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FIELD OF THE INVENTION
The present invention relates generally to in vivo filters that filter debris from a fluid stream in which the filter is disposed.
BACKGROUND OF THE INVENTION
In 1977 Andreas Gruntzig performed the first successful balloon angioplasty on an obstructed human artery, thereby opening the vessel and allowing improved flow of blood.
Balloon angioplasty is a catheter-based procedure in which a long, thin tube with a deflated balloon at the tip is inserted into an artery. The balloon is guided to a stenotic lesion using X-ray fluoroscopy, rapidly inflated to a pressure of several atmospheres and deflated. Several rounds of inflation and deflation cause the stenotic lesion to crack and squash radially outward, thereby opening the obstructed lumen.
Balloon Angioplasty may be indicated for improving circulation to virtually any stenosed organ vasculature or peripheral vasculature, including opening occluded vessels during an acute heart attack; and in place of surgical endarterectomy, treatment of carotid artery stenosis, in high-risk surgical patients.
A problem associated with balloon angioplasty is that the stenotic lesion may release debris that travels to vital organs, for example the brain and/or lungs, causing vascular blockage, tissue necrosis and/or patient death.
To prevent such draconian sequela, a number of in vivo debris filter devices have been developed that are designed to capture debris released from stenotic lesions during an angioplasty procedure.
Using a guide passage, such a debris filter is positioned downstream of the intended angioplasty site and expanded to press against the tissue surrounding the lumen, thereby effectively filtering all blood passing through the lumen. A balloon angioplasty catheter is then introduced into the artery and the balloon is positioned adjacent the stenotic lesion. The balloon is inflated, the lesion releases debris and the filter captures the debris. After deflation and removal of the balloon, the filter is contracted and removed with the captured debris.
The use of in vivo debris filters during balloon angioplasty, however, may fail to prevent vascular blockage, tissue necrosis and/or patient death. To be effective, in vivo debris filters are positioned quite a distance downstream from the lesion undergoing angioplasty; considerably raising the chances that a vessel branching off the treated vessel will be located between the angioplasty balloon and the filter. Debris generated by the angioplasty will likely find its way into the branch vessel and travel to the lungs or brain, causing the above-noted sequela.
Additionally the filter itself may pose a health hazard to the patient. The deployment zone for the filter often comprises healthy vascular tissue. Positional adjustments and expansion of the filter against the healthy vascular tissue can cause tissue scars and plaques that, of themselves, provide a breeding ground for additional, full-blown, stenotic lesions.
In spite of the above-noted risk and health hazard, use of a debris filter is indicated for patients having “rupture-prone” lesions; stenotic lesions characterized by thin fibrous caps and large lipid cores. Even though it is impossible to introduce a filter once the balloon angioplasty has begun, in theory, pre-operative identification of a rupture-prone stenotic lesion would allow the patient and surgeon to weigh the risks and benefits of using an in vivo debris filter in addition to the angioplasty balloon catheter.
Unfortunately, the above theoretical solution is almost totally unworkable in practice because the very lesions that are rupture-prone are often not visible by x-ray angiography.
(Z. A. Fayad et al: “Clinical Imaging of the High-Risk or Vulnerable Atherosclerotic Plaque”; Circulation Research. 2001; 89: 305.)
The surgeon and patient, therefore, are left to grope in the dark for answers as to whether to risk patient health and deploy a debris filter.
In general, existing devices and technology present a number of additional disadvantages associated with the stand-alone in vivo debris filter, including:
1) the additional thousands of dollars to pay for each disposable filter for each surgery; 2) the difficulty in surgically deploying the filter in addition to a balloon angioplasty; and 3) the additional surgical fee charged by the surgeon for performing a second surgical procedure associated with the filter.
SUMMARY OF THE INVENTION
Some embodiments of the present invention successfully address at least some of the shortcomings of the prior art by providing an assembly for filtering debris flowing in an in vivo fluid stream, the assembly comprises a balloon configured to volumetrically expand and, during at least a portion of the expansion, operatively connect with a filter, thereby expanding the filter.
There is thus provided an assembly for filtering debris flowing in an in vivo fluid stream, the assembly comprising at least one balloon configured to volumetrically expand and, during at least a portion of the expansion, operatively connect with a filter, and to contract following the expansion. The assembly further comprising a filter configured to operatively connect with the at least one balloon during at least a portion of the volumetric expansion of the at least one balloon, such that the filter expands during the operative connection in order to filter debris from a fluid flowing in a fluid stream within which the expanded filter is disposed.
In embodiments, the at least one balloon comprises at least one proximal portion and at least one distal portion. In embodiments, and the operative connection between the at least one balloon and the filter occurs in the at least one proximal portion. In embodiments, the operative connection between the at least one balloon and the filter occurs in the at least one distal portion.
In embodiments, a maximal expansion diameter of the at least one distal portion is greater than a maximal expansion diameter of the at least one proximal portion. In embodiments, a maximal expansion diameter of the at least one proximal portion is greater than a maximal expansion diameter of the at least one distal portion.
In embodiments, the at least one balloon comprises at least one angioplasty balloon. In embodiments, the at least one balloon comprises at least two balloons, at least one first balloon and at least one second balloon.
In embodiments, the at least one first balloon is positioned proximally to the at least one second balloon. In embodiments, the at least one first balloon has a first maximal inflation diameter and the at least one second balloon has a second maximal inflation diameter.
In embodiments, at least a portion of the filter is configured to removably connect to a luminal aspect associated with the fluid stream, in response to pressure by the at least one balloon of between at least about one atmosphere and no more than about 20 atmospheres.
In embodiments, at least a portion of the filter is configured to remain removably connected to the luminal aspect during the contraction of the at least one balloon. In embodiments, the at least one balloon is configured to sequentially pass through at least two sequences of the expansion and contraction of the at least one balloon.
In embodiments, at least a portion of the filter is configured to remain removably connected to a luminal aspect associated with the fluid stream during at least a portion of the at least two sequences.
In embodiments, the assembly includes at least one cord operatively associated with the filter and configured to disconnect at least a portion of the filter from the luminal aspect when tension is applied to the at least one cord.
In embodiments, at least a portion of the filter is configured to disconnect from the luminal aspect in response to tension applied to the at least one cord of at least about one Newton.
In embodiments, at least a portion of the filter is configured to disconnect from the luminal aspect in response to tension applied to the at least one cord of no more than about 20 Newtons.
In embodiments, at least a portion of the filter includes a pressure-sensitive adhesive having an affinity for a tissue associated with an in vivo luminal aspect.
In embodiments, the adhesive is an adhesive from the group of adhesives comprising fibrin, biological glue, collagen, hydrogel, hydrocolloid, collagen alginate, and methylcellulose.
In embodiments, at least a portion of the filter is configured to removably connect to a luminal aspect associated with the fluid stream, in response to pressure by the at least one balloon of between at least about one atmosphere and no more than about 20 atmospheres.
In embodiments, at least a portion of the filter is configured to remain removably connected to the luminal aspect during the contraction of the at least one balloon.
In embodiments, the at least one balloon is configured to sequentially pass through at least two sequences of the expansion and contraction of the at least one balloon.
In embodiments, at least a portion of the filter is configured to remain removably connected to the luminal aspect during at least a portion the at least two sequences.
In embodiments, the assembly includes at least one cord operatively associated with the filter and configured to disconnect at least a portion of the filter from the luminal aspect when tension is applied to the at least one cord.
In embodiments, at least a portion of the filter is configured to disconnect from the luminal aspect in response to tension applied to the at least one cord of at least about one Newton.
In embodiments, at least a portion of the filter is configured to disconnect from the luminal aspect in response to tension applied to the at least one cord of no more than about 20 Newtons.
In embodiments, the assembly includes a compression sleeve comprising a substantially curved wall having a proximal end, a distal end and a lumen extending from the proximal end to the distal end, the lumen having a cross sectional diameter that is substantially smaller than the maximal cross sectional diameter of the luminal aspect and at least one cord operatively associated with the filter, at least a portion of the at least one cord slidingly juxtaposed within the compression sleeve lumen, such that in response to at least one first distal sliding of the sleeve while the at least one cord is held stationary, the filter is caused to disconnect from the luminal aspect.
In embodiments, in response to at least one second distal sliding of the sleeve while the at least one cord is held stationary, the filter is caused to radially contract such that a maximal cross sectional diameter of the filter is smaller that a cross sectional diameter of the sleeve lumen.
In embodiments, in response to at least one third distal sliding of the sleeve while the at least one cord is held stationary; at least a portion of the filter is caused to enter the sleeve lumen.
In embodiments, the at least one balloon comprises an outer wall having a distal end and a proximal end and an inner wall defining a lumen, the lumen extending from the distal end to the proximal end, and
In embodiments, at least a portion of the at least one cord is configured to slidingly pass through the lumen.
In embodiments, the at least one cord is configured to pull at least a portion of the filter into contact with the distal end of the at least one balloon.
In embodiments, the assembly includes a catheter having a distal end and a proximal end and a lumen extending from the distal end to the proximal end, wherein the at least one balloon proximal end is operatively associated with the distal end of the catheter.
In embodiments, the at least one balloon lumen is substantially continuous with the catheter lumen.
In embodiments, at least a portion of the at least one cord additionally extends through the catheter lumen.
In embodiments, the filter includes a distal portion, a proximal portion, an opening to the filter associated with the proximal portion and at least one strut operatively associated with the proximal portion.
In embodiments, the assembly includes at least one cord operatively associated with the at least one strut, such that at least a portion of the opening is configured to contract radially inwardly in response to tension applied to the at least one cord.
In embodiments, the at least one strut comprises at least two struts operatively associated with the at least one cord.
In embodiments, each of the at least two struts is configured to resiliently flex outward to form at least one expanded cross sectional diameter.
In embodiments, the at least one expanded cross sectional diameter defines at least two sections, a first section having a first radius and a second section having a second radius.
In embodiments, the at least one strut comprises at least six struts operatively associated with the at least one cord.
In embodiments, the at least one cord comprises at least two cords and the at least one strut comprises at least two struts.
In embodiments, the at least one cord comprises at least six cords and the at least one strut comprises at least six struts.
In embodiments, the at least one balloon includes an inflation channel in fluid communication with an interior portion of the at least one balloon, wherein the channel is configured to inflate the at least a portion of the at least one balloon by introduction of a fluid through the inflation channel.
In embodiments, the assembly includes a catheter comprising a curved wall extending proximally from the at least one balloon and the inflation channel comprises a curved wall surrounding at least a portion of the catheter.
In embodiments, the at least one balloon comprises a material from the group consisting of: rubber, silicon rubber, latex rubber, polyethylene, polyethylene terephthalate, and polyvinyl chloride.
In embodiments, the filter includes a distal portion, a proximal portion, an opening to the filter associated with the proximal portion, and at least one cord guide channel circumferentially encircling at least a portion the proximal portion.
In embodiments, the assembly includes at least one cord, at least a portion of the at least one cord passes through the guide channel, such that at least a portion of the opening is configured to contract radially inwardly in response to tension applied to the at least one cord.
In embodiments, the filter comprises a flexible sheet material and the guide channel is formed from at least one of a bending of a portion of the sheet material, and a shaped component attached to the sheet material.
In embodiments, the at least one cord channel comprises at least two cord channels located substantially on the same cross sectional plane of the filter and the at least one cord comprises at least two cords.
An assembly for filtering debris flowing in an in vivo fluid stream, the assembly comprising at least one balloon configured to volumetrically expand and, during at least a portion of the expansion, operatively connect with a filter, and to contract following the expansion, and a filter comprising a material having tissue connective properties for a tissue associated with an in vivo fluid stream, the filter positioned to operatively connect with the at least one balloon and removably connect to least a portion of the tissue and remain so connected during the contractions of the at least one balloon.
In embodiments, the at least one balloon comprises at least one proximal portion and at least one distal portion. In embodiments, and the operative connection between the at least one balloon and the filter occurs in the at least one proximal portion.
In embodiments, the operative connection between the at least one balloon and the filter occurs in the distal portion.
In embodiments, a maximal expansion diameter of the at least one distal portion is greater than a maximal expansion diameter of the at least one proximal portion.
In embodiments, a maximal expansion diameter of the at least one proximal portion is greater than a maximal expansion diameter of the at least one distal portion.
In embodiments, the at least one balloon comprises at least one angioplasty balloon. In embodiments, the at least one balloon comprises at least two balloons, at least one first balloon and at least one second balloon.
In embodiments, the at least one first balloon is positioned distally to the at least one second balloon. In embodiments, the at least one first balloon has a first maximal inflation diameter that a maximal inflation diameter of the second balloon.
In embodiments, at least a portion of the filter is configured to removably connect to a luminal aspect associated with the fluid stream, in response to pressure by the at least one balloon of between at least about one atmosphere and no more than about 20 atmospheres.
In embodiments, the at least one balloon is configured to sequentially pass through at least two sequences of the expansion and contraction of the at least one balloon. In embodiments, at least a portion of the filter is configured to remain removably connected to a luminal aspect associated with the fluid stream during at least a portion of the at least two sequences.
In embodiments, the assembly includes at least one cord operatively associated with the filter and configured to disconnect at least a portion of the filter from a luminal aspect associated with the fluid stream when tension is applied to the at least one cord.
In embodiments, at least a portion of the filter is configured to disconnect from a luminal aspect associated with the fluid stream when the applied tension to the at least one cord is between at least about one Newton and no more than about 20 Newtons.
In embodiments, at least a portion of the filter includes a pressure-sensitive adhesive having an affinity for a tissue associated with an in vivo luminal aspect. In embodiments, the adhesive is an adhesive from the group of adhesives comprising fibrin, biological glue, collagen, hydrogel, hydrocolloid, collagen alginate, and methylcellulose.
In embodiments, at least a portion of the filter is configured to removably connect to a luminal aspect associated with the fluid stream, in response to pressure by the at least one balloon of between at least about one atmosphere and no more than about 20 atmospheres.
In embodiments, the at least one balloon is configured to contract following the expansion and at least a portion of the filter is configured to remain removably connected to the luminal aspect during the at least one balloon contraction.
In embodiments, the at least one balloon is configured to sequentially pass through at least two sequences of the expansion and contraction of the at least one balloon.
In embodiments, at least a portion of the filter is configured to remain removably connected to the luminal aspect during at least a portion the at least two sequences.
In embodiments, the assembly includes at least one cord operatively associated with the filter and configured to disconnect at least a portion of the filter from the luminal aspect when tension is applied to the at least one cord. In embodiments, at least a portion of the filter is configured to disconnect from the luminal aspect in response to tension applied to the at least one cord of between at least about one Newton and no more than about 20 Newtons.
There is thus provided a method for collecting debris from a stenotic lesion associated with a primary stenotic vessel while preventing passage of the debris into a branch vessel branching from the primary vessel, the method comprising detecting the stenotic lesion in the primary stenotic vessel, locating a filter in the primary stenotic vessel such that an opening of the filter is distal to a center of the stenotic lesion, locating at least a proximal portion an angioplasty balloon proximal to the opening in the filter, expanding the angioplasty balloon, contacting the opening of the filter with at least a distal portion of the angioplasty balloon during the expanding, causing the filter to open during the contacting, generating debris from the stenotic lesion by the expanding of the angioplasty balloon, capturing the debris in the filter, preventing passage of the debris into the branch vessel by the contacting of the opening of the filter with the at least a distal portion of the angioplasty balloon, contracting disengaging the angioplasty balloon, and removing the angioplasty balloon from the primary stenotic vessel.
In embodiments, the method further comprises contracting the filter. In embodiments, the method further comprises removing the filter from the primary stenotic vessel.
There is thus provided a method for collecting debris within a blood vessel, the method comprising juxtaposing an opening of an in vivo debris filter with at least one balloon, expanding the at least one balloon in a blood vessel, opening the filter during the expansion of the at least one balloon, collecting debris within the filter, disengaging the at least one balloon from the filter, and removing the at least one balloon from the vessel.
In embodiments, the method further comprises contracting the filter, and removing the filter from the blood vessel. In embodiments, the method further comprises contacting a stenotic vascular lesion during the expanding.
In embodiments, the method further comprises compressing the lesion during the expanding. In embodiments the method further comprises releasing debris from the lesion during the compressing.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention for safely collecting debris using a debris filter positioned in assembly with an angioplasty balloon is described by way of example with reference to the accompanying drawings. With specific reference now to the drawings in detail, it is stressed that the particulars shown are by way of example and for purposes of illustrative discussion of the preferred method of the present invention only, and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the invention. In this regard, no attempt is made to show structural details of the invention in more detail than is necessary for a fundamental understanding of the invention, the description taken with the drawings making apparent to those skilled in the art how the methods of the invention may be embodied in practice.
FIG. 1 a - 1 d show deployment of an in vivo filter and balloon assembly in a vessel shown in cross section, according to an embodiment of the invention; and
FIGS. 2 a - 2 d , 3 a - 3 c , 4 , and 5 a - 5 e show alternative embodiments of the filter and balloon assembly shown in FIGS. 1 a - 1 d , according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention relates to an in vivo filter that is biased to an open position in conjunction with inflation of an angioplasty balloon. In an exemplary embodiment, during balloon inflation against a stenotic lesion, the balloon presses the outer surface of the filter into a luminal aspect directly upstream from the lesion to capture stenotic debris. The filter maintains thus positioned throughout multiple angioplasty inflations and deflations, following which cords are used to remove the filter from the lumen.
The principles and uses of the teachings of the present invention may be better understood with reference to the accompanying description, Figures and examples. In the Figures, like reference numerals refer to like parts throughout.
Before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details set forth herein. The invention can be implemented with other embodiments, and can be practiced or carried out in various ways.
It is also understood that the phraseology and terminology employed herein is for descriptive purpose and should not be regarded as limiting.
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 the invention belongs. In addition, the descriptions, materials, methods, and examples are illustrative only and not intended to be limiting. Methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention.
As used herein, the terms “comprising” and “including” or grammatical variants thereof are to be taken as specifying the stated features, integers, steps or components but do not preclude the addition of one or more additional features, integers, steps, components or groups thereof. This term encompasses the terms “consisting of” and “consisting essentially of”.
As used herein, “a” or “an” mean “at least one” or “one or more”. The use of the phrase “one or more” herein does not alter this intended meaning of “a” or “an”.
Filter Assembly 100
FIG. 1 a shows an exemplary representation of an in vivo debris filter assembly 100 of the present invention, in a cross section of a blood vessel 141 . A filter 122 is shown in a contracted, pre-dilated, position with loose cords 110 attached to two struts 128 that are connected to filter 122 . Cords 110 exit filter 122 and pass through a lumen 138 and into and through a catheter 132 . Cords 110 typically exit lumen 138 ex vivo, thereby allowing ex vivo manipulation by an operator.
A balloon 130 projects downstream of catheter 132 and is positioned adjacent a stenotic lesion 144 . Balloon 130 typically comprises a biologically compatible elastomeric material, or semi compliance material, for example: rubber, silicon rubber, latex rubber, polyethylene, polyethylene terephthalate, Mylar, and/or polyvinyl chloride.
In FIG. 1 b , balloon 130 has been inflated by introducing fluid through a fluid channel 148 that is substantially coaxial to catheter 130 . During inflation of balloon 130 , after the diameter of balloon 130 reaches the distance between struts 128 , continued inflation of balloon 130 causes struts 128 to bias radially outwardly, thereby expanding filter 122 .
Once inflated, filter 122 filters debris 160 that is released from stenotic lesion 144 and continues to filter debris 160 even as balloon 130 is deflated, as explained below.
While filter 122 is shown in an expanded position as a generally curved structure, balloon 130 may alternatively have a variety of shapes, including a conus having an apex located downstream of balloon 130 .
Filter 122 typically comprises a mesh sheet material that is configured to filter debris 160 from a lumen 142 . Filter 122 typically includes apertures having diameters of between at least about 20 microns and no more than about 200 microns in diameter.
Additionally, filter 122 and/or struts 128 , are configured to flex outward until such flexion is limited by a luminal aspect 140 , for example a diameter of between 3.0 and 6.0 millimeters, depending on the size of lumen 142 in which filter 122 is deployed.
In further embodiments, portions of filter 122 and/or struts 128 comprise super elastic material, for example nitinol; an elastic material; and/or a plastic material; the many materials and their properties being well-known to those familiar with the art.
Similarly balloon 130 has an inflation diameter of between 3.0 and 6.0 millimeters, depending on the cross sectional diameter of lumen 142 . In larger vessels 141 , balloon 130 and filter 122 optionally are manufactured to have larger maximal diameters. In smaller vessels, for example to cut down on the bulk of deflated balloon 130 and filter 122 , smaller maximal diameters are optionally appropriate.
Filter 122 comprises materials and/or apertures that aid in removably connecting filter 122 to an in vivo luminal aspect 140 . In this manner, filter 122 remains connected to luminal aspect 140 for a period of time after balloon 130 has deflated, herein contracted, by egress of fluid through channel 148 . By remaining in contact with luminal aspect 140 , filter 122 continues to filter debris 160 that may be released into lumen 142 from lesion 144 while balloon 130 is in a contracted state.
In some embodiments, the material and configuration of filter 122 ensures that filter 122 remains removably connected to luminal aspect 140 following deflation of balloon 130 . In other embodiments, filter 122 includes a pressure sensitive adhesive having an affinity for luminal aspect 140 so that the adhesive, optionally in conjunction with the material of filter 130 , remain removably connect to vessel luminal aspect 140 following deflation of balloon 130 .
There are many adhesives that may be contemplated for use in providing a removable connection of filter 122 to luminal aspect 140 including, inter alia: fibrin, biological glue, collagen, hydrogel, hydrocolloid, collagen alginate, and methylcellulose, to name a few.
Whether filter 122 comprises a mesh material alone or in combination with an adhesive, filter 122 is optionally configured to removably connect to luminal aspect 140 from a pressure exerted by balloon 130 of, for example, between one and twenty atmospheres.
In further exemplary embodiments, for example when there is continued danger of debris 160 being generated after lesion 144 has been compressed, balloon 130 is optionally deflated and removed from lumen 142 while filter 122 is left in place. Filter 122 optionally is left connected to luminal aspect 140 by the configuration of filter 122 and/or biological glues noted above until the danger of generation of debris 160 has passed.
As noted above, during a typical balloon angioplasty, balloon 130 is sequentially inflated to a pressure of several atmospheres and deflated. In exemplary embodiments, filter 122 remains removably connected to luminal aspect 140 following the first inflation of balloon 130 and throughout several sequences of inflation and deflation.
As filter 122 is deployed relatively proximate to lesion 144 where luminal aspect 140 generally comprises unhealthy tissue, the chance that filter 122 will cause damage to healthy tissue of luminal aspect 140 is very low.
Additionally, the proximity of filter 122 to balloon 130 substantially lowers the odds that a branch artery will be located between filter 122 and balloon 130 , to act as a conduit for debris 160 . Further, as balloon 130 and filter 122 are deployed on single catheter 132 , the cost for each assembly 100 should be lower than existing technology employing a separate filter. Moreover, as assembly 100 includes balloon 130 and filter 122 mounted on a single catheter, the complexity of manufacture, deployment and the surgical fees to the surgeon should be reduced over existing technology.
As seen in FIG. 1 c , after stenotic lesion 144 has been cracked and squashed radially outwards, balloon 130 is deflated and filter 122 remains in an expanded state and continues to capture debris 160 . As the fluid contained in lumen 142 is moving in a direction 162 , in a distal or downstream direction with respect to filter 122 , debris 160 remains in place, captured within filter 122 .
As used herein, the terms distal and distally refer to a position and a movement, respectively, in downstream direction 162 .
To disconnect filter 122 from luminal aspect 140 , cords 110 are pulled proximally, upstream, in a direction 164 . As used herein, the terms proximal and proximally refer to a position and a movement, respectively, in upstream direction 164 .
While cords 110 , as shown, pass through catheter lumen 138 , in alternative embodiments, cords 110 pass to the side of balloon 130 without passing through a lumen 138 . Further, while balloon 130 is shown attached to catheter, 132 , there are many alternative options for delivering balloon 130 and filter 122 , for example using a guide wire. Those familiar with the art will readily recognize the many alternative modes and configurations available for delivery and operation of balloon 130 and filter 122 .
In an exemplary embodiment, filter 122 is configured to disconnect from luminal aspect 140 in response to tension applied to cords 110 of at least about one Newton and no more than about 20 Newtons.
As the diameter of lumen 142 is larger than the diameter of catheter lumen 138 , continued upstream pull in direction 164 on cords 110 , biases the proximal portions of struts 128 radially inward, causing the proximal edges of filter 122 to move radially inward so that filter 122 disconnects from luminal aspect 140 . Following disconnection of filter 122 from luminal aspect 140 , continued pulling of cords 110 in direction 164 causes struts 128 to inwardly bias, thereby reducing the upstream cross sectional diameter of filter 122 .
As the fluid in lumen 142 travels distally in direction 162 , pulling catheter 132 and filter 122 in proximal direction 164 causes debris 160 to move downstream against filter 122 so that debris 160 remains captured by filter 122 .
Thus, filter 122 maintains captured debris 160 even when there is a distance between struts 128 , as might occur when there is considerable volume of debris 160 , for example in large arteries. Optionally, cords 110 are pulled in direction 164 until a portion of filter 122 contacts balloon 130 and/or enters catheter lumen 138 .
