[0033] According to yet another derivative method of the present invention, an additional step may be applied wherein the lower connector 65 and the lower contact assembly 60 are also shrouded (step 105 ). According to yet another variation of this method, an opening 85 is provided to the volume surrounding the upper portion of the fuse receptacle formed by the upper and lower contact assemblies ( 25 , 60 ). In yet another variation of the present method, the opening is formed to facilitate attachment of the load-breaking tool to the hook assembly 30 and to a ring 40 included on the fuse holder assembly 35 such that the load breaking tool can be applied an some angle offset from an axial axis 111 defined by the fuse holder assembly 35 when it is disposed in the fuse receptacle formed by the upper and lower contact assemblies ( 25 , 60 ). The opening, according to one alternative method, is provided in a funnel-like shape fashioned in one end of a shrouded unit 110 that may be disposed over the upper end of a cutout 10 .
[0034] [0034]FIG. 3A is a pictorial representation of an insulator that illustrates application of a method for maintaining the dielectric integrity of the insulator. A common misconception is that electricity flows through a wire, often referred to as a “conductor”. This is not true. Electricity actually flows over the surface of a material and not through the material. In order to provide sufficient dielectric capability, the surface area of an insulator must be large enough so as to exhibit a sufficient leakage distance between an energized conductor and ground. A cutout 10 includes an insulator 15 applied in a manner so as to electrically insulate a conductor from ground.
[0035] As depicted in the figure, an insulator is typically fabricated in a form that includes some quantity of skirts 305 . The collective surface area of the skirts 305 must then provide sufficient leakage distance between a first terminal 300 and a second terminal 310 , which is most likely grounded, but may be attached to a second phase that is not in phase with power applied to the first terminal 300 . As can be appreciated from this figure, breaching the distance between two skirts 305 does not merely result in a reduction of some vertical distance d 315 , but rather reduces the surface area 320 around the entire skirt 305 .
[0036] Accordingly, in order to maintain the dielectric integrity of an insulator 15 , any shroud placed proximate to the isolative material from which the insulator 15 is formed must not short the surface area of a skirt 305 . This, according to one alternative method, is accomplished by not bridging the apex 325 of one skirt 305 to the apex 330 another skirt 305 included in the insulator 15 .
[0037] [0037]FIG. 4 is a pictorial diagram that depicts one illustrative method according to the present invention for shrouding the upper portion of a cutout. One aspect of the present method that provides for shrouding of an upper connector 20 , an upper contact assembly 25 and a volume capable of receiving the upper-end of a fuse holder assembly 35 (i.e. the upper-end of the fuse receptacle formed by the upper and lower contact assemblies ( 25 , 60 )) may be achieved by positioning a shroud 110 over a conductor 55 which is connected to the upper connector 20 . According to this illustrative variation of the present method, a shroud 110 may be positioned over a conductor 55 and the shroud 110 may then be drawn over the upper end of the cutout 10 . One example embodiment of a shroud 110 that enables this method comprises a slot 120 for receiving the conductor 55 . As such, the shroud 110 may be installed onto the cutout 10 without the need to first disconnect the conductor 55 from the connector 20 . This method may also be employed where power continues to flow through the conductor 55 . Hence, one alternative method according to the present invention provides for a step wherein shrouding of a cutout 10 is accomplished whilst the cutout 10 is energized.
[0038] [0038]FIG. 5 is a pictorial diagram that depicts one example method for securing a shroud unit installed on a cutout. Generally, once a shroud unit 110 is drawn over the upper end of a cutout 10 , it is susceptible to various forces, such as wind and other weather, which may act to dislodge the shroud unit 110 from its intended installation position. To preclude this, one variation of the present method provides for the installation of a pin 140 through a first side 130 of the shroud 110 and through a side of the shroud 110 opposing said first side. As the pin 140 is disposed through the two sides, it is positioned so as to be beneath the upper contact assembly 25 . Hence, any forces acting to dislodge the shroud cover 110 may be opposed when the pin 140 encounters the upper contact assembly 25 . According to one variation of the present method, the pin 140 comprises an eyelet 145 . The eyelet 145 facilitates the installation of the pin 140 using an installation tool known as a “hot-stick”. By using this or other types of tools to manipulate the pin 140 , the cutout cover 110 may be secured in place by personnel working either at ground level, off a power pole or out of a bucket truck.
[0039] [0039]FIG. 6 is a pictorial diagram that depicts one alternative method for securing a shroud unit once it is installed on a cutout. A first securing method provides for the installation of a pin beneath the upper contact assembly 25 (as depicted by a first pin placement 160 ).
[0040] [0040]FIG. 6 further illustrates that the shroud 110 does not bridge a first apex 325 of a first skirt included in the insulator 15 and a second apex 330 or a second skirt included in the insulator 15 .
[0041] [0041]FIGS. 7 and 8 are pictorial representations that depict one example of a derivative method of the present invention for shrouding a conductor. Once a shroud assembly 110 is positioned over a cutout 10 , this variation of the present method provides for shrouding the conductor 55 connected to the upper contact assembly 25 . According to this variation of the method, a flexible insulator 180 comprising a longitudinal slot 185 is spread apart about the slot 185 and positioned 187 over the conductor 55 . Once so positioned, the flexible insulator 180 envelopes the conductor 55 as shown in FIG. 8. The flexible insulator 180 may then be drawn partially into an internal cavity 190 of the shroud 110 or may be abutted to a top surface 200 of the shroud 110 . The flexible insulator may be formed of any suitable isolative material.
[0042] [0042]FIG. 9 is a pictorial diagram that depicts one example embodiment of a cutout cover according to the present invention. According to this example embodiment, a cutout cover comprises a first section 220 , a second section 225 and a third section 230 . It should be noted that the definition of these sections is made here for the purposes of illustrating the formation of a cutout cover 110 according to the present invention and should not be used to exclude from the scope of the appended claims any alternative embodiments that may become apparent upon the reading of this specification.
[0043] According to this illustrative embodiment of a cutout cover 110 , the first section 220 is formed to envelope a portion of the perimeter of the insulator 15 comprising the cutout 10 , said portion being substantially in opposition to the direction in which the upper contact assembly 25 protrudes outward from the insulator 15 . Accordingly, any appropriate perimeter shape may be used in fashioning the first section 220 of the cutout cover 110 . Generally, the perimeter of the insulator is followed to a point where a second section 225 begins. This, according to at least one embodiment of the invention, is a point where a wall comprising the insulator perimeter envelope may be extended tangentially in a direction substantially parallel to the upper contact assembly 25 . The perimeter wall 222 envelope in the insulator 15 has an upper edge 223 . The cutout cover 110 further comprises a first section top surface 224 . According to one alternative embodiment of the present invention, the first section 220 of the cutout cover 110 may further comprise a conductor slot 221 that breaches the insulator perimeter wall 222 and extends inward toward the center of the first section top surface 224 to a location where a conductor may be connected to the upper connector 20 of the cutout 10 .
[0044] The second section 225 of the cutout cover 110 begins where the first section leaves off. Two perimeter walls, substantially opposing each other, straddle the upper contact assembly 25 and are bridged by a second section top surface 226 . The second section top surface 226 flows from the first section top surface 224 . According to one alternative embodiment of the present invention, the second section may expand in width about the upper contact assembly in order to provide clearance for a hook assembly 30 included in a fuse holder assembly 35 . The second section perimeter walls may further comprise pin-holes, said pin holes being placed in substantial opposition to each other in opposing walls and further placed either below the upper contact assembly 25 or below the hook assembly 30 .
[0045] Third section 230 of the cutout cover 110 continues from the second section 225 . The third section 230 comprises a third section top surface 232 . Envelope walls blend downward way from the third section top surface 232 outward away from the upper contact assembly 25 . The purpose for this is to provide an additional containment volume for a hooks 30 included in one embodiment of a cutout 10 . Further, this outward slope forms a funnel-shape that is wider at the bottom of the cutout cover 110 . This funnel-shape enables attachment of a load-breaking tool to the hooks 30 and to a pull-ring 40 included in a fuse holder assembly 35 , wherein attachment can be accomplished at various angles relative to an axis defined by the fuse holder assembly 35 .
[0046] The height (H) of the various sections of a cutout cover 110 may be adjusted to accommodate various types of cutouts. The height (H) of the first section 220 is adjusted so as to prevent excessive encroachment over the insulator 15 . This height is selected empirically in order to minimize any possible reduction in electrical isolation to the mounting bracket 50 provided by the insulator 15 . The height of the second and third sections ( 225 , 230 ) is varied in order to accommodate the vertical placement of the hook assembly 30 relative to the upper contact assembly 25 and the vertical placement of the pull-ring 40 included in the fuse holder assembly 35 . Hence, where the height of the first section 220 is selected to minimize its impact on the isolative characteristics of the insulator 15 , the height of the second and third sections ( 225 , 230 ) are selected to provide a minimum volume about the upper end of the fuse receptacle so as to shield the hooks 30 , the upper end of the fuse holder assembly 35 and its associated pull-ring 40 .
[0047] According to one alternative embodiment of the present invention, a single piece cutout cover 110 may be constructed by molding a dialect material into the shapes described for the first, second and third sections. Such a molded part may be constructed using any suitable dialect material that provides sufficient electrical isolation and is resilient to the ultraviolet radiation present in ordinary sunlight. Various materials suitable for such molding of a cutout cover include, but are not necessarily limited to high-density polyethylene. It should be noted that the claims appended hereto are not to limited to any particular material listed herein.
[0048] The invention further comprises a flexible insulator conductor shroud 180 that is fabricated from dielectric material. The conductor shroud comprises a slot and is pliable to the extent that the slot may be spread apart in order to cover a conductor. The dielectric material is selected in order to provide the resilience necessary to return to its original shape so as to envelope the conductor. According to one example embodiment of the present invention, the flexible insulator conductor shroud 180 is fashioned from high-density polyethylene. It should be noted that the claims appended hereto are not to limited to any particular material listed herein.
[0049] [0049]FIGS. 10 and 11 are, respectively, a perspective and profile pictorial diagrams that depict one alternative method for shrouding a lower contact assembly of a cutout 10 . According to one alternative method, the lower contact assembly is shrouded by a second 355 . This is an optional step to a first example method wherein the upper contact assembly of a cutout 10 is shrouded by a first shroud 350 .
[0050] Alternative Embodiments
[0051] While this invention has been described in terms of several preferred embodiments, it is contemplated that alternatives, modifications, permutations, and equivalents thereof will become apparent to those skilled in the art upon a reading of the specification and study of the drawings. It is therefore intended that the true spirit and scope of the present invention include all such alternatives, modifications, permutations, and equivalents. | Method and apparatus for protecting wildlife from contact with an energized fuse assembly known as a “cutout”, also known as a “disconnect”. The cutout is shrouded from above and three sides. One side is left open to facilitate installation or removal of a fuse holder assembly. The shroud is formed to allow the use of a hot-stick for installation and removal of a fuse holder assembly into a fuse receptacle formed by upper and lower contact assemblies held in opposition to each other by an insulator. The shroud provides a slot enabling installation when a wire is connected to the upper contact assembly. A pin is used to hold the shrouding in place. | 7 |
This application claims the benefit of U.S. Provisional Application No. 60/678,894, filed May 5, 2005.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention is related in general to the field of dive computers. In particular, the invention consists of a method for calculating the formation of free gas in a human body due to a change in altitude, depth, or pressure.
2. Description of the Prior Art
An undersea diver needs to breathe air or some other gas mixture at a pressure that closely matches the pressure of the surrounding water. The pressure exerted on the diver increases dramatically as he increases his depth under the surface of the water. As a result, the concentrations or ‘tensions’ of dissolved inert gases in his body tissue can rise well beyond the levels than are common above the water surface.
Of special consequence is the inert gas nitrogen, which comprises 79% of the volume of air under normal atmospheric conditions. During a dive, excess nitrogen becomes dissolved in the body's tissues. The amount of nitrogen which is absorbed by the body's tissues is a function of the depth of the dive and the amount of time at this depth.
While dissolved, the nitrogen undergoes no reactions with the tissue. However, as the diver rises to the surface, the nitrogen leaves the body's tissues and travels through the diver's bloodstream, where it may be released as free gas. This released free gas may result in decompression sickness, which can result in pain, disability, or death of the diver. In order to reduce the likelihood of decompression sickness, a diver may need to slowly rise to the surface or stop at intervals along the way.
Decompression Sickness
Decompression sickness made its first appearance in the mid-nineteenth century among men who worked in submerged caissons to set the footings of bridges like the Brooklyn Bridge. At the time, the affliction was called caisson workers' disease. The symptoms were acute joint pain following emergence from the high pressure atmosphere in the caissons. Victims would often bend over in pain, so the affliction became commonly known as “the bends”. The bends were clearly caused by the fall in air pressure or “decompression” as the victims passed from submerged caissons to the surface, but the physiology remained otherwise obscure, an obscurity that persists to some degree today.
Haldane Models
The first systematic studies of caisson disease or decompression sickness were conducted at the start of the last century, stimulated by the appearance of the same symptoms among deep sea divers, who were subject to the same type of decompression as caisson workers. That early research culminated in a brilliant paper by Haldane and co-workers, who argued that “compressed air sickness” is caused by absorption of nitrogen in tissue during the compressive phase of a dive, followed by its release in gaseous form during decompression (Boycott, Damant, and Haldane 1908). Haldane and his group conducted extensive pressure chamber tests on goats and compared the results with divers' experience.
The Haldane group also developed a mathematical model of decompression sickness based on the idea that tissue absorbs nitrogen at a rate proportional to the difference between the partial pressure of nitrogen in the lungs and the “tension” of nitrogen dissolved in tissue and blood. They discovered that absorption at a single rate would not explain their data, and they conceived the idea of multiple “tissue compartments” with different rates of nitrogen absorption. Multiple tissue compartments with different absorption rates have come to be known as the “Haldane model”. Almost 100 years after its conception, the Haldane model remains the basis for today's dive computers.
The Haldane group posited five tissue compartments with absorption rates equivalent to half times of 5, 10, 20, 40, and 75 minutes. They assumed that a diver would suffer decompression sickness if the nitrogen tension in any one of the compartments reached a specific load common to all of the compartments. The nitrogen load was measured not in terms of concentration (ml/ml) or tension (mm Hg) but in terms of the depth where the nitrogen concentration would be in equilibrium with the air being breathed. Thus the critical nitrogen load was expressed in terms of feet of sea water (fsw).
Subsequent workers increased the number of hypothetical tissue compartments and assigned to them different critical nitrogen loads. Workman (1965) proposed six tissue compartments with half times of 5, 10, 20, 40, 80, and 120 min and assigned to them critical loads ranging from 100 down to 20 fsw. Workman's variant of the Haldane model became the basis for the US Navy dive tables and for the first generation of dive computers (Lewis and Shreeves 1993). More recent dive computers have increased the number of hypothetical compartments to twelve, and Lewis and Shreeves even invoke the ultimate dive computer HAL with 1530 tissue compartments and 3060 half times and loads! However, Hills (1977) has observed with amusement that the larger Haldane models have more parameters than data available to be fitted by them.
The largest relevant data set was published by Hamilton, Rogers, Powell, and Vann (1994) under the title “The DSAT Recreational Dive Planner”. The data are the results of 2943 dives, some in water, and some simulated in a pressure chamber at the Institute of Applied Physiology and Medicine in Seattle. To determine dive profiles with low risks of decompression sickness, they fitted the parameters of a Haldane model to an earlier data set of Spencer (1976). Only 301 or 10% of those dives produced measurable bubbles, and only one caused decompression sickness, an incidence rate of 0.03%. The Haldane parameters established by Hamilton et al. are the basis for many of the dive computers in use today.
Other Models
Despite their widespread use, the Haldane models invite some reservations. One is the notion of “tissue compartments”, which never have been correlated with physiological structures. Another is “perfusion”, the means by which gas is supposed to travel from the lungs into tissue. Perfusion describes the Haldane models but not an actual gas transport mechanism.
Among the first to try to improve upon those concepts was Hempleman (1952), who suggested that gas absorption could be modeled as a process of diffusion from blood vessels into homogeneous tissue. He first modeled the tissue as a one-dimensional slab bounded on one side by blood and unbounded on the other. An immediate result of that very simple model is that the mass of nitrogen absorbed during a dive is proportional to the partial pressure P of nitrogen above its value at sea level times the square root of the duration T of the dive. Hempleman assumed that the product “P-root-T” must remain below some allowable value for safe return to the surface. He determined the allowable limit by comparison with Workman's data, with the result that P-root-T is around 500 fsw−√{square root over (min)}. In 1968, Hempleman's simple model became the basis for the Royal Navy Dive Tables.
However, one-dimensional diffusion into an infinite slab could not allow for saturation, since the slab would absorb nitrogen indefinitely. To allow for saturation, Hempleman analyzed diffusion into a finite slab and obtained an infinite series of terms bearing a resemblance to Haldane “tissue compartments”. The finite slab model did not improve agreement with Workman's data and may never been used for dive computers.
The most obvious limitation of both the Haldane and Hempleman models is that they make no attempt to predict the formation of free nitrogen gas, the presumptive cause of decompression illness. The emphasis instead is on nitrogen storage in form of molecules dissolved in tissue. This lack to attention to a model for free gas formation is particularly odd for the Haldane group, who observed nitrogen gas bubbles in the eyes of severely afflicted goats.
Hills (1966, 1977) may have made the first serious effort to understand gas formation as a cause of decompression sickness. He proposed that gas volumes form in tissue wherever net gas tension exceeds the local ambient pressure, and he drew attention to the fact that any such gas cells would contain the so-called metabolic gases, oxygen, carbon dioxide, water vapor, and nitrogen. Many of Hills's physiological insights were brilliant, but they were not pulled together into a mathematical model of decompression sickness. Additionally, his qualitative proposal for gas formation would have resulted in calculations indicating far too much gas being formed in tissue, e.g., several liters for dives to 100 ft. Also, his proposed ascent strategies are clearly at odds with the experience of divers (Gernhardt 1991).
A nitrogen gas concept finally made its way into Haldane models as RGBM, the Reduced Gradient Bubble Model (Wienke 1990, 2003). The basic idea is that nitrogen filled microbubbles pervade body tissue at all times, even without dives and ascents. Without a special sustaining mechanism, gas in the hypothetical bubbles would diffuse into surrounding tissue in minutes, and the bubbles would close. Wienke assumes that “flexible seed skins” keep the bubbles open while a diver is on the surface or descending under water. During ascent, gas diffuses into the microbubbles, and they enlarge in accord with Boyle's law for expansion at constant temperature. The presumed presence of the bubbles reduces the allowable nitrogen loads of the Haldanian tissue compartments. The Gradient in the Reduced Gradient Bubble Model is proportional to the difference between the allowable Haldane tissue compartment loads and the partial pressure of nitrogen at sea level.
However, the Reduced Gradient Bubble Model has to assume the perpetual existence of gas bubbles held open by “flexible seed skins”. The concept of perpetual gas bubbles, moreover, conflicts with the common observation that bubbles in supersaturated liquids form on boundaries, not in the interiors of liquids (Knapp, Daily, and Hammitt 1970). The Reduced Gradient Bubble Model does not supercede the Haldane models, but rather changes the allowable nitrogen loads in response to specific dive scenarios, e.g., reversed dive profiles. Finally, the Reduced Gradient Bubble Model is not a real-time algorithm. RGBM computations are traditionally performed on a mainframe computer and incorporated into dive computers as modified Haldane allowable nitrogen loads.
Based on these models, the sport diving industry has developed dive computers to guide divers with regard to allowable times at depth and ascent procedures to avoid decompression sickness. Traditional dive computers measure time and water pressure, and perform computations to indicate the time a diver may remain at a particular depth and the recommended ascent procedures to minimize the possibility of decompression sickness.
However, these algorithms are not based on physiology and make no prediction with regard to the formation of free nitrogen. As a consequence, the algorithms are of uncertain validity when used outside of the dive data upon which they are based. Accordingly, it is desirable to have a dive computer that utilizes an algorithm to calculate the potential formation of free nitrogen when utilized in conditions outside of those covered by existing dive tables.
Because these dive computers do not incorporate physiological parameters as inputs, the algorithms cannot be tuned with any certainty to the needs of individual divers. Also, because existing algorithms are not based on physiology, they cannot be upgraded with modern research in physiology. Accordingly, it is desirable to have a method of calculating the potential formation of free nitrogen in the human body that can take into account physiological parameters of the user.
SUMMARY OF THE INVENTION
The invention disclosed herein employs an algorithm, the Gas Formation Model (“GFM”), to calculate the formation of free nitrogen in a human body. The GFM is based on a novel theory of the formation of free nitrogen relative to the physiology of the human cardiovascular system. Additionally, the GFM utilizes novel means for the solution of integro-differential equations, the type of equations that derive from the introduction of physiological parameters. The GFM is implemented as a practical computational tool by means of a incorporating the algorithm into a dive computer, which may be about the size of a wrist watch.
GFM-based dive computers can utilize novel inputs, including a measure of exercise at depth to reflect the state of an individual's cardiovascular system. GFM-based dive computers also produce novel outputs, including the maximum volume of free nitrogen gas present in a diver's cardiovascular system following ascent. The evaluation, prediction, and display of free gas volume are important elements of this invention.
Various other purposes and advantages of the invention will become clear from its description in the specification that follows and from the novel features particularly pointed out in the appended claims. Therefore, to the accomplishment of the objectives described above, this invention comprises the features hereinafter illustrated in the drawings, fully described in the detailed description of the preferred embodiments and particularly pointed out in the claims. However, such drawings and description disclose just a few of the various ways in which the invention may be practiced.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram of a cardiovascular system.
FIG. 2 is a schematic diagram illustrating the formation of gas layers at the boundary of a person's blood stream and body tissue.
FIG. 3 is a flow chart illustrating a gas formation model, according to the invention.
FIG. 4 is a plot of predictions by the gas formation model, according to the invention, compared with Behnke data.
FIG. 5 is a graph of predictions by the gas formation model, according to the invention, of nitrogen elimination compared to measured data.
FIG. 6 is a plot of gas formation model calculations of gas released from a solution, according to the invention.
FIG. 7 is a graph of gas formation model calculations of free gas remaining in the body, according to the invention.
FIG. 8 is a table of gas formation model predictions of no-decompression limits, according to the invention.
FIG. 9 is a plot of the data of FIG. 8 .
FIG. 10 is a graph of a qualitative comparison between audio data and gas formation model predictions.
FIG. 11 is a plot comparing gas formation model calculations with PADI RDP data for repetitive dives.
FIG. 12 is a graph predicting free gas volume during safety stops, using the gas formation model.
FIG. 13 is a block diagram illustrating a dive computer including a data input device, a computer processing device, and a data output device.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
This invention is based on the idea of using an algorithm to calculate the formation of free nitrogen in the human body. The invention disclosed herein may be implemented as a method, apparatus or article of manufacture using standard programming or engineering techniques to produce software, firmware, hardware, or any combination thereof. The term “article of manufacture” as used herein refers to code or logic implemented in hardware or computer readable media such as optical storage devices, and volatile or non-volatile memory devices. Such hardware may include, but is not limited to, field programmable gate arrays (“FPGAs”), application-specific integrated circuits (“ASICs”), complex programmable logic devices (“CPLDs”), programmable logic arrays (“PLAs”), microprocessors, or other similar processing devices.
The gas formation model (“GFM”) is based on the physics of gas formation in supersaturated substances and on the physiology of the human cardiovascular system. This requires an understanding of nitrogen gas formation during decompression, with nitrogen storage during compression as a mere precursor.
As with the Hempleman model, diffusion into tissue during compression must be accounted for. As with the Hills' model, a cylindrical diffusion geometry and metabolic gases must also be accounted for. However, a series of differential equations resembling Hempleman's finite slab model applied to Haldane's tissue compartments produces a novel means of solving a key integro-differential equation, i.e., the integral representing tissue “memory” of past nitrogen tension exposures.
Another element of the invention is the realization that a measurement of existing gas bubbles is not helpful in predicting subsequent formation of free nitrogen gas. Gas bubbles are certainly a signature of decompression sickness and are a useful diagnostic tool, but they are a consequence rather than a cause of gas formation. It is helpful to realize that the first manifestation of free gas is the production of gas layers, not gas bubbles.
Physics of Gas Formation:
Analyses and observations confirm a fact known from past literature (e.g. Knapp et al. 1970) that bubbles always form on surfaces rather than in the interiors of supersaturated liquids.
Gas bubbles associated with decompression illness start as gas sheets between blood and surrounding tissues. Because the gas sheets are too thin to see in casual tests like sudden decompression of carbonated water bottles, what an observer may see is bubbles that seem to grow from the walls. However, it has been determined that the bubbles result from instabilities in underlying sheets of gas.
This leads to the formation of a fundamental concept that gas sheets or layers are the original locales of free gas emerging from a solution. A surface between a liquid (blood) and solid (tissue) has a specific energy per unit area requirement for the passing of gas through the membrane of the tissue. However, more energy per unit area is required to bound a gas between the solid and the liquid. This is because the gas molecules dissolved in solids or liquids have both kinetic energy (due to vibration) and potential energy (also due to vibration), in equal amounts. When a gas layer forms, the vibrational potential energy of the gas molecules transforms into the required surface energy corresponds to the necessary surface tension.
Physiology
Boundaries within the body are the places where free nitrogen gas is likely to form during decompression. Conceivably such boundaries could be found in the interior of tissue, but gas pockets so formed would be constrained by the elasticity of the surrounding tissue and would likely diffuse back into the tissue.
Much more likely sites for the formation of gas layers are the boundaries between tissue and blood which are continuously swept away by the blood stream. Such gas layers are relatively flat and not subject to the strong compressive effects of surface tension which acts to force gas out of microbubbles. This formation of gas on the boundaries between tissue and blood accounts for the appearance of bubbles in the blood stream during decompression. These bubbles moving in the blood stream can be detected by Doppler velocimetry, a method often used as a measure of decompression stress (Pilmanis 1976).
By far the largest area of contact between tissue and blood resides in capillaries, the fine scale blood vessels responsible for most of the transfer of metabolic gases from blood to tissue and back. The diagram of FIG. 1 shows how capillaries are arranged in the cardiovascular system (Thibodeau and Patton 2000). The pulmonary capillaries 10 transfer dissolved gas between the lungs 12 and circulatory system, while the systemic capillaries 16 interface between blood and tissue. Probable sites for the formation of gas layers are the interior surfaces of the systemic capillaries 16 .
The total surface area of the capillaries of an average person is about 600 square meters, or 6500 square feet. The formation of gas in systemic capillaries 16 accounts for the fact that gas emboli induced by decompression are almost always found in the veins downstream of those capillaries, and rarely in the upstream arteries. This also accounts for the profound effect of exercise on decompression phenomena (Dick, Vann, Mebane, and Feezor 1984). Many of the systemic capillaries 16 have precapillary sphincter muscle cells, which act as valves to close off the capillaries during periods of rest (Caro, Pedley, Schrotter, and Seed 1978). The sphincter valves open during periods of exercise, thereby greatly enlarging the capillary surface area exposed to blood flow and increasing the rate of gas transfer between blood and tissue. The experiments of Dick et al. show that exercise can increase the amount of nitrogen dissolved in tissue by a factor better than two.
GFM Input Parameters
The input parameters for a Haldane model are mostly half times and gradients selected to fit dive data. In contrast, most input parameters for the GFM pertain to human physiology, and many of these parameters are measures of the cardiovascular system, in particular the systemic capillaries 16 , as follows:
a
capillary radius (microns);
b
radius of surrounding tissue (microns);
L
capillary length (microns);
S b
solubility of nitrogen in blood (ml/ml);
S t
solubility of nitrogen in tissue (ml/ml);
D t
diffusivity of nitrogen in tissue (microns 2 /min);
v b
average velocity of blood in capillary (microns/min);
N c
number of systemic capillaries;
θ
transpiration time for nitrogen gas from lungs (min).
Values of these parameters are presented in Appendix A, which includes a listing of a current implementation of the GFM in Visual Basic code. Natural units are microns for length (one-millionth of a meter), mm Hg for pressure (millimeters of mercury), ml for gas volume (milliliters), and min for time (minutes). Microns are used for length because of the small size of capillaries, typically having radii of around 4 microns and lengths of approximately 1000 microns.
Other input parameters relate to the diver's blood pressure and tension of metabolic gases: oxygen, carbon dioxide, and water vapor. The general formula for metabolic (“other”) gas pressure is:
p o =p O2 +p CO2 +p H2O . (1)
using the following input parameters:
P oa
metabolic pressure at arterial end of capillary (mm Hg);
P ov
metabolic pressure venous end of capillary (mm Hg);
P ba
blood pressure arterial end of capillary (mm Hg);
P bv
blood pressure venous end of capillary (mm Hg).
P amb
ambient pressure (mm Hg). It should be noted that the
ambient pressure of the dive computer is a critical variable and is,
therefore, continuously measured.
Additional input parameters relate to gas mixtures, in particular the fraction of nitrogen when the diver breaths “nitrox” and the fraction of helium when the diver breathes “heliox” or “Trimix”:
R N2
fractional partial pressure of nitrogen.
R He
fractional partial pressure of helium.
When a diver breaths air, the parameter R N2 is 0.79, the fractional partial pressure of nitrogen in the atmosphere.
Two additional input parameters define computational resolution in time and space:
delt
time step (min);
delx
spatial step along capillary (microns).
Finally and importantly is time itself:
t time (min).
Many of these parameters, such as capillary radius a, length L, solubility S t of nitrogen in tissue, are fixed in the firmware of a GFM dive computer. Others are measured in real time or inferred from measurements of physiological variables. The time dependent parameters include time t itself, ambient pressure p amb , the gas mixture fractions R N2 and R He , and the number N c of active systemic capillaries.
Exercise
As previously explained, exercise causes systemic capillaries to open up, increasing the capillary surface area available for the transfer of nitrogen from blood to tissue. This allows the tissue to store more nitrogen, resulting in a corresponding increase in the likelihood that gas may form during decompression as the nitrogen transfers from tissue to blood.
Exercise changes two of the GFM parameters, b and N c , and, possibly the parameter v b . As capillaries open up, the radius b characterizing the tissue attributable to each capillary decreases in such a way that the product
V t =N c ( t )π b 2 ( t ) L (2)
is preserved.
V t is the total volume of tissue surrounding all the capillaries. The capillary walls are inextensible, so their radius a changes little if at all. As a result, the ratio b/a decreases as the number of active capillaries increases. The ratio b/a has an important bearing on the memory integral described in the section on the GFM mathematical model and ultimately an important bearing on gas formation. N c and b/a, in turn, are related to the divers' level of exercise.
GFM dive computers can determine the diver's level of exercise in one or more of three ways:
1. by input from the diver as to his perceived level of exercise, e.g. rest, moderate (assumed default), or strenuous; 2. by continuous measurement of pulse rate; or 3. by continuous measurement of oxygen consumption, a direct measure of metabolic rate.
Mathematical Model
The mathematical model of gas formation starts with a set of first principles: convection and diffusion of nitrogen in blood; diffusion of nitrogen into tissue; diffusion of nitrogen from tissue during decompression; gas formation on the inside surfaces of capillaries; free gas transport in gas layers around blood streams; and gas transpiration out from the lungs. The GFM also involves a sequence of rational approximations, meaning approximations based on certain dimensionless groups.
The primary dependent variable of the mathematical model is the tension p(x,t) of nitrogen in the capillary blood stream. The word “tension” conveys a sense of mechanical stress, but it really is just a measure of concentration. A tension p means that the nitrogen concentration would be in equilibrium with free nitrogen gas at a partial pressure p.
The tension is a function of distance x along the capillary as well as of time t. The nitrogen tension p(0,t) at the entry of the capillary is the same as the tension of arterial blood and by assumption the same as the partial pressure of nitrogen in the alveoli of the lungs. Thus
p (0, t )= R N2 [p amb ( t )−47 mm Hg], (3)
where the correction within the square brackets takes into account the partial pressure of water vapor in alveoli. Since arterial tension is the same as alveolar partial pressure, equation (3) serves as a boundary condition at the upstream end of the capillary.
Two initial conditions are needed at all locations x along the capillary:
p ( x, 0)= p (0,0) and ∂ p ( x, 0)/∂ t= 0. (4)
Both conditions are applied when the dive computer is turned on, but their effects disappear as a pressure history evolves. Nitrogen tension changes along the capillary in accord with an integro-differential equation:
S
b
π
a
2
v
b
∂
p
(
x
,
t
)
∂
x
=
-
2
π
S
t
D
t
∫
-
∞
t
∂
p
(
x
,
t
′
)
∂
t
′
F
[
D
t
(
t
-
t
′
)
a
2
]
ⅆ
t
′
.
(
5
)
The left side of this equation represents the flow of nitrogen dissolved in the blood stream, and the right represents nitrogen diffusion into or from the surrounding tissue. F is a “memory function” that relates tension changes at past times t′ to the current flux of nitrogen through the capillary surface. The memory function can be expressed as an infinite series,
F [ D t ( t - t ′ ) a 2 ] = π ∑ n = 1 ∞ c n exp [ - b n 2 D t ( t - t ′ ) a 2 ] , ( 6 )
in which the b n 's and c n 's depend only on the ratio b/a. The constants b n are the eigenvalues of the cylindrical diffusion problem, and the terms in the series (6) are called eigenmodes. The eigenvalues are the roots of a rather complicated equation involving Bessel functions,
J 0 ( b n ) Y 1 ( b n b/a )− Y 0 ( b n ) J 1 ( b n b/a )=0, (7)
and the equation for the c n 's is even more complicated. Both can be found in standard texts on diffusion theory, for example Carslaw and Jaeger (1976).
Equation (5) prevails wherever the sum of p plus the metabolic pressures p o is less than the confining pressure, which in turn is the sum of ambient pressure p amb plus blood pressure p b :
p ( x,t )≦ p N2 ( x,t )≡ p amb ( t )+ p b ( x,t )− p o ( x ). (8)
A gas layer forms wherever criterion (8) is violated, as shown in the schematic drawing of FIG. 2 . Gas layers 18 form at the boundary between the blood stream 20 and body tissue 22 . At such locations and times, equation (5) must give way to a requirement for mechanical equilibrium,
p ( x,t )= p N2 ( x,t ). (9)
together with a formula for the rate of free gas formation:
GF ( x , t ) = - 2 π S t D t ∫ - ∞ t ∂ p ( x , t ′ ) ∂ t ′ F [ D t ( t - t ′ ) a 2 ] ⅆ t ′ . ( 9 )
GF has units of pressure times volume per unit length and is a measure of the rate at which nitrogen mass is released as gas per unit length of capillary.
The rate of growth of nitrogen gas in the body is proportional to the number N c of active capillaries times the integral of GF along each capillary, less the rate at which free gas transpires through the lungs:
∂
G
∂
t
=
N
c
∫
0
L
GF
(
x
,
t
)
ⅆ
x
-
G
θ
.
(
10
)
The first term on the right is the net source of nitrogen gas, and the second term is the rate at which the lungs exhale the gas. The transpiration time θ includes various delays as the gas layers break into bubbles and the bubbles make their way though the vascular system.
The final step in the mathematical model relates G to the total volume of nitrogen gas in the body:
V
(
t
)
=
G
(
t
)
p
N
2
(
L
,
t
)
.
(
11
)
The gas volume is the total amount of nitrogen gas currently in the body divided by the partial pressure of nitrogen at the venous end of the capillary. The volume includes the contributions of the metabolic gases, but (11) is the correct formula for volume when G(t) represents the mass of nitrogen (partial pressure times volume) and p N2 (L,t) is the partial pressure of nitrogen only.
Equations (1)-(11) represent the physics and physiology of the Gas Formation Model, but not the formulas used to provide output for displays. An example of such a formula is a sigmoid relationship between maximum gas volume and probability of decompression sickness. Such formulas will be obvious from the discussion of outputs and displays.
Memory Integral
The mathematical model includes four special aspects including the memory integral, inert gases other than nitrogen, multiple tissues, and forecasts of time remaining at depth and possible decompression procedures. All four give rise to specific patent claims.
The memory integral appears in equations (5) and (9). It expresses the amount of nitrogen gas stored in tissue as a function of the time derivative of nitrogen tension on the interior surface of the capillary. The integral extends over all past times t′ and involves both past and current times in the integrand. To all appearances, the integral would have to be re-evaluated at each time step, a procedure costly of both computational time and memory. Fortunately there is an alternative, developed especially for the Gas Formation Model but of potential use for any system that involves time varying inputs to bounded storage media. The alternative replaces the memory integral with a set of differential equations having parameters related to the eigenvalues of a series similar to (6).
The memory integral of (5) and (9) can be written in the form
∫
-
∞
t
∂
p
(
x
,
t
′
)
∂
t
′
F
[
D
t
(
t
-
t
′
)
a
2
]
ⅆ
t
′
=
π
r
(
x
,
t
)
,
where
(
12
)
r
(
x
,
t
)
=
∑
n
=
1
∞
c
n
q
n
(
x
,
t
)
,
(
13
)
q
n
(
x
,
t
)
=
∫
-
∞
t
∂
p
(
x
,
t
′
)
∂
t
′
exp
[
-
β
n
(
t
-
t
′
)
]
ⅆ
t
′
,
and
(
14
)
β
n
=
D
t
b
n
2
/
a
2
.
(
15
)
Equations (12)-(15) are nothing more than a restatement of the memory integral with the series representation (6) put in place of F. But now we notice that (14) is the solution of the partial differential equation
∂
q
n
(
x
,
t
)
∂
t
=
∂
p
(
x
,
t
)
∂
t
-
β
n
q
n
(
x
,
t
)
.
(
16
)
Equation (16) can be solved in time step by step without explicit memory of events in the distant past. The need to remember events over an infinite sequence of past times t′ has been replaced with an infinite series of terms q n evaluated at the current time t. In practice the series can be truncated to a few terms. The algorithm found in Appendix A uses eight terms.
Transformation of the memory integral into a set of differential equations affords an enormous reduction in computational time, typically by a factor of 1,000. The transformation, moreover, is of very general utility. It applies to the accumulation of a quantity in a bounded medium with internal transport subject to a linear partial differential equation. Examples can be found in the fields of heat transfer, chemical processors, nuclear power plants, and even auditorium acoustics. A curiosity of (16) is that it resembles the model for nitrogen accumulation in the “tissue compartments” of Haldane, but the temptation to identify the q n 's with tissue compartments should be resisted. The q n 's measure gas associated with the eigenmodes of a single homogeneous tissue medium. The time scales of the eigenmodes have as much to do with boundary conditions as tissue properties. Their values are not arbitrary but follow directly from the mathematical model.
Other Inert Gases
The GFM mathematical model is described for simplicity with nitrogen as the inert gas. With simple alterations, the same model can handle other inert gases and even mixtures of inert gases. Here is how GFM treats various gas mixtures.
Air
Air is a mixture of oxygen and nitrogen, the partial pressure of nitrogen being about 79% of the total. The GFM handles computations as described above with R N2 =0.79.
Nitrox
Nitrox is also a mixture of oxygen and nitrogen, but with a reduced percentage of nitrogen to forestall possible decompression sickness. GFM computes nitrox mixtures in the same way as air with a reduced value of R N2 .
Heliox
Heliox is a mixture of oxygen and helium. Helium reduces potential for nitrogen narcosis. GFM uses the appropriate value for R He and suitable values for the diffusivity of helium in tissue and solubilities of helium in tissue and blood. Otherwise computations proceed as with nitrogen.
Trimix
Trimix is a mixture of oxygen and both nitrogen and helium. Trimix has become popular among divers as an economical alternative to heliox. For trimix, the GFM computes blood tensions for nitrogen and helium separately and combines them only through the gas formation criterion
p N2 ( x,t )+ p He ( x,t )≦ p amb ( t )+ p b ( x,t )− p o ( x ) (16)
which replaces inequality (8). Of course the computation of free gas volume has to take both nitrogen and helium into account.
More exotic gas mixtures, for example with argon, are handled in the same way, with the sum on the left of (16) extending over all inert gases. In all cases, the metabolic gases (including water vapor) are treated as described in the section titled Mathematical Model.
Multiple Tissues
The GFM may be implemented to account for a single tissue model, or may be extended to compute nitrogen accumulation and elimination in multiple tissues. Each disparate tissue requires a distinct value of diffusivity and solubility, as well as a different values for b/a and N c . Computations for multiple tissues proceed in parallel, with the free gas volumes evaluated separately, then combined into a single volume. These multiple tissues are not the “tissue compartments” of a Haldane model. Rather they represent truly distinct tissues of the human body: skeletal muscle, adipose tissue (fat), bone marrow, and perhaps brain matter. It should be noted that skeletal muscle is virtually the only tissue that responds to exercise. While vigorous exercise increases overall blood flow by a factor of three, almost all of the increase goes through the skeletal muscles where the blood flow increases by a factor of ten. Fat has five times the solubility of muscle, and bone marrow has a very low blood flow rate, which could account for the long time persistence of nitrogen in the body.
The parameters of the GFM algorithm listed in the Appendix represent average tissue properties. However, the GFM algorithm may be adapted to implement parallel computations relative to multiple tissues.
Predicting Futures
The GFM computes free gas volume and other quantities on the basis of past and current measurements of time, pressure, and exercise parameters. That is important but by no means sufficient. A divers' main interest is in the future. What does he need to do to get to the surface safely? To answer that question, a GFM dive computer needs to compute into the future under various ascent scenarios and inform the diver of his best options. Fortunately, the efficiency of the algorithm with differential equations in place of the memory integral allows the computation of alternative futures with ease.
GFM dive computers compute multiple dive scenarios through future times of, for example, one hour. FIGS. 3 and 4 show ascent scenarios under two circumstances.
GFM Algorithm
FIG. 3 is a simplified flow chart of a GFM algorithm. A complete listing of the algorithm coded in Virtual Basic run in the context of an Excel™ spreadsheet is included in Appendix A. Steps 100 and 102 require the inputting of parameters. These inputs include physiological parameters from firmware, inputs that the diver may enter into the dive computer, and inputs derived in real time from sensors. The real time sensor inputs include time, ambient pressure, water temperature, and may include a measure or measures of exercise level.
Constants are calculated in step 104 and time is initialized in steps 106 and 108 . The main program loop includes steps 110 , 112 , 114 , 116 , 118 , 120 , 122 , 124 and 126 and computes the number N c of active capillaries, eigenvalues b n , and eigenmode amplitudes c n as functions of exercise level. It goes on to compute various functions of time, including the inert gas tension p(0,t) at the arterial end of the capillary.
Within the main time loop are spatial loops to evaluate quantities as functions of location along the capillary. Those include the q n 's as well as r, p, and p N2 , and the tensions of any other inert gases that may be present. The gas formation criterion tests the net inert gas tension and makes the appropriate downward adjustments if the criterion is exceeded. The local gas formation rates GF are computed and integrated over the capillary length to produce the total sources.
The main loop concludes by computing, in step 124 , total free gas amounts G and volume V, the key variable for evaluating the diver's situation with regard to possible decompression phenomena.
Outputs
Some of the outputs of the GFM are unique to GFM. Like conventional counterparts, a GFM dive computer will include a dive planning function for use before a dive. Six of the outputs have to do with the primary variables of time and depth:
Current time Current depth Accumulated water time Accumulated surface interval Maximum past depth Ascent rate
Four outputs concern air and oxygen management:
Tank pressure Partial pressure of oxygen Air time remaining Oxygen time remaining
Three of the outputs are conventional outputs that are based on the novel GFM algorithm:
No-decompression (NoD) time remaining Decompression obligations Time to fly
Finally, five of the outputs are unique to the GFM algorithm:
Exercise level Dissolved inert gas volume Current free inert gas volume Future free gas volume Probability of decompression sickness (P dcs )
The exercise level output is a simple index of exertion based on one or more of the measurement methods described above in the section titled Exercise. Exercise level is key to management of dive safety, since exercise has a strong influence on rates of accumulation and elimination of inert gas.
Dissolved inert gas volume is the GFM analogue of the “tissue loadings” of Haldane-based dive computers. The natural units are milliliters of gas at STP, though more intuitive units may be used for the actual display. Dissolved inert gas volume can be presented in graphical form to show to a diver the rise and fall of inert gas in his body. Current free gas volume will be zero during most of a dive but should be of great interest on the surface.
Future free gas volume is the most important output of a GFM dive computer. The output can be presented in graphical form for the time remaining at depth and the optimum ascent scenario. Plots of future free gas volume give divers profound insight into their situation with regard to safety from decompression sickness. Of special importance will be the maximum future free gas volume, which should remain below the critical gas volume explained in a subsequent section. Graphical output is especially interesting during safety or decompression stops, when the diver may monitor the elimination of future free gas from his body.
Probability of decompression sickness is related directly to the maximum future free gas volume through a sigmoid function developed from thousands of tests on decompression effects. Probability of decompression sickness may be a more intuitive output than maximum future free gas volume.
Parameter Selection
The GFM as currently implemented requires thirteen input parameters. Ten of them can be found in standard literature on physiology. Two must be derived from important experiments on nitrogen elimination by Behnke and Willmon (1941). The final parameter, transpiration time θ, involves special considerations and is deferred to the section called Transpiration.
Two of the parameters are blood pressures at the arterial and venous ends of the capillary, and those can be found in many sources. Scanlon and Sanders (1999) report that the arterial blood pressure just upstream of the capillaries is 30-35 mm Hg, and the venous blood pressure is 12-16 mm Hg. The selections below are appropriate and appear as inputs in the GFM listing of Appendix A:
p ba =30 mm Hg Scanlon and Sanders (1999)
p bv =12 mm Hg
Two more parameters are pressures, the sum of the partial pressures (tensions) of the metabolic or “other” gases including oxygen, carbon dioxide, and water vapor. Vann and Thalmann (1993) present the sum of the metabolic gases at the venous end of the capillaries as 131 mm Hg, and Hills (1977) argues that the sum should be nearly constant over most if not all of the capillary beds. Thus
p oa =131 mm Hg Hills (1977)
p ov =131 mm Hg Vann and Thalmann (1993)
In his classic text on the circulation system, Burton (1968) presents values for the radius a and length L of capillaries, as well as for the average velocity v b of blood in the capillaries:
a=4 microns Burton (1968)
L=1000 microns
v b =24000 microns/min
Burton also provides a value of 300 ml for the volume V c of systemic capillaries. Equation (2) relates the number of capillaries to volume and other dimensions, from which we conclude that
N c =6.0×10 9 Burton (1968) and equation (2)
A further geometrical parameter is the effective radius b of tissue surrounding a capillary. Because the capillaries are highly elongated, the ratio b/a can be found from the ratio of total tissue volume to capillary volume:
b/a=√{square root over (V t /V c )}.
Xu, Chao, and Bozkurt (2000) indicate that a person who weighs 70 kg has a typical tissue volume of 60,000 ml, from which
b/a=14 Xu et al. (2000)
Weathersby and Homer (1980) provide a value for the solubility of nitrogen in whole blood:
S b =0.0148 ml/ml Weathersby and Homer (1980)
To obtain the other two parameters, we must turn from standard physiology literature to the experiments of Behnke and Willmon (1941), who provide data on nitrogen elimination from a subject saturated with air at one atmosphere. They found the total amount of nitrogen to be 1076 ml evaluated at STPD, meaning standard temperature and temperature dry (1 atm, 0° C.).
The measured nitrogen volume must be altered in several ways to produce a solubility for the GFM algorithm. The solubility used in the algorithm is the volume of nitrogen in tissue at body temperature, saturated under a nitrogen partial pressure of one atmosphere or 760 mm Hg. The Behnke and Willmon experiments involved a nitrogen partial pressure of
0.79(760−46)=564 mm Hg,
where the correction of 46 mm Hg allows for water vapor in the lungs. Correcting to a partial pressure of 760 mm Hg increases the measured volume by a factor of 1.35, and correcting to body temperature increases the volume by a further factor of 310/273=1.14. Tissue at body temperature under one atmosphere of nitrogen would absorb
1029×1.35×1.14=1577 ml
of nitrogen. Using Xu et al.'s value for tissue volume, we find the solubility of nitrogen in tissue:
S t =0.0263 ml/ml Behnke and Willmon (1941), Xu et al. (2000)
To evaluate the tissue diffusion coefficient, we turn to the GFM model of diffusion in the body. The plot of FIG. 4 below shows the results of fitting the time history of nitrogen elimination as computed by the GFM algorithm to the data of Behnke and Willmon. The value
D t =40 microns 2 /min Behnke and Willmon (1941) and GFM provides the best fit and is our selection for the tissue diffusion coefficient.
It is equally important to compare GFM predictions with examples that include absorption during compression, and Dick et al (1984) provides such data. An example of the comparison of GFM nitrogen elimination predictions with measured data following 25 minutes at 100 feet, as shown in the plot of FIG. 5 , where the prediction is within the scatter of the data.
Critical Volume
When a diver is exposed to increased ambient pressure, nitrogen is absorbed in tissue. During the decompression following a dive, this gas diffuses from tissue into the blood and is transpired out of the body by the lungs during respiration. Most of this gas remains in solution, but under common conditions some is in the form of free gas. It is the later that is responsible for decompression sickness, with the body able to tolerate a critical volume.
An example of GFM calculations of the gas release that comes from solution and that in the form of free gas is shown in the plot of FIG. 6 . As can be seen, the majority of the gas release is from nitrogen that is dissolved in the blood, but a small portion has formed free gas.
An example of the free gas remaining in the body during decompression is shown in FIG. 7 . Initially the volume of free gas rises rapidly, but as gas is transpired by the lungs it reaches a maximum, and the maximum volume that the body can tolerate is the critical volume.
GFM calculates a maximum free gas volume of 47 ml for a 20 minute exposure at 100 feet. Using this value as a critical volume, GFM predicts NoD limits that are presented in the table of FIG. 8 and the plot of FIG. 9 compared to PADI and data supplied by Lewis (2005) for Pelagic dive computers.
Transpiration
There is one final computational parameter that must be selected, and that is the transpiration time constant, θ, that governs the elimination of free nitrogen gas by the lungs. Pilmanis (1976) Doppler monitored divers following exposures at several depths, and the time scale of these data provides a basis for selecting θ. The graph of FIG. 10 illustrates the qualitative comparison between these audio data and GFM free gas predictions for several values of θ, and it is clear that a value of θ=60 minutes provides the best fit.
Repetitive diving is limited both by residual nitrogen content of tissue and residual free gas, and θ plays an important role, particularly for short surface intervals. Just as was the case for single dive NoD limits, it is important to validate GFM predictions for repetitive dives. Since the PADI RDP is more conservative than the test data (Hamilton et al 1994), it represents a convenient basis for comparison with GFM. Many examples have been calculated, and typical results are illustrated in the plots below. Here an initial dive to 100 feet for the NoD limit of 20 minutes is followed by a repetitive dive to depths of 60 and 80 feet with a varying surface interval.
As can be seen, without a safety stop GFM is very conservative for the first 60 minutes. Following the PADI required 3 min safety stop at 15 feet, however, GFM predicts NoD limits for the repetitive dives that are in close agreement with the RDP. In summary, a value of θ=60 min is selected as being in agreement with the time dependence of the Doppler data of Pilmanis, and the agreement with the PADI RDP for repetitive diving demonstrates the overall validation of GFM for repetitive diving.
Display
GFM calculations provide the typical data that are important for divers, e.g., NoD time remaining, decompression obligations, nitrogen tissue loading, etc. However, GFM has a unique capability that represents an important display option. This is the prediction of the maximum free gas volume that will occur following surfacing. While nitrogen tissue loading is interesting, it is the critical free gas volume that controls NoD limits and repetitive dives. Further, while the nitrogen tissue loading changes little during a safety stop, the free gas volume changes rapidly and dramatically providing the diver with considerable incentive to use the safety stop, as illustrated by the graph of FIG. 12 .
FIG. 13 is a block diagram of a dive computer 200 including a data input device 202 , a computer processing device 204 , and a data output device 206 . A memory device 208 or an article of manufacture 210 may contain an algorithm 212 for calculating a value corresponding to formation of free inert gas in the body of a diver.
The data input device 202 may include a sensor, such as a pulse rate detector or oxygen use detector, or may include a plurality of buttons through which a user of the dive computer may manually enter data. The computer processing device 204 may include an FPGA, an ASIC, a programmable logic device (“PLD”), a complex PLD, a general purpose processor, a micro-processor, a micro-controller, or other computational device. The data output device may include a graphic display, one or more audio tones, or an interface to communicate with other external devices (not shown) such as a printer.
APPENDIX A
CODED GFM ALGORITHM
Dim hs As Double, pg As Double, ps As Double
Dim ve As Double, vr As Double, tr As Double
Dim rd As Double, db As Double, ra1 As Double, ds1 As Double
Dim ra2 As Double, ds2 As Double, ra3 As Double, rc As Double,
hc As Double
Dim t1 As Double, t2 As Double, t3 As Double, t4 As Double,
t5 As Double
Dim t6 As Double, t7 As Double, t8 As Double, t9 As Double,
t10 As Double
Dim RN2 As Double
Sub Decomp12( )
Dim ns As Integer
Dim nt As Integer
Dim nx As Integer
Dim b(1 To 8) As Double
Dim c(1 To 8) As Double
Dim beta(1 To 8) As Double
Dim p(0 To 20) As Double
Dim pold(0 To 20) As Double
Dim poldold(0 To 20) As Double
Dim q(1 To 8, 0 To 20) As Double
Dim GF(0 To 20) As Double
‘Physiological Parameters
a = 4
L = 1000
St = 0.0274
Sb = 0.0137
Dt = 38
Nc = 6090000000#
theta = 25
vdot = 0.4
‘Blood Pressure Parameters
poa = 131
pov = 131
pba = 30
pbv = 12
‘Water Level
hs = 0
‘Dive Profile
td = 2
rd = 60
db = 120
tb = 12
ra1 = 60
ds1 = 0
ts1 = 40
ra2 = −60
ds2 = 55
ts2 = 48
ra3 = 60
‘Flight Profile
tf = 180
rc = 1000
hc = 0
‘Blood Velocity Profile
ve = 24000
vr = 24000
tr = 120
‘Nitrox Ratio
RN2 = 0.79
‘Computational Parameters
delt = 0.1
tmax = 200
delx = 0.05
‘F Parameters
b(1) = 0.07203
b(2) = 0.34177
b(3) = 0.58973
b(4) = 0.83462
b(5) = 1.07831
b(6) = 1.32137
b(7) = 1.56406
b(8) = 1.80652
c(1) = 0.15577
c(2) = 0.0651
c(3) = 0.05719
c(4) = 0.05412
c(5) = 0.05253
c(6) = 0.05159
c(7) = 0.05097
c(8) = 0.05055
‘Computed Constants
Pi = 4 * Atn(1)
J = 2 * St * Dt * L / (Sb * a {circumflex over ( )} 2)
K = 2 * Pi * St * Dt * L
alpha = Dt / a {circumflex over ( )} 2
delpa = poa − pba
delpv = pov − pbv
For ns = 1 To 8
beta(ns) = alpha * b(ns) {circumflex over ( )} 2
Next
pg = 760 / 33
ps = 760 * (1 − 0.0000068634 * hs) {circumflex over ( )} 5.2583
‘Computed Times
t1 = td
If rd < 1 Then
t2 = t1
Else
t2 = t1 + Abs(db / rd)
End If
t3 = t2 + tb
t4 = t3 + Abs((db − ds1) / ra1)
t5 = t4 + ts1
t6 = t5 + Abs((ds1 − ds2) / ra2)
t7 = t6 + ts2
t8 = t7 + Abs(ds2 / ra3)
t9 = t8 + tf
t10 = t9 + Abs((hc − hs) / rc)
‘Time 0
t = 0
nt = 10
pambient = pamb(t)
fnitrogen = FN2(t)
pN2v = pambient − delpv
p(0) = fnitrogen * (pambient − 47)
For nx = 0 To 20
p(nx) = p(0)
For ns = 1 To 8
q(ns, nx) = 0
Next ns
Next nx
Source = 0
G = 0
V = 0
Worksheets(“Sheet1”).Cells(nt, 1) = t
Worksheets(“Sheet1”).Cells(nt, 2) = pambient
Worksheets(“Sheet1”).Cells(nt, 3) = p(20)
Worksheets(“Sheet1”).Cells(nt, 4) = Source
Worksheets(“Sheet1”).Cells(nt, 5) = V
‘Time delt
For nx = 0 To 20
pold(nx) = p(nx)
Next nx
t = t + delt
nt = nt + 1
pambient = pamb(t)
fnitrogen = FN2(t)
pN2v = pambient − delpv
p(0) = fnitrogen * (pambient − 47)
For nx = 0 To 20
p(nx) = p(0)
For ns = 1 To 8
q(ns, nx) = 0
Next ns
Next nx
Source = 0
G = 0
V = 0
Worksheets(“Sheet1”).Cells(nt, 1) = t
Worksheets(“Sheet1”).Cells(nt, 2) = pambient
Worksheets(“Sheet1”).Cells(nt, 3) = p(20)
Worksheets(“Sheet1”).Cells(nt, 4) = Source
Worksheets(“Sheet1”).Cells(nt, 5) = V
‘Time Loop
Do While t <= tmax − delt / 2
For nx = 0 To 20
poldold(nx) = pold(nx)
pold(nx) = p(nx)
Next nx
t = t + delt
nt = nt + 1
pambient = pamb(t)
fnitrogen = FN2(t)
pN2v = pambient − delpv
p(0) = fnitrogen * (pambient − 47)
velocity = vel(t)
For nx = 0 To 20
GF(nx) = 0
For ns = 1 To 8
q(ns, nx) = q(ns, nx) + pold(nx) − poldold(nx) − beta(ns) *
delt * q(ns, nx)
Next ns
Next nx
For nx = 1 To 20
r = 0
For ns = 1 To 8
r = r + c(ns) * q(ns, nx)
Next ns
p(nx) = p(nx − 1) − J * Pi * delx * r / velocity
If p(nx) < 0 Then p(nx) = 0
x = nx * delx
pN2 = pN2v + (delpa − delpv) * (x − 1)
If p(nx) > pN2 Then
p(nx) = pN2
GF(nx) = −K * Pi * r
End If
Next nx
Source = 0
For nx = 0 To 20
Source = Source + GF(nx) * delx
Next nx
Source = Source * Nc / 1000000000000#
G = G + delt * (Source − G / theta)
‘G = G + delt * (Source − pN2v * vdot)
If G < 0 Then G = 0
V = G / pN2v
Worksheets(“Sheet1”).Cells(nt, 1) = t
Worksheets(“Sheet1”).Cells(nt, 2) = pambient
Worksheets(“Sheet1”).Cells(nt, 3) = p(20)
Worksheets(“Sheet1”).Cells(nt, 4) = Source
Worksheets(“Sheet1”).Cells(nt, 5) = V
Loop
End Sub
Function pamb(t)
If rd < 1 Then
If t < t3 Then
pamb = ps + pg * db
ElseIf t < t4 Then
pamb = ps + pg * db − pg * (t − t3) * ra1
ElseIf t < t5 Then
pamb = ps + pg * ds1
ElseIf t < t6 Then
pamb = ps + pg * ds1 − pg * (t − t5) * ra2
ElseIf t < t7 Then
pamb = ps + pg * ds2
ElseIf t < t8 Then
pamb = ps + pg * ds2 − pg * (t − t7) * ra3
ElseIf t < t9 Then
pamb = ps
ElseIf t < t10 Then
z = hs + (t − t9) * rc
pamb = 760 * (1 − 0.0000068634 * z) {circumflex over ( )} 5.2583
Else
z = hc
pamb = 760 * (1 − 0.0000068634 * z) {circumflex over ( )} 5.2583
End If
Else
If t < t1 Then
pamb = ps
ElseIf t < t2 Then
pamb = ps + pg * (t − t1) * rd
ElseIf t < t3 Then
pamb = ps + pg * db
ElseIf t < t4 Then
pamb = ps + pg * db − pg * (t − t3) * ra1
ElseIf t < t5 Then
pamb = ps + pg * ds1
ElseIf t < t6 Then
pamb = ps + pg * ds1 − pg * (t − t5) * ra2
ElseIf t < t7 Then
pamb = ps + pg * ds2
ElseIf t < t8 Then
pamb = ps + pg * ds2 − pg * (t − t7) * ra3
ElseIf t < t9 Then
pamb = ps
ElseIf t < t10 Then
z = hs + (t − t9) * rc
pamb = 760 * (1 − 0.0000068634 * z) {circumflex over ( )} 5.2583
Else
z = hc
pamb = 760 * (1 − 0.0000068634 * z) {circumflex over ( )} 5.2583
End If
End If
End Function
Function vel(t)
If t < t8 Then
vel = ve
ElseIf t < t8 + tr Then
vel = ve − (ve − vr) * (t − t8) / tr
Else
vel = vr
End If
End Function
Function FN2(t)
If t < t1 Then
FN2 = 0.79
ElseIf t < t1 + 1 Then
FN2 = 0.79 + (t − t1) * (RN2 − 0.79) / 1
ElseIf t < t8 − 1 Then
FN2 = RN2
ElseIf t < t8 Then
FN2 = RN2 + (t − t8 + 1) * (0.79 − RN2) / 1
Else: FN2 = 0.79
End If
End Function
Those skilled in the art of modeling the formation of free nitrogen in the human body may develop other embodiments of the present invention. However, the terms and expressions which have been employed in the foregoing specification are used therein as terms of description and not of limitation, and there is no intention in the use of such terms and expressions of excluding equivalents of the features shown and described or portions thereof, it being recognized that the scope of the invention is defined and limited only by the claims which follow. | The invention disclosed herein employs an algorithm, the Gas Formation Model (“GFM”), to calculate the formation of free gas in a human body. The GFM is based on a novel theory of the formation of free gas relative to the physiology of the human cardiovascular system. Additionally, the GFM utilizes a novel means for the solution of integro-differential equations, the type of equations that derive from the introduction of physiological parameters. GFM-based dive computers utilize novel inputs, including a measure of exercise at depth to reflect the state of an individual's cardiovascular system. GFM-based dive computers also produce novel outputs, including the actual volume of free gas present in a diver's cardiovascular system. The GFM is implemented as a practical computational tool by means of a incorporating the algorithm into a dive computer. | 6 |
The invention relates to a balustrade support, which is provided for the mounting of a deflection wheel, which is provided for deflecting a handrail, of an escalator or a moving walkway, and to an escalator or a moving walkway with such a balustrade support.
BACKGROUND OF THE INVENTION
Escalators or moving walkways comprise a circulating step belt for the transport of persons or objects and a framework. The step belt is bounded along its conveying length on each side by a respective balustrade, which is arranged on the framework. A circulating handrail is arranged at such a balustrade along its terminal.
U.S. Pat. No. 6,102,186 shows an escalator with a balustrade and a deflection wheel for deflecting a handrail. A wheel mounting for mounting the deflection wheel is fastened exclusively to the balustrade so that the balustrade itself has to be of sufficiently stable construction in order to able to accept the forces acting by the deflection wheel on the wheel bearing.
GB-A-678454 shows an escalator with a balustrade and a handrail. The handrail is guided or deflected in a deflecting region of the balustrade by means of a deflection wheel. The deflection wheel is mounted on a wheel mounting stay. The cladding of the balustrade is fixed to this wheel mounting stay and is carried by this wheel mounting stay.
The illustrated solution has the disadvantage that such a wheel mounting stay has to be of extremely solid construction so as to enable faultless operation of the escalator or the moving walkway. For this reason the balustrade has a relative high width in the conveying direction of the escalator, which also leads to an increased requirement of the escalator for space.
BRIEF SUMMARY OF THE INVENTION
It is therefore the object of the invention to create a balustrade support which has the consequence of a reduced requirement of the balustrade or the escalator for space.
The object is fulfilled by a balustrade support for an escalator or for a moving walkway, which balustrade support is fixable at least partly in a deflecting region, which belongs to a balustrade, of a handrail, wherein the balustrade support has a mounting region for the mounting of a deflection wheel, a first fastening section for the fastening of the balustrade support to a framework of the escalator or moving walkway and a second fastening section for the fastening of the balustrade support to the balustrade, wherein a stiffness of the mounting region is increased by the fastening of the balustrade support to the balustrade by means of the second fastening section. The object is equally fulfilled by an escalator or a moving walkway with such a balustrade support.
The object is also fulfilled by an escalator or a moving walkway with a balustrade and a balustrade support, which balustrade support is fixed at least partly in a deflecting region, which belongs to the balustrade, of a handrail and has a mounting region for mounting a deflection wheel, a first fastening section for fastening the balustrade support to a framework of the escalator or the moving walkway and a second fastening section for fastening the balustrade support to the balustrade, wherein a stiffness of the mounting region is increased by the fastening of the balustrade support to the balustrade by means of the second fastening section.
The object is equally fulfilled by modernisation of an escalator or a moving walkway by such a balustrade support.
It was recognised that a wheel support, which is fastened on the framework or a support structure, has to be of very solid construction, because this wheel support alone takes over the supporting function for the deflection wheel for deflecting the handrail. This is particularly so because the deflection wheel during operation of the escalator or the moving walkway, thus during movement of the handrail, is exposed to forces which should not lead to oscillations of the balustrade. This necessary solid construction of the wheel support has the consequence of an increased requirement for space and material.
In order to minimise this increased requirement for space or material it was sought to reduce the forces acting on the wheel support. This is achieved by means of the balustrade support, which on the one hand is fastened or fixed to the framework or support structure and on the other hand to a balustrade, wherein the balustrade has an inherent load-bearing capability. The stability or stiffness of the balustrade is utilised in that way in order to reduce the loads acting on the balustrade support. It is advantageous that the balustrade of the escalator or moving walkway can be of very slender construction along its length for unchanged balustrade thickness. Accordingly, the balustrade support is preferably made of steel.
A development of the balustrade support comprises a balustrade stay, which balustrade stay is provided for stabilisation of the balustrade. It is possible by means of the balustrade stay to additionally support or stabilise the balustrade in the immediate vicinity of its deflecting region, thus the transport region of the balustrade, which has the consequence of increased stability of the deflecting region of the balustrade. The mounting region of the balustrade support can thus be additionally stabilised with the help of the intrinsic stiffness of the balustrade in its deflecting region. A development of the balustrade stay is provided for the support of a balustrade profile member. A stabilisation of the balustrade profile member produces an additional stabilisation of the balustrade and thus of the mounting region of the balustrade support.
In a development of the balustrade support the first fastening section, the mounting region and the second fastening section are arranged along a substantially straight line, wherein the mounting region can be arranged between the first and second fastening sections. A support limb can be constructed, preferably continuously, along this substantially straight line between the first fastening section and the mounting region or the second fastening section. An increase in the stability and load-bearing capability of the mounting of the deflection wheel in the mounting region is achievable by means of such an arrangement.
A development of the balustrade support is fastenable by means of the second fastening section to the balustrade wall. Alternatively thereto the balustrade support is fastenable by means of the second fastening section to a or the balustrade profile member of the balustrade. In a development of the balustrade support the second fastening section of the balustrade support is fastenable to a deflection curve of the balustrade. By means of the said arrangements of the second fastening section of the balustrade support increased stiffness of the mounting region can be achieved by the co-operation of the different interconnected balustrade components. For example, the deflection curve of the balustrade has in the immediate vicinity of the deflected handrail and the balustrade profile member an increased stability by virtue of the arrangement thereof at the balustrade.
A development of the balustrade support comprises a curve section, which can be arranged along the deflection curve of the balustrade, wherein the second fastening section is arranged along the curve section of the balustrade support such that the balustrade support is fastenable by means of the second fastening section along the deflection curve of the balustrade.
A development of the escalator or the moving walkway comprises such an afore-described balustrade support. By means of the fastening of the balustrade support to the balustrade wall or to the balustrade profile member fastened to the balustrade wall is possible to use the intrinsic stiffness or intrinsic load-bearing capability of the balustrade wall in order to increase the stiffness of the balustrade support and to be able to arrange the mounting region of the balustrade support in a more stable manner in the escalator or the moving walkway. The balustrade wall of the escalator or the moving walkway can have a wall thickness of 3 to 20 millimeters, preferably 10 to 12 millimeters. A correspondingly high wall thickness, thus also a high level of stiffness, of the balustrade wall equally makes possible a high level of stiffness of the balustrade support or of the mounting region.
BRIEF DESCRIPTION OF THE FIGURES
The invention is explained in more detail in the following by way of figures, in which:
FIG. 1 shows a side view of an escalator with a balustrade support in the installed state;
FIG. 2 shows a sectional illustration of the balustrade shown in FIG. 1 ;
FIG. 3 shows a further sectional illustration of the balustrade shown in FIG. 1 ; and
FIG. 4 shows a balustrade support arranged in a balustrade of an escalator or a moving walkway.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a side view of an escalator 4 with a balustrade support 2 in the installed state. The escalator 4 comprises a framework 8 , a balustrade 6 , a handrail 12 and the balustrade support 2 . The balustrade 6 has a balustrade wall 18 . 1 . The balustrade 6 forms a transport region 11 and a deflecting region 10 . The deflecting region 10 of the balustrade 6 is provided for the deflection of the handrail 12 . The balustrade 6 has a deflection curve 13 in the deflecting region 10 . The balustrade 6 can have a balustrade profile member 17 along its outer edge, which balustrade profile member 17 represents, for example, a suitable constructional boundary of the balustrade 6 . The balustrade profile member 17 is arranged in the deflecting region 10 along a deflection curve 13 . In the transport region 11 the balustrade 6 can have a handrail profile member 16 along its outer edge, on which handrail profile member 16 the handrail 12 is guided. The handrail 12 is deflected or guided in the deflecting region 10 along the deflection curve 13 by means of a deflection wheel 14 . In the further course—which is usually not visible to a passenger on the escalator 4 —of the handrail 12 , this handrail 12 can be guided within a balustrade base of the balustrade 6 or within the framework 8 of the escalator 4 .
The balustrade support 2 comprises a first fastening section 32 , a secondary, second fastening section 36 a and a mounting region 34 . The balustrade support 2 can comprise a balustrade stay 40 . The deflection wheel 14 can be or is rotatably mounted at the mounting region 34 of the balustrade support 2 . The balustrade support 2 is fastenable or fastened to the framework 8 by means of the first fastening section 32 . The balustrade support 2 is fastenable or fastened to the balustrade 6 by means of the secondary fastening section 36 a . The secondary fastening section 36 a can be equally used to fix the balustrade support 2 to the balustrade 6 , for example glue and/or clamp. By means of this fastening of the balustrade support 2 to the balustrade 6 the inherent stiffness or the stability of the balustrade 6 can be utilised in order to increase the stiffness of the balustrade support 2 so that the mounting region 34 of the balustrade support 2 or the defection wheel 14 is arranged more stably in or at the balustrade 6 . This means that the part of the support limb 3 arranged between the first fastening section 32 and the mounting region 34 can be constructed to be less stable or can be constructed to be more slender than would be the case with a balustrade support without such a secondary fastening section 36 a.
The secondary fastening section 36 a can, as an alternative to the illustrated construction, be arranged, for example, in the immediate vicinity of the mounting region 34 in order to increase the stiffness of the mounting region 34 by an additional fastening by means of the second fastening section 36 a to a balustrade wall of the balustrade 6 . The stability of the balustrade 6 in the deflecting region 10 or in the immediate vicinity of the deflecting region 10 can additionally be increased by means of the balustrade stay 40 .
The characteristics or components, which are mentioned within this description, of the illustrated escalator can equally be understood as characteristics or components of moving walkways.
FIG. 2 shows a sectional illustration through an upper part of the balustrade 6 shown in FIG. 1 , wherein the section is executed for illustration in the transport region 11 of the balustrade 6 . In addition, the balustrade 6 can have a second balustrade wall 18 . 2 . The balustrade stay 40 of the balustrade support 2 can be additionally reinforced in such a manner that the deflection wheel 14 according to the depicted sectional illustration is arranged partly behind the balustrade stay 40 . For stabilisation of the balustrade 6 a component of the balustrade 6 can be connected, preferably fixedly connected, with the balustrade stay 40 of the balustrade support 2 . For this purpose the handrail profile member 16 and/or the balustrade profile member 17 and/or the balustrade wall or one of the balustrade walls 18 . 1 , 18 . 2 can be fixed to the balustrade stay 40 . The balustrade 6 can have a high level of intrinsic stiffness, because the at least one balustrade wall 18 . 1 , 18 . 2 has, for example, a wall thickness 19 of 3 to 20 millimeters, preferably 10 to 12 millimeters. Such a balustrade wall 18 . 1 , 18 . 2 can be transparent. This balustrade wall 18 . 1 , 18 . 2 can be made of composite-pane safety glass and/or double-pane safety glass or single-pane safety glass or of stone.
FIG. 3 shows a further sectional illustration of the balustrade 6 depicted in FIG. 1 , wherein the section is taken for illustration through the deflecting region 10 , which is shown in FIG. 1 , of the balustrade 6 . The course of the section is characterised by the section line B-B in FIG. 1 . In the deflecting region 10 the balustrade 6 can have at least one balustrade profile member section 17 . 1 , 17 . 2 , wherein the balustrade profile member section 17 . 1 , 17 . 2 is arranged along the deflection curve of the balustrade 6 . The deflection wheel 14 for transport or guidance or support of the handrail 12 can be mounted at the mounting region 34 of the balustrade support 2 and, for example, arranged between the two balustrade walls 18 . 1 , 18 . 2 . The balustrade wall 18 . 1 can, by way of example, be fixed to a balustrade base (not illustrated) of the balustrade 6 . The fastening of the balustrade support 2 by means of the first fastening section 32 thereof to the framework 8 of the escalator can be realised, for example, by means of a screw connection and/or welded connection.
In addition to the secondary fastening section 36 a already shown in FIG. 1 the balustrade support 2 can comprise further secondary fastening sections 36 b , 36 c in order to be able to fasten or fix the balustrade support 2 to the balustrade 6 . For preference, the secondary fastening section 36 a , 36 c can accordingly be so positioned at the balustrade support 2 that the balustrade support 2 can be fastened by means of these secondary fastening sections 36 a , 36 c to a first one of the balustrade walls 18 . 1 of the balustrade 6 . The secondary fastening section 36 b can in addition or alternatively thereto be arranged in such a manner that the balustrade support 2 can be fastened to a first one 17 . 1 of the balustrade profile member sections.
In such a fastening by means of the at least one secondary fastening section 36 a , 36 b , 36 c the balustrade support 2 can be fastened merely to each balustrade wall 18 . 1 or to each balustrade profile member section 17 . 1 , which balustrade wall 18 . 1 or which balustrade profile member section 17 . 1 is disposed in accordance with the cross-section shown in FIG. 3 on the same side of the deflection wheel 14 as this at least one secondary fastening section 36 a , 36 b , 36 c of the balustrade support 2 itself.
The reason for that is that the at least one secondary fastening section 36 a , 36 b , 36 c in the case of a side view of the balustrade 6 can be projected onto the projection surface of the deflection wheel 14 . This means that a fastening of that kind of the balustrade support 2 to a second one of the balustrade walls 18 . 2 or to a second one of the balustrade profile member sections 17 . 2 is prevented by the positioning of the deflection wheel 14 between the at least one secondary fastening section 36 a , 36 b , 36 c and the respective component 17 . 2 , 18 . 2 of the balustrade 6 . A connection in the region of this projection surface between the first balustrade wall 18 . 1 and the second balustrade wall 18 . 2 and also between the first balustrade profile member section 17 . 1 and the second profile member section 17 . 2 is thereby made impossible.
The balustrade support 2 can have, by way of example, a material thickness of 10 to 50 millimeters, particularly 15 to 25 millimeters. The balustrade stay 40 can, independently thereof, be reinforced in such a manner that it is arranged in the transport region of the balustrade 6 to be partly below the handrail 12 . A reinforcement of that kind of the balustrade stay 40 increases the stability of the balustrade 6 surrounding the balustrade stay 40 .
FIG. 4 shows a balustrade support 2 which can be arranged in the deflecting region of a balustrade. The balustrade support 2 comprises a first fastening section 32 for fastening the balustrade support 2 to the framework of the moving walkway or the escalator and at least one secondary fastening section 36 a , 36 b , 36 c for fastening the balustrade support 2 to the balustrade 6 . The balustrade support 2 comprises a mounting region 34 , at which mounting region 34 a deflection wheel can be mounted to be rotatable. The balustrade support 2 can comprise a curve section 38 , which curve section 38 can be arranged along the deflection curve of the balustrade.
The first fastening section 32 , the mounting region 34 and a first one of the secondary fastening sections 36 a can in that case be arranged along a substantially straight line 54 , wherein the mounting region 34 can be arranged between the first fastening section 32 and the second fastening section 36 a . A support limb 3 is preferably constructed to be continuous along this line 54 between the first fastening section 32 and the mounting region 34 or the fastening section 36 a so as to increase to the stiffness of the mounting region 34 . A second secondary fastening section 36 c for fastening of the balustrade support 2 to the balustrade wall can, for example, be arranged at the curve section 38 . A third secondary fastening section 36 b can be arranged at the curve section 38 in order to be able to fasten the balustrade support 2 to the balustrade profile member of the balustrade. In order to increase the stiffness of the balustrade support 2 an optional balustrade stay 40 can be connected with the curve section 38 by means of a connecting web 41 , which connecting web 41 is, for example, provided for arrangement in the immediate vicinity of the balustrade profile member of the balustrade. | A balustrade support for an escalator or moving walk is located in a deflection area of the balustrade handrail. The support has a mounting region for mounting a handrail deflection wheel, a first fixing section for mounting the support to a framework of the escalator or moving walk, and a second fixing section for mounting the support to the balustrade. The rigidity of the support's mounting region for the deflection wheel is increased by the mounting of the support to the framework as well as to the balustrade. | 1 |
BACKGROUND OF THE INVENTION
This invention relates to an electronic computer sewing machine, and more particularly to a device for forming finish-up stitches thereof.
The finish-up stitches are formed after or during forming pattern stitches, and they are useful to prevent ravellings and as a sign of finishing the stitching.
The finish-up stitching has been hardly effective in a case of a needle dropping at the same position as the last pattern stitch, and since such a condition has damaged thread, needle dropping positions have been changed but not in a needle amplitude direction, i.e. transverse or oblique to the fabric feeding direction. Stitching data composed of only fine fabric feedings have been determined for applications to all stitching patterns.
However, if such determined finish-up stitching data is used, the patterns are not deformed with respect to stitched parts which are parallel to the fabric feeding direction (along vertical directions in the drawing of FIG. 1) in a straight stitching or a stitching pattern as shown in FIG. 1(A). But, with respect to the stitching patterns containing components in a needle amplitude direction as shown in FIG. 1(B), if the finish-up stitching data is changed in the fabric feeding direction only, the parts of the finish-up stitching are unsightly deformed.
As an improvement therefor, by storing a plurality of stitching data concerning the finish-up stitching in a program memory (ROM), a method has been proposed which selected appropriate finish-up stitching data in response to the patterns before forming the finish-up stitching or a stitching coordinate (Japanese Patent Disclosed Patent Document 194,782/84 "A method of finish-up stitchings in an electronic computer sewing machine"). This method has the following disadvantages:
(1) A plurality of stitching data are required, but the programming memory (ROM) is inferior in efficiency.
(2) Since the stitching data is used, the length to be taken for the finish-up stitching is made fixed, and if changings of the stitching coordinate before forming the finish-up stitching as shown in FIG. 1(C) are smaller than the length of the finish-up stitching, the finish-up stitching part is unsightly deformed.
SUMMARY OF THE INVENTION
Accordingly, it is an object of our invention to provide a device for controlling finish-up stitching providing an initiating finish-up stitching which prevents ravelling when beginning a desired stitching pattern.
The initiating finish-up stitching has been hardly effective in a case of a needle dropping at the same position as the first pattern stitch, and since such a situation has damaged thread, needle dropping positions have been changed but not in a needle amplitude direction. Stitching data composed of only fine fabric feedings have been determined for applications to all stitching patterns.
However, if such determined initiating finish-up stitching data is used, the patterns are not deformed with respect to stitched parts which are parallel to the fabric feeding direction (along vertical directions in the drawing of FIG. 8) in a straight stitching or a stitching pattern as shown in FIG. 8(A).
But, with respect to the stitching patterns containing components in a needle amplitude direction transverse to the fabric feed direction as shown in FIG. 8(B), if the initiating finish-up stitching data is changed in the fabric feeding direction only, the parts of the initiating finish-up stitching are unsightly deformed.
It is also an object of our invention to provide a device for controlling finish-up stitching in an electronic computer sewing machine so that the portions of the initiating finish-up stitching are not deformed in an unsightly manner.
In keeping with these objects and others which will be made more apparent hereinafter, the device for controlling finish-up stitching according to our invention comprises a finish-up information generating means for generating a predetermined finish-up stitching length and stitching number, a means for storing a plurality of stitching coordinates for two successive different stitching positions, a finish-up stitching data making means for obtaining before the finish-up stitching a stitching direction from the stitching coordinates from the stitching coordinate storing means and outputting in correlation with the means for selecting the finish-up stitching so as to define a direction opposite to a finish-up stitching direction and the finish-up stitching data making means also makes finish-up stitching data according to the finish-up stitching length from the finish-up stitching information generating means, whereby a plurality of stitches are formed according to the stitching number from the finish-up stitching information generating means according to the stitching data from the finish-up stitching already performed.
In the invention, the finish-up stitching direction is obtained with reference to the coordinates where two different stitches are formed prior to finish-up stitching, and the finish-up stitching coordinate is determined from said direction and a predetermined length of the finish-up stitching.
The finish-up stitching data is made up from the stitching coordinate before the finish-up stitching and said determined finish-up stitching coordinates, and a stop order for the finish-up stitching is issued after having stitched over the predetermined stitching number.
If the length between the stitches obtained from the different two stitching coordinates before carrying out the finish-up stitching is smaller than the length of the predetermined finish-up stitching, the finish-up stitching data is made up from the different two stitching coordinate before carrying out the finish-up stitching, and the end of the finish-up is ordered after having stitched over the predetermined stitching number. If the length is larger, the finish-up stitching data follows the stitching data of said means of making the finish-up stitching data.
In keeping with the above objects of our invention the device for controlling the finish-up stitching comprises an initiating finish-up stitching information generating means which stores a predetermined initiating finish-up stitching length and a stitching number, a stitching data pre-reading means for reading out from the stitching data generating means the stitching data of two different stitching positions subsequent to operation of the means for selecting the initiating finish-up stitching, a pre-reading coordinate storing means which stores the stitching coordinates from the two stitching positions in accordance with the stitching data and the pattern enlarging-reducing means, an initiating finish-up stitching data making means for making an initiating finish-up stitching data in accordance with a stitching direction obtained from the stitching coordinates of the two different stitching positions and the initiating finish-up stitching length, whereby the stitching pattern following the initiating finish-up stitching is formed after reaching the initiating finish-up stitching number.
In stitching of the pattern to be formed after an initiating finish-up stitching, the different two stitching coordinates at starting of the stitching are pre-read, from which a direction of the initiating finish-up stitching is obtained. The coordiante of the initiating finish-up stitching is determined from the stitching direction and the information of the predetermined initiating finish-up stitching length.
The above determined initiating finish-up stitching coordinate is made the stitching data, and when the stitches are formed up to the predetermined stitching number, the initiating finish-up stitching is ended and stitching patterns are formed following the initiating finish-up stitches.