While two struts 128 are shown connected to two cords 110 , the present embodiments, contemplate four or even eight struts 128 , with each strut 128 , or each pair of struts 128 , being attached to individual cords 110 that remove filter 122 from luminal aspect 140 .
Alternatively, assembly 100 contemplates using a single strut 128 with a single cord 110 connected to single strut 128 that encircles filter 122 and slidingly attaches to strut 128 in a lasso configuration. Pulling on single cord 110 causes contraction of struts 128 and of the associated cross-sectional circumference of filter 122 , thereby preventing egress of debris 160 filter 122 . The many options available for configuring cords 110 and struts 128 to effectively close filter 122 are well known to those familiar with the art.
Filter Assembly 200
FIG. 2 a shows an exemplary embodiment of an assembly 200 in which a single cord 112 passes distally in direction 162 through catheter lumen 138 . Cord 112 then curves within filter 122 to pass in a proximal direction 164 into a cord inlet 184 and through a cord channel 120 . Cord channel 120 guides cord 112 circumferentially around filter 122 . After circling filter 122 , cord 112 exits channel 120 through cord outlet 186 and passes distally in direction 162 into filter 122 . Cord 112 then curves within filter 122 to pass in a proximal direction 164 into and through catheter lumen 138 .
In this manner both ends of cord 112 exit catheter lumen 138 and, by pulling both ex vivo ends of cord 112 in direction 164 , filter 122 is contracted along channel 120 , as seen in FIG. 2 d . While a single cord 112 is shown, channel 120 optionally comprises multiple pairs of inlets 184 and outlets 186 , each associated with a separate cord 112 . The many configurations and modifications of channel 120 , inlet 184 , and outlet 186 are well known to those familiar with the art.
FIG. 2 d shows an exemplary embodiment of a tubular compression sleeve 134 that is coaxial with catheter 132 . Sleeve 134 has been slidingly pushed through vessel lumen 142 in direction 162 until sleeve 134 approaches filter 122 .
In an exemplary embodiment, pulling cord 112 and/or catheter 132 in direction 164 while holding sleeve 134 substantially stationary pulls filter 122 into compression sleeve 134 . Alternatively, compression sleeve 134 is advanced in direction 162 while catheter 132 and/or cord 110 are held substantially stationary.
In an exemplary embodiment, compression sleeve 134 serves as a housing for filter 122 to prevent filter 122 from scraping along luminal aspect 140 during removal from lumen 142 . Additionally or alternatively, compression sleeve 134 serves to compress filter 122 into a smaller maximal circumferential diameter so that filter 122 more easily passes through lumen 142 during removal of filter 122 .
Balloon Assembly 300
In embodiments, balloon 130 optionally includes alternative shapes, for example having varied cross sectional diameters. As seen in assembly 300 ( FIG. 3 a ), the diameter associated with a distal portion 133 of deflated balloon 130 is larger than the diameter associated with a proximal portion 139 .
As seen in FIG. 3 b , filter 122 reaches a maximal diameter initially as distal balloon portion 133 inflates. In this manner, filter 122 is fully in position and expanded prior to inflation of proximal balloon portion 139 .
As seen in FIG. 3 c , proximal balloon portion 139 has been fully inflated to compress lesion 144 , thereby releasing debris 160 that is captured by filter 122 . The many options for configuring alternative shapes of balloon 130 are well known to those familiar with the art.
Balloon and Filter Assembly 400
There are additionally many methods of assembling filter 122 and balloon 130 , as seen in assembly 400 ( FIG. 4 ). In a non-limiting embodiment, balloon 130 is seen having an overall length 209 of approximately 38 millimeters and a maximal inflation diameter 211 of approximately 5 millimeters.
Additionally, balloon 130 is shown with a proximal portion 207 having a length 235 of approximately 18 millimeters and a distal portion 208 having a length 233 of approximately 18 millimeters.
In an exemplary embodiment, filter 122 extends to substantially cover distal portion 208 while proximal portion 207 is unprotected by filter 122 .
In alternative configurations of assembly 400 , filter 122 optionally substantially fully covers distal balloon portion 208 and extends over at least a portion of proximal balloon portion 207 ; the many configurations of assembly 400 being well known to those familiar with the art.
Dual Balloon Assembly 500
Assembly 500 ( FIGS. 5 a - 5 e ) demonstrates just one more of the many embodiments of the instant invention that are easily contemplated by those familiar with the art. Assembly 500 comprises a proximal balloon 230 and a distal balloon 101 . As seen in FIG. 5 b , distal balloon 101 is inflated to expand filter 122 and substantially take up the volume within filter 122 . As seen in FIG. 5 c , proximal balloon 230 is inflated separately and pressed against lesion 144 .
After deflation of proximal balloon 230 as seen in FIG. 5 d , distal balloon 101 remains inflated so that debris 160 remains proximal to distal balloon 101 . Upon deflation of distal balloon 101 , debris 160 enters and is captured by filter 122 .
Alternative Environments
While assemblies 100 - 500 have been described with respect to vessel 141 , assemblies 100 - 500 can be easily configured for use in a wide variety of in vivo lumens 142 including inter alia: a lumen of a urethra, a biliary lumen and/or a renal calyx lumen. Additionally or alternatively, filter 122 can be easily modified to capture debris in virtually any in vivo lumen 142 including, inter alia: biliary stones and/or renal stones. The many applications, modifications and configurations of assemblies 100 - 500 for use in virtually any in vivo lumen 142 will be readily apparent to those familiar with the art.
Materials and Design
In embodiments, filter 122 comprises a sheet material configured to extend distally with respect to balloon 130 while filter 122 is expanded. In embodiments, the sheet material of filter 122 is selected from the group consisting of: meshes and nets.
In embodiments, bending of a portion of the sheet material of filter 122 forms filter cord channel 120 . In embodiments, attaching a shaped component to filter 122 forms filter cord channel 120 .
In embodiments, the material of filter 122 has a thickness of at least about 20 microns. In embodiments, the material of filter 122 has a thickness of no more than about 200 microns. In embodiments, the material of filter 122 includes apertures having diameters of at least about 20 microns. In embodiments, the material of filter 122 includes apertures having diameters of no more than about 80 microns in diameter. In embodiments, the material of filter 122 is manufactured using a technique from the group of techniques consisting of: interlacing, knitting, weaving, braiding, knotting, wrapping, and electro spinning.
In embodiments, filter 122 is configured to expand to a cross sectional diameter of at least about 1.0 millimeters. In embodiments, filter 122 is configured to expand to a cross sectional diameter of no more than about 6.0 millimeters. In embodiments, the extent of the expansion of filter 122 is configured to be limited by the walls of luminal aspect 140 in which filter 122 is deployed.
In embodiments, balloon 130 has a maximum inflation diameter of at least about 1.0 millimeter. In embodiments, balloon 130 has a maximum inflation diameter of no more than about 6.0 millimeters.
In embodiments, balloon 130 has a wall thickness of at least about 0.2 millimeters. In embodiments, balloon 130 has a wall thickness of no more than about 0.5 millimeters.
In embodiments, strut 128 has a substantially circular cross section having a diameter of at least about 0.1 millimeters. In embodiments, strut 128 has a substantially circular cross section having a diameter of no more than about 0.6 millimeters.
In embodiments, strut 128 has a cross section having greater and lesser measurements and the greater measurement is at least about 0.1 millimeters. In embodiments, strut 128 has a cross section having greater and lesser measurements and the greater measurement is no more than about 0.6 millimeters. In embodiments, strut 128 has a cross section having greater and lesser measurements and the lesser measurement is at least about 0.1 millimeters. In embodiments, strut 128 has a cross section having greater and lesser measurements and the lesser measurement is no more than about 0.6 millimeters.
In embodiments, filter 122 has an internal and an external aspect and strut 128 is attached to the internal aspect or the external aspect of filter 122 . In embodiments, strut 128 is attached to filter 122 using a process selected from the group consisting of: sewing, adhesion, gluing, suturing, riveting and welding.
In embodiments, cord channel 120 comprises at least two cord channels; and cord 112 comprises at least two cords.
In embodiments, catheter 132 has an outside diameter of at least about 1.0 millimeter. In embodiments, catheter 132 has an outside diameter of no more than about 5.0 millimeters. In embodiments, catheter 132 has a length of at least about 0.8 meter. In embodiments, catheter 132 has a length of no more than about 1.5 meters.
In embodiments, the walls of catheter 132 compression sleeve 134 have a thickness of at least about 2 millimeters. In embodiments, the walls of catheter 132 compression sleeve 134 have a thickness of more than about 5 millimeters.
In embodiments, filter 122 , cord 110 ( FIG. 1 a ) and cord 112 ( FIG. 2 a ), strut 128 , compression sleeve 134 , and catheter 132 , comprise a material from the group consisting of: polyethylene, polyvinyl chloride, polyurethane and nylon.
In embodiments, filter 122 , cord 110 ( FIG. 1 a ) and cord 112 ( FIG. 2 a ), strut 128 , compression sleeve 134 , and catheter 132 , comprise a material selected from the group consisting of: nitinol, stainless steel shape memory materials, metals, synthetic biostable polymer, a natural polymer, and an inorganic material. In embodiments, the biostable polymer comprises a material from the group consisting of: a polyolefin, a polyurethane, a fluorinated polyolefin, a chlorinated polyolefin, a polyamide, an acrylate polymer, an acrylamide polymer, a vinyl polymer, a polyacetal, a polycarbonate, a polyether, an aromatic polyester, a polyether (ether keto), a polysulfone, a silicone rubber, a thermoset, and a polyester (ester imide).
In embodiments the natural polymer comprises a material from the group consisting of: a polyolefin, a polyurethane, a Mylar, a silicone, a polyester and a fluorinated polyolefin.
In embodiments, filter 122 , cord 110 ( FIG. 1 a ) and cord 112 ( FIG. 2 a ), strut 128 , compression sleeve 134 , and catheter 132 , comprise a material having a property selected from the group consisting of: compliant, flexible, plastic, and rigid.
It is appreciated that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention, which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable subcombination.
Although the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art.
Accordingly, the invention is intended to embrace all such alternatives, modifications and variations that fall within the spirit and broad scope of the appended claims. All publications, patents and patent applications mentioned in this specification are herein incorporated in their entirety by reference into the specification, to the same extent as if each individual publication, patent or patent application was specifically and individually indicated to be incorporated herein by reference. In addition, citation or identification of any reference in this application shall not be construed as an admission that such reference is available as prior art to the present invention. | Disclosed is an assembly for filtering debris flowing in an in vivo fluid stream, the assembly comprising at least one balloon configured to volumetrically expand and, during at least a portion of the expansion, operatively connect with a filter, and to contract following the expansion. The assembly further comprising a filter configured to operatively connect with the at least one balloon during at least a portion of the volumetric expansion of the at least one balloon, such that the filter expands during the operative connection in order to filter debris from a fluid flowing in a fluid stream within which the expanded filter is disposed. | 0 |
BACKGROUND OF THE INVENTION
[0001] My invention is of a contact for a dry cell battery that directs electrical current through the battery when a battery is present but redirects the electrical current flow past that battery position when no battery is present.
[0002] This invention has been to solve the problem of a battery powered construction project. This device had desirable performance characteristics when powered by two, three or four AAA type alkaline batteries. It was difficult to find a cost effective switch and since the user would decide in advance which mode he would want today, he could simply add or remove batteries from the battery holder.
[0003] It can be appreciated that battery holders have been in use for years. Typically, battery holders are pre-determined to accommodate a given number of batteries.
[0004] The main problem with conventional battery holders is that the absence of even one battery breaks the serial chain and no voltage at all is available at the battery holder output terminals.
[0005] Another problem with conventional battery holders is that one is committed to the designed voltage of a given battery holder as all positions must be filled and little variation in supplied voltage is possible.
[0006] Another problem with conventional battery holders is that occasionally, an odd voltage may be desired and is extremely difficult to acquire a suitable battery holder.
[0007] While these devices may be suitable for the particular purpose to which they address, they are not as suitable for the provision of a battery holder that provides output voltage as a function of the number of batteries installed and is not committed to the filling of all battery positions.
[0008] In these respects, the BATTERY BYPASSING CONTACT, according to the present invention substantially departs from the conventional concepts and designs of the prior art, and in so doing provides an apparatus primarily developed for the purpose of the provision of a battery holder that provides output voltage as a function of the number of batteries installed. A thorough search of USPTO Classes 429/1, 429/96, 429/97, 429/100 and 439/500 has discovered no prior attempt to provide a bypassing battery contact. Voltage modification in a battery array is attempted in U.S. Pat. No. 5,489,486 but in no instance is a vacant battery position proposed in a serial connection.
BRIEF SUMMARY OF THE INVENTION
[0009] My “BATTERY BYPASSING CONTACT” provides a battery station electrical bypassing path when no battery is present but routes electrical current through the battery when a battery is present. A battery holder of multiple positions can be assembled, using my contacts, and containing a definite number of positions for the installation of batteries of the “AAA”, “AA”, “C” and “D” size, or others.
[0010] Each battery station may or may not contain a battery and thereby an array can provide output voltage as a function of the sum of number of batteries present and the voltage of each.
[0011] In an array of 4 battery positions, by mixing quantity and presence of 1.5-Volt and 1.2-Volt batteries, the array output voltages available are:
[0000]
PRESENCE
OF EACH
BATTERY
TOTAL VOLTS
1.2
1.2
1.5
1.5
1.2
1.5
2.7
1.5
1.5
3
1.2
1.2
1.5
3.9
1.5
1.2
1.5
4.2
1.5
1.5
1.5
4.5
1.2
1.2
1.2
1.2
4.8
1.2
1.2
1.2
1.5
5.1
1.5
1.2
1.2
1.5
5.4
1.5
1.2
1.5
1.5
5.7
1.5
1.5
1.5
1.5
6
[0012] It is also noted that when used to power an Electrostatic Discharge sensitive circuit, ESD, when no battery is present, the circuit is protected by the positive input buss shorted to the negative input buss.
[0013] In view of the foregoing disadvantages inherent in the known types of battery holders now present in the prior art, the present invention provides a new incremental voltage battery holder construction wherein the same can be utilized for the provision of a battery holder which provides output voltage as a function of the number of batteries installed.
[0014] The general purpose of the present invention, which will be described subsequently in greater detail, is to provide a new incremental voltage array when used on a printed wiring board or in battery holder that has many of the advantages of the holders mentioned heretofore and many novel features that result in a new incremental and selectable voltage battery holder which is not anticipated, rendered obvious, suggested, or even implied by any of the prior art, either alone or in any combination thereof.
[0015] To attain this, the present invention generally comprises a Normally Closed shorting battery contact that provides an alternate path for electrical current to pass directly from the negative contact to the positive contact when no battery is present. The installation of a battery physically interferes with the NC contact, causing it to open and thereby allowing electrical current to pass through said battery with the corresponding increase of voltage contributed by that battery.
[0016] There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof may be better understood, and in order that the present contribution to the art may be better appreciated. There are additional features of the invention that will be described hereinafter.
[0017] In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of the description and should not be regarded as limiting.
[0018] A primary object of the present invention is to provide an incremental voltage battery holder that will overcome the shortcomings of the prior art devices.
[0019] Another object is to provide an incremental voltage battery array that allows the use of any quantity of batteries desired in a universal type holder and thereby achieve the desired DC voltage.
[0020] Another object is to provide an incremental voltage battery holder so that in that the absence of one of several required batteries for an application it will still allow an attempt of continued operation of a device, although at reduced voltage.
[0021] Another object of my invention is to provide an incremental voltage battery holder that allows the revision of operating voltage in an existing device by the removal or addition of batteries, thereby modifying performance characteristics.
[0022] Another object is to provide an incremental voltage battery holder that will allow more refined voltage by the quantity of 1.5-volt batteries and 1.2-volt batteries.
[0023] Other objects and advantages of the present invention will become obvious to the reader and it is intended that these objects and advantages are within the scope of the present invention.
[0024] To the accomplishment of the above and related objects, this invention may be embodied in the form illustrated in the accompanying drawings, attention being called to the fact, however, that the drawings are illustrative only, and that changes may be made in the specific construction illustrated.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] Various other objects, features and attendant advantages of the present invention will become fully appreciated as the same becomes better understood when considered in conjunction with the accompanying drawings, in which like reference characters designate the same or similar parts throughout the several views, and wherein:
[0026] FIG. 1 is the schematic of any single battery station when no battery is present showing the current flow path bypassing that station.
[0027] FIG. 2 is the schematic of said battery station when a battery is present, resulting in operation in the conventional mode of passing the current through the battery.
[0028] FIG. 3 is the schematic of a battery holder of 6 stations when only two batteries are present. The output voltage is the sum of the two batteries.
[0029] FIG. 4 is an isometric view of the construction details of my preferred embodiment of a switching battery contact.
[0030] FIG. 5 is the contact of FIG. 4 having been deflected by the installation of a battery and opening the NC contacts.
[0031] FIG. 6 is my contact of FIG. 4 when in contact with an installed battery and is deflected to open the NC contacts.
[0032] FIG. 7 is an alternate embodiment of my invention showing a single clip to be used in an array of batteries on a planar surface.
[0033] FIG. 8 is the use of my alternate embodiment of FIG. 7 in a multiple battery, series connected, array.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0034] Turning now descriptively to the drawings, in which similar reference characters denote similar elements throughout the several views, the attached figures illustrate a battery contact that is basically a normally closed contact switch. If a battery is present, the NC contact is automatically opened by physical interference and current flow is diverted through the battery. If the battery is removed, the contact closes and the current flow bypasses that battery position with no voltage increase.
[0035] It has been noted earlier that the output voltage of a battery array can be modified by the selection of type and quantity of installed batteries.
[0036] FIG. 1 depicts the schematic of each battery station 10 in the absence of an installed battery. Item 20 is a Normally Closed contact switch, which is conductive past the battery station. Note that the output conductors are shorted together.
[0037] FIG. 2 depicts the schematic of each battery station in the presence of an installed battery 30 . Item 20 has been forced open by the presence of the installed battery 30 thereby deleting conductivity across the station. At this time battery voltage appears across the battery station.
[0038] FIG. 3 is a 6-position battery array 40 . A battery is installed in two random positions. Output voltage of the array is the sum of the two batteries due to the N.C. contacts passing current through unused positions.
[0039] FIG. 4 is the preferred embodiment of my invention. Contact 505 is the contact that is destined for being conductive to the negative end of an installed battery. The battery station negative output conductor is electrically attached to 505 . Lanced clip 525 can receive the positive terminal of a prior battery if present. Before battery installation, contact 505 is electrically conductive with positive contact 510 at interface 20 . Contact 510 is electrically conductive with the battery positive contact and also the positive output conductor.
[0040] FIG. 5 is the contact of FIG. 4 but deflected as a cantilever beam in the vicinity of 520 by the presence of a battery. The side portions are not constrained and so rotate with the upper portion of the clip. This rotation lifts the NC contact side portions 20 of 505 from the positive side of the battery station 510 and thereby opens the bypassing path. This places the battery in the path of through electrical current flow.
[0041] FIG. 6 is a battery 30 , in place and having deflected contact 505 away from contact 510 at 20 resulting in a current path thru the battery in a normal mode. When a battery is installed, the length of the battery forces contact 505 to flex resulting in the electrical separation of 505 and 510 at 20 .
A Brief Description of my Alternate Embodiment
[0042] FIG. 7 is an alternate embodiment of my invention specifically intended to accommodate numerous batteries in series on a planar surface. Clip 50 is used between batteries. Construction details are of the two battery holding clips 60 , the shorting bar 20 , which is inserted into hole 90 in the next clip, and the two battery retaining tabs 80 . The battery retaining tabs 80 also serve to assure the NC actuating end of the battery, the positive in this design, is inserted first. This assures contact 20 will “break before make” in order to prevent shorting of the battery during installation.
[0043] FIG. 8 is of three clips of my alternate embodiment 50 A, 50 B and 50 C used in tandem accommodating two batteries. The clip 50 A contains no battery so its shorting bar 20 A is sprung up to short at the hole 90 B in the next position. The next clip 50 B contains a battery, not shown, and the shorting bar 20 B is forced down away from the top edge of hole 90 C and no longer makes contact across that battery location. Electrical current flowing into 50 A passes thru to 50 B. At 50 B the flowing current passes thru the battery and on to 50 C.
[0044] With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.
[0045] Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention. | The inventive device describes an automatically switching battery contact that directs electrical current through a battery when a battery is present but redirects the electrical current flow past that battery position when no battery is present. This allows assembling of an incremental voltage battery holder for the provision of a battery holder that provides output voltage as a function of the number, as well as types of batteries installed. | 7 |
DESCRIPTION
Background of the Invention
It has long been known in the art of sewing machine construction that two different types of work supporting surfaces may be provided, each best suited to accommodate a different form of work piece; that is, a flat bed best accommodating planar work pieces, and a cantilevered bed, variously referred to as a cylinder bed, free arm or tubular bed, more conveniently accommodating cylindrical work pieces. It is known to provide a tubular bed sewing machine with a bed extension adapted to augment the tubular bed work supporting surface when flat work pieces are to be attached and which is detachable from the sewing machine and must be stored separately when tubular articles are to be sewn.
The present invention pertains to a type of bed extension referred to as "convertible bed" in which work supporting elements may be shifted selectively into parallelism with the tubular bed work supporting surface defining flat bed configuration but which need not be detached from the sewing machine when shifted out of such flat bed mode.
In known convertible bed constructions the work supporting elements are shiftably supported directly on portions of the machine frame which are integral with the tubular bed. As a result, high degree of accuracy is required in manufacture of the frame including costly machining steps and the like, which impair the cost effectiveness of such prior convertible bed constructions.
SUMMARY OF THIS INVENTION
A mounting bracket is provided for supporting a cylinder bed extension relatively to a sewing machine frame with provision for universal adjustment of the cylinder bed extension not only to provide for parallelism with the work supporting surface of the tubular bed, but also to provide for uniform close spacing of the extension adjacent to the tubular bed work supporting surface.
DESCRIPTION OF THE DRAWINGS
With the above and additional objects and advantages in view, as will hereinafter appear, this invention will now be described with reference to a preferred embodiment illustrated in the accompanying drawings in which:
FIG. 1 is an exploded perspective view of a sewing machine bed, a mounting bracket for a convertible bed extension, and the extension with portions of the bed and of the bracket broken away to expose fastening and adjusting means therefore in accordance with this invention,
FIG. 2 is an end elevational view of the sewing machine bed bracket, and convertible bed extension of FIG. 1 illustrated in a position in which the extension augments the flat bed mode,
FIG. 3 is a cross-sectional view of the assembled bed, mounting bracket, and bed extension taken substantially along line 3--3 indicated on the bed extension shown in FIG. 1, and
FIG. 4 is a cross-sectional view of the assembled mounting bracket and bed extension taken substantially along line 4--4 indicated on the bed extension shown in FIG. 1.
DESCRIPTION OF THE INVENTION
Referring to the drawing, 11 indicates generally the bed segment of a sewing machine frame which includes a base portion 12 from which a tubular bed portion 13 is cantilevered. As illustrated in FIG. 2, the sewing machine frame may also include a sewing head 14 arranged above the tubular bed and carrying stitch forming instrumentalities such as a presser device 15 and an endwise reciprocating thread carrying needle 16 for cooperation with other stitch forming mechanisms (not shown) in the tubular bed in the formation of stitches.
The tubular bed 13 when not augmented by any lateral extension is ideally suited to accommodate cylindrical work pieces such as sleeves, trouser legs and the like.
FIGS. 1 and 2 also illustrate a convertible bed extension device indicated generally at 21 and including a standard 22 to which a bed extension plate 23 is pivotally secured. Although the construction of the pivotal support for the bed extension plate may be of any known form, a preferred form as illustrated in FIGS. 1 and 2 involves the provision of a "U" shaped wire pintle member 24 secured to the standard 22 as by a clamp member 25 and fastening screw 26, with the extremities of the pintle member each being pivotally embraced between a pillow block 27 formed beneath the bed extension plate 23 and a spring clip 28 secured by a screw 29 beneath the pillow block 27.
The bed extension plate 23 as shown in FIG. 2 may include a leaf spring latch 30 secured beneather the bed extension plate by a screw 31 and engageable in a recess 32 in the tubular bed to retain the free edge of the extension plate in raised position contiguous to the work supporting surface of the tubular bed.
Referring to FIG. 1, the means by which the convertible bed device is supported on the sewing machine bed will now be described. Adjacent to the tubular bed 13 and toward the rear thereof, the base portion 12 of the bed is formed with a projection 41. The projection is formed with substantially vertical front and rear surfaces 42 and 43 and at the juncture of the rear surface 42 with the base portion 12 of the bed a raised rectangular block 44 is provided. In a recess 45 formed beneath the projection 41 two spaced cylindrical bosses 46, 47 depend, each formed with a threaded hole 48 for accommodation of respective fastening screws 49 and 50.
Fitted loosely within the recess 45 is a generally rectangular mounting bracket 51 which extends from the projection 41 substantially parallel to the tubular bed 13.