A comparison is made on the length L between the stitches obtained from the two stitching coordinates different at starting the stitching of the patterns following the initiating finish-up stitch as well as the information P of the predetermined initiating finish-up stitching length. If L≦P, the different two stitching coordinates are made the stitching data, and when the stitches are formed up to the predetermined stitching number, the initiating finish-up stitching is ended to start the forming of the patterns subsequent to the initiating finish-up stitching. If L>P, the stitching follows the stitching data of a means for making up said initiating finish-up stitching data.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1(A) and (B) are schematic diagrams showing conventional finish-up stitching example (the amplitude is fixed, and the feeding is changed), and FIG. 1(C) is a schematic diagram showing a conventional finish-up stitching example (the amplitude is changed, and the feeding is fixed);
FIG. 2 is an electric control block diagram of one example of an electronic computer sewing machine with a device for controlling finish-up stitching according to our invention;
FIG. 3 is a schematic diagram a means for storing stitching coordinates;
FIG. 4 is a graphical illustration of vector between the stitching coordinates of the example of FIG. 2;
FIG. 5(A) is a graphical illustration of a vector when L≦P;
FIG. 5(B) is a graphical illustration of a vector when L>P;
FIG. 6 is graphical illustration of a vector when L'≧nP (N≧2, n is an integer);
FIG. 7 is a graphical illustration of a vector for another finish-up stitching when L<P;
FIG. 8A and FIG. 8B are schematic diagrams showing conventional initiating finish-up stitchings (the amplitude is fixed, and the feeding is changed);
FIG. 9 is an electric control block diagram of an example 2;
FIG. 10 is a schematic diagram a means for storing pre-reading coordinates;
FIG. 11 is a graphical illustration of a vector between the stitching coordinates of example 2;
FIG. 12(A) is of a graphical illustration of a vector when L'≦P';
FIG. 12(B) is of a graphical illustration of a vector when L'>P';
FIG. 13 is of a graphical illustration of a vector of another initiating finish-up stitching when L'≧nP (n≧2, n is an integer); and
FIG. 14 is of a graphical illustration of a vector of another initiating finish-up stitching when L'<P'.
DETAILED DESCRIPTION OF THE INVENTION
EXAMPLE 1
The example of the invention will be explained with reference to the attached drawings.
FIG. 2 shows an example of an electric block diagram of the invention.
A pattern selecting means 1 comprises a plurality of key switches (not shown) for selecting patterns to be stitched, and outputs pattern information or data on command.
A finish-up stitching selection means 2 comprises one key switch, and outputs the command for the finish-up stitching.
A stitching data generating means 3 is a program memory (ROM) which store the needle amplitude data for forming stitching patterns and the stitching data including fabric feeding data, and issues the stitching data.
A detector means 4 of an upper shaft timing signal outputs an amplitude phase information and a feeding phase information in synchronism with the phase of the upper shaft of a sewing machine.
A generator means 5 of the finish-up information is a program memory (ROM) which stores the predetermined stitching length and the stitching number information, and outputs said information in accordance with said finish-up stitching order.
A central processing unit (CPU) 6 controls all of the connected information, and carries out calculations and comparisons in accordance with said information.
A pattern forming means 7 comprises an amplitude actuator (not shown) which controls the displacement or amplitude in the needle amplitude direction and a feed actuator (not shown) which controls the feeding amount in both back and forth feed directions of a fabric to be processed, and drives in accordance with said amplitude phase information and said feeding phase information so as to form stitches.
A machine motor 8 starts, drives and stops in response to the operations of a speed controller (not shown).
The stitching coordinate storing means 9 is a data memory (RAM) which can store, by the two stitchings, the stitching coordinates composed of the amplitude coordinates and the feeding coordinates successively in relation with forming of the stitches and prohibits the storing if the stitching coordinate to be stored is the same as the preceding stored stitching coordinate, so as to always store the different stitching coordinates of the two stitchings.
The finish-up data making means 10 makes and outputs the finish-up stitching data from the stitching coordinates of the two stitchings of the stitching coordinate storing means 9 and the information of the finish-up stitching length of the finish-up stitching information generating means 5, in accordance with the finish-up stitching order.
The operation now will be described.
(1) When a desired stitching pattern is selected from the pattern selecting means 1, the pattern information thereof is output.
(2) The machine motor 8 starts by operating the speed controller (not shown), and the upper shaft of the sewing machine rotates, accordingly.
(3) When the upper shaft is rotated, the upper shaft timing signal detector means 4 outputs the amplitude phase information or the feed phase information in synchronism with each of the rotation phases during one rotation of the sewing machine.
(4) CPU 6 reads out successively the stitching data from the stitching data generator means 3 each time it inputs the amplitude phase information, and obtains the amplitude coordinate from the needle amplitude data so as to drive the amplitude actuator of the pattern forming means 7. Further, it stores the amplitude coordinate in the stitching coordinate stitching means 9.
(5) CPU obtains the feeding coordinate from the fabric feeding data in the above mentioned read out stitching data each time it inputs the feeding phase information so as to drive the feed actuator of the pattern forming means 7. Further, it stores the feeding coordinate in the stitching coordinate storing means 9.
(6) Referring to FIG. 3, the stitching coordinate storing means 9 moves a value stored in R0 (present amplitude coordinate) to R1 (preceding amplitude coordinate) in relation with the amplitude phase information, and stores in R0 an amplitude coordinate obtained from the read out amplitude data.
The means 9 moves the value stored in R2 (present feeding coordinate) to R3 (preceding feeding coordinate) in relation with the feeding phase information, and stores in R2 a feeding coordinate obtained from the fabric feeding data in the read out stitching data.
With respect to the moving amount between the stitches, the amplitude direction is, as shown in FIG. 4, (R0-R1) and the feed direction is (R2-R3).
In the present example, for explaining convenience, the feeding coordinates R2 and R3 as the fabric feeding data are treated as absolute values, but actually relative values representing the feeding amount and the feeding direction are used in view of efficiency of the program memory (ROM).
{Actual fabric feeding data}={absolute value of (R2-R3)}+(fabric feeding direction}.
(7) When the finish-up stitching selection means 2 is operated during forming the stitches successively in synchronism with the rotation of the upper shaft of the sewing machine, CPU issues the finish-up stitch ordering information.
(8) CPU 6 makes effective the finish-up stitch ordering information in synchronism with the feeding phase information, and drives the feeding actuator of the pattern forming means 7 to the position of the feeding amount 0 (the same feeding coordinate such that the same position as the stitching position formed before the finish-up stitching is made a stitch from which the finish-up stitching starts.
(9) CPU reads out, from the stitching coordinate storing means 9, R0, R1, R2, R3 which are the information concerning the stitching coordinate in synchronism with the amplitude phase information, and outputs them to the finish-up data making means 10.
(10) CPU reads out the information of a predetermined finish-up stitching length from the finish-up information generating means 5, and outputs it to the finish-up data making means 10.
(11) The finish-up data making means 10 obtains the length L between the stitches before the finish-up stitching from values R0, R1, R2, R3 in accordance with FIG. 4. ##EQU1##
If P is the value of the information of the predetermined finish-up stitching length, Bx is the moving amount in the amplitude direction of the finish-up stitching data, and Fy is the moving amount in the feeding direction thereof, the calculations described below will be made according to comparison in the length of L and P.
(i) in a case of L≦P (refer to FIG. 5(A))
Bx1=-(R0-R1) (b)
Fy1=-(R2-R3) (c)
Herein, the minus (-) shows the movement in a reverse direction.
(ii) in a case of L>P (refer to FIG. 5(B))
Bx2=-(R0-R1)×P/L (d)
Fy2=-(R2-R3)×P/L (e)
The stitching data of two stitchings are made from Bx1, Fy1 or Bx2, Fy2.
(1) in a case of L≦P
______________________________________ Amplitude Feeding Coordinate Coordinate______________________________________Stitching Data (1) R0 R2Finish-up R1 R3Stitching Data (2)______________________________________
(2) in a case of L>P
______________________________________ Amplitude Feeding Coordinate Coordinate______________________________________Stitching Data (1) R0 R2Finish-up R0 + Bx2 R2 + Fy2Stitching Data (2)______________________________________
The most suitable value is selected by the actuator to be coordinate values.
(12) CPU 6 further reads out the information of the predetermined stitching number from the finish-up stitching information generating means 5, and sets them in a counter (not shown).
The stitches are formed while CPU decrements said counter each time it reads out alternately the stitching data of the two stitchings made by the finish-up stitching data making means 10.
(13) When the counter comes up to 0, the sewing machine is stopped to end the finish-up stitching, irrespective of setting of the speed controller.
The above statements refer to the basic concept of the present invention. Thus, according to the invention, various finish-up stitchings will be available. For example:
(A) In reference to Bx, Fy obtained when the finish-up stitching data making means 10 is L≦2P, the stitching data is also obtained for the coordinates of 2 Bx, 2Fy, whereby if the length between the stitches obtained from the two different stitching coordinates before the finish-up stitching as shown in FIG. 6 is larger than the determined multiple of the predetermined finish-up stitching length, the finish-up stitching direction is obtained in accordance with the two different stitching coordinates, and each of the stitching coordinates of the finish-up stitchings over the determined multiple of the finish-up stitching length is determined.
The finish-up stitching data is made from the stitching coordinates before the finish-up stitching and the determined finish-up stitching coordinates, and when the stitching is carried out over the predetermined stitching number, an order is issued to end the finish-up stitching.
The reason for using the coordinates formed with the two different stitches is to prevent that the stitching is performed at the stitching number predetermined at the same needle dropping so that the effect of the finish-up stitching is decreased and the thread is damaged.
(B) The stitching coordinate storing means 9 stores the different stitching coordinates of three stitchings, and if the finish-up stitching data making means is L<P, the stitching data is obtained with respect to the preceding stitching coordinate, thereby to enable the finish-up stitching as shown in FIG. 7.
EXAMPLE 2
Another second example of the invention will be explained with reference to the attached drawings.
FIG. 9 shows an example of an electric block diagram of the invention.
A pattern selecting means 1 comprises a plurality of key switches (not shown) for selecting the stitching pattern, and outputs a pattern information by operations.
An initiating finish-up selecting means 2 includes one key switch, and outputs the information of selecting the initiating finish-up stitching by operations.
A stitching data generating means 3 is a program memory (ROM) issuing the stitching data, which stores needle amplitude data for forming stitching patterns and stitching data including fabric feeding data.
An upper shaft timing signal detector outputs an amplitude phase information and a feeding phase information in synchronism with the phase of the upper shaft of a sewing machine.
An initiating finish-up information generator 50 is a program memory (ROM) which stores the predetermined initiating stitching length and the stitching number information, and issues said information in accordance with said initiating finish-up stitching order.
The central processing unit (CPU) 6 controls all of the connected information, and carries out calculations and comparisons in acordance with this information to control the sewing machine.
A pattern forming means 7 comprises an amplitude actuator (not shown) which controls the amplitude amount in the needle amplitude direction and a feed actuator (not shown) which control the feeding amount of the back and forth directions, of a fabric to be processed, and drives in accordance with said amplitude phase information and said feeding phase information for forming stitches.
A machine motor 8 starts, drives and stops in response to the operations of a speed controller (not shown).
A stitching data pre-reading means 110 reads out the stitching data of the two different stitchings at starting of the stitching pattern following the initiating finish-up stitching from the stitching data generating means 3 in accordance with the selection of the initiating finish-up stitching.
A pattern enlarging-reducing means 12 adjusts sizes of the stitching patterns as the operator's desire, and is in general composed of an amplitude manual key (not shown) for determining the needle amplitude amount and a feed manual key (not shown) for determining the feeding amount of the work fabric. The present means 12 sets automatic values of the stitching pattern selected by the operation of the pattern selecting means 1. The coordinate (amplitude coordinate) of the amplitude actuator is determined by the set values of the needle amplitude data and the amplitude manual keys.
The coordinate (feeding coordinate) of the feeding actuator is determined by the setting values (feeding manual values) of the fabric feeding data and the feeding manual key.
A pre-reading coordinate storing means 90 is a data memory (RAM) which stores, by the two stitchings, the amplitude coordinate obtained from the needle amplitude data and the amplitude manual values (or automatic values) as well as the feeding coordinate obtained from the fabric feeding data and the feeding manual value (or automatic values) in accordance with the stitching data from the stitching data pre-reading means 110.
An initiating finish-up stitching data making means 100 makes and outputs the initiating finish-up stitching data from the stitching coordinates (amplitude coordinate and feeding coordinate) by the two stitchings of the pre-reading coordinate storing means 90 and the information of the initiating finish-up stitching length of the initiating finish-up stitching information generating means 50.
The operation will now be described.
(1) When the desired stitching pattern is selected from the pattern selecting means 1, the pattern information thereof is output.
(2) The pattern enlarging-reducing means 12 determines the amplitude and feeding automatic values with reference to the pattern information.
The amplitude and feeding automatic values are varied in association with the operations of the amplitude manual key (not shown) and the feeding manual key (not shown) so as to generate the amplitude and feeding manual values.
(3) The machine motor 8 starts by the operation of the speed controller (not shown), and the upper shaft of the sewing machine motor.
(4) When the upper shaft is rotated, the upper shaft timing signal detector means 4 outputs the amplitude phase information or the feed phase information in synchronism with each of the rotation phases during one rotation of the sewing machine.
(5) CPU 6 reads out successively the stitching data from the stitching data generator means 3 each time it inputs the amplitude phase information.
The amplitude coordinates are obtained from the needle amplitude data and the amplitude manual values (or automatic values) for driving the amplitude actuator of the pattern forming means 7.
(6) CPU obtains the feeding coordinate from the fabric feeding data of the above mentioned read out stitching data and the feed manual values (or automatic values) each time it inputs the feeding phase information for driving the feed actuator of the pattern forming means 7.
(7) If the initiating finish-up stitching selecting means 2 is selected before the operation of the speed controller, the information of the initiating finish-up stitching selection is output.
(8) CPU 6 makes the stitching data pre-reading means 110 effective in accordance with the information of selecting the initiating finish-up stitching.
The stitching data pre-reading means 110 reads out from the stitching data generating means 3 the stitching data of the two different stitchings at starting of the pattern stitching selected by the pattern selecting means 1.
(9) CPU 6 obtains the stitching data of the two stitchings and the stitching coordinates of the two stitchings from the amplitude manual values (or automatic values) and the feeding manual values (or automatic values) from the pattern enlarging-reducing means 12, and stores them in the pre-reading coordinate storing means 90.
CPU obtains and stores therein the stitching coordinates each time the pattern enlarging-reducing means 12 is operated.
(10) The pre-reading coordinate storing means 90 will be described referring to FIG. 10.
If A0 is the first stitching coordinate of the two stitchings, the amplitude coordinate B0 and the feeding coordinate F0 are stored in the addresses R0, R1 of the data memory (RAM) If A1 is the second stitching coordinate, the amplitude coordiante B1 and the feeding coordinate F1 are stored in the addresses R2, R3 of the data memory (RAM).
(11) CPU 6 reads out the information of the predetermined initiating finish-up stitching length from the initiating finish-up stitching information generating means 50 in accordance with the information of selecting the initiating finish-up stitching, and outputs it to the initiating finish-up stitching data making means 100.
(12) The initiating finish-up data making means 100 obtains the length L' between the stitches A0 and A1 from the stitching coordinate values of the two stitchings stored in the pre-reading coordinate storing means 90 as shown in FIG. 11. ##EQU2##
If P' is the value of the information of the predetermined initiating finish-up stitching length, L' and P' are compared with respect to the length, and the stitching data by the two stitchings of the initiating finish-up stitching are made in accordance with the comparison result.
(i) in a case of L'≦P' (refer to FIG. 12(A))
______________________________________ Amplitude Feeding Coordinate Coordinate______________________________________Stitching Data S0 B0 F0Initiating B1 F1Finish-upStitching Data S1______________________________________
The stitching data are the same as the stitching coordinates A0, A1 stored in the pre-reading coordinate storing means 90.
(ii) in a case of L'>P' (refer to FIG. 12(B))
If Bx is the displacement in the amplitude direction in response to the length P' of the initiating finish-up stitching, and Fy is displacement in the feeding direction, results will be obtained from the following formulas:
Bx=(B1-B0)×P'/L' (b')
Fy=(F1-F0)×P'/L' (c')
The stitching data S0, S1 by the two stitchings are made from Bx and Fy.
______________________________________ Amplitude Feeding Coordinate Coordinate______________________________________Stitching Data S0 B0 F0Initiating B0 + Bx F0 + FyFinish-upStitching Data S1______________________________________
The initiating finish-up stitching data S0, S1 are obtained each time the pattern enlarging-reducing means 12 is operated.
(13) CPU 6 further reads out the information of the predetermined stitching number from the initiating finish-up stitching information generating means 50, and sets them in a counter (not shown).
(14) The machine motor 8 starts by operating the speed controller (not shown). When the upper shaft of the sewing machine is rotated, PCU 6 reads out alternately the stitching data S0, S1 of the two stitchings made by the initiating finish-up stitching data making means 100 in synchronism with the amplitude phase information from the upper shaft timing signal detector means 4.
The counter (not shown) is decrimented each time reading the stitching data S0, S1.
(15) When the counter comes up 0, the initiating finish-up stitching is ended to start the forming of the stitches continuously from the stitching coordinate A0 at starting of the stitching patterns selected by the pattern selection means 1.
The above statements refer to the basic concept of the present invention. Thus, according to the invention, various finish-up stitchings will be available. For example:
(A) When the initiating finish-up stitching data making means 100 is L'≦2P', the stitching data is further made for the coordinates of 2Bx, 2Fy in reference to the obtained Bx, Fy, whereby if the length between the stitches obtained from the different two stitching coordinates at starting of the patterns following the initiating finish-up stitching as shown in FIG. 13 is larger than a certain multiple of the predetermined initiating finish-up stitching length, the stitching direction is obtained from the two different stitching coordinates, and each of the stitching coordinates is successively obtained in reference to the information of the initiating finish-up stitching length up to the determined times of the information of the initiating finish-up stitching length.
The stitches are formed as the stitching data of a plurality of stitching coordiantes up to the predetermined stitching number and then the initiating finish-up stitching is ended to start the forming of the stitches continuously from the initiating finish-up stitching. If the present means is used for the same stitching coordinate, the stitching is carried out at the stitching number predetermined at the same needle dropping so that the effect of the finish-up stitching is decreased and the thread is injured.
For avoiding such an occassion, the two stitching coordinates different at starting of the stitching are used for prevention of the same needle dropping.
(B) The stitching data pre-reading means 110 reads out the stitching data of the three different stitchings at starting of the pattern stitching from the stitching data generating means 3. The pre-reading coordinate storing means 90 stores the stitching coordinate of the three stitchings after making the enlarging or reducing calculations, whereby if L'<P' is the stitching finish-up stitching data making means 100, the stitching data is similarly made for the second stitching coordinate A1 and the three stitching coordinate A2, thereby enabling to form the initiating finish-up stitching for forming a plurality of different stitches as shown in FIG. 14.
It will be understood that each of the elements described above, or two or more together, may also find a useful application in other types of structures differing from the types described above.
While the invention has been illustrated and described as embodied in a device for controlling finish-up stitching in an electronic computer sewing machine, it is not intended to be limited to the details, shown, since various modifications and structural changes may be made without departing in any way from the spirit of the present invention.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention.
What is claimed as new and desired to be protected by Letters Patent is set forth in the appended claims. | Stitching coordinates prior to finish-up stitching are used to produce finish-up stitching data, resulting in undistorted stitching in all cases. Also, stitching data is pre-read out at start-up for stitching patterns continuously and predetermined stitching coordinates are obtained from the stitching data for making initiating finish-up stitching data. Therefore, it is no longer necessary to store the finish-up stitching data or the initiating finish-up stitching data in advance in a programming memory (ROM) so that operating efficiency of the sewing machine is increased. | 3 |
BACKGROUND OF THE INVENTION
The present invention relates to an arrangement for heating and/or heat retaining of containers and their contents, for example ladles to be filled with molten metal. More particularly, it relates to an arrangement of this type which has an air-fuel mixture burner directed toward the interior of the container, a cover for a container opening, and a preheating device for combustion air.
Arrangements of this type are known in the art. The cover for the container opening is composed usually of a plate which is lined at its side facing the container interior with a refractory material. The burner is located in the center of this plate. The smoke gas generated during combustion escapes through the annular gap between the container opening and the cover plate. In addition to strong air contamination and heating and connected therewith poor working conditions, such an arrangement is not satisfactory in the sense of energy consumption. Since the container which accommodates the molten metal has a relatively thick refractory lining which possesses a considerable heat-accumulating capacity, the refractory lining must be supplied before filling of the metal into the container with a considerable quantity of heat energy so as to prevent strong cooling of the molten metal as a result of the temperature equalization between the refractory lining and metal. In correspondence with this, low efficiency and considerable energy loss take place in the heating arrangement.
From the field of furnaces it has been known to use recuperators into which the thermal energy of the waste gases is used to supply it to the combustion air and thereby to increase the efficiency of the installation. Such recuperators are mainly placed separately from the furnace, and therefore it is necessary to provide between the furnace and the recuperator expensive pipe conduits for transporting the waste gas and air. Such installations are not only expensive, but also do not provide a very high efficiency, since heat losses take place through the pipe conduits between the furnace and the recuperator.
Burners with small output are also known in which the waste gas is used directly for preheating the combustion air. These arrangements are, however, connected with certain conditions in the sense of control and construction. In burners of greater output, the direct preheating of the combustion air by the waste gas has not been utilized.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide an arrangement for heating and/or heat retaining of containers, which avoids the disadvantages of the prior art.
More particularly, it is an object of the present invention to provide an arrangement for heating and/or preheating of containers which has a compact construction and requires a lower fuel consumption as compared with the known arrangements, with increased combustion power.
In keeping with these objects and with others which will become apparent hereinafter, one feature of the present invention resides, briefly stated, in an arrangement for heating and/or heat retaining of containers in which a preheating device for preheating combustion air forms a component of a cover which covers a container opening.
With the arrangement designed according to the present invention, it combines a preheating device for containers for molten metals with a recuperative system in such a manner that the system forms a compact structural unit which has a high efficiency and at the same time eliminates pipe conduits, and the like.
A known arrangement for heating of containers for molten metals has a cover which is provided at its side facing the container interior with a lining of refractory material. Because of this refractory lining of the inner surface of the cover, the entire arrangement is relatively heavy and expensive, inasmuch as the refractory material must be mounted at the side facing the container and renewed at certain time intervals. In accordance with the applicant's invention, however, the wall of the arrangement, which limits the combustion chamber toward the container opening, forms at least partially a component of one or several cooling passages through which substantially cold combustion air is supplied. Because of these features, for which the individual protection also takes place, two advantageous results are obtained. On the one hand, the combustion air before reaching the burner is strongly heated, and on the other hand the wall facing the combustion chamber, for example a plate, is cooled by the heat exchange so that a refractory lining is no longer necessary.
In accordance with another advantageous feature of the present invention, it is provided that the arrangement of for example circular base contour has a centrally arranged burner provided with a fuel supply which extends normal to the cover, one or several combustion air supply passages provided substantially in the center and normal to the wall which limits the combustion chamber, cooling passages connected with the combustion air supply passages and openings into an annular chamber which is formed at the periphery of the arrangement and communicates via heat exchanger pipes extending through a heat exchange chamber with a combustion air conduit of the burner. The thus designed arrangement can be formed completely rotation-symmetrical. The combustion air is aspirated or blown from above through the center of the arrangement so as to flow first over the inner side of the container opening-covering plate and cool the latter, before it flows through the heat exchange pipes with simultaneous further heating and is then supplied to the burner via the combustion air conduit.
Depending upon the required output for heating a container, the arrangement can operate with full loading or partial loading. In accordance with the invention it is provided that the preheating device is subdivided into several segments, so that in the event of operation with partial loading only certain segments take part in the heat exchange.
With a rotation-symmetrical arrangement, it can be provided that not the entire periphery is occupied by the preheating device, but only certain segments form the heat exchange chamber, whereas the remaining segments are not used. These features provide for a simple adjustment of the arrangement to the desired output. An especial advantage of this feature is that the partial preheating devices provided in the individual segments are manufactured as indivdual pieces and when needed are used in more or less great number in the entire arrangement. During the manufacture it does not make any difference, in the sense of manufacture of the partial heat exchanger devices, whether these parts for the arrangement provide for greater or smaller output. The segment-like subdivision of the arrangement is also advantageous for repairs which are needed in many cases. When a heat exchanger part is damaged in a certain segment, it suffices to exchange only the respective heat exchanger part without dismounting of the entire arrangement.
The inventive arrangement can be formed basically as a direct-stream installation or a counterstream installation. In the arrangement formed advantageously as a counterstream installation, the wall which limits the combustion chamber is provided, advantageously in the region of the center of the wall, with a waste gas inlet opening, a plurality of laterally or upwardly and downwardly offset guiding sheets extend substantially normal to the heat exchange pipes, and above the heat exchange chamber at least one waste gas outlet chamber is formed which connects the peripheral region of the heat exchange chamber with an outlet passage arranged advantageously in the center of the arrangement. The flow path of the combustion air is clear from the above presented description. The waste gas which flows in counterstream to the combustion air travels in the central region of the plate into the inlet opening, then flows under the action of the guiding sheets around the heat exchanger pipes many times, so that the thermal energy is withdrawn via the pipes to the combustion air flowing in the heat exchanger pipes.
The main stream direction is radially outwardly. When the waste gas reaches the marginal region of the arrangement, its thermal energy is withdrawn in greater part and it can be theoretically discharged in the marginal region out of the arrangement. However, for providing a compact construction, the waste gas travels via the waste gas outlet chamber toward the center of the arrangement, and from there is withdrawn via the outlet passage.
A very compact construction and a simple guidance of cold and preheated combustion air in the center of the arrangement is obtained when the fuel supply takes place through a first pipe extending centrally in the arrangement, and a second pipe coaxially surrounds the first pipe and has axially extending segment chambers into which the heat exchanger pipes (advantageously alternating in the circumferential direction) are open and into which cold combustion air is axially supplied from above.
For withstanding high temperatures, and respectively guaranteeing a good cooling of the lower plate, the heat exchanger parts of the arrangement in accordance with the present invention are composed of steel or copper.
Depending upon the cross section of the passages provided for the supply of combustion air, the combustion air flows more or less fast, so that for example in the event of high flow speed of the combustion air cooling of the lower plate cannot be provided when the combustion air moves directly radially on the inner side of the wall or plate. For obtaining a longer dwell time of the cold air in this region and therefore improved cooling of the wall, in the arrangement in accordance with the present invention the cooling passages on the wall limiting the combustion chamber are formed spiral-shaped. This shape of the cooling passages provides for a turbulent air flow which guarantees a very good heat exchange and therefore a good cooling of the cover plate.
It has been shown that the heat exchanger parts of the arrangement for obtaining a high efficiency can be provided without difficulties when the ratio of the height and width, or respectively height and diameter of the preheating device, amounts to from 1:1.5 to 1:3.5, advantageously 1:2. When the burner lies in the plane of the wall or plate which limits the combustion chamber, it is possible that the burner will heat too strongly the surrounding region of the plate. For reliably avoiding this phenomenon, the burner of the inventive arrangement has a part which substantially projects outwardly of the wall which limits the combustion chamber.
In accordance with a further feature of the present invention, a shaped sealing member is provided in the marginal region of the arrangement so as to reliably avoid penetration of cold surrounding air into the pre-chamber, or escape of the hot air which can be used for preheating of the container into the surrounding atmosphere. By this sealing a further energy economy is obtained, and improved working conditions are provided since the surrounding air is not heated and dirtied.
The burner of the inventive arrangement can be formed as an oil, gas or solid matter burner. When the solid-matter burner is used, it is advantageous to provide an ash and flue dust separator, which guarantees that the operation of the heat exchanger parts are not affected by depositing of ash and flue dust.
In accordance with the present invention, the diameter of the heat exchanger chamber which forms the main component of the preheating device is kept as small as possible, so that this part can be used for ladles or containers having both small and very great diameters. When for a ladle with a small diameter only low combustion power is needed, only one part of the segments of the preheating device forms the heat exchanger parts. For higher power, respectively greater number of segments are used. For closing the combustion chamber, the annular chamber from which somewhat heated combustion air travels into the heat exchange pipes is corespondingly increased. In such a case it is advantageous to continuously use the thermal energy contained in the waste gas. It is known that in heat exchanger arrangements of this type the quantity of the transmitted thermal energy depends not only on the temperature of the waste gas and the surface as well as on the material of the heat exchange pipes, but also on the contact time of the waste gas with the heat exchange pipes. In the beginning of the flow path, the waste gas has left relatively high temperature, so that relatively much heat energy is exchanged. After a certain travel, the waste gas is colder, so that respectively less heat energy is exchanged.
For withdrawing as much thermal energy as possible from the waste gas, it is proposed in accordance with the present invention to form the flow cross section of the heat exchanger chamber for the waste gas increasing in the flow direction. Thereby the dwell or contact time of the waste gas with the heat exchange pipes to the end of the flow path is longer than in the beginning of the flow path. Therefore at the end of the flow path increased heat transmission takes place as compared with the constant flow cross section. The increase of the flow cross section can also be obtained when the distance of the above mentioned guiding sheets is selected greater in flow direction.
The novel features which are considered characteristic for the invention are set forth in particular in the appended claims. The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments when read in conjunction with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a partially sectioned lateral view of an arrangement for heating a ladle to be heated with molten metal;
FIG. 2 is a plan view of the partially sectioned arrangement of FIG. 1;
FIG. 3 is a view showing a partial section of a bundle of heat exchange pipes in the region of the innermost guiding sheet of the arrangement;
FIG. 4 is a view showing a partial section or a cross sectional development of a bundle of heat exchanger pipes in the region of the center of the arrangement;
FIG. 5 is a plan view from above of the arrangement shown in FIG. 1 without a burner; and
FIG. 6 is a view showing a horizontal section of the central region of the arrangement of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows an arrangement 1 for heating and/or heat retaining of a ladle 2 which is shown partially and identified with broken lines. The ladle 2 is to be filled for example by molten iron. The arrangement 1 has a lower wall which is formed by a plate 3 and together with the ladle 2 forms a combustion chamber 4. The combustion chamber 4 is heated by an oil burner 5.
The plate 3 of the arrangement 1 is flat. In contrast an upper side 6 of the arrangement 1 is roof-shaped, as can be seen in FIG. 2. The arrangement has a circular base contour and is provided with an annular chamber 7 extending around this contour. The annular chamber 7 has at its lower side a sealing shaped member 8 which engages in a recess provided at the lower edge of the ladle 2.
The fuel supply for the burner 5 takes place via a fuel supply pipe 9 which extends centrally and axially through the arrangement 1. The fuel supply 9 is coaxially surrounded by an air pipe 10. As can be seen from FIG. 6, the air pipes 10 is subdivided in an axial direction into small segment chambers 11 for fresh cold combustion air and larger segment chambers 12 for preheated combustion air. FIG. 1 shows in section a greater segment chamber 12 for preheated combustion air.
The cold combustion air is supplied axially in the direction of the arrow L in FIG. 1 through the small segment chambers 11 into the arrangement 1 and passes through the segment chambers 11, enters radial spiral-shaped (not shown) cooling passages 13, travels substantially preheated into the annular chambers 7 with flowing over and cooling of the cover plate 3 which has been heated by the smoke gas in the combustion chamber 4, and reaches via heat exchanger pipes 14 extending radially to the center, the larger segment chambers 12 of the air pipe 10. The preheated combustion air discharges at the lower end of the segment chambers 12 for combustion.
The waste gas whose direction is identified in FIG. 1 with the arrow travels from the combustion chamber 4 into waste gas inlet openings 15 which are arranged in the region of the burner 5 in a circumferential direction with distances therebetween, as can be seen in FIG. 5. From there it flows through a heat exchange chamber 16 formed by the heat exchanger pipes 14. The heat exchange chamber 16 is subdivided by four ring-shaped guiding sheets 17a-17d which are alternately offset upwardly and downwardly, so that the waste gas flows around the heat exchanger pipes 14 with multiple direction change partially in a counterstream, and partially in a cross counterstream. For the sake of clarity several arrows are provided in FIG. 1, which identify the flow path of the waste gas. In the region of an outer wall 18 of the arrangement 1, the waste gas is deflected upwardly and flows via an outlet chamber 19 into an outlet passage arranged in the center of the arrangement and not shown in the drawing.
As can be particularly seen from FIGS. 1 and 2, the heat exchange pipes 14 are inclined outwardly in a downward direction, so that they have practically substantially the same distances. Thereby the roof-shaped upper side 6 of the arrangement is formed, wherein the outlet chambers 19 form a "ridge" of the roof. Several, for example ten, heat exchange pipes 14 form a group or a pipe bundle. Each of these groups or bundles has a cross section which in the region of the guiding sheet 17c has the shape of the inverted letter "V" as shown in FIG. 3, and in the region of the air pipe 10 has the shape of two adjacent rows as shown in FIG. 4.
One or several pipe groups or bundles can be assembled with one another in a segment-like manner, so that for operation of the arrangement with partial loading only certain segments take part in the heat exchange. For example, it can be attained in that a radially extending partition 20 shown in FIG. 2 is provided between individual pipe bundles and the inlet openings for the smoke gas are formed closable individually or in groups.
The above described arrangement, particularly its parts which participate in the heat exchange, is composed of heat-resistant material, for example of steel. Copper is also suitable for this purpose, since it is known that copper has high heat conductive properties. The relation of the height of the preheating arrangement, or substantially its heat exchange chamber, to the diameter amounts to approximately 1:2. As can be seen from FIG. 1, the burner 5 extends substantially downwardly beyond the plane of the plate 3. This has the purpose of preventing excessively strong heating of the plate 3 around the burner.
Other embodiments of the present invention are also possible, for example a gas or solid-matter burner can be used. With the use of a solid-matter burner, a separator for ashes and dust is provided, so as to prevent that full functioning of the recuperator part of the arrangement be affected by depositing of these residues.
In the shown embodiment, the drawing of and discharging of the waste gas takes place by a drawing passage or flue provided in the region of the center axis of the arrangement. It is also possible to withdraw the waste gas in the marginal region of the arrangement. In this case several drawing passages are connected with the outer wall 18 or the marginal region of the upper side 6.
It is to be understood that, if needed, the residual heat still remaining in the smoke gas can be further reduced by a subsequently arranged heat exchanger. The cooling passages 13 provided in the region of the plate 3 are formed in the above described embodiment advantageously of spiral shape and have a triangular or wave-shaped cross section. However, it is possible to provide other shapes and cross sections.
The lower plate 3 does not need to be flat. It can be somewhat inclined similarly to the upper side 6. This inclination depends on the arrangement of the heat exchanger pipes inside the heat exchanger chamber.
In the above described embodiment the segment passages 11 and 12 are formed by shaped members welded to the air pipe 10. It is also possible to form these passages by sheets which connect the pipe 10 with the pipe 9.
It will be understood that each of the elements described above, or two or more together, may also find a useful application in other types of constructions differing from the types described above.
While the invention has been illustrated and described as embodied in an arrangement for heating and/or heat retaining of containers and their contents, it is not intended to be limited to the details shown, since various modifications and structural changes may be made without departing in any way from the spirit of the present invention.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention.
What is claimed as new and desired to be protected by Letters Patent is set forth in the appended claims. | An arrangement for heating and/or heat retaining of containers and their contents, for example ladles to be filled with molten metal, has a burner directed toward the container, a cover for a container opening, and a preheating device for combustion air which if formed as a component of the cover. | 1 |
BACKGROUND OF THE INVENTION
The present invention is directed toward a coin cup holder which is mounted to the wall of a toilet stall located in a casino. The invention is also useful for holding a coat and a pocket book.
A problem people often face when entering a public restroom is the lack of a hook or holding device to support coats, purses, and other personal items within a stall. This problem is even more pronounced in casinos. Patrons of casinos who play the slot machines often walk around the casino with a cup that holds coins which they use to play the machines and/or have won from the machines. Coat hooks can generally be found in any bathroom stall; however, any other type of holder usually cannot be found within the stall. Furthermore, coin cup holders mounted on the stall wall are unknown.
Various holders to be used in restrooms are known and have been described in various patents. For example, U.S. Pat. No. Des. 71,202 to Nitsche discloses a wall mounted toilet rack which includes an open receptacle for supporting a cup or the like. U.S. Pat. Nos. 1,215,495 and 679,807 also disclose wall mounted receptacles for supporting a cup or another cylindrical object, therein. However, none of these patents discloses additionally securing a pair of hooks for supporting a coat and/or purse to the holder.
Similarly, U.S. Pat. Nos. 776,332; 897,072; and 5,427,231 disclose various wall mounted devices which are adapted to support a variety of objects. Each of these patents contains some means for supporting a cup or the like therein and additional hooks for supporting additional objects. Yet, none of these patents is intended to be secured to the wall of a bathroom stall for supporting a coin cup, coat, or purse.
SUMMARY OF THE INVENTION
The present invention is designed to overcome the deficiencies of the prior art discussed above. It is an object of the present invention to provide a coin cup holder within a toilet stall located in a casino.
It is another object of the present invention to provide a holder with a pair of hooks where the hooks are used to support a coat and a pocket book, respectively.
It is a further object of the present invention to provide holders which may be mounted to either side of a common side wall of adjacent toilet stalls located in a casino.
In accordance with the illustrative embodiments, demonstrating features and advantages of the present invention, there is provided a holder mounted to a wall of a toilet stall and which includes a frame with a cup receptacle extending outwardly therefrom. The cup receptacle is adapted to receive and support a casino coin cup therein. The holder may also have a pair of hooks secured thereon. One hook may be used to support a coat and the other hook may be a swivel hook for supporting a pocket book.
BRIEF DESCRIPTION OF THE DRAWINGS
For the purpose of illustrating the invention, there is shown in the accompanying drawings forms which are presently preferred; it being understood that the invention is not intended to be limited to the precise arrangements and instrumentalities shown.
FIG. 1 is a front perspective view of the present invention including a right-handed coin cup holder mounted on a side wall of a toilet stall;
FIG. 2 is a front perspective view of the present invention including a left-handed coin cup holder mounted on the opposite side of the side wall in an adjacent toilet stall;
FIG. 3 is a cross-sectional view of the present invention taken along line 3--3 of FIG. 1, and
FIG. 4 is a front perspective view of the right-handed coin cup holder of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings in detail wherein like reference numerals have been used throughout the various figures to designate like elements, there is shown in FIG. 1 a coin cup holder constructed in accordance with the principles of the present invention and designated generally as 10.
The coin cup holder may be made in what may generally be referred to as a right-handed holder 12 or a left-handed holder 112 as shown in FIGS. 1 and 2. The right-handed holder 12 is essentially a frame 14 with a coin cup receptacle 16, a coat hook 18, and a swivel hook 20 mounted thereon. The left-handed holder 112 includes the same elements as the right-handed holder but the coin cup receptacle 116 and swivel hook 120 are mounted on the frame 114 in positions opposite that of the coin cup receptacle 16 and swivel hook 20 of the right-handed holder 12, respectively, as seen in FIGS. 1 and 2.
Looking now at the individual elements of the right-handed holder 12, FIGS. 1 and 4 show a frame 14 which may be made of plastic or metal. Although the frame 14 is shown to be rectangular, virtually any shape may be used. Holes 22a, 22b, 22c and 22d are formed in each of the four comers of the frame 14 and bolts 24a-24d are screwed into the holes 22a-22d, respectively, thereby securing the frame 14 to the toilet stall side wall 30, as seen in FIG. 1. Preferably, the bolts 24a-24d should be long enough to go through the side wall 30 and protrude from the opposite side 132 of the side wall, into an adjacent stall so that a left-handed holder 112 may be secured in the adjacent stall, as will be further described.
The frame 14 of the right-handed holder 12 has a coin cup receptacle 16 mounted thereon. The receptacle 16 is generally a square plate 26 although almost any shape may be used. The plate 26 is made from metal or plastic with an opening 28 in the center thereof. The opening 28 should have a diameter of approximately four inches so that a casino coin cup 34 may be inserted therein from the top of the plate 26 and held in place. The plate 26 is mounted to the frame 14 and extends outwardly so that it is perpendicular to the frame 14. Any means of mounting known in the art, such as gluing or molding, may be used to secure the receptacle 16 to the frame 14. Triangular braces 27 and 29 may be utilized to help support the plate 26.
The frame 14 also has a pair of hooks 18 and 20. The first hook is a coat hook 18. Hook 18 has a base 36 mounted to the frame 14 and a hooked portion 38 secured to the base 36, as seen in FIG. 4. The hooked portion 38 is turned upwardly so that a coat 40 may be supported thereon. Again, any means of mounting, as discussed above, may be used to the secure the hooked portion 38 to the base 36 and the base 36 to the frame 14. Although a two-pronged base is shown in the figures, any shape may be used. A coat may be placed on the hooked portion and will be fully supported.
The second hook is a swivel hook 20 for supporting a purse 54. Hook 20 has a mount 42 secured to the frame 14 where the mount extends outwardly from the frame. Generally, hook 20 is secured at the bottom center of the frame 14, as seen in FIG. 1. Mount 42 has an opening 44 through which a ring 46 fits and is freely rotatable. Ring 46 has a cylindrical portion 48 and from this portion 48 a hooked portion 50 extends downwardly, with the hook facing away from the frame 14. A spring-biased retainer 52 is connected to the hooked portion 50 at an end of the hooked portion 50 closest to the cylindrical portion 48. The retainer 52 extends downwardly and away from the hooked portion 50 so that an end of the retainer abuts the tip 50a of the hooked portion, as seen in FIG. 3. When a purse 54 is to be supported on the hook 20, the purse strap 54a is pushed against the retainer 52 displacing the retainer 52 toward the frame 14. The purse strap 54a rests on the hooked portion 50, as seen in FIG. 1. Because the retainer 52 is spring-biased, it returns to abutting the tip 50a of the hooked portion 50 so that the purse 54 is fully supported by and locked into the hook 20. In this way, the swivel hook 20 not only provides a convenient way of holding a purse; it also secures the purse so that a thief would be unable to reach over the stall door and steal the purse.
Turning now to the left-handed holder 112, it can be seen that the left-handed holder 112 has the same elements as the above-discussed right-handed holder. (See FIG. 2.) Specifically, the left-handed holder 112 has a frame 114 which may be made of plastic or metal. Again, although the frame 114 is shown to be rectangular, virtually any shape may be used. A hole is formed in each of the four corners of the frame 114. Two such holes, 122a and 122c, are seen in FIG. 3. When mounting the frame 114 to the toilet stall side wall 30, the four holes of the frame 114 are aligned with the holes 22a-22d of the frame 14, against opposite sides 132 and 32 of the side wall, respectively, so that when the bolts 24a-24d are screwed into the holes 22a-22d of the frame 14 they protrude from the side 32 of the side wall of the first stall and into the adjacent stall. The bolts 24a-24d are then screwed farther into the holes of frame 114. In this manner, frames 14 and 114 are secured to opposite sides of the side wall 30. (See FIG. 3.)
Just as in the right-handed holder 12, the left-handed holder 112 also has a coin cup receptacle 116. Again, the coin cup receptacle 116 is a square plate 126 mounted to the frame 112. The plate 126 extends perpendicularly, outwardly from the frame 112 and has an opening 128 through which a casino coin cup 134 is inserted and held in place. The opening 128 should have a diameter of approximately four inches so that the casino coin cup 134 may be inserted into the opening 128 from the top of the plate 126 and held in place. As in the right-handed holder 12, the plate 126 of the left-handed holder 112 may be made of plastic or metal and may be any shape, square being the preferred shape. Again, any means of mounting known in the art, such as gluing or molding, may be used to secure the receptacle 116 to the frame 114. The coin cup receptacle 116 differs from the coin cup receptacle 16 of the right-handed holder 12 in that the receptacle 116 is mounted in a position directly opposite the coin cup receptacle 16 of the right-handed holder 12. (Compare FIGS. 1 and 2.) In other words, the receptacles 16 and 116 mirror each other, as seen in FIG. 3.
The frame 114 of the left-handed handle 112 also has a pair of hooks 118 and 120. The first hook is a coat hook 118. Hook 118 has a base 136 mounted to the frame 114 and a hooked portion 138 secured to the base 136, as seen in FIG. 2. Hooked portion 138 is turned upwardly so that a coat may be supported thereon. Again, any means of mounting, as discussed above, may be used to the secure the hooked portion 138 to the base 136 and the base 136 to the frame 114. Although a two-pronged base is shown in the figures, any shape may be used. A coat may be placed on the hooked portion 138 and will be fully supported. Hook 138 differs from the coat hook 38 of the right-handed holder 12 in that hook 138 is mounted in a position directly opposite the coat hook 38 of the right-handed holder 12 so that the hooks 38 and 138 mirror each other, as seen in FIG. 3.
The second hook is a swivel hook 120 for supporting a purse 154. Hook 120 has a mount 142 secured to the frame 114 where the mount extends outwardly from the frame 114. Hook 120 is usually found in the bottom center of the frame 114. Mount 142 has an opening 144 through which a ring 146 fits and is freely rotatable. Ring 146 has a cylindrical portion 148 and from portion 148 a hooked portion 150 extends downwardly, with the hook facing away from the frame 114. A spring-biased retainer 152 is connected to the hooked portion 150 at an end of the hooked portion closest to the cylindrical portion 148. Retainer 152 extends downwardly and away from the hooked portion 150 so that an end of the retainer 152 abuts the tip 150a of the hooked portion 150, as seen in FIG. 3. When a purse 154 is to be supported on the hook, the purse strap 154a is pushed against the retainer 152 displacing the retainer 152 toward the frame 114. The purse strap 154a rests on the hooked portion 150, as seen in FIG. 2, and the retainer 152 returns to abutting the tip 150a of the hooked portion 150 so that the purse 154 is fully supported by and locked into the hook. Again, this swivel hook secures the purse and prevents it from being stolen.
While the present invention has been described as being attached to a side wall of a toilet stall, one of ordinary skill in the art would realize that either the right-handed holder or left-handed holder may be attached to a toilet stall door in the same manner. One should realize however, that the bolts used to secure the holder to the door cannot be as long as the above-described bolts. Rather, the bolts should only fit through the stall door and not protrude from the outer side of the stall door.
The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof and accordingly, reference should be made to the appended claims rather than to the foregoing specification as indicating the scope of the invention. | A coin cup holder mounted to the wall of a toilet stall located in a casino restroom includes a frame which has mounted on it a coin cup receptacle and a pair of hooks. The hooks include a coat hook and a swivel hook for supporting a purse. The coin cup holder may be mounted to a side wall, shared by adjacent stalls, via a bolt which goes through the wall and attaches to another holder mounted in the adjacent stall. The coin cup holder may also be mounted to a stall door. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application relates and claims priority to U.S. Provisional Patent Application No. 61/268,775, filed on Jun. 16, 2009.
FIELD OF THE INVENTION
This invention relates to the purification of water by distillation and more particularly to distillation processes in which the heat released during the condensation step is used for other purposes.
BACKGROUND OF THE INVENTION
Many hydrocarbon refining processes require water intake (excluding once-through cooling water) that is free of salts and suspended solids and the amount of water required for refinery operations is large: typical refineries might, for example, require from about 25,000 to about 150,000 m 3 /day. River water and sea water as well as recycled municipal waste water may be used as sources for the required amounts of water and with the amounts of dissolved salts and suspended solids typically encountered with such sources, a heavy load is imposed on water purification plants. A typical refinery limitation on the total dissolved solids (TDS) in bulk waste water can be as low as 2,000 wppm. While filtration, for example, through sand beds, may be effective to remove suspended solids, removal of the dissolved salts presents more difficult problems. Water purification by reverse osmosis or evaporation is an energy intensive process and with recent increases in the cost of energy, by a factor of approximately three since the year 2000, reliance on conventional source becomes progressively less tenable.
Solar power has been proposed for desalination using either flat panel evaporators as in U.S. Pat. No. 5,672,250 or concentrated solar power as described in U.S. Pat. No. 5,645,693. Solar energy, plentifully available in certain areas of the world, has been proposed both for the generation of electrical energy and for the provision of potable water. See, for example, “Concentrating Solar Power for Seawater Desalination”, Trieb, MENAREC 4, 20-24 Jun. 2007, estimating that the solar energy received on each square kilometer of desert land in the MENA region is sufficient to desalinate 165,000 m 3 /day of water, making such a plant capable of supplying the fresh water requirements of even a large petroleum refinery.
Refinery cooling tower systems will typically impose a concentration limit on total dissolved salts (TDS) of about 55,000 wppm at 50° C.; in the case of a typical seawater with 30,000 or 35,000 to 40,000 wppm TDS, repeated recycling through the cooling tower with these levels of dissolved salts cannot be accepted without resort to high blowdown rates. In addition, care must be taken in selecting the intake location to assure that the suspended solids do not exceed 200 wppm in the recirculated water.
The use of concentrated solar power or nuclear thermal energy presents an attractive option to the problem of providing desalinated water in large quantities for use in petroleum refineries. The primary advantages of using solar thermal or nuclear heat purified water in refining processes are:
a) fossil fuels such as natural gas or refined crude oil are not combusted for providing heat to the water purification process, thus leading to conservation of fossil fuel resources, b) the carbon footprint of water purification is significantly reduced, c) solar thermal or nuclear heat is available in sufficient quantity and quality to provide for water heat from the water purification to be utilized for other purposes.
SUMMARY OF THE INVENTION
According to the present invention, solar thermal or nuclear heat is used to desalinate by evaporation a water source having a dissolved salt content of at least 2,000 ppmw with the heat liberated during steam condensation to water used as low quality heat for petroleum refining operations. The coupling of the evaporative water purification process with refining processes enables the purified water to be used as process water with the low quality heat from the condensation of the steam in the water purification being used for refining operations. Sea water is most suitable for evaporative purification processes. Saline waters with very high dissolved salt levels, e.g. as high as the 30,000, 35,000 or 40,000 ppmw typical of sea waters may be effectively treated in this way.
DETAILED DESCRIPTION
Heat from a concentrated solar power (CSP) or nuclear thermal energy source may be supplied directly or indirectly to the evaporative water purification process. When solar energy sources provide the heat, the saline water may be passed directly through a solar furnace, e.g. at the focus of the furnace, to provide the heat directly or indirectly by heat exchangers passing a heat transfer medium from the solar source to the exchanger. With nuclear energy sources where circulation directly through the nuclear reactor is not possible, the feed water will be passed through heat exchangers fed from the nuclear reactor. The heat exchanger will normally be fed with heat transfer medium in a secondary loop heated in a heat exchanger with the nuclear reactor primary coolant in its own loop passing through the nuclear reactor core but if the primary coolant does not become radioactive in the reactor core, e.g. with helium in a gas-cooled reactor, the heat exchangers for the evaporation may be fed with the primary coolant.
Solar Thermal Energy Sources
Solar thermal energy is provided by the conversion of light to heat energy. This is typically achieved by focusing solar radiation onto a point source using mirrors, and the point source increases in temperature thus generating heat. For commercial applications, multiple mirrors are required to be installed to increase light capture. Once the solar radiation is focused on a point, the heat is transferred to fluid heat transfer medium. Three types of solar thermal device designs have been explored: solar tower, solar trough, and solar reactors.
Solar thermal installations with a tower design use mirrors to focus incoming solar radiation on to a point that is often located on a central tower. Typically, the mirrors in a heliostat system are motorized to follow the sun over the course of the day. At this focal point, a liquid heat transfer medium is heated to the required temperature. Solar trough power plants use curved, trough-shaped mirrors to focus light on to a heat transfer fluid that flows through a tube above them. These trough reflectors tilt throughout the day to track the sun for optimal heating. The heat transfer fluid is heated in the troughs and then flows to a heat exchanger, which is used to produce superheated steam. A modified version of the parabolic trough design, the Fresnel reflector design, is uses a series of flat mirrors with a number of heat transfer receivers. Solar reactors, or Concentrated Solar Power (CSP), are useful for applications such as the present that take advantage of the high-temperature capabilities of tower technology which uses reactors similar to closed volumetric receivers except that a rhodium or another catalyst is dispersed on the surface of the ceramic mesh, directly absorbing the solar energy to produce syngas, hydrogen, and carbon monoxide as disclosed by Moller, S. et al., in 2002: Solar production of syngas for electricity generation: SOLASYS Project Test-Phase, 11 th SolarPACES International Symposium on Concentrated Solar Power and Chemical Energy Technologies, Zurich. In its application to the present invention a solar reactor is used for directly heating the heat transfer fluid to high temperatures.
The solar energy source may be augmented with natural gas or nuclear heat at times the solar thermal reactor output is diminished due to lack of availability of solar radiation.
Nuclear Thermal Energy Sources
The high temperatures required for the present invention can also be provided by certain nuclear thermal energy sources. While conventional light water reactors are not adequate to supply these high temperatures, high temperature gas-cooled reactors and others have appropriate characteristics. One example is the Toshiba 4S (super safe, small, and simple) nuclear power system is based on a low-pressure, liquid-sodium design which is therefore capable of supplying the required high temperatures. It can be transported in modules and installed in a building measuring 22×16×11 metres and therefore commends itself for appropriate adaptation to refinery usage. High-temperature gas-cooled reactors (HTGRs) which typically use helium as a coolant are another next-generation reactor design that have the potential for driving endothermic chemical reactions, e.g., the regeneration reactions in the sulfur sorption cycle. One factor making HTGRs advantageous for the present application is that in principle the HTGCR can operate at temperatures well above 800° C., a range of refining operations including cracking, reforming and solid contact sulfur sorption as described above. The Siemens PBMR (the pebble bed modular reactor, or PBMR) is an example of a HTGCR which would be particularly useful for these purposes. The pebble bed modular reactor (PBMR) potentially meets US safety standards and includes a required airtight steel-lined reinforced-concrete containment structure. Operation of the PBMR is based on a single helium coolant loop, which exits the reactor core at 900° C. and 70 bar and therefore can be used to heat a heat transfer medium to comparable temperatures for use in refining processes. The PBMR is described in Weil, J., 2001: Pebble - Bed Design Returns, IEEE Spectrum, 38 (11), 37-40.
Heat Transfer From Source to Process Unit
As noted above, the heat from solar sources may be applied directly to the evaporator feed stream by passing it through heating coils in the solar furnace. In other cases, the heat from the solar or nuclear high temperature heat source will be applied by the use of a heat transfer medium and heat exchange device transferring the heat from the solar or nuclear power source to the reforming process unit. The heat transfer medium will be routed from the solar or nuclear source to a heat exchanger providing the heat to the evaporator, e.g. by passing the heat exchange medium through the interior of a plate type evaporator, to the heating coils of a multi-effect evaporator. Heat from solar and nuclear heat sources at temperatures potentially in excess of 1500° C. and heat of this quality can be used very effectively to provide the evaporation heat requirement, even when transferring heat to the water indirectly through a heat exchanger. Heat transfer at the high temperatures, typically above 800° C. and ideally higher, e.g. 900, 1000° C., even as high as 1500° C., can be effected using transfer media such as liquids, gases, molten salts or molten metals although molten salts and molten metals will often be preferred for their ability to operate at the very high temperatures required for high energy densities without phase changes; in addition, corrosion problems can be minimized by appropriate choice of medium relative to the metallurgy of the relevant units. Molten salt mixtures such as mixtures of nitrate salts, more specifically, a mixture of 60% sodium nitrate and 40% potassium nitrate are suitable but other types and mixtures of molten salts may be used as a heat transfer and a thermal storage medium. Liquid metals such as sodium as well as alloys such as sodium-potassium alloy, bismuth alloys such as Woods metal, (m.p. 70° C.) and alloys of bismuth with metals such as lead, tin, cadmium and indium; the melting point of gallium (30° C.) and its alloys would, but for the aggressiveness of this metal towards almost all other metals, generally preclude it from consideration. Mercury is excluded for environmental reasons. Hot helium from a HTGCR can be used in a single loop heat exchange circuit from the nuclear reactor to the hydrocarbon process unit since helium is incapable of becoming radioactive and HTGCR reactor design is inherently safe: in the event of a loss of coolant, the temperature in the core will increase until Doppler broadening leads to a breakdown in the fission chain reaction. Outlet temperature and pressure for the helium coolant of the HTGCR are 850° C. and 70 bar, respectively, making it suitable for the present purposes. If required for safety or other reasons, the primary heat exchange fluid can be used to heat a secondary heat exchange fluid in a secondary circuit with this secondary fluid passing to the hydrocarbon process unit.
Evaporative Purification
The evaporator is typically a multi-effect evaporator using up to four stages for thermal efficiency but other types of evaporator may be used as desired provided that suitable modifications are made, as necessary, to accommodate the high temperatures of the heat supplied and the quality of the feed water, e.g. depending on whether the water has a relatively low dissolved salt content around 2,000 to 3,000 ppm or, alternatively, is a sea water with a high level of dissolved salts, e.g. 30,000-40,000 ppm. The steam produced will normally be at a high temperature if the full capabilities of the CSP or nuclear heat are fully exploited and accordingly, a partial condensation may be effected by expansion of the steam through a power turbine prior to the final condensation step with the power from the turbine used to generate electricity or directly run rotary machinery. Finally, the steam will be condensed in a condenser to provide water with a low level of residual dissolved salts.
The evaporation is conducted in such a manner that the remaining brine concentrate remains capable of being handled as a liquid or slurry. A concentration gauge on the evaporator may be used to provide automatic process control so that the feed rate and/or evaporation rate are controlled to maintain the desired concentration in the discharge brine stream. The hot brine discharge stream may be mixed prior to discharge into the environment with cool sea or river water to minimize the heat/salinity plume from the purification unit. The selected concentration may be based on the construction of the unit including its metallurgy since the hot brine is corrosive and if sufficiently concentrated into a salt slurry, may also be abrasive. Consideration should also be given to the ability of the environment into which the discharge is being made to accept the discharge brine without unacceptable consequences.
Secondary Thermal Energy Utilization
During the evaporative purification process, the water is converted to steam by the heat from the CSP or nuclear thermal energy source with the steam being available at a high temperature as noted above. When this steam is condensed back into water, the heat given up on condensation is employed for providing process heat directly to a refining operation, e.g. as low or medium pressure steam to be supplied to feed pre-heaters, heat exchangers, reactor heating jackets, tracing, etc. In this way, the heat originally supplied by the CSP or nuclear thermal energy source is fully utilized within the refinery. | Saline waters are made suitable for use in large quantities in petroleum refining operations by evaporative desalination of a water source having a dissolved salt content of at least 30,000 ppmw with the heat liberated during the steam condensation used as low quality heat for petroleum refining operations. Sea water is most suitable for evaporative purification processes. | 8 |
PRIORITY
[0001] This application claims priority from U.S. Ser. No. 61/151,323 filed on Feb. 10, 2009, the entire contents of which are incorporated herein by reference.
BACKGROUND
[0002] The present patent application is directed to low density paper and paperboard and, more particularly, to low density paper and paperboard having a smooth, coated surface on both sides.
[0003] Paperboard is commonly used in various packaging applications. For example, high end personal care or commercial printing applications and the like. The paperboard often receives a variety of graphic treatments to enhance its visual impact on the shelf. Likewise, quality papers to be utilized as a medium for printing require smooth coated surfaces, with few imperfections to facilitate the printing of high quality text and graphics.
[0004] Conventionally, smoothness is achieved by calendering. Calendering serves to mechanically compress the sheet, providing a surface roughness low enough to produce final coated smoothness acceptable to the industry. However, this compression results in the severe densification of the sheet. Therefore, smooth papers and paperboard are typically more dense (i.e., less bulky) than less smooth paper and paperboard. This effect is magnified when a smooth, coated print surface is required on both sides of the paperboard.
[0005] For example, in FIG. 1 , the basis weight in pounds per ream (1 ream=3000 ft 2 ) of certain prior art coated two-side (C2S) solid bleached sulfate (SBS) paperboard products and C2S fine paper products is plotted against caliper thickness (1 point=0.001 inch=1 mil), thereby providing a visual representation of prior art paper and paperboard density (i.e., basis weight divided by caliper thickness). As can be seen, for a given caliper, the sheet will have typically been pressed to a given density range in order for the needed surface smoothness to be developed.
[0006] Nonetheless, low density is a desirable quality in many paper and paperboard applications. However, preparing a smooth surface using the conventional calendering process requires substantially increasing the density of the fiber substrate.
[0007] Accordingly, there is a need for a low density paper and paperboard that provides the desired smoothness on both sides for high quality printing, while reducing raw material cost.
SUMMARY
[0008] In one aspect, the disclosed low density paper or paperboard may include a fiber substrate and a coating applied to each side of the fiber substrate to form a coated structure, the coated structure having a Parker Print Surf (PPS 10, soft platen) smoothness on each side of at most about 2 microns, a caliper thickness and a basis weight, the basis weight being less than about Y 1 , wherein Y 1 is a function of the caliper thickness (X) in points and is calculated using Eq. 1 as follows:
[0000] Y 1 =29.15+11.95 X− 0.07415 X 2 (Eq. 1)
[0009] In another aspect, the disclosed low density paperboard may include a fiber substrate and a coating applied to each side of the fiber substrate to form a coated structure, the coated structure having a Parker Print Surf smoothness on each side of at most about 2 microns, a caliper thickness and a basis weight, the basis weight being at most about Y 2 , wherein Y 2 is a function of the caliper thickness (X) in points and is calculated using Eq. 2 as follows:
[0000] Y 2 =28.41+11.73 X− 0.07324 X 2 (Eq. 2)
[0010] In another aspect, the disclosed low density paperboard may include a fiber substrate and a coating applied to each side of the fiber substrate to form a coated structure, the coated structure having a Parker Print Surf smoothness on each side of at most about 2 microns, a caliper thickness and a basis weight, the basis weight being at most about Y 3 , wherein Y 3 is a function of the caliper thickness (X) in points and is calculated using Eq. 3 as follows:
[0000] Y 3 =27.78+11.51 X− 0.07207 X 2 (Eq. 3)
[0011] In another aspect, the disclosed low density paperboard may include a fiber substrate and a coating applied to each side of the fiber substrate to form a coated structure, the coated structure having a Parker Print Surf smoothness on each side of at most about 2 microns, a caliper thickness and a basis weight, the basis weight being at most about Y 4 , wherein Y 4 is a function of the caliper thickness (X) in points and is calculated using Eq. 4 as follows:
[0000] Y 4 =26.89+11.17 X− 0.07034 X 2 (Eq. 4)
[0012] In another aspect, the disclosed low density paperboard may include a fiber substrate, a topcoat, and a coating positioned between the fiber substrate and the topcoat, the fiber substrate, the basecoat and the topcoat forming a coated structure, wherein the coated structure has a Parker Print Surf smoothness of at most about 2 microns, a caliper thickness and a basis weight, the basis weight being between about Y 1 and about Y 5 , wherein Y 1 and Y 5 are functions of the caliper thickness (X) in points and are calculated used Eq. 1 above and Eq. 5 as follows:
[0000] Y 5 =26.15+10.83 X− 0.06815 X 2 (Eq. 5)
[0013] Other aspects of the disclosed low density paperboard will become apparent from the following description, the accompanying drawings and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a graphical comparison of density versus caliper thickness of certain prior art paper and paperboard materials to paper and paperboard according to the present disclosure;
[0015] FIG. 2 is a cross-sectional view of one aspect of the disclosed low density paper or paperboard;
[0016] FIG. 3 is a graphical representation of basis weight versus caliper thickness of various exemplary aspects of the disclosed low density paperboard;
[0017] FIG. 4 is a schematic illustration of a first aspect of a process for preparing the disclosed low density paperboard;
[0018] FIG. 5 is a schematic illustration of a second aspect of a process for preparing the disclosed low density paperboard;
[0019] FIG. 6 is a graphical representation of density versus smoothness (Parker Print Surf) of certain prior art 10 point (caliper) products; and
[0020] FIG. 7 is a graphical representation of density versus smoothness (Parker Print Surf) values of certain prior art 12 point (caliper) products.
DETAILED DESCRIPTION
[0021] Referring to FIG. 2 , one aspect of the disclosed low density paperboard, generally designated 10 , may include a fiber substrate 12 , a basecoat 14 a , 14 b and an optional topcoat 16 a , 16 b . The coating formulations may differ from side-to-side in formulation as well as in amount applied. Additionally, one side may have only a base coating, while the other side could be both base and top coated. The paperboard 10 may have a caliper thickness T and layers of coating on each side on which graphics may be printed. Additional layers may be used without departing from the scope of the present disclosure.
[0022] In one aspect, the fiber substrate 12 may be a paper or paperboard substrate. As used herein, “fiber substrate” broadly refers to any paper or paperboard material that is capable of being coated with a basecoat, and may be a single-ply substrate or a multi-ply substrate. Those skilled in the art will appreciate that the fiber substrate may be bleached or unbleached. Generally, the fiber substrates noted herein have uncoated basis weights of about 65 pounds per 3000 ft 2 or more. Examples of appropriate substrates include paper cover stock, linerboard and solid bleached sulfate (SBS). In one particular aspect, the fiber substrate 12 may include a substantially chemically (rather than mechanically) treated fiber, such as an essentially 100 percent chemically treated fiber. Examples of appropriate chemically treated fiber substrates 12 include solid bleached sulfate paperboard or solid unbleached sulfate paperboard.
[0023] Additional components, such as binders, fillers, pigments and the like, may be added to the fiber substrate 12 without departing from the scope of the present disclosure. Furthermore, the fiber substrate 12 may be substantially free of plastic pigments or other chemical bulking agents for increasing bulk, such as hollow plastic pigments or expandable microspheres, Still furthermore, the fiber substrate 12 may be substantially free of ground wood particles.
[0024] The topcoat 16 a , 16 b is an optional layer and may be any appropriate topcoat. For example, the topcoat 16 a , 16 b may include calcium carbonate, clay and various other components and may be applied to the basecoat 14 a , 14 b as a slurry. Topcoats are well known by those skilled in the art and any conventional or non-conventional topcoat 16 a , 16 b may be used without departing from the scope of the present disclosure.
[0025] The basecoat 14 a , 14 b may be any coating that improves the smoothness of the surface of the paperboard 10 without substantially reducing the caliper thickness T of the paperboard 10 , thereby yielding a smooth (e.g., Parker Print Surf smoothness below about 2.0 microns) and low density paper or paperboard. Those skilled in the art will appreciate that the basecoat 14 a , 14 b as well as the techniques (discussed below) for applying the basecoat 14 c , 14 b to the fiber substrate 12 , may be significant factors in maintaining a low density product.
[0026] In a first aspect, the basecoat 14 a , 14 b may be a carbonate/clay basecoat. The carbonate/clay basecoat may include a ground calcium carbonate component, a platy clay component and various optional components, such as latex binders, thickening agents and the like. The carbonate/clay basecoat may be dispersed in water such that it may be applied to the fiber substrate 12 as a slurry using, for example, a blade coater such that the carbonate/clay basecoat substantially fills the pits and crevices in the fiber substrate 12 without substantially coating the entire surface of the fiber substrate 12 .
[0027] Specific examples of appropriate carbonate/clay basecoats, as well as techniques for applying such basecoats to a fiber substrate 12 , are disclosed in U.S. Ser. No. 12/326,430 filed on Dec. 2, 2008, the entire contents of which are incorporated herein by reference.
[0028] Accordingly, in one aspect, a low density paperboard 10 may be prepared by the process 20 illustrated in FIG. 4 . The process 20 may begin at the head box 22 which may discharge a fiber slurry onto a Fourdrinier 24 to form a web 26 . The web 26 may pass through one or more wet presses 28 and, optionally, through one or more dryers 30 . A size press 32 may be used and may slightly reduce the caliper thickness of the web 26 and an optional dryer 34 may additionally dry the web 26 . In one aspect, the web 26 may pass through a calender 36 with the nip loads substantially reduced to minimize or avoid reduction in caliper thickness. Preferably, the calender 36 would be run as a dry calender. In another aspect, the calender 36 may be omitted or bypassed. Then, the web 26 may pass through another optional dryer 38 and to the first coater 40 a . The first coater 40 a may be a blade coater or the like and may apply the carbonate/clay basecoat 14 a onto the web 26 . An optional dryer 42 a may dry, at least partially, the carbonate/clay basecoat 14 a prior to application of the optional topcoat 16 a at the second coater 44 a . Optional dryer 46 a may dry the topcoat 16 a . Likewise coating will be applied to the opposite side of the sheet by passing through a coater 40 b which may be a blade coater or the like and may apply a basecoat 14 b onto the web 26 . An optional dryer 42 b may at least partially dry the basecoat 14 b prior to application of the optional topcoat 16 b at coater 44 b . Another optional dryer 46 b may finish the drying process before the web 26 proceeds to the optional gloss calender 48 and the web 26 is rolled onto a reel 50 .
[0029] In a second aspect, the basecoat 14 a , 14 b may be a film-forming polymer solution applied to the fiber substrate 12 and then brought into contact with a heated surface in a nip, causing the solution to boil and create voids in the film which remain after the film is dried, resulting in a smooth surface. The film forming polymer may be a starch and the heated surface may be a heated roll.
[0030] Specific examples of appropriate film-forming polymers, as well as techniques for applying such polymers to a fiber substrate, are disclosed in PCT/US07/04742 filed on Feb. 22, 2007, the entire contents of which are incorporated herein by reference, in U.S. Ser. No. 60/957,478 filed on Aug. 23, 2007, the entire contents of which are incorporated herein by reference, and in PCT/US07/19917 filed on Sep. 13, 2007, the entire contents of which are incorporated herein by reference.
[0031] Accordingly, in another aspect, a low density paper or paperboard 10 may be prepared by the process 60 illustrated in FIG. 5 . The process 60 may begin at the head box 62 which may discharge a fiber slurry onto a Fourdrinier 64 to form a web 66 . The web 66 may pass through one or more wet presses 68 and, optionally, through one or more dryers 70 . A size press 72 may be used, and may slightly reduce the caliper thickness of the web 66 and an optional dryer 74 may additionally dry the web 66 . In one aspect, the web 66 may pass through a calender 76 with the nip loads substantially reduced to minimize or avoid reduction in caliper thickness. If used, the calender 76 may be run as a dry calender. In another aspect, the calender 76 may be omitted or bypassed. Then, the web 66 may pass to an application 78 of the film forming polymer followed by contacting in a nip with a heated roll 80 and a press roll to form a smooth surface with voids in the polymer film. After application and heat/pressure treatment of the film forming polymer, the web 66 may pass through another optional dryer 82 and to the first coater 84 a . The first coater 84 a may be a blade coater or the like and may apply a conventional basecoat (e.g., as a second basecoat) onto the starch-coated web 66 . An optional dryer 86 a may dry, at least partially, the basecoat prior to application of an optional topcoat at the second coater 88 a . Dryer 90 a may dry the topcoat. The opposite side of the sheet may then be coated via coater 84 b which may be a blade coater or the like and may apply conventional basecoat onto web 66 . An optional dryer 86 b may at least partially dry the basecoat prior to application of an optional topcoat at the next coater 88 b . Another optional dryer 90 b may finish drying before the web 66 proceeds to the optional gloss calender 92 and finished product is rolled onto a reel 94 . The gloss calender 92 may be a soft nip calender, a hard nip calender, or may be omitted or bypassed.
[0032] At this point, those skilled in the art will appreciate that the basecoats 14 a , 14 b , topcoats 16 a , 16 b and associated application techniques disclosed above may substantially increase the smoothness of the resulting paper or paperboard 10 without substantially increasing the density of the paper or paperboard 10 (i.e., the caliper thickness of the fiber substrate 12 may be substantially maintained throughout the coating process).
[0033] FIGS. 6 and 7 demonstrate the typical trend that as a product becomes more dense it can become smoother. It is obvious from the graphs that the products formed in examples 1 and 2 herein described are significantly different in this regard than other products in the ability to maintain low parker print surf values at new low levels of density.
EXAMPLES
[0034] Specific examples of smooth, low density paperboard prepared in accordance with the present disclosure are presented below.
Example 1
[0035] A low density uncoated solid bleached sulfate (SBS) board having a basis weight of about 125 lbs/3000 ft 2 was prepared using a full-scale production process.
[0036] A high-bulk, carbonate/clay basecoat was prepared having the following composition: (1) 50 parts XP 6170 from Imerys Pigments, Inc. (a high aspect ratio clay), (2) 50 parts Hydracarb 60 from Omya, Inc. (a ground calcium carbonate), (3) 18 parts of a latex binder, and (4) a synthetic thickener in a quantity sufficient to raise the viscosity of the blend to 2000 centipoise, at 20 rpm, on a Brookfield viscometer.
[0037] A topcoat was prepared having the following composition: 70 parts fine carbonate; 30 parts fine clay; 14 latex binder and minor amounts of coating lubricant, dispersant, synthetic viscosity modifier, defoamer and dye.
[0038] The basecoat was applied to the uncoated board using a trailing bent blade applicator. 2-sided coating application was achieved utilizing four coating heads. In this example, the coatings (top and base) on each side of the sheet were identical in composition. The basecoat was applied such that the minimal amount of basecoat needed to fill the voids in the sheet roughness remained on the sheet, while scraping the excess basecoat from the sheet to leave a minimum amount of basecoat above the plane of the fiber surface. The basecoat was applied at a coat weight of about 7 lbs/3000 ft 2 . The topcoat was applied over the basecoat to further improve the surface smoothness. The topcoat was applied at a coat weight of about 7 lbs/3000 ft 2 . Coat weights were about the same on each side.
[0039] The resulting coated structure had a total basis weight of about 153 lbs/3000 ft 2 , a caliper of about 0.012 inches (12 points) and a Parker Print Surf (PPS 10S) smoothness of about 1.10 microns on the wire side and 1.30 microns on the felt side.
Example 2
[0040] A low density uncoated board having a basis weight of about 110 lb/3000 ft 2 was prepared using a pilot production process.
[0041] A high-bulk, carbonate/clay basecoat was prepared having the following composition: (1) 50 parts XP 6170 from Imerys Pigments, Inc. (a high aspect ratio clay), (2) 50 parts Hydracarb 60 from Omya, Inc. (a ground calcium carbonate), (3) 18 parts of a latex binder, and (4) a synthetic thickener in a quantity sufficient to raise the viscosity of the blend to 2000 centipoise, at 20 rpm, on a Brookfield viscometer.
[0042] A topcoat was prepared having the following composition: 70 parts fine carbonate; 30 parts fine clay; 14 parts latex binder; and minor amounts of coating lubricant, dispersant, synthetic viscosity modifier, defoamer and dye.
[0043] The basecoat was applied to the uncoated board using a trailing bent blade applicator. 2-sided coating application was achieved utilizing four coating heads. In this example, the coatings (top and base) on each side of the sheet were identical in composition. The basecoat was applied such that the minimal amount of basecoat needed to fill the voids in the sheet roughness remained on the sheet, while scraping the excess basecoat from the sheet to leave a minimum amount of basecoat above the plane of the fiber surface. The basecoat was applied at a coat weight of about 7 lbs/3000 ft 2 . The topcoat was applied over the basecoat to further improve the surface smoothness. The topcoat was applied at a coat weight of about 7 lbs/3000 ft 2 . Coat weights were about the same on each side.
[0044] The resulting coated structure had a total basis weight of about 134 lbs/3000 ft 2 , a caliper of about 0.010 inches (10 points) and a Parker Print Surf (PPS 10S) smoothness of about 1.20 microns on the wire side and 1.30 microns on the felt side.
[0045] The basis weight versus caliper data from Examples 1 and 2 is plotted in FIG. 3 , together with basis weight versus caliper data for prior art ( FIG. 1 ). The data points from Examples 1 and 2 fall below curve Y 1 , which is a plot of Eq. 1, while all of the prior art data is found above curve Y 1 .
[0046] While basis weight data is currently only presented in FIG. 3 for various caliper thickness ranges, those skilled in the art will appreciate that since the disclosed coatings and techniques were capable of achieving surprisingly low densities at about 10 and 12 point calipers, it is to be expected that similar low densities may be achieved at other caliper thicknesses.
[0047] Thus, the coated two-sided paperboard of the present disclosure provides desired smoothness (e.g., PPS 10S smoothness below 2 microns, and even below 1.5 microns), while maintaining low density (e.g., basis weight below the disclosed thresholds as a function of caliper thickness). While such paperboard has been desired, it has not yet been achievable in the prior art.
[0048] Although various aspects of the disclosed low density paper and paperboard with two-sided coating have been shown and described, modifications may occur to those skilled in the art upon reading the specification. The present patent application includes such modifications and is limited only by the scope of the claims. | A paper or paperboard including a cellulose substrate and a coating applied to each side of the paperboard substrate to form a coated structure, the coated structure having a basis weight, a caliper thickness and a Parker Print Surf smoothness, the Parker Print Surf smoothness being at most about 2 microns, the basis weight being less than about Y1 pounds per 3000 ft2, wherein Y1 is a function of the caliper thickness (X) in points and is calculated as follows: Y1=29.15+11.95X−0.07415X2. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] None.
BACKGROUND OF THE INVENTION
[0002] This invention relates to latches that are flush or near flush when mounted in a door or frame. Typically, the latch handle is contained with this low profile while not in use, but may be extended in some way to provide access to an operator. Once extended, the handle may be operated to open the door.
[0003] One example of such a generally flush mounted latch assembly is U.S. Pat. No. 5,450,735, issued to Takanobu Esaki, et al. of Tokyo, Japan on Sep. 19, 1995. Esaki discloses a pull-out-and-rotate type latch assembly. When locked, the latch handle lies nearly flush with the surrounding housing and door. When unlocked, the handle may be pivoted to an extended position and turned thereby turning a latching plate at the end of a spindle, allowing the door to be opened. Another example of a flush type latch assembly is U.S. Pat. No. 5,457,971, issued to Kenichi Yamada of Tokyo, Japan on Oct. 17, 1995. Yamada discloses a push-button spring-loaded rotary type latch assembly in which a torsion spring urges the handle into an extended position when a push-button is depressed.
[0004] In both Esaki and Yamada, the key cylinder is mounted in the handle and the shaft and latching plate can only rotate. Since the key cylinder is mounted in the handle, the length of the handle is dictated in part by how many fingers must fit between the key cylinder and the handle's pivot. Since the latching plate in each does not move axially but only rotates, it does not additionally cinch the door to the frame upon closing. Also, a separate push button mechanism is utilized to release the handle.
[0005] What is needed is a push-button type flush mounted latch assembly wherein the push button mechanism is greatly simplified. Additionally, what is needed is such a latch in which the key cylinder may work just as well if mounted in the housing rather than the handle. What is further needed is a latch assembly that causes the latching pawl to both rotate and draw in upon closing so that the door is cinched tightly to the frame.
BRIEF SUMMARY OF THE INVENTION
[0006] An object of the present invention is to provide a door latch assembly having a latch housing and handle that are substantially or near flush with the surrounding outer surface of the door in which they are mounted when the latch assembly is in its closed position.
[0007] A further object of the present invention is to provide such a latch assembly that utilizes a push-button mechanism in order to release at least a portion of the handle to be pivoted to an extended position and grasped and turned by an operator. Another object of the present invention is to provide such a flush mounted latch in which the push button unit comprises a greatly simplified configuration. Another object of the present invention is to provide such a flush mounted latch in which the locking cylinder itself may operate as the push button for releasing the handle.
[0008] It is a further object of the present invention to provide a locking shaft that is slidably connected to the handle so that the locking shaft may move axially as well as rotate at the same time so that a pawl member on the end of the locking shaft may cinch down on the frame to create a tight closure between the door and frame.
[0009] These objects are accomplished by the present invention of a latch assembly having a latch housing and handle that are substantially or near flush with the surrounding outer surface of the door in which they are mounted when the latch assembly is in its closed position. The latch assembly utilizes a greatly simplified push-button mechanism in order to release at least a portion of the handle, which then pivots to an extended position and grasped and turned by an operator. A spindle and latching pawl are slidably connected to the handle and bound by a camming surface in the latch housing so that the spindle and latching pawl moves both axially and rotationally at the same time so that, upon closing, the pawl will cinch down on the frame to create a tight closure between the door and frame.
[0010] Other aspects and advantages of the present invention will become readily apparent to those skilled in the art from the following detailed descriptions of preferred embodiments when considered in conjunction with accompanying drawings, which illustrate, by way of example, the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] [0011]FIG. 1 is a perspective view of one embodiment of the present invention.
[0012] [0012]FIG. 2 is a top view of one embodiment of the present invention.
[0013] [0013]FIG. 3 is an exploded view of the embodiment of FIG. 1.
[0014] [0014]FIG. 4 is a perspective view of a camming surface of one embodiment of the present invention.
[0015] [0015]FIG. 5 is a side elevation view of the camming surface of FIG. 4.
[0016] [0016]FIG. 6 is a top plan view of the camming surface of FIG. 4.
[0017] [0017]FIG. 7 is a perspective view of a push button unit of one embodiment of the present invention showing two retention members in which one retention member is partially depressed.
[0018] [0018]FIG. 8 is a top plan view of the push button unit of FIG. 7 in which no retention members are depressed.
[0019] [0019]FIG. 9 is a cross-section view taken along the line 9 - 9 in FIG. 8 showing a depressible retention member not depressed.
[0020] [0020]FIG. 10 is a cross-section view of a portion of the handle of one embodiment as shown in FIG. 2 taken along the line 10 - 10 in FIG. 2 showing an engagement surface having a ridge 65 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] The detailed description set forth below in connection with the appended drawings is intended as a description of presently-preferred embodiments of the invention and is not intended to represent the only forms in which the present invention may be constructed and/or utilized. The description sets forth the functions and the sequence of steps for constructing and operating the invention in connection with the illustrated embodiments. However, it is to be understood that the same or equivalent functions and sequences may be accomplished by different embodiments that are also intended to be encompassed within the spirit and scope of the invention.
[0022] Referring now to the drawings, FIGS. 1 and 2 show one embodiment of the present invention. In particular, this embodiment involves a low profile latch 10 , either flush or near flush with the surrounding top surface of the door or panel (not shown) in which the latch 10 is mounted. The latch 10 is comprised of a latch housing 15 , handle 60 , and locking shaft or spindle 50 .
[0023] The shaft or spindle 50 would ordinarily have a pawl member 90 mounted to it by any number of standard means. The effect would be that rotation of the shaft 50 would rotate the pawl 90 into a position to cause closure between the door and a mating surface on the surrounding frame or alternatively into a position behind the door so that the door may be opened relative to the surrounding frame. Similarly, axial movement of the shaft 50 causes the pawl 90 to move in the axial direction so that when the shaft 50 is drawn upward toward the latch housing 15 , the pawl 90 cinches down on the mating surface of the surrounding frame and create a tight seal between the door and the frame. Additionally, the application may or may not involve a gasket (not shown) between the door and frame. Either way, the rotary and axial movements of the locking shaft 50 are translated to the pawl 90 which is mounted on or fixed to the shaft 50 .
[0024] [0024]FIG. 3 illustrates an exploded view of an embodiment of the present invention showing a latch housing 15 comprising a first chamber 20 and a second chamber 30 and a generally longitudinal recess 14 intermediate the two chambers. A plug or retainer unit 40 is rotatably housed in the first chamber 20 . On its upper end, the retainer unit 40 has a whole that retains handle pivot 62 . On its lower end, the retainer unit 40 has a pair of slots 44 that slidably house follower members 24 .
[0025] Handle 60 is mounted on pivot 62 and can pivot between a closed and extended position. Torsion spring 66 is positioned between the retainer unit 40 and the handle 60 urging handle 60 toward the extended position. In FIG. 3, the torsion spring 66 is wrapped around pivot 62 of the handle 60 , but the handle 60 could be urged toward the extended position by any number of other means, including a compression spring anchored on one end in or by the upper surface of the retainer unit 40 , the other end imposing its compressive force on the lower surface of handle 60 . Other biasing methods well known in the art may be employed to bias the handle in the extended direction without going beyond the intent of the present invention.
[0026] When in the closed position, at least in part of handle 60 rests inside the longitudinal recess 14 of latch housing 15 , and is held in place by a push button unit 80 . In the embodiment shown in FIG. 3, the surface of push button unit 80 has one or more handle retention members 84 which engage with one or more engagement surfaces 64 of handle 60 to hold handle 60 in the closed position against the urging of biasing means 66 . Push button unit 80 is urged upward by a compression spring 36 . The force of compression spring 36 may be easily overcome, however, by the operator who presses downward on the top surface of the push button unit 80 .
[0027] Additionally, the push button unit 80 may optionally also be rotatable. That is, the top surface of push button unit 80 made may be configured with a slot or other depression into which a matching turning tool may be inserted in order to impart a torque to turn the push button unit 80 . In such an embodiment, the push button unit 80 may be depressible by the operator only after the push button unit has first been rotated into the proper position. In all other orientations, the push button unit is prevented from being depressed, and the handle 60 will not be released, as discussed below.
[0028] As an example, in the embodiment shown in FIGS. 3 and 7 through 9 , the push button unit 80 must be rotated first before it may be pushed, and it includes a key cylinder that may be rotated only by inserting a key made to operate the key cylinder. When the key is inserted into the keyhole and turned, the push button unit 80 rotates from a locked position in which it may not be depressed to an unlocked position in which it may be depressed.
[0029] The push button unit 80 of FIG. 3, for instance, is prevented from being depressed by the interaction of handle retention members 84 with engagement surface 64 . At least one of the handle retention members 84 of FIG. 3 is fixed and may not slide passed ridge 65 of engagement surface 64 . When the push button unit 80 is oriented so that this fixed handle retention member 84 is engaged with the engagement surface 64 , the push button unit 80 may not be depressed.
[0030] As shown in FIGS. 7 and 9, the handle retention members 84 also include at least one depressible handle retention member 84 ′ which may be depressed since it is partially inset in the push button unit 80 and spring-loaded by a compression spring 86 as shown in FIG. 9. As a result of this spring-loaded effect, a sufficient downward force on the top surface of push button unit 80 can cause the depressible handle retention member 84 ′ to encounter a radially inward force from the ridge 65 of engagement surface 64 and thereby be depressed radially inward. As a result, ridge 65 is allowed to pass by the depressible handle retention member 84 ′ and handle 60 is released to spring out to its extended position under the force of torsion spring 66 .
[0031] In FIG. 3, the handle retention members 84 are located on the surface of the push button unit 80 ; whereas the engagement surface 64 is located on the handle 60 . This configuration, however, could easily be reversed. That is, the fixed handle retention members 84 and depressible handle retention members 84 ′ could be mounted in the handle 60 with the engagement surface 64 and ridge 65 fashioned into the surface of the push button unit 80 . In either instance, at certain angular orientations of the push button unit 80 , the fixed handle retention members 84 interact with ridge 65 of engagement surface 64 to prevent depression of the push button unit 80 , and at another angular orientation or orientations of the push button unit 80 , the depressible handle retention members 84 ′ interact with ridge 65 of engagement surface 64 allowing the push button unit 80 to be depressed. The result is that at this latter angular orientation or orientations of push button unit 80 , an operator may depress push button unit 80 and thereby release the handle 60 from its closed position.
[0032] Once released from its closed position, handle 60 is urged to an extended position where it can be rotated relative to the latch housing 15 thereby rotating the retainer unit 40 . A pair of slots 44 are formed through the lower end of retainer unit 40 . The slots shown in FIG. 3 are closed at both ends, but a pair of slots that are not closed at one or both ends could work equally as well, provided that the follower members 24 are otherwise bound to a range of motion within the slots. Also, FIG. 3 illustrates a pair of slots 44 formed through a generally hollow retainer unit 40 , but if a generally solid retainer unit 40 is employed instead, a single slot could be fashioned through the width of the retainer unit 40 , which could function equally as well. Also, a pair of grooves rather than slots could be formed on the inner or outer surfaces of retainer unit 40 to function as slots 44 as described herein.
[0033] In either instance, follower members 24 extend into the slots 44 so that the torque on the retainer unit 40 is exerted on follower members 24 . Follower members 24 are also connected to shaft 50 so that the torque exerted on follower members 24 is also exerted on shaft 50 . As a result, by rotating the handle 60 , the operator rotates the shaft 50 and the pawl 90 which is mounted on shaft 50 .
[0034] Additionally, in one preferred embodiment, a camming surface 22 is either machined, molding, or mounted in the first chamber 20 , such as for example being friction pressed into the chamber. In the embodiments shown in FIGS. 4 through 6, the camming surface 22 has a local minimum and a local maximum and an identical pattern on the diametrically opposed camming surface. Follower members 24 are urged up against the camming surface 22 by compression spring 26 , which may be positioned in a recess in the retainer unit 40 and forcing shaft 50 away from retainer unit 40 . In FIG. 3, for example, an embodiment of the present invention is shown in which the follower members 24 are the central portions of a cross pin 25 on either side of the axis of rotation of the shaft 50 , and the opposing ends of the cross pin 25 operate as cam followers. That is, the cross pin 25 is positioned in an orifice at the top end of shaft 50 . The cross pin 25 extends through the pair of slots 44 of the retainer unit 40 , and the ends of cross pin 25 rest on the camming surface 22 , being urged up against camming surface 22 by compression spring 26 . Thus, cross pin 25 receives an angular force through retainer unit 40 when an operator turns handle 60 , in this embodiment, and rides along camming surface 22 , thereby causing shaft 50 to move axially as well as rotate between the latched and unlatched positions.
[0035] Alternatively, the shaft 50 could be connected to a second set of cross members, lugs or finger members, one pair extending through the slots 44 , and another pair resting on camming surface 22 . The embodiment shown in FIG. 3 is a presently preferred embodiment because it involves a simple configuration in which a single cross pin 25 accomplishes both of these functions. This results in relatively simple machining and assembly steps, reduces the number of required parts, and minimizes the exposure of the latch to wear and breakage. Other configurations, however, are equally contemplated by the present invention, including without limitation, using separate cross members in the place of the cross pin 25 , or housing the first compression spring 26 in the first chamber 20 rather than retainer unit 40 .
[0036] In the embodiment shown in FIGS. 4 through 6, a notch 23 is added to the camming surface at each local maximum and each minimum. These notches 23 provide local stable positions for the handle-shaft-and-pawl combination within the range of operation. The notches 23 provide a “snapping” effect that is pleasant to the operator and so that the operator can tell when the pawl and shaft are in the right positions, but the notches are by no means necessary. A camming surface without notches, as well as a camming surface of different shapes and orientations, would be equally effective to impart an axial force on the shaft 50 when follower members 24 are rotated as the result of the operator rotating the handle 60 . For example, the camming surface 22 may be shaped so that the path of the pawl can overcome an obstruction on the backside of the door or frame. Also, a notch is not required at the closed position for the additional reason that the handle 60 will be returned to the longitudinal recess 14 and thereby held in place when closed unable to be rotated until push button unit 80 is depressed once again.
[0037] While the present invention has been described with regards to particular embodiments, it is recognized that additional variations of the present invention may be devised without departing from the inventive concept. | A latch assembly having a latch housing and handle that are substantially or near flush with the surrounding outer surface of the door in which they are mounted when the latch assembly is in its closed position. The latch assembly utilizes a locking cylinder as a push-button mechanism in order to release at least a portion of the handle, which then pivots to an extended position where it can be grasped and turned by an operator. A spindle and latching pawl are slidably connected to the handle and bound by a camming surface in the latch housing so that the spindle and latching pawl moves both axially and rotationally at the same time so that, upon closing, the pawl will cinch down on the frame to create a tight closure between the door and frame. | 8 |
TECHNICAL FIELD
[0001] This patent document pertains generally to data communications, and more particularly, but not by way of limitation, to a system and method for obtaining frequency and time synchronization in wideband communication systems.
BACKGROUND
[0002] In a chirp-modulated communication system the offset of the carrier frequencies between the transmitter and receiver appears as a time offset at the receiver. Current chirp-modulated communication systems do not attempt to determine the actual frequency offset, and, therefore, the symbol timing at the receiver may be misaligned with the received data. This produces a non-optimal partial correlation or intersymbol interference (ISI) that degrades the sensitivity of the receiver. Additionally, if the receiver has no knowledge of the frequency offset it must track the signal based upon the demodulated data in order to maintain synchronization. However, if the frequency offset is known at the receiver, it can use a much more robust means of tracking the signal. If the symbol clock and carrier frequency are derived from the same oscillator at the transmitter and receiver, the frequency offset is proportional to the time drift. Thus, the frequency offset information can be used to track the incoming signal. This method of tracking is much more robust in high interference or low signal to noise ratio environments.
[0003] What is needed is a system and method for reducing ISI and enhancing receiver performance in a communication system.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] In the drawings, which are not necessarily drawn to scale, like numerals describe substantially similar components throughout the several views. Like numerals having different letter suffixes represent different instances of substantially similar components. The drawings illustrate generally, by way of example, but not by way of limitation, various embodiments discussed in the present document.
[0005] FIG. 1 illustrates a communication system according to the present invention;
[0006] FIG. 2 is a frequency domain representation of the transmitted and received synchronization signals;
[0007] FIG. 3 depicts the intersymbol interference that occurs due to the frequency offset of the received signal; and
[0008] FIG. 4 illustrates a synchronization signal formed by concatenating to the sync preamble an unmodulated sequence of chirps that are frequency swept in a direction opposite to the chirps that are part of the sync preamble.
DETAILED DESCRIPTION
[0009] In the following detailed description of the preferred embodiments, reference is made to the accompanying drawings which form a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. It is to be understood that other embodiments may be utilized and structural changes may be made without departing from the scope of the present invention.
[0010] As noted above, current chirp-modulated communication systems do not measure and attempt to remove the frequency offset of the received signal prior to the correlation with the expected chirp waveform. Without reducing the frequency offset, the time offset error induced by the frequency offset may significantly degrade the performance of the receiver. In addition, with a known frequency offset at the receiver a more robust time tracking algorithm can be employed.
[0011] A system and method for reducing the effects of frequency offset in spread spectrum and other wideband signals is shown in FIG. 1 . In FIG. 1 , system 100 includes a transmitter 102 and a receiver 120 . Transmitter 102 includes a data source 104 , a chirp generator 106 , a combiner 108 and a transmit circuit 110 . Data source 104 generates a stream of data. Chirp generator 106 generates a chirp signal that is combined with the stream of data from data source 104 using combiner 108 in a manner known in the art
[0012] A frequency domain representation of a chirp signal transmitted by transmitter 102 is shown as transmit signal 140 in FIG. 2 . In one embodiment, the chirp signal used in transmitter 102 is a complex sinusoid that rapidly sweeps across the frequency bandwidth of the signal. In one such embodiment, each frequency is occupied for only a single chirp sample.
[0013] At receiver 120 , the received signal 150 may be shifted in frequency due to the offset between the transmitter 102 's local oscillator and the local oscillator in receiver 120 , as well as any Doppler effects. The correlation of received signal 150 with the transmitted chirp is illustrated in FIG. 2 . Despite the presence of a large frequency offset, the received signal is perfectly correlated to the transmitted signal. Note that the received signal's higher frequency components will alias and correlate with the transmitted signal. Also note that a positive frequency offset has translated into a time offset.
[0014] If the chirps are modulated with information data, there will be intersymbol interference (ISI) introduced due to the misalignment of the receive chirp correlations with respect to the actual symbol boundaries. This is due to the property of the chirp waveform of translating a frequency offset into an apparent time offset. This phenomenon is illustrated in FIG. 3 .
[0015] It should be noted that, if a SAW filter is used to perform the chirp correlation instead of a digital FFT method, the ISI would not occur but there would still be a degradation due to an incomplete correlation. This is what is meant by the term “partial correlation”.
[0016] In one embodiment, transmitter 102 transmits an unmodulated sequence of chirps as a synchronization preamble. As noted in “SYSTEM AND METHOD FOR TRANSMITTING AND DETECTING SPREAD SPECTRUM SIGNALS,” U.S. patent application Ser. No. ______, filed herewith, the description of which is incorporated within by reference, it is possible to achieve coherent detection of a signal beyond the system's coherency bandwidth through the use of chirp modulation for a data-unmodulated sync or preamble.
[0017] In order to reduce receiver degradations due to inaccurate symbol timing, the frequency offset must be removed from the received signal. The chirp modulation, however, effectively hides the underlying frequency offset, making it difficult to distinguish the true timing offset from the time offset produced by the frequency offset. System 100 provides a means of determining the frequency offset, and, therefore, the time offset. It does this by transmitting an unmodulated sequence of chirps frequency swept in the opposite direction as those used in the sync preamble. This approach is illustrated in FIG. 4 .
[0018] FIG. 4 shows an unmodulated sequence of chirps frequency swept in the opposite direction as those used in the synchronization preamble. At the receiver, a positive frequency offset results in an early timing offset with positively swept chirps and a late timing offset with negatively swept chirps. The true timing offset is halfway between these two offsets. Likewise, the frequency offset is calculated based upon the difference between the positively and negatively swept chirps. The optimum symbol timing at the receiver can be maintained throughout the transmitted data duration by tracking the time offset based upon the calculated frequency offset and the phase estimates from the demodulator.
[0019] In one embodiment, frequency offset is reduced through the use of an NCO (Numerically Controlled Oscillator). The elimination of the frequency offset also results in the elimination of the ISI induced by the frequency offset.
[0020] Returning to FIG. 1 , receiver 120 includes a receiver circuit 122 , a digital correlator 124 , a chirp generator 126 , a complex conjugate calculator 128 , a demodulator 130 and a Numerically Controlled Oscillator (NCO) 132 . Complex conjugate calculator 128 calculates the complex conjugate of a chirp signal generated by chirp generator 126 . Digital correlator and offset correction 124 takes the complex conjugate of the chirp signal generated by chirp generator 126 and uses it to detect the transmitted synchronization signal. This transmission can be initial signaling for packet-based data transmissions or for access channels.
[0021] In the embodiment shown NCO 132 eliminates the frequency offset detected by receiver 120 . The elimination of the frequency offset also results in the elimination of the ISI induced by the frequency offset.
[0022] Current chirp-modulated communication systems do not attempt to determine the actual frequency offset, and, therefore, the symbol timing at the receiver may be misaligned with the received data. This produces a non-optimal partial correlation or intersymbol interference (IS) that degrades the sensitivity of the receiver. The above described system and method eliminates this partial correlation or ISI by providing a method for measuring the frequency offset of the received chirp-modulated signal.
[0023] It is to be understood that the above description is intended to be illustrative, and not restrictive. For example, the above-described embodiments (and/or aspects thereof) may be used in combination with each other. Many other embodiments will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. In the appended claims, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Also, in the following claims, the terms “including” and “comprising” are open-ended, that is, a system, device, article, or process that includes elements in addition to those listed after such a term in a claim are still deemed to fall within the scope of that claim. Moreover, in the following claims, the terms “first,” “second,” and “third,” etc. are used merely as labels, and are not intended to impose numerical requirements on their objects.
[0024] The Abstract is provided to comply with 37 C.F.R. §1.72(b), which requires that it allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. Also, in the above Detailed Description, various features may be grouped together to streamline the disclosure. This should not be interpreted as intending that an unclaimed disclosed feature is essential to any claim. Rather, inventive subject matter may lie in less than all features of a particular disclosed embodiment. | This document discusses, among other things, a system and method of measuring and correcting for frequency offset in wideband signals of bandwidth X within a communications system. A synchronization signal is generated and transmitted, wherein generating a synchronization signal includes generating a first chirp signal that sweeps a portion of bandwidth X and generating a second chirp signal to sweep approximately the same portion of bandwidth X but in the opposite direction. The synchronization signal is received at a receiver. The receiver then detects a first offset as a function of the first chirp signal and a second offset as a function of the second chirp signal and calculates the frequency offset as a function of the first and second offsets. | 7 |
BACKGROUND OF THE INVENTION
This application is a continuation-in-part of copending application Ser. No. 668,441 filed Nov. 4, 1984, now abandoned. The invention relates to air texturing of yarn and more particularly, to improvements in a fluid jet apparatus used to texture the yarn.
U.S. patent application Ser. No. 668,440, of common assignee, now U.S. Pat. No. 4,547,938 granted Oct. 22, 1985, discloses a self-stringing jet device which is compact and easy to string up. The jet includes a body, a yarn inlet section, a movable venturi and a cylindrical yarn guiding element for guiding yarn from the inlet to the outlet end of the jet and a gas inlet. The outer diameter of the yarn guiding element is reduced in the region of the gas inlet to provide an annular plenum chamber following which is a cylindrical portion or flange with an outer diameter approximately equal to the inside diameter of the central bore through the body. The flange has an orifice through it for passage of gas through the jet. The forward portion of the yarn guiding element is a portion of reduced diameter which forms a chamber with the bore that is in communication with the outlet end of the jet. The venturi may be set to a string up position or to an operating position by means of a rotatable rod having a cam surface intermediate its ends engaging a groove in a collar on the venturi. An external handle is attached to one end of the rod and is movable between first and second stops representing string up and operating positions, respectively. The second stop preferably is a rotatable disc eccentrically mounted to the body of the jet and readily adjustable to provide a range of settings for the operating position.
SUMMARY OF THE INVENTION
It has now been found that improved yarn texturing efficiency can be obtained by adding a second flange on the yarn guiding element upstream of the flange with the orifice. In one embodiment, the second flange has the same diameter as the first flange and is located within the plenum of the jet body; in another embodiment, the second flange has a diameter less than the first flange and in both embodiments, the second flange serves to reduce the turbulence of the gas behind the first flange which in turn provides a more uniform flow of gas through the orifice in the first flange.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a preferred embodiment of the invention.
FIG. 2 is an enlarged section view of FIG. 1 taken along line 2--2.
FIG. 3 is an enlarged section view similar to FIG. 2 of an alternate embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1 and 2, the major elements of the jet device are body 10, cylindrical yarn guiding element 12, movable venturi 14 with its attached collar 16 and baffle 18 with its supporting bracket 20 attached to body 10. Yarn guiding element 12 is press fitted into the bore 9 of the body 10 at the inlet end of the jet body and consists of an entrance 13 in communication with the yarn exit orifice 15 of the yarn guiding element. The outer portion of the yarn guiding element comprises a cylindrical portion 17 with a conical tip 19. Orifice 22 located in a first flange 21 formed on yarn guiding element 12 has its axis parallel to the axis of yarn guiding element 12 and is supplied with gas such as compressed air through fluid connection 23. Coacting with orifice 22 is a plenum 27 which is circumferentially bored in the side walls of body 10 forming an enlargement of the bore at a location in communication with fluid connection 23. From FIG. 2, it will be noted that incoming air can rush into plenum chamber 27 and immediately pass toward venturi 14 through orifice 22. A second cylindrical flange 21a is formed on the yarn guiding element 12 a distance d upstream from the first flange 21 within the bore 9 of the jet body downstream of the gas inlet 23. The second flange 21a has a diameter that is less than the diameter of the first flange and preferably extends about one-half the distance beyond the yarn guiding element 12 as does the first flange. Venturi 14 is free to move axially within the body 10 and a seal is formed between the venturi and body by O-ring seal 24 seated in an annulus 25 in the body. The venturi 14 is press fitted into collar 16 and collar 16 is free to move within the recess 26 at the outlet end of the jet body. A circumferential groove 28 is formed in collar 16. A rod 30 extends through body 10 and engages groove 28. The rod is rotatable in both the body and the groove. A handle 32 is attached to the end of the rod so that the rod may be easily rotated. The rod is not completely circular but has a cam surface 31 intermediate its ends which is coincident with the groove 28. First and second stops 34, 36 respectively on the surface 11 of the body 10 restrict the movement of handle 32 and consequently the movement of venturi 14. The first stop 34 is a set screw extending above surface 11 of body 10 and the second stop 36 is a disc 37 eccentrically mounted to the surface 11 by a screw 39 which may be tightened to lock the disc in place.
The embodiment shown in FIG. 3 is like that shown in FIGS. 1 and 2 except that the second flange 21a' is a distance d' upstream of the first flange and is now moved to a location within the plenum 27 and not within the bore 9. In this embodiment, the flange 21a' is the same diameter as the flange 21.
The operation of this device is as follows: when a yarn or yarns are to be strung up, rod 30 is turned by handle 32 to a position shown in FIG. 1, (i.e., handle 32 is against stop 34) so that movable venturi 14 is moved toward conical tip 19 thus restricting the flow of air until ambient air is aspirated through yarn inlet 13 into and through movable venturi 14. The operator then inserts yarn into the inlet 13 where the aspirated air assists in carrying the yarn through the venturi to the outlet end. The operator then rotates rod 30 to the position shown in phantom in FIG. 1, (i.e., handle 32 is against disc 37) so that the movable venturi 14 is allowed to move away from conical tip 19 under the force of the air pressure within the jet until it reaches the optimum operating setting established by the orientation of disc 37.
In a series of test runs using the jet of this invention, it was found that increased texturing speed and longer jet operating periods between cleaning cycles were obtained. | In a self-stringing yarn texturing air jet which is compact and easy to string up includes a body, a yarn inlet section, a movable venturi and a yarn guiding element through which yarn passes to the outlet end of the jet, a second flange on the yarn guiding element located upstream of a flange with an orifice improves texturing efficiency of the jet. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to detecting and quantitating molecules or influences and more particularly to an improved fiber optic photoluminescence sensor.
2. The Prior Art
The use of fiber optics in conjunction with photoluminometry is growing in fields as diverse as biophysics, remote sensing, immunodiagnostics, and chemical process monitoring. Photoluminescence is a well developed, powerful, and versatile technique for chemical or influence (i.e., temperature, pressure, etc.) sensing. Photoluminescence is a broad term which includes fluorescence, phosphorescence, Raman scattering, etc. The intrinsic wavelength difference between excitation and emission makes photoluminescence well suited for use with fiber optics. Fiber optics themselves have unique attributes which make them ideal for many sensing applications. Fiber optics permit remote, continuous monitoring of analytes in hazardous environments, and in the presence of electromagnetic interference or flammable atmospheres. Fiber optics are small and lightweight, making them useful on air-and spacecraft. Fibers have enormous information-carrying capacity due to the THz bandwidth of light, and signals of different colors can travel in the same fiber without interference. The hope (or necessity) of utilizing these advantages has fueled the development of fiber optic sensors employing photoluminometry.
The fundamental idea of photoluminescence-based sensors is to detect an analyte or influence by a change in the photoluminescence of a susceptible material. Several instrument configurations for performing photoluminometric measurements through fiber optics have been described in the literature, using a great variety of photoluminescence observables (intensity, spectra, lifetimes) and configurations for the sensing tip (evanescent wave or distal cuvette). Basically, as shown in the prior art photoluminescence sensor apparatus of FIG. 1, a susceptible photoluminescent material 20 localized at the distal end 9 of an optical fiber is excited by light coming down the optical fiber 8, and its photoluminescence is coupled back into the fiber 8, separated from the excitation, and observed at the proximal end 7 of the fiber 8. In FIG. 1, the solid line/arrows 1 represents the path of the exciting light, while the dashed line/arrows 1' represents the path of photoluminescence.
All fiber optic photoluminescence sensors have a light or excitation source 2, some means for coupling or coupling lens 6 the light into the fiber 8, a photoluminescent material 20 localized at the distal end 9, a means for separating the emission from the excitation 4, and a detector or photodetector 12 (FIG. 1). Fiber optics impose constraints on the optical configuration performing these functions that are not encountered in ordinary photoluminescence sensors, and which require attention to assure optimum performance. For instance, the positions of the excitation source 2, the coupling lens 6 and the proximal fiber end 7 along some axes must be controlled with micrometer precision, which is seldom required in a typical photoluminescence sensor. Also, fiber optic photoluminescence sensors are generally less sensitive than standard research grade photoluminescence sensors, and thus it is important to get the best performance out of the former; this seems to be particularly true for those using a waveguide binding (evanescent wave) sensing tip.
Various types of fiber optic photoluminescence sensors have been proposed (see U.S. Pat. Nos. 4,775,637; 4,582,809; and 4,447,546). Generically, such sensors consist of a light source 2 (FIG. 1), whose exciting light passes through a (spatially or spectrally) filtering mirror 4 and is focused into the fiber 8 by an objective 6 at the proximal end 7 of the fiber 8. The fiber 8 conducts the exciting light to the distal end 9 of the fiber 8, where the photoluminescent material 20 is present or is attached to the end of the fiber 8, where the exciting light is absorbed. The photoluminescent material 20 emits its characteristic emission, which re-enters the fiber 8 (the same fiber need not be used, but typically is) and is conducted back to the proximal end 7 of the fiber 8, where it passes through the objective 6, is reflected off the mirror 4 through a lens 3 and a filter 10 into the photodetector 12. Essentially all the fiber optic photoluminescence sensors described in the literature use this basic scheme, and differ in the details of the components used and their arrangement. For instance, some photoluminescence sensors in the prior art use separate optical fibers to carry the excitation and emission; such sensors have no mirror to separate excitation from emission, but require two objectives, one to direct the excitation into one fiber, and the other objective to receive the emission and focus it onto the detector. Many of the sensors described in the literature are insufficiently sensitive to detect many of the chemical analytes of interest, including pollutants, drugs, and poisons. The improvements described below are aimed at increasing the sensitivity of detecting any analyte or influence, irrespective of the distal end configuration (distal cuvette or waveguide binding), actual sensing chemistry, or wavelengths involved.
Typically, the mirror 4 is a dichroic mirror coated and oriented to pass the exciting light and reflect the (longer wavelength) photoluminescence emission into the detector 12 (or vice versa). Such mirrors have the disadvantages that they are not useful over a broad wavelength range, are a source of background photoluminescence, and have poor transmission. Andrade et al. (U.S. Pat. No. 4,368,047) used a perforated planar mirror to pass the narrow beam of a laser for excitation, and reflect the more broadly spread photoluminescence as it comes back out of the objective 6, towards the detector 12. Braun (U.S. Pat. No. 4,533,246) also discloses the use of a perforated planar mirror. The disadvantage of this is that it requires a separate lens 3 to focus the photoluminescence on the detector 12, which adds weight, complexity, insensitivity, and a propensity for misalignment to the sensor.
The purpose of the filter 10 in FIG. 1 is to block scattered shorter wavelength exciting light from entering the detector 12 and being confused with authentic (signal) photoluminescence. Such light scattered off the coupler or other components can be orders of magnitude stronger than the actual photoluminescence, and can seriously degrade the performance of the sensor. The colored glass or interference filters well known to the art will ordinarily serve in this respect. Unfortunately, nearly all of these filters themselves photoluminesce appreciably when struck by scattered exciting light, and this photoluminescence can be sensed as authentic sample photoluminescence.
The use of a chopper 16 or other light modulator together with a lock-in amplifier 14 or other phase-sensitive detector is well known in the art for improving the detectability of weak signals, such as in fiber optic sensors. Thus, a chopper 16 placed in the beam of exciting light will modulate it at a particular frequency, and the lock-in amplifier 14 can be tuned to measure the detector 12 output at only that frequency, eliminating spurious noise at other frequencies. Ordinarily, the chopper 16 is placed as closely to the light source 2 as is convenient.
Many sorts of lenses or objectives have been used to launch light into fiber optics, including gradient index rod lenses, simple lenses, spherical lenses, and most often, refracting microscope objectives. All of these optics are transmissive, and therefore suffer from two drawbacks: most transmit ultraviolet light poorly, and due to their transmissive nature they can photoluminesce when light passes through them. Ultraviolet excitation is very useful for detecting many photoluminescent molecules.
Many kinds of light detectors have been used to detect the photoluminescence signals. They include photomultipler tubes, PIN photodiodes, avalanche photodiodes, and phototransistors. Their usefulness is mainly determined by their sensitivity, which is well known in the art.
The advantages of fiber optical photoluminescence sensors per se are well known: they permit continuous monitoring of a variety of chemical analytes under circumstances inhospitable to conventional analytical chemical techniques or instrumentation. For instance, fiber optic photoluminescence sensors have been designed to sense carbon dioxide or pH in the bloodstream, pollutants deep underground, or toxic chemicals in the air. All of them have the same functional requirements as outlined in FIG. 1, although they differ in detail, and selection of components.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a fiber optic photoluminescence sensor which overcomes the deficiencies of the prior art.
Another object of the present invention is to provide a photoluminescence sensor with improved performance over those of the prior art.
Another object of the present invention is to utilize a concave mirror having at least one perforation for passing light through that perforation.
Another object of the present invention is to provide a reflecting microscope objective of a Schwarzchild type.
Another object of the present invention is to provide a chopper and a lock-in amplifier where the chopper is located close to the proximal end of the fiber.
Another object of the present invention is to provide a liquid filter for preventing scattered exciting light from entering the detector.
Another object of the present invention is to provide a photoluminescence sensor for use in a wide array of apparatus including but not limited to an immunoassay apparatus.
A further object of the present invention is to provide a photoluminescence sensor comprising a laser source of light directed through a perforation in a concave mirror, after which the light is focused by a Schwarzchild type reflecting microscope objective through a light modulating chopper and into an optical fiber at the end of which the light is absorbed and photoluminescence is emitted from some susceptible material. The photoluminescent light returns through the fiber, or another fiber, and reversely through the reflecting microscope objective, which sends the photoluminescent light onto the perforated concave mirror which, in turn, focuses the light through a liquid filter onto a detector.
This invention provides for reduction in noise produced by photoluminescence, including fluorescence, the Raman effect, phosphorescence and photoluminescence in mirrors, refracting lenses, and glass fiber elements.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic representation of a typical prior art photoluminescence sensor apparatus.
FIG. 2 is a schematic representation of a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 2 shows a schematic representation of the preferred embodiment of the present invention. The present invention comprises four novel features which can be used either singly as a new part added to prior art set ups or preferably all four features are used in combination as added new parts to the prior art set ups. The four novel features are the following:
(1) a perforated concave mirror 44;
(2) a reflective objective 46;
(3) the placement of a chopper 56 near the proximal end 47 (or the distal end 49) of an optical fiber or optical waveguide 48; and
(4) a liquid filter 50. The advantages of each novel feature will be brought out in the rest of this description.
The features of a preferred embodiment of the present invention include a light source 42, preferably a laser, as the source of the exciting light.
As mentioned above, the first novel feature, a perforated concave mirror 44 is used. The advantage of such a mirror 44 is that the exciting light is permitted to pass through the perforation in the mirror 44 while returning photoluminescence is focused by the mirror 44 onto a detector 52. The mirror 44 can have any surface which focuses light such as spherical, aspheric, or an off-axis paraboloid, all with holes drilled through them, preferably one to two millimeters in diameter, to allow laser excitation to pass.
The second novel feature is a reflecting microscope objective 46 which is used to launch light from the mirror 44 into an optical fiber or optical waveguide 48. The launcher is a means to direct light into the optical fiber 48 so that it is transmitted and contained within the fiber 48 by total internal reflection. The reflecting microscope objective 46 is preferably of the Schwarzchild design. These objectives 46, which have been known for many years, pass ultraviolet light well (indeed, are largely wavelength independent) and photoluminesce very little. The objective 46 is preferably used with the fiber axis aligned approximately 20° to the objective axis to assure the collection of the photoluminescence from the proximal end of the fiber 48. The objective of this invention may also comprise two separate components, one used for sending light to the material 60 and a second for receiving photoluminescent light from the material 60.
The third feature of the present invention is placement of a chopper 56 in a novel location between the reflective objective 46 and the proximal end 47 of the fiber 48. The chopper 56 can be any device which will modulate the intensity of the light. Thus, the exciting light, which hits other optical components, such as the mirror 44 and objective 46, remains unmodulated until it reaches the fiber's proximal end 47. Thus, scattered exciting light or particularly the photoluminescence it excites in optical components, such as the mirror 44 and objective 46, is also unmodulated and is discriminated against by the lock-in amplifier 54. This background photoluminescence is an important source of noise and can degrade sensitivity. Simply placing the chopper between the filter 50 and the detector 52 does not have this effect.
The fourth novel component of the present invention is the use of a liquid filter 50 to block scattered shorter wavelength exciting light from entering the detector 52 and being confused with authentic photoluminescence. The liquid filter 50 is preferably a low photoluminescence fused silica cuvette filled with a 1% solution of potassium dichromate or other colored solute in distilled water or other transparent, photoluminescent solvent. Liquid filters have much lower intrinsic photoluminescence than the solid glass filters commonly used.
The operation of a preferred embodiment of the photoluminescence sensor of the present invention is the same as that of the prior art except for the inclusion of the four novel components of the invention. Exciting light from the light source 42, following a path represented by the solid line/arrow 41, passes through the perforation in the first novel component, the perforated concave mirror 44, to the second novel component, the reflecting objective 46, where it is then modulated by chopper 56 the placement of which in this particular location makes up the third novel component. After being modulated by chopper 56, the exciting light is then passed into the proximal end 47 of fiber 48. The fiber 48 conducts the exciting light to the distant end 49 of fiber 48, where the photoluminescent material 60 is present or is attached thereto. This photoluminescent material 60 absorbs the exciting light at the distal end 49 of the fiber 48. The fiber 48 acts as a waveguide, and it should be noted that other waveguides may be used with this invention. The optical waveguide may be a bundle of fibers or a slab waveguide, and single or multimode. The fibers may be of different transparent materials, including glass, plastic, fused silica and the like. The photoluminescent material 60 emits its characteristic photoluminescence, which reenters the distal end 49 of the fiber 48, although the same fiber need not be used, and is conducted back to the proximal end 47 of the fiber 48. The light, following the path represented by the dashed line/arrow 41', is then reversely conducted through reflecting objective 46. The light is then reflected off of perforated concave mirror 44, which focuses the returning photoluminescence through a liquid filter 50 and onto detector 52. Filter 50 makes up the fourth novel component of the present invention. The liquid filter 50 blocks scattered shorter wavelength exciting light from entering the detector 52 and being confused with authentic photoluminescence. Liquid filters have much lower intrinsic fluorescence than the solid glass filters commonly used.
The reflecting objective 46 is used to insert the light into and receive light from fiber optic 48. However, two separate components may be used as objectives for launching light into a photoluminescent material 60 and for receiving photoluminescent light from such a sample, perhaps through a second optical fiber.
Although there are many components and systems available to do the same type of sensing as the present invention, it has been found that the arrangement of the components and apparatus of the present invention provide improved results over the prior art.
The source 42 may be a laser such as a Liconix 4214NB HeCd (Sunnyvale, CA 94089) laser which produces 12 milliwatts at 442 nm. The source 42 can also be a lamp or light emitting diode, but the laser is the preferred source because it produces a highly collimated, intense, monochromatic light.
The perforated concave mirror 44 selected was an off-axis parabolic mirror (catalog number MP-40Y-14) which was produced by Optics For Research (Caldwell, NJ 07006). This perforated concave mirror additionally acts as a spatial filter which filters out incoherent, poorly collimated plasma lines from the exciting laser beam. The perforation passes only coherent laser beam light.
The reflecting objective 46 may be a 15×0.28 NA reflecting (Schwarzchild) microscope objective produced by Ealing (Holliston, MA 01746). The reflecting objective 46 launches excitation into the fiber 48. Objective 46 focuses the laser beam on the proximal end 47 of the optical fiber or waveguide 48. The Schwarzchild reflecting objective 46 is wavelength independent and has low photoluminescence. There is a large working distance between the objective 46 and the proximal end 47 of the waveguide 48. This large working distance permits installation of the chopper 56 at the input of the fiber 48 (between the fiber 48 and the reflecting objective 46).
It has been found that the chopper 56 should be placed as close as possible to the photoluminescent material 60. Usually, the most convenient location is between the objective 46 and the proximal end 47 of the fiber or waveguide 48. However, if conditions permit, the chopper 56 could be placed at the distal end 49 of the fiber or waveguide 48. The closer the chopper 56 is to the material 60 being tested, the less noise from the light source is present.
The photoluminescence exiting the fiber 48 is spread out by passing through the objective 46 prior to striking the surface of the perforated concave mirror 44. The spread out light 41' from the material 60 striking the concave mirror 44 permits capture of the photoluminescence light, with very little loss through the perforation and back to the source 42. The concave mirror 44 reflects most of the photoluminescence, and is wavelength independent. The mirror 44 also does not photoluminesce itself, and focuses the photoluminescence onto a detector 52 without the introduction of additional photoluminescence by a focusing lens to the detector 52.
The liquid filter 50 may be a 50×50×3 mm liquid filter which was produced by NSG Precision cells (Farmingdale, NY 11735). In this case the cuvette was made of synthetic fused silica (chosen for its low photoluminescence) to the same dimensions as ordinary glass filters and filled with a 1% aqueous solution of K 2 CR 2 O 7 . This solution is totally nonfluorescent, and effective in blocking the laser light. This tactic is also applicable at other wavelengths, since the liquid filter can simply be refilled with another absorbing solution. The liquid filter 50 was filled with an appropriate absorbing solution which blocked scattered excitation from reaching the detector 52. The liquid filter 50 also provided the lowest photoluminescence as compared with interference filters or glass filters.
The detector 52 in the preferred embodiment may be a high sensitivity R928 photomultiplier tube produced by Hamamatsu (Bridgewater, NJ 08807), together with a suitable low noise power supply.
Signal amplification and processing were performed by an exemplary Stanford Research Systems (Sunnyvale, CA 94089) lock-in amplifier 54 connected to a chopper 56 from the same manufacturer. The chopper 56 was the modulator of the light.
The waveguide or fiber optic fibers were soft plasticclad silica fibers with 200 or 600 micron core diameters having low background photoluminescence. These fibers were obtained from General Fiber Optics (Cedar Grove, NJ 07009) (0.38 NA) or Quartz et Silice (Cedex 27, 92096 Paris, France) (0.40 NA).
The foregoing description of the specific embodiments will so fully reveal the general nature of the invention that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and therefore such adaptations and modifications are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology herein is for the purpose of description and not of limitation. | A photoluminescence sensor for detecting a photoluminescent light from a toluminescent material is disclosed. In a preferred embodiment the photoluminescence sensor comprises: a source of light; a concave mirror having at least one perforation for passing the source light through the at least one perforation; an optical waveguide having proximal and distal ends with the photoluminescent material being disposed at the distal end; an objective for directing the source light into the proximal end of the waveguide; an objective for receiving photoluminescent light and for focusing the photoluminescent light onto the perforated concave mirror; a liquid filter for passing the photoluminescent light reflected from the perforated concave mirror to a detector to detect the photoluminescent light. The sensor can also include a chopper disposed at the output end of the objective for modulating the light source at a select frequency and a lock-in amplifier tuned to measure the output from the detector at the select frequency. | 6 |
RELATED APPLICATIONS
[0001] This application is entitled to and hereby claims the priority of co-pending U.S. Provisional application Ser. No. 60/594,733 filed May 2, 2005.
FIELD OF THE INVENTION
[0002] The present invention generally relates to weight bearing structures useful for supporting selected items. More particularly, the present invention relates to brackets useful for outdoor lawn and gardening applications. The brackets of the present invention have particular usefulness for mounting water related accessory items for ground water gardens. The present invention also concerns a kit for the assembly of above-ground water gardens, using the brackets of the present invention. The present invention further concerns a method of mounting water garden accessory items to water garden vessels.
BACKGROUND OF THE INVENTION
[0003] Many people enjoy spending time in their back yards or around the premises of their domicile. As such, many hire landscapers or simply choose to work in their back yards, weeding, planting, and keeping their grounds manicured and pleasant.
[0004] Water gardens are becoming a very attractive addition for many backyards and patios and particularly those having water pumps, which power fountains or other water accessory items to provide movement to the water. Water gardens can be elaborate and incorporate waterfalls, lights, rockwork, and even fish. Alternatively, water gardens can be quite simple and include a conventional, submersible water pump connected to simple or decorative nozzles with various aquatic plants.
[0005] Whether elaborate or simple, water gardens are easy to take care of in that there is little weeding or water involved, while at the same time, these gardens can produce vibrantly colored and fragrant lilies and other aquatic flowers that are enjoyable. Coupled with the relaxation and comfort many tend to find from the sound of moving water, the water garden industry is increasing in popularity.
[0006] Above-ground water gardens that make efficient use of space can be ideal for those with limited space for landscaping. Many kits can be purchased for constructing such above-ground water gardens from whiskey barrels, or other similar vessels. Since whiskey barrels are not waterproof, they are provided with liners, such as pool liners or other plastic or rubber liners. Submersible pumps attached to decorative nozzles or spitters are also associated with these whiskey barrel water gardens. However, due to the limited size of whiskey barrels, it is sometimes difficult, if not impossible, to associate a spitter or other accessory with the garden. Many have opted to span a portion of the barrel with a plank of wood and place their desired items on the wood. However, this compromises the available space and, for some, is unsightly, detracting from the beauty of the garden.
[0007] Accordingly, there remains a need to provide alternatives for those who desire to have water gardens for associating those gardens with selected accessory items without detracting from the garden itself, or further making inefficient use of the available space. There is also a need for a new kit that provides such an alternative. The present invention is directed to meeting these needs.
OBJECTS OF THE INVENTION
[0008] An object of the present invention is to provide a device that supports a selected gardening accessory item at a desired location.
[0009] Another object of the present invention is to provide a device useful for supporting water accessory items associated with water gardens and that is not highly visible.
[0010] A further object of the present invention is to provide a kit that includes items useful for creating water gardens.
[0011] Yet another object of the present invention is to provide a simplified construction useful in connection with water garden accessories that is relatively easy to manufacture and relatively inexpensive.
[0012] These and other objects of the present invention will become more readily appreciated and understood from a consideration of the following detailed description of the exemplary embodiments of the present invention when taken together with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a perspective view of a water garden incorporating a bracket and a water garden accessory according to the first embodiment of the present invention.
[0014] FIG. 2 is a perspective exploded view of the water garden shown in FIG. 1 .
[0015] FIG. 3 is an exploded perspective view of a first exemplary embodiment of the bracket according to the present invention.
[0016] FIG. 4 is a back perspective view of the mounting platform of the bracket shown in FIG. 3 .
[0017] FIG. 5 is a perspective view of the support leg of the bracket shown in FIG. 3 .
[0018] FIG. 6 is a front view in elevation of the assembled mounting platform and support leg shown in FIG. 3 .
[0019] FIG. 7 is a back view in elevation of the mounting platform and support leg shown in FIG. 3 .
[0020] FIG. 8 is an exploded side view of the bracket and water garden accessory, shown in the form of a spitter fountain, wherein both the mounting rod and threaded nut are visable.
[0021] FIG. 9 is an exploded perspective view of the bracket and water garden accessory.
[0022] FIG. 10 is a side view of the bracket and water garden accessory.
[0023] FIG. 11 is a front view in elevation of the assembled water garden accessory and bracket.
[0024] FIG. 12 is a back view in elevation of the water garden accessory and bracket.
[0025] FIG. 13 is a perspective view of the assembled water garden accessory and bracket shown mounted on a sidewall of a water vessel wherein the sidewall and liner appear therewith in partial cross-section.
[0026] FIG. 14 is a back view in elevation of the mounted water garden accessory shown in FIG. 13 .
[0027] FIG. 15 ( a ) is a perspective view of the bracket showing the support leg and mounting post at a first selected location.
[0028] FIG. 15 ( b ) is a perspective view of the bracket showing both the support leg and mounting post at a second selected location that is different from that in FIG. 15 ( a ).
[0029] FIG. 15 ( c ) is a perspective view of the bracket showing both the support leg and mounting post at a third selected location that is different from both the first and second locations shown in FIGS. 15 ( a ) and 15 ( b ).
[0030] FIG. 16 is a perspective view of a bracket according to a second exemplary embodiment according to the present invention.
[0031] FIG. 17 is a perspective view of the mounting platform that is part of the bracket shown in FIG. 16 .
[0032] FIG. 18 is perspective view of the support leg of the bracket shown in FIG. 16 .
[0033] FIG. 19 is a front view in elevation of the assembled bracket shown in FIG. 16 .
[0034] FIG. 20 is an exploded perspective view of the bracket shown in connection with the hood that is inserted through the aperture of the mounting platform.
[0035] FIG. 21 is a front view in elevation of the bracket shown together with the mounting rod, threaded nut and hose.
[0036] FIG. 22 is a right side view in elevation of the bracket shown in FIG. 21 .
[0037] FIG. 23 is a back view in elevation of the bracket shown in FIG. 21 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0038] The present invention broadly concerns weight-bearing structures useful for supporting selected items. More particularly, the present invention concerns brackets useful for supporting accessory items associated with above-ground water gardens. The present invention also concerns a water gardening kit that includes, among various items, a bracket to support accessory items, such as a fountain spitter. The present invention further concerns a method of mounting a water garden accessory item to the sidewall of a vessel.
[0039] Generally, the bracket according to the present invention includes two components—a mounting platform that is adapted for support on a structure, such as a water garden vessel, to provide a surface upon which selected accessory items may be seated; and a support leg that cooperates with the mounting platform to retain its position relative to the support structure and enable it to bear the weight of the accessory item. The bracket components may be constructed as two individual pieces that, when assembled, form a bracket that straddles the sidewall of a water garden vessel. Preferably, the bracket is of sufficient size to bear the weight of the accessory item, while also being at least partly concealed from view so as not to detract from the aesthetic appearance of the water garden.
[0040] One type of above-ground water garden is shown in FIG. 1 . Here, water garden 10 includes vessel 12 , in the form of a whiskey barrel, which contains water and aquatic plants such as lily 14 floating on the water surface, cattails 16 , and grass 18 . The water garden may include real or faux plant life, as desired, and may further include fish or other water gardening accessories such as rocks and decorative pebbles, snails, and the like. As should be appreciated, a whisky barrel, as shown here, is for exemplary purposes only and any suitable vessel, that accommodates the structure of the bracket described below, may be used.
[0041] With continued reference to FIG. 1 and with additional reference to FIG. 2 , vessel 12 includes a circumferential sidewall 22 formed by a plurality of wooden barrel staves 13 extending upwardly from the bottom wall of the barrel (not shown) to terminate in a continuously extending circumferential top edge 24 and defining a vessel interior 26 . Sidewall 22 has an outer surface 21 and an oppositely facing inner surface 23 . Waterproof liner 28 is disposed in the interior 26 of vessel 12 thereby allowing vessel 12 to retain the water for the garden. Liner 28 may be any suitable liner, such as a pool or pond liner as known in the art and may be rigid or flexible and of a suitable size to be disposed within the interior of the vessel and line the sidewall thereof. However, should the selected vessel already be waterproof by other means, a liner, such as liner 28 , may be unnecessary.
[0042] Decorative spitter fountain 40 , shown here in the form of an antique water pump, is supported by vessel 12 and located proximate to top edge 24 . Spitter fountain 40 is in fluid communication with a submersible recirculating water pump 30 , by means of hose 32 . One end of hose 32 is fixed within spitter fountain 40 , while the opposite end is secured into pump 30 at connector 36 . Pump 30 includes electrical cord 34 that can be plugged into an electrical outlet. When activated, pump 30 , which is submerged in vessel 12 , pumps water from within the vessel and through spitter fountain 40 . The water is then dispensed through spout 42 , as shown in FIG. 1 , and returned back to vessel 12 .
[0043] The bracket of the present invention is interposed between top edge 24 of the vessel sidewall 22 and spitter fountain 40 . More particularly, the bracket is mounted to the sidewall and straddles the top edge 24 , supporting the spitter fountain thereabove. However, before discussing how the spitter fountain is mounted onto the bracket, it is perhaps first helpful to discuss the various features of the bracket.
[0044] Turning to FIGS. 3-5 , a first exemplary embodiment of the bracket according to the present invention is shown. Bracket 80 generally includes two components—mounting platform 50 and support leg 60 . First, mounting platform 50 includes a planar top surface 58 , which confronts the accessory item that the bracket supports when in an assembled state. Mounting platform 50 is generally rectangular in shape and includes a front end 82 , back end 84 , and a pair of side ends 86 extending therebetween. Back end 84 includes groove 81 for nestably receiving electrical cord 34 , shown above in FIG. 2 , which adds overall structural support to mounting platform 50 .
[0045] Mounting platform 50 also includes a centrally located entryway 90 that extends through a majority of the width of mounting platform 50 . Entryway 90 terminates in an end wall 61 and includes laterally extending flanges 62 and 64 on either side thereof. End wall 61 further includes groove 69 formed therethrough, which, like groove 81 , also is sized and adapted to nestably receive electrical cord 34 . Visually, entryway 90 divides mounting platform 50 into two identical sections, each having an aperture 66 formed therethrough, and a downwardly depending finger or tab 68 .
[0046] Support leg 60 is an elongate piece having an upper portion 71 which includes head 70 and shoulders 72 , 74 . Opposite upper portion 71 is lower portion 73 which includes feet 76 , 78 and hose channel 79 . Support leg 60 generally tapers toward the lower portion 73 such that the width of upper portion, W 1 , is generally greater than the width of lower portion W 2 .
[0047] Mounting platform 50 slidably receives support leg 60 . More particularly, head 70 is sized and adapted to be received by entryway 90 and travel the length of flanges 62 and 64 , so that when the two components of bracket 80 are engaged, as shown in FIGS. 6 and 7 , head 70 is flush with upper surface 58 of mounting platform, and shoulders 72 and 74 confront bottom surface 59 of mounting platform 50 . In this way, movement of support leg 60 is confined to lateral movement along the length of the flanges. In other words, when the bracket components are engaged, support leg 60 is prevented from moving above upper surface 58 by the contact between shoulders 72 and 74 and lower surface 59 . Similarly, support leg 60 is prevented from moving below lower surface 59 by the contact between head 70 and flanges 62 and 64 .
[0048] Both mounting platform 50 and support leg 60 may each be formed of plastic, metal, wood, or other suitable material. Each piece and their respective features described above may be formed as an integral piece, such as by plastic injection molding.
[0049] Now that the features of the bracket according to a first exemplary embodiment of the present invention have been described in some detail, the fastening of the bracket to the garden accessory, such as the spitter fountain shown in FIGS. 1 and 2 , may now be described. Turning now to FIGS. 8 and 9 , spitter fountain 40 has been provided with a mounting post in the form of threaded rod 56 projecting downwardly from base portion 44 . An opening in base portion 44 , which is concealed by rod 56 , provides access into the interior of spitter fountain 40 . Rod 56 is sized and adapted to receive hose 32 therein so that hose 32 is in fluid communication with the interior of spitter fountain 40 thereby to permit entry of water therein so that it may thereafter be dispensed via its spout 42 .
[0050] As shown, hose 32 is fed through a selected aperture 66 where it is next received by threaded nut 54 . Threaded nut 54 is adapted to engage threaded rod 56 so as to be releasably secured thereto. Accordingly, as shown in FIGS. 10-12 , when threaded nut 54 is secured to the threaded rod 56 on the spitter fountain, top surface 58 confronts base portion 44 of spitter fountain 40 such that spitter fountain 40 is seated on mounting platform 50 to define an assembled state. Hose 32 extends from threaded nut 54 along the length of support leg 60 where it then passes through hose channel 79 . Additionally, as should be appreciated, electrical cord 34 may be laced up through hose channel 79 from pump 30 and then through grooves 69 and 81 and then over the sidewall of the vessel. Channel 79 and grooves 81 , 69 help keep cord in place.
[0051] As perhaps best shown in FIGS. 10-13 , mounting platform 50 need not extend under the entire area of the base portion of the accessory item that it supports. Rather, it is preferred that mounting platform 50 be concealed from view when the item is mounted thereon so as not to detract from the accessory item when placed in the garden.
[0052] Turning now to FIGS. 13 and 14 , the assembled bracket and spitter fountain is shown mounted to sidewall 22 of vessel 12 . As shown, mounting platform 50 rests on top edge 24 of sidewall 22 . Fingers 68 (one finger 68 , partially in phantom, is shown in FIG. 13 ) of mounting platform 50 confront the outer surface 21 of sidewall 22 . Support leg 60 has been pushed into the entryway of the mounting platform so that it confronts the interior surface 23 of sidewall 22 and liner 28 . Foot 78 also rests against liner 28 . Fingers 68 and support leg 60 work together to achieve the appropriate balance on top edge 24 such that mounting platform 50 appropriately bears the weight of spitter fountain 40 .
[0053] Some of the various bracket features heretofore described enable the bracket of the present invention to be adjustable to accommodate various vessels. For example, both the size and configuration of apertures 66 and entryway 90 formed in the mounting platform permit the selective positioning of the mounting post and the support leg. Three examples of this adjustability are shown in FIGS. 15 ( a )- 15 ( c ). When compared to one another, the position of mounting post 56 and head 70 of support leg 60 as shown in FIG. 15 ( a ) are adjusted to mount bracket 80 to a sidewall having the largest width while the positioning of the same in FIG. 15 ( c ) is adjusted for a sidewall that is comparatively less in width. The positioning of mounting post 56 and head 70 , as shown in FIG. 15 ( b ) is adjusted for a sidewall width somewhere in between that shown in FIGS. 15 ( a ) and 15 ( b ).
[0054] As should now be appreciated, it is not necessary that positioning rod 56 be necessarily parallel with head 70 of support leg 60 . Rather, it is preferable that positioning rod 56 be located so that the water pump hose and the threaded nut do not interfere with the balance needed between the finger of the mounting platform and the support leg to mount the selected garden accessory item.
[0055] A bracket according to a second exemplary embodiment of the present invention is shown in FIGS. 16-18 . Here, bracket 180 includes two components—mounting platform 150 and support leg 160 that is slidably received therein. Here, mounting platform 150 is a generally rectangular piece having a top surface 158 , front wall 182 , a back wall 184 , and a pair of sidewalls 186 extending therebetween. Extending outwardly beyond sidewalls 186 are flanges 162 and 164 . Mounting platform 150 also includes one centrally located aperture 166 formed therethrough and having groove 169 , formed proximate to back wall 184 . Back wall 184 also includes groove 181 formed therethrough. Together, grooves 169 and 181 receive and retain the electrical cord associated with the pump. Further, two downwardly depending fingers 168 , which are proximate to back wall 184 and on either side of groove 181 , are provided.
[0056] Support leg 160 is an elongate piece having an upper portion 171 and a lower portion 173 . Upper portion 171 includes nubs 170 and 177 and shoulders 172 and 174 , which form respective grooves 194 and 196 . Support leg 160 generally tapers from upper portion 171 to lower portion 173 such that lower portion 173 has a smaller width than that of upper portion 171 . Additionally, support leg 160 includes opening 192 and a pair of hose channels 179 .
[0057] When mounting platform 150 and support leg 160 are assembled, as shown in FIGS. 16 and 19 , flanges 162 and 164 on the mounting platform are received in the grooves 194 and 196 of the support leg and, once fitted thereon, the support leg is able to be selectively positioned along the length of the flanges. Once assembled, nubs 170 and 177 are flush with top surface 158 and shoulders 172 and 174 confront bottom surface 159 so as to confine movement of support leg 160 to travel along the length of the flanges. Additionally, when assembled, the electrical cord can be passed through hose channels 179 and up through grooves 169 and 181 so as to be received and retained thereby and to provide discreet passage up and over the vessel sidewall for insertion into the electrical outlet.
[0058] As shown in FIG. 20 , hose 132 is fed through aperture 166 in mounting platform 150 . Similar to that described above, threaded nut 154 is received by threaded mounting rod 156 thereby to assemble the selected accessory item to the bracket. As shown here, mounting rod 156 is not shown in connection with a spitter fountain, but it should be appreciated that any water accessory item that can be associated with such a mounting rod is contemplated for assembly onto the bracket of the present invention. Further, it should be appreciated that non-water garden accessory items can also be mounted, such as flower pots, or decorative outdoor items such as weather vanes, or even a fish food dispenser.
[0059] FIGS. 21-23 show bracket 180 in the assembled state, whereby threaded nut 154 is received by mounting rod 156 and secured to the underside thereof. Hose 132 is received by hose channels 179 to facilitate placement of the hose when mounted to the sidewall of the vessel. Further, as shown in the figures, opening 192 formed in support leg 160 accommodates both mounting rod 156 and threaded nut 154 therein to permit the versatility of the bracket to mount accessory items to vessel sidewalls of varying thicknesses. As should be appreciated, assembled bracket and accessory item may then be mounted to the sidewall of a water garden vessel in the manner discussed above with reference to FIGS. 13 and 14 . Accordingly, fingers 168 and support leg 160 together stabilize the entire assembly when mounted on the sidewall.
[0060] The present invention further contemplates providing a kit. The kit would include a bracket according to the present invention, and may specifically include a bracket such as those described above. The kit may further include a liner, for lining a whisky barrel or other selected water vessel that needs to be water proofed. The kit may also include a spitter fountain or other water accessory item having a mounting post associated therewith for assembly with the bracket. Finally, the kit may also be provided with a conventional submersible recirculating water pump.
[0061] From the foregoing, it should be appreciated that the present invention is also directed to a method for supporting a selected garden accessory product to the sidewall of a vessel, or other appropriate support structure. The method includes providing a bracket having an aperture formed therein that is sized and adapted to receive a mounting post, such as a threaded rod. The method further includes the step of releasably securing the accessory item to the bracket, such as by fastening a threaded nut onto the mounting rod. Other suitable fasteners known in the art are also contemplated, such as snaps, ties and other matable fasteners. Once secured to the bracket, the method further includes adjusting the bracket to accommodate the width of the sidewall and then mounting the entire assembly onto the sidewall of the vessel. Further, it should be understood that this method includes any step contemplated by the structures described above.
[0062] Accordingly, the present invention has been described with some degree of particularity directed to the exemplary embodiments of the present invention, It should be appreciated, though, that the modifications or changes may be made to the exemplary embodiments of the present invention without departing from the inventive concepts contained herein. | An adjustable bracket for mounting and supporting a water garden accessory on the sidewall of a support structure to create a water garden, as well as a kit and method for creating a water garden using the bracket. The bracket includes a mounting platform and a support arm that is cooperatively adjustable with the platform to accommodate sidewalls of different widths. Elongated apertures in the mounting platform, through which the accessory is secured to the platform, also allow the water garden accessory to be mounted in a wide range of positions for proper balancing on the sidewall. | 5 |
FIELD OF THE INVENTION
[0001] The present invention relates to aza adamantane derivatives that have the ability to inhibit 11-β-hydroxysteroid dehydrogenase type 1 (11β-HSD-1) and which are therefore useful in the treatment of certain disorders that can be prevented or treated by inhibition of this enzyme. In addition the invention relates to the compounds, methods for their preparation, pharmaceutical compositions containing the compounds and the uses of these compounds in the treatment of certain disorders. It is expected that the compounds of the invention will find application in the treatment of conditions such as non-insulin dependent type 2 diabetes mellitus (NIDDM), insulin resistance, obesity, impaired fasting glucose, impaired glucose tolerance, lipid disorders such as dyslipidemia, hypertension and as well as other diseases and conditions.
BACKGROUND OF THE INVENTION
[0002] Glucocorticoids are stress hormones with regulatory effects on carbohydrate, protein and lipid metabolism. Cortisol (or hydrocortisone in rodent) is the most important human glucocorticoid. 11-beta hydroxyl steroid dehydrogenase or 11 beta-HSD1 (11β-HSD-1) is a member of the short chain dehydrogenase super-family of enzymes which converts functionally inert cortisone to active cortisol locally, in a pre-receptor manner. Given that the enzyme is abundantly expressed in metabolically important tissues, such as adipose, muscle, and liver, that become resistant to insulin action in Type 2 Diabetes, inhibition of 11β-HSD-1 offers the potential to restore the glucose lowering action of insulin in these tissues without impacting the central HPA. Another important 11-beta hydroxyl steroid dehydrogenase, namely Type 2 11-beta-HSD (11β-HSD-2), which converts cortisol into cortisone, is a unidirectional dehydrogenase mainly located in kidney and protects minerallocorticoid receptors from illicit activation by glucocorticoids.
[0003] Multiple lines of evidence indicate that 11β-HSD-1-mediated intracellular cortisol production may have a pathogenic role in Obesity, Type 2 Diabetes and its co-morbidities.
[0004] In humans, treatment with non-specific inhibitor carbenoxolone improves insulin sensitivity in lean healthy volunteers and people with type2 diabetes (Walker B R et al (1995)). Likewise, 11β-HSD-1 activity was decreased in liver and increased in the adipose tissue of obese individuate. Similarly 11β-HSD-1 mRNA was found to be increased in both visceral and subcutaneous adipose tissue of obese patients (Desbriere R et al (2006)) and was positively related to BMI and central obesity in Pima Indians, Caucasians and Chinese youth (Lindsay R S et al (2003), Lee Z S et al (1999)). Adipose tissue 11β-HSD-1 and Hexose-6-Phosphate Dehydrogenase gene expressions have also been shown to increase in patients with type 2 diabetes mellitus (Uçkaya G et al (2008)). In human skeletal muscle 11β-HSD-1 expression was found to be positively associated with insulin resistance (Whorwood C B et al (2002)). Increased 11β-HSD-1 expression was also seen in diabetic myotubes (Abdallah B M et al (2005)).
[0005] Various studies have been conducted in rodent models to substantiate the role of 11β-HSD-1 in diabetes and obesity. For example, over-expression of 11β-HSD-1 specifically in adipose tissue causes development of metabolic syndrome (glucose intolerance, obesity, dyslipidemia and hypertension) in mice (Masuzaki H et al (2001)). Conversely, when 11β-HSD-1 gene was knocked out, the resulting mice showed resistance to diet induced obesity and improvement of the accompanying dysregulation of glucose and lipid metabolism (Kotelevtsev Y et al (1997), Morton N M et al (2001), Morton N M et al (2004)). In addition, treatment of diabetic mouse models with specific inhibitors of 11β-HSD-1 caused a decrease in glucose output from the liver and overall increase in insulin sensitivity (Alberts P et al (2003)).
[0006] The results of the preclinical and early clinical studies suggest that the treatment with a selective and potent inhibitor of 11β-HSD-1 will be an efficacious therapy for type 2 diabetes, obesity and metabolic syndrome.
[0007] The role of 11β-HSD-1 as an important regulator of liver glucocorticoid level and thus of hepatic glucose production is well substantiated. Hepatic insulin sensitivity was improved in healthy human volunteers treated with the non-specific 11β-HSD-1 inhibitor carbenoxolone (Walker B R (1995)). Many in vitro and in vivo (animal model) studies showed that the mRNA levels and activities of two key enzymes (PEPCK and G6PC) in gluconeogenesis and glycogenolysis were reduced by reducing 11β-HSD-1 activity. Data from these models also confirm that inhibition of 11β-HSD-1 will not cause hypoglycemia, as predicted since the basal levels of PEPCK and G6Pase are regulated independently of glucocorticoids (Kotelevtsev Y (1997)).
[0008] In the pancreas cortisol is shown to inhibit glucose induced insulin secretion as well as increase stress induced beta cell apoptosis. Inhibition of 11β-HSD-1 by carbenoxolone in isolated murine pancreatic beta-cells improves glucose-stimulated insulin secretion (Davani B et al (2000)). Recently, it was shown that 11β-HSD-1 within alpha cells regulates glucagon secretion and in addition may act in a paracrine manner to limit insulin secretion from beta cells (Swali A et al (2008)). Levels of 11β-HSD-1 in islets from obob mice were shown to be positively regulated by glucocorticoids and were lowered by a selective 11β-HSD-1 inhibitor and a glucocorticoid receptor antagonist. Increased levels of 11β-HSD-1 were associated with impaired GSIS (Ortsater H et al (2005)). In Zuker diabetic rats, troglitazone treatment improved metabolic abnormalities with a 40% decline in expression of 11β-HSD-1 in the islets (Duplomb L et al (2004)). Cortisol inhibition may lead to an increase in the insulin gene transcription and a normalization of first phase insulin secretion (Shinozuka Y et al (2001)).
[0009] In human skeletal muscle 11β-HSD-1 expression is positively associated insulin resistance and increased expression of 11β-HSD-1 was also reported in type 2 diabetic myotubes (Abdallah B M et al (2005)). Recently the contribution of cortisol in muscle pathology is being considered for modulating its action. Very recently it has been demonstrated that targeted reduction or pharmacological inhibition of 11β-HSD-1 in primary human skeletal muscle prevents the effect of cortisone on glucose metabolism and palmitate oxidation (Salehzadeh F et al (2009)). Over activity of cortisol in muscle leads to muscle atrophy, fibre type switch and poor utilization of glucose due to insulin resistance. Cortisol might have a direct role in reducing muscle glucose uptake.
[0010] Obesity is an important factor in Metabolic syndrome as well as in the majority (>80%) of type 2 diabetics, and omental (visceral) fat appears to be of central importance. 11β-HSD-1 activity is increased in the both visceral and subcutaneous adipose tissue of obese individual (Lindsay R S et al (2003)). Cortisol activity in adipose is known to increase the adipogenic program. Inhibition of 11β-HSD-1 activity in pre-adipocytes has been shown to decrease the rate of differentiation into adipocytes (Bader T et al (2002)). This is predicted to result in diminished expansion (possibly reduction) of the omental fat depot, i.e., reduced central obesity (Bujalska I J et al (1997) and (2006)). Intra-adipose cortisol levels have been associated with adipose hypertrophy, independent of obesity (Michailidou Z et al (2006)).
[0011] Cortisol in coordination with adrenergic signalling is also known to increase lipolysis which leads to increase in plasma free fatty acid concentrations which, in turn, is the primary cause of many deleterious effects of obesity (TomLinson J W et al (2007)).
[0012] Adrenalectomy attenuates the effect of fasting to increase both food intake and hypothalamic neuropeptide Y expression. This supports the role of glucocorticoids in promoting food intake and suggests that inhibition of 11β-HSD-1 in the brain might increase satiety and therefore reduce food intake (Woods S C (1998)). Inhibition of 11β-HSD-1 by a small molecule inhibitor also decreased food intake and weight gain in diet induced obese mice (Wang S J Y et al (2006)).
[0013] The effects discussed above therefore suggest that an effective 11β-HSD-1 inhibitor would have activity as an anti-obesity agent.
[0014] Cortisol in excess can also trigger triglyceride formation and VLDL secretion in liver, which can contribute to hyperlipidemia and associated dyslipidemia. It has been shown that 11β-HSD-1−/− transgenic mice have markedly lower plasma triglyceride levels and increased HDL cholesterol levels indicating a potential atheroprotective phenotype (Morton N M et al (2001)). In a diet-induced obese mouse model, a non-selective inhibitor of 11β-HSD-1 reduced plasma free fatty acid as well as triacylglycerol (Wang S J et al (2006)). Over-expression of 11β-HSD-1 in liver increased liver triglyceride and serum free fatty acids with the up regulation of hepatic lipogenic genes (Paterson J M et al (2004). It has been illustrated that inhibition of 11β-HSD-1 improves triglyceridemia by reducing hepatic VLDL-TG secretion, with a shift in the pattern of TG-derived fatty acid uptake toward oxidative tissues, in which lipid accumulation is prevented by increased lipid oxidation (Berthiaume M et al (2007)).
[0015] Atherosclerotic mouse model (APOE −/−) which are susceptible to atheroma when fed high fat diet, are protected against development of atherosclerosis when treated with 11β-HSD-1 inhibitors (Hermanowski-Vostaka A et al, (2005)).
[0016] Inhibition of 11β-HSD-1 in mature adipocytes is expected to attenuate secretion of the plasminogen activator inhibitor 1 (PAI-1)—an independent cardiovascular risk factor (Halleux C M et al (1999)). Furthermore, there is a clear correlation between glucocorticoid activity and cardiovascular risk factor suggesting that a reduction of the glucocorticoid effects would be beneficial (Walker B R et al (1998), Fraser R et al (1999)).
[0017] The association between hypertension and insulin resistance might be explained by increased activity of cortisol. Recent data show that the intensity of dermal vasoconstriction after topical application of glucocorticoids is increased in patients with essential hypertension (Walker B R et al (1998)). Glucocorticoid was shown to increase the expression of angiotensin receptor in vascular cell and thus potentiating the renin-angiotensin pathway (Ullian M E et al (1996)), (Sato A et al (1994)). Role of cortisol in NO signalling and hence vasoconstriction has been proved recently (Liu Y et al (2009)). These findings render 11β-HSD-1 a potential target for controlling hypertension and improving blood-flow in target tissues.
[0018] In the past decade, concern on glucocorticoid-induced osteoporosis has increased with the widespread use of exogenous glucocorticoids (GC). GC-induced osteoporosis is the most common and serious side-effect for patients receiving GC. Loss of bone mineral density (BMD) is greatest in the first few months of GC use. Mature bone-forming cells (osteoblasts) are considered to be the principal site of action of GC in the skeleton. The whole differentiation of mesenchymal stem cell toward the osteoblast lineage has been proven to be sensitive to GC as well as collagen synthesis (Kim C H et al (1999)). The effects of GC on this process are different according to the stage of differentiation of bone cell precursors. The presence of intact GC signalling is crucial for normal bone development and physiology, as opposed to the detrimental effect of high dose exposure (Pierotti S et al (2008), Cooper M S et al (2000)). Other data suggest a role of 11β-HSD-1 in providing sufficiently high levels of active glucocorticoid in osteoclasts, and thus in augmenting bone resorption (Cooper M S et al (2000)). The negative effect on bone nodule formation could be blocked by the non-specific inhibitor carbenoxolone suggesting an important role of 11β-HSD-1 in the glucocorticoid effect (Bellows C G et al (1998)).
[0019] Stress and glucocorticoids influence cognitive function (de Quervain D J et al (1998)). The enzyme 11β-HSD-1 controls the level of glucocorticoid action in the brain also known to contributes to neurotoxicity (Rajan V et al (1996)). It has been also suggested that inhibiting 11β-HSD-1 in the brain may result in reduced anxiety (Tronche F et al (1999)). Thus, taken together, the hypothesis is that inhibition of 11β-HSD-1 in the human brain would prevent reactivation of cortisone into cortisol and protect against deleterious glucocorticoid-mediated effects on neuronal survival and other aspects of neuronal function, including cognitive impairment, depression, and increased appetite.
[0020] Recent data suggest that the levels of the glucocorticoid target receptors and the 11β-HSD-1 enzymes determine the susceptibility to glaucoma (Stokes, J. et al. (2000)). Ingestion of carbenoxolone, a non-specific inhibitor of 11β-HSD-1, was shown to reduce the intraocular pressure by 20% in normal subjects. There are evidences that 11β-HSD-1 isozyme may modulate steroid-regulated sodium transport across the NPE, thereby influencing intra ocular pressure (IOP). 11β-HSD-1 is suggested to have a role in aqueous production, rather than drainage, but it is presently unknown if this is by interfering with activation of the glucocorticoid or the mineralocorticoid receptor, or both (Rauz S et al (2001; 2003)).
[0021] The multitude of glucocorticoid action is exemplified in patients with prolonged increase in plasma glucocorticoids, so called “Cushing's syndrome”. These patients have prolonged increase in plasma glucocorticoids and exhibit impaired glucose tolerance, type 2 diabetes, central obesity, and osteoporosis. These patients also have impaired wound healing and brittle skin. Administration of glucocorticoid receptor agonist (RU38486) in Cushing's syndrome patients reverses the features of metabolic syndrome (Neiman L K et al (1985)).
[0022] Glucocorticoids have been shown to increase risk of infection and delay healing of open wounds. Patients treated with glucocorticoids have 2-5-fold increased risk of complications when undergoing surgery. Glucocorticoids influence wound healing by interfering with production or action of cytokines and growth factors like IGF, TGF-beta, EGF, KGF and PDGF (Beer H D et al (2000)). TGF-beta reverses the glucocorticoid-induced wound-healing deficit in rats by PDGF regulation in macrophages (Pierce G F et al (1989)). It has also been shown that glucocorticoids decrease collagen synthesis in rat and mouse skin in vivo and in rat and human fibroblasts (Oishi Y et al, 2002).
[0023] Glucocorticoids have also been implicated in conditions as diverse aspolycystic Ovaries Syndrome, infertility, memory dydsfunction, sleep disorders, myopathy (Endocrinology. 2011 January; 152(1)93-102. Epub 2010 Nov. 24. PMID: 21106871) and muscular dystrophy. As such the ability to target enzymes that have an impact on glucocorticoid levels is expected to provide promise for the treatment of these conditions.
[0024] Based on patent literature and company press releases, there are many compound tested for 11β-HSD-1 inhibition in the different stages of drug discovery pipeline.
[0025] Incyte Corporation's INCB13739 has proceeded furthest to phase IIb stage of clinical trial. The results of phase IIa trial for type 2 diabetes (28-days, placebo-controlled, two-step hyperinsulinemic clamp studies) showed that it was safe and well tolerated without any serious side effects and hypoglycemia.
[0026] Though this molecule significantly improved hepatic insulin sensitivity there was no appreciable improvement in plasma glucose levels. The molecule appeared to be having positive effects on risk factors for cardiovascular disease including reduction of LDL, total cholesterol and triglycerides as well as more modest increases in HDL. INCB13739 is currently being studied in a dose ranging phase IIb trials in T2D patients whose glucose levels are not controlled by metformin monotherapy.
[0027] In the pre-clinical stage, Incyte's lead inhibitor INCB13739 was tested in rhesus monkey and was shown to inhibit adipose 11β-HSD-1 (INCB013739, a selective inhibitor of 11β-Hydroxysteroid Dehydrogenase Type 1 (11βHSD1) improves insulin sensitivity and lowers plasma cholesterol over 28 days in patients with type 2 diabetes mellitus.
[0028] The evidence therefore strongly suggests that compounds that are inhibitors of 11β-Hydroxysteroid Dehydrogenase would be useful in the treatment of a number of clinical conditions associated with the expression of this enzyme. In addition it would be desirable if the inhibitors were selective inhibitors so as not to interfere with the functioning of closely related enzymes such as 11β-HSD-2 which is known to provide a protective effect in the body.
OBJECTS OF INVENTION
[0029] The principal object of the invention is to provide compounds that are inhibitors of 11β-Hydroxysteroid Dehydrogenase. These compounds would be expected to be useful in the treatment of 11β-Hydroxysteroid Dehydrogenase related conditions as discussed above.
[0030] A further object is to provide a pharmaceutical composition containing a compound that is an inhibitor of 11β-Hydroxysteroid Dehydrogenase and a pharmaceutically acceptable excipient, diluent or carrier.
[0031] A further object is to provide a method of prevention or treatment of a condition associated with 11β-Hydroxysteroid Dehydrogenase activity in a mammal.
Statement of Invention
[0032] The present invention provides compounds of Formula (I):
[0000]
[0033] wherein:
[0000] each R 1 , R 1α and R 2 is independently selected from the group consisting of H, halogen, OH, NO 2 , CN, SH, NH 2 , CF 3 , OCF 3 , OCH 3 , CH 2 OH, CH 2 CO 2 H, CH 2 CH 2 CO 2 H, CH 2 NH 2 , optionally substituted C 1 -C 12 alkyl, optionally substituted C 1 -C 12 haloalkyl optionally substituted C 2 -C 12 alkenyl, optionally substituted C 2 -C 12 alkynyl, optionally substituted C 2 -C 12 heteroalkyl, optionally substituted C 3 -C 12 cycloalkyl, optionally substituted C 3 -C 12 cycloalkenyl, optionally substituted C 2 -C 12 heterocycloalkyl, optionally substituted C 2 -C 12 heterocycloalkenyl, optionally substituted C 6 -C 18 aryl, optionally substituted C 1 -C 18 heteroaryl, optionally substituted C 1 -C 12 alkyloxy, optionally substituted C 2 -C 12 alkenyloxy, optionally substituted C 2 -C 12 alkynyloxy, optionally substituted C 2 -C 10 heteroalkyloxy, optionally substituted C 3 -C 12 cycloalkyloxy, optionally substituted C 3 -C 12 cycloalkenyloxy, optionally substituted C 2 -C 12 heterocycloalkyloxy, optionally substituted C 2 -C 12 heterocycloalkenyloxy, optionally substituted C 6 -C 18 aryloxy, optionally substituted C 1 -C 18 heteroaryloxy, optionally substituted C 1 -C 12 alkylamino, SR 3 , SO 3 H, SO 2 NR 3 R 4 , SO 2 R 3 , SONR 3 R 4 , SOR 3 , COR 3 , COOH, COOR 3 , CONR 3 R 4 , NR 3 COR 4 , NR 3 COOR 4 , NR 3 SO 2 R 4 , NR 3 CONR 3 R 4 , and NR 3 R 4 ;
[0034] Ar is an optionally substituted C 1 -C 18 heteroaryl group or an optionally substituted C 2 -C 12 heterocycloalkyl group;
[0035] A is selected from the group consisting of S, SO, SO 2 , O, and —CR a R b —;
[0036] B is a group of the formula —(CR c R d ) n —;
[0037] wherein each R a , R b , R c and R d is independently selected from the group consisting of H, halogen, OH, NO 2 , CN, SH, NH 2 , CF 3 , OCF 3 , optionally substituted C 1 -C 12 alkyl, optionally substituted C 2 -C 10 heteroalkyl, optionally substituted C 1 -C 12 haloalkyl, optionally substituted C 3 -C 12 cycloalkyl, optionally substituted C 6 -C 18 aryl, optionally substituted C 1 -C 18 heteroaryl, SR 3 , SO 3 H, SO 2 NR 3 R 4 , SO 2 R 3 , SONR 3 R 4 , SOR 3 , COR 3 , COOH, COOR 3 , CONR 3 R 4 , NR 3 COR4 3 , NR 3 COOR 4 , NR 3 SO 2 R 4 , NR 3 CONR 3 R 4 , NR 3 R 4 ;
[0038] or any two R a , R b , R c and R d on the same carbon atom when taken together may form a substituent of the formula:
[0000]
[0039] wherein each R 3 and R 4 is independently selected from the group consisting of H, optionally substituted C 1 -C 12 alkyl, optionally substituted C 2 -C 10 heteroalkyl, optionally substituted C 1 -C 12 haloalkyl, optionally substituted C 3 -C 12 cycloalkyl, optionally substituted C 6 -C 18 aryl, and optionally substituted C 1 -C 18 heteroaryl;
[0040] R 5 is selected from the group consisting of O, S, and NR 6 ;
[0041] R 6 is selected from the group consisting of H, OR 7 , optionally substituted C 1 -C 12 alkyl, optionally substituted C 1 -C 12 haloalkyl optionally substituted C 2 -C 12 alkenyl, optionally substituted C 2 -C 12 alkynyl, optionally substituted C 1 -C 12 alkyloxy, optionally substituted C 1 -C 12 haloalkyloxy, optionally substituted C 2 -C 10 heteroalkyl, optionally substituted C 3 -C 12 cycloalkyl, optionally substituted C 3 -C 12 cycloalkenyl, optionally substituted C 2 -C 12 heterocycloalkyl, optionally substituted C 2 -C 12 heterocycloalkenyl, optionally substituted C 6 -C 18 aryl, and optionally substituted C 1 -C 18 heteroaryl;
[0042] R 7 is selected from the group consisting of H, optionally substituted C 1 -C 12 alkyl, optionally substituted C 2 -C 10 heteroalkyl, optionally substituted C 3 -C 12 cycloalkyl, optionally substituted C 6 -C 18 aryl, and optionally substituted C 1 -C 18 heteroaryl;
[0043] or any two or more R a , R b , R c and R d may join together to form a multiple bond between adjacent carbon atoms such as a double or triple bond, or a cyclic moiety connecting the carbon atoms to which they are attached;
[0044] n is an integer selected from the group consisting of 0, 1, 2, 3, and 4;
[0045] a is an integer selected from the group consisting of 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, and 10;
[0046] or a pharmaceutically acceptable salt, N-oxide, or prodrug thereof.
[0047] As with any group of structurally related compounds which possess a particular utility, certain embodiments of variables of the compounds of the Formula (I), are particularly useful in their end use application.
[0048] In some embodiments A is S. In some embodiments A is SO. In some embodiments A is SO 2 . In some embodiments A is O. In some embodiments A is CR a R b .
[0049] In some embodiments where A is CR a R b , R a and R b are each independently selected from the group consisting of H, CH 3 , CH 2 CH 3 , CH 2 CH 2 CH 3 , CH(CH 3 ) 2 , (CH 2 ) 3 CH 3 , Cl, Br, F, I, OH, NO 2 , NH 2 , CN, SO 3 H, OCH 3 , OCH 2 CH 2 CH 3 , CF 3 , and OCF 3 . In some embodiments R a is H. In some embodiments R b is H. In some embodiments R a and R b are different such that the carbon is a chiral carbon. In some embodiments one of R a and R b is H and the other is an optionally substituted alkyl.
[0050] In some embodiments R b is H and R a is optionally substituted alkyl. In some embodiments R b is H and R a is selected from the group consisting of methyl, ethyl, propyl, isopropyl and butyl.
[0051] B is a group of the formula —(CR c R d ) n —. In some embodiments n is 0. In some embodiments n is 1. In some embodiments n is 2.
[0052] In some embodiments R c and R d are each independently selected from the group consisting of H, CH 3 , CH 2 CH 3 , CH 2 CH 2 CH 3 , CH(CH 3 ) 2 , (CH 2 ) 3 CH 3 , Cl, Br, F, I, OH, NO 2 , NH 2 , CN, SO 3 H, OCH 3 , OCH 2 CH 2 CH 3 , CF 3 , and OCF 3 . In some embodiments both R c and R d are H such that B is CH 2 .
[0053] In some embodiments any two or more R a , R b , R c and R d may join together to form a multiple bond between adjacent carbon atoms such as a double or triple bond, or a cyclic moiety connecting the carbon atoms to which they are attached.
[0054] In some embodiments two of R a , R b , R c and R d on adjacent carbon atoms are joined to form a double bond. In some embodiments four of R a , R b , R c and R d on adjacent carbon atoms are joined to form a triple bond.
[0055] In some embodiments one of R a and R b and one or R c and R d when taken together with the carbon atoms to which they are attached form a cyclic moiety. Examples of cyclic moieties that may be formed include cyclopropyl, cyclobutyl, cyclopentyl and cyclohexyl.
[0056] In some embodiments n=2 and one of R a and R b and one or R c and R d on the carbon atom two carbons removed (on the beta carbon) when taken together with the carbon atoms to which they are attached and the alpha carbon atom form a cyclic moiety. Examples of cyclic moieties that may be formed include cyclobutyl, cyclopentyl and cyclohexyl.
[0057] In some embodiments A is CR a R b and B is CH 2 , this provides compounds of formula (II):
[0000]
[0058] wherein R 1 , R 1α , R a , R b , R 2 and Ar, are as defined above.
[0059] The group Ar may be any optionally substituted C 1 -C 18 heteroaryl moiety. Suitable heteroaryl groups include thiophene, benzothiophene, benzofuran, benzimidazole, benzoxazole, benzothiazole, benzisothiazole, naphtho[2,3-b]thiophene, furan, isoindolizine, xantholene, phenoxatine, pyrrole, imidazole, pyrazole, pyridine, pyrazine, pyrimidine, pyridazine, tetrazole, indole, isoindole, 1H-indazole, purine, quinoline, isoquinoline, phthalazine, naphthyridine, quinoxaline, cinnoline, carbazole, phenanthridine, acridine, phenazine, thiazole, isothiazole, phenothiazine, oxazole, isooxazole, furazane, phenoxazine, pyridyl, quinolyl, isoquinolinyl, indolyl, and thienyl. In each instance where there is the possibility of multiple sites of substitution on the heteroaryl ring all possible attachment points are contemplated. Merely by way of example if the heteroaryl is a pyridyl moiety it may be a 2-pyridyly, a 3-pyridyl or a 4-pyridyl.