At one extremity the upper surface of the mounting bracket 51 is formed with spaced limbs 52, 53 having height somewhat less than that of a main body portion 54 located at the opposite extremity. Between limbs 52 and 53, a web 55 is formed in which apertures 56 and 57 are arranged, the apertures being aligned, respectively, with the threaded holes 48. The aperture 56 preferrably accommodates the fastening screw 50 snuggly, while aperture 57 is of considerably larger diameter than that of the fastening screw 49 to provide for a degree of rotational adjustment of the mounting bracket 51 about the axis of the fastening screw 50. This clearance between the aperture 57 and fastening screw 49 provides for a degree of horizontal adjustment of the main body portion 54 of the mounting bracket along the path illustrated by the arrow A in FIG. 1 which serves, as will be apparent from the ensuing description, as a means for adjusting the clearance "a" between the bed extension plate 23 and the tubular bed 13 as illustrated in FIG. 2.
Accommodated between the limbs 52 and 53 of the mounting bracket 51 and above the web 55 thereon is a threaded nut 58 into which a set screw 59 is threaded. The set screw passes through a clearance hole 60 in the web 55 so that it is accessible from beneath. The set screw 59 by being turned to bear more or less against the underside of the recess 45 in the projection 41 regulates the extent to which the web 55 may be drawn toward the boss 46 by the fastening screw 49. Stated otherwise, the set screw 59 influences a vertical adjustment of the free extremity of the mounting bracket 51 about the location of the fastening screw 50 along a path illustrated by the arrow B in FIG. 1. This adjustment serves, as will be apparent from the ensuing description as a means for minimizing any difference "b" in elevation as between the bed extension plate 23 and the tubular bed 13, as shown in FIG. 2.
The convertible bed extension device indicated generally at 21 may be rigidly attached by any conventional means to the mounting bracket 51 as to partake of the positional adjustment thereof. A preferred form of interengagement is illustrated in the drawings which provides for ready removal of the bed extension device so that in its place any one of a variety of ancillary attachments such as work shifting embroidery attachments, buttonhole attachments and the like (not shown) may be inserted.
In accordance with the preferred form of the interengagement between parts, the standard 22 of the convertible bed device is made hollow so as slidably to accommodate both the projection 41 and the mounting bracket 51 within its interior.
Referring to FIGS. 3 and 4, which show the cross-sectional relationship of parts adjacent to the inboard and outboard extremities of the convertible bed device, respectively, the preferred form of interengagement between parts will be described.
As shown in FIG. 3, the interior of the standard 22 of the convertible bed device is formed with a narrow recess 70 into which the rectangular block 44 on the projection 41 is snuggly accommodated. The block 44 is preferably enlarged slightly to provide localized contact between the parts; although the recess 70 might be constricted to provide the same results.
At the lower edges, the walls of the standard 22 are thickened inwardly as at 71 and 72 to provide localized contact with the front and rear surface 42 and 43 of the projection 41. Since the points of localized contact between the standard 22 and the projection 41 are located adjacent to the fastening screw 50 about which all movement of the mounting bracket 51 occurs, a minimum of interference will arise should the position of the mounting bracket have to be adjusted. The three spaced points of localized contact 70, 71 and 72 provide for maximum constraint against tilting of the convertible bed device about an axis parallel to its length.
At the outboard extremity of the convertible bed device, as shown in FIG. 4, the walls of the standard 22 are thickened inwardly as at 75 and 76 to provide localized contact with front and rear sidewalls 77 and 78, respectively, of the main body portion 54 of the mounting bracket. A spring retainer 79 secured as by a screw 80 beneath the standard 22 engages a web 81 formed beneath the main body portion 54 of the mounting bracket to maintain the standard and mounting bracket interengaged as shown in FIGS. 2 and 4, and also to deter accidential disengagement of the convertible bed device from the mounting bracket.
When the bed extension plate 23 is raised and retained by seating of the spring latch 30 in recess 32 to maintain such raised position augmenting the work supporting surfaces of the tubular bed, the spring latch 30 will also further deter removal of the convertible bed device from the mounting bracket.
It is understood that the present disclosure relates to a preferred embodiment of the invention which is for purposes of illustration only, and that various modifications may be made therein without departing from the spirit and scope of the invention as defined in the appended claims. | A bed extension support structure for a sewing machine is disclosed which not only provides for ready removal and replacement of the bed extension but which also permits adjustment of the alignment and registration of the bed extension with respect to the work supporting bed of the sewing machine. | 3 |
CROSS-REFERENCE TO RELATED APPLICATION
This Application claims priority to and is a Continuation-in-Part of U.S. patent application Ser. No. 12/706,864, filed on Feb. 17, 2010 and entitled “Telecom Fraud Using Social Pattern,” the disclosure of which is hereby incorporated by reference in its entirety.
SUMMARY
Embodiments of the invention are defined by the claims below, not this summary. A high-level overview of various aspects of the invention are provided here for that reason, to provide an overview of the disclosure, and to introduce a selection of concepts that are further described below in the detailed-description section. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in isolation to determine the scope of the claimed subject matter.
In one aspect, destinations that are frequently connected to by fraudulent devices are classified as fraudulent destinations. In another aspect, a set of computer-useable instructions provide a method for detecting fraudulent use of mobile devices in a wireless telecommunications environment. Devices that frequently connect to fraudulent destinations are classified as fraudulent devices. In a third aspect, the methods embodied by the previous aspects are incorporated into a system for detecting fraud in a wireless telecommunications device.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
Illustrative embodiments of the present invention are described in detail below with reference to the attached drawing figures, and wherein:
FIG. 1 a depicts an illustrative diagram showing the destination identifiers associated with certain mobile communications devices in accordance with an embodiment of the present invention;
FIG. 1B depicts a series of exemplary records of a communications between a mobile communications device and a destination identifier such as those in FIG. 1A ;
FIG. 2 depicts a flowchart for a method of detecting fraudulent mobile communications devices in accordance with one embodiment of one aspect of the present invention;
FIG. 3 depicts a graph showing the trade-off between a high true positive rate and a low false positive rate when detecting fraud;
FIG. 4 depicts an illustrative diagram showing the source identifiers associated with certain destination identifiers in accordance with a second embodiment of the present invention;
FIG. 5 depicts a flowchart for a method of detecting fraudulent destinations in accordance with one embodiment of another aspect of the present invention; and
FIG. 6 depicts a flowchart for an alternate method of detecting fraudulent destinations in accordance with a second embodiment of this aspect of the present invention.
DETAILED DESCRIPTION
The subject matter of embodiments of the present invention is described with specificity herein to meet statutory requirements. But the description itself is not intended to necessarily limit the scope of claims. Rather, the claimed subject matter might be embodied in other ways to include different steps or combinations of steps similar to the ones described in this document, in conjunction with other present or future technologies. Terms should not be interpreted as implying any particular order among or between various steps herein disclosed unless and except when the order of individual steps is explicitly described.
Throughout this disclosure, several acronyms and shorthand notations are used to aid the understanding of certain concepts pertaining to the associated system and services. These acronyms and shorthand notations are intended to help provide an easy methodology of communicating the ideas expressed herein and are not meant to limit the scope of the present invention. The following is a list of these acronyms:
ESN
Electronic Serial Number
FP
False Positive
IP
Internet Protocol
SMS
Simple Messaging Service
TP
True Positive
Further, various technical terms are used throughout this description. An illustrative resource that fleshes out various aspects of these terms can be found in Newton's Telecom Dictionary by H. Newton, 24th Edition (2008).
Embodiments of the present invention may be embodied as, among other things: a method, system, or set of instructions embodied on one or more nontransitory computer-readable media. Computer-readable media include both volatile and nonvolatile media, removable and nonremovable media, and contemplates media readable by a database, a switch, and various other network devices. By way of example, and not limitation, computer-readable media comprise media implemented in any non-transitory method or technology for storing information. Examples of stored information include computer-useable instructions, data structures, program modules, and other data representations. Media examples include, but are not limited to information-delivery media, RAM, ROM, EEPROM, flash memory or other memory technology, CD-ROM, digital versatile discs (DVD), holographic media or other optical disc storage, magnetic cassettes, magnetic tape, magnetic disk storage, and other magnetic storage devices. These technologies can store data temporarily or permanently.
Turning now to FIG. 1A , an illustrative example showing the destination identifiers associated with certain mobile communications devices in accordance with an embodiment of the present invention is presented. In one embodiment mobile communications devices 102 , 104 , and 106 are cellular telephones. In another embodiment, they are laptops communicating via cellular modems. Other communications devices are possible without departing from the scope of the claims below. Each of mobile communications devices 102 , 104 and 106 communicates with one or more destination identifiers; shown in this example are five such destination identifiers, destination identifiers 108 , 110 , 112 , 114 , and 116 . In one embodiment, these destination identifiers are ten-digit domestic telephone numbers. In another embodiment, these destination identifiers correspond to variable-length international telephone numbers. In a third embodiment, they may correspond to Internet Protocol (IP) addresses. Other forms for the destination identifier are possible without departing from the scope of the claims below.
Each destination identifier is associated with a fraud metric value. In this example, destination identifier 108 has fraud metric value −0.5, destination identifier 110 has fraud metric value −0.1, destination identifier 112 has fraud metric value 0.1, destination identifier 114 has fraud metric value 0.5, and destination identifier 116 has fraud metric value 0.5. In this example, mobile communications device 102 has initiated communication with destination identifiers 108 , 110 , and 112 . Similarly, mobile communications device 104 has initiated communication with destination identifier 110 , 112 , and 114 , and mobile communications device 106 has initiated communication with destination identifier 112 , 114 , and 116 .
Corresponding to each of these communications is a communications record 118 , as depicted in FIG. 1B . In some embodiments, each communication initiated by a mobile communications device to a given destination identifier is recorded separately; in other embodiments, only the fact that, e.g., mobile communications device 102 initiated communication with destination identifier 108 at least once is significant. Communications record 118 contains a plurality of fields, including a source identifier 120 and a destination identifier 122 .
The form of these identifiers will vary depending on the form of the communication. For example, if the communication is a domestic phone call, then the identifiers may be ten-digit domestic telephone numbers. If the communication is an international phone call, the identifiers may be international phone numbers of variable length. If the communication is a data communication, the identifiers may be IP addresses. Furthermore, the source and destination identifiers may not be in analogous form; for example, the destination identifier may be a ten-digit phone number, while the source identifier is a Electronic Serial Number (ESN) corresponding to the account associated with the mobile device.
In many cases, these identifiers will be in hierarchical form, with the leading digits indicating a coarse identification and subsequent digits successively refining the identification. For example, in an international phone number such as +39 06 1234 5678, a first group of digits (here “39”) indicate the country (Italy), a second group of digits (here “06”) represent a city (Rome), and so on, until the whole number uniquely identifies an individual telephone subscriber. Similarly, IP addresses are divided up into a network part and a host part; for example, the 32-bit IP address 192.168.123.156 is divided into a 16-bit network part (“192.168”) and a 16-bit host part (“123.156”), though other divisions of the 32 bits are possible.
Turning now to FIG. 2 , a flowchart for a method of detecting fraudulent mobile communications devices in accordance with one embodiment of one aspect of the present invention is presented and referenced generally by the numeral 200 . At step 202 , a fraud hypothesis variable associated with a mobile communications device is initiated. This fraud hypothesis variable represents the likelihood that the hypothesis that the associated mobile communications device is fraudulent is true. In some embodiments, a higher value for this variable indicates that the hypothesis is more likely to be true; in other embodiments, a lower value indicates that the hypothesis is more likely to be true. In one embodiment, this fraud hypothesis variable is initialized to 0; in another it is initialized to 0.5. In other embodiments, it may be initialized to other values without departing from the scope of the claims below.
At step 204 , a communications record such as communications record 118 is received. In one embodiment, this communications record takes the form of a voice call record. In another embodiment, it takes the form of an SMS message. In a third embodiment, it takes the form of an indication of a data communication. Each communication record so received is related to activity that took place over a given period of time; in one embodiment, this period of time may correspond to a billing cycle; in another embodiment, this period of time corresponds to the previous day. Other time intervals are possible without departing from the scope of the claims below.
At step 206 , a destination identifier is extracted from the communication record received in step 202 . As previously discussed, this identifier takes a variety of forms in different embodiments, and in some embodiments will be hierarchically organized so as to include a prefix. In embodiments that do not include hierarchically organized destination identifiers, step 208 will be omitted and processing will proceed directly to step 210 .
At step 208 , a prefix from the destination identifier is compared to a list of prefixes. In one embodiment, the list of prefixes contains only top-level prefixes. In another embodiment, the list of prefixes contains variable-length prefixes. Other prefix-matching schemes are possible without departing from the scope of the claims below. If the prefix from the destination identifier matches a prefix in the prefix list, a fraud metric value associated with the destination identifier is used to modify the fraud hypothesis variable associated with the mobile communications device at step 210 .
In one embodiment, this modification comprises adding the fraud metric value to the fraud hypothesis variable. In another embodiment, the modification comprises multiplying the fraud hypothesis variable by the fraud metric value. In yet another embodiment, the fraud hypothesis variable comprises an average of all fraud metric values encountered, and the modification comprises incorporating the fraud metric value associated with the destination identifier into that average. Other ways of modifying the fraud hypothesis variable using the fraud metric value associated with the destination identifier are possible without departing the scope of the claims below.
After this modification, or if the prefix does not match any prefix in the prefix list, the method continues to step 212 . At step 212 , it is determined whether more records remain to be processed for the given time period. If so, steps 204 et seq. are repeated until no records remain to be processed. Once no records remain, the method continues to step 214 . At step 214 , the fraud hypothesis variable is compared to the first threshold, denoted in FIG. 2 by T 1 to determine whether the fraud hypothesis is true. In one embodiment, a fraud hypothesis variable value greater than the first threshold indicates that the fraud hypothesis is true and that the mobile communications device is fraudulent. In another embodiment, a fraud hypothesis variable value less than the first threshold indicates that the fraud hypothesis is true. If the fraud hypothesis is determined to be true, a fraud alert associated with the mobile communications device is generated at step 216 and processing is continued at step 218 . Otherwise, if the fraud hypothesis is false, processing terminates.
At step 218 , the fraud hypothesis variable is compared to a second threshold, denoted in FIG. 2 by T 2 . This second threshold represents a higher level of confidence that the fraud hypothesis is true. Thus, if the fraud hypothesis is confirmed when the fraud hypothesis is greater than the threshold value, then the second threshold is higher than the first threshold value. Conversely, if a fraud hypothesis variable value less than the first threshold confirms the fraud hypothesis, then the second threshold is less than the first threshold. If the fraud hypothesis is not confirmed at this higher confidence level, information regarding the mobile device is passed to the confirmation component at step 220 .
In one embodiment, this confirmation takes the form of a review of the information by a human operator. In another embodiment it takes the form of further automated processing of the communications records associated with the mobile communications device by other methods. At step 222 , the results of this confirmation are received from the confirmation component. At step 224 , it is determined whether these results confirm the fraud hypothesis at the higher level of confidence or fail to confirm it. If the fraud hypothesis is confirmed at the higher confidence level, either at step 218 or by the confirmation component, at step 226 , the mobile communications device is classified as a fraudulent source for the purposes of destination fraudulence evaluation, as discussed elsewhere. After this, or if the fraud hypothesis could not be confirmed at step 224 , processing terminates.
To provide a concrete example of this method, consider again FIG. 1 . For the purposes of this example, the fraud hypothesis variable will be initialized to 0, and will be modified by adding the fraud metric value associated with the destination identifier. The first threshold will be 0.5 and the second threshold will be 1. Other embodiments have different values for these parameters. For the purposes of this example, we assume that prefixes matching each destination identifier shown are present in the prefix list. Thus the fraud hypothesis variable associated with mobile device 102 will be initialized to 0, and will be modified to become −0.5, −0.6, and −0.5 as the call records associated with destination identifiers 108 , 110 , and 112 are processed in turn and the respective fraud values added to the fraud hypothesis variable. As this does not satisfy the fraud hypothesis even at the lower confidence level, processing will terminate after step 214 .
Considering now mobile device 104 , the associated fraud hypothesis variable will begin at 0, and be modified to −0.1, 0, and then 0.5 as communications records associated with destination identifiers 110 , 112 , and 114 are processed. Since this value confirms the fraud hypothesis at the lower confidence level, a fraud alert will be generated at step 216 , but since it does not confirm the fraud hypothesis at the higher level, it will be passed to the confirmation component for further processing. Classification as a fraudulent source will depend on the result of this classification.
Considering now mobile device 106 , the associated fraud hypothesis variable will begin at 0, and be modified to 0.1, 0.6, and 1.1 as the communications records associated with destination identifiers 112 , 114 , and 116 are processed. This confirms the fraud hypothesis variable at the lower level, so a fraud alert is generated, and also at the higher level, so mobile communications device 106 is classified as a fraudulent source for the purposes of destination fraudulence evaluation.
Turning now to FIG. 3 , a graph showing the trade-off between a true positive rate and a false positive rate when detecting fraud is depicted for an exemplary data set. Curve 302 plots the fraction of fraudulent users correctly identified 304 (i.e., true positives) against the fraction of nonfraudulent users incorrectly identified as fraudulent 306 (i.e., false positives). Each point such as point 308 corresponds to a particular value for the first threshold T 1 . Thus it is clear that correctly identifying a very large fraction of fraudulent users (a very high true positive (TP) rate) may come at the cost of incorrectly identifying too large a fraction of nonfraudulent users as fraudulent (an unacceptably high false positive (FP) rate). For example, point 308 has a TP rate of approximately 95%, but only at the cost of an FP rate of approximately 20%. Since a high FP rate can adversely affect customer satisfaction, a low FP rate is desirable along with a high TP rate.
To quantify this idea, the idea of precision is used, where
precision
=
TP
TP
+
FP
Thus, point 308 has a precision of approximately 0.83. A precision value that is too low indicates that too many false positives are being generated, and that the threshold is correspondingly too low. Similarly, a precision rate that is too high means that it is likely that the false negative rate (i.e., fraudulent users who are incorrectly identified as non-fraudulent) is too high. For this reason, some embodiments of method 200 may incorporate the additional steps of obtaining feedback on fraud alerts and adjusting the threshold to keep the precision between an upper bound and a lower bound. This process will move operating point 308 along curve 302 : increasing the threshold will move operating point to the left, while decreasing the threshold will move operating point 308 to the right. In one embodiment, the upper bound is 0.9 and the lower bound is 0.8. Other embodiments may have other values for the upper bound and lower bound without departing from the scope of the claims below.
Turning now to FIG. 4 , an illustrative diagram showing the source identifiers associated with certain destination identifiers in accordance with a second embodiment of the present invention is presented. Nonfraudulent sources 402 and 404 are similar to mobile communications device 102 in FIG. 1A ; fraudulent sources 406 and 408 are similar to mobile communications device 106 in FIG. 1A . Destination identifiers 410 , 412 , 414 , and 416 are similar to destination identifiers 108 , 110 , 112 , 114 , and 116 , but do not necessarily correspond directly. Destination identifier 410 has been connected to by non-fraudulent sources 402 and 404 . Destination identifier 412 has been connected to by non-fraudulent sources 402 and 404 , and by fraudulent source 406 . Destination identifier 414 has been connected to by nonfraudulent source 404 and fraudulent sources 406 and 408 . Destination identifier 416 has been connected to by only fraudulent sources 406 and 408 .
As in FIG. 1A , in some embodiments, each communication initiated by a mobile communications device to a given destination identifier is recorded separately; in other embodiments, only the fact that, e.g., mobile communications device 402 initiated communication with destination identifier 410 at least once is significant.
Turning now to FIG. 5 , a flowchart for a method of detecting fraudulent destinations in accordance with one embodiment of the present invention is presented and referred to generally by reference numeral 500 . At step 502 , a communications record (such as communications record 118 ) associated with a destination identifier to be evaluated (such as destination identifier 122 ) is received. In various embodiments, this communications record will take different forms: in one embodiment, this communications record takes the form of a call record. In another embodiment, it takes the form of an SMS message. In a third embodiment, it takes the form of an indication of a data communication. Each communication record so received is related to activity that took place over a given period of time; in one embodiment, this period of time may correspond to a billing cycle; in another embodiment, this period of time corresponds to the previous month. Other time intervals are possible without departing from the scope of the claims below. In some embodiments, this time interval will differ from the time interval used in method 200 .
At step 504 , a count of all communications records so received is incremented, and at step 506 , a source identifier such as source identifier 120 is extracted from the communications record. As in step 206 of method 200 , the form this source identifier takes depends on the form of communications record 118 . In one embodiment, source identifier 120 takes the form of a ten-digit phone number when communications record 118 is a phone call. In another embodiment, it takes the form of an ESN.
At step 508 , it is determined whether the source identifier 120 obtained in step 506 corresponds to a fraudulent source. In some embodiments, this was previously determined via method 200 , and the resulting classification stored for the current use. In other embodiments, this determination is made on the fly via method 200 . In still other embodiments, this determination is made via other means. Other methods of making this determination are possible without departing from the scope of the claims below.
If the source corresponding to source identifier 120 is determined to be fraudulent, a count of fraudulent communications records is incremented at step 510 ; in either case, execution then proceeds to step 512 . At step 512 , it is determined whether more communications records 118 remain that are associated with the destination identifier being evaluated and the time period in question. If so, steps 502 et seq., are repeated.
Once no communications records 118 associated with the destination identifier being evaluated and the time period in question remain, execution proceeds to step 514 . At this step, the count of communications records and the count of fraudulent communications records are used to generate a raw value for the fraudulence of the destination. In one embodiment, this is accomplished by dividing the count of fraudulent communications records by the count of all communications records. In another embodiment, this is accomplished by using the unaltered count of fraudulent communications records. Other methods of generating the raw value for the fraudulence of the destination identifier are possible without departing from the scope of the claims below.
At step 516 , this raw result is mapped into a desired range. In some embodiments, this is accomplished by means of an affine transform. In an exemplary embodiment, the raw result is the result of the fraction of all communications records that come from fraudulent sources (as described above), and the desired range is [−½, ½]. The transformation in this case is simply subtracting one-half. In another example, the raw result still falls between 0 and 1, but the desired range is [−1,1]. In this case, the transformation is multiplying by 2 followed by subtracting 1. In yet another example, the range of raw results and the desired range coincide; in this case, the identity transformation (i.e., making no change) is used. Other transformations are possible without departing from the scope of the claims below. Finally, at step 518 , the result of this transformation is associated with the destination to obtain the destination fraud metric.
As a concrete example, consider again FIG. 4 . Destination identifier 410 has been connected to by two nonfraudulent sources and zero fraudulent sources. Assuming the desired range for fraud metric values is [−½, ½], as described above, the raw result is 0, and the fraudulence value is −0.5. Similarly, destination identifier 412 has been connected to by two nonfraudulent sources and one fraudulent source giving a raw result of 0.33, and a fraudulence value of −0.17.
Turning now to FIG. 6 , a flowchart for a method of detecting fraudulent destinations in accordance with an alternate embodiment of the present invention is presented and referred to generally by reference numeral 600 . Many of the steps in method 600 correspond to those in method 500 . Step 602 corresponds to step 502 . Step 604 corresponds to step 506 . At step 606 , a list of source identifiers previously observed to connect to the destination identifier 122 being evaluated is consulted to see if the source identifier 120 has been previously observed to connect to destination identifier 122 . If so, execution proceeds to step 608 , which corresponds to step 512 . Otherwise, source identifier 120 is added to the source list at step 610 . At step 612 , corresponding to step 508 of method 500 , it is determined whether source identifier 120 is associated with a fraudulent source. If so, source identifier 120 is added to the list of fraudulent sources that have been observed to connect to the destination identifier. In either case, execution then proceeds to step 608 .
At step 616 , the number of distinct sources observed to connect to the destination identifier and the number of distinct fraudulent sources observed to connect to the destination identifier are used to generate a raw fraudulence value for the destination identifier being evaluated. This is similar to step 514 of method 500 , but counts each source only once, regardless of the number of times the source connects to the destination identifier being evaluated. At step 618 , corresponding to step 516 , this raw value is transformed into the desired range. Finally, at step 620 , corresponding to step 518 , the result of this transformation is associated with the destination to obtain the destination fraud metric.
Many different arrangements of the various components depicted, as well as components not shown, are possible without departing from the scope of the claims below. Embodiments of our technology have been described with the intent to be illustrative rather than restrictive. Alternative embodiments will become apparent to readers of this disclosure after and because of reading it. Alternative means of implementing the aforementioned can be completed without departing from the scope of the claims below. Certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations and are contemplated within the scope of the claims. | A method, system, and medium are provided for detecting fraud, the method comprising: initializing a fraud hypothesis variable associated with a communications device, receiving data that describes a plurality of outgoing communication records that are associated with said communications device, wherein the data is related to activity that took place over a given period of time, extracting a plurality of destination identifiers from said plurality of communication records, for each of at least a portion of said plurality of destination identifiers, modifying said fraud hypothesis variable based on a fraud metric associated with said destination identifier, comparing said fraud hypothesis variable to a first predetermined threshold, and when said fraud hypothesis variable exceeds said first predetermined threshold, generating a fraud indication that is related to said communications device. | 7 |
TECHNICAL FIELD
This invention pertains to treating a porous substrate by impregnating the substrate with a foam. In one of its more specific aspects, this invention relates to transporting a porous substrate past an applicator which injects foam into the porous substrate, thereby impregnating or coating the porous substrate.