[0060] In some embodiments Ar is a group of the formula 3:
[0000]
[0061] wherein each V 1 , V 2 , V 3 , V 4 , V 5 and V 6 is independently selected from the group consisting of N and CR8;
[0062] U is selected from the group consisting of NR 9 , O, S and CR 9 2 ,
[0063] wherein each R 8 is independently selected from the group consisting of H, halogen, OH, NO 2 , CN, SH, NH 2 , CF 3 , OCF 3 , optionally substituted C 1 -C 12 alkyl, optionally substituted C 1 -C 12 haloalkyl, optionally substituted C 2 -C 12 alkenyl, optionally substituted C 2 -C 12 alkynyl, optionally substituted C 2 -C 12 heteroalkyl, optionally substituted C 3 -C 12 cycloalkyl, optionally substituted C 3 -C 12 cycloalkenyl, optionally substituted C 2 -C 12 heterocycloalkyl, optionally substituted C 2 -C 12 heterocycloalkenyl, optionally substituted C 6 -C 18 aryl, optionally substituted C 1 -C 18 heteroaryl, optionally substituted C 1 -C 12 alkyloxy, optionally substituted C 2 -C 12 alkenyloxy, optionally substituted C 2 -C 12 alkynyloxy, optionally substituted C 2 -C 10 heteroalkyloxy, optionally substituted C 3 -C 2 cycloalkyloxy, optionally substituted C 3 -C 12 cycloalkenyloxy, optionally substituted C 2 -C 12 heterocycloalkyloxy, optionally substituted C 2 -C 12 heterocycloalkenyloxy, optionally substituted C 6 -C 18 aryloxy, optionally substituted C 1 -C 1 heteroaryloxy, optionally substituted C 1 -C 12 alkylamino, SR 10 , SO 3 H, SO 2 NR 10 R 11 , SO 2 R 10 , OSO 2 R 10 , SONR 10 R 11 , SOR 10 , COR 10 , COOH, COOR 10 , CONR 10 R 11 , NR 10 COR 11 , NR 10 COOR 11 , NR 10 SO 2 R 11 , NR 10 CONR 10 R 11 , and NR 10 R 11 ;
[0064] wherein R 9 is selected from the group consisting of H, optionally substituted C 1 -C 12 alkyl, optionally substituted C 2 -C 12 alkenyl, optionally substituted C 2 -C 12 alkynyl, optionally substituted C 2 -C 12 heteroalkyl, optionally substituted C 3 -C 12 cycloalkyl, optionally substituted C 2 -C 12 heterocycloalkyl, optionally substituted C 6 -C 18 aryl, optionally substituted C 1 -C 18 heteroaryl, SO 3 H, SO 2 NR 10 R 11 , SO 2 R 10 , SONR 10 R 11 , SOR 10 , COR 10 , COOH, COOR 10 , and CONR 10 R 11 ;
[0065] wherein each R 10 and R 11 is independently selected from the group consisting of H, optionally substituted C 1 -C 12 alkyl, optionally substituted C 2 -C 10 heteroalkyl, optionally substituted C 1 -C 12 haloalkyl, optionally substituted C 3 -C 12 cycloalkyl, optionally substituted C 6 -C 18 aryl, and optionally substituted C 1 -C 18 heteroaryl.
[0066] In some embodiments Ar is selected from the group consisting of:
[0000]
[0067] wherein R 8 and R 9 is as defined above;
[0068] e is an integer selected from the group consisting of 0, 1, 2, 3 and 4;
[0069] f is an integer selected the group consisting of 0, 1, 2, and 3.
[0070] In some embodiments A is CR a R b , B is CH 2 and Ar is a group of formula (3a), this provides compounds of formula (IVa):
[0000]
[0000] wherein R 1 , R 1α , R a , R b , R 2 , R 8 , R 9 and e, are as defined above.
[0071] In some embodiments A is CR a R b , B is CH 2 and Ar is a group of formula (3b), this provides compounds of formula (IVb):
[0000]
[0072] wherein R 1 , R 1α , R a , R b , R 2 , R 8 , R 9 and f, are as defined above.
[0073] In some embodiments A is CR a R b , B is CH 2 and Ar is a group of formula (3c), this provides compounds of formula (IVc):
[0000]
[0074] wherein R 1 , R 1α , R a , R b , R 2 , R 8 , R 9 and e, are as defined above.
[0075] In some embodiments A is CR a R b , B is CH 2 and Ar is a group of formula (3d), this provides compounds of formula (IVd):
[0000]
[0076] wherein R 1 , R 1α , R a , R b , R 2 , R 8 and e, are as defined above.
[0077] In some embodiments A is CR a R b , B is CH 2 and Ar is a group of formula (3e), this provides compounds of formula (IVe):
[0000]
[0078] wherein R 1 , R 1α , R a , R b , R 2 , R 8 and e, are as defined above.
[0079] In some embodiments A is CR a R b , B is CH 2 and Ar is a group of formula (3f), this provides compounds of formula (IVf):
[0000]
[0080] wherein R 1 , R 1α , R a , R b , R 2 , R 8 , R 9 and e, are as defined above.
[0081] In some embodiments A is CR a R b , B is CH 2 and Ar is a group of formula (3 g), this provides compounds of formula (IVg):
[0000]
[0082] wherein R 1 , R 1α , R a , R b , R 2 , R 8 , and e, are as defined above.
[0083] In some embodiments e is 1. In some embodiments e is 2. In some embodiments e is 3. In some embodiments e is 4. In circumstances where e is 1 the R 8 group may be located at either the 4, 5, 6, or 7 position on the six membered ring. In some embodiments where e is 1 the R 8 substituent is located at the 4 position on the ring. In some embodiments where e is 1 the R 8 substituent is located at the 5 position on the ring. In some embodiments where e is 1 the R 8 substituent is located at the 6 position on the ring. In some embodiments where e is 1 the R 8 substituent is located at the 7 position on the ring.
[0084] In some embodiments f is 1. In some embodiments f is 2. In some embodiments f is 3. In some embodiments where f is 1 the R 8 substituent is located at the 4 position on the ring. In some embodiments where f is 1 the R 8 substituent is located at the 5 position on the ring. In some embodiments where f is 1 the R 8 substituent is located at the 6 position on the ring. In some embodiments where f is 1 the R 8 substituent is located at the 7 position on the ring.
[0085] In some embodiments of the compounds described above each R 1 is independently selected from the group consisting of H, OH, F, Cl, Br, CH 3 , CH 2 CO 2 H, CH 2 CH 2 CO 2 H, CO 2 H, CONH 2 , CH 2 OH, CH 2 NH 2 , CN, OCH 3 , Ocyclopropyl, and OCHF 2 . In some embodiments one R 1 is H and the other R 1 is OH. In some embodiments both R 1 are H.
[0086] In some embodiments of the compounds described above each R 1α is independently selected from the group consisting of H, OH, F, Cl, Br, CO 2 H, CONH 2 , CH 2 OH, CN, OCH 3 , and OCHF 2 . In some embodiments one R 1α is H and the other R 1α is OH. In some embodiments both R 1α are H.
[0087] In some embodiments each R 2 is independently selected from the group consisting of H, CH 3 , CH 2 CH 3 , CH 2 CH 2 CH 3 , CH(CH 3 ) 2 , (CH 2 ) 3 CH 3 , Cl, Br, F, I, OH, NO 2 , NH 2 , CN, SO 3 H, OCH 3 , OCH 2 CH 2 CH 3 , CF 3 , and OCF 3
[0088] In some embodiments a is 0. In some embodiments a is 1. In some embodiments a is 2. In some embodiments a is 3. In some embodiments a is 4. In some embodiments a is 5. In some embodiments a is 6. In some embodiments a is 7. In some embodiments a is 8. In some embodiments a is 9. In some embodiments a is 10.
[0089] In some embodiments of the compounds of the invention containing an R 3 group, the R 3 group is selected from H and C 1 -C 12 alkyl. In some embodiments R 3 is H. in some embodiments R 3 is methyl.
[0090] In some embodiments of the compounds of the invention containing an R 4 group, the R 4 group is selected from H and C 1 -C 12 alkyl. In some embodiments R 4 is H. in some embodiments R 4 is methyl.
[0091] In some embodiments of the compounds of the invention containing an R 5 group, the R 5 group is selected from O and S. In some embodiments R 5 is O. in some embodiments R 5 is S.
[0092] In some embodiments of the compounds of the invention containing an R 6 group, the R 6 group is selected from H and C 1 -C 12 alkyl. In some embodiments R 6 is H. in some embodiments R 6 is methyl.
[0093] In some embodiments of the compounds of the invention containing an R 7 group, the R 7 group is selected from H and C 1 -C 12 alkyl. In some embodiments R 7 is H. in some embodiments R 7 is methyl.
[0094] R 8 may be selected from a wide range of possible substituents as discussed above. In some embodiments each R 8 is independently selected from the group consisting of H, halogen, OH, NO 2 , CN, C 1 -C 12 alkyl, C 1 -C 12 haloalkyl, C 1 -C 12 alkoxyl, and C 1 -C 12 haloalkoxyl. Exemplary R 8 substituents include H, CH 3 , CH 2 CH 3 , CH 2 CH 2 CH 3 , CH(CH 3 ) 2 , (CH 2 ) 3 CH 3 , cyclopropyl, I, Br, F, I, OH, NO 2 , NH 2 , CN, SO 3 H, OCH 3 , OCH(CH 3 ) 2 , OCH 2 CH 2 CH 3 , OSO 2 CF 3 , CF 3 , and OCF 3 .
[0095] R 9 may be selected from a wide range of possible substituents as discussed above. In some embodiments each R 9 is independently selected from the group consisting of H, halogen, OH, NO 2 , CN, C 1 -C 12 alkyl, C 1 -C 12 haloalkyl, C 1 -C 12 alkoxyl, and C 1 -C 12 haloalkoxyl. Exemplary R 9 substituents include CH 3 , CH 2 CH 3 , CH 2 CH 2 CH 3 , CH(CH 3 ) 2 , (CH 2 ) 3 CH 3 , I, Br, F, I, OH, NO 2 , NH 2 , CN, SO 3 H, OCH 3 , OCH 2 CH 2 CH 3 , CF 3 , and OCF 3 .
[0096] Many if not all of the variables discussed above may be optionally substituted. If the variable is optionally substituted then in some embodiments each optional substituent is independently selected from the group consisting of halogen, ═O, ═S, —CN, —NO 2 , —CF 3 , —OCF 3 , alkyl, alkenyl, alkynyl, haloalkyl, haloalkenyl, haloalkynyl, heteroalkyl, cycloalkyl, cycloalkenyl, heterocycloalkyl, heterocycloalkenyl, aryl, heteroaryl, cycloalkylalkyl, heterocycloalkylalkyl, heteroarylalkyl, arylalkyl, cycloalkylalkenyl, heterocycloalkylalkenyl, arylalkenyl, heteroarylalkenyl, cycloalkylheteroalkyl, heterocycloalkylheteroalkyl, arylheteroalkyl, heteroarylheteroalkyl, hydroxy, hydroxyalkyl, alkyloxy, alkyloxyalkyl, alkyloxycycloalkyl, alkyloxyheterocycloalkyl, alkyloxyaryl, alkyloxyheteroaryl, alkyloxycarbonyl, alkylaminocarbonyl, alkenyloxy, alkynyloxy, cycloalkyloxy, cycloalkenyloxy, heterocycloalkyloxy, heterocycloalkenyloxy, aryloxy, phenoxy, benzyloxy, heteroaryloxy, arylalkyloxy, amino, alkylamino, acylamino, aminoalkyl, arylamino, sulfonylamino, sulfinylamino, sulfonyl, alkylsulfonyl, arylsulfonyl, aminosulfonyl, sulfinyl, alkylsulfinyl, arylsulfinyl, aminosulfinylaminoalkyl, —C(═O)OH, —C(═O)R e , —C(═O)OR e , C(═O)NR e R f , C(═NOH)R e , C(═NR e )NR f R g , NR e R f , NR e C(═O)R f , NR e C(═O)OR f , NR e C(═O)NR f R g , NR e C(═NR f )NR g R h , NR e SO 2 R f , —SR e , SO 2 NR e R f , —OR e , OC(═O)NR e R f , OC(═O)R e and acyl,
[0097] wherein R e , R f , R g and R h are each independently selected from the group consisting of H, C 1 -C 12 alkyl, C 1 -C 12 haloalkyl, C 2 -C 12 alkenyl, C 2 -C 12 alkynyl, C 1 -C 10 heteroalkyl, C 3 -C 12 cycloalkyl, C 3 -C 12 cycloalkenyl, C 1 -C 12 heterocycloalkyl, C 1 -C 12 heterocycloalkenyl, C 6 -C 18 aryl, C 1 -C 18 heteroaryl, and acyl, or any two or more of R a , R b , R c and R d , when taken together with the atoms to which they are attached form a heterocyclic ring system with 3 to 12 ring atoms.
[0098] In some embodiments each optional substituent is independently selected from the group consisting of: F, Cl, Br, ═O, ═S, —CN, —NO 2 , alkyl, alkenyl, heteroalkyl, haloalkyl, alkynyl, aryl, cycloalkyl, heterocycloalkyl, heteroaryl, hydroxy, hydroxyalkyl, alkoxy, alkylamino, aminoalkyl, acylamino, phenoxy, alkoxyalkyl, benzyloxy, alkylsulfonyl, arylsulfonyl, aminosulfonyl, —C(O)OR a , COOH, SH, and acyl.
[0099] In some embodiments each optional substituent is independently selected from the group consisting of: F, Br, Cl, ═O, ═S, —CN methyl, trifluoro-methyl, ethyl, 2,2,2-trifluoroethyl, isopropyl, propyl, 2-ethyl-propyl, 3,3-dimethyl-propyl, butyl, isobutyl, 3,3-dimethyl-butyl, 2-ethyl-butyl, pentyl, 2-methyl-pentyl, pent-4-enyl, hexyl, heptyl, octyl, phenyl, NH 2 , —NO 2 , phenoxy, hydroxy, methoxy, trifluoro-methoxy, ethoxy, and methylenedioxy.
[0100] Alternatively, two optional substituents on the same moiety when taken together may be joined to form a fused cyclic substituent attached to the moiety that is optionally substituted. Accordingly the term optionally substituted includes a fused ring such as a cycloalkyl ring, a heterocycloalkyl ring, an aryl ring or a heteroaryl ring.
[0101] In addition to compounds of formula I, the embodiments disclosed are also directed to pharmaceutically acceptable salts, pharmaceutically acceptable N-oxides, pharmaceutically acceptable prodrugs, and pharmaceutically active metabolites of such compounds, and pharmaceutically acceptable salts of such metabolites.
[0102] The invention also relates to pharmaceutical compositions including a compound of the invention and a pharmaceutically acceptable carrier, diluent or excipient.
[0103] In a further aspect the present invention provides a method of prevention or treatment of a condition in a mammal, the method comprising administering an effective amount of a compound of the invention. In one embodiment the condition is a condition that can be treated by inhibition of 11β-HSD1.
[0104] In yet an even further aspect the invention provides the use of a compound of the invention in the preparation of a medicament for the treatment of a condition in a mammal. In one embodiment the condition is a condition that can be treated by inhibition of 11β-HSD1.
[0105] In yet an even further aspect the invention provides the use of a compound of the invention in the treatment of a condition in a mammal. In one embodiment the condition is a condition that can be treated by inhibition of 11β-HSD1.
[0106] In some embodiments the condition is selected from the group consisting of is selected from the group consisting of diabetes, hyperglycemia, low glucose tolerance, hyperinsulinemia, hyperlipidemia, hypertriglyceridemia, hypercholesterolemia, dyslipidemia, obesity, abdominal obesity, glaucoma, hypertension, atherosclerosis and its sequelae, retinopathy and other ocular disorders, nephropathy, neuropathy, myopathy, osteoporosis, osteoarthritis, dementia, depression, neurodegenerative disease, psychiatric disorders, Polycystic ovaries syndrome, infertility, Cushing's Disease, Cushing's syndrome, viral diseases, and inflammatory diseases.
[0107] In some embodiments the condition is diabetes. In some embodiments the condition is type II diabetes.
[0108] In some embodiments the compound is administered in combination with an adjuvant. In some embodiments the adjuvant is selected from the group consisting of dipeptidyl peptidase-IV (DP-IV) inhibitors; (b) insulin sensitizing agents; (c) insulin and insulin mimetics; (d) sulfonylureas and other insulin secretagogues; (e) alpha.-glucosidase inhibitors; (f) GLP-1, GLP-1 analogs, and GLP-1 receptor agonists; and combinations thereof.
[0109] In one other embodiment the compound is administered as a substitute for monotherapy or combination therapy, in an event of failure of treatment by an agent selected from the group consisting of dipeptidyl peptidase-IV (DP-IV) inhibitors; (b) insulin sensitizing agents; (c) insulin and insulin mimetics; (d) sulfonylureas and other insulin secretagogues; (e) alpha.-glucosidase inhibitors; (f) GLP-1, GLP-1 analogs, and GLP-1 receptor agonists; and combinations thereof.
[0110] In one embodiment the insulin sensitizing agent is selected from the group consisting of (i) PPAR-gamma-agonists, (ii) PPAR-alpha-agonists, (iii) PPAR-alpha/gamma-dual agonists, (iv) biguanides, and combinations thereof.
[0111] These and other teachings of the invention are set forth herein.
DETAILED DESCRIPTION OF THE INVENTION
[0112] In this specification a number of terms are used which are well known to a skilled addressee. Nevertheless for the purposes of clarity a number of terms will be defined.
[0113] As used herein, the term “unsubstituted” means that there is no substituent or that the only substituents are hydrogen.
[0114] The term “optionally substituted” as used throughout the specification denotes that the group may or may not be further substituted or fused (so as to form a condensed polycyclic system), with one or more non-hydrogen substituent groups. In certain embodiments the substituent groups are one or more groups independently selected from the group consisting of halogen, ═O, ═S, —CN, —NO 2 , —CF 3 , —OCF 3 , alkyl, alkenyl, alkynyl, haloalkyl, haloalkenyl, haloalkynyl, heteroalkyl, cycloalkyl, cycloalkenyl, heterocycloalkyl, heterocycloalkenyl, aryl, heteroaryl, cycloalkylalkyl, heterocycloalkylalkyl, heteroarylalkyl, arylalkyl, cycloalkylalkenyl, heterocycloalkylalkenyl, arylalkenyl, heteroarylalkenyl, cycloalkylheteroalkyl, heterocycloalkylheteroalkyl, arylheteroalkyl, heteroarylheteroalkyl, hydroxy, hydroxyalkyl, alkyloxy, alkyloxyalkyl, alkyloxycycloalkyl, alkyloxyheterocycloalkyl, alkyloxyaryl, alkyloxyheteroaryl, alkyloxycarbonyl, alkylaminocarbonyl, alkenyloxy, alkynyloxy, cycloalkyloxy, cycloalkenyloxy, heterocycloalkyloxy, heterocycloalkenyloxy, aryloxy, phenoxy, benzyloxy, heteroaryloxy, arylalkyloxy, amino, alkylamino, acylamino, aminoalkyl, arylamino, sulfonylamino, sulfinylamino, sulfonyl, alkylsulfonyl, arylsulfonyl, aminosulfonyl, sulfinyl, alkylsulfinyl, arylsulfinyl, aminosulfinylaminoalkyl, —C(═O)OH, —C(═O)R e , —C(═O)OR e , C(═O)NR e R f , C(═NOH)R e , C(═NR e )NR f R g , NR e R f , NR e C(═O)R f , NR e C(═O)OR f , NR e C(═O)NR f R g , NR e C(═NR f )NR g R h , NR e SO 2 R f , —SR e , SO 2 NR e R f , —OR e , OC(═O)NR e R f , OC(═O)R e and acyl,
[0115] wherein R e , R f , R g and R h are each independently selected from the group consisting of H, C 1 -C 12 alkyl, C 1 -C 12 haloalkyl, C 2 -C 12 alkenyl, C 2 -C 12 alkynyl, C 1 -C 10 heteroalkyl, C 3 -C 12 cycloalkyl, C 3 -C 12 cycloalkenyl, C 1 -C 12 heterocycloalkyl, C 1 -C 12 heterocycloalkenyl, C 6 -C 18 aryl, C 1 -C 18 heteroaryl, and acyl, or any two or more of R a , R b , R c and R d , when taken together with the atoms to which they are attached form a heterocyclic ring system with 3 to 12 ring atoms.
[0116] In some embodiments each optional substituent is independently selected from the group consisting of: halogen, ═O, ═S, —CN, —NO 2 , —CF 3 , —OCF 3 , alkyl, alkenyl, alkynyl, haloalkyl, haloalkenyl, haloalkynyl, heteroalkyl, cycloalkyl, cycloalkenyl, heterocycloalkyl, heterocycloalkenyl, aryl, heteroaryl, hydroxy, hydroxyalkyl, alkyloxy, alkyloxyalkyl, alkyloxyaryl, alkyloxyheteroaryl, alkenyloxy, alkynyloxy, cycloalkyloxy, cycloalkenyloxy, heterocycloalkyloxy, heterocycloalkenyloxy, aryloxy, heteroaryloxy, arylalkyl, heteroarylalkyl, arylalkyloxy, amino, alkylamino, acylamino, aminoalkyl, arylamino, sulfonyl, alkylsulfonyl, arylsulfonyl, aminosulfonyl, aminoalkyl, —COOH, —SH, and acyl.
[0117] Examples of particularly suitable optional substituents include F, Cl, Br, I, CH 3 , CH 2 CH 3 , OH, OCH 3 , CF 3 , OCF 3 , NO 2 , NH 2 , and CN.
[0118] In the definitions of a number of substituents below it is stated that “the group may be a terminal group or a bridging group”. This is intended to signify that the use of the term is intended to encompass the situation where the group is a linker between two other portions of the molecule as well as where it is a terminal moiety. Using the term alkyl as an example, some publications would use the term “alkylene” for a bridging group and hence in these other publications there is a distinction between the terms “alkyl” (terminal group) and “alkylene” (bridging group). In the present application no such distinction is made and most groups may be either a bridging group or a terminal group.
[0119] “Acyl” means an R—C(═O)— group in which the R group may be an alkyl, cycloalkyl, heterocycloalkyl, aryl or heteroaryl group as defined herein. Examples of acyl include acetyl and benzoyl. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the carbonyl carbon.
[0120] “Acylamino” means an R—C(═O)—NH— group in which the R group may be an alkyl, cycloalkyl, heterocycloalkyl, aryl or heteroaryl group as defined herein. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the nitrogen atom.
[0121] “Alkenyl” as a group or part of a group denotes an aliphatic hydrocarbon group containing at least one carbon-carbon double bond and which may be straight or branched preferably having 2-12 carbon atoms, more preferably 2-10 carbon atoms, most preferably 2-6 carbon atoms, in the normal chain. The group may contain a plurality of double bonds in the normal chain and the orientation about each is independently E or Z. The alkenyl group is preferably a 1-alkenyl group. Exemplary alkenyl groups include, but are not limited to, ethenyl, propenyl, butenyl, pentenyl, hexenyl, heptenyl, octenyl and nonenyl. The group may be a terminal group or a bridging group.
[0122] “Alkenyloxy” refers to an alkenyl-O— group in which alkenyl is as defined herein. Preferred alkenyloxy groups are C 1 -C 6 alkenyloxy groups. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the oxygen atom.
[0123] “Alkyl” as a group or part of a group refers to a straight or branched aliphatic hydrocarbon group, preferably a C 1 -C 12 alkyl, more preferably a C 1 -C 10 alkyl, most preferably C 1 -C 6 unless otherwise noted. Examples of suitable straight and branched C 1 -C 6 alkyl substituents include methyl, ethyl, n-propyl, 2-propyl, n-butyl, sec-butyl, t-butyl, hexyl, and the like. The group may be a terminal group or a bridging group.
[0124] “Alkylamino” includes both mono-alkylamino and dialkylamino, unless specified. “Mono-alkylamino” means an Alkyl-NH— group, in which alkyl is as defined herein. “Dialkylamino” means a (alkyl) 2 N— group, in which each alkyl may be the same or different and are each as defined herein for alkyl. The alkyl group is preferably a C 1 -C 6 alkyl group. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the nitrogen atom.
[0125] “Alkylaminocarbonyl” refers to a group of the formula (Alkyl) x (H) y NC(═O)— in which alkyl is as defined herein, x is 1 or 2, and the sum of X+Y=2. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the carbonyl carbon.
[0126] “Alkyloxy” refers to an alkyl-O— group in which alkyl is as defined herein. Preferably the alkyloxy is a C 1 -C 6 alkyloxy. Examples include, but are not limited to, methoxy and ethoxy. The group may be a terminal group or a bridging group.
[0127] “Alkyloxyalkyl” refers to an alkyloxy-alkyl- group in which the alkyloxy and alkyl moieties are as defined herein. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the alkyl group.
[0128] “Alkyloxyaryl” refers to an alkyloxy-aryl- group in which the alkyloxy and aryl moieties are as defined herein. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the aryl group.
[0129] “Alkyloxycarbonyl” refers to an alkyl-O—C(═O)— group in which alkyl is as defined herein. The alkyl group is preferably a C 1 -C 6 alkyl group. Examples include, but are not limited to, methoxycarbonyl and ethoxycarbonyl. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the carbonyl carbon.
[0130] “Alkyloxycycloalkyl” refers to an alkyloxy-cycloalkyl- group in which the alkyloxy and cycloalkyl moieties are as defined herein. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the cycloalkyl group.
[0131] “Alkyloxyheteroaryl” refers to an alkyloxy-heteroaryl- group in which the alkyloxy and heteroaryl moieties are as defined herein. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the heteroaryl group.
[0132] “Alkyloxyheterocycloalkyl” refers to an alkyloxy-heterocycloalkyl- group in which the alkyloxy and heterocycloalkyl moieties are as defined herein. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the heterocycloalkyl group.
[0133] “Alkylsulfinyl” means an alkyl-S—(═O)— group in which alkyl is as defined herein. The alkyl group is preferably a C 1 -C 6 alkyl group. Exemplary alkylsulfinyl groups include, but not limited to, methylsulfinyl and ethylsulfinyl. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the sulfur atom.
[0134] “Alkylsulfonyl” refers to an alkyl-S(═O) 2 — group in which alkyl is as defined above. The alkyl group is preferably a C 1 -C 6 alkyl group. Examples include, but not limited to methylsulfonyl and ethylsulfonyl. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the sulfur atom.
[0135] “Alkynyl” as a group or part of a group means an aliphatic hydrocarbon group containing a carbon-carbon triple bond and which may be straight or branched preferably having from 2-12 carbon atoms, more preferably 2-10 carbon atoms, more preferably 2-6 carbon atoms in the normal chain. Exemplary structures include, but are not limited to, ethynyl and propynyl. The group may be a terminal group or a bridging group.
[0136] “Alkynyloxy” refers to an alkynyl-O— group in which alkynyl is as defined herein. Preferred alkynyloxy groups are C 1 -C 6 alkynyloxy groups. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the oxygen atom.
[0137] “Aminoalkyl” means an NH 2 -alkyl- group in which the alkyl group is as defined herein. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the alkyl group.
[0138] “Aminosulfonyl” means an NH 2 —S(═O) 2 — group. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the sulfur atom.
[0139] “Aryl” as a group or part of a group denotes (i) an optionally substituted monocyclic, or fused polycyclic, aromatic carbocycle (ring structure having ring atoms that are all carbon) preferably having from 5 to 12 atoms per ring. Examples of aryl groups include phenyl, naphthyl, and the like; (ii) an optionally substituted partially saturated bicyclic aromatic carbocyclic moiety in which a phenyl and a C 5-7 cycloalkyl or C 5-7 cycloalkenyl group are fused together to form a cyclic structure, such as tetrahydronaphthyl, indenyl or indanyl. The group may be a terminal group or a bridging group. Typically an aryl group is a C 6 -C 18 aryl group.
[0140] “Arylalkenyl” means an aryl-alkenyl- group in which the aryl and alkenyl are as defined herein. Exemplary arylalkenyl groups include phenylallyl. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the alkenyl group.
[0141] “Arylalkyl” means an aryl-alkyl- group in which the aryl and alkyl moieties are as defined herein. Preferred arylalkyl groups contain a C 1-5 alkyl moiety. Exemplary arylalkyl groups include benzyl, phenethyl, 1-naphthalenemethyl and 2-naphthalenemethyl. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the alkyl group.
[0142] “Arylalkyloxy” refers to an aryl-alkyl-O— group in which the alkyl and aryl are as defined herein. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the oxygen atom.
[0143] “Arylamino” includes both mono-arylamino and di-arylamino unless specified. Mono-arylamino means a group of formula arylNH—, in which aryl is as defined herein. Di-arylamino means a group of formula (aryl) 2 N— where each aryl may be the same or different and are each as defined herein for aryl. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the nitrogen atom.
[0144] “Arylheteroalkyl” means an aryl-heteroalkyl- group in which the aryl and heteroalkyl moieties are as defined herein. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the heteroalkyl group.
[0145] “Aryloxy” refers to an aryl-O— group in which the aryl is as defined herein. Preferably the aryloxy is a C 6 -C 18 aryloxy, more preferably a C 6 -C 10 aryloxy. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the oxygen atom.
[0146] “Arylsulfonyl” means an aryl-S(═O) 2 — group in which the aryl group is as defined herein. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the sulfur atom.
[0147] A “bond” is a linkage between atoms in a compound or molecule. The bond may be a single bond, a double bond, or a triple bond.
[0148] “Cycloalkenyl” means a non-aromatic monocyclic or multicyclic ring system containing at least one carbon-carbon double bond and preferably having from 5-10 carbon atoms per ring. Exemplary monocyclic cycloalkenyl rings include cyclopentenyl, cyclohexenyl or cycloheptenyl. The cycloalkenyl group may be substituted by one or more substituent groups. A cycloalkenyl group typically is a C 3 -C 12 alkenyl group. The group may be a terminal group or a bridging group.
[0149] “Cycloalkyl” refers to a saturated monocyclic or fused or spiro polycyclic, carbocycle preferably containing from 3 to 9 carbons per ring, such as cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl and the like, unless otherwise specified. It includes monocyclic systems such as cyclopropyl and cyclohexyl, bicyclic systems such as decalin, and polycyclic systems such as adamantane. A cycloalkyl group typically is a C 3 -C 12 alkyl group. The group may be a terminal group or a bridging group.
[0150] “Cycloalkylalkyl” means a cycloalkyl-alkyl- group in which the cycloalkyl and alkyl moieties are as defined herein. Exemplary monocycloalkylalkyl groups include cyclopropylmethyl, cyclopentylmethyl, cyclohexylmethyl and cycloheptylmethyl. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the alkyl group.
[0151] “Cycloalkylalkenyl” means a cycloalkyl-alkenyl- group in which the cycloalkyl and alkenyl moieties are as defined herein. The group, may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the alkenyl group.
[0152] “Cycloalkylheteroalkyl” means a cycloalkyl-heteroalkyl- group in which the cycloalkyl and heteroalkyl moieties are as defined herein. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the heteroalkyl group.
[0153] “Cycloalkyloxy” refers to a cycloalkyl-O— group in which cycloalkyl is as defined herein. Preferably the cycloalkyloxy is a C 1 -C 6 cycloalkyloxy. Examples include, but are not limited to, cyclopropanoxy and cyclobutanoxy. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the oxygen atom.
[0154] “Cycloalkenyloxy” refers to a cycloalkenyl-O— group in which the cycloalkenyl is as defined herein. Preferably the cycloalkenyloxy is a C 1 -C 6 cycloalkenyloxy. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the oxygen atom.
[0155] Failure of treatment can be defined as condition in which a non-fasting blood glucose level of less than 200 mg/dl and a blood glucose level during fasting (deprived of food for at least 8 hr) of less than 126 mg/dl are retained after administration of the agent in its recommended dose.
[0156] “Haloalkyl” refers to an alkyl group as defined herein in which one or more of the hydrogen atoms has been replaced with a halogen atom selected from the group consisting of fluorine, chlorine, bromine and iodine. A haloalkyl group typically has the formula C n H (2n+1−m) X m wherein each X is independently selected from the group consisting of F, Cl, Br and I. In groups of this type n is typically from 1 to 10, more preferably from 1 to 6, most preferably 1 to 3. m is typically 1 to 6, more preferably 1 to 3. Examples of haloalkyl include fluoromethyl, difluoromethyl and trifluoromethyl.
[0157] “Haloalkenyl” refers to an alkenyl group as defined herein in which one or more of the hydrogen atoms has been replaced with a halogen atom independently selected from the group consisting of F, Cl, Br and I.
[0158] “Haloalkynyl” refers to an alkynyl group as defined herein in which one or more of the hydrogen atoms has been replaced with a halogen atom independently selected from the group consisting of F, Cl, Br and I.
[0159] “Halogen” represents chlorine, fluorine, bromine or iodine.
[0160] “Heteroalkyl” refers to a straight- or branched-chain alkyl group preferably having from 2 to 12 carbons, more preferably 2 to 6 carbons in the chain, in which one or more of the carbon atoms (and any associated hydrogen atoms) are each independently replaced by a heteroatomic group selected from S, O, P and NR′ where R′ is selected from the group consisting of H, optionally substituted C 1 -C 12 alkyl, optionally substituted C 3 -C 12 cycloalkyl, optionally substituted C 6 -C 18 aryl, and optionally substituted C 1 -C 18 heteroaryl. Exemplary heteroalkyls include alkyl ethers, secondary and tertiary alkyl amines, amides, alkyl sulfides, and the like. Examples of heteroalkyl also include hydroxyC 1 -C 6 alkyl, C 1 -C 6 alkyloxyC 1 -C 6 alkyl, aminoC 1 -C 6 alkyl, C 1 -C 6 alkylaminoC 1 -C 6 alkyl, and di(C 1 -C 6 alkyl)aminoC 1 -C 6 alkyl. The group may be a terminal group or a bridging group.
[0161] “Heteroalkyloxy” refers to a heteroalkyl-O— group in which heteroalkyl is as defined herein. Preferably the heteroalkyloxy is a C 2 -C 6 heteroalkyloxy. The group may be a terminal group or a bridging group.
[0162] “Heteroaryl” either alone or part of a group refers to groups containing an aromatic ring (preferably a 5 or 6 membered aromatic ring) having one or more heteroatoms as ring atoms in the aromatic ring with the remainder of the ring atoms being carbon atoms. Suitable heteroatoms include nitrogen, oxygen and sulphur. Examples of heteroaryl include thiophene, benzothiophene, benzofuran, benzimidazole, benzoxazole, benzothiazole, benzisothiazole, naphtho[2,3-b]thiophene, furan, isoindolizine, xantholene, phenoxatine, pyrrole, imidazole, pyrazole, pyridine, pyrazine, pyrimidine, pyridazine, tetrazole, indole, isoindole, 1H-indazole, purine, quinoline, isoquinoline, phthalazine, naphthyridine, quinoxaline, cinnoline, carbazole, phenanthridine, acridine, phenazine, thiazole, isothiazole, phenothiazine, oxazole, isooxazole, furazane, phenoxazine, 2-, 3- or 4-pyridyl, 2-, 3-, 4-, 5-, or 8-quinolyl, 1-, 3-, 4-, or 5-isoquinolinyl 1-, 2-, or 3-indolyl, and 2-, or 3-thienyl. A heteroaryl group is typically a C 1 -C 18 heteroaryl group. The group may be a terminal group or a bridging group.
[0163] “Heteroarylalkyl” means a heteroaryl-alkyl group in which the heteroaryl and alkyl moieties are as defined herein. Preferred heteroarylalkyl groups contain a lower alkyl moiety. Exemplary heteroarylalkyl groups include pyridylmethyl. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the alkyl group.
[0164] “Heteroarylalkenyl” means a heteroaryl-alkenyl- group in which the heteroaryl and alkenyl moieties are as defined herein. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the alkenyl group.
[0165] “Heteroarylheteroalkyl” means a heteroaryl-heteroalkyl- group in which the heteroaryl and heteroalkyl moieties are as defined herein. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the heteroalkyl group.
[0166] “Heteroaryloxy” refers to a heteroaryl-O— group in which the heteroaryl is as defined herein. Preferably the heteroaryloxy is a C 1 -C 18 heteroaryloxy. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the oxygen atom.
[0167] “Heterocyclic” refers to saturated, partially unsaturated or fully unsaturated monocyclic, bicyclic or polycyclic ring system containing at least one heteroatom selected from the group consisting of nitrogen, sulfur and oxygen as a ring atom. Examples of heterocyclic moieties include heterocycloalkyl, heterocycloalkenyl and heteroaryl.
[0168] “Heterocycloalkenyl” refers to a heterocycloalkyl group as defined herein but containing at least one double bond. A heterocycloalkenyl group typically is a C 2 -C 12 heterocycloalkenyl group. The group may be a terminal group or a bridging group.
[0169] “Heterocycloalkyl” refers to a saturated monocyclic, bicyclic, or polycyclic ring containing at least one heteroatom selected from nitrogen, sulfur, oxygen, preferably from 1 to 3 heteroatoms in at least one ring. Each ring is preferably from 3 to 10 membered, more preferably 4 to 7 membered. Examples of suitable heterocycloalkyl substituents include pyrrolidyl, tetrahydrofuryl, tetrahydrothiofuranyl, piperidyl, piperazyl, tetrahydropyranyl, morphilino, 1,3-diazapane, 1,4-diazapane, 1,4-oxazepane, and 1,4-oxathiapane. A heterocycloalkyl group typically is a C 2 -C 12 heterocycloalkyl group. The group may be a terminal group or a bridging group.
[0170] “Heterocycloalkylalkyl” refers to a heterocycloalkyl-alkyl- group in which the heterocycloalkyl and alkyl moieties are as defined herein. Exemplary heterocycloalkylalkyl groups include (2-tetrahydrofuryl)methyl, (2-tetrahydrothiofuranyl)methyl. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the alkyl group.
[0171] “Heterocycloalkylalkenyl” refers to a heterocycloalkyl-alkenyl- group in which the heterocycloalkyl and alkenyl moieties are as defined herein. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the alkenyl group.
[0172] “Heterocycloalkylheteroalkyl” means a heterocycloalkyl-heteroalkyl- group in which the heterocycloalkyl and heteroalkyl moieties are as defined herein. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the heteroalkyl group.
[0173] “Heterocycloalkyloxy” refers to a heterocycloalkyl-O— group in which the heterocycloalkyl is as defined herein. Preferably the heterocycloalkyloxy is a C 1 -C 6 heterocycloalkyloxy. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the oxygen atom.
[0174] “Heterocycloalkenyloxy” refers to a heterocycloalkenyl-O— group in which heterocycloalkenyl is as defined herein. Preferably the Heterocycloalkenyloxy is a C 1 -C 6 heterocycloalkenyloxy. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the oxygen atom.
[0175] “Hydroxyalkyl” refers to an alkyl group as defined herein in which one or more of the hydrogen atoms has been replaced with an OH group. A hydroxyalkyl group typically has the formula C n H (2n+1−x) (OH) x . In groups of this type n is typically from 1 to 10, more preferably from 1 to 6, most preferably 1 to 3. x is typically 1 to 6, more preferably 1 to 3.
[0176] “Sulfinyl” means an R—S(═O)— group in which the R group may be OH, alkyl, cycloalkyl, heterocycloalkyl; aryl or heteroaryl group as defined herein. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the sulfur atom.
[0177] “Sulfinylamino” means an R—S(═O)—NH— group in which the R group may be OH, alkyl, cycloalkyl, heterocycloalkyl; aryl or heteroaryl group as defined herein. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the nitrogen atom.
[0178] “Sulfonyl” means an R—S(═O) 2 — group in which the R group may be OH, alkyl, cycloalkyl, heterocycloalkyl; aryl or heteroaryl group as defined herein. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the sulfur atom.
[0179] “Sulfonylamino” means an R—S(═O) 2 —NH— group. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the nitrogen atom.
[0180] It is understood that included in the family of compounds of Formula (I) are isomeric forms including diastereoisomers, enantiomers, tautomers, and geometrical isomers in “E” or “Z” configurational isomer or a mixture of E and Z isomers. It is also understood that some isomeric forms such as diastereomers, enantiomers, and geometrical isomers can be separated by physical and/or chemical methods and by those skilled in the art. For those compounds where there is the possibility of geometric isomerism the applicant has drawn the isomer that the compound is thought to be although it will be appreciated that the other isomer may be the correct structural assignment.
[0181] Some of the compounds of the disclosed embodiments may exist as single stereoisomers, racemates, and/or mixtures of enantiomers and/or diastereomers. All such single stereoisomers, racemates and mixtures thereof, are intended to be within the scope of the subject matter described and claimed.
[0182] Additionally, Formula (I) is intended to cover, where applicable, solvated as well as unsolvated forms of the compounds. Thus, each formula includes compounds having the indicated structure, including the hydrated as well as the non-hydrated forms.
[0183] The term “pharmaceutically acceptable salts” refers to salts that retain the desired biological activity of the above-identified compounds, and include pharmaceutically acceptable acid addition salts and base addition salts. Suitable pharmaceutically acceptable acid addition salts of compounds of Formula (I) may be prepared from an inorganic acid or from an organic acid. Examples of such inorganic acids are hydrochloric, sulfuric, and phosphoric acid. Appropriate organic acids may be selected from aliphatic, cycloaliphatic, aromatic, heterocyclic carboxylic and sulfonic classes of organic acids, examples of which are formic, acetic, propanoic, succinic, glycolic, gluconic, lactic, malic, tartaric, citric, fumaric, maleic, alkyl sulfonic, arylsulfonic. Additional information on pharmaceutically acceptable salts can be found in Remington's Pharmaceutical Sciences, 19th Edition, Mack Publishing Co., Easton, Pa. 1995. In the case of agents that are solids, it is understood by those skilled in the art that the inventive compounds, agents and salts may exist in different crystalline or polymorphic forms, all of which are intended to be within the scope of the present invention and specified formulae.
[0184] “Prodrug” means a compound that undergoes conversion to a compound of formula (I) within a biological system, usually by metabolic means (e.g. by hydrolysis, reduction or oxidation). For example an ester prodrug of a compound of formula (I) containing a hydroxyl group may be convertible by hydrolysis in vivo to the parent molecule. Suitable esters of compounds of formula (I) containing a hydroxyl group, are for example acetates, citrates, lactates, tartrates, malonates, oxalates, salicylates, propionates, succinates, fumarates, maleates, methylene-bis-p-hydroxynaphthoates, gestisates, isethionates, di-p-toluoyltartrates, methanesulphonates, ethanesulphonates, benzenesulphonates, p-toluenesulphonates, cyclohexylsulphamates and quinates. As another example an ester prodrug of a compound of formula (I) containing a carboxy group may be convertible by hydrolysis in vivo to the parent molecule. (Examples of ester prodrugs are those described by F. J. Leinweber, Drug Metab. Res., 18:379, 1987). Similarly, an acyl prodrug of a compound of formula (I) containing an amino group may be convertible by hydrolysis in vivo to the parent molecule (Many examples of prodrugs for these and other functional groups, including amines, are described in Prodrugs: Challenges and Rewards (Parts 1 and 2); Ed V. Stella, R. Borchardt, M. Hageman, R. Oliyai, H. Maag and J Tilley; Springer, 2007).
[0185] The term “therapeutically effective amount” or “effective amount” is an amount sufficient to effect beneficial or desired clinical results. An effective amount can be administered in one or more administrations. An effective amount is typically sufficient to palliate, ameliorate, stabilize, reverse, slow or delay the progression of the disease state.
[0186] Specific compounds of the invention include the following:
[0000]
[0000] or pharmaceutically acceptable salt, isomer or prodrug thereof.
[0187] The compounds have the ability to inhibit 11β-HSD1. The ability to inhibit 11β-HSD1 may be a result of the compounds acting directly and solely on the 11β-HSD1 to modulate/potentiate biological activity. However, it is understood that the compounds may also act at least partially on other factors associated with 11β-HSD1 activity.
[0188] The inhibition of 11β-HSD1 may be carried out in any of a number of ways known in the art. For example if inhibition of 11β-HSD1 in vitro is desired an appropriate amount of the compound may be added to a solution containing the 11β-HSD1. In circumstances where it is desired to inhibit 11β-HSD1 in a mammal, the inhibition of the 11β-HSD1 typically involves administering the compound to a mammal containing the 11β-HSD1.
[0189] Accordingly the compounds may find a multiple number of applications in which their ability to inhibit 11β-HSD1 enzyme of the type mentioned above can be utilised.
[0190] Accordingly compounds of the invention would be expected to have useful therapeutic properties especially in relation to diabetes, hyperglycemia, low glucose tolerance, hyperinsulinemia, hyperlipidemia, hypertriglyceridemia, hypercholesterolemia, dyslipidemia, obesity, abdominal obesity, glaucoma, hypertension, atherosclerosis and its sequelae, retinopathy, nephropathy, neuropathy, osteoporosis, osteoarthritis, dementia, depression, neurodegenerative disease, psychiatric disorders, Cushing's Disease, Cushing's syndrome, virus diseases, and inflammatory diseases.
[0191] Administration of compounds within Formula (I) to humans can be by any of the accepted modes for enteral administration such, as oral or rectal, or by parenteral administration such as subcutaneous, intramuscular, intravenous and intradermal routes. Injection can be bolus or via constant or intermittent infusion. The active compound is typically included in a pharmaceutically acceptable carrier or diluent and in an amount sufficient to deliver to the patient a therapeutically effective dose. In various embodiments the activator compound may be selectively toxic or more toxic to rapidly proliferating cells, e.g. cancerous tumours, than to normal cells.
[0192] In using the compounds of the invention they can be administered in any form or mode which makes the compound bioavailable. One skilled in the art of preparing formulations can readily select the proper form and mode of administration depending upon the particular characteristics of the compound selected, the condition to be treated, the stage of the condition to be treated and other relevant circumstances. We refer the reader to Remingtons Pharmaceutical Sciences, 19 th edition, Mack Publishing Co. (1995) for further information.
[0193] The compounds of the present invention can be administered alone or in the form of a pharmaceutical composition in combination with a pharmaceutically acceptable carrier, diluent or excipient. The compounds of the invention, while effective themselves, are typically formulated and administered in the form of their pharmaceutically acceptable salts as these forms are typically more stable, more easily crystallised and have increased solubility.
[0194] The compounds are, however, typically used in the form of pharmaceutical compositions which are formulated depending on the desired mode of administration. As such in some embodiments the present invention provides a pharmaceutical composition including a compound of Formula (I) and a pharmaceutically acceptable carrier, diluent or excipient. The compositions are prepared in manners well known in the art.
[0195] The invention in other embodiments provides a pharmaceutical pack or kit comprising one or more containers filled with one or more of the ingredients of the pharmaceutical compositions of the invention. In such a pack or kit can be found a container having a unit dosage of the agent(s). The kits can include a composition comprising an effective agent either as concentrates (including lyophilized compositions), which can be diluted further prior to use or they can be provided at the concentration of use, where the vials may include one or more dosages. Conveniently, in the kits, single dosages can be provided in sterile vials so that the physician can employ the vials directly, where the vials will have the desired amount and concentration of agent(s). Associated with such container(s) can be various written materials such as instructions for use, or a notice in the form prescribed by a governmental agency regulating the manufacture, use or sale of pharmaceuticals or biological products, which notice reflects approval by the agency of manufacture, use or sale for human administration.
[0196] The compounds of the invention may be used or administered in combination with one or more additional drug(s) for the treatment of the disorder/diseases mentioned. The components can be administered in the same formulation or in separate formulations. If administered in separate formulations the compounds of the invention may be administered sequentially or simultaneously with the other drug(s).
[0197] In addition to being able to be administered in combination with one or more additional drugs, the compounds of the invention may be used in a combination therapy. When this is done the compounds are typically administered in combination with each other. Thus one or more of the compounds of the invention may be administered either simultaneously (as a combined preparation) or sequentially in order to achieve a desired effect. This is especially desirable where the therapeutic profile of each compound is different such that the combined effect of the two drugs provides an improved therapeutic result.
[0198] Pharmaceutical compositions of this invention for parenteral injection comprise pharmaceutically acceptable sterile aqueous or nonaqueous solutions, dispersions, suspensions or emulsions as well as sterile powders for reconstitution into sterile injectable solutions or dispersions just prior to use. Examples of suitable aqueous and nonaqueous carriers, diluents, solvents or vehicles include water, ethanol, polyols (such as glycerol, propylene glycol, polyethylene glycol, and the like), and suitable mixtures thereof, vegetable oils (such as olive oil), and injectable organic esters such as ethyl oleate. Proper fluidity can be maintained, for example, by the use of coating materials such as lecithin, by the maintenance of the required particle size in the case of dispersions, and by the use of surfactants.
[0199] These compositions may also contain adjuvants such as preservative, wetting agents, emulsifying agents, and dispersing agents. Prevention of the action of micro-organisms may be ensured by the inclusion of various antibacterial and antifungal agents, for example, paraben, chlorobutanol, phenol sorbic acid, and the like. It may also be desirable to include isotonic agents such as sugars, sodium chloride, and the like. Prolonged absorption of the injectable pharmaceutical form may be brought about by the inclusion of agents that delay absorption such as aluminium monostearate and gelatin.
[0200] If desired, and for more effective distribution, the compounds can be incorporated into slow release or targeted delivery systems such as polymer matrices, liposomes, and microspheres.
[0201] The injectable formulations can be sterilized, for example, by filtration through a bacterial-retaining filter, or by incorporating sterilizing agents in the form of sterile solid compositions that can be dissolved or dispersed in sterile water or other sterile injectable medium just prior to use.
[0202] Solid dosage forms for oral administration include capsules, tablets, pills, powders, and granules. In such solid dosage forms, the active compound is mixed with at least one inert, pharmaceutically acceptable excipient or carrier such as sodium citrate or dicalcium phosphate and/or a) fillers or extenders such as starches, lactose, sucrose, glucose, mannitol, and silicic acid, b) binders such as, for example, carboxymethylcellulose, alginates, gelatin, polyvinylpyrrolidone, sucrose, and acacia, c) humectants such as glycerol, d) disintegrating agents such as agar-agar, calcium carbonate, potato or tapioca starch, alginic acid, certain silicates, and sodium carbonate, e) solution retarding agents such as paraffin, f) absorption accelerators such as quaternary ammonium compounds, g) wetting agents such as, for example, cetyl alcohol and glycerol monostearate, h) absorbents such as kaolin and bentonite clay, and i) lubricants such as talc, calcium stearate, magnesium stearate, solid polyethylene glycols, sodium lauryl sulfate, and mixtures thereof. In the case of capsules, tablets and pills, the dosage form may also comprise buffering agents.
[0203] Solid compositions of a similar type may also be employed as fillers in soft and hard-filled gelatin capsules using such excipients as lactose or milk sugar as well as high molecular weight polyethylene glycols and the like.
[0204] The solid dosage forms of tablets, dragees, capsules, pills, and granules can be prepared with coatings and shells such as enteric coatings and other coatings well known in the pharmaceutical formulating art. They may optionally contain opacifying agents and can also be of a composition that they release the active ingredient(s) only, or preferentially, in a certain part of the intestinal tract, optionally, in a delayed manner. Examples of embedding compositions which can be used include polymeric substances and waxes.
[0205] The active compounds can also be in microencapsulated form, if appropriate, with one or more of the above-mentioned excipients.
[0206] Liquid dosage forms for oral administration include pharmaceutically acceptable emulsions, solutions, suspensions, syrups and elixirs. In addition to the active compounds, the liquid dosage forms may contain inert diluents commonly used in the art such as, for example, water or other solvents, solubilizing agents and emulsifiers such as ethyl alcohol, isopropyl alcohol, ethyl carbonate, ethyl acetate, benzyl alcohol, benzyl benzoate, propylene glycol, 1,3-butylene glycol, dimethyl formamide, oils (in particular, cottonseed, groundnut, corn, germ, olive, castor, and sesame oils), glycerol, tetrahydrofurfuryl alcohol, polyethylene glycols and fatty acid esters of sorbitan, and mixtures thereof.
[0207] Besides inert diluents, the oral compositions can also include adjuvants such as wetting agents, emulsifying and suspending agents, sweetening, flavoring, and perfuming agents.
[0208] Suspensions, in addition to the active compounds, may contain suspending agents as, for example, ethoxylated isostearyl alcohols, polyoxyethylene sorbitol and sorbitan esters, microcrystalline cellulose, aluminium metahydroxide, bentonite, agar-agar, and tragacanth, and mixtures thereof.
[0209] Compositions for rectal or vaginal administration are preferably suppositories which can be prepared by mixing the compounds of this invention with suitable non-irritating excipients or carriers such as cocoa butter, polyethylene glycol or a suppository wax which are solid at room temperature but liquid at body temperature and therefore melt in the rectum or vaginal cavity and release the active compound.
[0210] Dosage forms for topical administration of a compound of this invention include powders, patches, sprays, ointments and inhalants. The active compound is mixed under sterile conditions with a pharmaceutically acceptable carrier and any needed preservatives, buffers, or propellants which may be required.
[0211] The amount of compound administered will preferably treat and reduce or alleviate the condition. A therapeutically effective amount can be readily determined by an attending diagnostician by the use of conventional techniques and by observing results obtained under analogous circumstances. In determining the therapeutically effective amount a number of factors are to be considered including but not limited to, the species of animal, its size, age and general health, the specific condition involved, the severity of the condition, the response of the patient to treatment, the particular compound administered, the mode of administration, the bioavailability of the preparation administered, the dose regime selected, the use of other medications and other relevant circumstances.
[0212] A preferred dosage will be a range from about 0.01 to 300 mg per kilogram of body weight per day. A more preferred dosage will be in the range from 0.1 to 100 mg per kilogram of body weight per day, more preferably from 0.2 to 80 mg per kilogram of body weight per day, even more preferably 0.2 to 50 mg per kilogram of body weight per day. A suitable dose can be administered in multiple sub-doses per day.
[0213] The compound of the invention may also be administered in combination with (or simultaneously or sequentially with) an adjuvant to increase compound performance. Suitable adjuvants may include (a) dipeptidyl peptidase-IV (DP-IV) inhibitors; (b) insulin sensitizing agents; (iv) biguanides; (c) insulin and insulin mimetics; (d) sulfonylureas and other insulin secretagogues; (e) alpha-glucosidase inhibitors; and (f) GLP-1, GLP-1 analogs, and GLP-1 receptor agonists. The adjuvants may be part of the same composition, or the adjuvants may be administered separately (either simultaneously or sequentially). The order of the administration of the composition and the adjuvant will generally known to the medical practitioner involved and may be varied.
Synthesis of Compounds of the Invention
[0214] The agents of the various embodiments may be prepared using the reaction routes and synthesis schemes as described below, employing the techniques available in the art using starting materials that are readily available. The preparation of particular compounds of the embodiments is described in detail in the following examples, but the artisan will recognize that the chemical reactions described may be readily adapted to prepare a number of other agents of the various embodiments. For example, the synthesis of non-exemplified compounds may be successfully performed by modifications apparent to those skilled in the art, e.g. by appropriately protecting interfering groups, by changing to other suitable reagents known in the art, or by making routine modifications of reaction conditions. A list of suitable protecting groups in organic synthesis can be found in T. W. Greene's Protective Groups in Organic Synthesis, 3 rd Edition, John Wiley & Sons, 1991. Alternatively, other reactions disclosed herein or known in the art will be recognized as having applicability for preparing other compounds of the various embodiments.
[0215] Reagents useful for synthesizing compounds may be obtained or prepared according to techniques known in the art.
[0216] The symbols, abbreviations and conventions in the processes, schemes, and examples are consistent with those used in the contemporary scientific literature. Specifically but not meant as limiting, the following abbreviations may be used in the examples and throughout the specification.
g (grams) L (liters) Hz (Hertz) mol (moles) RT (room temperature) min (minutes) MeOH (methanol) CHCl 3 (chloroform) DCM (dichloromethane) DMSO (dimethylsulfoxide) EtOAc (ethyl acetate) mg (milligrams) mL (milliliters) psi (pounds per square inch) mM (millimolar) MHz (megahertz) h (hours) TLC (thin layer chromatography) EtOH (ethanol) CDCl 3 (deuterated chloroform) HCl (hydrochloric acid) DMF (N, N-dimethylformamide) THF (tetrahydrofuran) K 2 CO 3 (potassium carbonate) Na 2 SO 4 (sodium sulfate) RM (Reaction Mixture)
[0243] Unless otherwise indicated, all temperatures are expressed in ° C. (degree centigrade). All reactions conducted at room temperature unless otherwise mentioned.
[0244] All the solvents and reagents used are commercially available and purchased from Sigma Aldrich, Fluka, Acros, Spectrochem, Alfa Aesar, Avra, Qualigens, Merck, Rankem and Leonid Chemicals.
[0245] 1 H NMR spectra were recorded on a Bruker AV 300. 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), or br (broad).
[0246] Mass spectra were obtained on single quadruple 6120 LCMS from Agilent technologies, using either atmospheric chemical ionization (APCI) or Electrospray ionization (ESI) or in the combination of these two sources.
[0247] All samples were run on SHIMADZU system with an LC-20 AD pump, SPD-M20A diode array detector, SIL-20A auto sampler.
Synthetic Scheme 1
[0248] One scheme for making certain compounds of the invention is shown in scheme 1 below.
[0000]
Synthesis of 4-oxotricyclo[3.3.1.1 3,7 ]dec-2-yl methanesulfonate (Intermediate-1)
[0249] A 1000 mL RB flask fitted with magnetic stirrer was charged with methanesulfonic acid (416.0 g, 4328.8 mmol) and Starting Material-1 (50.0 g, 333 mmol). To this sodium azide (23.0 g, 351 mmol) was added portion wise for 2 hours. Then reaction mixture was stirred at 20-25° C. for 3 days. Upon completion of the reaction (reaction monitored by TLC), reaction mixture was quenched with ice-water (3000 mL) and extracted with ethyl acetate (1000×3 mL). The organic layer was washed with brine solution, dried over anhydrous sodium sulfate and concentrated to give title Intermediate-1 (54.0 g, yield=66%).
Synthesis of bicyclo[3.3.1]non-6-ene-3-carboxylic acid (Intermediate-2)
[0250] A 2000 mL RB flask fitted with magnetic stirrer was charged with 1200 mL of ethanol and Intermediate-1 (54.0 g, 221.3 mmol). Potassium hydroxide (84.0 g, 150 mmol) was further added to this reaction mixture followed by addition of 950 mL of water. The reaction mixture was stirred at 110° C. for 12 hours. After completion of the reaction (reaction was monitored by TLC), reaction mixture was concentrated under vacuum. The resulted crude material was acidified with 1N HCl (pH=2) and extracted with ethyl acetate (250×3 mL). The organic layer was washed with brine solution, dried over anhydrous sodium sulfate and concentrated to give Intermediate-2 (32.0 g, yield=88%).
Synthesis of methyl bicyclo[3.3.1]non-6-en-3-ylcarbamate (Intermediate-3)
[0251] A 500 mL RB flask fitted with magnetic stirrer under nitrogen atmosphere charged with toluene (100 mL), Intermediate-2 (16.0 g, 96 mmol) and DPPA (28.8 g, 105 mmol). Reaction mixture was cooled to 0° C., and then triethylamine (15.4 g, 143.9 mmol) was added. The reaction mixture was stirred at room temperature for 1 hour. Then reaction mixture was heated at 80° C. for 8 h and 12 h at room temperature. To this 100 mL of methanol was added and refluxed for 12 hours. After the reaction, it was concentrated under vacuum. Obtained Crude was extracted with ethyl acetate. The organic layer was washed with 1N HCl, Saturated NaHCO 3 solution, brine solution and was then dried over anhydrous sodium sulfate and concentrated. Crude material was purified by silica gel column chromatography eluting with 6% of EtOAc in to give Intermediate-3 (8.0 g, yield=42%).
Synthesis of methyl 2-azatricyclo[3.3.1.1 3,7 ]decane-2-carboxylate (Intermediate-4)
[0252] A 100 mL RB flask fitted with magnetic stirrer was charged with 50 mL of dichloromethane and Intermediate-4 (5.0 g, 25.6 mmol). To this reaction mixture, triflouromethane sulfonic acid (19.2 g, 125.2 mmol) was added at 0° C. The reaction mixture was then stirred at room temperature for 12 hours. After completion of reaction, the reaction mixture was quenched with water and extracted with dichloromethane. The organic layer was washed with saturated sodium bicarbonate solution, brine solution and the reaction mass was dried over anhydrous sodium sulfate and was concentrated to give Intermediate-4 (4.3 g, yield=86%).
Synthesis of 2-azatricyclo[3.3.1.1 3,7 ]decane (Intermediate-5)
[0253] A 50 mL pressurized seal tube fitted with magnetic stirrer was charged with Intermediate-4 (3.0 g, 15 mmol) in HCl containing 1,4-Dioxane (20 mL). Then the reaction mixture was stirred at 90° C. for 8 hours. After completion of the reaction (reaction was monitored by LCMS) it was concentrated followed by trituration with mixture of hexane:ether (1:1) to give Intermediate-5 (3.0 g, yield=100%).
Synthesis of tert-butyl 5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]decane-2-carboxylate (Intermediate-6)
[0254] A 250 mL RB fitted with magnetic stirrer was charged with Intermediate 5 (3.0 g, 21.6 mmol), concentrated nitric acid (30 mL), and H 2 SO 4 (5 mL). The reaction mixture was stirred at 80° C. for 12 hours. Upon completion of the reaction (reaction was monitored by LC-MS) reaction mixture was quenched with water and basified with sodium carbonate. The aqueous layer was washed with DCM (100 mL) and resulting aqueous layer was diluted with THF (200 mL) and cooled to 0° C. The pH of the mixture was adjusted to basic using Triethyl amine (5 mL). To this reaction mixture Boc-anhydride (6.0 g, 27.52 mmol) was added. The resulting mixture was stirred at room temperature for 12 hours. Upon completion of the reaction (reaction was monitored by LC-MS) reaction mixture was extracted with Ethyl acetate (100 mL×3). Combined organic layer was washed with water and brine and the reaction mass was dried over sodium sulfate. Organic layer was concentrated to obtain a crude intermediate which was then purified by silica gel column chromatography eluting with 40% of EtOAc to give Intermediate-6 (2.5 g, yield=50%).
Synthesis of 2-azatricyclo[3.3.1.1 3,7 ]decan-5-ol (Intermediate-7)
[0255] A 100 mL RB flask fitted with magnetic stirrer was charged with Intermediate-6 (5.5 g, 21.5 mmol) in DCM (30 mL). The reaction mixture thus formed was cooled to 0° C. to which trifluoroacetic acid (7.4 g, 65.2 mmol) was added and stirred for 4 hours. After completion of the reaction (reaction was monitored by LCMS) the reaction mixture was concentrated followed by trituration with mixture of hexane:ether (1:1) to give Intermediate-7 (3.4 g, yield=100%).
Synthesis of methyl 2-azatricyclo[3.3.1.1 3,7 ]decane-5-carboxylate, intermediate-8
[0256] To 2-azatricyclo[3.3.1.1 3,7 ]decan-5-ol (Intermediate-7) (1.5 g, 5.9 mmol, 1 eq), 98% formic acid (9 ml) was added drop wise with vigorous gas evolution for over 30 minutes to a rapidly stirred 30% oleum (36 ml) heated to 60° C. Upon completion of this addition, 99% formic acid (9 ml) was slowly added for the next 30 minutes. The reaction mixture was stirred for another 1 hr at 60° C. (monitored by LCMS). The reaction mixture thus formed was then slowly poured into vigorously stirred methanol (75 ml) cooled to 00° C. The mixture was allowed to slowly warm to room temperature while stirring the reaction mixture for 4-5 hrs. The mixture was then concentrated under vacuum. The residue was poured into ice (30 g) and basified with saturated Na 2 CO 3 solution. The aqueous layer was extracted with 5% methanol in DCM (3×100 ml). Combined organic layer was washed with brine and dried over Na 2 SO 4 . The organic layer was finally concentrated to get intermediate-8, (550 mg, 50% yield) as an oily mass.
Synthesis of 2-tert-butyl 5-methyl 2-azatricyclo[3.3.1.1 3,7 ]decane-2,5-dicarboxylate, intermediate-9
[0257] Methyl 2-azatricyclo[3.3.1.1 3,7 ]decane-5-carboxylate, Intermediate-8 (0.32 g, 1.6 mmol) was added into THF (5 mL) and cooled to 0° C. Triethyl amine (1.3 mL) was added to the reaction mixture followed by addition of Boc-anhydride (0.5 g, 1.96 mmol). The resulting mixture was stirred at room temperature for 6 hours. Upon completion of the reaction (reaction was monitored by LC-MS) reaction mixture was extracted with Ethyl acetate (100 mL×3). Combined organic layer was washed with water and brine and was dried over sodium sulfate. Organic layer was concentrated to give crude intermediate-9, which was purified by silica gel column chromatography eluting with 15% of EtOAc to give Intermediate-9 (0.32 g, yield=66%).
Synthesis of 2-(tert-butoxycarbonyl)-2-azatricyclo[3.3.1.1 3,7 ]decane-5-carboxylic acid, Intermediate-10
[0258] To a 0° C. cooled stirred solution of 2-tert-butyl 5-methyl 2-azatricyclo[3.3.1.1 3,7 ]decane-2,5-dicarboxylate, intermediate-9 (0.16 g, 0.5 mmol) dissolved in methanol (3 ml), THF (1 ml) and water (1 ml), LiOH (50 mg, 2 mmol) was added and the resulting reaction mass was stirred at room temperature for 6 hrs. Upon completion of the reaction (reaction monitored by TLC), the solvent present in the reaction mixture was completely removed under vacuum and the crude residue was acidified with saturated citric acid solution and extracted with ethyl acetate (3×15 ml). The organic layer was then washed with brine solution and dried over sodium sulfate and was finally concentrated under vacuum to get intermediate-10 as an oily mass, 0.16 g (95%).
Synthesis of tert-butyl 5-carbamoyl-2-azatricyclo[3.3.1.1 3,7 ]decane-2-carboxylate, Intermediate-11
[0259] A 50 mL RB flask fitted with magnetic stirrer was charged with 5 mL of acetonitrile and 2-(tert-butoxycarbonyl)-2-azatricyclo[3.3.1.1 3,7 ]decane-5-carboxylic acid, Intermediate-10 (0.16 g, 0.56 mmol). Under N 2 atm, pyridine (60 mg, 0.6 mmol) and Boc-anhydride (0.148 g, 0.6 mmol) was added to the reaction mixture and was stirred for 1 hr. After 1 hr, ammonium bicarbonate solid (75 mg, 0.9 mmol) was added and the reaction mixture was stirred at room temperature for 12 hours. After completion of the reaction (reaction was monitored by TLC), reaction mixture was concentrated under vacuum. The resulted crude material was extracted with ethyl acetate (25 ml×3). The organic layer was washed with ammonium chloride solution and saturated sodium bi carbonate solution. It was then dried over anhydrous sodium sulfate and concentrated to give Intermediate-11, as an oily mass (0.14 g, yield=87%).
Synthesis of 2-azatricyclo[3.3.1.1 3,7 ]decane-5-carboxamide, Intermediate-12
[0260] To a 100 mL RB flask fitted with magnetic stirrer was charged tert-butyl 5-carbamoyl-2-azatricyclo[3.3.1.1 3,7 ]decane-2-carboxylate, Intermediate-11 (0.1 g, 0.0357 mmol) in DCM (5 mL). The reaction mixture was cooled to 0° C. and trifluoroacetic acetic anhydride (0.21 g, 0.17 mmol) was added and stirred for 4 hours. After completion of the reaction (reaction was monitored by LCMS) reaction mixture was concentrated followed by trituration with mixture of hexane:ether (1:1) to give Intermediate-12 (0.09 g, yield=90%).
Synthesis of tert-butyl 5-cyano-2-azatricyclo[3.3.1.1 3,7 ]decane-2-carboxylate, Intermediate-13
[0261] A 50 mL RB flask fitted with magnetic stirrer was charged with 5 mL of DCM and tert-butyl 5-carbamoyl-2-azatricyclo[3.3.1.1 3,7 ]decane-2-carboxylate, Intermediate-11 (0.8 g, 2.8 mmol). Under N 2 atm, triethyl amine (1.15 g, 11.4 mmol) and trifluoroacetic anhydride (2.4 g, 11.4 mmol) was added and stirred for 6 hr. After completion of the reaction (reaction was monitored by TLC), reaction mixture was quenched with KHSO4 solution and extracted with DCM (50 ml×3). The organic layer was washed with saturated sodium bi carbonate solution followed by brine solution. Finally the reaction mixture was dried over anhydrous sodium sulfate and concentrated to give crude Intermediate-13, which was subjected to column chromatogram (10% EtOAc in PE) as a off-white solid (0.5 g, yield=70%).
Synthesis of 2-azatricyclo[3.3.1.1 3,7 ]decane-5-carbonitrile, Intermediate-14
[0262] A 50 mL RB flask fitted with magnetic stirrer was charged with tert-butyl 5-cyano-2-azatricyclo[3.3.1.1 3,7 ]decane-2-carboxylate, Intermediate-13 (0.5 g, 1.98 mmol) in DCM (5 mL). Then reaction mixture was cooled to 0° C. and trifluoroacetic acid (1.1 g, 9.54 mmol) was added and stirred for 4 hours. After completion of the reaction (reaction was monitored by LCMS) the reaction mixture was concentrated followed by the process of trituration with mixture of hexane:ether (1:1) to give Intermediate-14 (0.5 g, yield=97%).
Synthesis of tert-butyl 5-(hydroxymethyl)-2-azatricyclo[3.3.1.1 3,7 ]decane-2-carboxylate, Intermediate-15
[0263] A 50 mL RB flask fitted with magnetic stirrer was charged with 5 mL of THF, 2-tert-butyl 5-methyl 2-azatricyclo[3.3.1.1 3,7 ]decane-2,5-dicarboxylate, Intermediate-9 (0.15 g, 0.5 mmol) and cooled to 0° C. Under N 2 atm, LAH was added portion wise (30 mg, 0.8 mmol) and stirred for 2 hr. After completion of the reaction (reaction was monitored by TLC), reaction mixture was quenched with ethyl acetate and washed with water followed by 1N HCl solution. The organic layer was washed with brine solution. Finally the organic layer was dried over anhydrous sodium sulfate and concentrated to give crude Intermediate-15, as an oily mass (0.12 g, yield=88%).
Synthesis of 2-azatricyclo[3.3.1.1 3,7 ]dec-5-ylmethanol, Intermediate-16
[0264] To a 50 mL RB flask fitted with magnetic stirrer tert-butyl 5-(hydroxymethyl)-2-azatricyclo[3.3.1.1 3,7 ]decane-2-carboxylate, Intermediate-15 (0.12 g, 0.45 mmol) in DCM (5 mL) was added. The reaction mixture was cooled to 00° C. followed by addition of trifluoroacetic acid (0.26 g, 2.2 mmol). This mixture was stirred for 4 hours. After completion of the reaction (reaction was monitored by LCMS) reaction mixture was concentrated followed by trituration with mixture of hexane:ether (1:1) to give Intermediate-16 (0.12 g, yield=97%) as an oily mass.
Synthesis of tert-butyl 5-methoxy-2-azatricyclo[3.3.1.1 3,7 ]decane-2-carboxylate, Intermediate-17
[0265] A 15 mL seal tube fitted with magnetic stirrer was charged with 5 mL of THF, tert-butyl 5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]decane-2-carboxylate, Intermediate-6 (0.15 g, 0.5 mmol). Potassium hydride (47 mg, 1.1 mmol) was added to this mixture at 0° C., under N 2 atm. The reaction mixture was then stirred at room temperature for 30 minutes. Methyl iodide was slowly added (0.12 g, 0.8 mmol) at 0° C. and the resulting reaction mass was refluxed at 60° C. under sealed condition for 12 hrs. After completion of the reaction (reaction was monitored by TLC), reaction mixture was quenched with cold water and extracted with ethyl acetate (25 ml×3). The organic layer was washed with sodium chloride solution, was dried over anhydrous sodium sulfate and was concentrated to give crude Intermediate-17, which was subjected to column chromatogram (22% EtOAc in PE) to obtain an oily mass (0.1 g, yield=70%).
Synthesis of 5-methoxy-2-azatricyclo[3.3.1.1 3,7 ]decane, Intermediate-18
[0266] To a 50 mL RB flask fitted with magnetic stirrer was charged tert-butyl 5-methoxy-2-azatricyclo[3.3.1.1 3,7 ]decane-2-carboxylate, Intermediate-17 (0.1 g, 0.037 mmol) in DCM (5 mL). Then reaction mixture was cooled to 0° C. and trifluoroacetic acid (0.22 g, 1.8 mmol) was added and stirred for 4 hours. After completion of the reaction (reaction was monitored by LCMS) reaction mixture was concentrated followed by trituration with mixture of hexane:ether (1:1) to give Intermediate-18 (0.09 g, yield=95%) as an oily mass.
Synthesis of tert-butyl 5-(cyclopropylmethoxy)-2-azatricyclo[3.3.1.1 3,7 ]decane-2-carboxylate, Intermediate-19
[0267] A 15 mL seal tube fitted with magnetic stirrer was charged with 5 mL of THF, tert-butyl 5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]decane-2-carboxylate, Intermediate-6 (50 mg, 0.2 mmol). To the tube, potassium hydride (20 mg, 0.5 mmol) was added at 0° C., under N 2 atm. The reaction mass was stirred at room temperature for 30 minutes. To this mixture, cyclopropyl methyl bromide (40 mg, 0.3 mmol) was slowly added at 0° C. and the resulting reaction mass was refluxed at 60° C. under sealed condition for 12 hrs. After completion of the reaction (reaction was monitored by TLC), reaction mixture was quenched with cold water and extracted with ethyl acetate (25 ml×3). The organic layer was washed with sodium chloride solution, dried over anhydrous sodium sulfate and concentrated to give crude Intermediate-17, which was subjected to column chromatogram (18% EtOAc in PE) to obtain an oily mass (50 mg, yield=80%).
Synthesis of 5-(cyclopropylmethoxy)-2-azatricyclo[3.3.1.1 3,7 ]decane, Intermediate-20
[0268] To a 50 mL RB flask fitted with magnetic stirrer was charged tert-butyl 5-(cyclopropylmethoxy)-2-azatricyclo[3.3.1.1 3,7 ]decane-2-carboxylate, Intermediate-19 (50 mg, 0.016 mmol) in DCM (5 mL). Then reaction mixture was cooled to 0° C. and trifluoroacetic acid (0.099 g, 0.084 mmol) was added and stirred for 4 hours. After completion of the reaction (reaction was monitored by LCMS) the reaction mixture was concentrated followed by trituration with mixture of hexane:ether (1:1) to give Intermediate-20 (50 mg, yield=95%) as an oily mass.
Example 1
1-(2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(1H-indol-3-yl) propan-1-one (1)
[0269]
[0000]
Example 1
1-(2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(1H-indol-3-yl)propan-1-one (1)
[0270] Starting Material-2 (0.2 mmol) was added to Intermediate-5 (0.2 mmol) in dichloromethane (DCM), followed by the addition of 1-ethyl-3-(3-dimethylaminopropyl) carbodiimide hydrochcloride (EDCl) (0.26 mmol) and 1-Hydroxybenztriazole (HOBt) (0.23 mmol). The reaction mixture was cooled to 0° C. and was maintained at the same temperature for 30 minutes. Further, Triethylamine (0.93 mmol) was added to the reaction mixture, and the resulting solution was stirred at room temperature for 15 hours. The reaction mass was then diluted with equal ratio of DCM and water, and was washed with 1N HCl solution followed by NaHCO 3 and brine solution. The organic layer was separated and dried over anhydrous sodium sulfate. The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (1) (9.5 mg, gummy material). 1 H NMR (300 MHz, CDCl3): δ7.91 (brs, 1H), 7.54 (d, 1H), 7.28 (d, 1H), 7.12 (t, 1H), 7.02 (t, 1H), 6.98 (s, 1H), 4.82 (s, 1H), 3.92 (s, 1H), 3.06 (t, 2H), 2.61 (t, 2H), 1.97-1.98 (m, 2H), 1.60-1.75 (m, 10H). LC-MS (M+H) + =309.2; HPLC purity=92.94%.
Example 2
1-(2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(4-methyl-1H-indol-3-yl)propan-1-one (2)
[0271]
[0000]
Synthesis of 4-methyl-1H-indole (Intermediate-21)
[0272] A 100 mL RB flask fitted with magnetic stirrer and reflux condenser was charged with 60 mL of DMF. To the stirred solvent Starting Material-3 (5 g, 33 mmol) was added followed by Dimethyl formamide dimethyl acetal (13.1 mL, 99.2 mmol). To this Pyrrolidie (3.2 mL, 39.6 mmol) was added and the reaction mixture was heated at 120° C. under Nitrogen atmosphere for 21 hours. After completion of the reaction the mixture was cooled to room temperature and the solvent was removed under reduced pressure. The resulting crude mass was taken in ether (250 mL) and was washed with water (50 mL×3), saturated brine solution (50 mL) and the organic layer was dried over anhydrous sodium sulphate and concentrated. Resulted crude material was taken in Ethyl acetate (50 mL). To this 10% Pd/C (1.0 g, 10% w/w) was added and hydrogenated in a parr shaker for 2 hours. After completion of the reaction (reaction monitored by TLC), the mixture was filtered through celite bed. Filtrate was concentrated to give crude product, which was purified by column chromatography on silica gel (120 meshe) using Petroleum ether (60-80) and ethyl acetate as eluent to give Intermediate-21 (1.2 g).
Synthesis of 3-(4-methyl-1H-indol-3-yl)propanoic acid (Intermediate-22)
[0273] A 100 mL RB flask fitted with magnetic stirrer was charged with 2.5 mL of acetic acid. To the stirred solvent acetic anhydride 2.0 mL was added followed by addition of acrylic acid (1.8 mL, 27.4 mmol). To this stirred mixture Intermediate-21 (1.2 g, 9.15 mmol) was added and the reaction mixture was stirred at room temperature for 1 week. After completion of the reaction (reaction was monitored by TLC), reaction mass was basified using 5N NaOH (5 mL) and washed with Ethyl acetate (100 mL×2). The aqueous layer was acidified with concentrated HCl (3 ML) and was extracted using Ethyl acetate (100 mL×3). The combined ethyl acetate layer was washed with brine solution and was concentrated to give Intermediate-22 (350 mg).
Synthesis of Compound (2)
[0274] Compound (2) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate as eluent to obtain Compound (2). 1 H NMR (300 MHz, CDCl3): δ 7.94 (brs, 1H), 7.12 (d, 1H), 6.99 (t, 1H), 6.92 (s, 1H), 6.76 (d, 1H), 4.82 (s, 1H), 3.94 (s, 1H), 3.21 (t, 2H), 2.64 (s, 3H), 2.58 (t, 2H), 2.12-2.17 (m, 1H), 1.64-1.76 (m, 11H). LC-MS (M+H) + =323.2; HPLC purity: 71.84%.
Example 3
1-(2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(1,4-dimethyl-1H-indol-3-yl)propan-1-one (3)
[0275]
Synthesis of Compound (3)
[0276] Compound (3) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate as eluent to obtain Compound (3). 1 H NMR (300 MHz, CDCl3): δ 6.98-7.05 (m, 2H), 6.75-6.78 (m, 2H), 4.82 (s, 1H), 3.93 (s, 1H), 3.63 (s, 3H), 3.16-3.22 (m, 2H), 2.64 (s, 3H), 2.55-2.61 (m, 2H), 1.97-2.01 (m, 2H), 1.75-1.79 (m, 2H), 1.70-1.72 (m, 3H), 1.59-1.65 (m, 5H). LC-MS (M+H) + =337.2; HPLC purity: 79.30%.
Example 4
3-(4-fluoro-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)propan-1-one (4)
[0277]
[0000]
Synthesis of 4-fluoro-1H-indole-3-carbaldehyde (Intermediate-23)
[0278] To a 25 mL RB flask fitted with magnetic stirrer were added DMF (0.413 g) and POCl 3 (0.623 g, 4 mmol) at 0° C. under N 2 atmosphere and the resulting mixture was stirred for 30 minutes at same temperature. Then Starting Material-4 (500 mg, 3.7 mmol) in DMF was added to the mixture and stirred at 40° C. for 1 hour. After completion of the reaction the reaction mixture was cooled to 0° C., quenched with NaOH solution and was extracted with ethyl acetate. Organic layers were concentrated to give crude material, which was then purified by silica-gel column chromatography eluting with hexane:EtOAc to give Intermediate-23 (230 mg) as brown material. LC-MS (M+H) + =164.2.
Synthesis of ethyl (2E)-3-(4-fluoro-1H-indol-3-yl)prop-2-enoate (Intermediate-24)
[0279] To a 100 mL RB flask fitted with magnetic stirrer was charged with Intermediate-23 (0.23 g, 1.4 mmol), Ethyl Malonate (0.204 g, 1.5 mmol) and Piperdine (0.011 g, 0.13 mmol) in Pyridine (10 mL). Resulted reaction mixture was heated at 110° C. for 14 hours. After completion of the reaction, the reaction mixture was concentrated to obtain a crude material which was then dissolved in ethyl acetate and washed with water and brine. Organic layer was then concentrated to give crude material, which was purified by silica-gel column chromatography eluting with hexane:EtOAc to give Intermediate-24 (250 mg).
Synthesis of ethyl 3-(4-fluoro-1H-indol-3-yl)propanoate (Intermediate-25)
[0280] Intermediate-24 (0.24 g, 1.0 mmol) was taken in EtOAc (10 mL) to which 10% Pd/C (50 mg) was added. The resulting reaction mass was stirred under H 2 atmosphere (30 psi) for 4 hours. The reaction mass was filtered through celite bed and concentrated to give Intermediate-25 (240 mg).
Synthesis of 3-(4-fluoro-1H-indol-3-yl)propanoic acid (Intermediate-26)
[0281] Intermediate-25 (100 mg, 0.4 mmol) was taken in EtOH:THF:H 2 O (5 mL:5 mL:1 mL). To this NaOH (51 mg, 1.2 mmol) was added. Resulting reaction mixture was refluxed for 4 hours. After completion of reaction (reaction monitored by TLC), the reaction mixture was concentrated which was diluted with water, acidified (pH=1 to 2) with 1N HCl, extracted with EtOAc and concentrated to give Intermediate-26 (90 mg).
Synthesis of Compound (4)
[0282] Compound (4) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (4). 1 H NMR (300 MHz, CDCl3): δ 8.04 (s, 1H), 6.97-7.07 (m, 2H), 6.94 (s, 1H), 6.65-6.71 (m, 1H), 5.01 (s, 1H), 4.21 (s, 1H), 3.08-3.13 (t, 2H), 2.62-2.67 (t, 2H), 2.24 (s, 1H), 1.53-1.74 (m, 10H) + . LC-MS (M+H) + =343.12; HPLC purity: 95.20%.
Example 5
1-(2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(6-fluoro-1H-indol-3-yl)propan-1-one (5)
[0283]
Synthesis of Compound (5)
[0284] Compound (5) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate as eluent to obtain Compound (5). 1 H NMR (300 MHz, CDCl3): δ 8.02 (brs, 1H), 7.41-7.46 (dd, 1H), 6.95-6.99 (m, 2H), 6.78-6.85 (m, 1H), 4.81 (s, 1H), 3.90 (s, 1H), 3.03-3.08 (t, 2H), 2.63-2.68 (t, 2H), 1.96-2.02 (m, 2H), 1.56-1.76 (m, 10H) + . LC-MS (M+H) + =327.3; HPLC purity: 95.25%.
Example 6
3-(5-fluoro-1H-indol-3-yl)-1-(4-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)propan-1-one (6)
[0285]
[0000]
Synthesis of methyl 4-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]decane-2-carboxylate (Intermediate-27)
[0286] To a 100 mL RB flask fitted with magnetic stirrer was charged 25 mL of Dichloromethane. To this Intermediate-3 (0.5 g, 2.5 mmol), followed by m-CPBA (0.69 g, 4.0 mmol) were added at 0° C. Then reaction mixture was stirred at room temperature for 16 hours. After completion of the reaction, the reaction mixture was quenched using aqueous NaHCO 3 solution and was extracted with dichloromethane. Organic layer was concentrated to give Intermediate-27 (0.5 g).
Synthesis of 2-azatricyclo[3.3.1.1 3,7 ]decan-4-ol hydrogen chloride salt (Intermediate-28)
[0287] A 50 mL pressurized seal tube fitted with magnetic stirrer was charged with Intermediate-27 (0.2 g, 0.9 mmol) in HCl containing 1,4-Dioxane (20 mL). Then reaction mixture was stirred at 90° C. for 8 hours. After completion of the reaction (reaction was monitored by LCMS), it was concentrated followed by trituration with mixture of hexane:ether (1:1) to give Intermediate-28 (0.2 g).
Synthesis of Compound (6)
[0288] Compound (6) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (6). 1 H NMR (300 MHz, CDCl3): δ 7.97 (brs, 1H), 7.17-7.23 (d, 1H), 7.14-7.15 (d, 1H), 7.02 (s, 1H), 6.84-6.90 (m, 1H), 4.67-4.73 (d, 1H), 3.83 (brs, 0.5H), 3.68 (s, 1H), 3.35 (brs, 1H), 2.98-3.03 (t, 2H), 2.56-2.64 (m, 2H), 2.07-2.11 (m, 1H), 1.97 (m, 1H), 1.61-1.69 (m, 7H). LC-MS (M+H) + =343.1; HPLC purity: 95.88%.
Example 7
1-(2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(5-fluoro-1H-indol-3-yl)propan-1-one (7)
[0289]
Synthesis of Compound (7)
[0290] Compound (7) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate as eluent to obtain Compound (7). 1 H NMR (300 MHz, CDCl3): δ 7.94 (s, 1H), 722 (d, 1H), 7.16 (s, 1H), 7.03 (s, 1H), 6.86-6.87 (t, 1H), 4.81 (s, 1H), 3.91 (s, 1H), 2.99-3.04 (t, 2H), 2.57-2.62 (t, 2H), 1.92-1.98 (m, 2H), 1.58-1.75 (m, 10H). LC-MS (M+H) + =327.2; HPLC purity: 96.53%.
Example 8
3-(4-fluoro-1-methyl-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)propan-1-one (8)
[0291]
Synthesis of Compound (8)
[0292] Compound (8) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (8). 1 H NMR (300 MHz, CDCl3): δ 6.96-7.07 (m, 2H), 6.78 (s, 1H), 6.63-6.69 (m, 1H), 5.01 (s, 1H), 4.21 (s, 1H), 3.64 (s, 3H), 3.05-3.10 (t, 2H), 2.59-2.64 (t, 2H), 2.24 (s, 1H), 1.53-1.74 (m, 10H). LC-MS (M+H) + =357.1; HPLC purity: 89.95%.
Example 9
3-(5-fluoro-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)propan-1-one (9)
[0293]
Synthesis of Compound (9)
[0294] Compound (9) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (9). 1 H NMR. (300 MHz, CDCl3): δ 7.94 (brs, 1H), 7.19-7.22 (d, 1H), 7.15-7.16 (d, 1H), 7.02 (s, 1H), 6.83-6.90 (m, 1H), 5.02 (s, 1H), 4.01 (s, 1H), 2.99-3.04 (t, 2H), 2.57-2.62 (t, 2H), 2.26 (s, 1H), 1.61-1.97 (m, 10H). LC-MS (M+H) + =343.1; HPLC purity: 93.42%.
Example 10
1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-methyl-3-(1-methyl-1H-indol-3-yl)butan-1-one (10)
[0295]
[0000]
Synthesis of methyl 1H-indol-3-ylacetate (Intermediate-29)
[0296] A 100 mL RB flask fitted with magnetic stirrer was charged with 15 mL of Methanol. To the stirred solvent Starting Material-5 (2.0 g, 11.41 mmol) was added. The resulting mixture was cooled to 0° C. and concentrated H 2 SO 4 (0.5 mL) was added. The reaction mixture was then stirred at room temperature for 1 hour. After completion of the reaction (reaction monitored by TLC), solvent from the reaction mass was removed under reduced pressure. The resulting crude mass was taken in Ethyl acetate (100 mL) and was washed with water (50 mL), Sodium bicarbonate solution (100 mL×2) and saturated brine solution (50 mL). The organic layer was then dried over anhydrous sodium sulphate. Then the solvent was removed under reduced pressure. The product Intermediate-29 was obtained as brown syrup. (2.1 g). LC-MS (M+H) + =190.2.
Synthesis of methyl 2-methyl-2-(1-methyl-1H-indol-3-yl)propanoate (Intermediate-30)
[0297] A 100 mL 3 neck RB flask fitted with magnetic stirrer was charged with 10 mL of dry THF. To the stirred solvent diisopropyl amine (401.12 mg, 3.964 mmol) was added and the resulting solution was cooled to −78° C. n-BuLi (2.5 mL, 3.964 mmol) was added and stirred for 1 hour at 0° C. The reaction mixture was again cooled to −78° C. to which Intermediate-29 (150 mg, 0.7928 mmol) was added. The reaction mixture was then stirred for 1 hour. This was followed by addition of Methyl Iodide. The resulting mass was then stirred at room temperature for 15 hours. After completion of the reaction (reaction monitored by TLC), the reaction mass was quenched with saturated ammonium chloride and was extracted using EtOAc (100 mL×3). The combined organic layers were washed with brine and dried after which the solvent was removed under reduced pressure. The resulting crude compound was purified by column chromatography on silica gel (120 meshes) using Petroleum ether (60-80) and ethyl acetate as eluent. The product Intermediate-30 was obtained as a brown syrup. (150 mg). LC-MS (M+H) + =232.2.
Synthesis of 2-methyl-2-(1-methyl-1H-indol-3-yl)propan-1-ol (Intermediate-31)
[0298] A 250 mL RB flask fitted with magnetic stirrer was charged with Lithium aluminum hydride (0.983 g, 25.951 mmol) and THF (20 mL) was added to it at 0° C. To this resulting suspension Intermediate-30 (2.0 g, 8.65 mmol) in THF (20 mL) was added and the resulting mixture was stirred at room temperature for 2 hours. After completion of the reaction, the reaction mixture was diluted with EtOAc (50 mL) and then quenched with Na 2 SO 4 (5 g). The resulting slurry was stirred at room temperature for 1 hour, filtered through celite and washed with ethyl acetate. The resulting filtrate was concentrated to give Intermediate-31 (0.9 g). 1 H NMR (300 MHz, DMSO-d6): δ 7.65-7.68 (d, 1H), 7.34-7.36 (d, 1H), 7.07-7.12 (t, 1H), 7.03 (s, 1H), 6.94-6.99 (t, 1H), 4.53-4.57 (t, 1H), 3.71 (s, 3H), 3.54-3.56 (d, 2H), 1.31 (s, 6H).
Synthesis of 2-methyl-2-(1-methyl-1H-indol-3-yl)propanal (Intermediate-32)
[0299] A 100 mL RB flask fitted with magnetic stirrer was charged with 30 mL DCM to which Pyridinium chloro chromate (2.466 g, 11.4419 mmol) was added followed by the addition of Intermediate-31 (1.55 g, 7.627 mmol) in 10 mL of DCM. The resulting mixture was stirred at room temperature for 2 hours. After completion of the reaction, the solvent from the reaction mass was removed under reduced pressure to yield the crude compound. Crude mass was purified by column chromatography using 60-120 silica gel and 9:1 Pet ether/ethyl acetate as eluent to give Intermediate-32 (0.79 g). 1 H NMR (300 MHz, DMSO-d6): δ 9.39 (s, 1H), 7.40-7.44 (t, 1H), 7.32 (s, 1H), 7.13-7.18 (t, 1H), 6.98-7.03 (t, 1H), 3.77 (s, 3H), 1.46 (s, H).
Synthesis of 3-[(3E)-4-methoxy-2-methylbut-3-en-2-yl]-1-methyl-1H-indole (Intermediate-33)
[0300] A 100 mL RB flask fitted with magnetic stirrer was charged with 20 mL of dry THF and Methoxy methyl triphenyl phosphonium chloride (2.566 g, 7.487 mmol) followed by Potassium tert butoxide (2.295 g, 20.451 mmol). The resulting mass was stirred at room temperature for 2 hours and then cooled to 0° C. Intermediate-32 (1.37 g, 6.807 mmol) in 10 mL of THF was added to the above reaction mass and was stirred at room temperature for 2 hours. After completion of the reaction the reaction mass was diluted with 10 mL of water and was extracted with ethyl acetate (100 mL×3). The combined organic layers were washed with brine solution and was dried over anhydrous sodium sulfate and concentrated to obtain the crude product. Crude product was purified by column chromatography using 60-120 silica gel and 6% of ethyl acetate in Pet ether as eluent to give Intermediate-33. Yield: 1.12 g (71.8%).
[0301] 1 H NMR (300 MHz, CDCl3): δ 7.73-7.80 (m1H), 7.33 (s, 1H), 7.16-7.21 (t, 1H), 7.03-7.08 (t, 1H), 6.81 (s, 1H), 5.79-6.34 (m, 1H), 4.58-5.15 (m, 1H), 3.73-3.74 (d, 3H), 3.49-3.53 (d, 3H), 1.55 (s, 6H).
Synthesis of 3-methyl-3-(1-methyl-1H-indol-3-yl)butanal (Intermediate-34)
[0302] A 100 mL RB flask fitted with magnetic stirrer was charged with 50.4 mL of 1,4 dioxane and 12.76 mL of water. To this Intermediate-33 (1.12 g, 4.884 mmol) was added followed by addition of p-toluene sulphonic acid (0.0424 g, 0.2232 mmol). The resulting mass was heated at 60° C. for 16 hours. After completion of the reaction, the reaction mixture was quenched with 10 mL of water and extracted with ethyl acetate (100 mL×3) and the combine organic layer was washed with saturated sodium bicarbonate solution followed by brine solution and was dried over anhydrous sodium sulfate and was concentrated to obtain the crude product.
[0303] The crude product was purified by column chromatography using 60-120 silica gel and 8% of ethyl acetate in Pet ether as eluent to give Intermediate-34. 1 H NMR (300 MHz, DMSO-d6): δ 9.47-9.49 (t, 1H), 7.73-7.76 (d, 1H), 7.37-7.40 (d, 1H), 7.11-7.16 (t, 1H), 7.10 (s, 1H), 6.99-7.04 (t, 1H) 3.72 (s, 3H), 2.78 (s, 2H), 1.49 (s, 6H).
Synthesis of 3-methyl-3-(1-methyl-1H-indol-3-yl)butanoic acid (Intermediate-35)
[0304] A 50 mL RB flask fitted with magnetic stirrer was charged with 10 mL of THF and was cooled to −78° C. to which 2-methyl-2-butene (3 mL) was added and stirred for 15 minutes. Another 100 mL RB flask fitted with magnetic stirrer was charged with Intermediate-34 (557 mg, 2.59 mmol) and tert butanol (15 mL) and was stirred at room temperature and the above prepared THF solution was added to it. Then the resulting mass was cooled to 0° C. to which NaH 2 PO 4 (1.42 g) in water was added followed by addition of NaClO 2 (0.35 g) in water. The resulting mixture was stirred at 0° C. for 20 minutes and quenched with water. The pH of the reaction mixture was adjusted to 1-2 using 1N HCl and the product was extracted with ethyl acetate and concentrated to give Intermediate-35 (480 mg). 1 H NMR (300 MHz, DMSO-d6): δ 11.82 (s, 1H), 7.69-7.71 (d, 1H), 7.35-7.38 (d, 1H), 7.09-7.14 (t, 1H), 7.05 (s, 1H), 6.96-7.01 (t, 1H), 3.71 (s, 3H), 2.66 (s, 2H), 1.48 (s, 6H)
Synthesis of Compound (10)
[0305] Compound (10) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (10). 1 H NMR (300 MHz, DMSO-d6): δ 7.70-7.73 (d, 1H), 7.34-7.37 (d, 1H), 7.10 (t, 1H), 7.04 (s, 1H), 6.98-7.04 (t, 1H), 4.75 (brs, 1H), 4.54 (s, 1H), 3.99 (brs, 1H), 3.70 (s, 3H), 2.60-2.65 (dd, 2H), 2.02 (s, 1H), 1.28-1.62 (m, 16H) LC-MS (M+H) + =367.3; HPLC purity: 88.74%.
Example 11
1-(2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(1,3-benzothiazol-2-yl)propan-1-one (11)
[0306]
[0000]
Synthesis of 3-(1,3-benzothiazol-2-yl)propanoic acid (Intermediate-36)
[0307] Starting material-7 (3.97 mmol) in benzene was added drop wise to the solution of Starting Material-6 (3.97 mmol) in benzene. The resulting solution was heated to reflux for 2 hours. After 2 hours the reaction mass was cooled to room temperature and was extracted with 10% sodium hydroxide solution. The aqueous layer was acidified using Conc.HCl (3 ml) at 0° C. The resulting solids were filtered and dried at room temperature to get Intermediate-36 (660 mg).
Synthesis of Compound (11)
[0308] Compound (11) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (11). 1H NMR (300 MHz, CDCl3): δ 7.89-7.91 (d, 1H), 7.76-7.78 (d, 1H), 7.36-7.41 (t, 1H), 7.26-7.31 (t, 1H), 4.79 (s, 1H), 4.01 (s, 1H), 3.40-3.46 (t, 2H), 2.82-2.88 (t, 2H), 1.98-2.02 (m, 2H), 1.66-1.81 (m, 10H). LC-MS: (M+H)+=327.3; HPLC purity=94.43%.
Example 12
3-(1,3-benzothiazol-2-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)propan-1-one (12)
[0309]
Synthesis of Compound (12)
[0310] Compound (12) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (12). 1H NMR (300 MHz, CDCl3): δ 7.91-7.93 (d, 1H), 7.76-7.79 (d, 1H), 7.37-7.43 (t, 1H), 7.28-7.33 (t, 1H), 4.99 (s, 1H), 4.28 (s, 1H), 3.42-3.47 (t, 2H), 2.88-2.93 (t, 2H), 2.28 (brs, 1H), 1.51-1.79 (m, 10H). LC-MS: (M+H)+=343.1; HPLC purity=99.27%.
Example 13
3-(1,3-benzothiazol-2-yl)-1-[5-(difluoromethoxy)-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl]propan-1-one (13)
[0311]
[0000]
Synthesis of Compound (13)
[0312] To a stirred solution of (80 mg, 0.28 mmol) in MeCN (3 mL) was added CuI (88 mg, 0.046 mmol) and heated to 45° C. To this difluoro(fluorosulfonyl)acetic acid (23 mg, 0.46 mmol) was added. The resultant mixture is allowed to stir at the same temperature for 30 minutes. After completion of the reaction, the reaction mixture is quenched with water, extracted with EtOAc and concentrated. Resulted crude material was purified by silica gel column chromatography eluting with hexane:EtOAc to give Compound (13) (40 mg) as dark yellow gummy material. 1H NMR (300 MHz, CDCl3): δ 7.87-7.89 (d, 1H), 7.76-7.78 (d, 1H), 7.35-7.40 (t, 1H), 7.26-7.31 (t, 1H), 5.97-6.48 (t, 1H), 5.03 (brs, 1H), 4.33 (brs, 1H), 3.39-3.44 (t, 2H), 2.85-2.89 (t, 2H), 2.33 (brs, 1H), 1.87-1.98 (m, 4H), 1.57-1.70 (m, 6H). LC-MS: (M+H)+=393.2; HPLC purity=89.63%.
Example 14
1-(2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(1H-pyrrolo[2,3-b]pyridin-3-yl)propan-1-one (14)
[0313]
[0000]
Synthesis of 3-(1H-pyrrolo[2,3-b]pyridin-3-yl)propanoic acid (Intermediate-37)
[0314] Intermediate-37 was synthesized by following the procedure used to make Intermediate-26 (Scheme 4).
Synthesis of Compound (14)
[0315] Compound (14) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (14). 1H NMR (300 MHz, CDCl3): δ 8.99 (brs, 1H), 8.22-8.21 (d, 1H), 7.9-7.88 (d, 1H), 7.07 (s, 1H), 7.03-6.99 (t, 1H), 4.81 (s, 1H), 3.92 (s, 1H), 3.07-3.02 (t, 2H), 2.62-2.57 (t, 2H), 1.97-1.98 (m, 3H), 1.76-1.56 (m, 11H). LC-MS: (M+H)+=310.2; HPLC purity=98.28%.
Example 15
1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(1H-pyrrolo[2,3-b]pyridin-3-yl)propan-1-one (15)
[0316]
Synthesis of Compound (15)
[0317] Compound (15) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (15). 1H NMR (300 MHz, CDCl3): δ 9.02 (brs, 1H), 8.20-8.22 (d, 1H), 7.86-7.88 (d, 1H), 7.07 (brs, 1H), 6.99-7.03 (dd, 1H), 5.00 (bs, 1H), 4.10 (brs, 1H), 3.02-3.07 (t, 2H), 2.57-2.62 (t, 2H), 2.22 (brs, 1H), 1.45-1.73 (m, 10H). LC-MS: (M+H)+=326.1; HPLC purity=98.04%.
Example 16
3-(1H-benzotriazol-1-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)propan-1-one (16)
[0318]
[0000]
Synthesis of ethyl 3-(1H-benzotriazol-1-yl)propanoate (Intermediate-38)
[0319] The starting material-8 (4.1 mmol) in dry THF (5 ml) was cooled to 0° C., followed by the addition of NaH (6.0 mmol). The reaction mixture was gradually warmed to room temperature and allowed to react for 20 minutes. The reaction mixture was again cooled to 0° C., followed by the drop wise addition of ethyl 3-bromopropanoate (4.6 mmol) in THF (2.5 ml). The reaction was allowed for 12 hours at room temperature. After 12 hours the reaction mixture was quenched with ice cooled water and extracted with ethyl acetate. The organic layer was dried over anhydrous MgSO 4 , and concentrated to obtain Intermediate-38 (70 mg). 1H NMR (300 MHz, CDCl3): δ 7.98-8.01 (1H, d), 7.55-7.58 (d, 1H), 7.41-7.46 (t, 1H), 7.28-7.33 (t, 1H), 4.82-4.87 (t, 2H), 4.00-4.07 (t, 2H), 3.00-3.05 (t, 2H), 1.08-1.1 (t, 3H).
Synthesis of 3-(1H-benzotriazol-1-yl)propanoic acid (Intermediate-39)
[0320] At 0° C., LiOH (1.5 mmol) in water (1 ml) was added to Intermediate-38 in the solvent THF:MeOH (1:1, 3 ml each). The reaction was allowed for 12 hours at room temperature. After 12 hours the reaction mixture was concentrated, further acidified with 1N HCl (pH=2). The reaction mixture was extracted with ethyl acetate. The organic layer was dried over anhydrous MgSO 4 , and evaporated under reduced pressure to obtain Intermediate-39 (60 mg). 1H NMR (300 MHz, CDCl3): δ 7.29-8.00 (4H, m), 4.82-4.87 (t, 2H), 3.09-3.14 (t, 2H).
Synthesis of Compound (16)
[0321] Compound (16) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (16). 1H NMR (300 MHz, CDCl3): δ 7.23-7.97 (m, 4H), 4.81-4.92 (m, 3H), 4.10 (brs, 1H), 3.01-3.05 (t, 2H), 2.21 (brs, 1H), 1.40-1.78 (m, 10H). LC-MS: (M+H)+=327.2; HPLC purity=98.35%.
Example 17
1-(2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(1H-indol-3-yl)butan-1-one (17)
[0322]
[0000]
Synthesis of 5-[1-(1H-indol-3-yl)ethyl]-2,2-dimethyl-1,3-dioxane-4,6-dione (Intermediate-40)
[0323] A 100 mL RB flask fitted with magnetic stirrer was charged with Starting Material-9 (4.0 g, 34 mmol), Starting Material-10 (4.92, 34 mmol) and Starting Material-11 (3 g, 68 mmol) in 75 mL of acetonitrile. The resulting solution was stirred at room temperature overnight. After completion of the reaction (reaction monitored by TLC), the solvent was removed under reduced pressure, and the resulting crude compound was purified by column chromatography on silica gel (230-400 mesh) using Petroleum ether (60-80) and ethyl acetate as eluent. The product (intermediate-40) was obtained as a brown liquid (2.51 g). LC-MS (M−H) + =286.
Synthesis of ethyl 3-(1H-indol-3-yl)butanoate (Intermediate-41)
[0324] A 100 mL RB flask fitted with magnetic stirrer was charged with intermediate-40 (2.5 g, 8.7 mmol) in 50 mL of pyridine and 8 ml of ethanol. To this mixture copper powder (0.4 g, 5 mol %) was added. Then the resulting reaction mass was refluxed at 110° C. for 3 hours. After completion of the reaction (reaction monitored by TLC), solvent was removed from the reaction mass and the reaction mass was diluted with 100 mL of ethyl acetate. This was followed by washing of the reaction mass with 50 mL 1.5N HCl (2×25 mL) and brine solution. Then the organic layer was dried over 10 g of anhydrous MgSO 4 . The solvent was removed under reduced pressure, and the resulting crude compound was purified by column chromatography on silica gel (230-400 mesh) using Petroleum ether (60-80) and ethyl acetate as eluent. The product (intermediate-41) was obtained as a brown liquid. (0.380 g). LC-MS (M+H) + ==232.
Synthesis of ethyl 3-(1H-indol-3-yl)butanoic acid (Intermediate-42)
[0325] A 50 mL RB flask fitted with magnetic stirrer was charged with 6 mL of methanol and 2 mL of water. To the stirred solvent intermediate-41 (0.145 g, 0.62 mmol) and KOH (0.098 g, 2.54 mmol) was added. Then the resulting reaction mass was refluxed at 70° C. for 3 hours. After completion of the reaction (reaction monitored by TLC), solvent was removed from the reaction mass and the reaction mass was diluted with 20 mL of water. The aqueous layer was washed with 20 mL of diethylether and was acidified by 1NHCl to pH 5.5. The product was then extracted with ethyl acetate and the solvent was removed under reduced pressure. The product (intermediate-42) was obtained as a brown liquid (0.115 g). The product obtained above was directly taken for next step without any purification.
Synthesis of Compound (17)
[0326] Compound (17) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (17). 1H NMR (300 MHz, CDCl3): δ 7.91 (brs, 1H), 7.60-7.63 (d, 1H), 7.27-7.30 (d, 1H), 7.09-7.13 (t, 1H), 7.01-7.03 (t, 1H), 6.96 (s, 1H), 4.80 (s, 1H), 3.93 (s, 1H), 3.54-3.61 (m, 1H), 2.72-2.79 (m, 1H), 2.45-2.50 (m, 1H), 2.10 (brs, 1H), 1.88-1.97 (m, 1H), 1.66-1.74 (m, 5H), 1.47-1.59 (m, 5H), 1.38-1.41 (d, 3H). LC-MS: (M+H)+=323.3; HPLC purity=90.83%.
Example 18
1-(4-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(1H-indol-3-yl)butan-1-one (18)
[0327]
Synthesis of Compound (18)
[0328] Compound (18) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (18). 1H NMR (300 MHz, CDCl3): δ 7.92 (brs, 1H), 7.75-7.54 (m, 1H), 7.35-7.27 (m, 1H), 7.14-7.01 (m, 2H), 6.96 (brs, 1H), 4.73-4.64 (d, 1H), 3.89 (s, 1H), 3.67 (s, 1H), 3.37-3.60 (m, 1H), 2.67-2.79 (m, 1H), 2.59-2.46 (m, 1H), 2.08-1.86 (m, 3H), 1.75-1.60 (m, 5H), 1.53-1.44 (m, 2H), 1.38-1.42 (m, 3H). LC-MS: (M+H)+=339.2; HPLC purity=98.80%.
Example 19
1-(4-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(1H-indol-3-yl)-4-methylpentan-1-one (19)
[0329]
Synthesis of Compound (19)
[0330] Compound (19) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (19). 1H NMR (300 MHz, CDCl3): δ 8.06-7.98 (d, 1H), 7.70-7.56 (d, 1H), 7.36-7.24 (m, 1H), 7.16-7.01 (m, 2H), 6.98-6.91 (d, 1H), 4.57-4.56 (d, 1H), 3.83-3.39 (m, 2H), 3.25-2.90 (m, 2H), 2.80-2.66 (m, 1H), 2.16-2.02 (m, 1H), 1.98-1.66 (m, 4H), 1.54-1.08 (m, 6H), 0.961-0.89 (d, 6H). LC-MS: (M+H)+=367.3; HPLC purity=98.74%.
Example 20
1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(1H-indol-3-yl)butan-1-one (20)
[0331]
Synthesis of Compound (20)
[0332] Compound (20) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (20). 1H NMR (300 MHz, CDCl3): δ 7.99 (brs, 1H), 7.59-7.62 (d, 1H), 7.27-7.29 (d, 1H), 7.08-7.13 (t, 1H), 7.01-7.06 (t, 1H), 6.96 (brs, 1H), 4.98 (brs, 1H), 4.09 (brs, 1H), 3.56-3.61 (q, 1H), 2.73-2.78 (t, 1H), 2.43-2.50 (m, 1H), 1.94-1.97 (m, 1H), 1.42-1.68 (m, 10H), 1.40 (d, 3H). LC-MS: (M+H)+=339.2; HPLC purity=94.22%.
Example 21
1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(1H-indol-3-yl)butan-1-one (21)
[0333]
Synthesis of Compound (21) (Peak-1)
[0334] Racemate of Compound (20) was separated by using HPLC to give enantiomer Compound (21) (peak-1). 1H NMR (300 MHz, CDCl3): 7.99 (brs, 1H), 7.59-7.62 (d, 1H), 7.27-7.29 (d, 1H), 7.08-7.13 (t, 1H), 7.01-7.06 (t, 1H), 6.96 (brs, 1H), 4.98 (brs, 1H), 4.09 (brs, 1H), 3.56-3.61 (q, 1H), 2.73-2.78 (t, 1H), 2.43-2.50 (m, 1H), 1.94-1.97 (m, 1H), 1.42-1.68 (m, 10H), 1.40 (d, 3H). LC-MS: (M+H)+=339.2; HPLC purity=98.2%, Chiral purity: (RT=19.9 min).
Example 22
1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(1H-indol-3-yl)butan-1-one (22)
[0335]
Synthesis of Compound (22) (Peak-1)
[0336] Racemate of Compound (20) was separated by using HPLC to give enantiomer Compound (22) (peak-2). 1H NMR (300 MHz, CDCl3): 7.99 (brs, 1H), 7.59-7.62 (d, 1H), 7.27-7.29 (d, 1H), 7.08-7.13 (t, 1H), 7.01-7.06 (t, 1H), 6.96 (brs, 1H), 4.98 (brs, 1H), 4.09 (brs, 1H), 3.56-3.61 (q, 1H), 2.73-2.78 (t, 1H), 2.43-2.50 (m, 1H), 1.94-1.97 (m, 1H), 1.42-1.68 (m, 10H), 1.40 (d, 3H). LC-MS: (M+H)+=339.2; HPLC purity=97.8%; Chiral purity: (RT=22.28 min).
Example 23
1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(1H-indol-3-yl)-4-methylpentan-1-one (23)
[0337]
Synthesis of Compound (23)
[0338] Compound (23) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain (23). 1H NMR (300 MHz, DMSO-d6): δ 10.77 (s, 1H), 7.50-7.53 (d, 1H), 7.28-7.31 (d, 1H), 7.07 (s, 1H), 6.99-7.04 (t, 1H), 6.90-6.95 (t, 1H), 4.67 (s, 1H), 4.55-4.62 (d, 1H), 4.26-4.29 (d, 1H), 3.22-3.26 (m, 1H), 2.65-2.67 (m, 2H), 1.98 (m, 2H), 1.55-1.62 (d, 5H), 1.36-1.48 (m, 3H), 1.15-1.19 (m, 1H), 1.01-1.06 (m, 1H), 0.77-0.87 (m, 6H). LC-MS: (M+H)+=367.2; HPLC purity=85.41%.
Example 24
1-(5-fluoro-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(1H-indol-3-yl)-4-methylpentan-1-one (24)
[0339]
[0000]
Synthesis of Compound (24)
[0340] Under N 2 atmosphere to a stirred solution of Compound (23) (0.035 g, 0.09 mmol), DAST (0.015 g, 0.09 mmol) was added at −78° C. The reaction mixture was stirred for 2 h at same temperature. After completion of the reaction (reaction monitored by TLC), reaction mass was quenched with NaHSO 3 Solution and extracted with DCM (3×25 mL). The organic layer was washed with saturated brine solution (15 mL), and concentrated to obtain the crude product. The crude product was loaded on Prep TLC plate (97:3. Chloroform:Methanol) and Compound (24) (12 mg) was collected as pale yellow solid. 1H NMR (300 MHz, CDCl3): δ 7.94 (s, 1H), 7.57-7.59 (d, 1H), 7.25-7.30 (m, 1H), 6.99-7.12 (m, 2H), 6.93 (s, 1H), 4.95 (s, 1H), 4.09 (s, 1H), 3.12-3.21 (m, 1H), 2.72-2.82 (m, 1H) 2.63-2.67 (m, 1H), 2.08-2.25 (m, 3H), 1.72-1.79 (m, 2H), 1.61-1.69 (m, 7H), 0.96-0.98 (d, 3H). 0.71-0.81 (d, 3H). LC-MS: (M+H)+=369.1; HPLC purity=96.16%.
Example 25
3-(4-fluoro-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-4-methylpentan-1-one (25)
[0341]
Synthesis of Compound (25)
[0342] Compound (25) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (25). 1H NMR (300 MHz, CDCl3): δ 8.29-8.26 (d, 1H), 7.14-7.02 (m, 2H), 6.98 (s, 1H), 6.77-6.71 (t, 1H), 4.93 (s, 1H), 4.21 (s, 1H), 3.25 (m, 1H), 2.91-2.66 (m, 2H), 2.25 (s, 1H), 2.16-2.05 (m, 2H), 1.72-1.34 (m, 9H), 0.79-0.81 (d, 6H). LC-MS: (M+H)+=385.2; HPLC purity=98.37%.
Example 26
3-(4-fluoro-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (26)
[0343]
Synthesis of Compound (26)
[0344] Compound (26) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (26). 1H NMR (300 MHz, CDCl3): δ 8.15 (brs, 1H), 7.00-7.09 (m, 3H), 6.67-6.73 (t, 1H), 4.99 (s, 1H), 4.25 (s, 1H), 3.59 (m, 1H), 2.90 (s, 1H), 2.63-2.70 (s, 1H), 2.26-2.31 (m, 2H), 1.85 (m, 3H), 1.60-1.72 (m, 6H), 1.35-1.40 (d, 3H). LC-MS: (M+H)+=357.2; HPLC purity=97.11%.
Example 27
3-(4-fluoro-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (27)
[0345]
Synthesis of Compound (27) (Peak-1)
[0346] Racemate of Compound (26) was separated by using chiral HPLC to give enantiomer, Compound (27) (peak-1). 1H NMR (300 MHz, CDCl3): δ 8.15 (brs, 1H), 7.00-7.09 (m, 3H), 6.67-6.73 (t, 1H), 4.99 (s, 1H), 4.25 (s, 1H), 3.59 (m, 1H), 2.90 (s, 1H), 2.63-2.70 (s, 1H), 2.26-2.31 (m, 2H), 1.85 (m, 3H), 1.60-1.72 (m, 6H), 1.35-1.40 (d, 3H). LC-MS: (M+H)+=357.2; HPLC purity=99.60%; Column: Chiralpak IA. 4.6 mm×250 mm, mobile phase: Hexanes:EtOH (8:2), chiral purity=92.25% (RT=12.52 min).
Example 28
3-(4-fluoro-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (28)
[0347]
Synthesis of Compound (28) (Peak-2)
[0348] Racemate of Compound (26) was separated by using chiral HPLC to give enantiomer, Compound (28) (peak-2). 1H NMR (300 MHz, CDCl3): δ 8.15 (brs, 1H), 7.00-7.09 (m, 3H), 6.67-6.73 (t, 1H), 4.99 (s, 1H), 4.25 (s, 1H), 3.59 (m, 1H), 2.90 (s, 1H), 2.63-2.70 (s, 1H), 2.26-2.3 (m, 2H), 1.85 (m, 3H), 1.60-1.72 (m, 6H), 1.35-1.40 (d, 3H). LC-MS: (M+H)+=357.2; HPLC purity=94.43%; Column: Chiralpak IA. 4.6 mm×250 mm, mobile phase: Hexanes:EtOH (8:2), Chiral purity=99.69% (RT=11.13 min).
Example 29
3-(4-fluoro-1H-indol-3-yl)-1-(5-methoxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (29)
[0349]
Synthesis of Compound (29)
[0350] Compound (29) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (29). 1H NMR (300 MHz, CDCl3): δ8.06 (brs, 1H), 7.02-7.07 (m, 1H), 6.97-7.01 (m, 1H), 6.94-6.95 (d, 1H), 6.66-6.72 (dd, 1H), 4.26 (brs, 1H), 4.26 (brs, 1H), 3.5-3.6 (m, 1H), 3.05-3.12 (d, 3H), 2.8-2.89 (m, 1H), 2.41-2.48 (m, 1H), 2.17-2.23 (m, 1H), 1.48-1.72 (m, 10H), 1.36-1.38 (d, 3H). LC-MS: (M+H)+=371.2; HPLC purity=97.80%.
Example 30
3-(4-fluoro-1H-indol-3-yl)-1-(5-methoxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (30)
[0351]
Synthesis of Compound (30) (Peak-1)
[0352] Racemate of Compound (29) was separated by using chiral HPLC to give enantiomer Compound (30) (peak-1). 1H NMR (300 MHz, CDCl3): δ8.06 (brs, 1H), 7.02-7.07 (m, 1H), 6.97-7.01 (m, 1H), 6.94-6.95 (d, 1H), 6.66-6.72 (dd, 1H), 4.26 (brs, 1H), 4.26 (brs, 1H), 3.5-3.6 (m, 1H), 3.05-3.12 (d, 3H), 2.8-2.89 (m, 1H), 2.41-2.48 (m, 1H), 2.17-2.23 (m, 1H), 1.48-1.72 (m, 10H), 1.36-1.38 (d, 3H). LC-MS: (M+H)+=371.2; HPLC purity=99.56%; Chiral purity=99.75% (RT=13.52 min, Column: Chiral pack IA, 4.6 mm×250 mm, mobile phase: MTBE:MeOH (98:02).
Example 31
3-(4-fluoro-1H-indol-3-yl)-1-(5-methoxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (31)
[0353]
Synthesis of Compound (31) (Peak-2)
[0354] Racemate of Compound (29) was separated by using chiral HPLC to give enantiomer Compound (31). 1H NMR (300 MHz, CDCl3): δ 8.06 (brs, 1H), 7.02-7.07 (m, 1H), 6.97-7.01 (m, 1H), 6.94-6.95 (d, 1H), 6.66-6.72 (dd, 1H), 4.26 (brs, 1H), 4.26 (brs, 1H), 3.5-3.6 (m, 1H), 3.05-3.12 (d, 3H), 2.8-2.89 (m, 1H), 2.41-2.48 (m, 1H), 2.17-2.23 (m, 1H), 1.48-1.72 (m, 10H), 1.36-1.38 (d, 3H). LC-MS: (M+H)+=371.2; HPLC purity=95.79%; Chiral purity=99.88% (RT=16.37 min, Column: Chiral pack IA, 4.6 mm×250 mm, mobile phase: MTBE:MeOH (98:02).
Example 32
1-(5-chloro-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(4-fluoro-1H-indol-3-yl)butan-1-one (32)
[0355]
[0000]
Synthesis of tert-butyl 5-chloro-2-azatricyclo[3.3.1.1 3,7 ]decane-2-carboxylate (Intermediate-43)
[0356] To a stirred solution of Intermediate-6 (70 mg, 0.19 mmol) in CCl4 (3 mL), SOCl2 (1.5 mL) was added and the reaction mixture was heated at 80° C. for 15 hours. After reaction was completed (reaction was monitored by LC-MS), reaction mass was concentrated to give Intermediate-43 (60 mg).
Synthesis of 5-chloro-2-azatricyclo[3.3.1.1 3,7 ]decane, trifluoroacetic acid salt (Intermediate-44)
[0357] Intermediate-44 was synthesized by following the procedure used to make Intermediate-20 (Scheme 1).
Synthesis of Compound (32)
[0358] Compound (32) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate as eluent to obtain Compound (32). 1H NMR (300 MHz, CDCl3): δ 8.02-8.06 (d, 1H), 7.01-7.09 (m, 2H), 6.94 (s, 1H), 6.67-6.73 (m, 1H), 4.95 (s, 1H), 4.20 (s, 1H), 3.54-3.61 (m, 1H), 2.79-2.88 (m, 1H), 2.40-2.49 (m, 1H), 2.12-2.26 (m, 4H), 1.81-2.02 (m, 3H), 1.5 (m, 4H), 1.36-1.43 (d, 3H). LC-MS: (M+H)+=376.1; HPLC purity=90.30%.
Example 33
1-[5-(cyclopropylmethoxy)-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl]-3-(4-fluoro-1H-indol-3-yl)butan-1-one (33)
[0359]
Synthesis of Compound (33)
[0360] Compound (33) was synthesized by using intermediate 20 and following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (33). 1H NMR (300 MHz, CDCl3): δ 8.07 (s, 1H), 6.97-7.07 (m, 2H), 6.95-6.94 (d, 1H), 6.66-6.72 (t, 1H), 4.97 (s, 1H), 4.25 (s, 1H), 3.53-3.60 (m, 1H), 3.00-3.12 (dd, 2H), 2.79-2.89 (m, 1H), 2.40-2.50 (m, 1H), 2.16-2.25 (d, 1H), 2.13-2.26 (d, 1H), 1.54-1.74 (m, 8H), 1.36-1.38 (d, 3H), 0.87-0.89 (m, 1H) 0.41-0.47 (m, 2H), 0.07 (m, 2H). LC-MS: (M+H)+=411.2; HPLC purity=96.10%.
Example 34
3-(1H-indol-3-yl)-1-(5-methoxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (34)
[0361]
Synthesis of Compound (34)
[0362] Compound (34) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (34). 1H NMR (300 MHz, CDCl3): δ 7.95 (brs, 1H), 7.59-7.62 (d, 1H), 7.26-7.29 (d, 1H) 7.07 (m, 2H), 6.95 (s, 1H), 4.99 (brs, 1H), 4.10 (brs, 1H), 3.50-3.67 (m, 1H), 3.00-3.12 (d, 3H), 2.74-2.82 (m, 1H), 2.42-2.52 (m, 1H), 2.15-2.12 (m, 1H), 1.46-1.72 (m, 6H), 1.36-1.38 (d, 3H), 0.99-1.46 (m, 4H). LC-MS: (M+H)+=353.2; HPLC purity=90.44%.
Example 35
3-(4-chloro-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (35)
[0363]
Synthesis of Compound (35)
[0364] Compound (35) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (35). 1H NMR (300 MHz, CDCl3): δ 8.44 (brs, 1H), 7.01-7.19 (m, 1H), 6.95-7.01 (m, 3H), 4.99 (brs, 1H), 4.23 (brs, 1H), 3.99-4.06 (m, 1H), 2.82-2.87 (m, 1H), 2.40-2.50 (m, 1H), 1.34-2.22 (m, 14H). LC-MS: (M+H)+=373.2; HPLC purity=93.64%.
Example 36
3-(4-chloro-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (36)
[0365]
Synthesis of Compound (36) (Peak-1)
[0366] Racemate of Compound (35) was separated by using chiral HPLC to give enantiomer Compound (36) (peak-1). 1H NMR (300 MHz, CDCl3) δ 8.44 (brs, 1H), 7.01-7.19 (m, 1H), 6.95-7.01 (m, 3H), 4.99 (brs, 1H), 4.23 (brs, 1H), 3.99-4.06 (m, 1H), 2.82-2.87 (m, 1H), 2.40-2.50 (m, 1H), 1.34-2.22 (m, 14H). LC-MS: (M+H)+=373.2; HPLC purity=91.31%; Chiral purity=98.36% (RT=17.89 min).
Example 37
3-(4-chloro-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (37)
[0367]
Synthesis of Compound (37) (peak-2)
[0368] Racemate of Compound (35) was separated by using chiral HPLC to give enantiomer Compound (37) (peak-2). 1H NMR (300 MHz, CDCl3) δ 8.44 (brs, 1H), 7.01-7.19 (m, 1H), 6.95-7.011 (m, 3H), 4.99 (brs, 1H), 4.23 (brs, 1H), 3.99-4.06 (m, 1H), 2.82-2.87 (m, 1H), 2.40-2.50 (m, 1H), 1.34-2.22 (m, 14H). LC-MS: (M+H)+=373.2; HPLC purity=97.96%; Chiral purity=99.11% (RT=15.94 min).
Example 38
1-[6-(cyclopropylmethoxy)-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl]-3-(1H-indol-3-yl)butan-1-one (38)
[0369]
Synthesis of Compound (38)
[0370] Compound (38) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (38). 1H NMR (300 MHz, CDCl3): δ 7.92 (brs, 1H), 7.59-7.62 (d, 1H), 7.26-7.29 (d, 2H), 7.01-7.02 (m, 2H), 4.98 (brs, 1H), 4.09 (brs, 1H), 3.45-3.61 (m, 1H), 3.08-3.16 (dd, 2H), 2.55-2.64 (m, 2H), 2.09-2.36 (m, 2H), 1.61-1.82 (m, 9H), 1.41-1.43 (d, 3H), 0.86-0.89 (m, 1H), 0.41-0.47 (m, 2H), 0.07 (m, 2H). LC-MS: (M+H)+=393.3; HPLC purity=95.10%.
Example 39
3-(4-chloro-1H-indol-3-yl)-1-[5-(difluoromethoxy)-2-azatricyclo[3.3.1.1 7 ]dec-2-yl]butan-1-one (39)
[0371]
Synthesis of Compound (39)
[0372] Compound (39) was synthesized by following the procedure used to make and Compound (1) (Scheme 2) and Compound (13) (Scheme 8). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether Ethyl acetate as eluent to obtain Compound (39). 1H NMR (300 MHz, CDCl3): δ 8.22 (brs, 1H), 7.06 (brs, 2H), 6.99-7.01 (m, 2H), 5.9-6.4 (t, 1H), 5.03 (brs, 1H), 4.26 (brs, 1H), 4.03-4.04 (m, 1H), 2.83-2.87 (m, 1H), 2.49-2.57 (m, 1H), 2.28 (brs, 1H), 1.93 (m, 1H), 1.62-2.01 (m, 10H), 1.38-1.41 (d, 3H). LC-MS: (M+H)+=423.2; HPLC purity=92.19%.
Example 40
3-(4-bromo-1H-indol-3-yl)-1-(6-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (40)
[0373]
Synthesis of Compound (40)
[0374] Compound (40) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether Ethyl acetate (1:4) as eluent to obtain Compound (40). 1H NMR (300 MHz, DMSO-d6): δ 11.21 (brs, 1H), 7.32-7.36 (m, 2H), 7.14-7.17 (d, 1H), 6.92-6.97 (t, 1H), 4.80 (brs, 1H), 4.66 (s, 1H), 4.33 (brs, 1H), 3.99-4.06 (m, 1H), 2.50-2.55 (m, 1H), 2.19 (brs, 1H), 1.69 (brs, 2H), 1.62-2.01 (m, 8H), 1.38-1.41 (d, 3H). LC-MS: (M+H)+=418.1; HPLC purity=92.77%.
Example 41
3-(4-cyclopropyl-1H-indol-3-yl)-1-(6-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (41)
[0375]
Synthesis of Compound (41)
[0376] Compound (41) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (41). 1H NMR (300 MHz, CDCl3): δ 7.97 (brs, 1H), 7.01-7.1 (d, 1H), 6.97-7.02 (m, 2H, 6.66-6.68 (d, 1H), 5.03 (brs, 1H), 4.19 (brs, 2H), 2.77-2.83 (m, 1H), 2.35-2.44 (m, 2H), 2.24 (brs, 1H), 1.75 (brs, 2H), 1.57-1.66 (m, 8H), 1.36-1.38 (d, 3H), 0.73-0.94 (m, 4H). LC-MS: (M+H)+=379.2; HPLC purity=97.64%.
Example 42
3-[4-(6-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-4-oxobutan-2-yl]-1H-indole-4-carbonitrile (42)
[0377]
Synthesis of Compound (42)
[0378] Compound (42) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (42). 1H NMR (300 MHz, CDCl3): δ8.97 (s, 1H), 7.47-7.50 (d, 1H), 7.38-7.40 (d, 1H), 7.18 (m, 1H), 7.07-7.13 (m, 1H), 4.95 (s, 1H), 4.30 (s, 1H), 3.86-3.93 (m, 1H), 2.81-2.91 (m, 1H), 2.56-2.66 (m, 1H), 2.23 (s, 1H), 1.57-1.74 (m, 10H), 1.39-1.41 (d, 3H). LC-MS: (M+H)+=364.2; HPLC purity=97.36%.
Example 41
3-(4-cyclopropyl-1H-indol-3-yl)-1-5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (41)
[0379]
Synthesis of Compound (41)
[0380] Compound (41) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether Ethyl acetate (1:4) as eluent to obtain Compound (41). 1H NMR (300 MHz, CDCl3): δ 7.97 (brs, 1H), 7.01-7.1 (d, 1H), 6.97-7.02 (m, 2H, 6.66-6.68 (d, 1H), 5.03 (brs, 1H), 4.19 (brs, 2H), 2.77-2.83 (m, 1H), 2.35-2.44 (m, 2H), 2.24 (brs, 1H), 1.75 (brs, 2H), 1.57-1.66 (m, 8H), 1.36-1.38 (d, 3H), 0.73-0.94 (m, 4H). LC-MS: (M+H)+=379.2; HPLC purity=97.64%.
Example 42
3-[4-(6-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-4-oxobutan-2-yl]-1H-indole-4-carbonitrile (42)
[0381]
Synthesis of Compound (42)
[0382] Compound (42) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (42). 1H NMR (300 MHz, CDCl3): δ8.97 (s, 1H), 7.47-7.50 (d, 1H), 7.38-7.40 (d, 1H), 7.18 (m, 1H), 7.07-7.13 (m, 1H), 4.95 (s, 1H), 4.30 (s, 1H), 3.86-3.93 (m, 1H), 2.81-2.91 (m, 1H), 2.56-2.66 (m, 1H), 2.23 (s, 1H), 1.57-1.74 (m, 10H), 1.39-1.41 (d, 3H). LC-MS: (M+H)+=364.2; HPLC purity=97.36%.
Example 43
2-[3-(4-chloro-1H-indol-3-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-carboxylic acid (43)
[0383]
[0000]
Synthesis of Compound (43)
[0384] Compound (43) was synthesized by following the procedure used to make Intermediate-26 (Scheme 4). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (43). 1H NMR (300 MHz, CDCl3): δ 12.25 (s, 1H), 11.20 (s, 1H), 7.29-7.31 (m, 2H), 6.96-7.04 (m, 2H), 4.78 (s, 1H), 4.28 (s, 1H), 3.92-3.99 (m, 1H), 2.55-2.76 (m, 2H), 2.11 (s, 1H), 1.59-1.89 (m, 10H), 1.26-1.28 (d, 3H). LC-MS: (M+H)+=401.1; HPLC purity=89.33%.
Example 44
3-[4-(4-chlorophenoxy)-1H-indol-3-yl]-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (44)
[0385]
Synthesis of Compound (44)
[0386] Compound (44) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (44). 1H NMR (300 MHz, CDCl3): δ 8.12 (s, 1H), 7.21-7.24 (m, 2H), 7.04-7.07 (m, 2H), 6.94-7.01 (m, 2H), 6.92-6.93 (m, 1H), 6.40-6.43 (d, 1H), 4.94 (s, 1H), 4.11 (s, 1H), 3.57-3.63 (m, 1H), 2.78-2.85 (m, 1H), 2.32-2.42 (m, 1H), 2.16 (s, 1H), 1.66-1.69 (d, 3H), 1.43-1.47 (m, 7H), 1.38-1.39 (d, 3H). LC-MS: (M+H)+=465.2; HPLC purity=99.73%.
Example 45
2-[3-(4-chloro-1H-indol-3-yl)butanoyl]-N-(4-fluorophenyl)-2-azatricyclo[3.3.1.1 3,7 ]decane-5-carboxamide (45)
[0387]
[0000]
Synthesis of Compound (45)
[0388] Compound (45) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (45). 1H NMR (300 MHz, CDCl3): δ 8.21-8.24 (d, 1H), 7.34-7.42 (m, 2H), 7.19 (m, 2H), 6.91-7.04 (m, 5H), 4.96 (s, 1H), 4.18 (s, 1H), 4.01-4.12 (m, 1H), 2.80-2.89 (m, 1H), 2.41-2.59 (m, 1H), 2.19-2.26 (m, 1H), 1.60-1.97 m, 10H), 1.37-1.40 (m, 3H). LC-MS: (M+H)+=494.2; HPLC purity=98.06%.
Example 46
3-[4-chloro-1-(methylsulfonyl)-1H-indol-3-yl]-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (46)
[0389]
Synthesis of Compound (46)
[0390] Compound (46) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether. Ethyl acetate (1:4) as eluent to obtain Compound (46). 1H NMR (300 MHz, CDCl3): δ 7.74-7.77 (m, 1H), 7.20-7.22 (m, 3H), 5.01 (s, 1H), 4.22 (s, 1H), 4.08 (s, 1H), 3.02 (s, 3H), 2.73-2.802 (m, 1H), 2.33-2.42 (m, 1H), 2.28 (s, 1H), 1.77 (s, 2H), 1.60-1.66 (m, 9H), 1.34-1.36 (d, 3H). LC-MS: (M+H)+=451.1; HPLC purity=94.52%.
Example 47
2-[3-(4-chloro-1H-indol-3-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-5-carboxamide (47)
[0391]
[0000]
Synthesis of tert-butyl 3-(4-(5-carbamoyl-2-azaadamantan-2-yl)-4-oxobutan-2-yl)-4-chloro-1H-indole-1-carboxylate (Intermediate-46)
[0392] To a stirred solution of compound 43 (0.070 g, 0.17 mmol) in MeCN (2 mL), pyridine (0.016 g, 0.21 mmol) was added, followed by di-tert-butyl dicarbonate (0.045 g, 0.21 mmol) and stirred for 1 hour at room temperature. To this solution solid ammonium bicarbonate (0.021 g, 0.27 mmol) was added and stirred at room temperature for 12 hours. After completion of the reaction, the reaction mixture was quenched with H 2 O and extracted with EtOAc and concentrated to give Intermediate-46 (30 mg) as white solid.
Synthesis of Compound (47)
[0393] To a stirred solution of Intermediate-46 (0.030 g, 0.017 mmol) in DCM (1 mL), TFA (0.013 g, 0.11 mmol) was added at 0° C. and stirred at room temperature for 4 hours. After completion of the reaction, the reaction mixture was concentrated to remove DCM and TFA. The reaction mixture was further diluted with H 2 O and extracted with EtOAc and was then concentrated to give crude material which was purified by using Silica-gel column chromatography eluting with mixture of hexanes:EtOAc to give Compound (47) (145 mg) as white solid. 1H NMR (300 MHz, CDCl3): δ 11.20 (s, 1H), 7.29-7.31 (d, 2H), 6.96-7.04 (m, 3H), 6.81 (s, 1H), 4.74 (s, 1H), 4.28 (s, 1H), 3.89-4.02 (m, 1H), 2.68-2.72 (m, 2H), 2.10 (s, 1H), 1.62-1.85 (m, 10H), 1.26-1.28 (d, 3H). LC-MS: (M+H)+=400.2; HPLC purity=99.92%.
Example 48
1-(6-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(4-methyl-1H-indol-3-yl)butan-1-one (48)
[0394]
[0000]
Synthesis of ethyl 3-(4-bromo-1H-indol-3-yl)butanoate (Intermediate-47)
[0395] Intermediate-47 was synthesized by following the procedure used to make Intermediate-41 (Scheme 11).
Synthesis of ethyl 3-(4-methyl-1H-indol-3-yl)butanoate (Intermediate-48)
[0396] A 100 mL RB flask fitted with magnetic stirrer and reflux condenser was charged with 25 mL of toluene and 5 mL of water. To the stirred solvent Intermediate-47 (4.4 g, 14.185 mmol) was added followed by the addition of methyl boronic acid (1.696 g, 28.37 mmol), Potassium phosphate tribasic (10.535 g, 49.647 mmol) and tricyclohexyl phosphine (0.397 g, 1.4185 mmol). The resulting mass was stirred at room temperature under argon purging for 30 minutes. Then Palladium acetate (0.159, 0.7092 mmol) was added and the resulting mixture was stirred at 100° C. for 16 hours. After completion of the reaction reaction mass was diluted with 10 mL of water and was extracted with ethyl acetate (100 mL×3) and the combine organic layer was washed with brine solution and was dried over anhydrous sodium sulfate and solvent from the organic layer was removed under reduced pressure to yield the crude compound. Crude mass was purified by column chromatography using 60-120 silica gel and 8% of ethyl acetate in Pet ether as eluent to give Intermediate-48 (2.55 g).
[0397] Synthesis of 3-(4-methyl-1H-indol-3-yl)butanoic acid (Intermediate-49):
[0398] Compound Intermediate-49 was synthesized by following the procedure used to make Intermediate-42 (Scheme 11).
Synthesis of Compound (48)
[0399] Compound (48) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether Ethyl acetate (1:4) as eluent to obtain Compound (48). 1H NMR (300 MHz, DMSO-d6): δ 10.78 (s, 1H), 7.12-7.15 (d, 2H), 6.87-6.92 (t, 1H), 6.67-6.69 (d, 1H), 4.80 (s, 1H), 4.64-4.65 (d, 1H), 4.33 (s, 1H), 3.69-3.76 (m, 1H), 2.63-2.68 (m, 2H), 2.60 (s, 3H), 2.15-2.19 (d, 1H), 1.68 (s, 2H), 1.42-1.63 (m, 8H), 1.23-1.25 (d, 3H). LC-MS: (M+H)+=353.2; HPLC purity=98.43%.
Example 49
1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(4-methyl-1H-indol-3-yl)butan-1-one (49)
[0400]
Synthesis of Compound (49) (Peak-1)
[0401] Racemate of Compound (48) was separated by using chiral HPLC to give enantiomer Compound (49) (peak-1). 1H NMR (300 MHz, DMSO-d6): δ 10.78 (s, 1H), 7.12-7.15 (d, 2H), 6.87-6.92 (t, 1H), 6.67-6.69 (d, 1H), 4.80 (s, 1H), 4.64-4.65 (d, 1H), 4.33 (s, 1H), 3.69-3.76 (m, 1H), 2.63-2.68 (m, 2H), 2.60 (s, 3H), 2.15-2.19 (d, 1H), 1.68 (s, 2H), 1.42-1.63 (m, 8H), 1.23-1.25 (d, 3H). LC-MS: (M+H)+=353.2; HPLC purity=95.87%; Chiral purity=100% (RT=17.45 min), Column: Chiralpak IC 4.6 mm×250 mm, Mobile phase, hexane:IPA:DCM (75:15:10).
Example 50
1-(6-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(4-methyl-1H-indol-3-yl)butan-1-one (60)
[0402]
Synthesis of Compound (50) (Peak-2)
[0403] Racemate of Compound (48) was separated by using chiral HPLC to give enantiomer, Compound (50) (peak-2). 1H NMR (300 MHz, DMSO-d6): δ 10.78 (s, 1H), 7.12-7.15 (d, 2H), 6.87-6.92 (t, 1H), 6.67-6.69 (d, 1H), 4.80 (s, 1H), 4.64-4.65 (d, 1H), 4.33 (s, 1H), 3.69-3.76 (m, 1H), 2.63-2.68 (m, 2H), 2.60 (s, 3H), 2.15-2.19 (d, 1H), 1.68 (s, 2H), 1.42-1.63 (m, 8H), 1.23-1.25 (d, 3H). LC-MS: (M+H)+=353.2; HPLC purity=98.64%; Chiral purity=100% (RT=21.17 min), Column: Chiralpak IC 4.6 mm×250 mm, Mobile phase, hexane:IPA:DCM (75:15:10).
Example 51
2-[3-(4-cyclopropyl-1H-indol-3-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-5-carboxylic acid (51)
[0404]
Synthesis of Compound (51)
[0405] Compound (51) was synthesized by following the procedure used to make Compound 43 (Scheme 14). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum DCM:MeOH as eluent to obtain Compound (51). 1H NMR (300 MHz, DMSO-d6): δ 12.23 (s, 1H), 10.801 (s, 1H), 7.11-7.17 (m, 2H), 6.88-6.93 (t, 1H), 6.55-6.58 (d, 1H), 4.75 (s, 1H), 4.26 (s, 1H), 4.01-4.04 (m, 1H), 3.37-3.41 (m, 2H), 2.68-2.73 (m, 1H), 2.09 (s, 1H), 1.62-1.88 (m, 13H), 0.85-00.91 (m, 2H), 0.70-0.77 (m, 2H). LC-MS: (M+H)+=407.2; HPLC purity=91.19%.
Example 62
2-[3-(4-cyclopropyl-1H-indol-3-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-6-carboxylic acid (52)
[0406]
Synthesis of Compound (52) (Peak-1)
[0407] Racemate of Compound (51) was separated by using chiral HPLC to give enantiomer Compound (52) (peak-1). 1H NMR (300 MHz, DMSO-d6): δ 12.23 (s, 1H), 10.801 (s, 1H), 7.11-7.17 (m, 2H), 6.88-6.93 (t, 1H), 6.55-6.58 (d, 1H), 4.75 (s, 1H), 4.26 (s, 1H), 4.01-4.04 (m, 1H), 3.37-3.41 (m, 2H), 2.68-2.73 (m, 1H), 2.09 (s, 1H), 1.62-1.88 (m, 13H), 0.85-00.91 (m, 2H), 0.70-0.77 (m, 2H). LC-MS: (M+H)+=407.3; HPLC purity=89.77%; Chiral purity=100% (RT=8.29 min), Column: Chiralpak IC 4.6 mm×250 mm, Mobile phase, hexane:IPA:DCM (75:15:10).
Example 53
2-[3-(4-cyclopropyl-1H-indol-3-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-5-carboxylic acid (53)
[0408]
Synthesis of Compound (53) Peak-2
[0409] Racemate of Compound (51) was separated by using chiral HPLC to give enantiomer, Compound (53) (peak-2). 1H NMR (300 MHz, DMSO-6): δ 12.23 (s, 1H), 10.801 (s, 1H), 7.11-7.17 (m, 2H), 6.88-6.93 (t, 1H), 6.55-6.58 (d, 1H), 4.75 (s, 1H), 4.26 (s, 1H), 4.01-4.04 (m, 1H), 3.37-3.41 (m, 2H), 2.68-2.73 (m, 1H), 2.09 (s, 1H), 1.62-1.88 (m, 13H), 0.85-00.91 (m, 2H), 0.70-0.77 (m, 2H). LC-MS: (M+H)+=407.3; HPLC purity=86.37%; Chiral purity=94.78% (RT=11.60 min), Column: Chiralpak IC 4.6 mm×250 mm, Mobile phase, hexane:IPA:DCM (75:15:10).
Example 64
2-[3-(4-cyclopropyl-1H-indol-3-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-5-carboxylic acid sodium salt (sodium salt) (54)
[0410]
[0000]
Synthesis of Compound (54) (Sodium Salt)
[0411] To a stirred solution of Compound (51) (306 mg, 0.72 mmol) in THF:MeOH:H 2 O (2 mL: 3 mL: 1 mL), sodium hydroxide (26 mg, 0.65 mmol) was added at 0° C. Resulted reaction mixture was allowed to stir at room temperature for 16 hours. Then reaction mixture was concentrated, followed by trituration with mixture of hexane:ether to give Compound (54) (sodium salt) (25 mg) as a white solid. 1H NMR (300 MHz, DMSO-6): δ. 10.92 (s, 1H), 7.12-7.15 (m, 2H), 6.87-6.92 (t, 1H), 6.54-6.57 (d, 1H), 4.69 (s, 1H), 4.17 (s, 1H), 4.02-4.03 (m, 1H), 3.39-3.41 (m, 2H), 2.61-2.7 (m, 2H), 1.28-1.79 (m, 13H), 0.89-0.92 (m, 2H), 0.70-0.76 (m, 2H) LC-MS: (M+H)+=407.3; HPLC purity=96.31%.
Example 55
2-[3-(4-bromo-1H-indol-3-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-5-carboxylic acid (55)
[0412]
Synthesis of Compound (55)
[0413] Compound (55) was synthesized by following the procedure used to make Compound (43) (Scheme 14). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum DCM:MeOH as eluent to obtain Compound (55). 1H NMR (300 MHz, DMSO-d6): δ 12.25 (s, 1H), 11.20 (s, 1H), 7.32-7.36 (m, 2H), 7.14-7.17 (d, 1H), 6.92-6.97 (t, 1H), 4.74 (s, 1H), 4.28 (s, 1H), 4.01-4.05 (m, 1H), 2.70-2.77 (m, 2H), 2.11 (s, 2H), 1.60-1.89 (m, 9H), 1.26-1.28 (d, 3H). LC-MS: (M+H)+=445.1; HPLC purity=90.50%.
Example 56
2-[3-(4-cyclopropyl-1H-indol-3-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-5-carboxamide (56)
[0414]
Synthesis of Compound (56)
[0415] Compound (56) was synthesized by following the procedure used to make Compound (47) (Scheme 16). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (56). 1H NMR (300 MHz, DMSO-d6): δ 10.79 (s, 1H), 9.50 (s, 2H), 7.01-7.17 (m, 1H), 6.88-6.93 (m, 1H), 6.79 (s, 1H), 6.55-6.58 (d, 1H), 4.74 (s, 1H), 4.26 (s, 1H), 4.01-4.04 (d, 1H), 2.6-2.8 (m, 3H), 2.07-2.08 (m, 2H), 1.15-1.98 (m, 12H), 0.83-0.95 (m, 2H), 0.70-0.95 (m, 2H). LC-MS: (M+H)+=406.2; HPLC purity=88.73%.
Example 57
2-[3-(4-methyl-1H-indol-3-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-5-carboxylic acid (57)
[0416]
Synthesis of Compound (57)
[0417] Compound (57) was synthesized by following the procedure used to make Compound (43) (Scheme 14). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (57). 1H NMR (300 MHz, DMSO-d6): δ 12.25 (s, 1H), 10.78 (s, 1H), 7.12-7.15 (m, 2H), 6.87-6.92 (t, 1H), 6.67-6.69 (d, 1H), 4.74 (s, 1H), 4.28 (s, 1H), 3.76-3.80 (m, 1H), 2.61-2.68 (m, 5H), 2.08-2.11 (m, 1H), 1.48-1.88 (m, 10H), 1.24-1.26 (d, 3H). LC-MS: (M+H)+=381.2; HPLC purity=99.05%.
Example 58
3-(4-chloro-1H-indol-3-yl)-1-[5-(hydroxymethyl)-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl]butan-1-one (58)
[0418]
Synthesis of Compound (58)
[0419] Compound (58) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (58). 1H NMR (300 MHz, CDCl3): δ 11.19 (s, 1H), 7.28-7.31 (m, 2H), 6.96-7.04 (m, 2H), 4.72 (s, 1H), 4.42-4.45 (m, 1H), 4.24 (s, 1H), 3.91-3.95 (m, 1H), 2.99-3.01 (m, 2H), 2.67-2.75 (m, 3H), 2.07 (s, 1H), 1.42-1.63 (m, 9H), 1.25-1.28 (d, 3H). LC-MS: (M+H)+=387.1; HPLC purity=97.41%.
Example 59
2-[3-(4-chloro-1H-indol-3-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-5-carbonitrile (59)
[0420]
Synthesis of Compound (59)
[0421] Compound (59) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (59). 1H NMR (300 MHz, CDCl3): δ 8.10 (s, 1H), 7.21-7.25 (m, 1H), 7.00-7.03 (m, 3H), 4.90 (s, 1H), 4.02-4.12 (m, 2H), 2.77-2.87 (m, 1H), 2.37-2.49 (m, 1H), 2.06-2.12 (m, 3H), 1.60-1.94 (m, 8H), 1.37-1.40 (m, 3H). LC-MS: (M+H)+=382.3; HPLC purity=97.62%.
Example 60
3-(4-chloro-2-methyl-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (60)
[0422]
Synthesis of Compound (60)
[0423] Compound (60) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (60). 1H NMR (300 MHz, CDCl3): δ 7.86-7.89 (d, 1H), 7.08-7.10 (d, 1H), 6.99-7.03 (m, 1H), 6.88-6.94 (t, 1H), 4.91-5.00 (m, 1H), 4.00-4.33 (m, 2H), 2.56-2.67 (m, 1H), 2.40 (s, 3H), 2.21-2.24 (m, 1H), 1.74-1.80 (m, 2H), 1.54 (m, 9H), 1.36-1.38 (d, 3H). LC-MS: (M+H)+=387.1; HPLC purity=98.42%.
Example 61
2-[3-(1H-indol-3-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-5-carboxylic acid (61)
[0424]
Synthesis of Compound (61)
[0425] Compound (61) was synthesized by following the procedure used to make Compound (43) (Scheme 14). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (61). 1H NMR (300 MHz, DMSO-d6): δ 12.21 (s, 1H), 10.77 (s, 1H), 7.51-7.54 (d, 1H), 7.29-7.32 (m, 1H), 7.12-7.13 (d, 1H), 7.01-7.06 (t, 1H), 6.92-6.97 (t, 1H), 4.72 (s, 1H), 4.20 (s, 1H), 3.39-3.45 (m, 1H), 2.65-2.72 (m, 1H), 2.09 (s, 1H), 1.85 (s, 2H), 1.73-1.77 (d, 3H), 1.43-1.66 (m, 6H), 1.29-1.31 (d, 3H). LC-MS: (M+H)+=367.2; HPLC purity=93.96%.
Example 62
2-{3-[4-(4-fluorophenyl)-1H-indol-3-yl]butanoyl}-2-azatricyclo[3.3.1.1 3,7 ]decane-5-carboxylic acid (62)
[0426]
Synthesis of Compound (62)
[0427] Compound (62) was synthesized by following the procedure used to make Compound (43) (Scheme 14). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (62). 1H NMR (300 MHz, CDCl3): δ 8.30 (s, 1H), 7.31-7.39 (m, 2H), 7.25-7.29 (d, 1H), 7.08-7.12 (t, 1H), 7.04-7.05 (m, 3H), 6.82-6.85 (d, 1H), 4.75 (s, 1H), 3.56-3.68 (t, 1H), 3.13-3.14 (d, 1H), 2.25-2.30 (m, 2H), 1.88-1.92 (m, 3H), 1.71-1.75 (m, 6H), 1.58 (s, 3H), 1.48-1.54 (d, 2H). LC-MS: (M+H)+=461.2; HPLC purity=95.42%.
Example 63
4-{[({2-[3-(4-cyclopropyl-1H-indol-3-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]dec-5-yl}carbonyl)amino]methyl}benzoic acid (63)
[0428]
[0000]
Synthesis of Compound (63)
[0429] Compound (63) was synthesized by following the procedure used to make Compound (43) (Scheme 14). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (63). 1H NMR (300 MHz, DMSO-d6): δ 12.80 (s, 1H), 10.81 (s, 1H), 8.12-8.20 (m, 1H), 7.86-7.89 (d, 2H), 7.28-7.31 (m, 2H), 7.12-7.17 (t, 2H), 6.88-6.93 (t, 1H), 6.55-6.58 (d, 1H), 4.77 (s, 1H), 4.30 (s, 2H), 4.04 (s, 1H), 2.61-2.80 (m, 1H), 2.50-2.54 (m, 2H), 2.08-2.13 (t, 1H), 1.86-1.91 (m, 4H), 1.63-1.78 (m, 6H), 1.50-1.55 (d, 1H), 1.28-1.31 (d, 3H), 0.89-0.91 (m, 2H), 0.69-0.74 (m, 2H). LC-MS: (M+H)+=540.3; HPLC purity=95.62%.
Example 64
1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(1H-indol-3-yl)pentan-1-one (64)
[0430]
Synthesis of Compound (64)
[0431] Compound (64) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether. Ethyl acetate (1:4) as eluent to obtain Compound (64). 1H NMR (300 MHz, CDCl3): δ 8.03 (s, 1H), 7.58-7.61 (d, 1H), 7.26-7.29 (d, 1H), 7.07-7.12 (t, 1H), 6.99-7.04 (t, 1H), 6.94 (s, 1H), 4.93 (s, 1H), 4.01-4.04 (d, 1H), 3.25-3.35 (m, 1H), 2.70-2.79 (m, 1H), 2.56-2.59 (m, 1H), 2.03-2.17 (d, 1H), 1.75-1.85 (m, 2H), 1.56-1.65 (m, 5H), 1.31-1.45 (m, 3H), 1.18-1.22 (m, 2H), 0.77-0.82 (m, 3H) LC-MS: (M+H)+=353.2; HPLC purity=94.01%.
Example 65
2-[3-1H-indol-3-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-5-carbonitrile (65)
[0432]
Synthesis of Compound (65)
[0433] Compound (65) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (65). 1H NMR (300 MHz, CDCl3): δ 7.92-7.95 (d, 1H), 7.58-7.61 (d, 1H), 7.27-7.32 (t, 1H), 7.09-7.13 (t, 1H), 7.01-7.06 (t, 1H), 6.95 (d, 1H), 4.83-4.87 (d, 1H), 3.83-3.94 (d, 1H), 3.55-3.62 (m, 1H), 2.69-2.77 (m, 1H), 2.42-2.50 (m, 1H), 2.07-2.10 (m, 1H), 1.93-2.00 (m, 4H), 1.86 (s, 1H), 1.74-1.79 (d, 1H), 1.57-1.64 (m, 4H), 1.40-1.43 (m, 3H). LC-MS: (M+H)+=348.2; HPLC purity=91.69%.
Example 66
3-cyclopropyl-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(1H-indol-3-yl)propan-1-one (66)
[0434]
Synthesis of Compound (66)
[0435] Compound (66) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (66). 1H NMR (300 MHz, CDCl3): δ 8.01-8.05 (m, 1H), 7.59-7.62 (d, 1H), 7.26-7.29 (d, 1H), 7.07-7.12 (t, 1H), 6.98-7.04 (m, 2H), 4.93 (s, 1H), 4.60-4.61 (d, 1H), 4.08-4.11 (d, 1H), 2.84-2.91 (m, 1H), 2.65-2.78 (m, 2H), 2.04-2.18 (s, 1H), 1.65 (s, 2H), 1.57 (s, 2H), 1.44 (m, 2H), 1.32-1.34 (m, 3H), 0.47-0.56 (m, 1H), 0.35-0.39 (m, 1H), 0.25-0.32 (m, 1H), 0.06-0.13 (m, 2H). LC-MS: (M+H)+=365.2; HPLC purity=93.07%.
Example 67
1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(1H-indol-3-yl)-3-phenylpropan-1-one (67)
[0436]
[0000]
Synthesis of 3-(1H-indol-3-yl)-3-phenylpropanoic acid (Intermediate-61)
[0437] Intermediate-51 was synthesized by following the procedure used to make Intermediate-42 (Scheme 11).
Synthesis of Compound (67)
[0438] Compound (67) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (67). 1H NMR (300 MHz, DMSO-d6): δ 10.85 (s, 1H), 7.28-7.33 (m, 5H), 7.18-7.23 (t, 2H), 7.07-7.12 (t, 1H), 6.97-7.02 (t, 1H), 6.83-6.88 (t, 1H), 4.67-4.71 (m, 1H), 4.62-4.65 (m, 1H), 4.56 (s, 1H), 4.35 (s, 1H), 3.01-3.08 (m, 2H), 1.98-2.13 (d, 1H), 1.63 (s, 2H), 1.55 (s, 1H), 1.47-1.50 (d, 3H), 1.38-1.41 (m, 2H), 1.25-1.28 (m, 2H). LC-MS: (M+H)+=401.2; HPLC purity=94.67%.
Example 68
3-(5-chloro-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (68)
[0439]
Synthesis of Compound (68)
[0440] Compound (68) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (68). 1H NMR (300 MHz, CDCl3): δ 8.10 (s, 1H), 7.55-7.56 (d, 1H), 7.21-7.25 (d, 1H), 7.04-7.07 (d, 1H), 6.99 (s, 1H), 4.97 (s, 1H), 4.03-4.13 (m, 1H), 3.54-3.62 (m, 1H), 2.64-2.72 (d, 1H), 2.44-2.54 (d, 1H), 2.15-2.30 (m, 2H), 1.76 (s, 4H), 1.70 (s, 3H), 1.62 (s, 2H), 1.38-1.40 (d, 3H). LC-MS: (M+H)+=373.1; HPLC purity=92.50%.
Example 69
3-(6-chloro-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (69)
[0441]
Synthesis of Compound (69)
[0442] Compound (69) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (69). 1H NMR (300 MHz, CDCl3): δ 8.03 (s, 1H), 7.49-7.51 (d, 1H), 7.27 (s, 1H), 6.95-7.01 (m, 2H), 4.91-5.01 (s, 1H), 4.08 (s, 1H), 3.56-3.58 (m, 1H), 2.69-2.73 (d, 1H), 2.54 (s, 1H), 2.11-2.27 (m, 1H), 1.8 (s, 1H), 1.68 (s, 9H), 1.37-1.40 (d, 3H). LC-MS: (M+H)+=373.1; HPLC purity=91.91%.
Example 70
2-[3-(4-methyl-1H-indol-3-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-5-carbonitrile (70)
[0443]
Synthesis of Compound (70)
[0444] Compound (70) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether. Ethyl acetate (1:4) as eluent to obtain Compound (70). 1H NMR (300 MHz, CDCl3): δ 7.94 (s, 1H), 7.12-7.14 (d, 1H), 6.96-7.02 (m, 2H), 6.77-6.79 (d, 1H), 4.91 (s, 1H), 4.04 (s, 1H), 3.89 (s, 1H), 2.65 (s, 3H), 2.37-2.48 (m, 1H), 2.25-2.30 (m, 1H), 2.12 (s, 2H), 2.06 (s, 2H), 1.98-2.02 (d, 2H), 1.86-1.94 (s, 2H), 1.71-1.77 (m, 3H), 1.34-1.36 (d, 3H). LC-MS: (M+H)+=362.2; HPLC purity=95.85%.
Example 71
3-(4-chlorophenyl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(1H-indol-3-yl)propan-1-one (71)
[0445]
Synthesis of Compound (71)
[0446] Compound (71) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (71). 1H NMR (300 MHz, CDCl3): δ 8.01-8.13 (t, 1H), 7.25-7.28 (d, 2H), 7.18 (m, 4H), 7.05-7.10 (t, 1H), 6.93-6.96 (d, 2H), 4.92 (s, 1H), 4.79 (s, 1H), 4.11 (s, 1H), 2.97-3.05 (m, 2H), 2.15 (s, 1H), 1.69 (s, 7H), 1.45 (d, 3H). LC-MS: (M+H)+=435.1; HPLC purity=95.96%.
Example 72
1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ′]dec-2-yl)-3-(4-methyl-1H-indol-3-yl)-3-phenylpropan-1-one (72)
[0447]
Synthesis of Compound (72)
[0448] Compound (72) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (72). 1H NMR (300 MHz, CDCl3): δ 8.13-8.21 (d, 1H), 7.14-7.15 (d, 4H), 7.04-7.11 (m, 2H), 6.99 (s, 1H), 6.90-6.96 (m, 1H), 6.64-6.66 (d, 1H), 5.08-5.13 (t, 1H), 4.92 (s, 1H), 4.13 (s, 1H), 2.89-3.02 (m, 2H), 2.4 (d, 3H), 2.08-2.21 (m, 1H), 1.81 (s, 1H), 1.68 (s, 2H), 1.62 (s, 2H), 1.39 (s, 2H), 0.78-0.90 (m, 3H). LC-MS: (M+H)+=415.2; HPLC purity=99.51%.
Example 73
3-(4-fluorophenyl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(1H-indol-3-yl)propan-1-one (73)
[0449]
Synthesis of Compound (73)
[0450] Compound (73) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (73). 1H NMR (300 MHz, DMSO-d6): δ 10.87 (s, 1H), 7.28-7.31 (m, 5H), 6.98-7.05 (m, 3H), 6.84-6.89 (t, 1H), 4.58-4.71 (m, 3H), 4.36 (s, 1H), 2.97-3.12 (m, 2H), 2.08-2.13 (d, 1H), 1.64 (s, 2H), 1.41-1.55 (m, 6H), 1.20.-1.35 (m, 2H). LC-MS: (M+H)+=419.2; HPLC purity=95.83%.
Example 74
1-(5-hydroxy-2-azatricyclo[3.3.1.1 7 ]dec-2-yl)-4-methyl-3-(4-methyl-1H-indol-3-yl)pentan-1-one (74)
[0451]
Synthesis of Compound (74)
[0452] Compound (74) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (74). 1H NMR (300 MHz, DMSO-d6): δ 10.77 (s, 1H), 7.11-7.13 (d, 2H), 6.85-6.90 (t, 1H), 6.64-6.66 (d, 1H), 4.66 (s, 1H), 4.58-4.62 (d, 1H), 4.38-4.40 (d, 1H), 3.70 (s, 1H), 2.67-2.76 (m, 2H), 2.64 (s, 3H), 2.05-2.16 (d, 1H), 1.84-1.86 (m, 1H), 1.52-1.64 (m, 5H), 0.1.36-1.48 (m, 5H), 0.82-0.90 (m, 6H). LC-MS: (M+H)+=381.2; HPLC purity=97.77%.
Example 76
3-(5-fluoro-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (75)
[0453]
Synthesis of Compound (75)
[0454] Compound (75) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (75). 1H NMR (300 MHz, DMSO-d6): δ 10.88 (s, 1H), 7.28-7.32 (m, 2H), 7.21-7.24 (m, 1H), 6.85-6.91 (m, 1H), 4.78 (s, 1H), 4.58-4.64 (d, 1H), 4.23-4.25 (d, 1H), 3.16-3.39 (m, 2H), 2.53-2.69 (m, 2H), 2.15-2.17 (m, 1H), 1.65 (s, 2H), 1.54-1.57 (m, 3H), 1.36-1.49 (m, 4H), 1.29-1.30 (d, 3H). LC-MS: (M+H)+=356.1; HPLC purity=98.0%.
Example 76
3-(4-chloro-1H-indol-3-yl)-1-[5-(1H-tetrazol-5-yl)-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl]butan-1-one (76)
[0455]
Synthesis of Compound (76)
[0456] Compound (76) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (76). 1H NMR (300 MHz, CD3OD): δ 7.10-7.21 (m, 3H), 6.93 (s, 2H), 4.30-4.35 (d, 1H), 4.08 (s, 1H), 2.89 (s, 1H), 2.54-2.61 (m, 2H), 1.90-1.94 (m, 4H), 1.74-1.77 (m, 5H), 1.24-1.37 (m, 6H). LC-MS: (M+H)+=426.1; HPLC purity=99.36%.
Example 77
3-(4-methyl-1H-indol-3-yl)-1-[5-(1H-tetrazol-5-yl)-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl]butan-1-one (77)
[0457]
[0000]
Synthesis of Compound (77)
[0458] To a stirred solution of Intermediate-52 (20 mg, 0.05 mmol) in toluene (10 mL) NaN 3 (37 mg, 0.5 mmol) was added along with trimethyltin chloride (49 mg, 0.25 mmol) under N 2 atmosphere, Resulted reaction mixture was heated at 110° C. for 12 hours. After completion of the reaction (monitored by TLC), the reaction mixture was quenched with water and was extracted with ethyl acetate (3×10 mL). The combined organic layer was concentrated to obtain a crude product. The resulted crude product was purified by prep. TLC eluted with DCM:MeOH to give Compound (77) (8 mg) as white solid. 1H NMR (300 MHz, CD3OD): δ 7.06-7.15 (m, 2H), 6.84-6.94 (m, 11H), 6.67-6.72 (m, 1H), 4.69-4.81 (m, 1H), 4.30-4.35 (d, 1H), 3.92-3.98 (m, 1H), 2.82-2.90 (m, 1H), 2.68 (d, 3H), 2.57-2.64 (m, 1H), 2.21 (s, 1H), 1.96-2.11 (m, 5H), 1.8 (s, 3H), 1.70-1.74 (m, 2H), 1.57-1.61 (d, 1H), 1.38-1.40 (d, 3H). LC-MS: (M+H)+=405.2; HPLC purity=98.31%.
Example 78
1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(7-methyl-1H-indol-3-yl)butan-1-one (78)
[0459]
Synthesis of Compound (78)
[0460] Compound (78) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (78). 1H NMR (300 MHz, CDCl3): δ 7.88 (s, 1H), 7.44-7.46 (d, 1H), 6.90-7.03 (m, 3H), 3.52-3.61 (m, 1H), 2.72-2.79 (m, 1H), 2.40-2.50 (m, 1H), 2.40 (m, 3H), 2.22-2.23 (m, 1H), 1.70 (s, 3H), 1.49-1.61 (m, 6H), 1.45 (s, 3H), 1.40-1.43 (m, 3H). LC-MS: (M+H)+=353.2; HPLC purity=97.30%.
Example 79
3-(6-fluoro-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (79)
[0461]
Synthesis of Compound (79)
[0462] Compound (79) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (79). 1H NMR (300 MHz, CDCl3): δ 7.99 (s, 1H), 7.55-7.60 (m, 1H), 6.98-7.04 (m, 2H), 6.84-6.91 (m, 1H), 5.04 (s, 1H), 4.15 (s, 1H), 3.56-3.68 (m, 1H), 2.74-2.82 (m, 1H), 2.48-2.55 (m, 1H), 2.29-2.18 (s, 1H), 1.76 (s, 2H), 1.67 (s, 2H), 1.57-1.62 (m, 4H), 1.48-1.50 (m, 2H), 1.43-1.46 (m, 3H). LC-MS: (M+H)+=357.2; HPLC purity=91.94%.
Example 80
3-[4-cyclopropyl-1-(2-hydroxyethyl)-1H-indol-3-yl]-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (80)
[0463]
Synthesis of Compound (80)
[0464] Compound (80) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (80). 1H NMR (300 MHz, CDCl3): δ 7.14-7.19 (m, 1H), 7.06-7.11 (m, 1H), 7.00 (s, 1H), 6.73-6.75 (d, 1H), 5.06 (s, 1H), 4.27 (s, 1H), 4.20-4.24 (m, 3H), 3.91-3.95 (m, 2H), 2.76-2.90 (m, 1H), 2.56-2.64 (m, 1H), 2.43-2.51 (m, 1H), 2.31 (s, 1H), 1.79 (s, 2H), 1.68 (s, 2H), 1.63-1.65 (d, 4H), 1.57 (s, 3H), 1.42-1.46 (m, 3H), 0.97-1.02 (m, 2H), 0.79-0.90 (m, 2H). LC-MS: (M+H)+=423.2; HPLC purity=97.26%.
Example 81
3-(4-fluorophenyl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(1H-indol-3-yl)propan-1-one (81)
[0465]
Synthesis of Compound (81) (Peak-1)
[0466] Racemate of Compound (73) was separated by using chiral HPLC to give enantiomer Compound (81) (peak-1) 1H NMR (300 MHz, CDCl3): δ 10.87 (s, 1H), 7.20 (m, 5H), 7.00-7.05 (m, 3H), 6.83 (m, 1H), 4.66-4.68 (m, 1H), 4.58 (m, 2H), 4.40 (s, 1H), 3.10 (s, 2H), 2.08-2.13 (d, 1H), 1.61.23-1.55 (m, 8H), 1.11-1.15 (m, 2H). LC-MS: (M+H)+=419.2; HPLC purity=94.26%; Chiral purity=100% (RT=8.57 min), Chiral column: Chiralpak IC 4.6 mm×250 mm, Mobile phase hexane:EtOH:DCM (75:15:10).
Example 82
3-(4-fluorophenyl)-1-(6-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(1H-indol-3-yl)propan-1-one (82)
[0467]
Synthesis of Compound (82) (Peak-2)
[0468] Racemate of Compound (73) was separated by using chiral HPLC to give enantiomer Compound (82) (peak-2). 1H NMR (300 MHz, CDCl3): δ 10.87 (s, 1H), 7.20 (m, 5H), 7.00-7.05 (m, 3H), 6.83 (m, 1H), 4.66-4.68 (m, 1H), 4.58 (m, 2H), 4.40 (s, 1H), 3.10 (s, 2H), 2.08-2.13 (d, 1H), 1.61.23-1.55 (m, 8H), 1.11-1.15 (m, 2H). LC-MS: (M+H)+=419.2; HPLC purity=97.71%; Chiral purity=100% (RT=10.56 min), Chiral column: Chiralpak IC 4.6 mm×250 mm, Mobile phase hexane:EtOH:DCM (75:15:10).