BACKGROUND OF THE INVENTION
A common practice in the manufacture of porous substrates is to apply a coating of various materials thereto. In the manufacture of carpet material, for example, it is necessary to dye the carpet to the desired color during the manufacturing process. Also, many types of fibrous and non-fibrous webs or blankets require a binder to bond the fibers or other particles together to form a cohesive product. An example of this is an insulation pack produced by bonding together mineral fibers, such as glass fibers. A typical binder for a glass fiber insulation pack is a phenol-formaldehyde-urea binder. The binder is applied to the fibers, and, when cured, the binder enables the insulation pack to be compressed with nearly full recovery upon release of the compression.
Previously, the application of binder, dye or any other coating material to porous substrates, such as carpets or mineral fiber webs, has been by one of several methods. The common method in the manufacture of mineral fiber packs is to spray a binder material or coating material onto the fibers prior to collecting the fibers in the form of an insulation pack. This process has certain deficiencies in that the binder has to be applied in a hot fiber-forming zone, thereby creating air pollution problems. Also, binder application onto air-borne fibers is inherently non-uniform. Another process for applying coatings to porous substrates is that of transporting the substrate through a liquid bath, such as is used to dye fabrics, including carpets. This process is deficient in that a large percentage of water or other carrier medium remains in the porous substrate after the coating process, and must be removed by costly methods, such as by drying ovens. Also, liquid bath applicators provide no control of penetration of the liquid into the substrate.
Another method for coating porous substrates is that of creating a foam containing the coating material, such as the binder or the dye, and impregnating the porous material with the foam. The use of the foam material facilitates a uniform coating on all the material of the substrate, and applies the coating with a minimum amount of carrier medium, such as water. Typically, the foams are applied as a layer to the substrate, and caused to impregnate the substrate by the use of a doctor blade. A process for forcing a layer of foam into a porous substrate is disclosed in U.S. Pat. No. 4,188,355, to Graham et al., which provides for a suction apparatus to force the binder foam into the insulation pack. The use of a suction device to force the foam into the pack is not entirely satisfactory, however, and is made more difficult by the inherent difficulty in transporting a fragile pack of fibers through a narrow opening and past a foam applicator. Also, suction devices are limited in not being able to produce any pressures higher than one atmosphere. There is a need for a method and apparatus for applying foam to a porous substrate in the absence of a vacuum apparatus, which is inherently pressure limited.
SUMMARY OF THE INVENTION
There has now been developed a method and apparatus for applying foam to a porous substrate in which the substrate is passed through a nip region defined by a foraminous surface and the surface plate of a foam discharge head. The function of the foraminous surface is to press the insulation material down tight against the surface plate and the discharge openings, thereby sealing the surface plate and insuring that the foam will pass directly into the insulation pack rather than leaking along the interface between the surface plate and the insulation pack. Such a pressure device has two requirements. First, it must not create so much friction between the insulation material and the surface plate that the insulation material cannot be transported past the foam discharge head. The friction which can be tolerated by any particular porous substrate is a function of the tensile strength of that porous substrate. Also, the foraminous nature of the surface enables air to escape from the pack during the compression process. The pressurized foam is able to partially or fully impregnate the insulation pack, and the urging of the substrate into sealed relation with the surface plate at the nip region insures that the foam material will pass through the surface and into the interior of the insulation pack rather than travel along the interface between the insulation pack and the discharge head. The method and apparatus of this invention can apply foams at very high pressures, and are not limited to sub-atmospheric pressures. Also, the invention can be used to apply foam to substrates having very low tensile strengths, since the substrate is driven by the foraminous surface. Further, a greater control of the penetration of the foam can be effected with the present invention.
According to this invention, there is provided apparatus for impregnating a porous substrate with a foam comprising a foam discharge head having a surface plate adapted with one or more discharge openings for the discharge of foam therefrom, a foraminous surface positioned opposite the discharge openings to define a nip region having a thickness less than the thickness of the porous substrate, with the foraminous conveyor being adapted to transport the porous substrate through the nip region and to urge, with the foam discharge head, the porous substrate into sealed relation with the surface plate at the nip region, and means for supplying foam to the foam discharge head with pressure sufficient to impregnate the porous substrate.
In specific embodiment of the invention, the means for supplying foam supplies foam to the foam discharge head at a pressure within the range of from about 3 to about 18 psig.
In another specific embodiment of the invention, the means for supplying foam supplies foam to the foam discharge head at a pressure within the range of from about 5 to about 10 psig.
In a preferred embodiment of the invention, a radio-frequency dryer removes water from the porous substrate subsequent to its being impregnated with foam.
In a more preferred embodiment of the invention, a second foraminous surface and a second foam discharge head are adapted to discharge foam through another side of the porous substrate.
In another specific embodiment of the invention, the discharge openings comprise a plurality of holes positioned in the surface plate. The holes can be arranged in rows, with the holes in one row being offset or staggered with respect to its adjacent row.
In another specific embodiment of the invention, a surface support conveyor is positioned between the foraminous surface and the porous substrate.
According to this invention, there is also provided apparatus for impregnating a fibrous web with a foam comprising a foam discharge head having a surface plate adapted with one or more discharge openings for the discharge of foam therefrom, a rotatably mounted foraminous drum positioned opposite the discharge openings to define a nip region, with the foraminous drum being adapted to transport the fibrous material through the nip region, and the foraminous drum being adapted to urge, with the foam discharge head, the fibrous web into sealed relation with the surface plate so that foam is prevented from accumulating at the interface between the foam discharge head and the fibrous web as it is transported through the nip region, and means for supplying foam to the foam discharge head with pressure sufficient to impregnate the fibrous web. The web can be a web of mineral fibers, and the foam can be a binder foam supplied by a foamer.
In a specific embodiment of the invention, the nip region has a minimum thickness within the range of from about 5 to about 20 percent of the thickness of the fibrous web when uncompressed.
In a preferred embodiment of the invention, the foraminous surface is convex within the nip region in the direction of the foam discharge head.
According to this invention, there is also provided a method for impregnating a porous substrate with a foam comprising transporting the porous substrate through a nip region defined by a foraminous surface and a foam discharge head, the foam discharge head including a surface plate having one or more discharge openings, where the transport of the porous substrate through the nip region causes the porous substrate to be urged into sealed relation with the surface plate as the substrate passes the discharge openings, and supplying foam to the discharge head with pressure sufficient to impregnate the porous substrate.
In another specific embodiment of the invention, water is removed from the porous substrate with a radio-frequency dryer subsequent to impregnating the substrate with foam.
In a preferred embodiment of the invention, one side of the porous substrate is impregnated with the first foraminous conveyor and first foam discharge head, and the other side of the porous substrate is impregnated with a second foraminous conveyor and a second foam discharge head.
In another preferred embodiment of the invention, the discharge openings comprise at least 2 rows of holes, with the holes in one row being offset with respect to its adjacent row.
In another embodiment of the invention, two or more porous substrates are simultaneously impregnated with foam by being passed in laminated form through the nip region. In such a case, the porous substrates, which could be of a textile fabric, could be laid one on top of another to form a bonded or unbonded laminate which then could be fed into the nip region for impregnation with foam. Such a method would provide greater uniformity of foam application than previous foam application methods for textiles.
According to this invention, there is also provided a method for impregnating a fibrous web with a foam comprising transporting the web through a nip region defined by a rotating foraminous drum and a foam discharge head, the foam discharge head having a surface plate adapted with one or more discharge openings, where the transport of the web through the nip region urges the web into sealed relation with the surface plate to prevent foam from accumulating at the interface between the foam discharge head and the web as the web passes the discharge openings, and supplying foam to the discharge head with pressure sufficient to impregnate the web. The fibrous web can be a web of mineral fibers and the foam can be a binder foam.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view in elevation of apparatus for impregnating a porous substrate with a foam according to the principles of this invention.
FIG. 2 is a schematic view in perspective of the apparatus shown in FIG. 1.
FIG. 3 is a view in elevation of a different embodiment of the foraminous surface.
FIG. 4 is a view in elevation of yet another embodiment of the foraminous surface.
DESCRIPTION OF THE INVENTION
This invention will be described in terms of a method and apparatus for applying a binder foam to an insulation pack of glass fibers. It is to be understood that the invention can be practiced with other coating materials, such as dyes, sizes, lubricants, finishes, oils, waxes, asphalts, latex materials and paints, and with other porous substrates, such as insulation packs of other mineral fibers, paper products, polymer products, and textile material, such as carpeting.
As shown in FIGS. 1 and 2, the unimpregnated porous substrate, such as glass fiber insulation pack 10, is driven past bottom foam discharge head 12 by a foraminous surface, such as first rotating foraminous drum 14. The foraminous drum can be made of any suitable material, such as stainless steel, and is adapted with a plurality of perforations, such as perforations 15. Preferably, the perforations give the drum a porosity of about 0.5. The positioning of the first foraminous drum opposite the foam discharge head defines nip region 17 through which the insulation material must pass. Preferably, the foraminous surface, such as the foraminous drum, is convex within the nip region in the direction of the foam discharge head, i.e., in a downward direction for the apparatus shown in FIG. 2. In the nip region, the insulation material can be considerably compressed, as shown. Preferably, the insulation material is compressed in the nip region to a thickness within the range of from about 5 to about 20 percent of the thickness of the uncompressed insulation material.
The partially impregnated insulation pack 16 can then be drawn past another foam application station, which can be comprised of top foam discharge head 18 and second rotating foraminous drum 20 to produce fully impregnated insulation pack 22. In the alternative, any number of foam application stations can be employed for either the top or bottom (or both) of the porous substrate. As shown in FIG. 2, the nip region 21 is defined by the positioning of the second foraminous drum adjacent the top foam discharge head. The foraminous drums can be driven by any suitable means, such as motors 23. The fully impregnated pack can then be passed through a dryer, such as radio-frequency dryer 24, which can remove water from the impregnated pack without curing the binder. Subsequently, either in an on-line operation or in an off-line operation, the impregnated, dried insulation pack can be passed through a curing station, such as curing oven 26, to produce cured insulation product 28. Alternatively, the dried, uncured insulation material can be molded using conventional wool molding techniques for such uses as automobile hoodliners and headliners.
The foam discharge head is adapted with surface plate 32 across which the insulation pack is transported. Preferably, the surface plate and other parts of the foam discharge heads are comprised of stainless steel, or some other wear-resistant, corrosion-resistant material. The surface plate is adapted with a plurality of discharge openings 34 for dispensing foam from the foam discharge head into the insulation pack. The discharge openings can comprise a single slot, not shown. Preferably, the discharge openings comprise a plurality of holes, and preferably they are arranged in two or more rows, with the holes in one row being offset or staggered from the holes in another row. This provides the most uniform coverage of the foam across the width of the insulation pack, without providing holes so large as to enable the compressed insulation material to be torn by being forced into the holes, or catching on the hole edges. The foam discharge head can be spring-mounted with either hydraulic means, springs or pneumatic means 36 to accommodate solid or incompressible objects, such as glass slugs or density variations in the glass insulation pack, passing through the nip region between the foam discharge head and the foraminous drum. The pneumatic means also accommodate eccentricities in the foraminous drum.
Since the nip region has a minimum thickness less than the thickness of the insulation material, the insulation material is urged into sealed relation to the surface plate so that the foam is prevented from accumulating on the interface of the surface plate and the insulation material. The foam is substantially prevented from leaking or traveling laterally along the surface plate, and is forced to impregnate or penetrate into the insulation material.
The foam discharge heads can be supplied with the binder foam from foamers 38a and 38b via any suitable means, such as hoses 40a and 40b. A mechanical foamer that has been found suitable for use for the invention is a 14 inch foamer manufactured by Oakes Corporation, Islip, N.Y. Such a foamer can produce the binder foam at a pressure within the range from about 40 to about 100 psig, or higher. The foam pressure within the foam discharge head is limited only by the construction materials and the foam delivery capacity. Preferably the pressure is within the range of from about 3 to about 18 psig, and most preferably within the range from about 5 to about 10 psig. The pressure reduction from the foamer to the foam discharge head is provided by the hoses, and different size and length hoses can be used to produce the desired pressure drop. The pressure developed in the foam discharge head is dependent on the product produced and on nature of the foam. The foam within the foam discharge head can have a density within the range of 0.01 g/cc to 0.05 g/cc or higher, and preferably, 0.03 g/cc (densities calculated at atmospheric pressure).
As shown in FIG. 3, foraminous surface 14a need not be a rotatable drum, but can follow a path which defines the nip region and seals the insulation pack against the foam discharge head.
Scrim 42 can be directed by scrim transport rolls 44 to lie between foraminous surface 14b and the insulation pack as the pack passes through the nip region, as shown in FIG. 4. The scrim would be advantageous to supplement the tensile strength of the insulation pack.
EXAMPLE
A dry 2-inch thick, 1 pcf glass fiber insulation pack having an initial binder content of 2 percent by weight was subjected to binder foam impregnation according to the principles of this invention. A foam binder material was prepared using an aqueous phenol-formaldehydeurea resin with 2 percent by weight of Union Carbide's TERGITOL NP-10 as a foaming agent, and was applied to the insulation material with the apparatus of this invention using both a bottom and a top application. The minimum thickness of the nip region was about 3/8 inch, the foam pressure in the discharge head was about 5 psig, and the foam density was about 0.03 g/cc. The pressure applied to the insulation pack was about 21 pounds per lineal inch width of the pack. The impregnated pack was placed in a radio-frequency dryer which removed substantially all of the water, resulting in an uncured product having about 20 percent binder by weight. Subsequently, the product was cured in a mold to make a final product having a thickness of about 3/4 inch.
It will be evident from the foregoing that various modifications can be made to this invention. Such, however are considered as being within the scope of the invention.
INDUSTRIAL APPLICABILITY
This invention will be found to be useful in the manufacture of packs of mineral fibers for such uses as glass fiber thermal insulation products, and for the manufacture of textile material. | A method and apparatus for impregnating a pourous substrate with foam the method comprising transporting the porous substrate through a nip region defined by a moving foraminous surface such as a rotating foraminous drum and a foam discharge head, the foam discharge head comprising one or more discharge openings, where the transport of the porous substrate through the nip region causes the porous substrate to be compressed as it passes the discharge openings, and supplying foam to the discharge head with pressure sufficient to discharge foam through the discharge openings to impregnate the porous substrate. A surface support conveyor is positioned between the foraminous surface and the porous substrate. | 3 |
CROSS REFERENCE TO RELATED APPLICATION
This application claims the priority of German Application No. 195 09 928.1 filed Mar. 18, 1995, which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
This invention relates to an apparatus which is associated with a sliver processing textile machine, such as a card or a drawing frame and serves for advancing and presenting coiler cans to the fiber processing machine for being filled with sliver. The apparatus is of the type which includes a conveyor device having a driven conveying element such as a conveyor belt, a roller track or the like, coupled with an openable and closable coiler can blocking device.
In a known apparatus of the above-outlined type, disclosed, for example in German Offenlegungsschrift (application published without examination) 39 08 832, the coiler cans are advanced by a horizontally circulating, driven conveyor belt. The lateral surface of the coiler cans is situated between a reach of the conveyor belt, having a high coefficient of friction and a stationarily held railing. During transport the bottom rollers of the coiler cans roll on the floor of the spinning preparation plant. The known apparatus positively entrains the coiler cans along the entire conveying path and thus all coiler cans are simultaneously moved. It is not feasible to line up the coiler cans in a series without applying a pressing force and to separate the cans from one another. If a new empty can is to be advanced to the coiler can replacing device, in each instance the conveying apparatus has to be set in motion to simultaneously move all the coiler cans, that is, the supply of the leading can, the transport of all the cans and the adding of a new empty can are always necessarily coupled to one another. It is a further disadvantage of the conventional apparatus that the constructional outlay is substantial. Also, a lateral handling is prevented by the conveyor belt and the railing.
SUMMARY OF THE INVENTION
It is an object of the invention to provide an improved apparatus of the above-outlined type from which the discussed disadvantages are eliminated and which, in particular, ensures an improved conveyance and presentation of coiler cans and which permits the separation of the coiler cans in a structurally simple manner.
This object and others to become apparent as the specification progresses, are accomplished by the invention, according to which, briefly stated, the coiler can transporting assembly for advancing coiler cans in a transporting direction to a sliver-producing textile machine includes coiler cans each having a bottom forming a conveying face; and a conveyor element having a discharge end and an upper transporting surface engaging the conveying face of the coiler cans when in an upright, standing position on the conveyor element. The conveying face and the transporting surface have a low friction value relative to one another. A can-stopping device is situated at a location along the conveyor element and has first and second states. In the first state the can-stopping device blocks advancement of a coiler can while the conveyor element continues to move in the transporting direction. In the second state the can-stopping device allows advancement of a coiler can therethrough.
Thus, according to the invention, for supplying, removing and/or storing coiler cans at a sliver producing textile machine, the coiler cans are positioned on driven conveyor elements, such as conveyor belts and advanced against can-stopping devices. When the coiler cans have reached their destination, they are held by the can-stopping devices, while the conveyor element, such as a belt, continues to move and thus a relative sliding motion between the conveyor belt and the coiler cans takes place. In this manner, a structurally simple coiler can accumulator is provided which permits a conveyance, storage and separation of the coiler cans.
As the conveyor element advances, the slight sliding friction between the conveyor element and the bottom of the coiler cans is of importance for the accumulation of coiler cans, while for the conveyance of the cans, the pressure (gravity) of the coiler can bottom on the conveyor element is of significance.
If a coiler can is to be taken out of the accumulator, the can-stopping device (such as a gate) is placed in a releasing state and after the conveyor element, such as a conveyor belt, has run through a distance which corresponds to the diameter of the coiler, it is stopped, the designated coiler can is removed and the can-stopping device is again placed into its operative, can-blocking position. The conveyor element is activated and deactivated by a control device which cooperates with the control of a machine situated upstream and/or downstream of the can conveyor apparatus. The start of the conveyor element may be triggered manually by the operating person whereupon a period is triggered which corresponds to the longest possible conveyor path. Thereafter the conveyor drive automatically stops. Such an operation reduces the period during which relative sliding motion occurs between the coiler cans and the conveyor element and thus diminishes the wear on the belt and the cans.
Instead of a conveyor belt, two toothed belts may be used which move parallel and in unison. The two belts are spaced from one another at a distance which is in the order of magnitude of the diameter of the coiler cans. The two outer edges of the parallel belts have a distance which is preferably slightly greater than the outer can diameter in the region of the standing surface of the can. The can transport device and/or accumulator preferably cooperate with the can supplying and removing devices. The can supplying and/or removing device is expediently a coiler can replacing mechanism which may be a linear or rotary can exchanger. The accumulator may have sensors for detecting the coiler cans. The belts preferably run in protective troughs which are of low friction and wear-resistant material such as low-pressure polyethylene. Advantageously, the belts are individually driven. Expediently, a plurality of belts are simultaneously operated from a common drive. In the drive system reversal gears may be used. According to a further feature of the invention a centering device is provided for the coiler cans at the inlet end of the conveyor belt. The can surface which contacts the conveyor element may be constituted by a planar can bottom, an additional base plate or an annular attachment.
The invention further has the following additional advantageous features:
The conveying path of the conveyor element is adjustable when the can-blocking device is either in its blocking or in its pass-through state. The drive of the can-blocking device and the drive of the conveyor element are electrically connected to one another. An electronic control and regulating device, such as a microcomputer is provided, to which the drive for the sliver producing textile machine, the drive for the conveyor element and the drive for the can-blocking device are connected to coordinate the operation of the various components. Sensors, such as optical barriers may be provided for detecting the presence of the coiler cans. The can-blocking device may be constituted by an arm, roller, or the like of a can-replacing device which supplies an empty can to the sliver producing textile machine from the conveyor element. The conveyor element which supplies empty coiler cans slopes downwardly towards the sliver producing textile machine. The conveyor element which moves away full coiler cans slopes downwardly from the sliver producing textile machine. The can-blocking device may be formed by a detent or hook which immobilizes a coiler can on the running conveyor element by engaging from below into a recess provided in the coiler can.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1a is a schematic top plan view of a preferred embodiment of an apparatus according to the invention.
FIG. 1b is a schematic side elevational view of the construction shown in FIG. 1a, as viewed in the direction of the arrow Ib.
FIGS. 2a, 2b and 2c are views similar to FIG. 1b, illustrating various coiler can distribution patterns.
FIG. 3a is a schematic sectional end view taken along line III--III of FIG. 1b.
FIG. 3b is an enlarged view of the inset IIIb of FIG. 3a.
FIG. 3c is an exploded view of a protective trough, a toothed belt and a coiler can.
FIG. 4a is a schematic side elevational view of a terminal portion of a conveyor element of the preferred embodiment of the invention.
FIG. 4b is a schematic top plan view of the construction shown in FIG. 4a.
FIG. 5 is a perspective view of conveying elements for moving empty and full coiler cans.
FIG. 6 is a schematic perspective view of a retaining gate for stopping a coiler can.
FIGS. 7a-11a are bottom plan views of various can bottom configurations.
FIGS. 7b-11b are schematic side elevational views of coiler can configurations, paired with FIGS. 7a-11a, respectively.
FIG. 12 is a schematic side elevational view of a preferred embodiment showing support rolls.
FIG. 13a is still another embodiment of the invention including a roller track.
FIG. 13b is a side elevational detail of the structure shown in FIG. 13a.
FIG. 14a illustrates the embodiment shown in FIG. 1a, together with a can transporting carriage.
FIG. 14b is a schematic front elevational view of the construction shown in FIG. 14a.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1a shows a drawing frame 3 which may be, for example, an HS model high-output drawing frame manufactured by Trutzschler GmbH & Co. KG, Monchengladbach, Germany. The drawing frame 3 has a drive 3a. With the drawing frame 3 an apparatus 1 and an apparatus 2 are associated for supplying empty coiler cans 5 to, and for moving coiler cans 6 filled with sliver away from the drawing frame 3, respectively. The empty cans 5 are advanced by the apparatus 1 in the direction of the arrow A, whereas the filled cans 6 are advanced by the apparatus 2 in the direction of the arrow B. Further, a coiler can replacing apparatus 4 is provided which may be a turnstile-type rotary can moving arrangement for moving, during the same turning motion, a full coiler can away from, and an empty coiler can into the operational range of a sliver-depositing coiler head 30 in a curvilinear path designated by the arrow C. The coiler can positioned underneath the coiler head 30 which deposits sliver into the coiler can, is designated at 7. The leading empty can 5a on the apparatus 1 cooperates with an openable and closable gate 8 whereas the leading full can 6a on the apparatus 2 cooperates with an openable and closable gate 9. The cans 5 are advanced on a conveyor 10 such as a conveyor belt, whereas the cans 6 are advanced on a conveyor 11 which also may be a conveyor belt. Downstream of the gate 9, as viewed in the direction of advance B a stationary, fixed gate 31 is disposed in the path of the cans.
Turning to FIG. 1b, the conveyor belt 10 has an upper, horizontal run on which coiler cans 5a, 5b and 5c are positioned in an upright orientation. Stated differently, the coiler cans 5a, 5b and 5c stand on the conveyor belt 10 and exert a pressure by gravity on the outer surface 10' of the upper run of the conveyor belt 10. The conveyor belt 10 is supported by two end rollers 12 and 13, the latter being driven by a motor 14. The apparatus 2 has a conveyor belt 11 provided with a horizontal upper run which has an outer face 11'. The outer faces 10' and 11' of the conveyor belts 10 and 11, respectively and the conveying surfaces 5' and 6' of the coiler cans 5 and 6 oriented towards the belt surfaces 10', 11' of the respective conveyor belts 10 and 11 have a mutually low frictional coefficient and are smooth. Arrows D and E indicate the direction of rotation of the end rollers 12 and 13, respectively. The conveyor belt 11 may have its own drive motor or the two conveyor belts 10 and 11 may be driven by the common drive motor 14. The drive motor 14 is connected with an electronic control and regulating device 28 which is also connected to the drive 3a of the drawing frame 3 as well as to a drive 8a of the gate 8 to coordinate the operation of the drawing frame 3, the gate 8 and the conveyor belts 10, 11.
The conveyor belt 10 shown in FIGS. 2a, 2b and 2c runs in the conveying direction A. As shown in FIG. 2a, the leading can 5a abuts the closed gate 8 while the upper belt surface 10' which is in engagement with the lower conveying surface 5' of the coiler can 5a slides through in the direction A. At the same time, the coiler cans 5b and 5c, standing on the surface 10', are conveyed in the direction F until the can 5b abuts against the can 5a. Thereafter the surface 10' also slides through underneath the cans 5b and 5c which are immobile, similarly to the leading can 5a. To permit the leading coiler can 5a to be introduced into the drawing frame 3 (FIG. 1a), the gate 8 is lifted as shown in FIG. 2c. In this manner the retaining force exerted on the can 5a is removed and the can 5a is advanced by the belt 10 in the direction of the arrow F. At the same time, the cans 5b and 5c are also conveyed in the direction F until the coiler can 5b reaches the gate 8 whereupon the gate 8 is again closed to retain the coiler can 5b and the coiler can 5c therebehind.
The coiler can 5a exerts a force by virtue of its weight (gravity) on the belt surface 10'. According to FIGS. 2a and 2b, the slowly moved belt surface 10' presses with a normal force N upwardly on the stationary conveying surface 5' of the can 5a. The pulling force P of the belt 10 is opposed by the retaining force exerted by the gate 8. During the sliding friction between the surface 10' and the conveying face 5' the pulling force P=μ×N, where μ is the coefficient of friction. In the operational phase according to FIG. 2c, the retaining force of the gate 8 is removed by lifting the gate, so that the can 5a is advanced by the pulling force P of the belt 10 in the direction F.