Example 83
3-(4-fluoro-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-phenylpropan-1-one (83)
[0469]
Synthesis of Compound (83)
[0470] Compound (83) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (83). 1H NMR (300 MHz, DMSO-d6): 511.17 (s, 1H), 7.35-7.37 (m, 1H), 7.14-7.27 (m, 4H), 7.06-7.11 (m, 2H), 6.93-7.00 (m, 1H), 6.58-6.64 (m, 1H), 4.80-4.85 (t, 1H), 4.70 (s, 1H), 4.60-4.65 (d, 1H), 4.37 (s, 1H), 2.93-3.17 (m, 2H), 2.07-2.27 (m, 2H), 1.64 (s, 2H), 1.40-1.53 (m, 3H), 1.36 (m, 2H), 1.23-1.28 (m, 2H). LC-MS: (M+H)+=419.2; HPLC purity=96.72%.
Example 84
3-(1,3-benzothiazol-2-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (84)
[0471]
[0000]
Synthesis of Compound (84)
[0472] Intermediate-53 was synthesized by following the procedure used to make Intermediate-36 (Scheme 7). Compound (84) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain (84). 1H NMR (300 MHz, CDCl3): δ 7.90-7.93 (d, 1H), 7.76-7.79 (d, 1H), 7.36-7.41 (t, 1H), 7.26-7.31 (t, 1H), 4.96 (s, 1H), 4.33 (s, 1H), 3.84-3.86 (d, 1H), 3.04-3.11 (m, 1H), 2.58-2.73 (m, 1H), 2.23-2.27 (d, 1H), 1.72-1.76 (d, 4H), 1.55-1.65 (m, 6H), 1.45-1.47 (d, 3H). LC-MS: (M+H)+=357.1; HPLC purity=98.96%.
Example 86
1-(2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-1H-pyrrolo[2,3-b]pyridin-3-yl)butan-1-one (86)
[0473]
[0000]
Synthesis of 3-(1H-pyrrolo[2,3-b]pyridin-3-yl)butanoic acid (Intermediate-64)
[0474] Intermediate-54 was synthesized by following the procedure used to make Intermediate-42 (Scheme 11).
Synthesis of Compound (85)
[0475] Compound (85) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether Ethyl acetate as eluent to obtain Compound (85). 1H NMR (300 MHz, CDCl3): δ 9.29 (s, 1H), 8.19-8.21 (m, 1H), 7.93-7.96 (m, 1H), 7.07 (s, 1H), 6.97-7.01 (m, 1H), 4.76 (s, 1H), 3.89 (s, 1H), 3.52-3.66 (m, 1H), 2.65-2.73 (m, 1H), 2.42-2.49 (m, 1H), 1.97 (s, 11H), 1.84 (s, 1H), 1.65-1.68 (m, 4H), 1.61-1.65 (m, 3H), 1.56-1.57 (d, 2H), 1.41-1.49 (m, 1H), 1.35 (d, 3H). LC-MS: (M+H)+=324.2; HPLC purity=94.58%.
Example 86
1-(5-hydroxy-2-azatricyclo[3.3.1.1]dec-2-yl)-3-(1H-pyrrolo[2,3-b]pyridin-3-yl)butan-1-one (86)
[0476]
Synthesis of Compound (86)
[0477] Compound (86) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (86). 1H NMR (300 MHz, CDCl3): δ 8.82-9.01 (m, 1H), 8.19-8.21 (d, 1H), 7.94-7.96 (m, 1H), 7.05 (s, 1H), 6.98-7.02 (m, 1H), 4.96 (s, 1H), 4.08 (s, 1H), 3.55-3.62 (m, 1H), 2.65-2.72 (m, 1H), 2.42-2.55 (m, 1H), 2.09-2.29 (m, 1H), 1.69 (s, 3H), 1.50 (s, 2H), 1.18-1.44 (m, 5H), 1.18 (s, 1H), 0.78-0.98 (m, 2H). LC-MS: (M+H)+=340.2; HPLC purity=99.20%.
Example 87
3-(4-chloro-1H-pyrrolo[2,3-b]pyridin-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (87)
[0478]
Synthesis of Compound (87)
[0479] Compound (87) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (87). 1H NMR (300 MHz, DMSO-d6): δ11.77 (s, 1H), 8.09-8.11 (d, 1H), 7.38-7.43 (m, 1H), 7.10-7.11 (d, 1H), 4.80 (s, 1H), 4.66 (s, 1H), 4.35 (s, 1H), 3.84 (s, 1H), 2.69 (m, 3H), 2.18 (s, 1H), 1.45-1.68 (m, 9H), 1.23-1.30 (m, 3H). LC-MS: (M+H)+=374.2; HPLC purity=96.68%.
Example 88
1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(4-methyl-1H-pyrrolo[2,3-b]pyridin-3-yl)butan-1-one (88)
[0480]
Synthesis of Compound (88)
[0481] Compound (88) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether. Ethyl acetate (1:4) as eluent to obtain Compound (88). 1H NMR (300 MHz, CDCl3): δ11.91-11.95 (d, 1H), 7.97-7.99 (d, 1H), 7.26-7.29 (d, 1H), 7.05-7.06 (d, 1H), 4.89-4.94 (d, 1H), 4.26 (s, 1H), 3.91 (s, 1H), 3.04-3.06 (m, 1H), 2.90 (s, 3H), 2.50-2.66 (m, 2H)(, 2.27 (s, 1H), 1.36-1.78 (m, 9H), 1.29-1.32 (d, 3H). LC-MS: (M+H)+=354.2; HPLC purity=99.38%.
Example 89
1-(6-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-phenyl-3-(1H-pyrrolo[2,3-b]pyridin-3-yl)propan-1-one (89)
[0482]
Synthesis of Compound (89)
[0483] Compound (89) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (89). LC-MS: (M+H)+=402.2; HPLC purity=95.83%.
Example 90
1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-4-methyl-3-(1H-pyrrolo[2,3-b]pyridin-3-yl)pentan-1-one (90)
[0484]
Synthesis of Compound (90)
[0485] Compound (90) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (90). 1H NMR (300 MHz, CDCl3): δ11.48-11.50 (d, 1H), 8.28-8.33 (t, 1H), 8.14-8.16 (d, 1H), 7.22 (m, 2H), 4.75-4.80 (d, 1H), 4.13 (s, 1H), 3.32-3.37 (m, 1H), 2.63-2.69 (m, 3H), 2.12-2.20 (d, 1H), 1.95-2.04 (m, 1H), 1.36-1.70 (m, 9H), 0.89-0.93 (m, 3H), 0.77-0.81 (m, 3H). LC-MS: (M+H)+=368.2; HPLC purity=94.67%.
Example 91
2-[3-(1H-pyrrolo[2,3-b]pyridin-3-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-5-carboxylic acid (91)
[0486]
Synthesis of Compound (91)
[0487] Compound (91) was synthesized by following the procedure used to make Intermediate-26 (Scheme 4). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (91). 1H NMR (300 MHz, CDCl3): δ 11.09 (s, 1H), 8.08-8.13 (m, 2H), 7.06-7.10 (m, 2H), 4.71 (s, 1H), 3.64-3.72 (m, 2H), 2.66-2.74 (t, 1H), 2.36-2.41 (m, 1H), 2.01-2.04 (d, 1H), 1.80-1.84 (d, 1H), 1.48-1.70 (m, 8H), 1.43-1.45 (d, 3H), 1.18-1.22 (m, 1H). LC-MS: (M+H)+=368.2; HPLC purity=98.93%.
Example 92
2-[4-methyl-3-(1H-pyrrolo[2,3-b]pyridin-3-yl)pentanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-5-carbonitrile (92)
[0488]
Synthesis of Compound (92)
[0489] Compound (92) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (92). 1H NMR (300 MHz, CDCl3): δ 10.75-10.78 (d, 1H), 8.18-8.25 (m, 2H), 7.19-7.20 (m, 2H), 4.72 (s, 1H), 4.03 (s, 1H), 3.33-3.35 (m, 1H), 2.61-2.70 (m, 2H), 2.13 (s, 1H), 1.97-2.02 (m, 4H), 1.81-1.90 (m, 2H), 1.09-1.68 (m, 5H), 0.90-0.92 (m, 3H), 0.77-0.79 (d, 3H). LC-MS: (M+H) + =377.2; HPLC purity=97.71%.
Example 93
3-(4-fluorophenyl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(4-methyl-1H-indol-3-yl)propan-1-one (93)
[0490]
Synthesis of Compound (93)
[0491] Compound (93) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (93). 1H NMR (300 MHz, DMSO-d6): δ 10.91 (s, 1H), 7.36 (m, 1H), 7.18-7.23 (m, 2H), 7.12-7.15 (d, 1H), 7.01-7.06 (t, 2H), 6.85-6.902 (t, 1H), 6.58-6.60 (d, 1H), 4.99-5.02 (m, 1H), 4.74 (m, 1H), 4.58-4.66 (d, 1H), 4.36 (m, 1H), 2.95-2.97 (m, 2H), 2.42 (s, 3H), 2.07-2.17 (m, 1H), 1.28-1.65 (m, 10H). LC-MS: (M+H) + =433.2; HPLC purity=94.79%.
Example 94
3-(6-fluoro-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-phenylpropan-1-one (94)
[0492]
Synthesis of Compound (94)
[0493] Compound (94) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (94). 1H NMR (300 MHz, DMSO-d6): δ 10.94 (s, 1H), 7.30-7.32 (m, 4H), 7.19-7.26 (m, 2H), 7.04-7.13 (m, 2H), 6.69-6.75 (t, 1H), 4.71 (s, 1H), 4.56-4.65 (m, 2H), 4.35 (s, 1H), 3.02-3.05 (m, 2H), 2.06-2.13 (d, 1H), 1.63 (s, 2H), 1.20-1.59 (m, 8H). LC-MS: (M+H) + =419.1; HPLC purity=93.86%.
Example 95
3-cyclopropyl-3-(4-fluoro-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)propan-1-one (95)
[0494]
Synthesis of Compound (95)
[0495] Compound (95) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (95). 1H NMR (300 MHz, CDCl3): δ 8.13 (s, 1H), 6.93-7.08 (m, 3H), 6.66-6.73 (m, 1H), 4.93 (s, 1H), 4.24 (s, 1H), 2.94-3.04 (m, 1H), 2.66-2.75 (m, 1H), 2.60 (s, 1H), 2.08-2.20 (d, 1H), 1.21-1.67 (m, 10H), 0.76-0.97 (m, 1H), 0.49-0.53 (m, 1H), 0.26-0.32 (m, 2H), 0.05-0.07 (m, 1H). LC-MS: (M+H) + =383.1; HPLC purity=96.02%.
Example 96
3-(2,4-difluorophenyl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(1H-indol-3-yl)propan-1-one (96)
[0496]
Synthesis of Compound (96)
[0497] Compound (96) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (96). 1H NMR (300 MHz, DMSO-d6): δ 10.90 (s, 1H), 7.36-7.41 (m, 1H), 7.32 (m, 2H), 7.29 (m, 1H), 7.11-7.15 (t, 1H), 6.97-7.05 (t, 1H), 6.88-6.95 (m, 2H), 4.93 (t, 1H), 4.69 (s, 1H), 4.62-4.64 (d, 1H), 4.40 (s, 1H), 2.72-3.11 (m, 2H), 2.14-2.27 (m, 1H), 1.24-1.66 (m, 10H). LC-MS: (M+H)=437.1; HPLC purity=92.20%.
Example 97
3-(6-fluoro-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one Peak-1 (97)
[0498]
Synthesis of Compound (97) (Peak-1)
[0499] Racemate of (79) was separated by chiral HPLC column chromatography to give Compound (97) (peak-1). 1H NMR (300 MHz, CDCl3): δ 7.90 (S, 1H), 7.48-7.53 (m, 1H), 6.92-6.97 (m, 2H), 6.78-6.84 (t, 1H), 4.97 (s, 1H), 4.09 (s, 1H), 3.52-3.96 (m, 1H), 2.67-2.75 (m, 1H), 2.41-2.48 (m, 1H), 2.11-2.22 (d, 1H), 1.60 (m, 6H), 1.36-1.39 (m, 6H). LC-MS: (M+H) + =357.1; HPLC purity=93.22%; Chiral purity: 100% (RT=15.45 min); Column: Chiralpak IC, 4.6 mm×250 mm; Mobile phase: hexanes:i-PrOH:DCM (7.5:1.5:1.0).
Example 98
3-(6-fluoro-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one Peak-) (98)
[0500]
Synthesis of Compound (98) (Peak-2)
[0501] Racemate of Compound (79) was separated by chiral HPLC column chromatography to give Compound (98) (peak-2). 1H NMR (300 MHz, CDCl3): δ 7.89 (S, 1H), 7.48-7.53 (m, 1H), 6.93-6.97 (m, 2H), 6.78-6.84 (t, 1H), 4.97 (s, 1H), 4.08 (s, 1H), 3.52-3.59 (m, 1H); 2.67-2.75 (m, 1H), 2.41-2.48 (m, 1H), 2.11-2.22 (d, 1H), 1.54-1.69 (m, 9H), 1.36-1.38 (d, 3H). LC-MS: (M+H) + =357.2; HPLC purity=95.14%; Chiral purity: 99.35% (RT=19.0 min); Column: Chiralpak IC, 4.6 mm×250 mm; Mobile phase: hexanes:i-PrOH:DCM (7.5:1.5:1.0).
Example 99
3-(4-fluoro-1H-indol-3-yl)-3-(4-fluorophenyl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)propan-1-one (99)
[0502]
Synthesis of Compound (99)
[0503] Compound (99) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (99). 1H NMR (300 MHz, DMSO-d6): δ 11.19-11.23 (d, 1H), 7.37 (s, 1H), 7.27-7.29 (t, 2H), 7.12-7.14 (d, 1H), 6.93-7.05 (m, 3H), 6.58-6.65 (m, 1H), 4.80-4.84 (m, 1H), 4.70 (s, 1H), 4.59-4.65 (d, 1H), 4.37 (s, 1H), 2.96-3.11 (m, 2H), 2.08-2.16 (d, 1H), 1.29-1.65 (m, 1 OH). LC-MS: (M+H) + =437.1; HPLC purity=99.01%.
Example 100
2-[3-(4-chloro-1H-indol-3-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-6-carbonitrile Peak-1 (100)
[0504]
Synthesis of Compound (100) (Peak-1)
[0505] Racemate of Compound (59) was separated by preparative chiral column to give Compound (100) (peak-1). 1H NMR (300 MHz, CDCl3): δ 8.06 (s, 1H), 7.32 (m, 1H), 7.00-7.02 (m, 3H), 4.90 (s, 1H), 3.96-4.11 (m, 2H), 2.77-2.87 (m, 1H), 2.40-2.48 (m, 1H), 1.60-2.12 (m, 11H), 1.37-1.40 (m, 3H). LC-MS: (M+H) + =382.1; HPLC purity=98.74%; Chiral purity: 100% (RT=16.17 min); Column: Chiralpak IC, 4.6 mm×250 mm; Mobile phase: hexanes:i-PrOH:DCM (7.5:1.5:1.0).
Example 101
2-[3-(4-chloro-1H-indol-3-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-6-carbonitrile Peak-2 (101)
[0506]
Synthesis of Compound (101) (Peak-2)
[0507] Racemate of Compound (59) was separated by preparative chiral column to give Compound (101) (peak-2). 1H NMR (300 MHz, CDCl3): δ 8.07 (s, 1H), 7.00-7.04 (m, 4H), 4.90 (s, 1H), 3.96-4.11 (m, 2H), 2.77-2.87 (m, 1H), 2.40-2.48 (m, 1H), 1.60-2.12 (m, 11H), 1.37-1.40 (m, 3H). LC-MS: (M+H) + =382.1; HPLC purity=98.08%; Chiral purity: 100% (RT=30.89 min); Column: Chiralpak IC, 4.6 mm×250 mm; Mobile phase: hexanes:i-PrOH:DCM (7.5:1.5:1.0).
Example 102
3-(4-cyclopropyl-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one Peak-1 (102)
[0508]
Synthesis of Compound (102) (Peak-1)
[0509] Racemate of Compound (41) was separated by preparative chiral column to give Compound (102) (peak-1). 1H NMR (300 MHz, DMSO-d6): δ 10.80 (s, 1H), 7.12-7.16 (m, 2H), 6.88-6.963 (t, 1H), 6.55-6.58 (d, 1H), 4.81 (s, 1H), 4.65 (d, 1H), 4.32 (s, 1H), 4.01-4.06 (m, 1H), 2.67-2.72 (m, 2H), 2.17 (s, 1H), 1.43-1.68 (m, 11H), 1.27-1.30 (d, 3H), 0.89-0.95 (m, 2H), 0.73-0.86 (m, 2H). LC-MS: (M+H) + =379.2; HPLC purity=98.53%; Chiral purity: 100% (RT=15.36 min); Column: Chiralpak IC, 4.6 mm×250 mm; Mobile phase: hexanes:i-PrOH:DCM (7.5:1.5:1.0).
Example 103
3-(4-cyclopropyl-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one Peak-2 (103)
[0510]
Synthesis of Compound (103) (Peak-2)
[0511] Racemate of Compound (41) was separated by preparative chiral column to give Compound (103) (peak-2). 1H NMR (300 MHz, DMSO-d6): δ 10.80 (s, 1H), 7.12-7.16 (m, 2H), 6.88-6.93 (t, 1H), 6.55-6.58 (d, 1H), 4.81 (s, 1H), 4.65 (d, 1H), 4.32 (s, 1H), 3.97-4.05 (m, 1H), 2.67-2.72 (m, 2H), 2.17 (s, 1H), 1.43-1.68 (m, 11H), 1.27-1.30 (d, 3H), 0.83-0.95 (m, 2H), 0.70-0.74 (m, 2H). LC-MS: (M+H) + =379.2; HPLC purity=99.43%; Chiral purity: 100% (RT=22.17 min); Column: Chiralpak IC, 4.6 mm×250 mm; Mobile phase: hexanes:i-PrOH:DCM (7.5:1.5:1.0).
Example 104
1-(5-fluoro-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(4-methyl-1H-indol-3-yl)butan-1-one (104)
[0512]
Synthesis of Compound (104)
[0513] Compound (104) was synthesized by following the procedure used to make Compound (24) (Scheme 12). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using hexane:EtOAc as eluent to obtain Compound (104). 1H NMR (300 MHz, DMSO-d6): δ 10.79 (s, 1H), 7.12-7.16 (m, 2H), 6.87-6.92 (mt, 1H), 6.67-6.69 (d, 1H), 4.92 (s, 1H), 4.48 (s, 1H), 3.73-3.80 (m, 1H), 2.65-2.72 (m, 1H), 2.61 (s, 3H), 2.27-2.36 (m, 2H), 1.42-1.93 (m, 10H), 1.24-1.26 (d, 3H). LC-MS: (M+H) + =355.2; HPLC purity=98.31%.
Example 106
1-(2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(1,3-benzothiazol-2-yl)butan-1-one (106)
[0514]
Synthesis of Compound (105)
[0515] Compound (105) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using hexane:EtOAc as eluent to obtain Compound (105). 1H NMR (300 MHz, CDCl3): δ 7.87-7.89 (d, 1H), 7.74-7.77 (d, 1H), 7.33-7.38 (tm1H), 7.23-7.28 (t, 1H), 4.77 (s, 1H), 4.05 (s, 1H), 3.65-3.89 (m, 1H), 2.96-3.03 (m, 1H), 2.55-2.57 (m, 1H), 1.66-2.01 (m, 12H), 1.33-1.35 (d, 3H). LC-MS: (M+H) + =341.1; HPLC purity=98.67%.
Example 106
3-(1,3-benzothiazol-2-yl)-1-(5-fluoro-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (106)
[0516]
Synthesis of Compound (106)
[0517] Compound (106) was synthesized by following the procedure used to make Compound (24) (Scheme 12). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using hexane:EtOAc as eluent to obtain Compound (106). 1H NMR (300 MHz, CDCl3): δ 7.85-7.88 (d, 1H), 7.75-7.78 (m, 1H), 7.33-7.39 (m, 1H), 7.23-7.29 (m, 1H), 5.04 (s, 1H), 4.40 (s, 1H), 3.79-3.88 (m, 1H), 3.01-3.09 (m, 1H), 2.53-2.61 (m, 1H), 2.36 (d, 1H), 1.50-1.88 (m, 10H), 1.42-1.47 (d, 3H). LC-MS: (M+H) + =359.1; HPLC purity=95.97%.
Example 107
3-(1,3-benzothiazol-2-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-phenylpropan-1-one (107)
[0518]
Synthesis of (107)
[0519] Compound (107) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (107). 11H NMR (300 MHz, DMSO-d6): δ 7.91-8.00 (m, 2H), 7.22-7.50 (m, 7H), 4.95-5.00 (m, 1H), 4.64-4.69 (m, 2H), 4.43 (s, 1H), 3.52-3.59 (m, 1H), 2.95-3.04 (m, 1H), 2.08-2.20 (m, 1H), 1.23-1.79 (m, 10H). LC-MS: (M+H) + =419.1; HPLC purity=99.70%.
Example 108
3-(1,3-benzothiazol-2-yl)-1-(5-fluoro-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-phenylpropan-1-one (108)
[0520]
Synthesis of Compound (108)
[0521] Compound (108) was synthesized by following the procedure used to make Compound (24) (Scheme 12). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using hexane:EtOAc as eluent to obtain Compound (108). 1H NMR (300 MHz, DMSO-d6): δ7.90-8.00 (m, 2H), 7.22-7.50 (m, 7H), 4.95-5.01 (m, 1H), 4.82 (s, 1H), 4.60 (s, 1H), 3.53-3.61 (m, 1H), 2.96-3.09 (m, 1H), 2.27-2.35 (m, 1H), 1.23-1.79 (m, 10H). LC-MS: (M+H) + =421.1; HPLC purity=92.61%.
Example 109
1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(5-methoxy-1H-indol-3-yl)butan-1-one (109)
[0522]
Synthesis of Compound (109)
[0523] Compound (109) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (109). 1H NMR (300 MHz, DMSO-d6): δ 10.61 (s, 1H), 7.18-7.22 (d, 1H), 7.09 (s, 1H), 6.96 (s, 1H), 6.68-6.71 (m, 1H), 4.79 (s, 1H), 4.59-4.64 (d, 1H), 4.25-4.28 (m, 1H), 3.74 (s, 3H), 3.37-3.40 (m, 1H), 2.63-2.72 (m, 2H), 2.07-2.37 (m, 1H), 1.27-1.65 (m, 13H). LC-MS: (M+H) + =369.2; HPLC purity=98.14%.
Example 110
1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(5-methyl-1H-indol-3-yl)butan-1-one (110)
[0524]
Synthesis of Compound (110)
[0525] Compound (110) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (110). 1H NMR (300 MHz, DMSO-d6): δ 10.62 (s, 1H), 7.29 (s, 1H), 7.18-7.21 (d, 1H), 7.06 (s, 1H), 6.85-6.88 (d, 1H), 4.80 (s, 1H), 4.61-4.65 (d, 1H), 4.28 (s, 1H), 3.39 (m, 1H), 2.62-2.72 (m, 2H), 2.36 (s, 3H), 2.10-2.27 (m, 1H), 1.27-1.66 (m, 13H). LC-MS: (M+H) + =353.2; HPLC purity=95.0%.
Example 111
2-[3-(4-fluoro-1H-indol-3-yl)-3-phenylpropanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-5-carboxylic acid (111)
[0526]
Synthesis of Compound (111)
[0527] Compound (111) was synthesized by following the procedure used to make Compound (43) (Scheme 14). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (111). 1H NMR (300 MHz, DMSO-d6): δ 12.17 (s, 1H), 11.18 (s, 1H), 7.37 (s, 1H), 7.17-7.31 (m, 4H), 7.05-7.14 (m, 2H), 6.92-6.99 (m, 1H), 6.57-6.64 (m, 1H), 4.81-4.86 (t, 1H), 4.64 (s, 1H), 4.31 (s, 1H), 3.00-3.07 (m, 2H), 1.30-2.07 (m, 11H). LC-MS: (M+H) + =447.3; HPLC purity=98.60%.
Example 112
2-[3-(6-fluoro-1H-indol-3-yl)-3-phenylpropanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-5-carboxylic acid (112)
[0528]
Synthesis of Compound (112)
[0529] Compound (112) was synthesized by following the procedure used to make Compound (43) (Scheme 14). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (112). 1H NMR (300 MHz, DMSO-d6): δ 12.19 (s, 1H), 10.94 (s, 1H), 7.30-7.33 (m, 4H), 7.18-7.27 (m, 2H), 7.03-7.13 (m, 2H), 6.69-6.74 (m, 1H), 4.61-4.66 (m, 2H), 4.29 (s, 1H), 3.02-3.05 (d, 2H), 2.72 (m, 2H), 1.32-2.08 (m, 9H). LC-MS: (M+H) + =447.2; HPLC purity=96.93%.
Example 113
3-(5-fluoro-2-methyl-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (113)
[0530]
Synthesis of Compound (113)
[0531] Compound (113) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (113). 1H NMR (300 MHz, DMSO-d6): δ 10.74 (s, 1H), 7.26-7.31 (m, 1H), 7.15-7.20 (m, 1H), 6.73-6.80 (m, 1H), 4.72 (s, 1H), 4.51-4.61 (m, 1H), 4.09 (s, 1H), 3.35-3.39 (m, 1H), 2.70-2.80 (m, 2H), 2.29 (s, 3H), 1.97-2.14 (d, 1H), 0.74-1.60 (m, 13H). LC-MS: (M+H) + =371.2; HPLC purity=97.40%.
Example 114
3-(1,3-benzothiazol-2-yl)-1-(6-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one Peak-1 (114)
[0532]
Synthesis of Compound (114) (Peak-1)
[0533] Racemate of Compound (84) was separated by preparative chiral HPLC column to give Compound (114) (peak-1). 1H NMR (300 MHz, CDCl3): δ 7.86-7.89 (d, 1H), 7.75-7.78 (d, 1H), 7.34-7.39 (t, 1H), 7.24-7.29 (t, 1H), 4.96 (s, 1H), 4.31 (s, 1H), 3.79-3.86 (m, 1H), 2.99-3.07 (m, 1H), 2.54-2.62 (m, 1H), 2.22-2.27 (m, 1H), 1.43-1.75 (m, 14H). LC-MS: (M+H) + =357.1; HPLC purity=99.8%; Chiral purity: 100% (RT=16.99 min); Column: Chiralpak IC, 4.6 mm×250 mm; Mobile phase: hexanes:i-PrOH:DCM (7:2:1).
Example 115
3-(1,3-benzothiazol-2-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one Peak-2 (115)
[0534]
Synthesis of Compound (115) (Peak-2)
[0535] Racemate of Compound (84) was separated by preparative chiral HPLC column to give Compound (115) (peak-2). 1H NMR (300 MHz, CDCl3): δ 7.86-7.89 (d, 1H), 7.75-7.78 (d, 1H), 7.34-7.39 (t, 1H), 7.24-7.29 (t, 1H), 4.96 (s, 1H), 4.31 (s, 1H), 3.79-3.86 (m, 1H), 2.99-3.07 (m, 1H), 2.54-2.62 (m, 1H), 2.22-2.27 (m, 1H), 1.43-1.76 (m, 14H). LC-MS: (M+H) + =357.1; HPLC purity=99.85%; Chiral purity: 100% (RT=23.47 min); Column: Chiralpak IC, 4.6 mm×250 mm; Mobile phase: hexanes:i-PrOH:DCM (7:2:1).
Example 116
1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(4-methyl-1H-indol-3-yl)propan-1-one (116)
[0536]
Synthesis of Compound (116)
[0537] Compound (116) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (116). 1H NMR (300 MHz, CDCl3): δ 7.90 (s, 1H), 7.10-7.13 (d, 1H), 6.96-7.01 (t, 1H), 6.92 (d, 1H), 6.76-6.78 (d, 1H), 5.02 (s, 1H), 4.13 (s, 1H), 3.18-3.23 (m, 2H), 2.64 (s, 3H), 2.58-2.63 (m, 2H), 2.24 (s, 1H), 1.49-1.74 (m, 11H). LC-MS: (M+H)=339.3; HPLC purity=91.46%.
Example 117
3-(6-chloro-5-methoxy-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (117)
[0538]
Synthesis of Compound (117)
[0539] Compound (117) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (117). 1H NMR (300 MHz, CDCl3): δ 7.85 (brs, 1H), 7.30-7.31 (d, 1H), 7.09 (brs, 1H), 6.92-6.93 (m, 1H), 4.98 (brs, 1H), 4.09 (brs, 1H), 3.87 (s, 3H), 3.52-3.59 (m, 1H), 2.63-2.71 (m, 1H), 2.40-2.44 (m, 1H), 2.10 (brs, 1H), 1.41-1.70 (m, 10H), 1.35-1.38 (d, 3H). LC-MS: (M+H) + =403.2; HPLC purity=99.36%.
Example 118
2-[3-(1,3-benzothiazol-2-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-5-carbonitrile (118)
[0540]
Synthesis of Compound (118)
[0541] Compound (118) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (118). 1H NMR (300 MHz, CDCl3): δ 7.84-7.89 (dd, 1H), 7.76-7.78 (d, 1H), 7.34-7.40 (m, 1H), 7.25-7.30 (m, 1H), 4.86 (brs, 1H), 4.23 (brs, 1H), 3.79-3.87 (m, 1H), 3.00-3.09 (m, 1H), 2.49-2.59 (m, 1H), 1.90-2.18 (m, 8H), 1.63-1.76 (m, 3H), 1.45 (d, 3H). LC-MS: (M+H) + =366.2; HPLC purity=93.68%.
Example 119
1-(2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(4-chloro-1,3-benzothiazol-2-yl)butan-1-one (119)
[0542]
Synthesis of Compound (119)
[0543] Compound (119) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using hexane:EtOAc as eluent to obtain Compound (119). 1H NMR (300 MHz, CDCl3): δ 7.64-7.67 (d, 1H), 7.36-7.39 (d, 1H), 7.15-7.21 (dd, 1H), 4.74 (brs, 1H), 4.10 (brs, 1H), 3.85-3.92 (q, 1H), 3.04-3.11 (dd, 1H), 2.53-2.61 (dd, 1H), 1.98-2.02 (m, 2H), 1.65-1.79 (m, 10H), 1.45 (d, 3H). LC-MS: (M+H) + =375.1; HPLC purity=98.71%.
Example 120
3-(4-chloro-1,3-benzothiazol-2-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (120)
[0544]
Synthesis of Compound (120)
[0545] Compound (120) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (120). 1H NMR (300 MHz, DMSO-d6): δ 8.02-8.05 (d, 1H), 7.56-7.58 (d, 1H), 7.36-7.41 (t, 1H), 4.65-4.72 (m, 2H), 4.34 (s, 1H), 3.80 (m, 1H), 2.80-3.20 (m, 2H), 1.45-2.22 (m, 11H), 1.39-1.42 (d, 3H). LC-MS: (M+H) + =391.1; HPLC purity=98.58%.
Example 121
3-(1H-benzotriazol-1-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-phenylpropan-1-one (121)
[0546]
[0000]
Synthesis of 3-(1H-benzotriazol-1-yl)-3-phenylpropanoic acid (Intermediate-55)
[0547] A 30 mL ACE pressure tube fitted with magnetic stirrer was charged with Starting Material-13 (2 g, 13.4 mmol) and Starting Material-8 (4.8 g, 40.4 mmol). Reaction mixture was heated at 150° C. for 12 hours. After completion of reaction, the mixture was diluted with ethyl acetate and concentrated. Resulted crude product was purified by Combiflash column chromatography eluting with hexanes:EtOAc to give Intermediate-55 (2.1 g).
Synthesis of Compound (121)
[0548] To a stirred solution of Intermediate-55 (75 mg, 0.28 mmol) in THF (4 mL) Intermediate-7 (43 mg, 0.28 mmol) and HBTU (126 mg, 0.3 mmol) was added. This was followed by addition of DIPEA (108 mg, 0.84 mmol) at 0° C. Resulted reaction mixture was stirred at room temperature for 1 hour. After completion of reaction, the resultant mass was first quenched with water, then extracted with ethyl acetate and then concentrated. Resulted crude product was purified by preparative TLC eluting with hexanes:EtOAc to give compound compound (121)(40 mg) as white solid. 1H NMR (300 MHz, DMSO-d6): δ 7.99-8.02 (d, 1H), 7.88-7.91 (d, 1H), 7.45-7.52 (m, 3H), 7.24-7.39 (m, 3H), 6.52-6.54 (d, 1H), 4.66-4.67 (d, 1H), 4.62 (s, 1H), 4.46 (s, 1H), 4.01-4.10 (m, 1H), 3.23-3.25 (m, 1H), 2.16 (s, 1H), 1.23-1.67 (m, 11H). LC-MS: (M+H)+=403.2; HPLC purity=93.95%.
Example 122
2-[3-(4-fluoro-1H-indol-3-yl)-3-(thiophen-2-yl)propanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-4-carboxylic acid (122)
[0549]
[0000]
Synthesis of methyl 4-oxo-2-azatricyclo[3.3.1.1 3,7 ]decane-2-carboxylate (Intermediate-56)
[0550] To a stirred solution of Intermediate-27 (0.5 g, 2.3 mmol) in DCM (10 mL), PCC (1.01 g, 4.7 mmol) was added. The reaction mixture was then stirred at room temperature for 16 hours. After completion of reaction, the resultant mass was quenched with water and extracted with DCM. Organic layer was washed with 10% NaHCO 3 solution and concentrated. Resulted crude material was purified by silica gel column chromatography eluting with hexanes:EtOAc to give Intermediate-56 (230 mg).
Synthesis of methyl 4-cyano-2-azatricyclo[3.3.1.1 3,7 ]decane-2-carboxylate (Intermediate-57)
[0551] To a stirred solution of Intermediate-56 (0.23 g, 1.1 mmol) and Tos MIC (0.3 g, 1.5 mmol) in DME:EtOH (5 mL: 0.2 mL), t-BuOK (0.37 g, 3.30 mmol) was added at 0′C. The reaction mixture was stirred at room temperature for 2 hours. Then reaction mixture was filtered. Filtrate portion was concentrated to give Intermediate-57 (230 mg).
Synthesis of 2-tert-butyl 4-ethyl 2-azatricyclo[3.3.1.1 3,7 ]decane-2,4-dicarboxylate (Intermediate-58)
[0552] A 100 mL RB fitted with magnetic stirrer was charged with Intermediate-57 (0.23 g, 1.04 mmol), and 5N H 2 SO 4 (25 mL). The reaction mixture was heated at 100° C. for 36 hours. After completion of reaction (monitored by LC-MS), the mixture was cooled to 0° C. Conc. HCl was added to the cooled mixture, followed by addition of EtOH. The mixture was then heated at 90° C. for 16 hours. The resultant mass was quenched with water, basified with sodium carbonate and washed with DCM. The aqueous layer was diluted with THF (40 mL) to which TEA (5 mL) and Boc-anhydride (0.360 g, 1.4 mmol) was added. The resulting mixture was stirred at room temperature for 12 hours. Then reaction mixture was extracted with ethyl acetate and concentrated. Resulted crude material was purified by silica gel column chromatography eluting with hexanes:EtOAc to give Intermediate-58 (130 mg).
Synthesis of ethyl 2-azatricyclo[3.3.1.1 3,7 ]decane-4-carboxylate. Trifluoroacetic acid salt (Intermediate-69)
[0553] To a stirred solution of Intermediate-58 (0.13 g, 0.4 mmol) in DCM (5 mL), TFA (0.1 g, 0.8 mmol) was added at 0° C. Resulted reaction mixture was stirred for 4 hours at room temperature. After completion of the reaction (reaction was monitored by LC-MS), the resultant mass was concentrated followed by trituration with mixture of hexanes:ether (1:1) to give Intermediate-59 (130 mg).
Synthesis of ethyl 2-[3-(4-fluoro-1H-indol-3-yl)-3-(thiophen-2-yl)propanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-4-carboxylate (Intermediate-60)
[0554] Intermediate-60 was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using hexanes:EtOAc as eluent to obtain Intermediate-60.
Synthesis of Compound (122)
[0555] Compound (122) was synthesized by following the procedure used to make Compound (43) (Scheme 14). 1H NMR (300 MHz, CDCl3): δ 8.30-9.30 (m, 1H), 7.00-7.02 (m, 2H), 6.87-6.89 (m, 1H), 6.77-6.79 (m, 2H), 6.62-6.65 (m, 1H), 6.46-6.56 (m, 1H), 5.02-5.33 (m, 1H), 4.34-4.73 (m, 1H), 3.99-4.12 (m, 1H), 2.92-3.61 (m, 2H), 1.45-2.64 (m, 11H). LC-MS: (M+H)+=453.2; HPLC purity=98.96%.
Example 123
2-[3-(4-chloro-1,3-benzothiazol-2-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-5-carbonitrile (123)
[0556]
Synthesis of Compound (123)
[0557] Compound (123) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using hexanes:EtOAc as eluent to obtain Compound (123). 1H NMR (300 MHz, CDCl3): δ 7.65-7.67 (d, 1H), 7.36-7.40 (m, 1H), 7.22 (m, 1H), 4.84 (s, 1H), 4.26 (s, 1H), 3.84-3.91 (m, 1H), 3.11-3.20 (m, 1H), 2.48-2.58 (m, 1H), 1.55-2.15 (m, 11H), 1.45-1.47 (m, 3H). LC-MS: (M+H)+=400.1; HPLC purity=96.66%.
Example 124
2-[3-(4-chloro-1,3-benzothiazol-2-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-5-carbonitrile Compound (124) peak 1
[0558]
Synthesis of Compound (124) (Peak-1)
[0559] Racemic compound Compound (123) was separated by chiral preparative HPLC to give Compound (124) (peak-1). LC-MS: (M+H)+=400.1; HPLC purity=91.31%; Chiral column, Chiralpak IC, 4.6 mm×250 m; Mobile Phase: hexane:i-PrOH:DCM (7:2:1); RT=23.47 minutes.
Example 126
2-[3-(4-chloro-1,3-benzothiazol-2-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-5-carbonitrile Compound (125) peak 2
[0560]
Synthesis of Compound (126) (Peak-2)
[0561] Racemate of Compound (123) was separated by chiral preparative HPLC to give Compound (125) peak-2 (125). LC-MS: (M+H)+=400.1; HPLC purity=97.74%; Chiral column, Chiralpak IC, 4.6 mm×250 m; Mobile Phase: hexane:i-PrOH:DCM (7:2:1); RT=27.72 minutes.
Example 126
3-(4-cyclopropyl-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)propan-1-one (126)
[0562]
Synthesis of Compound (126)
[0563] Compound (126) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (126). 1H NMR (300 MHz, CDCl3): δ 8.00 (brs, 1H), 7.09-7.12 (d, 1H), 6.96-7.01 (t, 1H), 6.93-6.94 (d, 1H), 6.64-6.66 (1H, d), 5.01 (brs, 1H), 4.14 (brs, 1H), 3.31-3.36 (t, 2H), 2.65-2.70 (m, 2H), 2.32-2.41 (m, 1H), 2.23 (brs, 1H), 1.45-1.73 (m, 10H), 0.88-0.94 (m, 2H), 0.74-0.81 (M, 2H). LC-MS: (M+H)+=365.2; HPLC purity=98.22%.
Example 127
3-(4-fluoro-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(thiophen-2-yl)propan-1-one (127)
[0564]
Synthesis of Compound (127)
[0565] Compound (127) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (127). 1H NMR (300 MHz, CDCl3): δ 8.34 (brs, 0.5H), 8.30 (brs, 0.5H), 6.99-7.06 (m, 2H), 6.96-6.97 (m, 2H), 6.81-6.83 (m, 2H), 6.61-6.68 (m, 1H), 5.14-5.20 (m, 1H), 4.94 (brs, 1H), 4.23 (brs, 1H), 3.02-3.20 (m, 2H), 2.14 (brs, 1H), 1.35-1.70 (m, 10H). LC-MS: (M+H)+=425.2; HPLC purity=99.56%.
Example 128
1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(4-propyl-1H-indol-3-yl)propan-1-one (128)
[0566]
Synthesis of Compound (128)
[0567] Compound (128) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (128). 1H NMR (300 MHz, CDCl3): δ 7.99 (brs, 1H), 7.10-7.13 (d, 1H), 6.99-7.04 (t, 1H), 6.91-6.92 (d, 1H), 6.80-6.82 (d, 1H), 5.02 (brs, 1H), 4.13 (brs, 1H), 3.14-3.19 (t. 2H), 2.87-2.92 (t, 2H), 2.59-2.64 (m, 2H), 2.24 (brs, 1H), 1.53-1.74 (m, 12H), 0.93-0.98 (t, 3H). LC-MS: (M+H)+=367.2; HPLC purity=96.54%.
Example 129
3-(6-chloro-5-methoxy-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (129) peak 1
[0568]
Synthesis of Compound (129) (Peak-1)
[0569] Racemate of Compound (117) was separated by chiral preparative HPLC to give Compound (129) (peak-1). 1H NMR (300 MHz, CDCl3): δ 7.85 (brs, 1H), 7.30-7.31 (d, 1H), 7.09 (brs, 1H), 6.92-6.93 (m, 1H), 4.98 (brs, 1H), 4.09 (brs, 1H), 3.87 (s, 3H), 3.52-3.59 (m, 1H), 2.63-2.71 (m, 1H), 2.40-2.44 (m, 1H), 2.10 (brs, 1H), 1.41-1.70 (m, 10H), 1.35-1.38 (d, 3H). LC-MS: (M+H)+=403.2; HPLC purity=99.32%; Chiral Column: Chiralpak IC, 4.6 mm×250 mm; Mobile phase: hexane:i-PrOH:DCM (7:2:1); RT=11.65 minutes.
Example 130
3-(6-chloro-5-methoxy-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (130) peak 2
[0570]
Synthesis of Compound (130) (Peak-2)
[0571] Racemate of compound (117) was separated by chiral preparative HPLC to give Compound (130) (peak-2). 1H NMR (300 MHz, CDCl3): δ 7.85 (brs, 1H), 7.30-7.31 (d, 1H), 7.09 (brs, 1H), 6.92-6.93 (m, 1H), 4.98 (brs, 1H), 4.09 (brs, 1H), 3.87 (s, 3H), 3.52-3.59 (m, 1H), 2.63-2.71 (m, 1H), 2.40-2.44 (m, 1H), 2.10 (brs, 1H), 1.41-1.70 (m, 10H), 1.35-1.38 (d, 3H). LC-MS: (M+H)+=403.2; HPLC purity=99.76%; Chiral Column: Chiralpak IC, 4.6 mm×250 mm; Mobile phase: hexane:i-PrOH:DCM (7:2:1); RT=14.60 minutes.
Example 131
1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-4-methyl-3-(4-methyl-1H-benzotriazol-1-yl)pentan-1-one (131)
[0572]
Synthesis of Compound (131)
[0573] Compound (131) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (131). 1H NMR (300 MHz, CDCl3): δ 7.37-7.40 (d, 1H), 7.26-7.31 (t, 1H), 7.02-7.04 (d, 1H), 5.00-5.06 (m, 1H), 4.81 (brs, 1H), 4.25 (brs, 1H), 3.47-3.65 (m, 2H), 2.72 (s, 3H), 2.2-2.34 (m, 1H), 2.10 brs, 1H), 1.35-1.75 (m, 10H), 0.96-0.98 (d, 3H), 0.72-0.74 (d, 3H). LC-MS: (M+H)+=383.2; HPLC purity=94.65%.
Example 132
3-(4-cyclopropyl-1H-pyrrolo[2,3-b]pyridin-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (132)
[0574]
Synthesis of Compound (132)
[0575] Compound (132) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (132). 1H NMR (300 MHz, CDCl3): δ 9.30 (brs, 11H), 8.03-8.05 (d, 1H), 7.03 (s, 1H), 6.47-6.49 (d, 11-1H), 5.02 (brs, 1H), 4.21 (brs, 1H), 4.01 (brs, 1H), 2.73-2.78 (m, 1H), 2.33-2.49 (m, 2H), 2.26 (brs, 1H), 1.42-1.75 (m, 10H), 1.35-1.37 (d, 3H). LC-MS: (M+H)+=380.2; HPLC purity=98.45%.
Example 133
3-(6-chloro-5-fluoro-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (133)
[0576]
Synthesis of Compound (133)
[0577] Compound (133) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (133). 1H NMR (300 MHz, CDCl3): δ 7.91 (brs, 1H), 7.31-7.34 (d, 1H), 7.28-7.30 (d, 1H), 6.99-7.00 (d, 1H), 4.98 (brs, 1H), 4.10 (brs, 1H), 3.47-3.54 (q, 11H), 2.63-2.71 (m, 1H), 2.40-2.44 (m, 1H), 2.15 (brs, 11H), 1.40-1.71 (m, 10H), 1.34-1.36 (d, 3H). LC-MS: (M+H)+=391.2; HPLC purity=97.57%.
Example 134
2-[3-(6-chloro-1H-indol-3-yl)-3-phenylpropanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-5-carboxylic acid (134)
[0578]
Synthesis of Compound (134)
[0579] Compound (134) was synthesized by following the procedure used to make Compound (43) (Scheme 14). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (134). 1H NMR (300 MHz, DMSO-d6): δ 12.34 (brs, 1H), 11.03 (s, 1H), 7.10-7.40 (m, 8H), 6.84-6.91 (m, 1H), 4.66 (brs, 2H), 4.30 (brs, 1H), 3.01-3.10 (m, 2H), 2.05 (brs, 1H), 1.55-1.98 (m, 10H). LC-MS: (M+H)+=463.2; HPLC purity=99.58%.
Example 135
3-(5-chloro-1H-pyrrolo[2,3-b]pyridin-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (135)
[0580]
Synthesis of Compound (135)
[0581] Compound (135) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (135). 1H NMR (300 MHz, CDCl3): δ 9.15 (brs, 0.5H), 9.01 (brs, 1H), 8.15-8.16 (d, 1H), 7.91 (s, 1H), 7.09-7.10 (d, 1H), 4.97 (brs, 1H), 4.10 (brs, 1H), 3.51-3.58 (q, 1H), 2.61-2.68 (dd, 1H), 2.42-2.50 (dd, 1H), 2.24 (brs, 0.5H), 2.14 (brs, 0.5H), 1.44 (1.71 (m, 10H), 1.35-1.38 (d, 3H). LC-MS: (M+H)+=374.2; HPLC purity=98.36%.
Example 136
2-[3-(4-cyclopropyl-1H-pyrrolo[2,3-b]pyridin-3-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-5-carbonitrile (136)
[0582]
Synthesis of Compound (136)
[0583] Compound (136) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (136). 1H NMR (300 MHz, DMSO-d6): δ 11.28 (brs, 1H), 7.99-8.00 (d, 11H), 7.25 (s, 11H), 6.52-6.53 (d, 1H), 4.72 (brs, 1H), 4.29 (brs, 1H), 3.85-3.89 (m, 11H), 2.55.-2.72 (m, 3H), 2.09 (brs, 1H), 1.45-1.99 (m, 10H), 1.28-1.30 (d, 3H), 1.00-1.05 (m, 2H), 0.83-0.88 (m, 2H). LC-MS: (M+H)+=389.3; HPLC purity=98.69%.
Example 137
2-[3-(6-chloro-1H-pyrrolo[2,3-b]pyridin-3-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ′]decane-5-carbonitrile (137)
[0584]
Synthesis of Compound (137)
[0585] Compound (137) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (137). 1H NMR (300 MHz, CDCl3): δ 8.98 (brs, 0.5H), 8.88 (brs, 0.5H), 8.15-8.20 (m, 1H), 7.90 (s, 1H), 7.10 (s, 1H), 4.90 (brs, 1H), 4.00 (brs, 1H), 3.50-3.60 (m, 1H), 2.58-2.62 (dd, 1H), 2.40-2.45 (m, 1H), 2.13-2.16 (m, 1H), 1.60-1.93 (m, 10H), 1.38-1.40 (d, 3H). LC-MS: (M+H)+=383.2; HPLC purity=97.99%.
Example 138
3-(6-chloro-5-cyclopropyl-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (138)
[0586]
Synthesis of Compound (138)
[0587] Compound (138) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (138). 1H NMR (300 MHz, CDCl3): δ 7.98 (brs, 0.5H), 7.95 (brs, 0.5H), 7.29 (s, 1H), 7.23 (s, 1H), 6.88 (s, 1H), 4.96 (brs, 1H), 4.09 (brs, 1H), 3.46-3.52 (q, 1H), 2.64-2.72 (dd, 1H), 2.38-2.45 (dd, 1H), 2.21-2.24 (m, 1H), 2.08-2.14 (m, 2H), 1.40-1.70 (m, 9H), 1.34-1.36 (d, 3H), 0.83-0.95 (m, 2H), 0.58-0.63 (m, 2H). LC-MS: (M+H)+=413.3; HPLC purity=95.14%.
Example 139
3-(5-fluoro-4-methyl-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one Compound (139)
[0588]
Synthesis of Compound (139)
[0589] Compound (139) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (139). 1H NMR (300 MHz, CDCl3): δ 7.89 (br s, 1H), 7.00-7.05 (dd, 1H), 6.98-6.99 (d, 1H), 6.81-6.87 (t, 1H), 5.04 (br s, 1H), 4.20 (br s, 1H), 3.84-3.93 (m, 1H), 2.65-2.71 (dd, 1H), 2.54-2.55 (d, 3H), 2.37-2.48 (dd, 1H), 2.26 (br s, 1H), 1.54-1.66 (m, 8H), 1.75 (br s, 2H), 1.39-1.43 (d, 3H). LC-MS: (M+H)+=371.2; HPLC purity=96.42%.
Example 140
2-[3-(6-chloro-1H-indol-3-yl)-3-phenylpropanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-6-carboxylic acid (Peak-1) (140)
[0590]
Synthesis of Compound (140)
[0591] Racemate of compound (134) was separated by chiral preparative HPLC to give Compound (140). 1H NMR (300 MHz, DMSO-d6): δ 12.34 (brs, 1H), 11.03 (s, 1H), 7.10-7.40 (m, 8H), 6.84-6.91 (m, 1H), 4.66 (brs, 2H), 4.30 (brs, 1H), 3.01-3.10 (m, 2H), 2.05 (brs, 1H), 1.55-1.98 (m, 10H). LC-MS: (M+H)+=463.1; HPLC purity=99.56%; Chiral RT=7.95 min [column: ChiralPak IC, Mobile phase: hexane:IPA:DCM (7:2:1)].
Example 141
2-[3-(6-chloro-1H-indol-3-yl)-3-phenylpropanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-5-carboxylic acid (Peak-2) (141)
[0592]
Synthesis of Compound (141)
[0593] Racemate of compound (134) was separated by chiral preparative HPLC to give Compound (141). 1H NMR (300 MHz, DMSO-d6): δ 12.34 (brs, 1H), 11.03 (s, 1H), 7.10-7.40 (m, 8H), 6.84-6.91 (m, 1H), 4.66 (brs, 2H), 4.30 (brs, 1H), 3.01-3.10 (m, 2H), 2.05 (brs, 1H), 1.55-1.98 (m, 10H). LC-MS: (M+H)+=463.1; HPLC purity=99.15%; Chiral RT=11.99 min [column: ChiralPak IC, Mobile phase: hexane:IPA:DCM (7:2:1)].
Example 142
2-[3-(5-phenyl-1H-indol-3-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-5-carboxylic acid (142)
[0594]
Synthesis of Compound (142)
[0595] Compound (142) was synthesized by following the procedure used to make Compound (43) (Scheme 14). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (142). 1H NMR (300 MHz, CDCl3): δ 7.96 (br s, 1H), 7.80 (br s, 1H), 7.56-7.59 (d, 2H), 7.32-7.39 (m, 4H), 7.24-7.29 (dd, 1H), 6.97-6.99 (m, 1H), 4.89 (br s, 1H), 4.04 (br s, 1H), 3.61-3.63 (m, 1H), 2.75-2.81 (dd, 1H), 2.48-2.52 (dd, 1H), 1.54-2.09 (m, 11H), 1.41-1.44 (dd, 3H). LC-MS: (M+H)+=443.2; HPLC purity=98.51%.
Example 143
2-[3-(6-chloro-1H-indol-3-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-6-carboxylic acid (143)
[0596]
Synthesis of Compound (143)
[0597] Compound (143) was synthesized by following the procedure used to make Compound (43) (Scheme 14). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (143). 1H NMR (300 MHz, DMSO-d6): δ 12.20 (br s, 1H), 11.00 (br s, 1H), 7.54 (br s, 1H), 7.30-7.34 (dd, 1H), 7.23 (br s, 1H), 7.01-7.05 (m, 1H), 4.71 (br s, 1H), 4.18 (br s, 1H), 3.67-3.78 (m, 1H), 2.62-2.68 (m, 1H), 2.43-2.47 (m, 1H), 1.39-1.97 (m, 11H), 1.29-1.31 (d, 3H). LC-MS: (M+H)+=401.2; HPLC purity=97.21%.
Example 144
3-(6-chloro-4-methyl-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (144)
[0598]
Synthesis of Compound (144)
[0599] Compound (144) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (144). 1H NMR (300 MHz, CDCl3): δ 7.95 (br s, 1H), 7.09-7.12 (d, 1H), 7.03-7.06 (d, 1H), 6.93-6.98 (d, 1H), 5.03 (br s, 1H), 4.19 (br s, 1H), 3.88-3.90 (m, 1H), 2.68 (s, 3H), 2.62-2.65 (m, 1H), 2.37-2.45 (m, 1H), 2.27 (br s, 1H), 1.54-1.76 (m, 10H), 1.32-1.34 (d, 3H). LC-MS: (M+H)+=387.2; HPLC purity=97.47%.
Example 145
{2-[3-(4-chloro-1H-indol-3-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]dec-5-yl}acetic acid (145)
[0600]
Synthesis of Compound (145)
[0601] Compound (145) was synthesized by following the procedure used to make Compound (43) (Scheme 14). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (145). 1H NMR (300 MHz, CDCl3): δ 8.39 (br s, 1H), 7.16-7.20 (m, 1H), 6.92-6.97 (m, 3H), 4.88 (br s, 1H), 4.20 (br s, 1H), 3.98-4.13 (m, 1H), 2.76-2.94 (m, 1H), 2.52-2.59 (m, 1H), 2.08 (br s, 2H), 2.04 (br s, 1H), 1.52-1.68 (m, 10H), 1.37-1.39 (d, 3H). LC-MS: (M+H)+=415.2; HPLC purity=97.51%.
Example 146
3-{2-[3-(4-cyclopropyl-1H-indol-3-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]dec-6-yl}propanoic acid (146)
[0602]
Synthesis of Compound (146)
[0603] Compound (146) was synthesized by following the procedure used to make Compound (43) (Scheme 14). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (146). 1H NMR (300 MHz, DMSO-d6): δ 12.01 (br s, 1H), 10.81 (br s, 1H), 7.17 (br s, 1H), 7.12-7.15 (d, 1H), 6.88-6.93 (t, 1H), 6.56-6.58 (d, 1H), 4.71 (br s, 1H), 4.20 (br s, 1H), 4.02-4.04 (m, 1H), 2.26-2.28 (m, 1H), 2.06-2.16 (m, 5H), 1.32-1.60 (m, 12H), 1.25-1.29 (d, 3H). LC-MS: (M+H)+=435.2; HPLC purity=98.38%.
Example 147
3-(5-fluoro-4-methyl-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (Peak-1) (147)
[0604]
Synthesis of Compound (147)
[0605] Racemic compound (139) was separated by using chiral preparative column chromatography to give Compound (147). 1H NMR (300 MHz, CDCl3): δ 7.89 (br s, 1H), 7.00-7.05 (dd, 1H), 6.98-6.99 (d, 1H), 6.81-6.87 (t, 1H), 5.04 (br s, 1H), 4.20 (br s, 1H), 3.84-3.93 (m, 1H), 2.65-2.71 (dd, 1H), 2.54-2.55 (d, 3H), 2.37-2.48 (dd, 1H), 2.26 (br s, 1H), 1.54-1.66 (m, 8H), 1.75 (br s, 2H), 1.39-1.43 (d, 3H). LC-MS: (M+H)+=371.2; HPLC purity=96.98%. Chiral RT=10.82 min [Column: ChiralPak IC, Mobile phase: hexane:THF (7:3)].
Example 148
3-(5-fluoro-4-methyl-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (Peak-2) (148)
[0606]
Synthesis of Compound (148)
[0607] Racemic compound (139) was separated by using chiral preparative column chromatography to give Compound (148). 1H NMR (300 MHz, CDCl3): δ 7.89 (br s, 1H), 7.00-7.05 (dd, 1H), 6.98-6.99 (d, 1H), 6.81-6.87 (t, 1H), 5.04 (br s, 1H), 4.20 (br s, 1H), 3.84-3.93 (m, 1H), 2.65-2.71 (dd, 1H), 2.54-2.55 (d, 3H), 2.37-2.48 (dd, 1H), 2.26 (br s, 1H), 1.54-1.66 (m, 8H), 1.75 (br s, 2H), 1.39-1.43 (d, 3H). LC-MS: (M+H)+=371.2; HPLC purity=99.16%; Chiral RT=9.69 min [Column: ChiralPak IC, Mobile phase: hexane:THF (7:3)].
Example 149
3-(4-cyclopropyl-1H-indol-3-yl)-1-[5 (1H-tetrazol-5-yl)-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl]butan-1-one (149)
[0608]
Synthesis of Compound (149)
[0609] Compound (149) was synthesized by following the procedure used to make Compound (77) (Scheme 21). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (149). 1H NMR (300 MHz, CDCl3): δ 8.38 (br s, 0.5H), 8.25 (br s, 0.5H), 7.02-7.07 (t, 1H), 6.98-7.00 (d, 1H), 6.89-6.94 (m, 1H), 6.56-6.66 (dd, 1H), 4.88-4.92 (d, 1H), 4.20 (br s, 1H), 3.47-3.50 (m, 1H), 2.78-2.85 (m, 1H), 2.46-2.59 (m, 1H), 2.29-2.34 (m, 1H), 2.17-2.19 (m, 1H), 1.61-2.01 (m, 10H), 1.32-1.38 (m, 3H), 0.72-0.79 (m, 2H), 0.63-0.65 (m, 2H). LC-MS: (M+H)+=431.2; HPLC purity=92.97%.
Example 150
3-(4-cyclopropyl-5-fluoro-1H-indol-3-yl)-1-(6-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (150)
[0610]
Synthesis of Compound (160)
[0611] Compound (160) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (160). 1H NMR (300 MHz, CDCl3): δ 7.93 (br s, 1H), 7.04-7.06 (d, 1H), 7.01-7.02 (d, 1H), 6.74-6.84 (dd, 1H), 5.02 (br s, 1H), 4.21-4.24 (m, 1H), 4.20 (br s, 1H), 2.68-2.75 (dd, 1H), 2.34-2.43 (dd, 1H), 2.22-2.25 (m, 1H), 2.00-2.09 (m, 1H), 1.52-1.75 (m, 10H), 1.31-1.34 (d, 3H), 0.99-1.03 (m, 2H), 0.83-0.87 (m, 2H). LC-MS: (M+H)+=397.2; HPLC purity=97.0%.
Example 151
3-(6-chloro-4-cyclopropyl-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (161)
[0612]
Synthesis of Compound (151)
[0613] Compound (161) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (161). 1H NMR (300 MHz, DMSO-d6): δ 11.04 (br s, 11H), 7.29 (br s, 1H), 7.17-7.20 (d, 1H), 6.98-7.00 (d, 1H), 4.79 (br s, 1H), 4.64-4.65 (d, 1H, OH group), 4.31 (br s, 1H), 4.22-4.23 (m, 1H), 2.60-2.72 (m, 2H), 2.07-2.27 (m, 2H), 1.38-1.68 (m, 10H). 1.24-1.27 (d, 3H), 0.80-0.85 (m, 2H), 0.70-0.75 (m, 2H). LC-MS: (M+H)+=413.1; HPLC purity=95.99%.
Example 152
{2-[3-(4-cyclopropyl-1H-indol-3-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]dec-5-yl}acetic acid (162)
[0614]
Synthesis of Compound (162)
[0615] Compound (162) was synthesized by following the procedure used to make Compound (43) (Scheme 14). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (152). 1H NMR (300 MHz, DMSO-d6): δ 10.82 (br s, 1H), 7.17 (br s, 1H), 7.12-7.15 (d, 1H), 6.88-6.93 (t, 1H), 6.56-6.58 (d, 1H), 4.72 (br s, 1H), 4.22 (br s, 1H), 4.00-4.06 (m, 1H), 2.68-2.73 (m, 2H), 2.43-2.46 (m, 3H), 1.99-2.05 (m, 1H), 1.45-1.68 (m, 10H), 1.28-1.30 (d, 3H), 0.85-0.90 (m, 2H), 0.70-0.75 (m, 2H). LC-MS: (M+H)+=421.2; HPLC purity=98.6%.
Example 153
1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-[4-(thiophen-2-yl)-1H-indol-3-yl]butan-1-one (153)
[0616]
Synthesis of Compound (153)
[0617] Compound (153) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (163). 1H NMR (300 MHz, CDCl3): δ 8.16 (br s, 1H), 7.31-7.34 (d, 1H), 7.23-7.26 (m, 1H), 7.10-7.15 (t, 1H), 7.02-7.08 (m, 4H), 4.89 (br s, 1H), 3.80 (br s, 1H), 3.38-3.40 (m, 1H), 2.38-2.43 (m, 1H), 2.19-2.22 (m, 1H), 1.97-2.01 (m, 1H), 1.45-1.71 (m, 10H), 1.37-1.39 (d, 3H). LC-MS: (M+H)+=421.1; HPLC purity=96.43%.
Example 154
(2-{3-[4-(thiophen-2-yl)-1H-indol-3-yl]butanoyl}-2-azatricyclo[3.3.1.1 3,7 ]dec-5-yl)acetic acid (154)
[0618]
Synthesis of Compound (154)
[0619] Compound (154) was synthesized by following the procedure used to make Compound (43) (Scheme 14). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (154). 1H NMR (300 MHz, CDCl3): δ 8.68 (br s, 0.5H), 8.57 (br s, 0.5H), 7.22-7.30 (m, 2H), 7.01-7.09 (m, 5H), 4.77 (br s, 1H), 3.46 (br s, 11-1H), 3.31-3.35 (m, 1H), 2.35-2.48 (m, 2H), 2.07 (br s, 1H), 1.40-1.78 (m, 13H). LC-MS: (M+H)+=463.1; HPLC purity=92.86%.
Example 155
{2-[3-(4-cyclopropyl-1H-indol-3-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]dec-5-yl}acetic acid (Peak-1) (155)
[0620]
Synthesis of Compound (155)
[0621] Racemic compound (152) was purified by using chiral preparative HPLC chromatography to give Compound (155). 1H NMR (300 MHz, CDCl3): δ 7.98 (br s, 1H), 7.09-7.12 (d, 1H), 6.99-7.01 (d, 1H), 6.97 (br s, 1H), 6.66-6.78 (d, 1H), 4.89 (br s, 1H), 4.14-4.16 (m, 1H), 4.06 (br s, 1H), 2.75-2.82 (dd, 1H), 2.37-2.45 (m, 2H), 2.08 (s, 2H), 2.04 (br s, 1H), 1.52-1.71 (m, 10H), 1.36-1.38 (d, 3H), 0.90-0.95 (m, 2H), 0.76-0.81 (m, 2H). LC-MS: (M+H)+=421.2; HPLC purity=98.67%; Chiral RT=9.07 min [column: ChiralPak IC, mobile phase: hexane:IPA:DCM (7.5:1.5:1)].
Example 156
{2-[3-(4-cyclopropyl-1H-indol-3-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]dec-5-yl}acetic acid (Peak-2) (166)
[0622]
Synthesis of Compound (166)
[0623] Racemic compound (152) was purified by using chiral preparative HPLC chromatography to give Compound (156). 1H NMR (300 MHz, DMSO-d6): δ 10.82 (br s, 1H), 7.17 (br s, 1H), 7.12-7.15 (d, 1H), 6.88-6.93 (t, 1H), 6.56-6.58 (d, 1H), 4.72 (br s, 1H), 4.22 (br s, 1H), 4.00-4.06 (m, 1H), 2.68-2.73 (m, 2H), 2.43-2.46 (m, 3H), 1.99-2.05 (m, 1H), 1.45-1.68 (m, 10H), 1.28-1.30 (d, 3H), 0.85-0.90 (m, 2H), 0.70-0.75 (m, 2H). LC-MS: (M+H)+=421.2; HPLC purity=99.66%; Chiral RT=12.93 min [column: ChiralPak IC, mobile phase: hexane:IPA:DCM (7.5:1.5:1)].
Example 157
3-(4-cyclopropyl-6-fluoro-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (Peak-1) (167)
[0624]
Synthesis of Compound (157) (Peak-1)
[0625] Racemic compound (160) was purified by using chiral preparative HPLC chromatography to give Compound (157). LC-MS: (M+H)+=397.2; Chiral RT=10.98 min [column: ChiralPak IC, mobile phase: hexane:IPA:DCM (7.5:1.5:1)].
Example 168
3-(4-cyclopropyl-5-fluoro-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (Peak-2) (168)
[0626]
Synthesis of Compound (1658) (Peak 2)
[0627] Racemic compound (160) was purified by using chiral preparative HPLC chromatography to give Compound (157). LC-MS: (M+H)+=397.2; HPLC purity=98.48%; Chiral RT=14.93 min [column: ChiralPak IC, mobile phase: hexane:IPA:DCM (7.5:1.5:1)].
Example 169
{2-[3-(4-fluoro-1H-indol-3-yl)-3-(thiophen-2-yl)propanoyl]-2-azatricyclo[3.3.1.1 7 ]dec-5-yl}acetic acid (169)
[0628]
Synthesis of Compound (169)
[0629] Compound (169) was synthesized by following the procedure used to make Compound (43) (Scheme 14). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (169). 1H NMR (300 MHz, DMSO-d6): δ 11.93 (br s, 1H), 11.21 (br s, 1H), 7.35 (s, 1H), 7.21-7.23 (m, 1H), 7.15-7.18 (d, 1H), 6.97-7.04 (m, 1H), 6.85-6.88 (m, 1H), 6.81-6.83 (m, 1H), 6.63-6.70 (dd, 1H), 5.09-5.11 (t, 1H), 4.65 (br s, 1H), 4.27 (br s, 1H), 3.10-3.17 (m, 1H), 2.95-3.05 (m, 1H), 2.01 (s, 2H), 1.97 (s, 2H), 1.40-1.66 (m, 10H). LC-MS: (M+H)+=467.1; HPLC purity=99.63%.
Example 160
3-(4-cyclopropyl-5-methyl-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (160)
[0630]
Synthesis of Compound (160)
[0631] Compound (160) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (160). 1H NMR (300 MHz, CDCl3): δ 7.84 (br s, 1H), 7.04-7.07 (d, 1H), 6.97 (br s, 1H), 6.88-6.91 (d, 1H), 5.00 (br s, 1H), 4.34-4.47 (m, 1H), 4.20 (br s, 1H), 2.67-2.73 (dd, 1H), 2.43 (s, 3H), 2.29-2.37 (dd, 1H), 2.15-2.22 (m, 1H), 2.00-2.05 (m, 1H), 1.45-1.78 (m, 10H), 1.33-1.36 (m, 3H), 1.04-1.10 (M, 2H), 0.64-0.69 (m, 2H). LC-MS: (M+H)+=393.3; HPLC purity=98.30%.
Example 161
3-(4-chloro-6-cyclopropyl-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (161)
[0632]
Synthesis of Compound (161)
[0633] Compound (161) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (161). 1H NMR (300 MHz, CDCl3): δ 8.03 (br s, 1H), 7.08-7.10 (d, 1H), 7.01-7.01 (d, 1H), 6.74-6.77 (d, 1H), 5.02 (br s, 1H), 4.26 (br s, 1H), 4.10-4.12 (m, 1H), 2.37-2.46 (m, 1H), 2.26-2.29 (m, 1H), 2.15-2.24 (m, 1H), 1.45-1.75 (m, 11H), 1.36-1.39 (d, 3H), 0.89-0.96 (m, 2H), 0.59-0.62 (m, 2H). LC-MS: (M+H)+=413.1; HPLC purity=98.97%.
Example 162
{2-[3-(4-bromo-5-chloro-1H-indol-3-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]dec-5-yl}acetic acid (162)
[0634]
Synthesis of Compound (162)
[0635] Compound (162) was synthesized by following the procedure used to make Compound (43) (Scheme 14). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (162). 1H NMR (300 MHz, CDCl3): δ 8.70 (br s, 0.5H), 8.62 (br s, 0.5H), 7.12-7.15 (d, 1H), 7.07-7.09 (d, 1H), 7.01 (s, 1H), 4.87 (br s, 1H), 4.15-4.21 (m, 1H), 4.01 (br s, 1H), 2.72-2.85 (m, 1H), 2.45-2.60 (m, 1H), 2.29 (s, 2H), 2.04 (s, 1H), 1.50-1.75 (m, 10H). LC-MS: (M+H)+=493.2; HPLC purity=91.99%.
Example 163
3-(5-chloro-4-cyclopropyl-1H-indol-3-yl)-1-(5,7-dihydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (163)
[0636]
Synthesis of Compound (163)
[0637] Compound (163) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (163). 1H NMR (300 MHz, CDCl3): δ 8.01 (br s, 1H), 7.06 (s, 2H), 7.01-7.02 (d, 1H), 4.27-4.42 (m, 1H), 3.50 (br s, 1H), 3.43 (br s, 1H), 2.62-2.77 (dd, 1H), 2.37-2.46 (dd, 1H), 2.11-2.13 (m, 1H), 1.83-1.98 (m, 4H), 1.62-1.68 (m, 4H), 1.55-1.58 (m, 2H), 1.33-1.35 (d, 3H), 1.12-1.16 (m, 2H), 0.76-0.84 (m, 2H). LC-MS: (M+H)+=429.1; HPLC purity=99.90%.
Example 164
3-(4,5-dimethyl-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (164)
[0638]
Synthesis of Compound (164)
[0639] Compound (164) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (164). 1H NMR (300 MHz, CDCl3): δ 7.92 (br s, 1H), 7.01-7.03 (d, 1H), 6.91-6.93 (d, 1H), 6.90 (s, 1H), 5.03 (br s, 1H), 4.18 (br s, 1H), 3.92-3.95 (m, 1H), 2.68-2.74 (dd, 1H), 2.54 (s, 3H), 2.35-2.43 (dd, 1H), 2.29 (s, 3H), 2.20-2.25 (m, 1H), 1.52-1.75 (m, 11H), 1.33-1.35 (d, 3H). LC-MS: (M+H)+=367.2; HPLC purity=97.04%.
Example 165
1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(5-methoxy-4-methyl-1H-indol-3-yl)butan-1-one (165)
[0640]
Synthesis of Compound (165)
[0641] Compound (165) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (165). 1H NMR (300 MHz, CDCl3): δ 7.77 (br s, 1H), 7.05-7.08 (d, 1H), 6.95-6.96 (d, 1H), 6.82-6.85 (d, 1H), 5.04 (br s, 1H), 4.19 (br s, 1H), 3.87-3.89 (m, 1H), 3.77 (s, 3H0, 2.67-2.73 (dd, 1H), 2.54 (s, 3H), 2.36-2.44 (dd, 1H), 2.24-2.26 (m, 1H), 1.55-1.75 (m, 10H), 1.33-1.35 (d, 3H). LC-MS: (M+H)+=383.2; HPLC purity=95.78%.
Example 166
3-(4-chloro-5-methyl-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (166)
[0642]
Synthesis of Compound (166)
[0643] Compound (166) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (166). 1H NMR (300 MHz, CDCl3): δ 8.00 (br s, 1H), 7.08-7.10 (d, 1H), 6.98-7.00 (d, 1H), 6.95 (s, 1H), 5.02 (br s, 1H), 4.25 (br s, 1H), 4.09-4.11 (m, 1H), 2.82-2.87 (m, 1H), 2.40-2.44 (m, 1H), 2.38 (s, 3H), 2.23-2.25 (m, 1H), 1.55-1.78 (m, 11H). LC-MS: (M+H)+=388.2; HPLC purity=99.97%.
Example 167
2-{2-[3-(4-cyclopropyl-1H-indol-3-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]dec-5-yl}propanoic acid (167)
[0644]
Synthesis of Compound (167)
[0645] Compound (167) was synthesized by following the procedure used to make Compound (43) (Scheme 14). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (167). 1H NMR (300 MHz, DMSO-d6): δ 12.01 (br s, 1H), 10.81 (s, 1H), 7.16-7.17 (d, 1H), 7.12-7.15 (d, 1H), 6.88-6.93 (t, 1H), 6.55-6.58 (d, 1H), 4.72 (br s, 1H), 4.24 (br s, 1H), 4.02-4.04 (m, 1H), 2.67-2.723 (m, 2H), 2.38-2.43 (m, 1H), 2.05-2.07 (m, 1H), 1.99-2.02 (m, 1H), 1.46-1.74 M, 10H), 1.28-1.30 (d, 3H), 0.95-0.98 (d, 3H), 0.83-0.88 (m, 2H), 0.70-0.74 (m, 2H). LC-MS: (M+H)+=435.2; HPLC purity=96.54%.
Example 168
3-(4,5-dichloro-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (168)
[0646]
Synthesis of Compound (168)
[0647] Compound (168) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (168). 1H NMR (300 MHz, CDCl3): δ 8.18 (br s, 1H), 7.10-7.13 (d, 2H), 7.06-7.07 (d, 1H), 5.00 (br s, 1H), 4.24 (br s, 1H), 4.04-4.07 (m, 11-1H), 2.78-2.84 (m, 1H), 2.37-2.47 (dd, 1H), 2.24-2.26 (m, 1H), 1.73-1.78 (m, 3H), 1.61-1.65 (m, 7H), 1.35-1.38 (d, 3H). LC-MS: (M+H)+=407.1; HPLC purity=99.28%
Example 169
3-(4,5-dimethyl-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (Peak-1) (169)
[0648]
Synthesis of Compound (169)
[0649] Racemic compound (164) was purified by using chiral preparative HPLC chromatography to give Compound (169). 1H NMR (300 MHz, CDCl3): δ 7.92 (br s, 1H), 7.01-7.03 (d, 1H), 6.91-6.93 (d, 1H), 6.90 (s, 1H), 5.03 (br s, 1H), 4.18 (br s, 1H), 3.92-3.95 (m, 1H), 2.68-2.74 (dd, 1H), 2.54 (s, 3H), 2.35-2.43 (dd, 1H), 2.29 (s, 3H), 2.20-2.25 (m, 1H), 1.52-1.75 (m, 11H), 1.33-1.35 (d, 3H). LC-MS: (M+H)+=367.2; HPLC purity=93.27%; Chiral RT=20.93 min [column: ChiralPak IC, mobile phase: hexane:IPA:DCM (7.5:1.5:1)].
Example 170
3-(4,5-dimethyl-1H-indol-3-yl)-1-(6-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (Peak-2) (170)
[0650]
Synthesis of Compound (170)
[0651] Racemic compound (164) was purified by using chiral preparative HPLC chromatography to give Compound (170). 1H NMR (300 MHz, CDCl3): δ 7.92 (br s, 1H), 7.01-7.03 (d, 1H), 6.91-6.93 (d, 1H), 6.90 (s, 1H), 5.03 (br s, 1H), 4.18 (br s, 1H), 3.92-3.95 (m, 1H), 2.68-2.74 (dd, 1H), 2.54 (s, 3H), 2.35-2.43 (dd, 1H), 2.29 (s, 3H), 2.20-2.25 (m, 1H), 1.52-1.75 (m, 11H), 1.33-1.35 (d, 3H). LC-MS: (M+H)+=367.2; HPLC purity=99.81%; Chiral RT=25.61 min [column: ChiralPak IC, mobile phase: hexane:IPA:DCM (7.5:1.5:1)].
Example 171
3-(4-cyclopropyl-5-methoxy-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (171)
[0652]
Synthesis of Compound (171)
[0653] Compound (171) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (171). 1H NMR (300 MHz, CDCl3): δ 7.83 (br s, 1H), 7.06-7.09 (d, 1H), 6.98-6.99 (d, 1H), 6.78-6.81 (d, 1H), 5.02 (br s, 1H), 4.26-4.29 (m, 1H), 4.19 (br s, 1H), 3.78 (s, 3H), 2.69-2.76 (dd, 1H), 2.31-2.39 (dd, 1H), 2.22-2.25 (m, 1H), 1.95-1.99 (m, 2H), 1.45-1.75 (m, 9H), 1.34-1.36 (d, 3H), 0.99-1.01 (m, 2H), 0.79-0.81 (m, 2H). LC-MS: (M+H)+=409.2; HPLC purity=92.57%.
Example 172
3-(4,5-dichloro-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (Peak-1) (172)
[0654]
Synthesis of Compound (172)
[0655] Racemic compound (168) was purified by using chiral preparative HPLC chromatography to give Compound (172). 1H NMR (300 MHz, CDCl3): δ 8.18 (br s, 1H), 7.10-7.13 (d, 2H), 7.06-7.07 (d, 1H), 5.00 (br s, 1H), 4.24 (br s, 1H), 4.04-4.07 (m, 1H), 2.78-2.84 (m, 1H), 2.37-2.47 (dd, 1H), 2.24-2.26 (m, 1H), 1.73-1.78 (m, 3H), 1.61-1.65 (m, 7H), 1.35-1.38 (d, 3H). LC-MS: (M+H)+=407.0; HPLC purity=94.74%; Chiral RT=8.15 min [column: ChiralPak IC, mobile phase: hexane:IPA:DCM (7:2:1)].
Example 173
3-(4,6-dichloro-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (Peak-2) (173)
[0656]
Synthesis of Compound (173)
[0657] Racemic compound (168) was purified by using chiral preparative HPLC chromatography to give Compound (173). 1H NMR (300 MHz, CDCl3): δ 8.18 (br s, 1H), 7.10-7.13 (d, 2H), 7.06-7.07 (d, 1H), 5.00 (br s, 1H), 4.24 (br s, 1H), 4.04-4.07 (m, 1H), 2.78-2.84 (m, 1H), 2.37-2.47 (dd, 1H), 2.24-2.26 (m, 1H), 1.73-1.78 (m, 3H), 1.61-1.65 (m, 7H), 1.35-1.38 (d, 3H). LC-MS: (M+H)+=407.0; HPLC purity=99.34%; Chiral RT=11.31 min [column: ChiralPak IC, mobile phase: hexane:IPA:DCM (7:2:1)].
Example 174
3-(4-chloro-5-methyl-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (Peak-1) (174)
[0658]
Synthesis of Compound (174)
[0659] Racemic compound (166) was purified by using chiral preparative HPLC chromatography to give Compound (174). 1H NMR (300 MHz, CDCl3): δ 8.00 (br s, 1H), 7.08-7.10 (d, 1H), 6.98-7.00 (d, 1H), 6.95 (s, 1H), 5.02 (br s, 1H), 4.25 (br s, 1H), 4.09-4.11 (m, 1H), 2.82-2.87 (m, 1H), 2.40-2.44 (m, 1H), 2.38 (s, 3H), 2.23-2.25 (m, 1H), 1.55-1.78 (m, 11H). LC-MS: (M+H)+=387.1; HPLC purity=95.57%; Chiral RT=15.30 min [column: ChiralPak IC, mobile phase: hexane:THF (7:3)].
Example 175
3-(4-chloro-5-methyl-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (peak 2) (175)
[0660]
Synthesis of Compound (176)
[0661] Racemic compound 166) was purified by using chiral preparative HPLC chromatography to give Compound (175). 1H NMR (300 MHz, CDCl3): δ 8.00 (br s, 1H), 7.08-7.10 (d, 1H), 6.98-7.00 (d, 1H), 6.95 (s, 1H), 5.02 (br s, 1H), 4.25 (br s, 1H), 4.09-4.11 (m, 1H), 2.82-2.87 (m, 1H), 2.40-2.44 (m, 1H), 2.38 (s, 3H), 2.23-2.25 (m, 1H), 1.55-1.78 (m, 11H). LC-MS: (M+H)+=387.1; HPLC purity=98.33%; Chiral RT=17.15 min [column: ChiralPak IC, mobile phase: hexane:THF (7:3)].
Example 176
3-(4,5-dimethyl-1H-indol-3-yl)-1-(5-fluoro-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (176)
[0662]
Synthesis of Compound (176)
[0663] Compound (176) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (176). 1H NMR (300 MHz, CDCl3): δ 8.06 (br s, 1H), 8.02-8.04 (d, 1H), 7.31-7.34 (d, 1H), 7.11-7.13 (d, 1H), 4.99-5.05 (m, 1H), 4.70-4.71 (m, 1H), 4.61-4.62 (m, 1H), 2.57-2.62 (m, 1H), 2.33-2.41 (m, 1H), 2.25 (s, 3H), 2.10 (s, 3H), 1.33-1.87 (m, 14H). LC-MS: (M−19)+=413.3; HPLC purity=90.92%.
Example 177
1-(6-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-[4-(propan-2-yloxy)-1H-indol-3-yl]butan-1-one (177)
[0664]
Synthesis of Compound (177)
[0665] Compound (177) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (177). 1H NMR (300 MHz, CDCl3): δ 7.91 (br s, 1H), 7.03-7.08 (t, 1H), 6.91-6.93 (d, 1H), 6.90 (s, 1H), 6.46-6.49 (d, 1H), 5.06 (br s, 1H), 4.74-4.80 (m, 1H), 4.22 (br s, 1H), 3.76-3.88 (m, 1H), 2.97-3.06 (m, 1H), 2.52-2.56 (m, 1H), 2.22-2.27 (m, 1H), 1.55-1.77 (m, 10H), 1.42-1.45 (m, 9H). LC-MS: (M+H)+=397.2; HPLC purity=90.56%.
Example 178
1-(6-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-[4-(propan-2-yloxy)-1H-indol-3-yl]butan-1-one (Peak-1) (178)
[0666]
Synthesis of Compound (178)
[0667] Racemic compound (177) was purified by using chiral preparative HPLC chromatography to give Compound (178). LC-MS: (M+H)+=397.2; HPLC purity=99.12%. Chiral RT=9.72 min [column: ChiralPak IC, mobile phase: hexane:IPA:DCM (8:1:1)].
Example 179
1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-[4-(propan-2-yloxy)-1H-indol-3-yl]butan-1-one (Peak-2) (179)
[0668]
Synthesis of Compound (179)
[0669] Racemic compound (177) was purified by using chiral preparative HPLC chromatography to give Compound (179). LC-MS: (M+H)+=397.2; HPLC purity=99.65%. Chiral RT=11.97 min [column: ChiralPak IC, mobile phase: hexane:IPA:DCM (8:1:1)].
Example 180
1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-[4-(piperidin-1-yl)-1H-indol-3-yl]butan-1-one (180)
[0670]
Synthesis of Compound (180)
[0671] Compound (IOU) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (180). 1H NMR (300 MHz, CDCl3): δ 7.90 (br s, 1H), 7.00-7.04 (m, 2H), 6.90-6.94 (m, 1H), 6.73-6.76 (m, 1H), 5.03 (br s, 1H), 4.13 (br s, 1H), 3.76-3.79 (m, 1H), 3.64-3.66 (m, 1H), 3.15-3.25 (m, 2H0, 2.86-2.92 (m, 1H), 2.76-2.77 (m, 1H), 2.37-2.41 (m, 1H), 2.19-2.21 (m, 1H), 1.34-1.98 (m, 19H). LC-MS: (M+H)+=422.2; HPLC purity=97.45%.