Turning to FIGS. 3a, 3b and 3c, in a housing 15 parallel-spaced toothed belts 22a, 22b are arranged to serve as conveying elements. On both sides of a holding element 16a, 16b stationarily affixed supporting troughs 17a, 17b are provided which extend in the longitudinal direction of the apparatus 1a. On the upper side in each support trough 17a, 17b a longitudinal groove 18 of rectangular cross-sectional outline is provided which accommodates the lower zone of the upper run of the respective belts 22a, 22b. The respective upper zones extend beyond the longitudinal groove 18 and are, by means of their respective outer surfaces 22', in engagement with the lower conveying surface 5' of the coiler can 5 as shown in the exploded view of FIG. 3c. In this manner the support troughs 17a, 17b support the can 5 and the toothed belts 22a, 22b and at the same time form a guiding element for the toothed belts 22a, 22b.
FIGS. 4a and 4b show an end region of the toothed belts 22a, 22b. In the upwardly open housing 15 a shaft 18 supports two end sprockets 20a, 20b about which the respective endless toothed belts 22a, 22b are trained. As shown in FIG. 5, at the other, opposite end region of the toothed belts 22a, 22b a shaft 19 supports two end sprockets 21a, 21b about which the respective endless toothed belts 22a, 22b are trained. As also shown in FIG. 5, between the shaft 18 of the conveyor apparatus 1a which includes the toothed belts 22a, 22b and the shaft 24 of the conveyor apparatus 2a which includes the toothed belts 23a, 23b, a reversing gear 25 is provided so that the conveying devices of the apparatuses 1a and 2a may be driven by a driving arrangement, such as the drive 14 illustrated in FIG. 1b.
In FIG. 6 the gate 8 is shown in more detail. It includes a gate bar 8a which is swingable in a vertical plane between an operative (blocking) position and an open (pass-through) position about an articulation 8b provided on a stationary vertical post 8c. The movement of the gate 8 is controlled by an actuator 29. The gate 9 shown in FIG. 1a is similarly constructed.
It is to be understood that the can-stopping device may be of a construction other than the described gates 8 and 9. Thus, the can-stopping device may have a hook or pawl mechanism which may engage from below into an annulus, a groove or a recess provided in the coiler can.
The coiler can has, according to FIGS. 7a and 7b, a circular cross-sectional outline. The underface of the can bottom, having a circular area, constitutes the conveying surface 5'.
Turning to FIGS. 8a and 8b, the coiler can 5 of circular cross-sectional outline is mounted on a square bottom 5 III , whereas in FIGS. 9a and 9b a coiler can is shown which has a circular bottom 5 IV . The bottom plates 5 III and 5 IV project horizontally beyond the lateral surface of the can 5 and thus constitute a spacer between adjoining cans, preventing the lateral can faces from contacting one another. According to FIGS. 10a and 10b, underneath the can bottom 5 II a circular bottom plate 5 V is provided. FIGS. 11a and 11b show a coiler can 5 having an elongated, rectangular, horizontal cross-sectional outline.
According to FIG. 12, between the upper and the lower runs of the conveyor belt 10 (or between the upper and lower runs of the toothed belts 22a, 22b of FIG. 3a) rotatable supporting rollers 26 are disposed. The same arrangement may be provided between the upper and lower runs of the respective toothed belts 22a, 22b, 23a and 23b.
In FIG. 13a, the conveyor device is composed of a roller track formed of driven conveyor rollers 27 which have a smooth upper surface which, as shown in FIG. 13b, may be a low-friction coating 27a.
According to FIGS. 14a, 14b, the empty cans 5 may be moved to the apparatus 1 by a can transporting carriage 32. Similarly, the full cans 6 may be moved away from the apparatus 2 by a transporting carriage (not shown). The transporting carriage 32 may, for example, receive four coiler cans and laterally approach the conveyor apparatus 1. According to FIG. 14b, the supporting surfaces 32' of the carriage 32 and the upper surfaces 10' of the conveyor 10 are at the same height level so that the cans may be moved between the carriage 32 and the conveyor 10 without any vertical step.
It will be understood that the above description of the present invention is susceptible to various modifications, changes and adaptations, and the same are intended to be comprehended within the meaning and range of equivalents of the appended claims. | A coiler can transporting assembly for advancing coiler cans in a transporting direction to a sliver-producing textile machine. The assembly includes coiler cans each having a bottom forming a conveying face; and a conveyor element having a discharge end and an upper transporting surface engaging the conveying face of the coiler cans when in an upright, standing position on the conveyor element. The conveying face and the transporting surface have a low friction value relative to one another. A can-stopping device is situated at a location along the conveyor element and has first and second states. In the first state the can-stopping device blocks advancement of a coiler can while the conveyor element continues to move in the transporting direction. In the second state the can-stopping device allows advancement of a coiler can therethrough. | 3 |
TECHNICAL FIELD
[0001] This invention relates to equipment used in electronic media reading and writing, and more particularly to systems using data recording tape.
BACKGROUND
[0002] Tape read/write head assemblies include one or more read/write transducer heads positioned transverse to the intended path of a recording tape. The transducer heads write data on and read data from parallel tracks on the tape called “data tracks.” The head assembly can move laterally across the width of the tape to position a particular transducer head relative to a particular data track, with the head assembly's position controlled by a servo.
[0003] The tape itself may include tracks called “servo tracks,” which provide information to control the lateral position of the head assembly. Servo tracks serve as reference features or guide marks on the tape. By monitoring the position of the head assembly relative to the servo tracks, the head assembly can dynamically adjust the position of the transducer heads to keep the heads in a correct position relative to the tape tracks. Ideally, the tape path past the head assembly should not vary, but in practice lateral tape movement affects the position of a transducer head relative to a track. Dynamic repositioning is important because it compensates for the lateral movement.
[0004] In part because of servo control, data track widths have been made significantly narrower and the capacity of the recording medium has been increased. With a decrease of the width of data tracks and an increase of the number of tracks on a width of tape, servo control takes on added significance and greater precision is advantageous. The position of the transducer heads of the head assembly relative to tape tracks can become sensitive to a variety of disturbances, some of them minute.
[0005] Disturbances may arise, for example, from the equipment used to dispense the tape that is being fed past the transducer heads and from the equipment used to take up the tape after it had passed the transducer heads. In a typical case, for example, tape is dispensed from a first reel, which includes a hub and which often includes a flange, and is taken up by second reel. If a hub or a spindle supporting a reel is not perpendicular to the reel, the reel may wobble as it rotates. This wobble causes the tape to move laterally relative to the head assembly.
[0006] In addition, contact between the tape edge and the flange may produce lateral movement of the tape. When tape is taken up on a reel at high speed, for example, small pockets of air may become trapped between layers of tape, allowing one layer to slip laterally relative to another. Another potential source of lateral tape motion may come about due to the interaction between the head assembly and the tape. At times when the head assembly moves laterally relative to the tape to find a particular track, friction between the head assembly and the tape causes the tape to adhere to the head assembly and “follow” the head assembly.
[0007] Some of the lateral movements described above involve rapid changes in the lateral position of the tape relative to the head assembly, and other movements involve gradual changes. In the case where the tape follows the moving head assembly, for example, the initial tape movement may be gradual. There may come a point, however, at which the tension in the tape overcomes the frictional force, and the tape rapidly snaps back to a previous position.
SUMMARY
[0008] The invention provides systems that sense the lateral movement of data recording tape such as magnetic recording tape. One system monitors the tape position and adjusts the tape path based upon the tape position. Another system monitors the tape position and adjusts the position of the head assembly. The systems will be described separately, but typically the systems cooperate with each other to compensate for rapid (or “high-frequency”) changes and for more gradual (or “low-frequency”) changes in tape position.
[0009] In one embodiment, the present invention provides a system for positioning data recording tape. The system includes a sensor that detects the position of the tape and issues a position signal as a function of the tape position. The sensor may be, for example, an optical sensor or a magnetic sensor, and the signal may indicate how close the tape is to a target tape path. The system also includes a guide that interacts with the tape and a controller that moves the guide as a function of the position signal. By moving, the guide steers the tape. One technique for steering the tape with the guide is by tilting the guide.
[0010] In another embodiment, the present invention presents a system for positioning a head for reading and writing to data recording tape. The system includes a head, a sensor configured to detect the position of the tape and generate a signal as a function of the position, and a servo coupled to the head. The servo is configured to move the head as a function of the signal. Typically the sensor is located such that the sensor detects the tape's position before the tape passes the head. The system may also include an adaptive estimator, which receives the signal. Based upon the detected position or movement of the tape, the adaptive estimator may generate a second signal, which is used by the servo to move the head. With this system, the servo may move the head in anticipation of a disturbance that has not yet reached the head.
[0011] In a further embodiment, the present invention provides a method for steering data recording tape. The method includes passing the tape over a guide, sensing the position of the tape, generating a signal as a function of the position, and moving the guide as a function of the signal.
[0012] In still another embodiment, the present invention provides a method for moving the head in anticipation of tape disturbances. The method comprises detecting a disturbance in the path of the tape before the disturbance reaches the head, generating a signal as a function of the disturbance, and moving the head as a function of the signal.
[0013] In an additional embodiment, the present invention presents a system that includes a sensor that detects the position of data recording tape and issues a position signal as a function of the position of the tape. The system also includes a guide that interacts with the tape, a first controller that moves the guide as a function of the position signal, a head and a second controller that moves the head as a function of the position signal. The controllers may send signals to each other.
[0014] In a further embodiment, the present invention presents a control method. The method includes passing data recording tape over a guide and past a head. The position of the tape is sensed, and a position signal is generated as a function of the position of the tape. The method further includes moving the guide as a function of the position signal and moving the head as a function of the position signal.
[0015] The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims.
DESCRIPTION OF DRAWINGS
[0016] [0016]FIG. 1 is a diagram of a tape guiding system.
[0017] [0017]FIG. 2 is a diagram of a movable tape guide.
[0018] [0018]FIG. 3 is a block diagram showing a feedback system.
[0019] [0019]FIG. 4 is a block diagram showing a feedback and feed forward system.
[0020] Like reference symbols in the various drawings indicate like elements.
DETAILED DESCRIPTION
[0021] [0021]FIG. 1 shows a system 10 that guides a tape 12 past a read/write head 18 . Tape 12 includes a lower edge 14 and an upper edge 16 . Tape 12 is dispensed from some apparatus such as a first reel (not shown in FIG. 1), and is taken up by other apparatus such as a second reel (not shown in FIG. 1). Tape 12 may travel past read/write head 18 from right to left or from left to right. When tape 12 is moving from left to right, tape 12 is dispensed and passes over a first guide 22 . Tape 12 then passes head 18 . Tape 12 passes over a second guide 26 before being taken up.
[0022] Head 18 moves up and down, allowing head 18 access to different tracks on tape 12 . The position of head 18 is governed by a head servo 20 , which is controlled by a servo controller (not shown in FIG. 1). In the example of FIG. 1, head 18 is a magnetic head that reads data from and writes data to tape 12 , which is magnetic recording tape. In other embodiments, however, head 18 and tape 12 may be arranged for optical recording.
[0023] Guides 22 and 26 stabilize tape 12 as tape 12 moves past head 18 , and guides 22 and 26 maintain tape 12 in or near the “target,” or desired, tape path. Guides 22 and 26 steer tape 12 in a manner to be described in more detail below. Guides 22 and 26 may be roller guides with smooth cylindrical surfaces and have a low coefficient of friction with tape 12 . Guides 22 and 26 may rotate about axes 24 and 28 , respectively. Alternatively, guides 22 and 26 may be fixed, with tape 12 sliding over the guides or tape 12 flying on entrained air over the guides. As shown in FIG. 1, guides 22 and 26 do not include flanges to guide tape edges 14 and 16 . Interaction between tape edge 14 or tape edge 16 and a flange tends to cause damage to the edge and affects the quality of the edge. Optionally, guides 22 and 26 could have flanges, with the flanges being removed from the tape path. The flanges would not serve to steer tape 12 during ordinary operation, but would serve as a safety feature to prevent tape 12 from slipping off guides 22 and 26 in rare cases of extreme tape movement.
[0024] Tape 12 may be housed, for example, in a tape cartridge. Some components of system 10 , including components described below, may be included in the tape cartridge. Alternatively, some components may be included in a tape drive that receives the cartridge and runs tape 12 past head 18 . Guides 22 and 26 , for example, may be mounted on a baseplate in the tape cartridge, or guides 22 and 26 may be mounted on a deck within the tape drive. The invention is intended to encompass system 10 without regard to whether its components are included in the cartridge, the driver, or any combination thereof.
[0025] Guides 22 and 26 are movable, with axes 24 and 28 being configured to change orientation. A first guide actuator 34 regulates the orientation of axis 24 , and consequently regulates the orientation of first guide 22 . Similarly, a second guide actuator 36 regulates the orientation of axis 28 and consequently regulates the orientation of second guide 28 . Guide actuators 34 and 36 , by regulating the orientation of guides 22 and 26 , can cause one or both guides to tilt relative to an axis substantially perpendicular to a tape drive deck across which tape 12 is moved.
[0026] Tilting of a guide changes the path of tape 12 , as illustrated in FIG. 2. FIG. 2 shows first guide actuator 34 tilting axis 24 by an angle α to a tilted position 24 ′, causing guide 22 to move to a new position 22 ′. In the example in which guide 22 does not rotate, the tilting creates unequal longitudinal tension in tape 12 . Upper edge 16 is in greater tension than lower edge 14 . As tape 12 moves across guide 22 , tape 12 tends to slide downward on guide 22 to reduce the tension in upper edge 16 . By tilting guide 22 in an opposite direction, guide 22 places lower edge 14 in greater tension than upper edge 16 , thus steering tape 12 upward. In the example in which guide 22 rotates, steering techniques may differ. When tape 12 crosses a rotating guide, tape 12 may not necessarily move in a direction to decrease tension, and may be drawn in some circumstances in a direction that increases tension. Tape 12 may still be steered however by tilting guide 22 , but the tilting techniques may be different from the techniques employed when guide 22 is fixed.
[0027] The tilting shown in FIG. 2 is for purposes of illustration and is not intended to limit the invention. In FIG. 2, a tilt fulcrum 38 , where axes 24 and 24 ′ cross, is depicted near the bottom of guide 24 , but fulcrum 38 may be positioned at any other location, including a location other than one coincident with axes 24 or 24 ′. In addition, actuator 34 can be configured not only to tilt axis 24 of guide 22 , but also to translate guide 22 in one, two or three dimensions. For example, actuator 34 can move guide 22 downward, thus steering tape 12 downward. In addition, although FIG. 2 shows only first guide 22 , second guide 26 can be configured to move in a similar manner.
[0028] Returning to FIG. 1, sensors 30 and 32 are positioned between guides 24 , 28 and the reels that dispense or take up tape 12 . Sensors 30 and 32 are shown monitoring upper edge 16 of tape 12 , but sensors 30 and 32 could also monitor lower edge 14 . Additional sensors may also be added, the additional sensors allowing upper edge 16 and lower edge 14 to be monitored simultaneously, for example, or monitoring edge positions between guides 24 , 28 and head 18 . Sensors 30 and 32 may generate electrical signals indicative of the position of upper edge 16 . Sensors 30 and 32 may be optical sensors. Optical sensors offer good sensitivity and high accuracy, i.e., optical sensors are capable of monitoring upper edge 16 position very precisely. Furthermore, optical sensors also provide large bandwidth, i.e., optical sensors respond quickly to rapid changes in tape position. The invention is not limited to optical sensors, however. Sensors 30 and 32 may be other kinds of sensors, such as magnetic sensors configured to sense a magnetic track near the edge of tape 12 .
[0029] As will be described in more detail below, output signals from sensors 30 and 32 can be used by first guide servo 34 and second guide servo 36 to position first guide 22 and second guide 26 . Output signals from sensors 30 and 32 can be also used by head servo 20 to position read/write head 18 .
[0030] [0030]FIG. 3 is a block diagram illustrating a feedback system 40 . For illustrative purposes, it will be assumed that the system applies to edge sensor 30 and guide 22 . A tape position set point 42 , representing the ideal upper edge 16 position when tape 12 is aligned with the target tape path, is the input to feedback system 40 . The actual upper edge 16 position 50 is the output to feedback system 40 . The upper edge 16 position is sensed 48 by sensor 30 . The actual position 50 is subtracted 44 from the ideal position 42 , resulting in an error signal 52 . A guide controller that manages guide servo 34 steers tape 12 toward the target position, thus driving the error signal to zero. A similar feedback system may be employed with edge sensor 32 and guide 26 .
[0031] Steering of tape 12 by moving guide 22 or 26 generally cannot change the tape position quickly. For this reason, feedback system 40 tends to be more responsive to low-frequency changes in tape position and less responsive to high-frequency changes. A system that is better able to respond to high-frequency changes is shown in FIG. 4. FIG. 4 is a block diagram illustrating a feedback/feed forward system 60 . Feedback/feed forward system 60 uses signals from sensors 30 and 32 to correct for read/write head 18 position errors and to anticipate movement of tape 12 . Although feedback/feed forward system 60 uses some common components as feedback system 40 , such as sensors 30 and 32 , the two systems 40 and 60 are shown as separate block diagrams for clarity.
[0032] Input to feedback/feed forward system 60 is the desired position of head 18 ( 62 ), relative to a point on tape 12 . The desired position of head 18 may be specified, for example, with respect to a particular data track or a particular servo track. Servo controller 72 places head 16 at a position relative to the tape ( 74 ). The actual head position relative to tape 12 ( 74 ) is negatively fed back ( 64 ) to correct for errors in the position of head 18 . The actual position ( 74 ), subtracted ( 64 ) from the desired position ( 62 ), produces an error signal ( 78 ), which is used by servo controller 72 .
[0033] Tape disturbance 70 , such as a high-frequency tape lateral motion, may affect the position of the head 18 with respect to tape 12 ( 74 ). Tape disturbance 70 also affects the position of tape 12 as detected by sensor 30 or 32 ( 68 ). Because many disturbances 70 are detected by sensors 30 or 32 before they reach head 18 , an adaptive estimator ( 66 ) may use sensor 68 signals to feed forward ( 64 ) signals to servo controller 72 to anticipate impending motion caused by tape disturbance 70 . As a result, servo controller 72 can position head 18 quickly when the disturbance reached head 18 , and can wholly or partially compensate for the disturbance when the disturbance reaches head 18 .
[0034] Adaptive estimator 66 may include, e.g., a differentiator to convert position signals from a sensor 68 to signals indicative of the velocity of tape movement. Adaptive estimator 66 may further include instructions or logic for recognizing tape disturbances caused by head 18 itself For example, adaptive estimator may correlate tape position 68 with signals 76 from servo controller 72 to recognize cases in which friction between head 18 and tape 12 causes tape 12 to adhere to head 18 and follow head 18 . In such a case, adaptive estimator 66 may feed forward signals to counteract the feedback signals, thus keeping head 18 stationary. The advantage of counteracting is that it prevents head 18 from trying to pursue a track on tape 12 that friction prevents head 18 from reaching.
[0035] Although feedback system 40 and feedback/feed forward system 60 have been described separately above, and although systems 40 and 60 may operate alone or independently, it is usually advantageous for systems 40 and 60 to cooperate with each other. Cooperation allows improved compensation for high-frequency changes and low-frequency changes in tape position. For example, feedback system 40 may send a signal to feedback/feed forward system 60 that shows that feedback system 40 is steering tape 12 downward. Feedback/feed forward system 60 may use that signal to adjust the head position to follow the downward motion of tape 12 .
[0036] A number of embodiments of the invention have been described. These and other embodiments are within the scope of the following claims. | Data recording tape is passed along guides and past a read/write head. Sensors detect the position of the tape and adjust the guides and the head as a function of the position. If the tape deviates from the target tape path, a controller moves a guide to steer the tape back to the target tape path, using the sensor signals. In cases of tape disturbance such as those involving rapid tape motion, an adaptive estimator uses the sensor signals to position the head to anticipate the expected position of the tape when the disturbance arrives at the head. | 6 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates to a rail support system for glass panels to enable the panel to function as a door, window or partition. More particularly, the rail support system of the present invention is of the dry-set or dry glazing type that is easily installed in a variety of applications and includes readily replaceable decorative faceplates.
[0002] Glass panels have been used for years in buildings as doors, windows and partitions. A currently popular method of supporting such panels is the use of dry-set rails or “dry glazing” wherein the glass panel is held within a support rail by a clamping means without the use of a cement or other sealant material that requires time to set and makes what is called a “wet glazing” process more labor intensive and time consuming and producing results that are relatively permanent. Dry-set rails address these issues in that they can be economical to manufacture and install and allow for the adjustment, removal and replacement of the glass pane contained therein. While they also can be very versatile in that they can be readily adaptable for a variety of applications, they are relatively inflexible in appearance. Typically, such support rails are formed of extruded aluminum and are provided with a decorative cladding or side covers, (e.g. typically stainless, copper or brass) that are secured to the rails by an adhesive or double-sided tape that effectively permanently affixes the cladding to the support rail. If the side covers become scratched or otherwise damaged or if one merely wishes to change the appearance of the support rail, the options are quite limited. One can either paint the side covers (if not damaged) or replace virtually the entire rail support system. An example of such a rail support system with permanently affixed cladding is found in U.S. Pat. No. 5,069,010. It would be highly desirable to provide a dry-set rail support system for glass panels which retains or improve upon the benefits of existing dry-set rail systems, but which additionally allows for the simple replacement of the decorative side covers on the support rails in the event of damage, or simply to effect an aesthetic change of the rail support system, without the need to replace the entire system. The present invention obtains these results.
SUMMARY OF THE INVENTION
[0003] Briefly, the rail support system of the present invention comprises a pair of longitudinally extending rail sections joined together in an opposed parallel disposition so as to define an upper U-shaped channel for receiving an edge portion of a glass panel and a lower inverted U-shaped channel for receiving a portion of a window or door frame or other mounting structure, and an adjustable securement means for operatively connecting the two rail sections and drawing the sections together about the glass panel and to the mounting structure to effect securement of the support rail to the glass panel and mounting structure. A decorative replaceable side cover is slidably mounted on each rail section and a removable end plate is affixed to the ends of the joined sections, securing the side covers in place on the rails.
[0004] To provide the removable mounting of the decorative side covers, the opposed rail sections preferably each define a vertically extending cover support surface and a longitudinally extending groove formed in an upper surface of the rail section, inwardly of the cover support surface, for receiving in a sliding fitment a depending flange formed by the upper inner edge portion of one of the side covers. The lower edge portions of the side covers preferably each define an inwardly extending flange terminating in a raised lip portion adapted to extend about and mate with the lower end portion of the adjacent rail section whereby the decorative side covers can be slid onto the rails and secured in place by a pair of complimentary end plates that are removeably secured to the extended ends of the two joined rail sections. To remove the side covers, it is only necessary to remove one of the end plates from the joined rail sections and slide the side covers along and off the two rail sections.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is an end view of the rail support system of the present invention secured to the upper and lower end portions of a glass panel.
[0006] FIG. 2 is a cross-sectional end view of the lower portion of the rail support system of the present invention.
[0007] FIG. 3 is an exploded perspective view of an end portion of the glass panel rail support system of the present invention.
[0008] FIG. 4 is a partial perspective view of an alternate embodiment of a decorative side panel for use with the rail support system of the present invention.
[0009] FIG. 5 is a cross-sectional view of the support rail system of the present invention illustrating the use of an alternate side panel configuration.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0010] Referring now in detail to the drawings, the glass panel rail support system 10 of the present invention typically comprises a lower support rail 12 and an upper support rail 14 , as illustrated in FIG. 1 . In certain smaller applications, only the lower support rail 12 of the glass support system is employed. As both the upper and lower support rails are identical in configuration, the following description will be of the lower rail 12 only. It is to be understood, unless otherwise stated, that the terms upper and lower are used herein with respect to the orientation of the lower support rail 12 .
[0011] The lower support rail 12 of system 10 is adapted to be secured to and extend substantially the entire length of the bottom edge portion of a glass panel 100 . Support rail 12 comprises a male section 18 , a female section 20 and a clamping assembly 22 for joining together rail sections 18 and 20 , as will be described.
[0012] The male rail section 18 is preferably formed of extruded aluminum so as to be durable and light weight and defines an upper mounting portion 24 , a lower mounting portion 26 , a vertical wall 28 extending therebetween and a horizontal flange 30 projecting inwardly from wall 28 . The upper mounting portion 24 of the male rail section 18 defines a vertical upstanding arm 32 and a horizontal support surface 34 , the inner surface of arm 32 defining an upper clamping surface 33 . The lower mounting portion 26 of the male rail section 18 defines a vertical depending leg 36 and a horizontal wall 38 , the inner surface of leg 36 defining a lower clamping surface 37 and the inner surface of wall 38 defining a channel wall surface 39 .
[0013] The female rail section 20 also is preferably formed of extruded aluminum and defines an upper mounting portion 44 , a lower mounting portion 46 , a vertical wall 48 extending therebetween and upper and lower vertically spaced and inwardly projecting horizontal flanges 50 and 52 . The flanges 50 and 52 define a recess 54 therebetween sized so as to receive the horizontal flange 30 on the male rail section 18 , as seen in FIG. 1 . The upper mounting portion 44 of the female rail section 20 defines a vertical upstanding clamping surface 56 and a horizontal support surface 58 adapted to cooperate with surfaces 33 and 34 of the male rail section 18 to define the upper channel 40 for receiving a lower edge portion of glass panel 100 . The lower mounting portion 46 of female rail section 20 defines a vertical depending leg 60 and a horizontal wall 62 , the inner surface of leg 60 defining a lower clamping surface 61 that cooperates with surfaces 36 and 37 of the male rail section 18 to define channel 42 .
[0014] In the embodiment of the invention illustrated in the drawings, the clamping assembly 22 comprises a plurality of equidistantly spaced, threadably engaged, bolts 64 and nuts 66 that project through a corresponding plurality of aligned apertures 66 ′ and 66 ″ in the central walls 28 and 48 of rail sections 18 and 20 , as seen in FIG. 3 . Tightening of the nuts 66 about bolts 44 , preferably with a torque wrench to ensure uniform tightening, pulls the two rail sections together, causing the upper clamping surfaces 33 and 56 to bear against the sides of a gasket 70 and glass panel 100 and the lower clamping surfaces 37 and 61 to bear against the mounting surface to effect the securement of the rail 16 to the glass panel and mounting structure. A U-shaped gasket 70 formed of a suitable flexible rubber or plastic material preferably is provided in channel 40 between clamping surfaces 33 and 56 to enable the rail sections to securely grip the glass panel without scratching or otherwise damaging the panel.
[0015] As seen in FIG. 2 , with the rail sections joined together by the clamping assembly 22 , the extended end 38 ′ of the wall 38 on the male rail section 18 abuts the upper end of the clamping surface 61 on the female rail section 20 , defining the minimum widths of channels 40 and 42 that are sized for given glass panel thicknesses and for the thickness of the mounting surface to which the rail 12 is to be secured. However, the extended ends 50 ′ and 52 ′ of flanges 50 and 52 respectively are preferably spaced slightly from vertical wall 28 and the end 30 ′ of flange 30 is slightly spaced from the end 54 ′ of recess 54 so as to provide a relatively loose fit of the flange 30 on rail section 18 within the recess 54 of rail section 20 and allow for slight relative pivotal movement between the male and female rail sections 18 and 20 upon the tightening of nuts 66 on bolts 44 , to ensure a tight gripping of the glass panel by the two rail sections.
[0016] In the rail configuration illustrated in FIGS. 1-3 , rail walls 28 and 48 are preferably inwardly offset to define longitudinally extending recesses 72 and 74 in the two rail sections to accommodate the head portions 65 of bolts 64 and the nuts 66 in the clamping assembly 22 , as seen in FIG. 2 .
[0017] To provide the support rail 12 with a removable decorative side covers or faceplates 80 and 82 , the upper mounting portions of the male and female rail sections 18 and 20 each define a longitudinally extending groove 76 or 78 therein which, upon the joining together of the two rail sections, extend in parallel disposition along the length of the support rail 12 . The lower inner end portions of the depending legs 36 and 60 of the two rail sections define cutout areas 84 and 86 . The decorative covers 80 and 82 preferably conform to the general profile of the rail sections. Thus, in the rail configurations illustrated in FIGS. 1-3 , the side covers define vertical walls 80 ′ and 82 ′ that taper inwardly at 80 ″ and 82 ″ into inclined upper surfaces 80 ′″ and 82 ″′. The upper inner end portions of the inclined cover surfaces 80 ′″ and 82 ″′ define downwardly inclined flanges 88 and 90 respectively. The lower ends of the vertical cover walls 80 ′ and 82 ′ define inwardly extending flanges 92 and 94 that terminate in upstanding lips 96 and 98 . So configured, the decorative cover 80 can be easily slid over and along the male rail section 18 with its upper flange 88 being disposed within groove 76 and the lower flange 92 thereon extending under the lowermost end of the depending leg 36 of the male rail section 18 such that the upstanding lip 96 at the lower end of the cover is received within cutout area 84 of the leg so as to continue to provide a smooth wall surface for the lower channel 42 . Decorative panel 82 is similarly slid onto and over the female rail section with the upper flange 94 thereon disposed within groove 78 and the lower panel flange 94 extending about the underside of leg 60 such that the upstanding lip 98 is received within cutout area 86 . When the panels are slid into position such that the extended ends thereof are substantially flush with the extended ends of the opposed rail sections, end plates 102 and 104 are removably secured to the extended ends of the support rail 12 , preferably by means of threaded fastening members 106 , to prevent any relative sliding movement between the decorative side covers and the rail section. So secured, panels 80 and 82 provide the glass panel support rail system of the present invention with an attractive appearance and allow the user to readily replace the panels in the event of scratching or other damage to the existing side covers or to change the color or ornamental appearance of the rails by simply removing the end plates from the rails, sliding the old covers off the rails, sliding the new panels onto the rails and replacing the end plates.
[0018] The above described side cover configuration is well suited for aluminum anodized finishes or for painting. However, if the user desires a stainless steel, polished brass, satin or copper finish, the use of removable cladded side covers is preferable to provide uniform coloration. An example of such a cladded side cover 200 is illustrated in FIG. 4 . As seen therein, a backing 201 , preferably formed of extruded aluminum and having the same configuration as side cover 80 and 82 is employed and a thin outer metal sheet 202 formed of the desired outer cover material is adhered to the outer surface of the backing 201 by means of double-sided adhesive tape 202 or other suitable adhesive. As seen in FIG. 4 , the outer metal sheet 202 extends adjacent to the flat surface on the backing 201 and the securement of the cladded cover 200 is provided by the flange 204 and upstanding lips 206 formed by the backing 201 in the same manner as described above with respect to decorative side plates 80 and 82 .
[0019] While the present invention was illustrated with respect to a support rail configuration employing a tapered upper portion, the invention could also be employed with rail sections having different configurations, different clamping mechanisms and different side cover configurations.
[0020] FIG. 5 illustrates the use of a different side cover configuration with the same support rail sections 18 and 20 illustrated in FIGS. 1-3 , giving the support rail 212 an overall rectangular appearance. As seen in FIG. 5 , the side panels 280 and 282 define vertical side walls 280 ′ and 282 ′ that extend the entire height of the support rail 212 and are bent inwardly at their upper ends 280 ″ and 282 ″ respectively to define inwardly extending upper cover surfaces 280 ″′ and 282 ′″. Upper surfaces 280 ″′ and 282 ″′ terminate at their inner ends in downwardly extending flanges 288 and 290 respectively. Flanges 288 and 290 are slidably received in the grooves 76 and 78 in the upper mounting portions of the male and female rail sections 18 and 20 as previously discussed in connection with the depending flanges 88 and 90 on side covers 80 and 82 . The lower ends of the vertical side walls of side covers 280 and 282 ′ define inwardly extending flanges 292 and 294 that terminate in upstanding lips 296 and 298 that cooperate with the lower ends of the rail sections 18 and 20 in the same manner as previously described in connection with the side covers 80 and 82 . Thus, by varying the configuration of the walls of the side covers, the outer configuration of the support rails can be varied as well as the decorative finish thereon.
[0021] Other rail configurations also could be employed in the present invention, as could different mechanisms for drawing together the two rail sections to effect securement of the rails to the glass panels and mounting surfaces. Insofar as such changes and modifications are within the purview of the appended claims, they are to be considered as part of the present invention. | A support rail having replaceable decorative side covers for mounting a glass panel on a window, door frame or other mounting structure. The support rail includes opposed longitudinally extending rail sections that cooperate to define an upper U-shaped channel for receiving an edge portion of a glass panel and a lower inverted U-shaped channel for receiving a portion of a mounting structure. A clamping assembly carried by the rail sections operatively connects the sections together to effect securement of the rail to the glass panel and mounting structure. A pair of decorative side covers are slidably mounted along the rail sections by means of flanges formed at the upper and lower ends of the side covers that project into grooves formed in the rail section. A pair of end plates are removably mounted on the rail sections for holding the side covers in place on the rail sections and allowing the removal thereof. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to orthopaedic implants, and, more particularly, to orthopaedic bodies which are inserted into an opening in a bone during orthopaedic surgery.
2. Description of the Related Art
An orthopaedic implant is typically implanted into an end of a bone, such as the proximal end of a femur. Occasionally, the bone includes an opening which is larger than necessary to receive the orthopaedic implant. For example, an end of a bone which is to receive a revision implant during a revision orthopaedic surgery may include an opening which is larger than the new revision implant which is to be implanted. As another example, a bone may include an opening which is larger than an implant as a result of a disease condition such as cancer. It is occasionally thus necessary to fill an enlarged opening in a bone to a desired extent to form a "neo-medullary" canal of appropriate size and shape to receive an implant.
A known method of filling an opening in a bone is to impact bone chips into the intramedullary (IM) canal to partially fill the IM canal. Such bone chips are commonly obtained from similar bones retrieved from donor cadavers. Such bone chips are known as "allograft" bone chips since they are obtained from cadavers. The bones are normally kept in a frozen state within a hospital and the surgeon grinds up the bones immediately prior to surgery. The bone chips are then poured into the opening in the bone and impacted in the opening using successively smaller tamps until a neo-medullary canal of proper size and shape is formed. A layer of bone cement is injected into the neo-medullary canal and the implant is cemented into the bone.
A problem with using allograft bone chips as described above is that the effectiveness of the technique is in large part dependent upon the skill of the surgeon. The size and shape of the bone particles may vary dependent upon how the bone particles are formed. Additionally, the type of tamp and force used during the tamping affects the impaction of the bone particles within the opening in the bone.
What is needed in the art is a surgical technique which allows a surgeon to more easily use an impaction allograft technique, and which reduces variability associated with presently uncontrolled parameters.
SUMMARY OF THE INVENTION
The present invention provides an impaction allograft form with a plurality of bone particles which are frozen together into a pre-shaped form which may be inserted into an opening in a bone during orthopaedic surgery.
The invention comprises, in one form thereof, a method of performing orthopaedic surgery on a bone, including the steps of: preparing an allograft form with a predetermined outside shape and including a plurality of allograft bone particles; freezing the allograft form; placing the frozen allograft form in an opening in the bone; and impacting the frozen allograft form within the opening to cause the allograft form to at least partially fill the opening.
The invention comprises, in another form thereof, an orthopaedic body for insertion into an opening in a bone during orthopaedic surgery. The orthopaedic body includes an impaction allograft form with a plurality of allograft bone particles frozen together with a predetermined outside shape. The form includes a cannulation hole extending therethrough.
An advantage of the present invention is that the allograft form can be installed into an opening in a bone as a preformed body.
Another advantage is that the quality and consistency of the allograft form can be better controlled.
Yet another advantage is that the time necessary to impact the allograft bone within the bone is reduced.
A further advantage is that the allograft form can be coated or mixed with a bone growth enhancer to stimulate bone growth into the allograft form.
A still further advantage is that different allograft forms can be made with different outside shapes which allow the form to optimally fit the opening in the bone.
BRIEF DESCRIPTION OF THE DRAWINGS
The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent and the invention will be better understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is a perspective view of a femur having an opening into which a guide wire and plug are inserted;
FIG. 2 illustrates an embodiment of an allograft form of the present invention being slid over the guide wire and placed into the opening in the femur;
FIG. 3 illustrates impaction of the allograft form using a cylindrical tamp;
FIG. 4 illustrates further impaction of the allograft form using an implant-shaped tamp;
FIG. 5 illustrates an implant in the femur after the allograft form has been impacted; and
FIG. 6 illustrates another embodiment of an allograft form of the present invention.
Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate one preferred embodiment of the invention, in one form, and such exemplifications are not to be construed as limiting the scope of the invention in any manner.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings, and more particularly to FIGS. 1-5, an embodiment of an impaction allograft form 10 of the present invention and a method of performing orthopaedic surgery using allograft form 10 will be described. Allograft form 10 shown in FIGS. 1-4 is illustrated for use with a femur 18. However, it is to be understood that allograft form 10 and the method of manufacture and surgery using allograft form 10 may be carried out on any bone where use of an impaction allograft technique is necessary or desirable.
During a normal orthopaedic surgery using allograft bone particles to fill in part of an opening in a bone such as femur 18, a plug 12 is attached to a guide wire 14, such as by piercing a sharpened end of guide wire 14 into plug 12. Plug 12 is selected with an outside diameter which closely approximates the inside diameter of an IM canal 16 within femur 18. Guide wire 14 is used to place plug 12 within IM canal 16 in femur 18. Plug 12 is inserted from proximal end 20 of femur 18 to a depth which is beyond the length of a femoral implant 22 (FIG. 5) to be implanted within femur 18. Normally, after plug 12 and guide wire 14 are placed within femur 18, loose bone chips are poured into opening 24 in proximal end 20 of femur 18 and impacted within opening 24 using successively smaller tamps until opening 24 is filled to a desired amount.
When using loose bone chips as described above, the quality and consistency of the bone chips varies depending upon the equipment used to make the bone chips, the skill of the surgeon, the impaction technique utilized, etc. Accordingly, the results of conventional impaction allograft techniques very widely dependent upon the skill of the surgeon and other uncontrolled factors.
According to an aspect of the present invention, loose bone particles are not poured into opening 24 of femur 18. Rather, a preformed impaction allograft form 10 is provided. Allograft form 10 can have any predetermined outside shape and includes a plurality of allograft bone particles, a portion of which are shown and referenced as 26. Rather than being formed during surgery by a surgeon, bone particles 26 are formed in a manufacturing setting under much tighter controls and tolerances. Bone particles 26 may be screened or otherwise sorted so that the particles are of substantially uniform size and shape. In the embodiment shown, bone particles 26 are in the form of bone chips with a controlled size and shape. The size and shape of bone particles 26 may vary from one allograft form 10 to another so that a surgeon may select an allograft form 10 with bone particles 26 which are suitable for a specific application.
Allograft form 10 includes a cannulation hole 28 which extends the longitudinal length thereof, and which has a diameter which is at least slightly larger than the diameter of guide wire 14. Cannulation hole 28 allows allograft form 10 to be slide over guide wire 14, as indicated by directional arrow 30. Since guide wire 14 substantially coincides with an anatomical axis 29 of femur 18, cannulation hole 28 also substantially aligns with anatomical axis 29 when allograft form 10 is slid over guide wire 14.
Allograft form 10 may also include a coating of a bone growth enhancer 32 over the exterior thereof. Bone growth enhancer 32 stimulates live bone in femur 18 to grow into the porous surface of allograft form 10, thereby interlocking the impacted allograft bone particles with femur 18. Bone growth enhancer 32 is in the form of either hydroxylapatite (HA) or hydroxylapatite-tricalciumphosphate (HATCP) in the embodiment shown; however, other bone growth enhancers may be utilized such as bone morphogenic protein (BMP).
As indicated above, allograft form 10 may be configured with any suitable exterior size and shape. In the embodiment shown in FIGS. 1-4, allograft form 10 has a cylindrical outside shape with an outside diameter which is just slightly smaller than the inside diameter of IM canal 16 of femur 18. A plurality of allograft forms 10 may be provided with different diameters so that a surgeon may select an allograft form 10 which fills opening 24 in femur 18 to a desired extent More than one graft form 10 may be used advantageously to fill opening 24 by using forms with different diameters at different locations within opening 24.
During manufacture, bone particles 26 are formed by grinding, machining, etc., selected bones such as femurs. The bone particles may be screened, sorted or graded so that bone particles 26 of a selected size and shape are segregated together. Bone chips 26 are then placed within a mold (not shown) having a shape which is complimentary to the desired shape of an allograft form 10 which is to be manufactured. Bone particles 26 may be loosely placed within the mold, but are preferably compressed within the mold to a desired extent. The mold with the bone chips therein is then frozen and the moisture within the bone chips bonds the bone chips together when in a frozen state. It is also possible to add a liquid such as sterile water to the bone chips within the mold to ensure that the bone chips freeze together. When frozen, allograft form 10 is removed from the mold and placed within a freezer for further use by a surgeon. Alternatively, dependent upon factors such as moisture content, particle size and shape, and/or the presence of a temporary binding additive, it may also be possible to compact bone particles within the mold and remove allograft form 10 from the mold prior to freezing.
During surgery, guide wire 14 is inserted into plug 12. Plug 12 is then inserted into IM canal 16 of femur 18 to a proper depth, as described above and shown in FIG. 2. Allograft form 10 is then slid over guide wire 14 such that cannulation hole 28 surrounds guide wire 14. Allograft form 10 is then slid into opening 24 of femur 18, as indicated by arrow 30 in FIG. 2. When allograft form 10 is placed within IM canal 16 (FIG. 3), a series of progressively larger tamps 34 and 36 are used to both axially and radially impact allograft form 10 within opening 24 to cause allograft form 10 to at least partially fill opening 24 to a desired extent. Tamp 34 has a cylindrical shape with an outside diameter which is larger than the inside diameter of cannulation hole 28 in allograft form 10. Preferably, the outside diameter of cylindrical tamp 34 is selected so that the leading end 38 of cylindrical tamp 34 at least partially slides into cannulation hole 28 to radially expand allograft form 10 as tamp 34 is repeatedly moved in an axial direction 30 against allograft form 10. A series of cylindrical tamps 34 with progressively larger diameters may be utilized if desired.
Tamp 36 illustrated in FIG. 4 has an outside shape which approximates an implant 22 to be implanted within femur 18. Tamp 36 is normally used after one or more cylindrical tamps 34 are used. However, implant-shaped tamp 36 may be used in place of cylindrical tamp 34.
After allograft form 10 has been expanded to some extent as shown in FIG. 4, tamp 36 may be used to further expand allograft form 10 within opening 24 and define a neo-medullary canal for receiving an implant 22 to be implanted within femur 18. A series of tamps 36 with progressively larger outside sizes may be used, as indicated by phantom line 40 in FIG. 4. Additional allograft forms 10 may be inserted over guide wire 14 as necessary. It is also possible to pour in a limited amount of loose bone particles 26 at proximal end 20 during the final impacting stages of bone particles 26 within femur 18.
After bone particles 26 are impacted within IM canal 16 to a desired extent (FIG. 5), bone cement 42 is placed within neo-medullary canal 48. Preferrably the bone cement is pressurized such that it is incorporated into, or interdigitates to some extent, with the allograft. A distal centralizer 44 is placed over the distal end of stem 46 of implant 22 to keep the distal end of stem 46 substantially centered within neo-medullary canal 48 such that bone cement 42 substantially surrounds stem 46. Implant 22 may be oriented to obtain a proper alignment relative to an acetabular cup with which it mates, in known manner. Implant 22 is then placed into neo-medullary canal 48 until proximal end 50 extends from opening 24 in femur 18 a desired amount.
FIG. 6 illustrates another embodiment of an impaction allograft form 52 of the present invention. Allograft form 52 has an outside shape which approximates the shape of the IM canal. Such a canal shaped allograft form advantageously has features such as a medial curve, trapezoidal cross-section, and/or a distal-to-proximal anterior/posterior flare so that the form fills the canal as much as possible and matches the known canal geometry as closely as possible. Final fitting is accomplished by tamping as described above. Alternatively, the allograft form 52 has an outside shape which approximates the shape of the implant 22 to be implanted within femur 18. Allograft form 52 includes a plurality of bone particles 26 with a controlled size and shape, similar to bone particles 26 shown in FIGS. 1-5. Allograft form 52 also includes a cannulation hole 54, similar to carmulation hole 28 of allograft form 10. Allograft form 52 may be formed with any suitable size such as the larger size indicated by phantom line 56, so that a surgeon may select an allograft form 52 which better fills opening 24 in femur 18 to a desired extent.
While this invention has been described as having a preferred design, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims. | A method of performing orthopaedic surgery on a bone includes the steps of: preparing an allograft form including a plurality of allograft bone particles with a predetermined outside shape (e.g., cylindrical or implant shaped); freezing the allograft form; placing the frozen allograft form in an opening in the bone; and impacting the frozen allograft form within the opening to cause the allograft form to at least partially fill the opening. The form includes a cannulation hole extending therethrough. | 8 |
CLAIM OF PRIORITY
The present application claims the benefit of priority to U.S. Provisional Application No. 61/764,044 filed on Feb. 13, 2013, which is incorporated herein in its entirety by reference.
FIELD OF THE INVENTION
The present invention relates to the operation of hydraulic clutches and more specifically to a method of prefilling a hydraulic clutch.
BACKGROUND OF THE INVENTION
In the shifting of a stepped ratio transmission, clutches are engaged and disengaged to allow for power transfer through a plurality of different power paths. Typically, when a shift is performed, one clutch is disengaged (also known as an off-going clutch) by decreasing an oil pressure on a piston of the clutch and another clutch is engaged (also known as an oncoming clutch) by increasing a pressure on a piston of the clutch. During an overlap shift, this process happens simultaneously in a coordinated manner. In a filling phase of a shift, the piston of the ongoing clutch is positioned adjacent a plurality of friction plates by regulating a pressure of the transmission fluid.
One of the problems with filling the ongoing clutch is a repeatability of the filling process. For a system that is actuated using feedforward control, a changing system is problematic. Feedforward control means that the system responds to a control signal in a predefined way, and does not take into account a reaction based on a load. A needed width (also known as a length in time) of a pressure profile that is used to actuate a piston depends on an amount of air that is present in a plurality of hydraulic lines associated with the piston and a total length of the hydraulic lines. There is also considerable variability in an amount of oil which is present in the hydraulic lines and in the clutch. This is a result of temperature, rotational speed, a varying amount of time between shifts, and pressure dependent draining and leakage. Furthermore, some mechanical parameters of the system are uncertain. One such parameter is a stiffness of a return spring, which has a large tolerance in production. While some of these effects can be counteracted using a calibration procedure, the system is hard to accurately characterize and the system will still exhibit inconsistent behavior. Consequently, a shift quality of the system is affected negatively.
A current state of the art of control techniques does not account for a draining of the clutch. A set of optimized parameters for a filling phase is determined during a calibration session in which the clutch is repeatedly opened and closed. The process is performed with a fixed time between the opening and closing, ignoring the effect that the time between shifts has on a behavior of the system. While this method is also performed at a relatively fixed temperature, a correction factor is used during the filling process to account for the temperature.
In conclusion, the state of the art disregards for the effect of draining, aside from a temperature dependent correction on the filling time, instead of a time dependent correction. Shifts are performed using feedforward control with a considerably changing reaction. As a result, poor shifts occur in situations where the conditions vary from the parameters present during the calibration. However, even when the calibration parameters are present, large variability can have a detrimental effect on the shift quality. FIG. 1 illustrates several consecutive fillings that were performed with the same or similar pressure signals, and are shown using dashed lines. As shown in FIG. 1 , a plurality of measured response to the pressure signals, shown using solid lines, differ vastly.
The measured response is dependent on a temperature as well as a time between shifts. A precise correction for both temperature and time between shifts is needed. The state of the art only contemplates temperature compensation. While a compensation for the time between shifts could also be added, the number of parameters influencing the system makes such a task increasingly complex. Furthermore, it is expected that large variability would still remain, despite compensating for the time between shifts.
It would be advantageous to develop a method of prefilling a hydraulic clutch that increases a repeatability of a clutch filling process, accounts for a draining of the clutch, accounts for a temperature at which a shift is performed, and accounts for a time between shifts.
SUMMARY OF THE INVENTION
Presently provided by the invention, a method of prefilling a hydraulic clutch that increases a repeatability of a clutch filling process, accounts for a draining of the clutch, accounts for a temperature at which a shift is performed, and accounts for a time between shifts, has surprisingly been discovered.
In one embodiment, the present invention is directed to a method for controlling a wet clutch. The clutch comprises a pump, a piston, and a fluid conduit. The pump provides a housing with a hydraulic fluid. The piston is movably disposed in the housing. The piston is movable into an extended position by a preloaded spring and into a retracted position by applying an engagement pressure on the piston by the hydraulic fluid. In the retracted position torque is transmittable through the clutch. The fluid conduit connects the pump and the housing. The method comprises the steps of prefilling the clutch by applying a prefill pressure on the piston, thereby prefilling the fluid conduit line and the housing with the hydraulic fluid. The prefill pressure is lower than the engagement pressure required to move the piston into the retracted position.
In another embodiment, the present invention is directed to an apparatus for controlling a wet clutch. The apparatus includes a pump, a piston, a fluid conduit, and an electroproportional valve. The pump provides a housing with a hydraulic fluid. The piston is movably disposed in the housing. The piston is movable into an extended position by a preloaded spring and into a retracted position by applying a engagement pressure on the piston by the hydraulic fluid. In the retracted position torque is transmittable through the clutch. The fluid conduit connects the pump and the housing. The electroproportional valve is disposed between the pump and the housing for regulating the pressure of the hydraulic fluid in the housing. The electroproportional valve is configured to prefill the housing by applying a prefill pressure on the piston, thereby prefilling the fluid conduit and the housing with the hydraulic fluid. The prefill pressure is lower than the engagement pressure required to move the piston into the retracted position.
Various aspects of this invention will become apparent to those skilled in the art from the following detailed description of the preferred embodiment, when read in light of the accompanying drawings.