Example 181
1-(2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-[4-(propan-2-yloxy)-1H-indol-3-yl]butan-1-one (181)
[0672]
Synthesis of Compound (181)
[0673] Compound (181) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (181). 1H NMR (300 MHz, CDCl3): δ 7.85 (br s, 1H), 7.04-7.07 (m, 1H), 6.89-6.92 (m, 2H), 6.46-6.48 (m, 1H), 4.87 (br s, 1H), 4.75-4.79 (m, 1H), 4.04 (br s, 1H), 3.80-3.84 (m, 1H), 2.49-2.54 (m, 1H), 2.31-2.35 (m, 1H), 2.00-2.05 (m, 1H), 1.55-1.80 (m, 11H), 1.42-1.45 (m, 9H). LC-MS: (M+H)+=381.2; HPLC purity=99.41%
Example 182
1-(5-fluoro-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-[4-(propan-2-yloxy)-1H-indol-3-yl]butan-1-one (182)
[0674]
Synthesis of Compound (182)
[0675] Compound (182) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (182). 1H NMR (300 MHz, CDCl3): δ 7.82 (br s, 1H), 6.97-7.02 (t, 1H), 6.84-6.86 (d, 1H), 6.83 (s, 1H), 6.40-6.42 (d, 1H), 5.07 (br s, 1H), 4.65-4.73 (m, 1H), 4.21 (br s, 1H), 3.71-3.78 (m, 1H), 2.90-3.00 (m, 1H), 2.39-2.50 (m, 1H), 2.21-2.24 (m, 1H), 1.53-1.90 (m, 10H), 1.35-1.39 (m, 9H). LC-MS: (M+H)+=399.2; HPLC purity=93.52%.
Example 183
1-{3-[4-(2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-4-oxobutan-2-yl]-1H-indol-4-yl}piperidine-4-carboxylic acid (183)
[0676]
Synthesis of Compound (183)
[0677] Compound (183) was synthesized by following the procedure used to make Compound (43) (Scheme 14). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (183). LC-MS: (M+H)+=450.2; HPLC purity=97.82%.
Example 184
1-(5-fluoro-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-[4-(propan-2-yloxy)-1H-indol-3-yl]butan-1-one (Peak-1) (184)
[0678]
Synthesis of Compound (184)
[0679] Racemic compound (182) was purified by using chiral preparative HPLC chromatography to give Compound (184). LC-MS: (M+H)+=399.2; HPLC purity=95.51%. Chiral RT=13.60 min [column: ChiralPak IC, mobile phase: hexane:IPA:DCM (8:1:1)].
Example 185
1-(5-fluoro-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-[4-(propan-2-yloxy)-1H-indol-3-yl]butan-1-one (Peak-2) (185)
[0680]
Synthesis of Compound (185)
[0681] Racemic compound 182) was purified by using chiral preparative HPLC chromatography to give Compound (185). LC-MS: (M+H)+=399.2; HPLC purity=97.38%. Chiral RT=18.54 min [column: ChiralPak IC, mobile phase: hexane:IPA:DCM (8:1:1)].
Example 186
2-{2-[3-(4-chloro-1H-indol-3-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]dec-5-yl}propanoic acid (186)
[0682]
Synthesis of Compound (186)
[0683] Compound (186) was synthesized by following the procedure used to make Compound (43) (Scheme 14). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (186). LC-MS: (M+H)+=429.13; HPLC purity=90.92%.
Example 187
1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-[4-(thiophen-3-yl)-1H-indol-3-yl]butan-1-one (187)
[0684]
Synthesis of Compound (187)
[0685] Compound (187) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (187). LC-MS: (M+H)+=421.1; HPLC purity=96.22%.
Example 188
1-(6-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-[4-(thiophen-2-yl)-1H-indol-3-yl]butan-1-one (Peak-1) (188)
[0686]
Synthesis of Compound (188)
[0687] Racemic compound (163) was purified by using chiral preparative HPLC chromatography to give Compound (188). LC-MS: (M+H)+=421.1; HPLC purity=92.0%; Chiral RT=6.57 min [column: ChiralPak IC, mobile phase: hexane:THF:EtOH (8:1:1)].
Example 189
1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-[4-(thiophen-2-yl)-1H-indol-3-yl]butan-1-one (Peak-2) (189)
[0688]
Synthesis of Compound (189)
[0689] Racemic compound (163) was purified by using chiral preparative HPLC chromatography to give Compound (189). LC-MS: (M+H)+=421.1; HPLC purity=93.52%; Chiral RT=9.17 min [column: ChiralPak IC, mobile phase: hexane:THF:EtOH (8:1:1)].
Example 190
3-(5-chloro-1,3-benzothiazol-2-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (190)
[0690]
Synthesis of Compound (190)
[0691] Compound (190) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (190). LC-MS: (M+H)+=391.1; HPLC purity=96.40%.
Example 191
2-[3-(5-chloro-1,3-benzothiazol-2-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-5-carbonitrile (191)
[0692]
Synthesis of Compound (191)
[0693] Compound (191) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (191). LC-MS: (M+H)+=400.1; HPLC purity=97.71%.
Example 192
3-(6-chloro-1,3-benzothiazol-2-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (192)
[0694]
Synthesis of Compound (192)
[0695] Compound (192) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (192). LC-MS: (M+H)+=391.1; HPLC purity=94.40%.
Example 193
2-[3-(6-chloro-1,3-benzothiazol-2-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-6-carbonitrile (193)
[0696]
Synthesis of Compound (193)
[0697] Compound (193) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (193). LC-MS: (M+H)+=400.1; HPLC purity=94.39%.
Example 194
3-(6-chloro-1,3-benzothiazol-2-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (Peak-1) (194)
[0698]
Synthesis of Compound (194)
[0699] Racemic compound (192) was purified by using chiral preparative HPLC chromatography to give Compound (194). LC-MS: (M+H)+=391.1; HPLC purity=99.6%.
Example 195
3-(6-chloro-1,3-benzothiazol-2-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (Peak-2) (195)
[0700]
Synthesis of Compound (195)
[0701] Racemic compound (192) was purified by using chiral preparative HPLC chromatography to give Compound (195). LC-MS: (M+H)+=391.1; HPLC purity=99.56%.
Example 196
2-[3-(6-chloro-1,3-benzothiazol-2-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-5-carboxamide (196)
[0702]
Synthesis of Compound (196)
[0703] Compound (196) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (196). LC-MS: (M+H)+=418.1; HPLC purity=97.62%.
Example 197
3-(4,5-dichloro-1H-pyrrolo[2,3-b]pyridin-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (197)
[0704]
Synthesis of Compound (197)
[0705] Compound (197) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (197). LC-MS: (M+H)+=408.1; HPLC purity=94.42%.
Example 198
3-(5-chloro-4-cyclopropyl-1H-pyrrolo[2,3-b]pyridin-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (198)
[0706]
Synthesis of Compound (198)
[0707] Compound (198) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (198). LC-MS: (M+H)+=414.2; HPLC purity=98.68%.
Example 199
3-(5-chloro-4-cyclopropyl-1H-pyrrolo[2,3-b]pyridin-3-yl)-1-(6-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (Peak-1) (199)
[0708]
Synthesis of Compound (199)
[0709] Racemic compound (198) was purified by using chiral preparative HPLC chromatography to give Compound (199). LC-MS: (M+H)+=414.2; HPLC purity=94.06%. Chiral RT=15.94 min [column: ChiralPak IC, mobile phase: hexane:IPA:DCM (7.5:1.5:1)].
Example 200
3-(5-chloro-4-cyclopropyl-1H-pyrrolo[2,3-b]pyridin-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (Peak-2) (200)
[0710]
Synthesis of Compound (200)
[0711] Racemic compound (198) was purified by using chiral preparative HPLC chromatography to give Compound (200). LC-MS: (M+H)+=414.2; HPLC purity=98.40%. Chiral RT=20.09 min [column: ChiralPak IC, mobile phase: hexane:IPA:DCM (7.5:1.5:1)].
Example 201
3-(4,5-dicyclopropyl-1H-pyrrolo[2,3-b]pyridin-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (201)
[0712]
Synthesis of Compound (201)
[0713] Compound (201) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (201). LC-MS: (M+H)+=420.2; HPLC purity=90.88%.
Example 202
3-(6-chloro-1H-benzimidazol-2-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (202)
[0714]
Synthesis of Compound (202)
[0715] Compound (202) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (202). LC-MS: (M+H)+=372.1; HPLC purity=84.69%.
Example 203
3-(6-cyclopropyl-1H-benzimidazol-2-yl)-1 (6-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (203)
[0716]
Synthesis of Compound (203)
[0717] Compound (203) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (203). LC-MS: (M+H)+=380.1; HPLC purity=98.88%.
Example 204
{2-[3-(4-cyclopropyl-1H-pyrrolo[2,3-b]pyridin-3-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]dec-6-yl}acetic acid (204)
[0718]
Synthesis of Compound (204)
[0719] Compound (204) was synthesized by following the procedure used to make Compound (43) (Scheme 14). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (204). LC-MS: (M+H)+=422.2; HPLC purity=99.63%.
Example 205
3-(1-cyclopropyl-4-methyl-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (205)
[0720]
Synthesis of Compound (205)
[0721] Compound (205) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (205). LC-MS: (M+H)+=393.2; HPLC purity=99.04%.
Example 206
3-(1,4-dimethyl-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (206)
[0722]
Synthesis of Compound (206)
[0723] Compound (206) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (206). LC-MS: (M+H)+=367.2; HPLC purity=98.36%.
Example 207
3-(4-chloro-1-methyl-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (207)
[0724]
Synthesis of Compound (207)
[0725] Compound (207) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (207). LC-MS: (M+H)+=387.1; HPLC purity=99.49%.
Example 208
3-[4-chloro-5-(furan-2-yl)-1H-indol-3-yl]-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (208)
[0726]
Synthesis of Compound (208)
[0727] Compound (208) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (208). LC-MS: (M+H)+=439.1; HPLC purity=91.39%.
Example 209
1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(4-methoxy-5-methyl-1H-indol-3-yl)butan-1-one (209)
[0728]
Synthesis of Compound (209)
[0729] Compound (209) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (209). LC-MS: (M+H)+=383.2; HPLC purity=93.48%.
Example 210
1-(6-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-[5-methyl-4-(thiophen-2-yl)-1H-indol-3-yl]butan-1-one (210)
[0730]
Synthesis of Compound (210)
[0731] Compound (210) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (210). LC-MS: (M+H)+=435.2; HPLC purity=91.98%.
Example 211
4-chloro-3-[4-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-4-oxobutan-2-yl]-5-methyl-1,3-dihydro-2H-indol-2-one (211)
[0732]
[0000]
Synthesis of Compound (211)
[0733] To a stirred solution of Compound (166) (15 mg, 0.03 mmol) in DMF (2 mL) was added pyridinium tribromide (16 mg, 0.050 mmol) at 0° C. Resulted reaction mixture was stirred at room temperature for 3 hours. After reaction quenched with H 2 O (10 mL), extracted with ether (2×20 mL). The combined organic layers were washed with brine and concentrated. Resulted crude material was purified by preparative TLC eluting with DCM:MeOH (95:05) to give Compound (211) (5.5 mg, off white solid).
Example 212
4-cyclopropyl-3-[4-(6-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-4-oxobutan-2-yl]-1,3-dihydro-2H-indol-2-one (212)
[0734]
Synthesis of Compound (212)
[0735] Compound (212) was synthesized by following the procedure used to make Compound (211) (Scheme 26). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (212). 1H NMR (300 MHz, CDCl3): δ 7.50 (br s, 1H), 7.07-7.12 (t, 1H), 6.59-6.62 (d, 1H), 6.48-6.51 (d, 1H), 5.11 (br s, 1H), 4.54 (br s, 1H), 3.81 (br s, 1H), 3.79-3.81 (m, 1H), 2.37-2.41 (m, 2H), 2.21-2.23 (m, 1H). 1.43-1.88 (m, 11H), 1.06-1.08 (m, 2H), 0.83-0.88 (m, 2H), 0.72-0.74 (d, 3H). LC-MS: (M+H)+=395.2; HPLC purity=99.65%.
Example 213
3-(4-cyclopropyl-1H-indol-3-yl)-1-(5-fluoro-7-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (213)
[0736]
Synthesis of Compound (213)
[0737] Compound (213) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (213). 1H NMR (300 MHz, CDCl3): δ 8.06 (br s, 1H), 7.18-7.20 (d, 1H), 7.05-7.10 (t, 1H), 7.04 (s, 1H), 6.74-6.76 (d, 1H), 5.26 (br s, 1H), 4.40 (br s, 1H), 4.23-4.25 (m, 1H), 2.85-2.90 (m, 1H), 2.45-2.53 (m, 2H), 1.99 (br s, 2H), 1.62-1.81 (m, 8H), 1.44-1.46 (d, 3H), 0.95-0.99 (m, 2H), 0.81-0.85 (m, 2H). LC-MS: (M+H)+=397.3; HPLC purity=93.84%.
Example 214
1-(6-hydroxy-7-methyl-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-[4-(propan-2-yloxy)-1H-indol-3-yl]butan-1-one (214)
[0738]
Synthesis of Compound (214)
[0739] Compound (214) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (214). 1H NMR (300 MHz, CDCl3): δ 7.86 (br s, 1H), 6.96-7.01 (t, 1H), 6.84-6.86 (d, 1H), 6.83 (s, 1H), 6.39-6.42 (d, 1H), 5.00 (br s, 1H), 4.67-4.72 (m, 1H), 4.20 (br s, 1H), 3.72-3.79 (m, 1H), 2.89-3.01 (m, 1H), 2.39-2.51 (m, 1H), 1.25-1.65 (m, 19H). LC-MS: (M+H)+=411.3; HPLC purity=90.45%.
Example 215
2-(2-(3-(4-(5-fluorofuran-2-yl)-1H-indol-3-yl)butanoyl)-2-azaadamantan-5-yl)acetic acid (215)
[0740]
Synthesis of Compound (216)
[0741] Compound (216) was synthesized by following the procedure used to make Compound (43) (Scheme 14). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (215). LC-MS: (M+H)+=465.4; HPLC purity=99.37%.
Example 216
1-(5-hydroxy-2-azaadamantan-2-yl)-3-(4-methyl-1-(quinolin-8-ylsulfonyl)-1H-indol-3-yl)butan-1-one (216)
[0742]
Synthesis of Compound (216)
[0743] Compound (216) was synthesized by following the procedure used to make Compound (1) (Scheme 2). LC-MS: (M+H)+=544.3; HPLC purity=98.61%.
Example 217
4-chloro-3-(4-(6-hydroxy-2-azaadamantan-2-yl)-4-oxobutan-2-yl)-5-methyl-1H-indole-2-carbonitrile (217)
[0744]
Synthesis of Compound (217)
[0745] Compound (217) was synthesized by following the procedure used to make Compound (1) (Scheme 2). LC-MS: (M+H)+=412.3.
Example 218
4-chloro-3-(4-(6-hydroxy-2-azaadamantan-2-yl)-4-oxobutan-2-yl)-1H-indole-2-carbonitrile (218)
[0746]
Synthesis of Compound (218)
[0747] Compound (218) was synthesized by following the procedure used to make Compound (1) (Scheme 2). LC-MS: (M+H)+=398.2; HPLC purity=98.47%.
Example 219
3-(4-chloro-5-methyl-1H-indol-3-yl)-1-(5-hydroxy-7-methyl-2-azaadamantan-2-yl)butan-1-one (219)
[0748]
Synthesis of Compound (219)
[0749] Compound (219) was synthesized by following the procedure used to make Compound (1) (Scheme 2). LC-MS: (M+H)+=401.2; HPLC purity=89.36%.
Example 220
4-cyclopropyl-3-(4-(5-hydroxy-2-azaadamantan-2-yl)-4-oxobutan-2-yl)-1H-indole-2-carbonitrile (220)
[0750]
Synthesis of Compound (220)
[0751] Compound (220) was synthesized by following the procedure used to make Compound (1) (Scheme 2). LC-MS: (M+H)+=404.3; HPLC purity=98.29%.
Example 221
2-(3-(4,5-dimethyl-1H-indol-3-yl)butanoyl)-2-azaadamantane-5-carbonitrile (221)
[0752]
Synthesis of Compound (221)
[0753] Compound (221) was synthesized by following the procedure used to make Compound (1) (Scheme 2). LC-MS: (M+H)+=376.3; HPLC purity=85.11%.
Example 222
2-(3-(4-(furan-2-yl)-1H-indol-3-yl)butanoyl)-2-azaadamantane-5-carboxylic acid (222)
[0754]
Synthesis of Compound (222)
[0755] Compound (222) was synthesized by following the procedure used to make Compound (43) (Scheme 14). LC-MS: (M+H)+=433.3; HPLC purity=98.85%.
Example 223
4-cyclopropyl-3-(4-(6-hydroxy-2-azaadamantan-2-yl)-4-oxobutan-2-yl)-1H-indole-2-carboxylic acid (223)
[0756]
[0000]
Synthesis of Compound (223)
[0757] Compound 220 (0.070 g, 0.17 mmol) was taken in a sealed tube and MeOH (3 mL) was added to it followed by addition of 50% aqueous KOH solution (2 mL). The reaction mixture was then heated at 110° C. for 24 hours and concentrated to give crude material, which was diluted with H 2 O, acidified with 2N HCl (PH=2), extracted with EtOAc and concentrated to give crude product. The crude product was then purified by using silica gel column chromatography eluting with mixture of DCM:MeOH to give 30 mg of Compound (223) as brown solid. LC-MS: (M+H)+=423.1; HPLC purity=98.09%.
Example 224
1-(5-fluoro-2-azaadamantan-2-yl)-3-(5-methoxy-1H-indol-3-yl)butan-1-one (224)
[0758]
Synthesis of Compound (224)
[0759] Compound (224) was synthesized by following the procedure used to make Compound (1) (Scheme 2). LC-MS: (M+H)+=371.2; HPLC purity=92.10%.
Example 226
3-(4-(5-bromo-2-azaadamantan-2-yl)-4-oxobutan-2-yl)-1H-indol-5-yl trifluoromethanesulfonate (225)
[0760]
Synthesis of Compound (225)
[0761] Compound (225) was synthesized by following the procedure used to make Compound (1) (Scheme 2). LC-MS: (M+H)+=549.2; HPLC purity=92.61%.
Example 226
1-(2-azaadamantan-2-yl)-3-(5-methoxy-1H-indol-3-yl)butan-1-one (226)
[0762]
Synthesis of Compound (226)
[0763] Compound (226) was synthesized by following the procedure used to make Compound (1) (Scheme 2). LC-MS: (M+H)+=353.2; HPLC purity=90.02%.
Example 227
3-(5-methoxy-1H-indol-3-yl)-1-(5-methyl-2-azaadamantan-2-yl)butan-1-one (227)
[0764]
Synthesis of Compound (227)
[0765] Compound (227) was synthesized by following the procedure used to make Compound (1) (Scheme 2). LC-MS: (M+H)+=367.3; HPLC purity=92.59%.
Example 228
3-(4-(2-azaadamantan-2-yl)-4-oxobutan-2-yl)-1H-indol-6-yl trifluoromethanesulfonate (228)
[0766]
Synthesis of Compound (228)
[0767] Compound (228) was synthesized by following the procedure used to make Compound (1) (Scheme 2). 1H NMR (300 MHz, DMSO-d6): δ 11.24 (br s, 1H), 7.59 (s, 1H), 7.44-7.47 (d, 1H), 7.36 (s, 1H), 7.11-7.14 (d, 1H), 4.62 (br s, 1H), 4.01 (br s, 1H), 3.43-3.48 (m, 1H), 2.62-2.65 (m, 1H), 2.43.2.47 (m, 1H), 2.10 (s, 1H), 2.00 (s, 1H), 1.44-1.86 (m, 10H), 1.30-1.33 (d, 3H). LC-MS: (M+H)+=471.1; HPLC purity=89.84%.
Example 229
3-(4-(2-azaadamantan-2-yl)-4-oxobutan-2-yl)-1H-indol-5-yl methanesulfonate (229)
[0768]
Synthesis of Compound (229)
[0769] Compound (229) was synthesized by following the procedure used to make Compound (1) (Scheme 2). 1H NMR (300 MHz, CDCl3): δ 8.37 (br s, 1H), 7.50 (s, 1H), 7.23-7.26 (d, 1H), 6.98-7.05 (m, 2H), 4.74 (br s, 1H), 3.92 (br s, 1H), 3.51-3.58 (m, 1H), 3.08 (s, 1H), 2.68-2.75 (m, 1H), 2.41-2.48 (m, 1H), 1.96 (br s, 1H), 1.84 (br s, 1H), 1.45-1.72 (m, 10H), 1.39-1.42 (d, 3H). LC-MS: (M+H)+=417.1; HPLC purity=92.90%.
Example 230
2-(3-(5-methoxy-1H-indol-3-yl)butanoyl)-2-azaadamantane-5-carbonitrile (230)
[0770]
Synthesis of Compound (230)
[0771] Compound (230) was synthesized by following the procedure used to make Compound (1) (Scheme 2). 1H NMR (300 MHz, CDCl3): δ 7.95 (br s, 1H), 7.22-7.28 (m, 1H), 7.09-7.12 (m, 1H), 6.99-7.00 (d, 1H), 6.83-6.89 (m, 1H), 4.91-4.95 (d, 1H), 3.97-4.03 (d, 1H), 3.86 (s, 3H), 3.61-3.67 (m, 1H), 2.72-2.81 (m, 1H), 2.45-2.55 (m, 1H), 2.13-2.16 (m, 1H), 1.58-2.05 (m, 10H) 1.48-1.51 (d, 3H). LC-MS: (M+H)+=378.3; HPLC purity=99.49%.
Example 231
1-(5-amino-2-azaadamantan-2-yl)-3-(4-cyclopropyl-1H-indol-3-yl)butan-1-one (231)
[0772]
[0000]
Synthesis of Intermediate-61
[0773] To a stirred solution of compound-41 (0.10 g, 0.26 mmol) in DCM (5 mL) in AcOH (2 mL), chloroaceto nitrile (117 mg, 1.56 mmol) was added at 0° C. The reaction mixture was then treated with sulfuric acid (0.75 mL). The reaction mixture was stirred at 0° C. for 1 hour and continued to stir at room temperature for 12 hours. After completion of the reaction, the reaction mixture was quenched with saturated aqueous NaHCO 3 solution and extracted with EtOAc to give Intermediate-61 (90 mg). It was used for next step without any purification.
Synthesis of Compound 231
[0774] A stirred solution of Intermediate-61 (0.090 g, 0.19 mmol)) and thiourea (0.028 g, 0.38 mmol) in EtOH (5 mL) at 0° C. was treated with acetic acid (0.5 mL). The reaction mixture was heated to reflux for 12 hours. After completion of the reaction, the reaction mixture was quenched with saturated sodium bicarbonate solution, extracted with DCM and concentrated to give Compound 231 (30 mg).
Example 232
3-(4-cyclopropyl-1H-indol-3-yl)-1-(5-(methylamino)-2-azaadamantan-2-yl)butan-1-one (232)
[0775]
[0000]
Synthesis of 232
[0776] To a stirred solution of Compound 231 (0.020 g, 0.053 mmol)) in DMF, K 2 CO 3 (14.6 mg, 0.16 mmol) was added at 0′C. To this solution Mel was added and stirred at room temperature for 2 hours. After completion of the reaction, the reaction mixture was quenched with H 2 O, extracted with EtOAc, and concentrated to give crude product, which was purified by using prep TLC to give Compound 232 (5 mg).
Example 233
3-(4-cyclopropyl-1H-indazol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)propan-1-one (233)
[0777]
[0000]
Synthesis of Intermediate-62
[0778] To a stirred solution of Starting Material-14 (2.0 g, 8.6 mmol) in THF:MeOH (40 mL, 1:1), activated Zn powder (3.71 g, 69.5 mmol) was added, followed by saturated NH 4 Cl solution and stirred at room temperature for 3 hours. After completion of the reaction, the reaction mixture it was concentrated and diluted with H 2 O, extracted with EtOAc and concentrated to give Intermediate-62 (1.7 g) as pale yellow solid.
Synthesis of Intermediate-63
[0779] To a stirred solution of Intermediate-62 (1.8 g, 9.7 mmol) in chloroform (20 mL), Ac 2 O (2.25 mL, 22.0 mmol) was added at 0° C. The resulted reaction mixture was stirred at room temperature for 24 hours. Then KOAc (0.28 g, 2.9 mmol), followed by isoamylnitrite (2.44 g, 20 mmol) were added, and heated at 60° C. for 18 hours. After completion of the reaction, the reaction mixture quenched with H 2 O and concentrated, to this conc HCl (5 mL) was added and heated at 60° C. for 2 hours. The reaction mixture was then basified with 50% aqueous NaOH solution and extracted with EtOAc and concentrated to give Intermediate-63 (420 mg) as brown solid.
Synthesis of Intermediate-64
[0780] To a stirred solution of Intermediate-63 (0.50 g. 2.5 mmol) in DMF (5 mL), KOH (0.28 g, 5.0 mmol) was added and stirred at room temperature for 20 minutes. To the reaction mixture iodine (0.26 g, 5.0 mmol) in DMF was added and the reaction was continued at room temperature for 12 hours. After completion of the reaction the reaction mixture was quenched with H 2 O, extracted with EtOAc and concentrated to give Intermediate-64 (750 mg) as brown solid, which was used in next step without any purification.
Synthesis of Intermediate-66
[0781] To a stirred solution of Intermediate-64 (0.75 g, 2.3 mmol) in MeCN (5 mL), TEA (0.696 g, 6.9 mmol), DMAP (0.024 g, 0.2 mmol) and (Boc) 2 O (1.00 g, 4.6 mmol) were added at 0° C. The resulted reaction mixture was stirred at room temperature for 4 hours. After completion of the reaction, the reaction mixture was quenched with H 2 O, extracted with EtOAc and concentrated to give crude material. The crude material was purified by using silica gel column chromatography eluting with mixture of hexane:EtOAc to give Intermediate-65 (700 mg) as white solid.
Synthesis of Intermediate-66
[0782] To a stirred solution of Intermediate-65 (0.25 g, 0.7 mmol) in DMF (5 mL), TEA (0.31 mL, 2.3 mmol), ethyl crotanoate (0.11 g, 1.1 mmol) and TBAl (0.05 g, 0.14 mmol) were added, and purged with argon gas for 15 minutes. To the reaction mixture PdCl 2 (dppf) (0.06 g, 0.07 mmol) was added. The resulted reaction mixture was kept under micro wave conditions at 100° C. for 2 hours. After completion of the reaction, the reaction mixture was filtered through celite and concentrated, resulted crude material was purified by using silica gel column chromatography eluting with mixture of hexanes:EtrOAc to give Intermediate-66 (20 mg) as white solid.
Synthesis of Intermediate-67
[0783] To a stirred solution of Intermediate-66 (0.05 g, 0.12 mmol) in dioxane:H2O (4 mL, 3:1) cyclopropyl boronic acid (0.02 g, 0.25 mmol), Cs 2 CO 3 (0.136 g, 0.42 mmol) were added, and purged with argon gas for 10 minutes. To the reaction mixture PdCl 2 (dppf) 0.009 g, 0.012 mmol) was added. The resulted reaction mixture was kept under micro wave conditions at 120° C. for 1 hour. After completion of the reaction, the reaction mixture was quenched with H 2 O, extracted with EtOAc and concentrated. The resulted reaction mixture was purified by using silica gel column chromatography eluting with mixture of hexane:EtOAc to give Intermediate-67 (30 mg) as brown gummy material.
Synthesis of Intermediate-68
[0784] To a stirred solution of Intermediate-67 (0.030 g, 0.11 mmol) in DMF:MeOH (2 mL, 1:1), NaBH 4 (0.006 g, 0.17 mmol) was added, followed by cobalt chloride (0.002 g, 0.022 mmol). The resulted reaction mixture was stirred at rt for 45 min. After completion of the reaction, the reaction mixture was quenched with H 2 O, extracted with EtOAc and concentrated to give Intermediate-68 (25 mg) as brown gummy material.
Synthesis of Intermediate-69
[0785] Intermediate-69 was synthesized by following the procedure used to make Intermediate-26 (scheme-4).
Synthesis of Compound (233)
[0786] Compound (233) was synthesized by following the procedure used to make Compound (1) (Scheme 2). 1H NMR (300 MHz, CDCl3): δ 7.22-7.33 (m, 2H), 6.75-6.78 (m, 1H), 5.09 (br s, 1H), 4.40 (br s, 1H), 3.61-3.66 (t, 2H), 2.93-2.98 (t, 2H), 2.18-2.22 (t, 1H), 1.60-2.04 (m, 11H), 1.06-1.08 (m, 2H), 0.86-0.88 (m, 2H). LC-MS: (M+H)+=366.1.
Example 234
2-(3-(4-fluoro-6-methyl-1H-indol-3-yl)butanoyl)-2-azaadamantane-5-carbonitrile (234)
[0787]
Synthesis of Compound (234)
[0788] Compound (234) was synthesized by following the procedure used to make Compound (1) (Scheme 2). 1H NMR (300 MHz, CDCl3): δ 7.97 (br s, 1H), 7.02-7.06 (m, 1H), 6.93-6.99 (m, 2H), 4.96 (br s, 1H), 4.17-4.21 (m, 1H), 3.60-3.68 (m, 1H), 2.84-2.88 (m, 1H), 2.47-2.56 (m, 1H), 2.36 (s, 3H), 2.10-2.13 (m, 1H), 1.61-2.05 (m, 10H), 1.45-1.48 (d, 3H). LC-MS: (M+H)+=380.2. HPLC purity=99.13%.
Example 235
2-(4-cyclopropyl-1H-indol-3-yl)-1-(5-hydroxy-2-azaadamantan-2-yl)propan-1-one (235)
[0789]
[0000]
Synthesis of Intermediate-70
[0790] To a stirred solution of Starting Material-15 (40 g, 206 mmol) in ether (400 mL), oxalyl chloride (23.2 mL, 268 mmol) was added at 0° C., and stirred at room temperature for 5 hours. The reaction mixture was then filtered and washed with ether to get solid material (42 g), which was treated with MeOH (28 mL) in ether (200 mL) at 0° C. to room temperature for 5 hours. After completion of the reaction the reaction mixture was diluted with hexanes, resulted precipitate was filtered and dried to get Intermediate-70 (35 g) as yellow solid.
Synthesis of Intermediate-71
[0791] To a stirred solution of Intermediate-70 (35 g, 129 mmol) in MeOH (350 mL), tosyl hydrazine (23.1 g, 129 mmol) was added and refluxed for 4 hours. After completion of the reaction, the reaction mixture was concentrated to give crude mixture, which is diluted with H 2 O, extracted with DCM and concentrated to give Intermediate-69 (35 g) as pale yellow solid.
Synthesis of Intermediate-72
[0792] To a stirred solution of Intermediate-71 (14 g, 31 mmol) in THF (140 mL), NaBH 4 (1.8 g, 46 mmol) was added at 0° C. and continued to stir at room temperature for 6 hours. After completion of the reaction, the reaction mixture was quenched with H 2 O, extracted with DCM and concentrated. The resulted crude product was purified by using silica gel column chromatography elutive with mixture of hexanes, EtOAc to give Intermediate-72 (3 g) as pale yellow liquid.
Synthesis of Intermediate-73
[0793] Intermediate-73 was synthesized by following the procedure used to make Intermediate-67 (Scheme 30).
Synthesis of Intermediate-74
[0794] Intermediate-74 was synthesized by following the procedure used to make Intermediate-65 (Scheme 30).
Synthesis of Intermediate-75
[0795] Intermediate-75 was synthesized by following the procedure used to make intermediate-30 (Scheme 6).
Synthesis of Intermediate-76
[0796] Intermediate-76 was synthesized by following the procedure used to make Intermediate-26 (Scheme 4).
Synthesis of Intermediate-77
[0797] Intermediate-77 was synthesized by following the procedure used to make Intermediate-7 (Scheme 1).
Synthesis of Compound (233)
[0798] Compound (233) was synthesized by following the procedure used to make Compound (1) (Scheme 2). 1H NMR (300 MHz, CDCl3): δ 8.13 (br s, 1H), 7.13-7.16 (d, 1H), 6.96-7.04 (m, 2H), 6.75-6.78 (d, 1H), 5.08 (br s, 1H), 4.62-4.67 (m, 1H), 4.32 (br s), 2.25-2.30 (m, 1H), 2.05-2.08 (m, 1H), 1.53-1.79 (m, 10H), 1.46-1.49 (d, 3H), 0.93-0.98 (m, 2H), 0.83-0.88 (m, 2H). LC-MS: (M+H)+=365.2. HPLC purity=95.44%.
Example 236
3-(4-cyclopropyl-1-methyl-1H-indazol-3-yl)-1-(5-hydroxy-2-azaadamantan-2-yl)propan-1-one (236)
[0799]
Synthesis of Compound 236
[0800] Compound (236) was synthesized by following the procedure used to make Compound (233) (Scheme 30). LC-MS: (M+H)+=380.3. HPLC purity=99.86%.
Example 237
1-(2-azaadamantan-2-yl)-3-(4-cyclopropyl-1-methyl-1H-indazol-3-yl)propan-1-one (237)
[0801]
Synthesis of Compound (237)
[0802] Compound (237) was synthesized by following the procedure used to make Compound (233) (Scheme 30). LC-MS: (M+H)+=364.3. HPLC purity=91.66%.
Example 238
1-(2-azaadamantan-2-yl)-2-(4-cyclopropyl-1H-indol-3-yl)propan-1-one (238)
[0803]
Synthesis of Compound (238)
[0804] Compound (238) was synthesized by following the procedure used to make Compound (233) (Scheme 27). LC-MS: (M+H)+=349.2.
Biological Activity
In Vitro HSD11β1 Inhibition Assay:
[0805] CHO cells were maintained in Dulbecco's modified Eagle's medium/nutrient mixture F-12 containing 5% fetal bovine serum (v/v) and 2 mM glutamine. Cells were cultured at 37° C. with 5% CO 2 . For transient expression of human full length HSD11β1 expression vector (OriGene Technologies), cells were seeded at a density of 2×105 cells/well in a 6-well plate. Transfection was done using Turbofectin8 reagent (OriGene Technologies), according to the protocol provided with the reagent. After 24 hours post-transfection, cells were trypsinized and pooled together before they were re-seeding to 96-well plate at a density of 40000 cells/well. 24 hours after re-seeding, cells were incubated with 200 nM cortisone+500 uM NADPH (or along with small molecule inhibitors) overnight. The enzymatic activity or inhibition of enzyme activity was measured by estimating the conversion of cortisone to cortisol by LC/MS-MS method. The IC50 in nM was calculated from a 8 point log scale of concentration versus inhibition.
[0806] The results of the biological testing are shown in table 1:
[0000]
Cmpd No
11βHSD1 (IC50)
1
*
2
****
3
*
4
*
5
**
6
*
7
*
8
*
9
*
10
*
11
*
12
*
13
*
14
****
15
*
16
*
17
****
18
****
19
**
20
*
21
*
22
*
23
*
24
*
25
*
26
**
27
*
28
**
29
****
30
***
31
*****
32
***
33
*
34
*
35
*****
36
**
37
*****
38
*
39
****
40
*****
41
*****
42
*
43
*
44
**
45
*
46
*
47
***
48
*****
49
*****
50
*
51
*
52
*
53
*
54
*
55
*
56
*****
57
*
58
*****
59
****
60
*
61
*
62
*
63
*
64
****
65
**
66
*
67
****
68
*
69
****
70
***
71
*
72
*
73
******
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***** = <100 nM
**** = 100 nM< and <150 nM
*** = 150 nM< and <200 nM
** = 200 nM< and <250 nM
* = 250 nM< | The present invention relates to certain amide derivatives that have the ability to inhibit 11-β-hydroxysteroid dehydrogenase type 1 (11β-HSD-1) and which are therefore useful in the treatment of certain disorders that can be prevented or treated by inhibition of this enzyme. In addition the invention relates to the compounds, methods for their preparation, pharmaceutical compositions containing the compounds and the uses of these compounds in the treatment of certain disorders. It is expected that the compounds of the invention will find application in the treatment of conditions such as non-insulin dependent type 2 diabetes mellitus (NIDDM), insulin resistance, obesity, impaired fasting glucose, impaired glucose tolerance, lipid disorders such as dyslipidemia, hypertension and as well as other diseases and conditions. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application claims priority of German patent application No. 10 2009 037 315.2 filed on Aug. 14, 2009, the content of which is incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to a device for receiving of disposable items.
BACKGROUND OF THE INVENTION
Disposal items include, in particular, surgical instruments, expendable medical items, and sterile packagings, that is, containers in which a sterile material remains until its immediate use.
A device for receiving of disposable items for an operating room is disclosed in patent DE-OS 2146823.
Surgical instruments and sterile materials such as swabs and surgical cloths required in operations, after use, are deposited directly into such a disposal container or are placed in other receptacles such as sieve baskets. For medical documentation it is then customary to document the used articles in an OR documentation list. This task is performed entirely manually. It is very laborious and time-consuming, and therefore requires highly specialized nursing staff who are familiar with the individual instruments, expendable materials, and sterile supplies and can perform the manual documentation without transmission errors.
The complexity of handling sterile materials, in the meantime, requires a sterile materials management that is capable of rapidly capturing and mastering all procedures connected with sterility in a hospital. The principle of identification and retraceability is just one of the essential tasks.
It is the object of the present invention to perfect a device for receiving of disposable items in such a way that improved documentation becomes possible.
SUMMARY OF THE INVENTION
This object is achieved by means of a device for receiving of disposable items, with the traits of claim 1 . The subsidiary claims indicate elaborations of the invention.
The inventive device includes a container equipped with an opening and an identification unit, which is positioned in the area of the container's opening.
On the basis of the inventive device it is possible securely to acquire an object equipped with one or more data carriers and to read out data from the data carrier when said carrier is subjected to the detection area of the identification unit. The primary advantages that result from this are: time saving in acquiring the objects, fewer errors in documentation, and the fact that the device can be used easily and intuitively and consequently requires no specialized training of personnel.
The inventive identification unit advantageously comprises at least one reader head, which shows a continuing detection area that completely covers the container's opening and acquires it while extending horizontally in particular, preferably parallel to the surface of the container's opening, and corresponds to the profile of the perimeter of the opening of the container. The area of detection here corresponds in particular to the container's opening. This ensures that every object that is equipped with a data carrier and is inserted into the container is reliably acquired and the data of the data carrier can be correspondingly read out. In addition, thanks to the selected configuration of the identification unit, the possibility of erroneous detection is also excluded, that is, the risk of unwittingly capturing objects that are found outside the container and are conducted along the identification unit in close proximity to it. Thus, thanks to the identification unit, one can ensure the acquisition exclusively of the objects that in fact are to be disposed of, and in a preferred embodiment, in addition, they are also identified. In addition to the acquired data, in addition and alternatively, other data can be documented for the identified objects and subjected to an additional evaluation.
In another preferred embodiment of the inventive device, the identification unit comprises two or more reader heads. These are preferably positioned and oriented in such a way that the respective detection areas of the mutually adjoining and/or facing reader heads overlap and together form a continuous detection area. Such a configuration has the advantage of ensuring the reliable acquisition of objects equipped with data carriers. According to the invention, a secure record is nevertheless achieved, in particular with objects whose data carrier is found in a non-readable position for an individual reader head and/or objects that comprise screening components that disturb the process.
One or more of the reader heads of the inventive device can preferably be configured as barcode scanners and/or RFID reader devices. These devices are appropriate for their ability to read out information without contact from data carriers, such as barcode labels or RFID data carriers—also known as RFID tags. This occurs largely independently of the soiling of the objects that are to be removed. Additional advantages of RFID data carriers and RFID laser devices consist in the higher storage capacity, and greater speed of reading and identification in comparison with other conventional data carriers and related reader devices such as barcode systems. Data can also be acquired directly and precisely. The data, in particular, can be taken from the data group product name, article designation, lot number, usability/expiration date, or series number.
In addition, such reader devices constitute standardized components with a high capturing precision, thanks to which it is possible to produce an economical device. The advantage of a barcode or barcode scanner system resides, in particular, in the fact this technology in the field of automatic recognition systems has matured and has already been widely used in many fields for several years. The objects that are to be removed can also be labeled in simple and reliable manner and thus can be especially simply acquired and subjected to documentation.
By means of the reader heads, which preferably are configured as barcode scanners and/or RFID reader devices, data can be read out as an object to be removed from its data carrier and later can be documented. In the framework of an additional evaluation, these data can then be complemented with additional data, in particular from a database, and correspondingly subjected to an additional evaluation and documentation. This can lead, for instance, to material flow information. In the framework of an optional identification by means of the identification unit, it is possible on the basis of the acquired data also to make an identification by comparison with previously stored material data, where these data are filed in a remote database or in a database associated with the identification unit. In the latter case the database is updated regularly or, depending on the situation, on the basis of a remote database, in particular in the hospital's central computer. As a result, a very current and reliable documentation can be maintained.
An additional configuration of the inventive device provides that the identification unit is connected by means of a communication link with an evaluation unit that is remote from it, and the data read out by the identification unit are transmitted to the evaluation unit preferably over this communication link. To achieve a local data transfer, the identification unit in this case can be physically connected with the evaluation unit by a data cable. The use of a data cable, however, involves the risk of stumbling over the cable or of unintended severing of the cable from the identification unit and/or the evaluation unit by an impact or pulling motion.
Alternatively and preferably, the data transfer should occur wirelessly, for instance by means of an IR or Bluetooth connection, which proves especially useful with frequent changes of location for the inventive device.
Transmission of data can proceed in real time, that is, during an ongoing identification and the reading of an object directed to a reader head and equipped with a data carrier, without substantial delay. Consequently it is possible in advantageous manner to dispense with particular data storage systems for intermediate storage within the identification unit and to keep said unit correspondingly small and economical to produce.
Alternatively, it is also possible in the area of the identification unit or of the communication link to produce data storage devices by which the data can first be stored and then, or at least with a time delay, read and forwarded.
It is also possible to conduct a simple pre-processing of the acquired data still in the area of the identification unit. Thus, in the context of this pre-processing, these data can be standardized for a simple processing later.
In an advantageous embodiment of the inventive device, the evaluation unit here can be, for instance, a PC workplace with a monitor and keyboard or a mobile hand device. Thus, by means of the keyboard, for instance, patient identification information can additionally be entered, ensuring an unequivocal allocation of the acquired objects to the patient.
In an especially useful and preferred configuration of the inventive device, the evaluation unit is connected with a touch screen to form a single unit that makes possible the processing of the scanned information in connection with an input by touching the display surface and/or by corresponding entry of operating and control commands.
The evaluation unit can be positioned inside the operating room, preferably in immediate proximity to the operating table and/or in an area of the operating room. Thus, the materials to be removed can be subjected to evaluation and further documentation immediately after, or even during, the operation to reach the acquisition and expanded documentation by a short route.
In a particularly advantageous embodiment, the evaluation unit is positioned outside the operating room. This has the advantage that the acquisition and documentation can be conducted in a non-sterile area and consequently, because of the decreased risk of contamination, by the support personnel, who are not required to wear protective clothing for hygienic reasons as required for an operating room. In addition, the evaluation unit is not required to be made of specialized, complex, and thus expensive sterilizable materials.
It is expected that the evaluation unit first receives the raw data and/or raw data sets from an identification unit and that the data are then entered and stored, for instance in a standard tabular calculation program, so that the data sets contain information from the group product name, article designation, lot number, usability/expiration date, series number, which are selectively arranged in the tabular fields. After the data distribution is complete, evaluation data can then be automatically generated. For instance, an inventory file or material flow information can be produced.
An inventory file, stored in the evaluation unit, thus contains for instance the number of objects that were provided and used or applied for the patient during the operation. The generated inventory file can then be compared with a previous one, which was produced at the start of the procedure. Depending on the queries used, information can be provided, for instance by an OR documentation list, on whether and/or how many objects were actually used during the procedure. In particular, this allows a determination of whether all instruments and other materials applied were listed in complete and updated manner at the end of the operation. This information is important in the patient's interest.
In a preferred embodiment, the evaluation unit is connected electronically, for instance via GPRS/WLAN, with the central database, preferably of the hospital, also known as hospital information system (HIS). The evaluation results generated in the evaluation unit can then be controlled, for instance regularly or depending on the situation, particularly after a procedure is completed, sent to the central database of the hospital and/or called up by it and stored in the computer of the central database and/or further processed.
Thanks to the data acquisition which is constantly possible, material flow information within the hospital can be called up at any time, communicated, and/or displayed.
Because decisive data on every object are regularly registered in the central computer database at the moment of its entry into the hospital's sterile storage system and also at the time of acquisition in the operating room, it is particularly possible to conduct a permanent balance sheet of the stored inventory by using an electronic quantity and value recording method.
Thus the respective current inventory level and changes in inventory, for instance, can be displayed at any time by means of a graph or inventory list. In addition it is also possible to automatically deduct the depleted and/or applied objects and to allocate them to certain usage categories such as individual operating rooms, in order finally to produce a corresponding patient-based cost record.
The inventive device regularly comprises a container with an opening pointed upward, a base surface, and an interior space into which the conveyed objects are introduced using gravitational force. The container here can be produced from various materials. It is especially effective to select materials in such a way that they are autoclavable, that is, capable of withstanding water pressure treatment under pressures up to about 134 degrees C. without damage. Autoclavability is particularly essential and therefore of great advantage for the inventive device if the container for instance should be contaminated with blood and/or germs. In this case autoclaving allows a reuse of the container and thus a greater lifetime for the receptacle altogether, while non-autoclavable containers must be removed expensively as special medical waste after every contamination with germs.
In an additional advantageous embodiment, the container can be slid with respect to the storage and/or work space, for instance on rollers, or for example it should be capable of pivoting or tipping by means, for instance, of a weighing frame, by about 10 to 15 degrees. Thus the container can be moved, for instance placed first on rollers, totally without problems to the utilization site and there can be brought into the particular operating or moving position by the user according to need or preference, without any problems, making comfortable and ergonomic operation possible. This ensures that the inventive device is always available at the desired location and thereby an efficient documentation of the objects can be achieved.
An additional advantageous embodiment of the inventive device consists in the fact that the interior space of the container comprises dividing walls and, depending on the number of dividing walls, the interior space is divided into at least two compartments. In this manner this container makes it possible that at least two categories of object can be sorted out and, in keeping with their sorting criteria, can be directed to one of the compartments. Thus just about all objects made of plastic, such as catheters and tubes, can be sorted, collected, and finally conveyed to the recycling facility. Objects thus removed and sorted into various compartments are documented, preferably selectively, so that a detailed evaluation becomes possible, for instance according to the size of the objects by category.
In another preferred embodiment an individual compartment can be configured so that an adaptation to various application requirements becomes possible on the basis of the prescribed objects used during the procedure. Thus, a compartment for the selective depositing of syringes can be configured with a particularly puncture-resistant wall to prevent possible injury during removal of the compartment. In addition, there can be differentiations in the capacity of compartments' volume or in the cross-sections of their openings.
This can be achieved either through differentiated combinations of modular components in the manufacturing process or through subsequent adjustments, or a combination of both. Thus, for instance, objects such as reusable surgical instruments can be collected by the sorting process so that they are subjected finally to a sterilization process in the course of instrument reconditioning.
In another practical embodiment, the containers and/or a compartment in the interior can be lined with a removable plastic sack. The sack is preferably provided with individualized markings that make documentation possible and/or improve logistics and/or removal.
In addition, a compartment an also be produced as a plastic sack or synthetic pouch and thus be used for objects that are not recyclable and are to be conveyed to refuse removal.
Another configuration of the inventive device concerns a container with an opening that faces upward and is provided with a lid to cover the opening. In any case, the opening of the container can be provided with a lid to cover the opening. It can also be arranged that several compartments each have a lid or cover and thus not all compartments require lids. This ensures a controlled insertion into the container or compartments, reducing erroneous deposits and thus improving the data quality of the documentation.
The one or more lids can be opened and closed manually. As a preferred alternative, lids can be opened and closed by electronic switches on the basis of a signal, received by the identification unit, for detecting objects to be removed. The control is configured in such a way that the container and/or compartment is closed after insertion of the object, thus preventing any unintended additional dropping or steering of a non-sorted object into the container and/or the compartment.
The inventive device is also preferably provided with a sorting device, which is positioned in the area of the container's opening and controlled as necessary, and which can use the information from the identification unit to control the device. Thus data are culled from the data carrier of the object by the identification unit, allowing in particular data on the specific sorting of an object. Thus the sorting destination is determined on the basis of such criteria as size, shape, material, type, and so on.
Then, in accordance with the sorting assignment, the object is mechanically transported away, for instance, and directed to a corresponding compartment. Thus the object itself transmits to the sorting device the data required for optimal removal. It is possible in this preferred manner to automatically document, sort, and unequivocally collect objects that resemble one another in the form and/or type of recycling they undergo, such as opened product packaging or surgical instruments.
Mechanical conveyance and/or sorting of objects can thus be effected by an alterable switch, for instance, which is mounted around a pivot axis and, by the position it assumes, determines into which compartment the sorted products are sent. Another possibility is a pivotable, sloping chute by which the sorted objects are selectively removed on the basis of gravity and finally fall into a compartment. In addition, an ejector or blowing nozzle can be provided for conveyance on a chute. This allows a very reliable selection of the objects, in particular with respect to logistics and removal, and consequently an informative documentation.
In another preferred embodiment of the inventive device, the device comprises a hand device that is connected by a connecting device, in particular with wireless support, with the identification unit. This makes it possible to read out the acquired, evaluated, or stored data, in particular, from the identification unit. In addition, object-related data that are necessary or helpful for the identification can be entered by the hand device and forwarded for instance, to the identification unit, and these data can be used in additional identification or evaluation.
It is also possible to connect a hand scanner for acquiring and reading from data carriers by means of the connection device. The connection between the hand device, hand scanner, and connection device should preferably be wireless. These embodiments are marked by the mobility of the hand devices or hand scanners, which allow for better data quality thanks to improved handling for the user.
According to an especially advantageous embodiment of the inventive device, it should be provided with a filling-level detection device in order to improve the additional logistical process of disposal with intermediate storage, transport, and final, especially thermal, disposal, on the basis of acquired filler-level data and its documentation.
The weight and/or volume of inserted objects is determined by the filler-level detection device. In addition the weight and volume of a container and/or compartment can be measured by means of a filler-level detection device upon insertion into the container and/or into a compartment. Also, depending on the case, the total weight and/or total volume of all inserted objects can be computed from these data. The measured weight and/or volume value can then be conveyed to a display unit. The filler level can thus be recognized and, for instance, stored and/or displayed, if and when the maximum filler volume of the container and/or compartment has been reached and consequently the container and/or compartment needs to be emptied or replaced.
Inserted refuse can be weighed, for instance, by a weighing platform that is positioned below the container and/or compartment and is equipped with a weight recorder/sensor to detect changes in weight. This configuration can be especially advantageously used when the refuse exceeds a drop height after it is inserted into the interior space of the container and/or compartment. In another advantageous embodiment, the weighing platform is constructed so that it comprises several force transducers corresponding to the number of compartments, each being positioned under one compartment. This has the advantage that the change in a compartment's weight can be individually measured and displayed, especially when an object is directed to this compartment.
Another preferred embodiment provides that the container and/or compartment has at least one distance sensor available for detecting volume. It is particularly advantageous if the distance sensor is positioned immediately below the predetermined filler height of the container and/or compartment, so that the filler height of the container and/or of a compartment is measurable with its help automatically and continuously, and also any overfilling of the container and/or compartment is reliably prevented. In addition, identified objects can be verified against stored object profiles by weighing them. This permits a clear increase in security.
Even without weighing or determining volume, information on the weight or volume of the identified objects can be determined by object profiles stored in the database and from that the filler status of the container is determined. Thus it is possible to reliably document which objects are present in the container, particularly a filled container, and which are jointly removed in a sack. The sacks removed from the container are preferably provided with individualized markers that make the additional documentation possible.
In another practical configuration of the invention, the identification unit is a component of a cap, particularly a ring-shaped one, that can be positioned so that it can be removed from and applied to a container. This cap is preferably in a single piece and self-supporting. Thus the ring opening of the cap continues into the opening of the container and thus allows a clear identification by means of the cap. With this inventive structure, the container can be emptied in especially simple and rapid manner by removing the cap. In addition the cap can also be mounted on other containers without problem and/or can be subjected to a sterilization process after acquisition of objects, thus increasing the operational readiness of the invention.
An additional especially advantageous embodiment of the inventive device concerns a video camera whose field of vision includes the area of the container's opening and which is capable of clearly identifying objects that are conducted to the area of the opening of the container and/or compartment, for instance on the basis of their formal properties. Thus it is also possible and advantageous to acquire and document objects which, for instance, are not equipped with a data carrier. In addition it is possible, nevertheless, to identify objects whose data carrier for instance has been damaged and which thus can no longer be scanned by a given reader head. The likelihood that an object equipped with a data carrier cannot be read is additionally reduced by this refinement, further improving the quality of the documentation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an operating room including a device for receiving of disposable items.
FIG. 2 shows details of a device for receiving of disposable items.
FIG. 3 shows one embodiment of an identification unit which comprises three reader heads.
DETAILED DESCRIPTION OF THE INVENTION
An exemplary embodiment of the inventive device and of the technical environment of the invention is now further described with reference to FIG. 1 . The invention is not restricted to this illustrated embodiment.
Here FIG. 1 shows an operating room 20 whose sterile area is separated by a wall 25 from the non-sterile area 30 . In addition, FIG. 1 shows a device, standing on the floor of the operating room, for receiving objects for an operation room 20 that are to be removed. The device shows and comprises a two-chamber container 1 with an identification unit 2 positioned in the area of the opening of the container 1 along with a sorting device 6 . This device's positioning is selected below the identification unit 2 .
The identification unit 2 is positioned on the upper edge of the container 1 and integrated into a removable ring-shaped cap 12 , so that its opening continues into the opening of the container 1 . As shown in FIG. 3 , the identification unit 2 comprises a first reader head 3 , a second 4 . 1 , and a third reader head 4 . 2 . They are configured for the detection of objects that are to be removed and for the reading of information from data carriers connected with the objects as soon as they are brought into their detection areas. The data carriers contain information that serves for individual identification and are applied on the respective object.
The reader heads 4 . 1 and 4 . 2 are positioned with respect to one another so that their detection areas overlap in FIG. 1 in a manner not shown in closer detail and cover the entire area of the opening of the container 1 .
On the basis of this arrangement of two reader heads in facing position, it is guaranteed that if one reader head cannot acquire and read the data carrier, for instance if the data carrier is covered up, then at least the other reader head is capable of doing so.
The illustrated reader heads 3 , 4 . 1 , and 4 . 2 read the barcode and/or RFID identification data as a rule from data carriers that are brought into the range of their detection areas and are accordingly configured as barcode or RFID scanners.
FIG. 2 shows that a video camera 13 is provided on the upper edge of the container 1 in order to acquire the area of the opening for data relating to the identify objects to be disposed of into the container 1 . Such data include, for instance, the basis of the objects' formal properties. The video camera 13 then transmits the data to an evaluation unit 9 .
In addition, FIG. 1 shows a two-chamber container that comprises an essentially trapezoidal-shaped longitudinal section. The interior of the container 1 is divided in its lower area into two compartments 7 . 1 and 7 . 2 , separated from one another by a dividing wall 6 that extends from the floor of the container upward. The deposited objects are sorted with the help of a sorting unit 6 . The first 7 . 1 and second 7 . 2 compartments serve to receive selectively sorted objects, which differ in their product characteristics, for instance their material and/or function. The separating wall 6 ensures that the objects sorted in the container according to differing product characteristics can no longer be mingled together.
Mounted downstream of the identification unit 2 is the sorting unit 5 , which is positioned in the area of the opening but is smaller in dimension. The position of a conductor element determines in which compartment the sorted objects end up. The sorting of objects here can be done for instance by means of an angular profile alterable switch as conductor element, which is mounted to pivot around an axis. The sorting device 5 thus receives information that has been read out by the identification unit 2 from the data carriers of the objects and contains or admits indications on the sorting categories of an object. The object is then diverted and removed according to the sorting assignment.
The container 1 comprises two compartments 7 . 1 and 7 . 2 , positioned side by side. The diverted objects, according to their sorting category, by which they are sorted, are fed toward the left into the first compartment 7 . 1 or toward the right into the second compartment 7 . 2 . Each compartment 7 . 1 or 7 . 2 may have a lid 11 . 1 or 11 . 2 as shown in FIG. 2 . The lids 11 . 1 and 11 . 2 can be connected to a controller such that they can be opened and closed by electronic switches on the basis of a signal, received by the identification unit 2 , for detecting objects to be removed.
The identification unit 2 and the evaluation unit 9 are connected to one another by a communication link 8 for the exchange of data. The data transfer here can occur through a cable between the identification unit 2 and the evaluation unit 9 or through an IR connection or Bluetooth connection.
All of the data ascertained and read out by the identification unit 2 run together in the evaluation unit 9 . The transmitted data are first stored, so that they can be read out again and further evaluated or processed.
Evaluation of the entered data can be processed, for instance on the basis of evaluation procedures that may require no additional particular input operations by the user. Thus, after arrival of the data, total information on the conveyed objects is for instance determined or objects are grouped and/or displayed in tables according to their sorting categories. It is possible to continually modify and document the displays on the basis of a running input of data.
Entered data can be displayed on the monitor 9 . 1 of the evaluation unit 9 as a raw data set and/or in their evaluated form.
The acquired, evaluated, or stored data can also be read out in a hand device 12 , as shown in FIG. 2 . The hand device 12 is connected by a connecting device, in particular with wireless support, with the identification unit 2 . Object-related data can also be entered by the hand device 12 and forwarded to the identification unit 2 .
The final step is the indication of what type of surgical instrument or which medical expendable material is primarily present. Other acquired data such as the date and time of the data acquisition can also be displayed as needed, of course.
These data can be supplemented on the evaluation unit 9 by manual and/or speech-activated input of additional data such as patient identification data or indications on the operating room 20 . Thus, data acquired in the area of the identification unit 2 and stored in the evaluation unit 9 can be unequivocally associated with a patient and/or an operating room 20 from which they were obtained. This is particularly important when an evaluation unit 9 is associated with various operating rooms 20 and/or used in a number of procedures.
Data and evaluation results processed by the evaluation unit 9 are then made available on a central computer 11 of the hospital, which is installed in a non-sterile area 30 of the hospital. The communication line 10 between the evaluation unit 9 and the central computer 11 of the hospital is configured here as a fiberglass cable. The data transmission can also be processed here with link-up to the Internet as data transfer system. In this case an update of the company/software of the evaluation unit and/or of the identification unit can be conducted by the evaluation unit, so that the user can use the current software versions in each case. The care and expansion of the data acquisition and/or data evaluation possibility in the context of the existing hardware is thus simple, reasonable in price, and rapid.
Positioned on the central computer 11 of the hospital is a database in which, in addition to the acquired and/or supplemented data, additional data are stored and contained, by means of which, in particular, the material flow in an operating room 20 can be depicted.
With the arrival of an object in the hospital's sterile storage unit, various identifying data on each object are registered and filed in the database. This occurs either manually or semi- or completely automatically. Thus, from these data on registered objects an allocation data set can then be produced. This allocation data set allows, among other things, a later allocation of raw data and evaluation results for a particular operating room 20 or the identification of objects acquired by the inventive device that are to be disposed of on the basis of the read-out data from data carriers. On the basis of this documentation it is possible to depict the material flow within the hospital thanks to the ongoing use of objects, and to simplify the removal logistics, the utilization or removal of the object. | A system for receiving of disposable items in an operating room, where the objects that are to be disposed of and which are equipped with a data carrier are automatically acquired and electronically registered in databases. The data carrier on the objects can be RFID tags or a barcode. The data read out are used in particular to individually recognize the type, quantity, and value of an object and to be able to document and display the type, quantity, and value of an object by using an electronic inventory and value determination process. | 1 |
BACKGROUND OF THE INVENTION
This invention relates to compounds whose structure includes phenols, and alkyl esters thereof, having in the 2-position a cycloalkanol or cycloalkanone group as well as a sila-alkane substituent in the 5-position. These compounds are useful as CNS agents, especially as analgesics for treatment in mammals.
There is a continuing need for analgesic agents for the control of broad levels of pain and accompanied by a minimum of side-effects. The most commonly used agent, aspirin, is of no practical value for the control of severe pain and is known to exhibit various undesirable side-effects. Other analgesics such as d-propoxyphene, codeine and morphine, possess addictive liability. It is therefore desirable to discover compounds having improved and potent analgesic properties.
SUMMARY OF THE INVENTION
The present invention comprises novel compounds of the formula ##STR2## or pharmaceutically acceptable salts thereof, wherein: G is hydroxymethylene or carbonyl;
R is hydrogen or alkanoyl having from one to seven carbon atoms;
R 1 and R 2 are each methyl or ethyl;
R 3 is an alkyl of from five to seven carbon atoms;
m is 0 or 1; and
n is 1, 2 or 3.
A preferred compound is one in which m is zero, n is one or G is hydroxymethylene. Also preferred are compounds in which R 1 and R 2 are methyl. Additional preferred compounds include those wherein R is hydrogen or acetyl. A preferred compound is Z-3-(4'-(dimethyl-n-hexylsilyl)-2'-hydroxyphenyl)-cyclohexanol.
The invention further comprises pharmaceutical compositions containing these compounds. In accordance with the present invention, these compounds when administered in an effective amount to mammals are useful as CNS agents including analgesics, tranquilizers, sedatives, anticonvulsants, antidiarrheals, antiemetics and antianxiety agents.
DETAILED DESCRIPTION OF THE INVENTION
A convenient starting material for the synthesis of the compounds of the present invention wherein m is zero is m-bromophenol. The bromophenol hydroxyl is protected, for example, by reaction with benzyl chloride under basic conditions. Other phenol protective groups, such as lower alkyl ethers, for example methyl or ethyl, may also be employed. The resulting bromophenyl benzyl ether is known: ##STR3## See Y.-H. Wu et al., Journal of Medicinal and Pharmaceutical chemistry, volume 5, pages 752-62 (1962).
The bromo ether is reacted with magnesium in an ether solvent such as tetrahydrofuran, 2-methyltetrahydrofuran or diethyl ether at reflux to form the Grignard reagent. The Grignard reagent is in turn reacted in situ with an appropriate dialkyldichlorosilane at about -10° to 25° C., preferably 0° C., to form the corresponding dialkylchlorosilylphenol benzyl ether. The resulting chlorosilane is then reacted with an alkyl Grignard reagent in an ether such as tetrahydrofuran, 2-methyltetrahydrofuran or diethyl ether at -10° to 25° C., preferably 0° C., so that the resulting trialkylsilane has the desired alkyl groups. ##STR4##
The benzyl protective group is now cleaved. A palladium on carbon catalyst can be employed in a hydrogenation reaction in an alcohol such as ethanol at 10°-40° C., preferably 25° C., to remove the benzyl group.
The resulting m-trialkylsilylphenol's hydroxyl group is protected by forming, for example, a methyl ether: ##STR5## A convenient procedure is to employ an aprotic solvent under basic conditions, for example, dimethylformamide with sodium hydride or acetone with potassium carbonate, to form the phenolate at -10° to 25° C., preferably 0° C. The phenolate is reacted in situ at 10° to 40° C., preferably 25° C., with an alkylating agent such as dimethylsulfate or methyl iodide.
An alternate procedure to obtain the m-trialkylsilylanisole is to begin with m-bromoanisole. The Grignard reagent is formed in an ether solvent such as tetrahydrofuran, 2-methyltetrahydrofuran or diethyl ether at reflux and reacted with a dialkyldichlorosilane in situ at -10° to 25° C., preferably 0° C., to form the corresponding m-dialkylchlorosilylanisole which is in turn reacted with the appropriate alkyl Grignard reagent in an ether solvent such as tetrahydrofuran, 2-methyltetrahydrofuran or diethyl ether at -10° to 25° C., preferably 0° C., to form the m-trialkylsilylanisole.
The m-trialkylsilylanisole is reacted with the appropriate six, seven or eight numbered ring alpha, beta-unsaturated cycloalkanone to obtain the desired cycloalkanone trialkylsilyl anisole: ##STR6## wherein n is 1, 2 or 3. Compounds wherein n is one are preferred. These addition compounds can be obtained by reacting the trialkylsilylanisole with an alkyl-lithium in the presence of a chelating agent such as N,N,N,N-tetraethylenediamine at 10°-50°, preferably 25° C. followed by in situ reaction with a 1-alkyne copper-lithium reagent at -78° to -20° C., preferably -78° C., in an ether solvent such as tetrahydrofuran or 2-methyltetrahydrofuran. The intermediate copper-lithium anisole is reacted in situ with the alpha, beta-unsaturated cycloalkanone at -78° to -20° C., preferably -78° C.
The ketone can be reduced, if desired, using any convenient reducing agent such as sodium borohydride in alcoholic solvents such as methanol at -78° to -20° C., preferably -78° C.
The methyl ether group protecting the phenolic hydroxyl can be removed with a lithium alkyl mercaptide such as lithium n-propyl mercaptide in a polar, aprotic solvent such as hexamethylphosphoramide at about 50°-150° C., preferably 105° C.
If the ketone is not to be reduced, a ketal can be formed to protect the carbonyl group during removal of the methyl ether protecting group. One method of ketalization is reacting the ketone with an alkyl alcohol, especially one having one to four carbon atoms, in the presence of an acid such as sulfuric acid, p-toluenesulfonic acid or hydrogen chloride under conditions which remove the by-product water. In one method an alcohol having a boiling point higher than water is employed and the water is distilled off. Alternatively, if an azeotrope forms between water and the alcohol, the azeotrope can be distilled off. Cyclic ketals can be formed using diols such as ethylene glycol as the starting alcohol. Another reaction method for ketal formation is the reaction of the ketone with an orthoformate ester in an alcohol solution where the alcohol corresponds to the alkoxy moiety of the orthoformate ester. Trimethyl orthoformate and methanol can be employed in this reaction with concentrated sulfuric acid, anhydrous hydrogen chloride or ammonium chloride as the acid catalyst.
When the ketal is no longer desired, it can be converted back to the ketone by known procedures such as treatment with aqueous acid at 10°-50° C., preferably 25° C.
Alternatively, the cycloalkanol can be reoxidized to the ketone following removal of the methyl ether protecting group using an oxidizing agent such as aqueous potassium dichromate or chromium trioxide in glacial acetic acid or pyridine.
If the phenolic ester of an alkyl carboylic acid having 1-7 carbon atoms is desired, the phenol can be reacted with the corresponding acid anhydride with an acid acceptor such as 4-N,N-dimethylaminopyridine at -10° to 25° C., preferably 0° C., or with the corresponding acid chloride in the presence of an acid acceptor such as sodium or potassium carbonate in an non-nucleophilic solvent to obtain the desired phenolic ester product. The preferred alkanoyl has two carbon atoms, i.e., acetyl.
If the desired compound has a methylene group interposed between the phenyl and trialkylsilyl groups an appropriate starting material is: ##STR7## which can be prepared from 3-methoxybenzyl alcohol (W. Q. Beard, Jr., et al., Journal of Organic Chemistry, Volume 26, page 2310 (1961)). Other phenol hydroxyl protecting groups such as benzyl ether which was employed for compounds without an interposed methylene group can also be used in the present case. The same general synthetic sequences employed for m-bromoanisole as the starting material can be employed for m-bromomethylanisole. Of course other halogen-substituted anisoles can also serve as starting materials.
The alkyl groups about the silicon are R 1 and R 2 each being independently methyl and ethyl, R 1 and R 2 both being methyl is preferred; and R 3 being alkyl having five to seven carbon atoms, preferably six.
When R is hydrogen, phenolic cationic salts can be formed. Pharmaceutically acceptable cations can include lithium, sodium, potassium, calcium, magnesium and the like.
The analgesic properties of the compounds of this invention are determined by tests using nociceptive stimuli.
Test Using Thermal Nociceptive Stimuli
Mouse Hot Plate Analgesic Testing
The method used is modified after Woolfe and MacDonald, J. Pharmacol. Exp. Ther., 80, 300-307 (1944). A controlled heat stimulus is applied to the feet of mice on a 1/8 inch thick aluminum plate. A 250 watt reflector infrared heat lamp is placed under the bottom of the aluminum plate. A thermal regulator, connected to thermistors on the place surface, programs the heat lamp to maintain a constant temperature of 57° C. Each mouse is dropped into a glass cylinder (61/2 inch diameter) resting on the hot plate, and timing is begun when the animal's feet touch the plate. The mouse is observed at 0.5 and 2 hours after treatment with the test compound for the first "flicking" movements of one or both hind feet, or until 10 seconds elapse without such movements. Morphine has an MPE 50 =4-5.6 mg./kg.(s.c.).
Test Using Chemical Nociceptive Stimuli
Suppression of Phenylbenzoquinone Irritant-Induced Writhing
Groups of 5 Carworth Farms CF-1 mice are pretreated subcutaneously or orally with saline, morphine, codeine or the test compound. Twenty minutes (if treated subcutaneously) or fifty minutes (if treated orally) later, each group is treated with an intraperitoneal injection of phenylbenzoquinone, an irritant known to produce abdominal contractions. The mice are observed for 5 minutes for the presence or absence of writhing starting 5 minutes after the injection of the irritant. MPE 50 's of the drug pretreatments in blocking writhing are ascertained.
Test Using Pressure Nociceptive Stimuli
Effect on the Haffner Tail Pinch Procedure
A modification of the procedure of Haffner, Experimentelle Prufung Schmerzstillender. Deutch Med. Wschr., 55, 731-732 (1929) is used to ascertain the effects of the test compound on aggressive attacking responses elicited by a stimulus pinching the tail. Male albino rats (50-60 g.) of the Charles River (Sprague-Dawley) CD strain are used. Prior to drug treatment, and again at 0.5, 1, 2 and 3 hours after treatment, a Johns Hopkins 2.5 inch "bulldog" clamp is clamped onto the root of the rat's tail. The endpoint at each trial is clear attacking and biting behavior directed toward the offending stimulus, with the latency for attack recorded in seconds. The clamp is removed in 30 seconds if attacking has not yet occurred, and the latency of response is recorded as 30 seconds. Morphine is active at 17.8 mg./kg.(i.p.).
Test Using Electrical Nociceptive Stimuli
The "Flinch-Jump" Test"
A modification of the flinch-jump procedure of Tenen, Psychopharmacologia, 12, 278-285 (1968) is used for determining pain thresholds. Male albino rats (175-200 g.) of the Charles River (Sprague-Dawley) CD strain are used. Prior to receiving the drug, the feet of each rat are dipped into a 20% glycerol/saline solution. The animals are then placed in a chamber and presented with a series of 1-second shocks to the feet which are delivered in increasing intensity at 30 second intervals. These intensities are 0.26, 0.39, 0.52, 0.78, 1.05, 1.31, 1.58, 1.86, 2.13, 2.42, 2.72 and 3.04 mA. Each animal's behavior is rated for the presence of (a) flinch, (b) squeak and (c) jump or rapid forward movement at shock onset. Single upward series of shock intensities are presented to each rat just prior to, and at 0.5, 2, 4 and 24 hours subsequent to drug treatment.
Results of the above tests are recorded as percent maximum possible effect (%MPE). The %MPE of each group is statistically compared to the %MPE of the standard and the predrug control values. The %MPE is calculated as follows: ##EQU1##
The compounds of this invention, when used as analgesics via oral or parenteral administration, are conveniently administered in composition form. Such compositions include a pharmaceutical carrier selected on the basis of the chosen route of administration and standard pharmaceutical practices. For example, they can be administered in the form of tablets, pills, powders or granules containing such excipients as starch, milk sugar, certain types of clay, etc. They can be administered in capsules, in admistures with the same or equivalent excipients. They can also be administered in the form of oral suspensions, solutions, emulsions, syrups and elixers which may contain flavoring and coloring agents. For oral administration of the therapeutic agents of this invention, tablets or capsules containing from about 0.01 to about 100 mg. are suitable for most applications.
The physician will determine the dosage which will be most suitable for an individual patient and it will vary with the age, weight and response of the particular patient and the route of administration. Generally, however, the initial analgesic dosage in human adults weighing about 68 kg will range from about 0.1 to about 750 mg. per day in single or divided doses. In many instances, it is not necessary to exceed 100 mg. daily. The favored oral dosage range is from about 1.0 to about 300 mg./day; the preferred dose is from about 1.0 to about 50 mg./day. The favored parenteral dose is from about 0.1 to about 100 mg./day; the preferred range from about 0.1 to about 20 mg./day.
This invention also provides pharmaceutical compositions, including unit dosage forms, valuable for the use of the herein described compounds as analgesics and other utilities disclosed herein. The dosage form can be given in single or multiple doses, as previously noted to achieve the daily dosage effective for a particular utility.
The compounds described herein can be formulated for administration in solid or liquid form for oral or in liquid form for parenteral administration. For example, capsules containing drugs of this invention can be prepared by mixing one part by weight of drug with nine parts of excipient such as starch or milk sugar and then loading the mixture into telescoping gelatin capsules such that each capsule contains 100 parts of the mixture. Tablets containing said compounds can be prepared, for example, by compounding suitable mixtures of drug and standard ingredients used in preparing tablets, such as starch, binders and lubricants, such that each tablet contains from about 0.10 mg. of drug per tablet.
Suspensions and solutions of these drugs are often prepared just prior to use in order to avoid problems of stability of the suspensions or solution (e.g. precipitation) of the drug upon storage. Compositions suitable for such are generally dry solid compositions which are reconstituted for injectable administration.
The tranquilizer activity of the compounds of this invention is determined by orally administering them to rats at doses of from about 0.01 to about 50 mg./kg. of body weight and observing the subsequent decreases in spontaneous motor activity. The daily dosage range in mammals is from about 0.01 to about 100 mg.
Anticonvulsant activity is determined by subcutaneously administering the test compound to male Swiss mice (Charles River) weighing 14-24 g. in a suitable vehicle. The mice are used in groups of five. The day before use, the mice are fasted overnight but watered ad lib. Treatments are given at volumes of 10 ml. per kg. via a 25 gauge hypodermic needle. Subjects are treated with the test compound followed one hour later by challenge electroconvulsive shock, 50 mA. at 60 Hz. administered transcorneally. Controls are simultaneously run in which the mice are given only the vehicle as control treatment. The electroconvulsive shock treatment produces tonic extensor convulsions in all control mice with a latency of 1.5-3 seconds. Protection is recorded when a mouse exhibits no tonic extensor convulsions for 10 seconds after administration of electroconvulsive shock.
Antianxiety activity is determined in a manner similar to that for evaluating anticonvulsant activity except that the challenge convulsant is pentylenetetrazole, 120 mg./kg. administered intraperitoneally. This treatment produces chronic convulsions in less than one minute in over 95% of control mice treated. Protection is recorded when the latency to convulse is delayed at least 2-fold by a drug pretreatment.
Sedative/depressant activity is determined by treating groups of six mice subcutaneously with various doses of test agents. At 30 and 60 minutes post treatment, the mice are placed on a rotorod for one minute and evaluated for their performance on the rotorod. Inability of the mice to ride the rotorod is taken as evidence of sedative/depressant activity.
The antiemetic properties of the compounds of the present invention can be determined in unanesthetized cats according to the procedure described in Proceedings of the Society of Experimental Biology and Medicine, volume 160, pages 437-40 (1979). The antidiarrheeal utility can be determined by a modification of the procedure of Neimgeers et al. Modern Pharmacology-toxicology, van Bever et al. Eds., volume 7, pages 68-73 (1976). In general the dosage levels and routes of administration for use of these compounds as tranquilizers, anticonvulsants, sedatives or antianxiety, antiemetic or antidiarrheal agents parallels those with respect to their use as analgesic agents.
The present invention will be illustrated by means of the following examples. It is to be understood, however, that the invention is not meant to be limited by the details described therein.
Infrared (IR) spectra were measured in chloroform (CHCl 3 ) solutions and diagnostic absorption bands are reported in wave numbers (cm -1 ). Proton nuclear magnetic resonance spectra (PMR) were measured at 60 MHz for solutions in deutero-chloroform and peak positions are expressed in parts per million downfield from tetramethylsilane. The peak shapes are denoted as follows: s, singlet; d, doublet; t, triplet; q, quartet; m, multiplet; b, broad. Mass spectra (MS) or high resolution mass spectra (HRMS) are reported as positive ion mass per electron charge (m/e) with the parent ion denoted M + .
EXAMPLE 1
Z-3-(4'-(Dimethyl-n-hexylsilyl)-2'-hydroxyphenyl)cyclohexanol
To a degassed, solution, of 150 mg (0.432 mmole) of Z-3-(4'-(dimethyl-n-hexylsilyl)-2'-methoxyphenyl)-cyclohexanol in hexamethylphosphoramide at 25° C. was added 2.16 ml of 1 M lithium n-propylmercaptide in hexamethylphosphoramide. The reaction mixture was kept at 105° C. for 1 hour and then added to 100 ml of aqueous pH 7 buffer at 25° C. The quenched reaction mixture was extracted with 300 ml diethyl ether. The ether extract was washed three times with 200 ml water, washed once with 200 ml saturated aqueous sodium chloride, dried over anhydrous magnesium sulfate and evaporated to an oil. The oil was purified by preparative layer chromatography on silica gel plates (2 mm×20 cm×20 cm) eluted with 50% diethyl ether-hexane to give, after crystallization in hexane, 100 mg (69%) of the title compound, m.p. 93°-95° C.
PMR: 0.22 (s, Si(CH 3 ) 2 ), 3.0 (bm, CH), 3.8 (bm, CH) and 6.8-7.2 (m, aromatic H) ppm.
The title compound was tested using suppression of phenylbenzoquinone irritant-induced writhing as previously described. The MPE 50 was 2.2 mg/kg if the title compound was administered subcutaneously and 2.4 mg/kg, if administered orally.
Example 2
3-(4'-(Dimethyl-n-hexylsilyl)-2'-hydroxyphenyl)-cyclohexanone
The same procedures and materials can be employed as in Example 1 except the starting material is 3-(4'-(dimethyl-n-hexylsilyl)-2'-methoxyphenyl)cyclohexanone rather than Z-3-(4-dimethyl-n-hexylsilyl-2-methoxyphenyl)cyclohexanol.
Example 3
Z-3-(4'-(Dimethyl-n-hexylsilylmethyl)-2'-hydroxyphenyl)-cyclohexanol
The same procedures and materials as in Example 1 can be employed except the starting material is Z-3-(4'-dimethyl-n-hexylsilylmethyl)-2'-methoxyphenyl)-cyclohexanol rather than Z-3-(4'-(dimethyl-n-hexyl)-silyl)-2'-methoxyphenyl)cyclohexanol.
Example 4
Z-3-(4'-(Dimethyl-n-hexylsilyl)-2'-acetoxyphenyl)-cyclohexanol
To a 0° solution of 2.0 g of Z-3-(4'-(dimethyl-n-hexylsilyl)-2'-hydroxyphenyl)cyclohexanol in 10 ml of dichloromethane is added 0.73 g. of 4-N,N-dimethylaminopyridine and 0.56 ml of acetic anhydride. The reaction is stirred 2 hrs. at 0° and then added to 200 ml diethyl ether and 50 ml 1 N hydrochloric acid. The organic phase is washed with 100 ml saturated aqueous sodium bicarbonate, dried over anhydrous magnesium sulfate and evaporated to yield the title compound as an oil. Purification, if needed, can be achieved via recrystallization from hexane-ether or column chromatography on silica gel eluted with diethyl ether-hexane.
PREPARATION A
1-Benzyloxy-3-(dimethyl-n-hexylsilyl)benzene
To a refluxing slurry of 3.6 g. (0.15 mole) of magnesium in 100 ml. tetrahydrofuran was slowly added a solution of 26.3 g. (0.1 mole) of 1-benzyloxy-3-bromobenzene in 100 ml. tetrahydrofuran. After addition the reaction was allowed to cool to 25° C. The resulting Grignard reagent was added over a 30 minute period to 64.5 g. (0.504 mole) of dichlorodimethylsilane at 0° C. The reaction mixture was allowed to warm to 25° C. and the excess dichlorodimethylsilane and tetrahydrofuran were removed in vacuo. The residual gel was dissolved in 100 ml. tetrahydrofuran and cooled to 0° C. To this 0° C. solution was added, over a 30 minute period, 80 ml. of 2 M n-hexylmagnesium bromide in diethyl ether and the reaction was then allowed to warm to 25° C. The reaction was quenched by addition to 1 liter saturated ammonium chloride and the quenched reaction mixture was extracted with 1 liter diethyl ether. The diethyl ether extract was washed twice with 1 liter water, dried over anhydrous magnesium sulfate and evaporated to an oil. This oil was purified by column chromatography on 500 g. silica gel eluted with 3% diethyl ether-hexane to yield 28.4 g. (87%) of the title compound as an oil.
PMR: 0.27 (s, Si(CH 3 ) 2 ), 0.88 (m, SiCH 2 and CH 3 ), 1.28 (m, (CH 2 ) 4 ), 5.08 (s, CH 2 ) and 6.9-7.4 (m, aromatic H) ppm.
IR: (CHCl 3 ) 1575 cm -1 .
MS: m/e 326 (M+), 311, 241, 235, 227, 151, 135, 122 and 91.
PREPARATION B
3-(Dimethyl-n-hexylsilyl)phenol
A mixture of 34.8 g. (0.107 mole) of 1-benzyloxy-3-(dimethyl-hexylsilyl)benzene, 2.0 g. of a 1:1 mixture by weight to volume of 5% by weight palladium on carbon and water, and 100 ml. ethanol was stirred under 1 atm. hydrogen at 25° C. until hydrogen uptake ceased (after an uptake of 2.5 liters). The reaction was filtered through Supercel with ethanol and the filtrate evaporated to a quantitative yield of the title compound as an oil.
PMR: 0.23 (s, Si(CH 3 ) 2 , 0.89 (m, SiCH 2 and CH 2 ), 1.30 (m, (CH 2 ) 4 ), 4.89 (bs, OH) and 6.75-7.38 (m, aromatic H) ppm.
IR: (CHCl 3 ) 3571, 3279 and 1580 cm -1 .
MS: m/e 236 (M+), 221, 209, 200, 181, 151 and 137.
PREPARATION C
3-(Dimethyl-n-hexylsilyl)-1-methoxybenzene
To a 0° C. slurry of 3.98 g. (0.166 mole) of sodium hydride in 50 ml. dimethylformamide was slowly added a solution of 26.1 g. (0.111 mole) of 3-(dimethyl-n-hexylsilyl)phenol in 50 ml. dimethylformamide. Following addition, the reaction mixture was stirred 1 hr at 25° C. and cooled to 0° C. To the cooled reaction mixture, 20.9 g. (0.166 mole) of dimethyl sulfate was slowly added. Following addition, the reaction was stirred for 2 hr at 25° C. and then added to 200 ml. water. The quenched reaction mixture was extracted with three 100 ml. portions of hexane. The hexane extract was dried over anhydrous magnesium sulfate and evaporated to an oil. This oil was purified by column chromatography on 500 g. of silica gel eluted with 1% diethyl ether hexane to yield 14.8 g. (53%) of the title compound as an oil.
PMR: 0.26 (s, Si(CH 3 ) 2 ), 0.78 (m, CH 2 and CH 3 ), 1.20 (m, (CH 2 ) 4 ), 3.67 (s, OCH 3 ) and 6.6-7.3 (m, aromatic H) ppm.
IR: (CHCl 3 ) 1600 and 1574 cm -1 .
HRMS: m/e 250.1776 (M+, calcd for C 15 H 26 OSi: 250.1746), 235, 166, 165 and 151.