BRIEF DESCRIPTION OF THE FIGURES
The above, as well as other advantages of the present invention will become readily apparent to those skilled in the art from the following detailed description when considered in the light of the accompanying drawings in which:
FIG. 1 is a graph which illustrates several pressure profiles of an engaging hydraulic piston associated with a wet clutch known in the prior art;
FIG. 2 is a schematic illustration of a multi-plate clutch system according to the present invention;
FIG. 3 is a graph which illustrates several pressure profiles of an engaging hydraulic piston associated with a wet clutch, the hydraulic position engaging according to a method of the present invention;
FIG. 4 is a graph which illustrates a self-generated hydraulic force with respect to rotational speed of the multi-plate clutch system shown in FIG. 3 ; and
FIG. 5 is a graph which illustrates an increase in hydraulic force with respect to initial pressure and a spring force of the multi-plate clutch system shown in FIG. 3 .
DETAILED DESCRIPTION OF THE INVENTION
It is to be understood that the invention may assume various alternative orientations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are simply exemplary embodiments of the inventive concepts defined herein. Hence, specific dimensions, directions or other physical characteristics relating to the embodiments disclosed are not to be considered as limiting, unless expressly stated otherwise.
FIG. 2 illustrates a multi-plate clutch system 10 . The multi-plate clutch system 10 is an electrohydraulically actuated wet plate clutch system. The multi-plate clutch system 10 comprises a sump 12 , a high pressure pump 14 , an electroproportional valve 16 , an accumulator 18 , a piston assembly 20 , a clutch assembly 22 , a controller 24 , and a plurality of fluid conduits 26 . The high pressure pump 14 is in fluid communication with the sump 12 and the electroproportional valve 16 . The piston assembly 20 is in fluid communication with the electroproportional valve 16 and the accumulator 18 . The clutch assembly 22 is disposed adjacent to and may be placed in contact with a portion of the piston assembly 20 . The controller 24 is in communication with the electroproportional valve 16 .
The sump 12 is a container in which a hydraulic fluid is stored. The sump 12 is in fluid communication with the high pressure pump 14 . One of the fluid conduits 26 affords fluid communication between the sump 12 and the high pressure pump 14 . A filter 28 forms a portion of the fluid conduit 26 between the sump 12 and the high pressure pump 14 . The sump 12 includes a breather 30 , to facilitate fluid communication between an ambient environment of the multi-plate clutch system 10 and an interior of the sump 12 .
The high pressure pump 14 is a fixed displacement hydraulic pump. The high pressure pump 14 is in fluid communication with the sump 12 and the electroproportional valve 16 . As a non-limiting example, the high pressure pump 14 may generate a pressure of about 20 bar. One of the fluid conduits 26 affords fluid communication between the high pressure pump 14 and the electroproportional valve 16 . A filter 32 forms a portion of the fluid conduit 26 between the high pressure pump 14 and the electroproportional valve 16 . A pressure relief valve 33 is present to limit a pressure difference across the filter 32 created by the high pressure pump 14 , such as if the filter 32 becomes obstructed. Further, it is understood that the high pressure pump 14 may also be in fluid communication with a pressure limiting valve (not shown). The pressure limiting valve limits a pressure within the fluid conduit 26 between the high pressure pump 14 and the electroproportional valve 16 .
The electroproportional valve 16 is a hydraulic valve in fluid communication with the high pressure pump 14 , the piston assembly 20 , and the accumulator 18 . The electroproportional valve 16 is in electrical communication with the controller 24 . The electroproportional valve 16 is supplied with a pulse width modulated signal to apply a current to a solenoid 34 forming a portion of the electroproportional valve 16 . Upon receipt of the pulse width modulated signal, the electroproportional valve 16 may be placed in at least a partially open position. In the open position, the electroproportional valve 16 afford fluid communication between the fluid conduit 26 between the high pressure pump 14 and the electroproportional valve 16 and a fluid conduit 26 between the electroproportional valve 16 , the piston assembly 20 , and the accumulator 18 . It is understood that the controller 24 may adjust the pulse width modulated signal to adjust a pressure within the fluid conduit 26 between the electroproportional valve 16 , the piston assembly 20 , and the accumulator 18 by placing the electroproportional valve 16 in at least the partially open position. As shown in FIG. 2 , the electroproportional valve 16 includes a draining orifice 36 . A flow of hydraulic fluid through the draining orifice 36 is dependent on a pressure within the electroproportional valve 16 , but also a viscosity of the hydraulic fluid and a temperature of the hydraulic fluid.
The accumulator 18 is a hydraulic device that dampens rapid changes in pressure (such as pressure drops or pressure peaks) within the fluid conduit 26 between the electroproportional valve 16 and the piston assembly 20 . The accumulator 18 facilitates smooth operation of the clutch assembly 22 . The accumulator 18 is in fluid communication with the piston assembly 20 and the electroproportional valve 16 . As shown in FIG. 2 , the accumulator 18 includes a draining orifice 38 . A flow of hydraulic fluid through the draining orifice 38 is dependent on a pressure within the fluid conduit 26 between the electroproportional valve 16 and the piston assembly 20 , but also a viscosity of the hydraulic fluid and a temperature of the hydraulic fluid.
The piston assembly 20 comprises a housing 40 , a piston 42 , a piston rod 44 , and at least one return spring 46 . The housing 40 is a hollow, cylindrical member in fluid communication with the electroproportional valve 16 through the fluid conduit 26 between the electroproportional valve 16 , the piston assembly 20 , and the accumulator 18 . The piston 42 is a cylindrical member sealingly and slidingly disposed within the housing 40 . The piston rod 44 is an elongate member in driving engagement with the piston 42 . The piston rod 44 is sealingly and slidingly disposed through the housing 40 . The at least one return spring 46 is a biasing member disposed between the piston 42 and the housing 40 . When pressure at or above an engagement threshold is applied to the housing 40 by the electroproportional valve 16 , the pressure within the housing 40 urges the piston 42 and the piston rod 44 towards the clutch assembly 22 , while also compressing the at least one return spring 46 . When pressure at or below a disengagement threshold is present within the housing 40 , the at least one return spring 46 urges the piston 42 and the piston rod 44 into a starting position. As shown in FIG. 2 , the housing 40 includes a draining orifice 48 . A flow of hydraulic fluid through the draining orifice 48 is dependent on a pressure within the housing 40 , a portion of which may be generated by centripetal forces, but also a viscosity of the hydraulic fluid and a temperature of the hydraulic fluid.
The clutch assembly 22 comprises a housing 50 , a first plurality of plates 52 , a second plurality of plates 54 , and a pressure plate 56 . The housing 50 is a hollow member into which a transmission fluid is disposed. The first plurality of plates 52 and the second plurality of plates 54 are rotatingly disposed within the housing 50 . The pressure plate 56 is disposed adjacent the first plurality of plates 52 and the second plurality of plates 54 and may be urged towards the first plurality of plates 52 and the second plurality of plates 54 by the piston rod 44 . The first plurality of plates 52 is interleaved with the second plurality of plates 54 . Within the clutch assembly 22 , an input member (not shown) is drivingly engaged with one of the first plurality of plates 52 and the second plurality of plates 54 and an output member (not shown) is drivingly engaged with a remaining one of the first plurality of plates 52 and the second plurality of plates 54 . A pressure in which the piston rod 44 contacts the pressure plate 56 and where additional pressure would result in at least variable driving engagement between the first plurality of plates 52 and the second plurality of plates 54 is known as a kiss pressure. At pressures greater than the kiss pressure, torque is able to be transferred from the first plurality of plates 52 to the second plurality of plates 54 . When pressure at or above the engagement threshold is applied to the housing 40 by the electroproportional valve 16 , the pressure within the housing 40 urges the piston 42 and the piston rod 44 towards the clutch assembly 22 , applying a pressure to the first plurality of plates 52 and the second plurality of plates 54 through the pressure plate 56 . In response to the pressure, the first plurality of plates 52 becomes at least variably drivingly engaged with the second plurality of plates 54 , causing the input member to be at least variably drivingly engaged with the output member.
It is understood that the schematic illustration shown in FIG. 2 is merely exemplary in nature, and that the invention may be adapted for use with any wet plate clutch system.
A method which includes the use of a prefill pulse at discrete times in relation to a shift, allows the piston assembly 20 and the clutch assembly 22 to be operated in a manner having increased repeatability, through accurate positioning of the piston 42 prior to initiating at least variable driving engagement between the first plurality of plates 52 and the second plurality of plates 54 . As a result of accurately positioning the piston 42 prior to initiating at least variable driving engagement between the first plurality of plates 52 and the second plurality of plates 54 , a shift quality of a vehicle (not shown) the method is incorporated in is improved.
The method which includes the use of a prefill pulse is based on an understanding of the components of the multi-plate clutch system 10 and how the components of the multi-plate clutch system 10 react to a filling profile.
The method relies on the piston 42 to be accurately positioned using the return spring 46 . Further, an assumption needs to be made that an amount of hydraulic fluid between the piston 42 and the electroproportional valve 16 is relatively constant. This means that the fluid conduit 26 between the electroproportional valve 16 and the piston assembly 20 is full of hydraulic fluid. Through the application of a small pressure to the piston 42 , the fluid conduit 26 between the electroproportional valve 16 and the piston assembly 20 is filled. However, the small pressure must not fully compensate for the force exerted by the return spring 46 .
Under such an assumption, the piston 42 is able to react very quickly to the electroproportional valve 16 when a filling profile is performed.
Flow (q s ) through the electroproportional valve 16 can be calculated through Bernoulli's principle (or the deduced law of Torricelli), which is shown in Equation 1. In Equation 1, flow is represented by q s , A 0 is a surface area of a valving orifice, P s and P c are respectively pressures inside and outside of a pressure vessel and K 0 is a factor depending on a density of the fluid. A correction factor may be added to account for a viscosity and a shape of the valving orifice.
q s =K 0 A 0 sgn ( P s −P c )√{square root over (|P s −P c |)} Equation 1
The method also accounts for an effect of a pressure rise that occurs at an outer radius of the housing 50 of the clutch assembly 22 that occurs due to centripetal forces. Equation 2 is an equation for calculating a radial pressure distribution in a presence of rotational speed of the clutch assembly 22 . Equation 2 relies on an assumption that the transmission fluid within the housing 50 is rotating at the same speed as one of the first plurality of plates 54 and the second plurality of plates 56 . Furthermore, there is an assumption that the housing 50 is filled with transmission fluid. Such an assumption is a desired and an expected situation. Such an assumption also exhibits a greatest amount of pressure, indicating that the situation should be accounted for in the method. It is also assumed that the electroproportional valve 16 compensates for a pressure loss due to fluid flow.
Equation 2 does not account for pressure dependent leaking which is more properly accounted for using Equation 1. However, pressure dependent leaking is largely dependent on a configuration of a multi-plate clutch system.
P ( r )=½ρω 2 r 2 +P 0 Equation 2
In Equation 2, the pressure at the center of clutch assembly 22 is represented by P 0 , ρ is a density of the transmission fluid, ω is a rotational speed of one of the first plurality of plates 54 and the second plurality of plates 56 , and r is a radius at which P(r) is calculated. The force applied by the hydraulic fluid can be calculated by integrating the pressure distribution along the effective surface of the pressure plate 56 . A result is shown in Equation 3.
In Equation 3, r o represents an outer radius and r i represents an inner radius The force is a function of initial pressure, a size of the clutch, and rotational speed. The force should remain smaller than a force of the return spring 46 at a fully extended position.
F =¼ρω 2 π( r 0 4 −r i 4 )+ P 0 ρ( r 0 2 −r i 2 ) Equation 3: Force Applied to Piston by ATF
FIG. 3 illustrates several consecutive fillings that were performed according to the method which includes the use of a prefill pulse. The fillings were performed with the same or similar pressure signals, and are shown using dashed lines. As shown in FIG. 3 , a plurality of measured response to the pressure signals, shown using solid lines, are fairly consistent.
As can be seen from FIG. 3 , with a prefill pulse implemented, the filling is much more consistent. As a non-limiting example, in FIG. 3 , the prefill pulse is shown to occur at 0.7 seconds in the pressure signal; the measured responses to the prefill pulse are shown to occur closer to 0.8 seconds. Even with varying fill times (represented using dashed lines), a consistent behavior is achieved. The prefill pulse could be made dependent on a time between shifts or temperature, but depending on the implemented solution, corrections are unnecessary. As a result of implementing the prefill pulse, the filling is only dependent on temperature, there is a vastly faster pressure response in all situations, and the response of the multi-plate clutch system 10 is much more repetitive. Control of the multi-plate clutch system 10 is also simplified as a result of only requiring temperature compensation. The measured responses are more repeatable, and allow for a greatly improved robustness of the multi-plate clutch system 10 .
It is possible to implement the method which includes the use of the prefill pulse in a plurality of different ways. The method which includes the use of the prefill pulse can be implemented by incorporating the prefill pulse into a shifting procedure, by executing the prefill pulse periodically for all disengaged clutches, by executing the prefill pulse to only a set of relevant clutches, and adapt the prefill pulse as a continuous signal
When the prefill pulse is incorporated into a shifting procedure, the prefill pulse can be treated as an extension of a filling phase. While such an implementation achieves a desired goal of having repetitive behavior and a known starting point for the filling phase, it also causes the shifting procedure to take a longer amount of time.
The prefill pulse may be sent out periodically for all disengaged clutches. A period is then defined as an amount of time for which the variability on the clutch filling is within an acceptable parameters or a time in which the resulting variation can be characterized in a reliable way. While this method does not increase a time of the shifting procedure, the initial conditions of a given clutch may not be as consistent.
The prefill pulse may only be applied to a set of relevant clutches, instead of applying the prefill pulse to all of the clutches. Depending on a type of transmission, identifying the set of relevant clutches that will be used is easily determined. As the prefill pulse is not executed for all of the clutches, there are fewer losses without a loss of performance and repeatability. Building further on such an implementation, the prefill pulse may also be executed on an even more relevant set of clutches, such as the next clutch to be used. Instead of performing the prefill pulse periodically, it is done in time for the shift. In embodiments of the invention in which an automatic shift scheduler is used, predicting a timing of a shift is easily determined. While more difficult; such a method may also be adapted for use with a manual transmission.
Lastly, the prefill pulse can also be executed as a continuous signal. By using a continuous signal, the method ensures that the fluid conduits are filled at substantially all times and that each of the clutches is in a substantially fixed and known condition. In view of the centrifugal effect described hereinabove, care must be taken so that a pressure is low enough proportional to the speed so that the pressure does not cause the piston to move. The continuous signal which provides the prefill pulse can be performed for all clutches or for only the relevant ones, either at all times or just before a shifting procedure.
In use, the controller 24 sends out the prefill pulse or the continuous signal as a feedforward pressure signal. Depending on the type of implementation, the controller 24 calculates an amplitude of the signal based on a number of parameters. As non-limiting examples, these parameters include a time between shifts, a temperature, and a rotational speed. After the prefill pulse, or during the continuous signal, the pressure is held at a pressure that is low enough not to move the piston 42 against the force applied by the return spring 46 at a maximum extended position.
This pressure depends on a rotational speed of the transmission fluid within the clutch assembly 22 . Due to centripetal forces, the pressure in the transmission fluid can increase along an outer edge of the housing 50 , as described hereinabove. Such a pressure should not be too high as not to override the force applied by the return spring 46 which holds the piston 42 back. The relation between rotational speed and pressure along the radius can be calculated as described hereinabove and shown in Equation 1. Equation 1 can be experimentally verified by determining a pressure at which the piston 42 starts moving at a given rotational speed. The radial pressure can then be integrated along a useful radius of the pressure plate 56 and compared to a pressure necessary to move the piston 42 , divided by the effective surface of the pressure plate 56 .
A relationship between a generated hydraulic force with respect to rotational speed is shown in FIG. 4 . In FIG. 4 , an inner and outer radius, an initial pressure, and a spring force have been maintained constant. The effect of the rotational speed, however, is substantial and cannot be neglected.
FIG. 5 illustrates an increase in hydraulic force with respect to initial pressure. In FIG. 5 , the rotational speed is maintained as a constant. The force of the return spring 46 at a fully extended position is also indicated in FIG. 5 . The controlled variable is indicated as the initial pressure on a horizontal axis. From FIG. 5 , it is clear that the initial pressure should be calculated so that a resulting hydraulic force is smaller than the force applied by the return spring 46 .
By using the strategies and operation described above, the multi-plate clutch system 10 according to the invention has greatly improved repeatability. The improved repeatability results in improved performance of shift control algorithms and consequently shift quality. The multi-plate clutch system 10 according to the invention eliminates variability without requiring a complex scheduling of several parameters as known in the prior art. In the multi-plate clutch system 10 according to the invention, the filling phase only has to be scheduled in terms of a single parameter, temperature. Accordingly, a control of wet plate clutch system such as the multi-plate clutch system 10 becomes more robust and less complex.
In accordance with the provisions of the patent statutes, the present invention has been described in what is considered to represent its preferred embodiments. However, it should be noted that the invention can be practiced otherwise than as specifically illustrated and described without departing from its spirit or scope. | A method and an apparatus for controlling a wet clutch are provided. The clutch comprises a pump, a piston, and a fluid conduit. The pump provides a housing with a hydraulic fluid. The piston is movably disposed in the housing and is movable into an extended position by a preloaded spring and into a retracted position by applying an engagement pressure on the piston by the hydraulic fluid. In the retracted position torque is transmittable through the clutch. The fluid conduit connects the pump and the housing. The method comprises the steps of prefilling the clutch by applying a prefill pressure on the piston, prefilling the fluid conduit line and the housing with the hydraulic fluid. The prefill pressure is lower than the engagement pressure required to move the piston into the retracted position. | 5 |
RELATED APPLICATIONS
[0001] This application claims the benefit of co-pending U.S. Provisional Patent Application Ser. No. 61/732,671, filed 3 Dec. 2012, and entitled “Torque Limiting Clutch.”
BACKGROUND OF THE INVENTION
[0002] The invention relates to releasable torque transmitting couplings and it is concerned more particularly with a self-releasing clutch which will disengage when a predetermined amount of torque is experienced.
[0003] While the principal purpose of torque limiting clutches is to protect various types of power driven equipment against overload, such clutches have heretofore also been perfected to take care of several specific requirements. For instance, in many installations it is desirable that once the clutch has become disengaged due to an overload it should stay disengaged as long as the overload condition persists, and that the clutch can be reengaged by torque reversal at will when the overload condition has abated to the point where operation of the driven equipment can be resumed. When the clutch idles, that is, while its driving member continues to rotate and its driven member is at a standstill, friction losses between the driving and driven members and wear of the relatively engageable and disengageable clutch elements should be kept to a minimum.
[0004] Further, the torque load at which the clutch becomes disengaged should be precisely fixed, that is, disengagement should take place at the exact moment when the torque reaches a given limit. In its engaged driving condition the clutch should provide a positive driving connection between the driving and driven shafts, that is, there should be no gradual yielding between the driving and driven clutch parts. The driving connection should be disrupted instantaneously when the given torque limit has been reached. In some installations it is also desirable that the driving and driven clutch parts can be reengaged in only one rotatively adjusted position relative to each other. This requirement usually has the purpose of maintaining a time relationship between several operating units that are driven from a single power source. Provisions should also be made to vary the torque limit at which the clutch will automatically disengage under an overload, and such variation to increase or decrease the torque limit should be possible conveniently without dismantling the clutch. Another provision which is frequently desired is that the clutch should be unidirectional, that is, it should provide torque control in one direction and solid drive in the opposite direction. Incorporated herein by reference is U.S. Pat. No. 3,893,553.
[0005] Additionally, fluid or other contaminates entering a mechanism like the present invention may cause premature wear or failure. For example, fluid or other contaminants may enter during a parts cleaning procedure. Therefore, where exposure to fluid or dirt is possible, a clutch capable of limiting the exposure of internal parts to fluids or contaminates would be desirable.
[0006] Furthermore, clutch characteristics may change upon clutch break-in. Therefore, a clutch that is manufactured to take into account break-in patterns would be desirable.
SUMMARY OF THE INVENTION
[0007] The invention disclosed herein relates generally to a torque limiting clutch, and more particularly to a more versatile and higher strength torque limiting clutch which may comprise additional drive pins to share torque loads, sealed components to prevent contaminants from entering the clutch, and machined components which replicate break-in wear patterns to maintain consistent clutch performance characteristics.
[0008] One aspect of the invention provides a torque-limited clutch having a positive drive direction and a torque-limited drive direction with an outer clutch assembly and an inner clutch member separated radially by a rotor, the outer clutch assembly comprising a first housing coupled to a second housing, the first housing comprising at least one milled pocket having a first stop end and a second stop end, the first housing and the second housing each comprising a plurality of ball pockets each having a ball egress, the rotor comprising a first planar surface and a second planar surface wherein a plurality of overload assembly through-holes extend from the first planar surface through the second planar surface and at least one drive pin extends outward from the first planar surface, and a plurality of overload assemblies positioned substantially within the rotor overload assembly through-holes, the plurality of overload assemblies each comprising at least one ball and a biasing mechanism, whereby when the torque-limited clutch is used in the positive drive direction the at least one drive pin is positioned against the first stop end of the at least one milled pocket and when the torque-limiting clutch is used in the torque-limited drive direction the at least one ball is biased in one of the plurality of ball pockets and wherein the at least one ball exits the ball pocket along the ball egress upon the clutch experiencing a torque level exceeding a predetermined torque limit.
[0009] The ball egress may be a circumferential chamfer about the ball pocket.
[0010] The ball egress may also be a circumferential rounded path about the ball pocket.
[0011] The ball egress may also be a contoured path following the path of the ball during a torque overload.
[0012] The milled pocket first stop end and the milled pocket second stop end may be of substantially similar curvature of the drive pin.
[0013] Another aspect of the invention provides a sealed torque-limited clutch having a positive drive direction and a torque-limited drive direction with an outer clutch assembly and an inner clutch member separated radially by a rotor, the outer clutch assembly comprising a first housing coupled to a second housing with a gasket placed therebetween, wherein the first housing is coupled to the second housing with self-sealing type screws, the first housing comprising a first housing protrusion with a first housing o-ring groove, a first housing o-ring positioned in the first-housing o-ring groove, and at least one milled pocket having a first stop end and a second stop end the second housing comprising a second housing protrusion with a second housing o-ring groove and a second housing o-ring positioned in the second housing o-ring groove, the first housing and the second housing each comprising a plurality of ball pockets each having a ball egress, the inner clutch having an inner clutch first sealing surface and an inner clutch second sealing surface, wherein the inner clutch first sealing surface is in contact with the first housing o-ring and the inner clutch second sealing surface is in contact with the second housing o-ring the rotor comprising a first planar surface and a second planar surface, a plurality of overload assembly through-holes extend from the first planar surface through the second planar surface and at least one drive pin extends outward from the first planar surface, and a plurality of overload assemblies positioned substantially within the rotor overload assembly through-holes, the plurality of overload assemblies each comprising at least one ball and a biasing mechanism, whereby when the torque-limited clutch is used in the positive drive direction the at least one drive pin is positioned against the first stop end of the at least one milled pocket, and when the torque-limiting clutch is used in the torque-limited drive direction, the at least one ball is biased in one of the plurality of ball pockets, and wherein the at least one ball exits the ball pocket along the ball egress upon the clutch experiencing a torque level exceeding a predetermined torque limit.
[0014] The ball egress may be a circumferential chamfer about the ball pocket.
[0015] The ball egress may also be a circumferential rounded path about the ball pocket.
[0016] The ball egress may also be a contoured path following the path of the ball during a torque overload.
[0017] The milled pocket first stop end and the milled pocket second stop end may be of substantially similar curvature of the drive pin.
[0018] The first housing ball pockets may each have a first housing threaded channel extending through the exterior of the first housing wherein torque-adjustment screws may be inserted from the exterior of the first housing and through the first housing threaded channel to disengage the at least one ball from the first housing ball pockets.
[0019] The torque-adjustment screws may be self-sealing type screws.
[0020] The second housing ball pockets may each have a second housing threaded channel extending through the exterior of the second housing wherein torque-adjustment screws may be inserted from the exterior of the second housing and through the second housing threaded channel to disengage the at least one ball from the second housing ball pockets.
[0021] The torque-adjustment screws may be self-sealing type screws.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 is a perspective view of a torque limiting clutch according to the present invention.
[0023] FIG. 2 is a perspective, exploded view of the torque limiting clutch of FIG. 1 utilizing a proposed embodiment according to the present invention.
[0024] FIG. 3 is a perspective view of an embodiment of the inner hub shown in FIG. 2 .
[0025] FIG. 4 is a perspective view of an embodiment of the rotor shown in FIG. 2 .
[0026] FIG. 5 is a side view of the torque limiting clutch shown in FIG. 1 .
[0027] FIG. 6 is a cross-sectional view of the torque limiting clutch along line 6 - 6 of FIG. 1 .
[0028] FIG. 7A is a cross-sectional view of the torque limiting clutch along line 7 A- 7 A of FIG. 1 in a drive position.
[0029] FIG. 7B is a cross-sectional view of the torque limiting clutch along line 7 B- 7 B of FIG. 7A engaged in a solid drive rotation.
[0030] FIG. 7C is a cross-sectional view of the torque limiting clutch along line 7 C- 7 C of FIG. 7A engaged in a solid drive rotation.