PREPARATION D
3-(4'-(Dimethyl-n-hexylsilyl)-2'-methoxyphenyl)cyclohexanone
To a 25° C. solution of 2.00 g. (8.0 mmole) of 3-(dimethyl-n-hexylsilyl)-1-methoxybenzene and 1.32 ml. (8.8 mmole) of N,N,N',N'-tetramethylethylenediamine in 8 ml. diethyl ether was added 3.2 ml. of 2.5 M n-butyllithium in hexane. The reaction solution was heated at reflux for 1 hr and then cooled to -78° C. To the -78° C. solution was added 9.68 mmole of 1-hexynyl copper lithium in 20 ml. tetrahydrofuran. The resultant yellow mixture was stirred 5 minute at -78° C. and then 768 mg. (8.0 mmole) of cyclohex-2-en-1-one was slowly added. The reaction mixture was stirred for 5 minute longer at -78° C. and then warmed to -20° C. and stirred for 5 minute. The reaction mixture was added to 500 ml. saturated aqueous ammonium chloride adjusted to pH 9 with saturated aqueous ammonium hydroxide. The quenched reaction was extracted five times with 500 ml. diethyl ether. The diethyl ether extracts were dried over magnesium sulfate and evaporated to an oil. The crude oil was purified by column chromatography on 200 g. of silica gel eluted with 10% diethyl ether-hexane to yield 1.0 g. (36%) of the title compound as an oil.
PMR: 0.22 (s, Si(CH 3 ) 2 ), 3.80 (s, OCH 3 ) and 6.9-7.2 (m, aromatic H).
HRMS: m/e 346.2342 (M+, calcd for C 21 H 34 O 2 Si: 346.2319), 261 and 247.
PREPARATION E
Z-3-(4'-(Dimethyl-n-hexylsilyl)-2'-methoxyphenyl)cyclohexanol
To a -78° C. solution of 1.0 g. (2.8 mmole) of 3-(4-dimethyl-n-hexylsilyl-2-methoxyphenyl)cyclohexanone in 10 ml. methanol and 2 ml. tetrahydrofuran was added 1.0 g. (26.3 mmole) of sodium borohydride. The reaction was stirred 30 minute at -78° C. and then added to 500 ml. aqueous saturated sodium chloride and 350 ml. diethyl ether. The diethyl ether portion was dried over anhydrous magnesium sulfate and evaporated to an oil. The crude oil was purified by column chromatography on 200 g. of silica gel eluted with 30-50% diethyl ether-hexane to yield in order of elution 35 mg. (3%) of E-3-(4-dimethyl-n-hexylsilyl-2-methoxyphenyl)cyclohexanol and 296 mg. (30%) of the title compound as oils.
Title compound PMR: 0.23 (s, Si(CH 3 ) 2 ), 3.75 (bm, CH), 3.80 (s, OCH 3 ) and 6.9-7.3 (m, aromatic H) ppm.
PREPARATION F
3-(Dimethyl-n-hexylsilyl)methyl-1-methoxysilane
The same materials and procedures as in Preparation A can be employed except the starting material is 3-bromo-methoxybenzene rather than 1-benzyloxy-3-bromobenzene.
PREPARATION G
3-(4'-(Dimethyl-n-hexylsilyl)methyl)-2'-methoxyphenyl)cyclohexanone
The same materials and procedures as in Preparation D can be employed except the starting material is 3-(dimethyl-n-hexylsilyl)methyl-1-methoxybenzene rather than 3-(dimethyl-n-hexylsilyl)-1-methoxybenzene.
PREPARATION H
Z-3-(4'-Dimethyl-n-hexylsilyl)methyl)-2'-methoxyphenyl)cyclohexanol
The same procedures and materials as in Preparation E can be employed except the starting material is 3-(4'-(dimethyl-n-hexylsilyl)methyl)-2'-methoxy-phenyl)cyclohexanone rather than 3-(4'-(dimethyl-n-hexyl)-silyl-2'-methoxyphenyl)cyclohexanone. | A compound of the formula ##STR1## or a pharmaceutically acceptable salt thereof, wherein: G is hydroxymethylene or carbonyl;
R is hydrogen or alkanoyl having from one to seven carbon atoms;
R 1 and R 2 are each methyl or ethyl;
R 3 is an alkyl of from five to seven carbon atoms;
m is 0 or 1; and
n is 1, 2 or 3.
A preferred compound is one in which m is zero, n is one or G is hydroxymethylene. Also preferred are compounds in which R 1 and R 2 are methyl. Additional preferred compounds include those where R is hydrogen or acetyl. A preferred compound is Z-3-(4'-(dimethyl-n-hexylsilyl)-2'-hydroxyphenyl)cyclohexanol.
The invention further comprises pharmaceutical compositions containing these compounds. In accordance with the present invention, these compounds when administered in an effective amount to mammals are useful as CNS agents including analgesics, tranquilizers, sedatives, anticonvulsants, antidiarrheals, antiemetics and antianxiety agents. | 2 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a 371 of International application no. PCT/US2013/058878, filed Sep. 10, 2013, which claims priority to U.S. provisional application, Serial No. 61/702,548, filed Sep. 18, 2012, the contents of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates generally to commercial cargo van-style vehicles, and, more particularly, to a ladder adapted to be clamped to a rear access door of such vehicles to allow convenient access by a work person to a roof area of the vehicle.
[0004] 2. Discussion of the Prior Art
[0005] Various automotive vehicle manufacturers offer cargo vans for carrying supplies and tools to a work site. Such vans have a raised roof sufficiently high to allow an adult worker to stand upright within the vehicle's box and a pair of rear access doors that are hinged to the vehicle's sidewalls along rear edges thereof and which, when swung closed, meet and latch at a midline of the vehicle's rear end. Frequently, such vans will be equipped with a roof rack on which items, such as extension ladders, step ladders and other tools, are carried. Due to the height of the roof, typically about six to seven feet above the ground, it is difficult to reach the rooftop for placement and removal of objects intended for rooftop storage.
[0006] To solve this problem, the present invention provides a ladder that is generally universally attachable to one of the rear doors of the vehicle whereby a worker can safely climb onto the vehicle's roof
SUMMARY OF THE INVENTION
[0007] The present invention comprises a ladder, preferably fabricated from aluminum, having a pair of elongated side rails held in parallel, spaced-apart relation by a plurality of transversely extending longitudinally spaced apart rungs and where the side rails are appropriately bent along their length to better conform to the contour profile of a vehicle door on which the ladder is adapted to be mounted. Adjustable brackets are attached to the upper and lower ends of the ladder side rails with clips for clamping to the top and bottom edge portions of one of the vehicle's rear doors to thereby rigidly mount the ladder to the vehicle door.
DESCRIPTION OF THE DRAWINGS
[0008] The foregoing features, objects and advantages of the invention will become apparent to those skilled in the art from the following detailed description of a preferred embodiment, especially when considered in conjunction with the accompanying drawings in which like numerals in the several views referred to corresponding parts.
[0009] FIG. 1 is a perspective rear view of a typical prior art cargo van on which the present invention finds use;
[0010] FIG. 2 is a perspective view of a van door mountable ladder comprising a preferred embodiment of the present invention;
[0011] FIG. 3 is an exploded detailed view of the clamping structure for engaging a top edge of a van door;
[0012] FIG. 4 is an exploded detailed view of the clamping structure for engaging a bottom edge of a van door; and
[0013] FIG. 5 is an end view of the tubular mounting bracket shown in FIG. 3 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0014] This description of the preferred embodiments is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description of this invention. In the description, relative terms such as “lower”, “upper”, “horizontal”, “vertical”, “above”, “below”, “up”, “down”, “top” and “bottom” as well as derivatives thereof (e.g., “horizontally”, “downwardly”, “upwardly”, etc.) should be construed to refer to the orientation as then described or as shown in the drawings under discussion. These relative terms are for convenience of description and do not require that the apparatus be constructed or operated in a particular orientation. Terms such as “connected”, “connecting”, “attached”, “attaching”, “join” and “joining” are used interchangeably and refer to one structure or surface being secured to another structure or surface or integrally fabricated in one piece, unless expressively described otherwise.
[0015] FIG. 1 illustrates a rear view of a conventional cargo van with which the present invention finds use. It illustrates the van with the rear doors open and, as can be seen by the view, the roof of the van is sufficiently elevated relative to its floor so that a workman may stand erect within the van's box. The van is indicated generally by numeral 10 and has a roof structure 12 , sidewalls 14 and 16 , and with left and right rear doors 18 and 20 hinged to the sidewalls 16 and 14 , respectively.
[0016] Looking closely at the bottoms of the doors 18 and 20 in FIG. 1 , an edge portion 22 of the left door's sheet metal front panel extends down a short distance below the inside rear bottom edge of the door. This can also be seen at 24 on the right rear door 20 . While somewhat difficult to see in the view of FIG. 1 , the top edge of the door's front panel also extends slightly above the inner rear door panel, as at 26 and 28 . Also, by viewing the door 20 , it can be seen that the sheet metal front panel of that door is contoured such that approximately the lower half thereof is generally vertically oriented and then the upper approximately half curves such that when the door are closed, that upper portion slopes in a forward direction.
[0017] FIG. 2 is a perspective view of the ladder comprising a preferred embodiment of the present invention. It is seen to comprise first and second longitudinally extending aluminum rails 30 and 32 that are held in parallel, spaced-apart relation by a plurality of transversely extending, longitudinally spaced-apart rungs 34 . Attached to the upper end portion of each of the rails 30 and 32 is a pair of upper end door-mounting bracket devices 36 and, likewise, affixed to the lower end of the rails 30 and 32 are door-bottom mounting bracket devices 38 .
[0018] With continued reference to FIG. 2 , it will be noted that the rails 30 and 32 rise generally vertically over a length identified by bracket 40 and then bend slightly in a forward direction, thus, following the contours of the exterior of the doors 18 and 20 .
[0019] Turning next to FIG. 3 , there is shown an exploded detailed view of the upper door-edge mounting bracket devices 36 . Bolted or otherwise affixed to the upper end portions of the ladder rails 30 and 32 are mounting plates, as at 42 . More particularly, bolts, as at 44 , extend through washers 46 into selected ones of a series of regularly spaced threaded bores 48 that are formed through the rails 30 and 32 such that the placement of the mounting brackets 42 is adjustable over a limited range along the length dimension of the rails. A somewhat tubular clamp member 50 is adapted to be affixed to each of the bracket-mounting plates 42 by bolts 52 that pass through bores 54 and 56 in the legs of the tubular clamp 50 and the mounting bracket 42 , respectively.
[0020] FIG. 5 is an end view of the extrusion comprising the tubular mounting bracket 50 and it is seen to include an inwardly protruding key 58 , which is adapted to mate with a keyway groove 60 formed in an insert rod 62 adapted to fit into the tubular opening of the bracket 50 . In this fashion, the degree of extension of the rod 62 from the tubular bracket 50 can be adjusted and then fixed when the bolts 52 are tightened into the nuts 64 which serve to compress the legs 66 of the bracket member 50 together and reduce the I.D. of the tubular portion thereof. Bolted to the outer end of the rod 62 is a clip 68 which is arranged to engage the upper portion 26 of the vehicle's door as seen in FIG. 1 .
[0021] Referring next to FIG. 4 , there is shown a similar arrangement for securing the bottoms of the ladder rails 30 and 32 to the lower edge 22 or 24 on the vehicle's rear door 18 or 20 . As in the attachment arrangement shown in FIG. 3 , the lower ladder attachment bracket assemblies include an attachment plate 70 of a somewhat different shape attached to each of the ladder rails 30 and 32 by bolts 72 that pass through washers and slotted apertures 74 into selected ones of the threaded bores 75 formed in the ladder rails. The mounting plates 70 provide a means whereby a tubular mounting bracket 76 can be attached by bolts, as at 78 , that extend through apertures in the legs of the tubular mounting bracket 76 and through apertures, as at 80 , formed in the mounting plate to be secured by nuts, as at 82 . The tubular mounting bracket 76 has an end view like that shown in FIG. 5 including a key 58 for cooperating with a keyway or groove 84 formed in a rod 86 . Again, the extent to which the rod 84 projects out from the tubular mounting bracket 76 is slideably adjustable and then can be rigidly secured upon tightening of the bolts 78 into the nuts 82 .
[0022] Affixed to the outer end of the rod 86 is a clip member 88 which fastens to the rod 86 by means of a bolt 90 that is arranged to pass through aligned apertures in the clip 88 and the rod 86 . A nut 92 , when tightened on to the bolt 90 , establishes a rigid connection with the end of the rod 86 .
[0023] In assembling a ladder on to the door 18 or 20 of the van, the ladder will be suspended from the upper edge of the door 26 or 28 by the upper door-edge mounting bracket devices 36 illustrated in FIG. 3 with the clips 68 fitted over and engaging the upper edges 26 or 28 of door. Then, the rods 86 of the lower door-edge ladder attachments will be inserted into the tubular brackets 76 and raised therein until the clips 88 fit behind and engage the lower edge 22 or 24 of the vehicle's rear doors. At this point, all bolts as at 90 , 78 , and 52 will be tightened to rigidly clamp the ladder to a selected one of the vehicle's rear door. The upper and lower ladder attachment brackets are designed so as not to mar the vehicle's doors in any way while yet rigidly securing the mounting ladder to the vehicle at a location so that it can be easily climbed to reach the exterior roof area of the cargo van.
[0024] This invention has been described herein in considerable detail in order to comply with the patent statutes and to provide those skilled in the art with the information needed to apply the novel principles and to construct and use such specialized components as are required. However, it is to be understood that the invention can be carried out by specifically different equipment and devices, and that various modifications, both as to the equipment and operating procedures, can be accomplished without departing from the scope of the invention itself. | A ladder specially designed for attachment to a rear door of a cargo van to facilitate the ability of a person to climb onto the vehicle's roof. The ladder has two parallel rails joined by a plurality of transversely extending rungs. Affixed to the upper and lower ends of the ladder rungs are length adjustable brackets supporting door engaging clips designed to fit about the upper and lower edges of a van door without interfering with the ability of the door to open and close. The ladder rails are preferably bent to conform to the contour of the van door. | 4 |
BACKGROUND
[0001] Transportable storage sheds are not new. Fully assembled storage sheds are normally hauled on bulky trailers, to and from their destination. Upon delivery, sheds are physically slid off of the trailer. Separate leveling equipment, such as jacks, hoists or pry bars must then be used to block and level the shed.
[0002] During pick-up, the sheds are usually pulled back onto the trailer with a winch. This repetitive routine often causes damage to the shed, and reduces is useful lifetime. This routine can also damage the delivery site, as well as any contents that may remain in the shed.
[0003] This specialized shed installation and removal system allows a single person to deliver a storage shed safely and accurately. The unique construction of the system, lends itself to an extremely efficient and versatile technique, which can prolong the useful life of the shed and make delivery possible in tighter areas.
SUMMARY OF THE INVENTION
[0004] It is an object of the present invention to provide a system of delivery and removal for storage sheds, which allows for access to tighter areas than would otherwise be possible.
[0005] It is another object of the present invention to use the same jacks for the leveling and blocking procedure, as well as the delivery and removal process. This allows a single person to deliver and block and level a large all-wood shed without any help.
[0006] It is another object of the present invention to provide safe and simple components that are easy to handle, attach, and stow in the towing vehicle. Additionally, some components remain on the shed and actually protect it from damage during transit.
[0007] It is another object of the present invention to provide removable braces (outriggers) on the trailer to reduce the trailer's overall weight and width. The narrow trailer (without outriggers) can then be removed from under the shed and clear the front jacks even if the truck is at an angle to the trailer (jackknifed to some degree). In situations where the trailer is at such an angle that it will hit the front jack on the way out, a front jack can be removed and the shed can be blocked or supported by a 4″×6″ or larger timber approx. 24″ to 30″ long or other appropriate blocking. This support would be placed farther back on the skid to allow the trailer to be removed. After the trailer is removed the jack assembly can be re-attached and the shed can be lowered into place. The lightweight trailer design allows it to be moved by hand or by winch, in certain situations. The number of outriggers required can vary with the weight and length of the cargo being hauled.
[0008] It is another object of the present invention to provide folding fenders on the trailer, which swing away from the tires and allow the shed to ride much lower on the trailer, creating a lower center of gravity for safe hauling. The shed covers the wheels during transit, and acts as fenders.
DESCRIPTION OF DRAWING VIEWS
[0009] FIG. 1 is a street-level perspective view of the invention.
[0010] FIG. 2 is a close-up perspective view.
[0011] FIG. 3 is an overhead perspective view of a portion of the jack assembly.
[0012] FIG. 4 is an overhead perspective view of a portion of the jack assembly.
[0013] FIG. 5 is a close-up perspective view.
[0014] FIG. 6 is
[0015] FIG. 7 is a close-up perspective view.
[0016] FIG. 8 is a street-level close-up view.
[0017] FIG. 9 is a street-level view of a portion of the invention.
[0018] FIG. 10 is a perspective view of a portion of the invention.
[0019] FIG. 11 is a perspective view of a portion of the invention.
[0020] FIG. 12 is a street-level close-up view
[0021] FIG. 13 is an overhead perspective view of a portion of the invention.
[0022] FIG. 14 is a street-level close-up view.
[0023] FIG. 15 is a street-level close-up view.
[0024] FIG. 16 is a close-up perspective view.
[0025] FIG. 17 is a close-up perspective view.
[0026] FIG. 18 is a close-up perspective view.
[0027] FIG. 19 is a close-up perspective view.
[0028] FIG. 20 is a street-level view of the invention.
[0000]
Item List
Item numbers
SHED
10
SKID
11
SKID PROTRUSION
12
JACK ASSEMBLY
20
SLIDE COLLAR
21
OUTER SLIDE COLLAR PIPE
22
HOOK
23
FOOT PAD
24
INNER DOWEL PIPE
25
LOWER SEGMENT LIFT PIPE
26
UPPER SEGMENT LIFT PIPE
27
HOIST
28
TRAILER
30
FOLDING FENDERS
31
OUTRIGGERS
32
SET BOLT
33
TIE-DOWN CHAINS
34
DESCRIPTION OF THE INVENTION
[0029] FIG. 1 shows a Shed 10 that has been loaded onto its Trailer 30 , appearing so as part of the system that comprises the invention.
[0030] FIG. 2 shows the complete system being utilized at once. The Shed 10 has been lifted into loading position and held there with the four Jack Assemblies 20 , as the Trailer 30 backs into place.
[0031] FIG. 3 shows three of the four components of a single Jack Assembly 20 : the Slide Collar 21 , the Foot Pad 24 , and the Upper Segment Lift Pipe 27 .
[0032] The metal Slide Collar 21 slides over a Skid Protrusions (not shown in this figure) at the base of a specialized Shed (not shown in this figure). They also possess a short Outer Slide Collar Pipe 22 and a Hook 23 , which are all welded together as shown.
[0033] The metal Foot Pad 24 has a square base welded to an Inner Dowel Pipe 25 and an Lower Segment Lift Pipe 26 .
[0034] The metal Upper Segment Lift Pipe 27 assembles to the Foot Pad 24 and guides the Slide Collar 21 vertically.
[0035] FIG. 4 shows the components listed in FIG. 3 , in their assembled state. Here, the Upper Segment Lift Pipe 27 has been assembled onto the Foot Pad 24 , and the Slide Collar 21 has been slid thereon. When lifted by the Hook 23 , the Slide Collar 21 will be guided up and down the Pipe Assembly.
[0036] FIG. 5 Shows One Foot Pad 24 and one Slide Collar 21 assembled just prior to mounting onto the Shed 10 , which possesses a Skid Protrusion 12 at each corner for mounting the Slide Collars 21 . A Skid 11 runs along each side of the specialized Shed 10 , at its base.
[0037] FIG. 6 shows the foot pad/slide collar assembly of FIG. 5 after it has been mounted onto the Skid Protrusion 12 of the specialized Shed 10 .
[0038] FIG. 7 shows the Upper Segment Lift Pipe 27 in place within the Outer Slide Collar Pipe 22 of the Slide Collar 21 , and mounted over the Inner Dowel Pipe (not visible in this figure) of the Foot Pad 24 .
[0039] FIG. 8 shows one complete Jack Assembly 20 , which also includes a Hoist 28 . In this case, it is a chain-type hoist. Any appropriate means for hoisting objects can be used. The Hoist 28 hooks into open end at the top of the Upper Segment Lift Pipe 27 .
[0040] FIG. 9 shows a single operator able to adjust each Jack Assembly 20 incrementally, able to keep the Shed level, and able to gradually raise it high enough for the Trailer. (Four jack assemblies are used at one time, one at each corner of the shed.)
[0041] FIG. 10 shows an operator preparing to swing one of the Folding Fenders 31 out of the way. The Trailer 30 is a low-profile, open frame (no decking), tandem-axle unit. The rear frame area is 2-3 feet narrower than the rest of the frame. This helps in the removal of the Trailer from under the lifted shed.
[0042] FIG. 11 shows one of the Folding Fenders 31 after it has been moved away from the tires.
[0043] FIG. 12 shows the Trailer 30 being backed under the Shed 10 , to prepare it for removal.
[0044] FIG. 13 shows a single metal Outrigger 32 , which is made of a square stock piece with an angle piece welded to the outer top portion, and a stop piece welded to the end. ( FIG. 14 shows this from a different angle.)
[0045] FIG. 14 shows the Outrigger 32 in position, after it has been inserted into the Trailer 30 . This figure gives a better view of the angle piece near the outer end of the Outrigger 32 , which helps to keep the wooden skid of the shed from sliding forwards and backwards on the trailer. A set bolt is used to secure the Outrigger 32 to the Trailer 30 .
[0046] FIG. 15 shows the Shed 10 as it is ready to be lowered onto the Trailer 30 . The Outriggers 32 extend a total of a few inches wider than the Shed. This allows some latitude for loading the Shed 10 within the stops.
[0047] FIG. 16 show the Shed 10 as it is being lowered onto the Trailer 30 . The Shed is built with a pair of wood Skids at its base, which protrude past each corner of the Shed at floor level. The Skid Protrusions allow the Slide Collars to attach, for lifting and loading.
[0048] FIG. 17 shows the Shed 10 after it has been lowered onto the Trailer 30 . The Hoist and Upper Segment Lift Pipe have been removed from the Jack Assembly in the foreground.
[0049] FIG. 18 shows all but the Slide Collar 21 removed from one corner of the Shed 10 . A Tie-Down Chain 34 has been hooked to the Slide Collar, which stays with the shed during transport.
[0050] FIG. 19 shows the operator securing the front Tie-Down Chains 34 to the Trailer 30 . When the rear ones are also secure, the specialized Shed 10 is ready to be hauled away safely.
[0051] FIG. 20 shows a shed being hauled away. | A system for installation and removal of a storage shed is disclosed. The system includes a custom trailer, a specialized storage shed, and a complete set of unique lifting components. The system allows a single operator to conveniently and safely deliver/remove a storage shed, without causing damage to the it in the process. | 1 |
FIELD OF THE INVENTION
This invention relates to a method for collecting a sample for subsequent use in the detection of an analyte in the sample. In one particular embodiment, this invention relates to a method for sampling faecal material for the purposes of subsequent detection in the sample of occult blood or one or more other indicators of a pathological condition.
The present invention also extends to an assay kit which is particularly suitable for the purposes of detection in a sample derived from faecal material of occult blood or one or more other indicators of a pathological condition.
BACKGROUND OF THE INVENTION
A well known and widely-used clinical reagent for the detection of occult blood in a sample, particularly a faecal sample, is guaiac (also known as gum guaiac or resin guaiac). When used in association with an appropriate developer solution, guaiac provides a colorimetric assay system for detecting haemoglobin in the sample. Such tests are commercially available, for example, Hemoccult II and Hemoccult II Sensa (SmithKline Diagnostics, San Jose, Calif., USA).
Prior Australian Patent No. 665956 (International Patent Application No. PCT/US92/04425) notes that among the many analytical systems used for detection and/or determination of analytes, particularly analytes of biological interest, are chromatographic assay systems. Among the analytes of biological interest frequently assayed with such systems are:
1. hormones, such as human chorionic gonadotropin (hCG), frequently assayed as a marker of human pregnancy; 2. antigens, particularly antigens specific to bacterial, viral, and protozoan pathogens, such as Streptococcus , hepatitis virus, and Giardia; 3. antibodies, particularly antibodies induced as a result of infection with pathogens, such as antibody to the bacterium Helicobacter pylori and to human immunodeficiency virus (HIV); 4. other proteins, such as haemoglobin, frequently assayed in determinations of faecal occult blood, an early indicator of gastrointestinal disorders such as colon cancer; 5. enzymes, such as aspartate aminotransferase, lactate dehydrogenase, alkaline phosphatase, and glutamate dehydrogenase, frequently assayed as indicators of physiological function and tissue damage; 6. drugs, both therapeutic drugs, such as antibiotics, tranquillisers and anticonvulsants, and illegal drugs of abuse, such as cocaine, heroin, and marijuana; and 7. vitamins.
Such chromatographic systems are frequently used by physicians and medical technicians for rapid in-office diagnosis and therapeutic monitoring of a variety of conditions and disorders. They are also increasingly used by patients themselves for at-home monitoring of such conditions and disorders.
Among the most important of such chromatographic systems are the “thin layer” membrane-based systems in which a solvent moves as a solvent front across a thin, flat absorbent medium (e.g., nitrocellulose membrane). Among the most important of tests that can be performed with such thin layer systems are immunoassays, which depend on the specific interaction between an antigen or hapten and a corresponding antibody. The use of immunoassays as a means of testing for the presence and/or amount of clinically important molecules has been known for some time.
Chromatographic techniques used in conjunction with immunoassays include a procedure known as immunochromatography. In general, this technique uses a disclosing reagent or particle that has been linked to an antibody to the analyte to be assayed, forming a conjugate. This conjugate is then mixed with a specimen and, if the analyte to be assayed is present in the specimen, the disclosing reagent-linked antibodies bind to the analyte to be assayed, thereby giving an indication that the analyte to be assayed is present. The disclosing reagent or particle can be identifiable by colour, magnetic properties, radioactivity, specific reactivity with another molecule, or another physical or chemical property. The specific reactions that are employed vary with the nature of the analyte being assayed and the sample to be tested.
The present invention is particularly, but not exclusively, directed to collection of samples derived from faecal material for occult blood detection, for example in screening for colorectal cancer. As previously described, guaiac testing provides a colorimetric assay system for detection of haemoglobin in a sample, however because of the large number of false positives obtained in guaiac testing, in screening programs the use of two or three guaiac tests has been recommended, confirmed when positive by an immunological test for human haemoglobin (Favennic L., Kapel N., Meillet D., Chochillon C. and Gobert J. G., Annales de Biologie Clinique, 50(5):311-3, 1992). More recently, a combination of guaiac and immunological testing has been suggested (Allison, J. E., Tekawa, I. S., Ransom, L. J. and Adrian, L. L. N. Engl. J. Med., 334:155-9, 1996).
It is an object of the present invention to provide a sample collection method which is simple and economic, and which enables subsequent detection and/or determination of analyte in the sample to be readily carried out, for example using a guaiac test, and/or an immunochromatographic or other immunodiagnostic procedure.
SUMMARY OF THE INVENTION
In accordance with the present invention, there is provided a method for collecting a sample derived from faecal material, comprising contacting the faecal material with a fluid and subsequently collecting a sample of the fluid with a brush or brush-like device having flexible or semi-flexible bristles, wherein the sample of the fluid is collected within the bristles of the brush or brush-like device.
Preferably, the fluid is water.
The term “brush” as used herein is used to denote device comprising a stem or handle, usually elongate, and a clump, bunch or group of bristles, hair or other similar flexible or semi-flexible elongate strands, laminar flaps or the like attached to the stem or handle. The term “brush-like device” is used herein to denote a device which is similar to a brush in that it includes a bunch, clump or group of bristles, hair or other similar flexible or semi-flexible elongate strands, laminar flaps or the like. Whilst reference is made throughout the present specification to the collection of a sample within the bristles of a brush or brush-like device, it is to be understood that the reference to “bristles” is used to include the hairs or other similar flexible or semi-flexible elongate strands, laminar flaps or the like of a brush or brush-like device.
Preferably, the bristles of the brush or brush-like device will have a length of about 0.2 to 3 cm long, more preferably a length of 1 to 2 cm.
In another embodiment, the present invention also extends to an assay kit for testing faecal material which comprises a sample collection device which is a brush or brush-like device having flexible or semi-flexible bristles, together with means for detection of an analyte in a sample derived from faecal material.
Such an assay kit is particularly suited for use in detection of occult blood in a sample derived from faecal material. The detection of occult gastrointestinal bleeding is a common method for screening for colorectal cancer. Commonly referred to as the aecal occult blood (FOB) test, a variety of formats are known in the art (see, for example, U.S. Pat. Nos. 3,996,006; 4,225,557; 4,789,629; 5,064,766; 5,100,619; 5,106,582; 5,171,528; 5,171,529; and 5,182,191). The majority of test formats are based on the chemical detection of the heme groups present in faecal material as a breakdown product of blood. In such tests, the pseudoperoxidase nature of the heme group is used to catalyse a colorimetric reaction between an indicator dye and peroxide. The oxygen sensitive dye can be gum guaiac, orthodianisidine, tetramethylbenzidine, or the like, with guaiac being preferred.
The means for detection of an analyte in a sample which is incorporated into an assay kit as described above may, for example, be means for carrying out a guaiac test for the detection of occult blood in the sample. Alternatively, or additionally, the means for detection of an analyte in a sample may be means for detection of occult blood (or other diagnostic antigens) in the sample by means of a chromatographic procedure, particularly by an immunochromatographic or other immunodiagnostic procedure which is well known in the art. Suitable immunochromatographic procedures are described, by way of example, in U.S. Pat. Nos. 5,591,645 and 5,622,871, the disclosures of which are incorporated herein by reference.
Whilst the present invention is particularly useful in FOB testing as described in detail herein, it is to be understood that the method and assay kit as broadly described herein may be used in sampling faecal material and subsequent testing of the sample to detect the presence of one or more other indicators of a pathological condition, for example, tumour-derived antigens, in addition to or instead of FOB testing.
Throughout this specification, unless the context requires otherwise, the word “comprise”, and or variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.
DETAILED DESCRIPTION OF THE INVENTION
In the most preferred embodiment, the present invention relates to the use of a brush as a device for obtaining a sample derived from faecal material, and particularly stool, in a fluid such as water, particularly for the detection of occult blood as an indicator of colorectal cancer (CRC) or its precursor conditions.
Most existing faecal occult blood tests (FOBTs) use a sampling stick or paddle to take smears directly from the surface of a collected faecal sample. European Patent Application No. EP 0 727653 discloses the use of a brush device having stiff bristles to collect a sample from the surface of faecal material directly on the bristles. Many CRCs or their precursors (e.g. adenomas>1 cm), bleed into the lumen of the small intestine. As these malignancies arise as protrusions from the wall of the intestine they make contact with the surface of the stool in their region of contact as the stool passes that point. The blood, therefore, may not be evenly distributed through or over the stool. As a result, existing tests that rely on surface sampling of the stool may or may not sample from that portion of the stool where blood is present.
If the stool or other faecal material is sampled in a fluid, for example, when it is in the water of the toilet bowl, there is a better opportunity to gain a representative sampling of the whole stool. This is particularly the case where a small brush (e.g. a small artist's paint brush having bristles about 1 to 2 cm in length) is used for sampling. A brush may be used to “paint” the surface of the stool so as to displace any blood on the surface of the stool into the water surrounding the stool. The flexible or semi-flexible bristles of the brush will be relatively “open” during this brushing and sampling process, but will “close” as the brush is withdrawn from the water, thereby keeping a ample of the water (and any blood contained therein), surrounding the stool within the interstitial spaces of the bristles. This sample may then be transferred to a suitable assay device for subsequent testing.
By way of contrast, if an absorbent sampling device, such as a swab, was used for sampling, water would infiltrate the fibre windings of the swab on its first contact with the water in the toilet bowl. In this case, there would be little chance of effective displacement of the infiltrated water by any blood-containing water in the vicinity of the stool, and as a result the sampling procedure would not effectively sample any such blood-containing water.
Alternatively, if a solid sampling device such as a solid sampling stick or paddle, or a loop or barbed probe was used, the water sampled from around the stool would be lost as the device was withdrawn through the water of the bowl, and once again the sampling procedure would not effectively sample any blood-containing water.
A further advantage which is obtained by the use of a brush or brush-like sampling device in accordance with the present invention is that the fluid sample collected within the bristles of the sampling device as described above is collected in a semi-quantitative manner, in that the amount of fluid held within the interstitial spaces of the bristles of the sampling device will be a reasonably constant amount for any particular size and configuration of the sampling device.
As described above, an important feature of the sampling device is that the bristles of the device, as defined above, are flexible or semi-flexible. This enables the device to be used to obtain a sample of fluid surrounding the faecal material into which any occult blood on or at the surface of the faecal material has been dispersed, instead of attempting to obtain a sample directly from the surface of the faecal material where it may only be present in isolated locations, and accordingly where there is a risk that any sample taken directly from the surface of the faecal material may not be taken from a location where any blood is present.
As previously described, colorectal cancers and adenomas often bleed into the lumen of the large bowel. Initially, only a small, localised amount of blood leakage may occur, leading to isolated spots or areas of blood occurring on the surface of faecal material in the large bowel which will be exposed to the blood first. It is not unreasonable to assume that much of this blood will remain on the surface of this faecal material after it is passed. Similarly, almost all colorectal cancers and all adenomas occupy only a small portion of the diameter of the large bowel. Therefore, it is also likely that the blood from such lesions will be striped along the faecal material. If this is the case, the brush method of the present invention for sampling faecal material will have an advantage over traditional FOBT sampling methods because the sampling method of the present invention takes a more representative sample than that of the traditional methods.
Further features of the present invention are more fully described in the following Example(s). It is to be understood, however, that this detailed description is included solely for the purposes of exemplifying the present invention, and should not be understood in any way as a restriction on the broad description of the invention as set out above.
EXAMPLE 1
The suitability of a brush for sampling blood in water has been shown to be effective by several means:
1. Blood (10 μL) was added to water (50 mL) in a beaker. After the blood settled to a discrete drop at the bottom of the beaker, a brush (#5, LiFung, Hong Kong) was first used to sample the surface water from the beaker. This sample tested negative in a faecal occult blood (FOB) test (Enterix). After mixing the contents of the beaker, a second, similar brush was shown to be capable of selectively sampling sufficient of the blood to be detected in a similar FOB test. 2. A stool sample was injected with blood (50 μL) so that the blood was sequestered within a crevice in the stool. The stool was added to a toilet bowl and brushes as described above were used to sample:
(a) The water of the bowl. (b) The water surrounding the stool after the surface of the stool was “brushed”. When tested in FOB tests (Enterix), samples (a) tested negative for blood, whereas samples (b) tested positive. In this experiment it may be expected that the sequestered blood would have been missed by conventional sampling of the stool surface with a stick or paddle.
3. Table 1 below shows the results of a series of experiments to test the effectiveness of sampling of stool samples with a brush as described above. Blood was added directly to normal stool samples, before or after the deposition of the stools into a toilet bowl. Normal stools and the bowl water before stool addition were also sampled. In each case samples collected by the brush method were tested for the presence of blood by an FOB test (Enterix).
TABLE 1
Normal stool
25 μL
50 μL
100 μL
FOB Test
(i.e. no
blood
blood
blood
Results
Bowl Water
addition)
added
added
added
No. positive
—
—
4/4
15/15
27/27
No. negative
2/2
15/15
—
—
—
As shown in the Table, all toilet bowl water and normal stool samples tested negative in the FOB test, whereas all samples with added blood (≧25 μL) gave a positive test result. These results compare favourably with the sensitivity and specificity data reported with tests that use direct stool sampling with a sampling stick Rosen, P., Knaai, J. and Samuel, Z. Dig. Dis. Sci., 42(10):2064-71, 1997).
EXAMPLE 2
The aim of this study was to determine if the sampling method of the present invention is more capable of detecting significant quantities of blood than a traditional method of FOBT sampling when the blood is striped along one side of the surface of a stool.
Methods
Ten faecal samples were collected from three individuals and spiked with blood to a concentration of 0.5 milligrams of haemoglobin per gram faeces. Spiking was achieved by spotting the blood along the surface of the stool in a stripe.
Five spiked stools were tested both by the method of the present invention (EnterixOBT) and by FlexSureOBT (Beckman Coulter Personal Care Diagnostics, Palo Alto, Calif., U.S.A.). The samples for testing were collected as per the manufacturer's instructions for each test exactly as if the person had been defecating directly into the toilet bowl (EnterixOBT) or into a paper saddle (FlexSureOBT). In the EnterixOBT test, the sampling device is a brush (LiFung, Hong Kong) having a plastic stem or handle (approx. 185 mm length, 4-6 mm diameter) and flexible bristles (approx. 15 mm length). The sampling device for the FlexSureOBT test is a solid paddle or “popsicle” stick. To avoid bias, sampling for each test was standardised. and blinded For EnterixOBT, samples were collected by five brush strokes of the upright surface of the stool. Where loose stools were concerned, the brush was swirled around the stool five times. For FlexSureOBT, sampling was carried out as per manufacturer's instructions at random points on the stool.
All tests were developed three-four days after sampling and all tests were read by two independent readers. The results are shown in Table 2 below.
Results
TABLE 2 Test results for stripe-spiked stool samples. EnterixOBT FlexSureOBT (n = 5) (n = 5) Reader A Reader B Reader A Reader B Positive 5 5 1 1 Negative 0 0 4 4
Discussion
Although the number of samples tested in this study is small, EnterixOBT appears to be able to detect a significant quantity of blood better than FlexSureOBT when the blood is striped along the surface of the stool. This difference is presumably due to the different methods of sampling employed by each test. As a result, EnterixOBT appears to have a clear advantage over FlexSureOBT in terms of the clinical detection of occult blood on faecal material, for example, in the detection of colorectal neoplasia.
Persons skilled in this art will appreciate that variations and modifications may be made to the invention as broadly described herein, other than those specifically described without departing from the spirit and scope of the invention. It is to be understood that this invention extends to include all such variations and modifications. | The present invention relates to methods for the collection of a sample from faecal material and, further, the detection of occult blood in or on the faecal material via the testing of the sample collected from the faecal material. The present invention also relates to collection methods comprising the use of a brush-like device having flexible or semi-flexible bristles wherein the brush-like device is contacted to the faecal material. The present invention also relates to detection of occult blood from the sample collected from the faecal material by means of a guaiac test or immunochromatographic test. The present invention additionally relates to the detection of one or more indicators of a pathological condition in or on the faecal material from which the sample is derived. | 8 |
FIELD OF THE INVENTION
[0001] This invention relates to a method of updating, maintaining and verifying electronic mail (email) address information for various contacts stored in a database.
BACKGROUND OF THE INVENTION
[0002] In the past, people have maintained contact lists on paper. The proverbial “black book” is a good example of a list of individuals and their contact information. Unfortunately, it is not uncommon that upon attempting to contact someone one discovers that the information is no longer accurate. This is of tremendous inconvenience, especially during emergency or time limited situations. Unfortunately, the task of maintaining a large contact list current is often too onerous for the few times one need to contact each individual.
[0003] Therefore, whenever someone changes address, phone numbers or any other piece of contact information, there is a necessity for them to provide their contacts with the most current contact data. Conventional methods of accomplishing this task include sending updated information by email, via facsimile, or even by telephoning to contacts in an address book and making, others aware that some information has changed and they need to manually update their contact list, which is time consuming.
[0004] A service offering automated updating of electronic contact information and ensuring most current contact information is offered by PeopleStreet through their World Wide Web site PeopleStreet.com. PeopleStreet addresses the difficult task of enabling people to stay connected to their many circles of contacts. The service provided by PeopleStreet manages the personal information and provides a dynamic link to all personal and professional relationships. This is performed by providing a method for each user to update their own address book entry, thereby automatically updating all the other user contacts of their new address book entry, wherever they may be.
[0005] Although the service that PeopleStreet provides does automate this tedious process, it does require that each party is a member of the service. In this manner information is updated from and to all parties subscribed to the service. This facilitates updating your personal information and being updated of others. A shortcoming of the method is that members of the address book, which are not already subscribed, still have to manually inform the subscribed user of their updated contact information according to the prior art updating method.
[0006] Contact.com also offers a similar type of contact service, which provides for the exchange of personal information. Once again, subscribed users decide which of their contacts are privileged to which information fields and as a result when the contact changes their personal information all the other address books linked to the contact are updated. This form of service requires the information to be stored on a central storage system. Although security may be strictly enforced, there arc still security concerns because all personal information is accessible from outside the server.
[0007] Of course, when using email applications, a user is typically notified when a mail delivery error occurs. As such, the user is apprised of a possibly erroneous email address. The user must then proceed to try to correct the address or locate another valid email address. Once corrected, the user can only access the corrected address through their address database. Unfortunately, this is both inconvenient and prone to error. As such, it is generally a nuisance when email addresses expire or change.
[0008] It would be highly advantageous to provide a method for updating email address information in an automated fashion absent either security concerns or mandatory subscription to a service by each party within a given email address list.
SUMMARY OF THE INVENTION
[0009] In accordance with the invention there is provided a method for updating an electronic a contact information database comprising the steps of:
[0010] a) sending at least an electronic mail message to a contact destination of at least one contact from a plurality of contacts stored within the electronic contact information database of a user; and
[0011] b) upon receiving a return message indicative of electronic mail message delivery failure, automatically flagging the contact destination as potentially expired within the contact information database.
[0012] In accordance with another aspect of the invention there is provided a method for updating an electronic contact information database wherein:
[0013] upon receiving an email message from a known contact using a previously unrecognized email address;
[0014] updating the contact information database to include the previously unrecognized email address in addition to the email address that is already stored;
[0015] wherein both addresses are associated with the contact.
BRIEF DESCRIPTION OF DRAWINGS
[0016] The invention will now be described with reference to the attached drawings. in which:
[0017] [0017]FIG. 1 a is a simplified diagram of a computer system in execution of an electronic mail application;
[0018] [0018]FIG. 1 b is a simplified flow diagram of a prior art method of using an electronic mail application;
[0019] [0019]FIG. 1 c is a simplified flow diagram of another prior art method of using an electronic mail application;
[0020] [0020]FIG. 2 is a simplified flow diagram of a method of manually updating an address book;
[0021] [0021]FIG. 3 is a simplified flow diagram of a method of automatically updating an address book:
[0022] [0022]FIG. 4 is a simplified flow diagram of a method of automatically updating an address book for use with a reply feature of an electronic mail application;
[0023] [0023]FIG. 5 is a simplified flow diagram of a method of locating a message that resulted in a transmission error and prompting a user to re-send the message with a known current email address for the destination individual;
[0024] [0024]FIG. 6 is a simplified diagram of an email address book entry for Slugger;
[0025] [0025]FIG. 7 is a simplified diagram of the email address book entry of FIG. 6 with the destination address expired; and,
[0026] [0026]FIG. 8 is a simplified diagram of the email address book entry of FIG. 7 wherein an updated current email address is known for the destination.
DETAILED DESCRIPTION OF INVENTION
[0027] Generally, according to the invention a method is provided for automatically maintaining an updated email address list in order to facilitate creation and sending of email messages and in order to facilitate address book maintenance.
[0028] Referring to FIG. 1 a, a simplified block diagram of a computer system in execution of an electronic mail application is shown. The computer system 1 is in communication with a public network 2 such as the Internet for providing a communication medium across which to transmit electronic messages. The computer system 1 is connected to the internet via a local area network such as an Ethernet network, through a telephone line using a modem or another communication device, through a cable connections through a fibre optic connection or through a wireless connection. The computer is provided with a data entry transducer in the form of keyboard 3 and mouse 4 . The computer system also includes a monitor 5 .
[0029] Typically, the public network is in a process of directing many electronic mail messages at any time. The messages are provided to the network from a source system and are then directed within the network until they arrive at a destination computer system. Most often, the source and destination computer systems are in execution of an electronic mail program for creating and sending electronic mail messages and for receiving and displaying electronic mail messages.
[0030] Referring to FIG. 1 b, a simplified flow diagram of a prior art method of using electronic mail is shown. A user selects an option within an electronic mail application in execution to create a new email message. The email message typically requires a destination address and a return address. Though this is the case, typical email applications also provide for a subject line, message text, and attached electronic files. Once the text is entered, any files are attached, and a destination address is specified, the email message is transmitted via the network to its destination. Unfortunately, current email addresses are often less than intuitive. For example, an account for an employee at a large multinational company named, for example, Company whose name is John Smith may be john@Company.com, smith@Company.com, john 13 smith@Company.com. jsmith@Company.com, johns@Company.com, john 13 smith 23 @Company.com, or any other contraction, expansion, variation, or modification of the employee name. Also some companies don't use names in email addresses resulting in unintuitive names such as bf 001 @Company.com.
[0031] In order to facilitate the use of electronic mail applications, they are typically provided with an address book feature. The address book feature allows an individual user to store email addresses along with an identifier they specify. For example, John Smith at Company is a great baseball player and his nickname is Slugger so a user might enter his destination address and then provide the nickname slugger for him. Upon creating a new email message, the destination slugger is automatically converted to the entered destination email address. Now, the address book is customised.
[0032] Of course, it is also possible to use external address book applications that are not integral to the electronic mail application.
[0033] As is shown in FIG. 1 c, the user enters the nickname where before the complete destination email address was entered.
[0034] Referring to FIG. 2, a method of manually updating an address book is shown. For example, a message is received indicating that the email message addressed for destination John Smith is not deliverable. The user then calls John Smith to determine their correct email address. In the mean time, the user may delete the entry in the address book or leave it there. Once the new email address is received, the address book destination address for slugger is updated and the address book is maintained. This process is both cumbersome and prone to errors. The new destination address may be inserted with typos, the nickname may be reused countless times before it is updated, the entire entry may be deleted when only the email address was expired and so forth.
[0035] Another common method of determining a destination email address involves a reply feature common in most email applications. A message from the desired destination is located and a reply feature is invoked. Now a new message is created with the destination specified as the source of the located message. With people moving from one Internet provider to another, their email addresses change frequently. Thus it is common to locate an old email message that has an outdated source address and to then receive an error message because the reply message was undeliverable. These are common problems in dealing with email messages that require solutions.
[0036] Referring to FIG. 3, a method of automatically updating an email address list is shown. Here a new message is created and a destination address from the address book is used. If the message is delivered—no error is received—then the address is assumed to be valid. Though this is not always the case, statistically, a lack of a returned error message indicates safe delivery of an email message. Alternatively. when a message indicative of mail delivery failure is received, the message is parsed and the destination address within the address book is flagged as suspect. Once flagged, that address is no longer permitted by the email program.
[0037] The flagged address is maintained within the address book but is considered expired. When another email address exists for the destination individual, that email address becomes the email address of that destination individual. For example, Slugger's home email account address becomes the current email address for all electronic messages to John Smith at Company. Because the address book maintains information relating to expired addresses, attempting to direct a message to an expired address results in a notification to the user that the address is considered expired and that a newer address is known. The user is provided with an option of replacing the entered destination address with the newer address. Alternatively, the newer address is substituted for the expired address transparent to the user.
[0038] Similarly, as shown in FIG. 4, when a user selects a reply feature the reply address is verified to determine that it has not expired. If it has expired, a notification is provided to the user that the address is considered expired and that a newer address is known. The user is provided with an option of replacing the entered destination address with the newer address. Alternatively, the newer address is substituted for the expired address transparent to the user. As such, a user is prevented from accidentally using an old expired email address.
[0039] When a newer email address is not known to the system, the user is still notified that the email address is considered expired. Thus, the user can avoid sending messages that merely result in errors and can wait to locate a current email address for the destination prior to sending out the email message.
[0040] Referring to FIG. 5, another feature of the invention is shown. Here, the email application locates the message that resulted in an error and prompts the user to re-send the message with a known current email address. Alternatively, when a current email address is unknown, the email application stores data indicative of the failed email message delivery such that when the address book is provided with a current email address for the destination individual, the user is automatically prompted to re-send each failed message to the now current email address. As such, fewer messages are not sent correctly where the sender believes them to be sent when in fact transmission fails.
[0041] Referring to FIG. 6, an email address book entry is shown for Slugger.
[0042] Referring to FIG. 7, the email address book entry of FIG. 6 is shown with the destination address expired.
[0043] Now an option is provided to the user to view messages that failed in transmission due to the incorrect address.
[0044] Referring to FIG. 8, the email address book entry of FIG. 7 is shown wherein an updated current email address is known for the destination.
[0045] In an alternative embodiment, once flagged the email application attempts to address messages to the flagged address over a period of time to verify that the address is indeed expired before the address is considered expired.
[0046] Numerous other embodiments may be envisioned without departing from the spirit or scope of the invention. | A method is proposed for automatically updating and maintaining email contact information for various contacts stored in a contact database within or outside of an email application without requiring an individual to manually verify and update email addresses. The method flags an invalid email address of a destination individual when an error message is received indicative of mail delivery failure. Another available email address of the destination individual is then automatically designated as their primary address. | 7 |
CROSS-REFERENCE TO PRIORITY APPLICATION
This application claims priority pursuant to 35 U.S.C. § 119(e) to U.S. Provisional Application Ser. No. 60/677,402 filed on May 3, 2005 entitled “Modified Asphalt Binder Material Using Crosslinked Crumb Rubber and Methods of Manufacturing the Modified Asphalt Binder”, the entire contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
The present invention is directed, in one aspect, to bituminous asphalt binder materials which are modified by the addition of crumb rubber or ground tire rubber and a cross-linking agent. In a second aspect, the present invention is directed to methods of producing a modified asphalt binder containing crumb rubber or ground tire rubber and a cross-linking agent. The modified asphalt binders of the present invention comprise neat asphalt, crumb rubber, one or more acids and a cross-linking agent. Optionally, the modified asphalt binder may include one or more polymer additives. The crumb rubber may be obtained from recycled truck and/or automobile tires.
The addition of crumb rubber in asphalt binders can improve the consistency and properties of the asphalt binders at high and low temperatures. In particular, the modified asphalt binders of the present invention exhibit improved elastic behavior, resulting in improved performance of roads or other surfaces paved using the modified asphalt binder. Road resistance to permanent deformation, fatigue cracking and thermal cracking is improved by use of the modified asphalt binder. The addition of the cross-linking agent may also improve the stability of the modified asphalt binder for storage.
BACKGROUND
As used herein and in the claims, the phrase “asphalt binder” refers to a bituminous material, sometimes referred to as bitumen, used as a binder in asphalts used to pave roads or other surfaces, or used in construction materials such as roofing materials, coatings, and water sealants. Examples of bitumen that may be used in the compositions and methods of the present invention include natural bitumens, pyrobitumens and artificial bitumens. Bitumens that are particularly preferred are those used for roadways, such as asphalt or maltha. Asphalt paving material is made by mixing the asphalt binder with aggregate.
As used herein and in the claims, the phrase “crumb rubber” refers to rubber particles which have a particle size of less than about 5 mm, and preferably have a particle size of less than about 2 mm. Crumb rubber may be obtained from grinding of used truck tires or automobile tires, or from any other appropriate source of ground rubber.
The use of crumb rubber and polyphosphoric acid in asphalt binders was described previously in publication number WO 04/081098, titled “Bituminous Binder and Method for the Production Thereof.” As described in that published patent application, by combining between 0.5% by weight to 5% by weight polyphosphoric acid, and between 0.5% by weight to 25% by weight crumb rubber (or ground tire rubber) with the bituminous asphalt binder, the properties of the asphalt binder may be advantageously modified without increasing the rotational viscosity such that the mixing process requires high temperature conditions.
Asphalt binders are frequently used in applications where there can be a wide variation in environmental conditions, particularly when used in pavements. Accordingly, the properties of the asphalt binder in high and low temperature conditions is a concern. At low temperatures, some binder materials can become brittle, leading to long transverse fissures due to thermal stress. At higher temperatures, the asphalt binder becomes more fluid (i.e. the viscosity is lower), which can lead to rutting of a pavement due to the passage of vehicles over the surface. Resistance to fatigue and impact, and the adherence of the asphalt binder to aggregate in paving applications, are properties of a particular binder that also must be considered in particular applications.
Some asphalt binders may require a relatively high elastic behavior, for example where the corresponding asphalt paving mixture is used in areas of high traffic rates and high loads. Crumb rubber (or ground tire rubber), used alone or used in combination with polyphosphoric acid, does not sufficiently improve the elastic behavior of the asphalt paving mixture for high traffic and high load uses. When a high elasticity is required, large amounts of crumb rubber must be added to the asphalt binder. This can cause an undesirable increase in rotational viscosity, as well as problems related to storage of the binder material.
Accordingly, among the objects of the present invention is to provide an asphalt binder material with a relatively high elasticity, an acceptable rotational viscosity, and that can be stored for adequate periods of time. Another object of the present invention is to provide methods of making an asphalt binder having these properties.
SUMMARY OF THE INVENTION
In one aspect, the present invention is directed to a modified asphalt binder material comprising asphalt, crumb rubber, one or more acids, a cross-linking agent, and, optionally, one or more polymers. In one embodiment of the invention, neat asphalt is modified by adding 0.5% to 30% by weight of crumb rubber, 0.05% to 5% by weight of one or more acids, and 0.01% to 5% by weight of a cross-linking agent. The modified asphalt binder may also include between 0.5% by weight and 30% by weight of one or more polymer additives. The asphalt binders of the present invention typically have between about 10% to about 90% elastic recovery under a standard elastic recovery test, such as the test protocols set forth in AASHTO T51, ASTM D6084-04, NLT329 or other standard tests.
In another aspect, the present invention is directed to methods of producing a modified asphalt binder material comprising asphalt, crumb rubber, one or more acids, one or more cross-linking agents, and, optionally, one or more polymers.
In yet another aspect, the modified asphalt binders of the present invention may be mixed with water and an emulsifier to form a emulsion. The emulsified asphalt binder may be mixed with an aggregate material, spread to form a layer of the desired thickness, and the emulsion will be broken to form an asphalt pavement. Alternatively, the emulsified asphalt binder may be spread upon a surface, an aggregate material may be spread over the emulsified binder, and the emulsion may be broken.
DESCRIPTION OF PREFERRED EMBODIMENTS
The present invention is directed to modified asphalt binders and methods of making modified asphalt binders. The modified asphalt binders comprise neat asphalt, crumb rubber, one or more acids, and one or more cross-linking agents. Optionally, the compositions may further include one or more polymers. It will be understood that “crumb rubber” as used herein includes crumb rubber, such as ground tire rubber or any other rubber provided in particle form suitable for mixture with an asphalt binder. Typically, a substantial portion of the crumb rubber will have a particle size less than about 5 mm, preferably less than about 2 mm, and more preferably less than 1 mm. The invention is not limited in this regard, and the crumb rubber may have any particle size distribution that results in an asphalt binder with the desired properties.
The modified asphalt binders of the present invention comprise between about 60% by weight to about 98.9% by weight neat asphalt, between about 0.1% by weight to about 30% by weight crumb rubber, between about 0.05% by weight to about 5% by weight of one or more acids, and between about 0.01% by weight to about 5% by weight of a cross-linking agent. Optionally, the modified asphalt binder may further comprise between about 0.5% by weight to about 30% by weight of one or more synthetic polymers.
In one embodiment, the modified asphalt binder is comprised of between about 82% by weight and 99% by weight neat asphalt, between about 0.5% by weight and 10% by weight crumb rubber, between about 0.5% by weight to about 3% by weight of one or more acids, and between about 0.01% by weight and 5% by weight of one or more cross-linking agents.
In another embodiment, the modified asphalt binder is comprised of between about 52% by weight and 98.5% by weight neat asphalt, between about 0.5% by weight and 10% by weight crumb rubber, between about 0.5% by weight to about 3% by weight of one or more acids, between about 0.01% by weight and 5% by weight of one or more cross-linking agents, and between about 0.5% by weight to about 30% by weight of one or more synthetic polymers.
Preferred acids for use in the modified asphalt binder of the present invention include phosphoric acid, polyphosphoric acid (more than 100% expressed as orthophosphoric content)(“PPA”), sulfuric acid at more than 90% wt, boric acid, and carboxylic acids such as, for example, adipic acid, citric acid, oxalic acid, tartaric acid, maleic acid, valeric acid, succinic acid, fumaric acid, glutamic acid, phtalic acid, acetic acid, and combinations of the above acids. The invention is not limited in this regard, and any appropriate acid known to those skilled in the art may be used in the modified asphalt binder.
The acid may be added to the asphalt binder in either a solid form or in a liquid solution. Where a solid form of the acid is used, the acid can be either a pure acid, such as boric acid or polyphosphoric acid, or the acidic component may be combined with an inert component for ease of handling, such as for example a SiO 2 -PPA additive.
Preferred cross-linking agents include sulfur based compounds such as, for example, benzothiazoles, diphenylguanidine, dithiocarbamate, and elementary sulfur and/or a mixtures thereof. The butaphalt crosslinker is also suitable, as are the croslinkers cited in the following United States patents and published applications: U.S. Pat. No. 6,451,886; application Ser. No. 2003144387 and U.S. Pat. No. 5,256,710. The invention is not limited in this regard and any appropriate rubber cross-linking agent known to those skilled in the art may be utilized in the present invention.
In those embodiments of the present invention in which a synthetic polymer is used, preferred synthetic polymers include styrene butadiene, styrene butadiene styrene (“SBS”) three block, ethylene vinyl acetate, ethylene propylene copolymers, polyvinylchorlide (PVC), nylon, polysterene, polybutadiene, acrylate resins, flurorocarbone resins, phenolic resins, alkyd resins, polyesters, polyethylene (linear or crosslinked), epoxy terpolymer, polypropylene (attactic or isotactic), and combinations of the above polymers. The invention is not limited in this regard, and any appropriate synthetic polymer known to those skilled in the art may be used in the modified asphalt binder.
In a second aspect, the present invention is directed to methods of producing the modified asphalt binder. For those embodiments of the present invention which do not include a synthetic polymer additive, the preferred methods for manufacturing the modified asphalt binder comprise the steps of (1) heating the asphalt to a temperature of between about 120° C. and about 200° C., (2) adding a first modifying ingredient, (3) mixing the asphalt and the first modifying ingredient with a high shear mixer, such as, for example, a rotor-stator type mixer (i.e. a SILVERSON type mixer) for a period of between about 5 minutes and about 10 hours, (4) adding a second modifying ingredient to the modified asphalt binder, (5) mixing the second modifying ingredient and the modified asphalt binder in a high shear mixer for a period of between about 5 minutes and about 10 hours, (6) adding a third modifying ingredient to the modified binder material, and (7) agitating the third modifying ingredient and the modified asphalt binder in a low shear mixer (such as, for example, a propeller type mixer driven by a motor at about 250 rpm, similar to an IKA type lab mixer) for a period of between about 5 minutes and about 48 hours.
In these embodiments of the methods of the present invention, the first modifying ingredient may be either crumb rubber or one or more acids. Where the first modifying ingredient is crumb rubber, the second modifying ingredient is the cross-linking agent, and the third modifying ingredient is one or more acids. Alternatively, where the first modifying ingredient is one or more acids, the second modifying ingredient is crumb rubber and the third modifying ingredient is a cross-linking agent. Preferably, crumb rubber is added to the asphalt to achieve a crumb rubber level of between about 0.1% by weight and about 30% by weight in the final modified asphalt material, one or more acids are added to achieve a total acid concentration of between about 0.05% by weight and about 5% by weight in the modified asphalt material, and the cross-linking agent is added to achieve a level of between about 0.01% by weight to about 5% by weight of the cross-linking agent.
In other embodiments of the methods of the present invention, one or more synthetic polymers are added to the modified asphalt composition. In these embodiments of the present invention, the preferred methods of modifying the asphalt binder generally include the steps of (1) heating the asphalt to a temperature of between about 120° C. and about 200° C, (2) adding a first modifying ingredient, (3) mixing the asphalt and the first modifying ingredient with a high shear mixer, such as, for example, a rotor-stator type mixer (i.e. a SILVERSON type mixer) for a period of between about 5 minutes and about 10 hours, (4) adding a second modifying ingredient to the modified asphalt binder, (5) mixing the second modifying ingredient and the modified asphalt binder in a high shear mixer for a period of between about 5 minutes and about 10 hours, (6) adding a third modifying ingredient to the modified binder material, (7) optionally, mixing the third modifying ingredient and the modified asphalt binder for a period of between about 5 minutes and about 10 hours, (8) adding a fourth modifying agent to the modified binder material, and (9) agitating the fourth modifying ingredient and the modified asphalt binder in a low shear mixer (such as, for example, a propeller type mixer driven by a motor at about 250 rpm, similar to an IKA type lab mixer) for a period of between about 5 minutes and about 48 hours.
The modifying ingredients used in these embodiments of the methods are crumb rubber, one or more acids, one or more synthetic polymers, and a cross-linking agent as described above. The crumb rubber, acids and synthetic polymers may be added to the asphalt in any order. The cross-linking agent is added to the asphalt after the crumb rubber has been added, but the cross-linking agent may be added before or after either the acids or the polymers.
In these embodiments of the methods of the present invention, crumb rubber is added to the asphalt to achieve a crumb rubber level of between about 0.1% by weight and about 30% by weight in the final modified asphalt material, one or more acids are added to achieve a total acid concentration of between about 0.05% by weight and about 5% by weight in the modified asphalt material, one or more synthetic polymers are added to achieve a total polymer concentration of between about 0.5% by weight and about 30% by weight, and the cross-linking agent is added to achieve a level of between about 0.01% by weight to about 5% by weight of the cross-linking agent.
It will be understood by those skilled in the art that low shear mixers may be used in place of high shear mixers in the methods described above depending upon the temperatures and the mixing times used, and one skilled in the art can readily determine the appropriate mixing times based upon the temperature and the additive materials used.
The preferred synthetic polymers and the preferred acids used in the methods of the present invention are described above.
Several exemplary embodiments of the methods of the present invention are described below:
Crumb Rubber—Acid—Cross-Linking Agent System
EXAMPLE 1
Neat asphalt is heated to a temperature of between about 120° C. to about 200° C.
Add from between about 0.1% by weight to about 10% by weight of crumb rubber
Mix with high shear mixer for between about 5 minutes to about 10 hours
Add from between about 0.01% by weight to about 5% by weight of a cross-linking agent
Mix with a high shear mixer for between about 5 minutes to about 10 hours
Add from between about 0.5% by weight to about 3% by weight of one or more acids
Agitate the modified asphalt obtained with low shear mixer from 5 minutes to 48 hours
EXAMPLE 2
Neat asphalt is heated to a temperature of between about 120° C. to about 200° C.
Add from between about 0.5% by weight to about 3% by weight of one or more acids
Mix with high shear mixer for between about 5 minutes to about 10 hours
Add from between about 0.1% by weight to about 10% by weight of crumb rubber
Mix with a high shear mixer for between about 5 minutes to about 10 hours
Add from between about 0.01% by weight to about 5% by weight of a cross-linking agent
Agitate the modified asphalt obtained with low shear mixer from 5 minutes to 48 hours
Crumb Rubber—Polymer—Acid—Cross-Linking Agent System
EXAMPLE 3
Neat asphalt is heated to a temperature of between about 120° C. to about 200° C.
Add from between about 0.5% by weight to about 5% by weight of one or more synthetic polymer
Mix with high shear mixer for between about 5 minutes to about 10 hours
Add from between about 0.1% by weight to about 10% by weight of crumb rubber
Mix with a high shear mixer for between about 5 minutes to about 10 hours
Add from between about 0.5% by weight to about 3% by weight of one or more acids
Add from between about 0.01% by weight to about 5% by weight of a cross-linking agent
Agitate the modified asphalt obtained with low shear mixer from 5 minutes to 48 hours
EXAMPLE 4
Neat asphalt is heated to a temperature of between about 120° C. to about 200° C.
Add from between about 0.5% by weight to about 5% by weight of one or more synthetic polymer
Mix with high shear mixer for between about 5 minutes to about 10 hours
Add from between about 0.5% by weight to about 3% by weight of one or more acids
Mix with a high shear mixer for between about 5 minutes to about 10 hours
Add from between about 0.1% by weight to about 10% by weight of crumb rubber
Mix with a high shear mixer for between about 5 minutes to 10 hours
Add from between about 0.01% by weight to about 5% by weight of a cross-linking agent
Agitate the modified asphalt obtained with low shear mixer from 5 minutes to 48 h
EXAMPLE 5
Neat asphalt is heated to a temperature of between about 120° C. to about 200° C.
Add from between about 0.1% by weight to about 10% by weight of crumb rubber
Mix with high shear mixer for between about 5 minutes to about 10 hours
Add from between about 0.5% by weight to about 5% by weight of one or more synthetic polymers
Mix with a high shear mixer for between about 5 minutes to about 10 hours
Add from between about 0.5% by weight to about 3% by weight of one or more acids
Add from between about 0.01% by weight to about 5% by weight of a cross-linking agent
Agitate the modified asphalt obtained with low shear mixer from 5 minutes to 48 hours
EXAMPLE 6
Neat asphalt is heated to a temperature of between about 120° C. to about 200° C.
Add from between about 0.1% by weight to about 10% by weight of crumb rubber
Mix with high shear mixer for between about 5 minutes to about 10 hours
Add from between about 0.5% by weight to about 3% by weight of one or more acids
Mix with a high shear mixer for between about 5 minutes to about 10 hours
Add from between about 0.5% by weight to about 5% by weight of one or more synthetic polymers
Mix with a high shear mixer for between about 5 minutes to about 10 hours
Add from between about 0.01% by weight to about 5% by weight of a cross-linking agent
Agitate the modified asphalt obtained with low shear mixer from 5 minutes to 48 hours
EXAMPLE 7
Neat asphalt is heated to a temperature of between about 120° C. to about 200° C.
Add from between about 0.5% by weight to about 3% by weight of one or more acids
Mix with high shear mixer for between about 5 minutes to about 10 hours
Add from between about 0.5% by weight to about 5% by weight of one or more synthetic polymers
Mix with a high shear mixer for between about 5 minutes to about 10 hours
Add from between about 0.1% by weight to about 10% by weight of crumb rubber
Mix with a high shear mixer for between about 5 minutes to about 10 hours
Add from between about 0.01% by weight to about 5% by weight of a cross-linking agent
Agitate the modified asphalt obtained with low shear mixer from 5 minutes to 48 hours
EXAMPLE 8
Neat asphalt is heated to a temperature of between about 120° C. to about 200° C.
Add from between about 0.5% by weight to about 3% by weight of one or more acids
Mix with high shear mixer for between about 5 minutes to about 10 hours
Add from between about 0.1% by weight to about 10% by weight of crumb rubber
Mix with a high shear mixer for between about 5 minutes to about 10 hours
Add from between about 0.5% by weight to about 5% by weight of one or more synthetic polymers
Mix with a high shear mixer for between about 5 minutes and about 10 hours
Add from between about 0.01% by weight to about 5% by weight of a cross-linking agent
Agitate the modified asphalt obtained with low shear mixer from 5 minutes to 48 hours
Tests were conducted to measure the properties of modified asphalt binders using cross-linking agents according to the present invention. In one set of tests, a modified asphalt binder was prepared using only crumb rubber and PPA, while a second modified asphalt binder was prepared using crumb rubber, 0.1% sulfur as a cross-linking agent, and PPA. In both cases, crumb rubber was first added to the asphalt binder and stirred with a high shear mixer for about two hours. For the first modified binder, PPA was added and mixed using a high shear mixer for about 30 minutes. For the second modified binder, sulfur was added and mixed using a high shear mixer for about 15 minutes, followed by addition of PPA and further mixing with a high shear mixer for about 30 minutes. The measured properties of the resulting modified asphalt binders are summarized below in Table 1.
TABLE 1
% CR
5
5
% PPA
0.5
0.5
Cross-linker
None
0.1% S
Asphalt
PG 64-22
PG 64-22
Temperature
320° C.
160° C.
Visc, cP, 135° C.
890
1020
ER, %, 25° C.
35
45
Top end tru-grade
72
72.9
BBR, Stiffness, MPa
180
205
BBR, m-value
0.323
0.321
A series of tests were conducted in which a modified asphalt binder was produced by addition of SBS, polyphosphoric acid and crumb rubber to an asphalt binder. In one of the modified asphalt binders, a cross-linking agent was added to the asphalt binder following the addition of the crumb rubber. The mixing times using a high shear mixer were as follows (mixing times following the addition of each component was the same regardless of the order of addition): following addition of crumb rubber, about 2 hours; following addition of SBS, about 6 hours; following addition of sulfur, about 30 minutes; following addition of PPA, about 30 minutes. The properties of the modified asphalt binders obtained in the tests are summarized in Table 2.
TABLE 2
Order of addition
CR-Crosslinker-
SBS-PPA-CR
SBS-CR-PPA
SBS-PPA
% CR
5
5
5
% PPA
0.5
0.5
0.5
% SBS
1.0
1.0
1.0
Crosslinker, %
None
None
1% SULFUR
Temperature
160° C.
160° C.
160° C.
Visc, cP, 135° C.
1400
1320
1320
ER, %, 25° C.
50
50
57.5
Top end tru-grade,
74.4
75.6
74.8
° C.
BBR, Stiffness,
143
156
163
MPa
BBR, m-value
0.329
0.326
0.321
As can be seen in the above tables, in each case, the modified asphalt binder containing crumb rubber and a cross-linking agent demonstrated improved elasticity compared to formulations that did not include a cross-linking agent.
The modified asphalt composition may be used in an emulsion type process to apply the asphalt binder material. In one embodiment, the emulsion process comprises the following steps:
1. the modified asphalt composition is prepared as described above; 2. an emulsion of the modified asphalt composition obtained in step 1 is prepared by mixing water, the modified asphalt composition and an emulsifier at ambient temperature; 3. the emulsion obtained in step 2 is spread in order to obtain a uniform layer of the emulsified asphalt binder; and 4. the emulsion is broken.
Prior to breaking the emulsion, an aggregate material may be spread on the emulsified asphalt binder. Alternatively, the process described above may include an additional step in which aggregate is added, with stirring and at ambient temperature, to the emulsion obtained in step 2 of the process to form an asphalt pavement material. The asphalt pavement material is spread to the desired thickness and the emulsion is broken. The emulsifier may be any appropriate emulsifier known to those skilled in the art. Also, the emulsion may be broken using conventional methods for breaking asphalt emulsions.
It will be recognized by those skilled in the art that the compositions or methods described above may be altered in numerous ways without departing from the scope of the present invention. For example, one or more of the mixing steps described above may be omitted, two or more of the modifying ingredients may be added to the asphalt together or at the same time, or additional modifying agents may be added to the composition to further modify the properties of the composition. Accordingly, the preferred embodiments described herein are intended to be illustrative rather than limiting in nature. | Bituminous asphalt binder materials which are modified by the addition of crumb rubber or ground tire rubber and a cross-linking agent are described. In addition, methods are provided for producing a modified asphalt binder containing crumb rubber or ground tire rubber and a cross-linking agent. The modified asphalt binders comprise neat asphalt, crumb rubber, one or more acids and a cross-linking agent. Optionally, the modified asphalt binder may include one or more polymer additives. The crumb rubber may be obtained from recycled truck and/or automobile tires. The addition of crumb rubber in asphalt binders can improve the consistency and properties of the asphalt binders at high and low temperatures. In particular, the modified asphalt binders of the present invention exhibit improved elastic behavior, resulting in improved performance of roads or other surfaces paved using the modified asphalt binder. Road resistance to permanent deformation, fatigue cracking and thermal cracking is improved by use of the modified asphalt binder. | 2 |
This application is a 35 U.S.C. 371 National Stage filing of PCT/EP94/03348 published as WO95/11210 on Apr. 27, 1995.
BACKGROUND OF THE INVENTION
This invention relates to a process fort the production of fatty alcohols based on vegetable fats and oils with an iodine value in the range from 20 to 110, to fatty alcohols based on vegetable fats and oils with an iodine value of 20 to less than 95 and to the use of these products for the production surface-active formulations.
STATEMENT OF RELATED ART
Fatty compounds, particularly unsaturated fatty alcohols, are important intermediates for a large number of products of the chemical industry, for example for the production of surfactants and skin-care products. An overview of these intermediate products is provided, for example, by U. Ploog et al. in Seifen-ole-Fette-Wachse 109, 225 (1983). They are produced from more or less unsaturated fatty acid methyl esters which may be hydrogenated, for example, in the presence of chromium- or zinc-containing mixed catalysts Ullmann's Enzyclopaedie der technischen Chemie, Verlag Chemie, Weinheim, 4th Edition, Vol. 11, pages 436 et seq.!.
The prior art in this field is an industrial process using animal fats and oils which has also been carried out by applicants and in which the unsaturated fatty alcohols accumulating after hydrogenation are distilled at a bottom temperature of, for example, 220° to 250° C. and under a reduced pressure of 1 to 20 mbar, as measured at the head of the column. Since the production of unsaturated fatty alcohols involves high costs, the distillation conditions were designed to minimize the loss of raw materials. In fact, a yield of around 90% of the theoretical (and hence a loss of 10%) was achieved in this way. Unfortunately, the products had a distinct odor. Another disadvantage was that the fatty alcohols of the prior art show unsatisfactory storage and low-temperature behavior.
Unsaturated fatty alcohols with iodine values of 20 to 95 are particularly preferred for applicational reasons because they have a particularly favorable solidification point for use in cosmetic products. Hitherto, unsaturated fatty alcohols with iodine values in the range mentioned have always been based on animal fats. The desired iodine value range is established by blending various products with different iodine value ranges. The iodine value range cannot be established by distillation-based processes because the iodine value or rather the iodine value range of fatty alcohols or fatty acids based on animal fats remains substantially constant during fractionation.
However, animal fats have the disadvantage that they are extremely heterogeneous. For example, animal fats contain nitrogen-containing compounds, such as amides or steroids, such as cholesterol for example, which are directly or indirectly responsible for the unpleasant odor of the products mentioned above. The nitrogen-containing compounds can enter into secondary reactions which adversely affects product stability, particularly oxidation stability, and leads to discolored products.
There is an urgent need in the cosmetic market in particular for purer raw materials of higher quality--a requirement which normally can only be satisfied by increasingly more expensive technical processes and additional purification steps. In the case of unsaturated fatty alcohols, there is a need above all for products with improved color and odor quality and more favorable low-temperature behavior. Added to this is the fact that, in recent years, consumer behavior has changed to the extent that consumers now attribute considerable importance to purely vegetable products.
Known vegetable fatty alcohols have iodine values below 20 or very high iodine values above 100. Fatty alcohols with iodine values in the applicationally preferred range of 20 to 95 mentioned above are not known. The blending of fatty alcohols with very different iodine values does not lead to satisfactory products.
The problem addressed by the present invention was to provide fatty alcohols based on vegetable fats and oils which would have iodine values in the applicationally preferred range and which, at the same time, would have greater oxidation stability than unsaturated fatty alcohols based on animal fats and equivalent or better low-temperature behavior.
DESCRIPTION OF THE INVENTION
The present invention relates to a process for the production of fatty alcohols based on vegetable fats and oils with an iodine value in the range from 20 to 110 which contain substantially unsaturated fatty alcohols and mixtures of saturated and unsaturated fatty alcohols corresponding to general formula (I):
R.sup.1 OH (I)
where R 1 is a saturated or unsaturated, linear or branched alkyl group containing 8 to 22 carbon atoms, in which the triglycerides present in the vegetable fats and oils as raw materials
a) are hydrolyzed to the fatty acids by pressure hydrolysis and then optionally esterified with methanol or b) are transesterified to the fatty acid methyl esters and c) the fatty acid or the fatty acid methyl ester is hydrogenated to the fatty alcohol, characterized in that the fatty acid, the fatty acid methyl ester and/or the hydrogenation product are fractionated by removing a head fraction in such a quantity that the end product has an iodine value of 20 to 110.
Surprisingly, it has been found that, in contrast to products based on animal fats, it is possible to produce fatty alcohols based on vegetable fats and oils with iodine values in the range mentioned above which contain substantially unsaturated fatty alcohols and mixtures of saturated and unsaturated fatty alcohols corresponding to general formula (I), the iodine value being adjustable to the desired range by simple fractionation in accordance with applicational requirements. The products based on vegetable fats and oils obtained by the process according to the invention show better oxidation stability and less odor than corresponding products based on animal fats.
The present invention also relates to fatty alcohols based on vegetable fats and oils with an iodine value of 20 to less than 95 which contain substantially unsaturated fatty alcohols and mixtures of saturated and unsaturated fatty alcohols corresponding to general formula (I):
R.sup.1 OH (I)
in which R 1 is a saturated or unsaturated, linear or branched alkyl group containing 8 to 22 carbon atoms. The fatty alcohols according to the invention based on vegetable fats and oils have an iodine value of 40 to 85. In addition, compounds corresponding to formula (I), in which R 1 is an alkyl group containing 12 to 20 carbon atoms, are preferred.
The fatty alcohols according to the invention show particularly high stability when only a low percentage of conjugated compounds is present. The fatty alcohols according to the invention based on vegetable fats and oils preferably have a content of conjugated compounds below 6% by weight and, more preferably, below 4.5% by weight.
Unsaturated or partly unsaturated vegetable fats and oils are used as starting materials for the process according to the invention. Palm oil, palm stearin oil, palm kernel olein oil, coconut oil, palm kernel oil, sunflower oil, new rapeseed oil, soybean oil, peanut oil, rapeseed oil, linseed oil and olive oil are particularly preferred. The fats consisting essentially of triglycerides are converted into the fatty acids in known manner by pressure hydrolysis and optionally esterified with methanol or are transesterified with methanol to the fatty acid methyl ester. The fatty acid or the fatty acid methyl ester is then hydrogenated to the corresponding fatty alcohol by known methods. The percentage content of saturated and unsaturated constituents and the chain length distribution are determined by the vegetable oils used. In the above compounds corresponding to formula (I), R 1 is an alkyl radical containing 8 to 22 carbon atoms and preferably 12 to 20 carbon atoms.
Through the use of vegetable fats and oils as starting products, the fatty acids/fatty acid methyl esters used or the hydrogenation product are mixtures of fatty acids, fatty acid methyl esters or fatty alcohols differing in their chain lengths. According to the invention, the iodine value of the fatty alcohols to be produced is adjusted by fractionating the fatty acids obtained by pressure hydrolysis, the fatty acid methyl esters obtained by transesterification of the triglycerides or the hydrogenation product obtained by hydrogenation of the fatty acid or the fatty acid methyl ester. The iodine value of the product to be fractionated is determined before fractionation. Depending on the starting product or its iodine value and the desired iodine value, a certain quantity of head fraction is removed during fractionation. By removing the head fraction, the iodine value of the fatty alcohol is increased. To adjust the iodine value of the product, the iodine value of the product which has not yet distilled over is monitored during fractionation. For example, it is possible by the process according to the invention to obtain from coconut oil/palm kernel oil a fatty acid or fatty acid methyl ester fraction which contains fatty acid or fatty acid methyl ester with chain lengths of 16 to 18 carbon atoms, so-called C 16/18 fatty acid or fatty acid methyl ester, as its principal constituent. The required chain length distribution can also be adjusted by corresponding fractionation of the fatty alcohol.
The fractionation conditions under reduced pressure for the unsaturated fatty alcohols obtained, for example, from the hydrogenation stage have long been known. Fractionation may be carried out in batches or continuously under reduced pressure. Superheated steam, for example, may be used for heating, the bottom temperature being in the range from 220° to 250° C. for example.
The actual fractionation process takes place in a packed column with fittings characterized by a low pressure loss. Suitable fittings are, for example, ordered metal packs. Further examples can be found in ROMPP Chemie Lexikon, Thieme Verlag, Stuttgart, 9th Edition, Vol. 3, page 2305 (1990) under the keyword "column fittings" and in the literature cited therein.
The necessary fine vacuum of 1 to 20 mbar at the head of the column can be obtained, for example, with water ring pumps and preceding steam jet pumps. The pressure drop throughout the distillation plant should preferably be no more than 20 mbar.
An improvement in the end product can be obtained by distilling the unsaturated fatty alcohols in such a way that a residue of up to 10% by weight and preferably from 2 to 7% by weight is obtained. The color value and odor of the end products are distinctly further improved by this measure.
Industrial Applications
The unsaturated fatty alcohols based on vegetable fats and oils obtainable by the process according to the invention are substantially colorless and odorless and show particularly favorable low-temperature behavior. Accordingly, they are suitable as raw materials for the production of laundry detergents, dishwashing detergents and cleaning products and also hair-care and body-care products, in which they may be present in quantities of 1 to 50% by weight and preferably 5 to 30% by weight, based on the particular product.
The invention is illustrated by the following Examples:
EXAMPLES
Fatty acid methyl esters were hydrogenated in a typical hydrogenation reactor under a pressure of around 225 bar and at a temperature of 275° to 330° C. in the presence of a CuCrO 4 catalyst. The hydrogenation product is distilled, a corresponding head fraction being removed.
Example 1
A C 12/18 palm kernel oil methyl ester obtained from the transesterification of palm kernel oil and subsequent fractionation was fractionated to a C 12/14 and C 16/18 methyl ester. The C 16/18 methyl ester was hydrogenated to the fatty alcohol as described above. The crude product was distilled in a two-stage vacuum fractionating unit, a head fraction of 3% by weight being removed and a residue of 3% by weight remaining.
A fatty alcohol (FA) with the following chain distribution and the following characteristic data was obtained:
______________________________________FA C 12 0.2% by weightFA C 14 4.5% by weightFA C 15 0.3% by weightFA C 16 25.1% by weightFA C 16 ' 0.4% by weightFA C 17 0.3% by weightFA C 18 8.9% by weightFA C 18 ' 52.5% by weightFA C 18 ' ' 2.9% by weightFA C 18 ' ' conj. 3.2% by weightFA C 18 ' ' ' 0.1% by weightFA C 20 0.6% by weightAcid value = 0.02Saponification value = 0.35OH value = 213.5Iodine value = 61.3H.sub.2 O content = 0.02Softening point = 26.6° C.Hydrocarbon content = 0.87% by weightCO value = 360Hazen = <10______________________________________
Example 2
The product obtained from the hydrogenation in Example 1 is distilled in such a way that a head fraction of around 18% by weight is removed, a fatty alcohol with a relatively high iodine value of 75 being obtained.
This fatty alcohol has the following chain distribution and the following characteristic data:
______________________________________FA C 12 0.0% by weightFA C 14 0.1% by weightFA C 15 0.1% by weightFA C 16 12.1% by weightFA C 16 ' 0.2% by weightFA C 17 0.3% by weightFA C 18 11.5% by weightFA C 18 ' 66.5% by weightFA C 18 ' ' 3.7% by weightFA C 18 ' ' conj. 4.3% by weightFA C 18 ' ' ' 0.2% by weightFA C 20 0.4% by weightAcid value = 0.02Saponification value = 0.40OH value = 210.5Iodine value = 75H.sub.2 O content = 0.02Softening point = 23.2° C.Hydrocarbon content = 0.13% by weightCO value = 306Hazen = 5______________________________________
Example 3
Starting out from a mixture of a C 16/18 palm kernel oil methyl ester (70% by weight) and rapeseed oil methyl ester (30% by weight) prepared from new rapeseed oil, a fatty alcohol with the following chain distribution and the following characteristic data was prepared as described in Example 1:
______________________________________FA C 12 0.0% by weightFA C 14 0.0% by weightFA C 15 0.2% by weightFA C 16 23.1% by weightFA C 16 ' 0.8% by weightFA C 17 0.4% by weightFA C 18 6.4% by weightFA C 18 ' 60.3% by weightFA C 18 ' ' 4.6% by weightFA C 18 ' ' conj. 3.2% by weightFA C 18 ' ' ' 0.1% by weightFA C 20 0.6% by weightAcid value = 0.02Saponification value = 0.35OH value = 213Iodine value = 73.9H.sub.2 O content = 0.03Softening point = 22.9° C.Hydrocarbon content = 0.2% by weightCO value = 279Hazen = <10______________________________________ | Fatty alcohols of the formula I
R.sup.1 OH (I)
wherein R 1 is a saturated or unsaturated, linear or branched aliphatic radical having from about 8 to about 22 carbon atoms are made by an improvement in the process which comprises hydrogenating a fatty acid, a fatty acid methyl ester or a combination thereof to form a fatty alcohol. The improvement comprises removing a head fraction from the fatty acid, the fatty acid methyl ester or the fatty alcohol in such a quantity that the fatty alcohol has an iodine value of from about 20 to about 110 and less than about 4.5% by weight of conjugated compounds. | 2 |
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