[0031] FIG. 8A is a cross-sectional view of the torque limiting clutch along line 8 A- 8 A of FIG. 1 in a disengaged position.
[0032] FIG. 8B is a cross-sectional view of the torque limiting clutch along line 8 B- 8 B of FIG. 8A in a disengaged position.
[0033] FIG. 8C is a cross-sectional view of the torque limiting clutch along line 8 C- 8 C of FIG. 8A in a disengaged position.
[0034] FIG. 9A is a cross-sectional view of the torque limiting clutch along line 9 A- 9 A of FIG. 8A during the process of clutch re-engagement.
[0035] FIG. 9B is a cross-sectional view of the torque limiting clutch along line 9 B- 9 B of FIG. 8A during the process of clutch re-engagement.
[0036] FIG. 9C is a cross-sectional view of the torque limiting clutch along line 9 C- 9 C of FIG. 7A re-engaged.
[0037] FIG. 9D is a cross-sectional view of the torque limiting clutch along line 9 D- 9 D of FIG. 7A re-engaged.
[0038] FIG. 10A is an exploded view of a second embodiment of the torque limiting clutch according to the present invention with a switch plate.
[0039] FIG. 10B is an exploded view of the torque limiting clutch of FIG. 10A without the switch plate.
[0040] FIGS. 11A and 11B illustrate the first housing with a second embodiment milled pocket according to the present invention.
[0041] FIGS. 12A and 12B illustrate the first housing with a second embodiment ball pocket according to the present invention.
[0042] FIGS. 13A and 13B illustrate the second housing with a third embodiment ball pocket according to the present invention.
[0043] FIGS. 14A and 14B illustrate the first housing with the third embodiment ball pocket shown in FIGS. 13A and 13B without a threaded channel according to the present invention.
[0044] FIGS. 15A and 15B illustrate the first housing with a fourth embodiment ball pocket according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0045] Although the disclosure hereof is detailed and exact to enable those skilled in the art to practice the invention, the physical embodiments herein disclosed merely exemplify the invention which may be embodied in other specific structures. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims.
[0046] As shown in FIG. 1 , an assembled view of an embodiment of the torque limiting clutch 10 according to the present invention is depicted. A first housing 110 and a second housing 150 are married together to create an outer clutch assembly 100 in which a rotor 400 (see FIG. 2 ) and an inner hub body 350 (see FIG. 2 ) reside. Each housing 110 and 150 has through-holes 114 and 154 (see FIG. 2 ) that align with threaded holes 156 and 116 (see FIG. 2 ), respectively, of the other housing to allow for a secured assembly with assembly screws 170 (see FIG. 10A ).
[0047] Continuing with FIG. 2 , an exploded view of the torque limiting clutch 10 embodying the invention is shown. It comprises the outer clutch assembly 100 comprising the first housing 110 and the second housing 150 ; a drive key 200 ; the inner hub 300 ; at least one overload assembly 500 comprising torque adjustment screws 510 , balls 520 , and coil springs 540 ; and the rotor 400 which radially surrounds the inner hub 300 and is itself enclosed within the outer clutch assembly 100 .
[0048] The first housing 110 comprises a substantially hollow cylindrical shape comprising a first planar surface 118 recessed within the first housing 110 and perpendicular to the central axis, a second planar surface 120 defining an interface, and an exterior planar surface 124 opposite the second planar surface 120 . Extending along the first housing 110 between the first planar surface 118 and the second planar surface 120 is an inner surface 122 and extending along the first housing 110 between the first planar surface 118 and the exterior planar surface 124 is a bearing surface 126 (best seen in FIG. 11A ) in which a sleeve bearing 102 is placed.
[0049] Additionally, an arcuate seating recess 112 is shown positioned in the inner surface 122 and at least one drive pin pocket 494 is located in the first planar surface 118 .
[0050] Furthermore, the first planar surface 118 of the first housing 110 has ball pockets 530 in which the balls 520 of the overload assemblies 500 sit when the torque limited clutch 10 is in the drive position, discussed infra. For a more detailed look at the ball pockets 530 of the first housing 110 see FIG. 11B . The ball pockets 530 are shown having a non-tapered sidewall 528 with a diameter D that is slightly less than the diameter of the balls 520 , thereby permitting each engaged ball 520 to sit in the respective ball pocket 530 wherein a minority of the ball 520 resides in the ball pocket 530 , thus promoting departure of the ball 520 from the ball pocket 530 upon a torque overload, discussed further below.
[0051] A second embodiment ball pocket 550 is shown in FIGS. 12A and 12B , wherein a chamfered path 552 extends about the periphery of the ball pocket 550 .
[0052] Additionally, a third embodiment ball pocket 532 is depicted in FIGS. 13A and 13B . Here, the ball pocket 532 has a contoured path 534 . The contoured path 534 provides a smoother egress for the residing ball 520 and reduces the break-in time as the path of egress is pre-formed, not formed over time by continuous wear. It is contemplated further that a second contoured path (not shown) may be formed opposite the first contoured path 534 .
[0053] A method for producing the contoured path 534 may comprise providing tooling (not shown) for drilling the ball pocket 532 , drilling the ball pocket 532 , forming the contoured path 534 with the tooling as the tooling exits the ball pocket 532 .
[0054] Moreover, a fourth embodiment 536 of the ball pockets is shown in FIGS. 15A and 15B . Here the ball pocket 536 has a circumferential rounded path 538 for much the same reason as the contoured path 534 shown in FIGS. 13A and 13B .
[0055] Generally the radius of the contoured path 534 and the rounded path 538 will allow the ball to have a rolling contact with the rounded path 538 rather than a point contact as may occur with a non-contoured path like that of the ball pocket 530 .
[0056] Sleeve bearings 102 may be placed in contact with the bearing surface 126 . A sleeve bearing 102 promotes smooth rotation of the inner hub 300 relative to the outer clutch assembly 100 . Although roller-type bearings are depicted here, other types of bearings or bushings are also contemplated by the present invention.
[0057] The second housing 150 is nearly a mirror image of the first housing 110 whereby it has a first planar surface 158 having ball pockets 530 , a second planar surface 160 , an exterior planar surface 164 , an inner surface 162 having an arcuate seating recess 152 , and a bearing surface 166 for placement of a sleeve bearing 102 .
[0058] Looking now to the inner hub 300 but still referring to FIG. 2 and additionally to FIG. 3 , the inner hub 300 has an exterior surface 310 , which has a slightly smaller diameter than the inner diameter of the rotor 400 . This slight variance allows for rotational movement of the inner hub 300 relative to the rotor 400 , while minimizing movement in a radial direction. Additionally, the inner hub 300 has two ends 340 which are positioned within the bearings 102 of the first housing 110 and the second housing 150 . Furthermore, a tangential pocket 610 is located on the exterior surface 310 . The pocket 610 interfaces with a detent assembly 600 comprising a plunger 630 and a coil spring 640 . Additionally, there is an arcuate seating recess 320 located in the exterior surface 310
[0059] FIG. 4 illustrates the rotor 400 . The rotor 400 has a series of coil spring through-holes 470 that extend through the first planar surface 410 and the second planar surface 420 (hidden). Additionally, there is at least one drive pin opening 450 on the first planar surface 410 . Furthermore, the rotor 400 has a key slot 460 extending from the second planar surface 420 towards, but not to, the first planar surface 410 , and extends through the outer surface 440 and the inner surface 430 . The size of the key slot 460 corresponds to the diameter of the drive key 200 (see FIG. 2 ).
[0060] The rotor 400 also has a plunger through-hole 480 extending through the outer surface 440 and the inner surface 430 . It is in the plunger through-hole 480 in which the plunger 630 of the detent assembly 600 resides. The plunger through-hole 480 is positioned so as not to interfere with any of the coil spring through-holes 470 and so that at least a portion of the plunger through-hole 480 is at a position along the rotor's outer surface 440 so that the plunger 630 will not plunge into the arcuate seating recess 320 of the inner hub 300 when there is an overload and the inner hub 300 rotates freely relative to the rotor 400 .
[0061] The drive key 200 resides in inner clutch arcuate seating recess 320 and the rotor key slot 460 when the clutch 10 is in the drive position. However, the drive key 200 resides in the rotor key slot 460 and the first and second housing arcuate seating recesses 112 and 152 when the clutch 10 is in a disengaged state, discussed further below.
[0062] Additionally, the torque limiting clutch 10 has a torque drive means 490 comprising at least one drive pin 492 having a first end 494 and a second end 496 . The drive pin first end 494 is pressed into the drive pin opening 450 in the first planar surface 410 of the rotor, and the drive pin second end 496 resides in a milled pocket 498 located in the first planar surface 118 of the first housing 110 (as shown in FIG. 6 ). The milled pocket 498 in the embodiment shown is larger than the drive pin 492 . This allows the drive pin 492 , and the rotor 400 it is pressed into, to rotate to some degree in order to allow the overload assemblies 500 to disengage (shown in FIG. 8C ).
[0063] Alternatively, FIG. 11A illustrates an alternative milled pocket 894 . The milled pocket 894 comprises a slot extending from a first stop end 896 to a second stop end 898 . The first stop end 896 and the second stop end 898 are arcuate to substantially match the curvature of the drive pin 492 . Additionally, the milled pocket 894 is milled into the first housing first planar surface 118 to follow the same path as the drive pin 492 . As the milled pocket 894 is more adaptive to the shape and travel path of the drive pin 492 , less material is removed from the first housing 110 which provides more rigidity (especially if more than one drive pin 492 are utilized) and promotes a more consistent and solid bushing/bearing 102 fit.
[0064] Continuing to look at FIG. 4 , along with FIGS. 11A and 5 , a plurality of drive pins 492 and a plurality of milled pockets 894 are shown. Additional drive pins 492 located in additional milled pockets 894 will disperse the load more evenly across the outer clutch assembly 100 and will also increase the amount of force that may be transferred from an input shaft 20 to an output shaft 30 when the clutch is being used in a non-torque limiting direction (discussed further below) because the force will be more evenly divided among the drive pins 492 . It should be understood that reference to the input shaft and the output shaft is for reference only and therefore should not limit the torque limiting clutch to only this operational orientation.
[0065] FIG. 7A is a cross-sectional view of the torque limiting clutch 10 , further illustrating the internal elements. Here, it can be seen that each overload assembly 500 comprises torque adjustment screws 510 , balls 520 residing in their respective ball pockets 530 located in the first and second housings 110 and 150 , and coil springs 540 located in their respective coil spring through-holes 470 . Additionally, nitrogen cylinders or Belleville springs or another type of biasing mechanism known to one having ordinary skill in the art may be used in place of, or in conjunction with, the coil springs 540 .
[0066] Furthermore, the torque required to disengage the torque limiting clutch 10 is determined by how many of the overload assemblies 500 are active. The overload torque setting may be adjusted by adding or removing short or long torque adjustment screws 510 . For example, if less overload torque is desired, long torque adjustment screws 510 are installed. The additional length of the long screw pushes the ball 520 out of its pocket 530 and into the through-bore 470 , thereby removing it from contact with the respective housing 110 or 150 . Installing long torque adjustment screws 510 in each end of an overload assembly 500 effectively disengages that overload assembly 500 making disengagement of the torque limiting clutch 10 achievable under less overload torque. Conversely, if more overload torque is desired, more of the overload assemblies 500 should be activated. This is accomplished by replacing long screws with short screws until the desired overload torque is achieved.
[0067] Additionally, a sealed torque limiting clutch 700 more impervious to fluid or other contaminants is also contemplated by the present invention and is depicted in FIGS. 10A and 10B . FIG. 10A depicts a sealed torque limiting clutch 700 with switch plate 40 . The sealed torque limiting clutch 700 comprises a first sealed housing 710 and a second sealed housing 750 , an extended inner clutch member 770 , and a gasket. As the sealing elements of the first sealed housing 710 are hidden from view in this figure, explanatory focus will be placed on the similar sealing elements of the second sealed housing 750 . As shown, the second sealed housing 750 comprises an o-ring protrusion 752 and an o-ring groove 754 . Similarly, the first sealed housing 710 comprises an o-ring protrusion 712 and an o-ring groove 714 , both hidden here but visible in FIG. 14A .
[0068] Furthermore, the extended inner clutch member 770 comprises a first sealing surface 772 and a second sealing surface 774 .
[0069] Additionally, the gasket 780 provides a sealed junction between the first sealed housing 710 and the second sealed housing 750 . Moreover, housing o-rings 790 placed in the o-ring grooves 714 and 754 may comprise dynamic o-rings (for example, those made by Parker-Hannifin Corp.) as they will be used in a location subject to rotary movement of the extended inner clutch member first sealing surface 772 and the extended inner clutch member second sealing surface 774 when the clutch 700 is in a disengaged state.
[0070] Furthermore, the switch plate 40 comprises studs 42 having rounded tips 44 that are inserted through switch plate holes 716 in at least one of the first sealed housing 710 and the second sealed housing 750 and which reside in depressions 482 in the rotor 400 . When the clutch 700 experiences a disengaging torque, the rotor 400 rotates while the switch plate studs 42 remain relatively stationary causing them to be forced out of the depressions 482 and against the planar surface 410 , 420 of the rotor 400 . The lateral movement of the studs 42 relative to the clutch 700 is transferred to the switch plate 40 and moves the switch plate 40 to make a signaling connection, whether electrical or mechanical, to signal the torque overload. O-rings 46 located on the studs 42 reduce the likelihood of fluid or other contaminates entering the clutch 700 through the switch plate holes 716 .
[0071] FIG. 10B shows the sealed torque limiting clutch 700 of FIG. 10A but without the switch plate 40 . As the switch plate 40 is absent, the switch plate holes 716 may be filled with plugs 50 incorporating o-rings 46 to decrease the potential of fluid or other contaminates from entering the clutch 700 .
[0072] Moreover, as shown in FIGS. 14B and 15B , ball pockets 532 and 536 do not have a threaded channel 526 like those illustrated in FIGS. 11B , 12 B, and 13 B. This design feature may be provided to further reduce the likelihood of fluid or other contaminates from entering the clutch 700 . However, it is also contemplated that this design feature may be preferable on only one of the two housings 710 , 750 because adjustability of the amount of force required to disengage the clutch 700 may still be desired.
[0073] Furthermore, it is contemplated that certain pieces of the clutch 700 may comprise stainless steel and the screws (i.e., the assembly screws 170 and the torque adjustment screws 510 ) in the clutch 700 may comprise self-sealing stainless steel screws to further limit damage due to exposure to fluid or other contaminants. As a non-limiting example, ZAGO® seal screws may be used.
[0074] It is contemplated that the sealing measures herein disclosed reduce the likelihood of contaminants from entering the clutch 700 under pressure. The sealing measures would preferably maintain a seal up to approximately 14 psi, but maintaining a seal at greater pressures is also contemplated.
[0075] Additionally, it should be known that the switch plate 40 may be used with the non-sealed torque limiting clutch 10 as well; however, the o-rings 46 may be optional.
Drive Position
[0076] FIG. 7A illustrates the clutch 10 according to the present invention in the drive position. In the drive position, the clutch 10 may be used in the torque limiting direction, as described below, or in a non-torque limiting direction as a solid drive unit (as depicted in FIGS. 7B and 7C ). In FIG. 7A , the overload assemblies 500 are engaged with the balls 520 located in their respective ball pockets 530 . FIG. 7B shows detent assembly 600 , wherein the plunger 630 is abutting a wall 620 of the tangential pocket 610 . Furthermore, the drive key 200 is located partially in the arcuate seating recess 320 of the inner hub 300 and the key slot 460 of the rotor 400 , thereby operably joining the rotor 400 and the inner hub 300 together. FIG. 7C illustrates the at least one drive pin 492 abutting the wall of the milled pocket 494 at point A, thereby operably joining the outer clutch assembly 100 to the rotor 400 . When used as a solid drive unit, the clutch 10 transfers input force from the input shaft 20 to the output shaft 30 through the at least one drive pin 492 in the direction of the arrows. All in all, the outer clutch assembly 100 , the rotor 400 , and the inner hub 300 are all operably joined together and move as one when in the drive position.
Torque Overload State
[0077] FIGS. 8A-C show the torque limiting clutch 10 when disengaged due to a torque overload. When the clutch 10 is used in the torque-limiting direction (the reverse of the solid drive direction), the input force is transferred from the input shaft 20 to the output shaft 30 through the overload assemblies 500 . Therefore, when a force is experienced by the clutch 10 that exceeds the predetermined torque limit, the clutch 10 will disengage.
[0078] On a global level, in the event of a torque overload the inner hub 300 disengages from operable engagement with the rotor 400 , thereby disengaging the outer clutch assembly 100 and allowing the inner hub 300 to rotate independently. On a more local level, when the clutch 10 is in the drive position as depicted in FIGS. 7A-C , the inner hub 300 and the rotor 400 are separably fixed together by the drive key 200 . When a load above the torque limit of the overload assemblies 500 is experienced, the excessive load causes the balls 520 of the overload assemblies 500 to overcome the spring force of the coil springs 540 and roll out of their respective ball pockets 530 . The inner hub 300 and the rotor 400 then continue to rotate, but independent of the outer clutch assembly 100 .
[0079] Looking at FIGS. 8B and 8C , as the inner hub 300 and the rotor 400 rotate together, the rotor 400 is stopped when the at least one drive pin 492 makes contact with the wall of the milled pocket 494 at point B. At this position the arcuate seating recesses 112 and 152 (not shown) of the outer clutch assembly 100 are in line with the drive key 200 and the arcuate seating recess 320 of the inner hub 300 . As the rotor 400 is now prohibited from further rotation, the continuing input force will further rotate the inner hub 300 relative to both the rotor 400 and the outer clutch assembly 100 . As the inner hub continues to rotate, the arcuate seating recess 320 of the inner hub 300 acts against the drive key 200 and forces the drive key 200 into the arcuate seating recesses 112 and 152 (see FIG. 13A ) of the outer clutch assembly 100 , thereby operably linking the rotor 400 and the outer clutch assembly 100 and allowing the inner clutch member 300 to rotate independently of the rotor 400 and the outer clutch assembly 100 . Adjustment to the amount of overload force needed to disengage the clutch is achieved through the number of active torque adjustment screws 510 (shown in FIG. 7A ) as discussed supra.
Re-Engagement of the Clutch
[0080] After an overload disengages the clutch 10 , and the cause for the overload has been remedied, the clutch 10 may be reset to the drive position. This is accomplished by either rotating the inner hub 300 , the outer clutch assembly 100 , or both, in a direction opposite one another. As illustrated in FIG. 9A , the inner hub 300 is rotated in the solid drive direction. Looking to FIG. 9B , as the inner hub 300 is rotated, the plunger 630 , which is biased against the inner hub 300 by the spring 640 acting against the inner surface 122 of the outer clutch assembly 100 , abuts the wall 620 of the tangential pocket 610 located within the exterior surface 310 of the inner hub 300 . This operably links the inner hub 300 and the rotor 400 . The two continue to rotate together in the solid drive direction and the key slot 460 acts against the drive key 200 , and the drive key 200 moves from the arcuate seating recesses 112 and 152 (see FIG. 13A ) of the outer clutch assembly 100 to the arcuate seating recess 320 of the inner hub 300 .
[0081] Further rotation permits the balls 520 of the overload assemblies 500 to reseat in their respective ball pockets 530 (see FIG. 9C ). Moreover, the at least one drive pin 492 is once again engaged with the wall of its respective milled pocket 494 at point A (as shown in FIG. 9D ) and thereby re-engaging the clutch 10 in the drive position.
[0082] The foregoing is considered as illustrative only of the principles of the invention. Furthermore, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims. | Apparatus directed to the art of disengaging an input from an output at predetermined torque values. A torque limiting clutch capable of use as a solid drive unit and a torque limited unit for which the torque disengagement value is selectable. The torque limiting clutch has an overload assembly and a torque drive mechanism which may comprise a plurality of drive pins. Additionally, the torque limiting clutch may comprise seals to discourage contaminants from entering the clutch. | 5 |
This is a Continuation Application of application Ser. No. 13/217,916 filed Aug. 25, 2011. The disclosure of the prior application is hereby incorporate by reference herein in its entirety.
BACKGROUND OF THE INVENTION
This application claims the entire benefit of Japanese Patent Application Number 2010-217589 filed on Sep. 28, 2010 and Japanese Patent Application Number 2011-002143 filed on Jan. 7, 2011, the entirety of which is incorporated by reference.
TECHNICAL FIELD
The present invention relates to a rechargeable electric tool in which a battery pack serving as an electric power source is detachably mounted to a mounting part formed lower than openings provided at a housing.
BACKGROUND ART
For example, Japanese Patent Application Laid-Open Publication No. 2009-78322 discloses a rechargeable electric tool in which a battery pack is detachably mounted to a battery mounting part a grip part. The grip part is continuously provided at a housing in which a motor, a driving mechanism, and the like are mounted.
In general, a hole is provided at a housing to expose a trigger of a switch necessary for electrical operations or/and a ventilation hole is provided at the housing to cool a motor in such rechargeable electric tool.
However, for example, in the case where such rechargeable electric tool is left outside during rain, the rainwater or the like occasionally enters the housing from an opening such as the hole or the ventilation hole. In such a case, the rainwater or the like having entered the housing passes through the grip part or the battery mounting part, and then enters a gap between the battery mounting part and the battery pack. Thus, the waterproof property of the battery mounting part and the battery pack has been insufficient.
The present invention has been proposed in view of the foregoing circumstances, and an object thereof is to provide a rechargeable electric tool in which the waterproof property of the battery mounting part and the battery pack is improved.
SUMMARY OF THE INVENTION
According to a first aspect of the present invention, a rechargeable electric tool including a housing having openings, a mounting part that is located lower than the openings and is formed at the housing, a battery pack detachably mounted to the mounting part to serve as an electric power source, and a seal member disposed in the housing to seal between the openings and the battery pack mounted to the mounting part.
According to a second aspect of the present invention, an electric component is accommodated in the opening side of the housing in which openings are provided, and the seal member includes a covering member that closely covers a lead line connecting the electric component to the battery pack and penetrating the seal member, and elastic members that are pressed into and brought into contact with the covering member in the first aspect of the present invention.
According to a third aspect of the present invention, a projection projecting toward the opening side at the seal member, and a passing hole that penetrates the projection and the seal member and allows the lead line connecting the electric component accommodated on the opening side in the housing to the battery pack to pass therethrough is formed in the first aspect of the present invention.
According to a fourth aspect of the present invention, the housing is formed by combining two divided housings with each other. Ribs capable of pressing the seal member may protrude from inner surfaces of the two divided housings while facing each other. The ribs hold the seal member in the housing in a state where the two divided housings are combined with each other in any one of the first to third aspects of the present invention.
According to a fifth aspect of the present invention, the electric component is accommodated on the opening side in the housing, and the seal member is held in the housing in a state where the seal member is twisted around an outer circumferential surface of the electric component in the first aspect of the present invention.
According to a sixth aspect of the present invention, the seal member is held in the housing in a state where the seal member is inclined relative to a bottom surface of the battery pack mounted to the mounting part. A drainage port which communicates inside of the housing to outside thereof is provided near an inclined lower end of the seal member on the opening side in the housing in the first aspect of the present invention.
According to a seventh aspect of the present invention, the electric component is a switch that includes an operation part to control supplying of electric power to a motor that drives an output shaft protruding from a tip end of the housing. The operation part is allowed to be exposed from the opening. The seal member is held in the housing in a state where the seal member is inclined relative to the bottom surface of the battery pack mounted to the mounting part and the inclined lower end is directed toward the opening in the fifth aspect of the present invention.
According to the rechargeable electric tool in the first aspect of the present invention, even if rainwater or the like enters inside of the housing from the openings of the housing, the seal member can prevent the rainwater or the like from entering a gap between the mounting part and the battery pack, and the battery pack. Accordingly, it is possible to improve the waterproof property of the gap and the battery pack.
According to the second aspect of the present invention, the covering member is closely attached to the lead line to cover it. As a result, there is no gap between the covering member and the lead line. Therefore, the rainwater or the like having entered inside of the housing from the openings can be prevented from flowing toward the battery pack along the lead line.
In addition, the elastic members are pressed into and brought into contact with the covering member to seal the surfaces of the covering member facing the elastic members. Accordingly, there is no gap between the covering member and the elastic members, and the rainwater or the like can be prevented from flowing toward the battery pack along the covering member.
According to the third aspect of the present invention, even if the rainwater or the like having entered inside of the housing from the openings passes between an inner surface of the housing and the electric component and flows toward the seal member, the projection of the seal member can prevent the rainwater or the like from flowing back to the opening side, and the rainwater or the like can be prevented from flowing toward the passing hole. Accordingly, the rainwater or the like can be prevented from flowing toward a gap between the mounting part for the battery pack and the battery pack, and the battery pack along the lead line passing through the passing hole.
According to the fourth aspect of the present invention, the seal member is not shaken by being pressed between the both ribs, and the seal member can be prevented from being moved in the housing. Accordingly, the seal member can be preferably positioned in the housing.
According to the fifth aspect of the present invention, the electric component around the outer circumferential surface of which the seal member is twisted is only combined with and accommodated in the housing, so that the seal member can be positioned in the housing. Accordingly, the seal member can be easily positioned.
According to the sixth aspect of the present invention, even if the rainwater or the like having entered the inside of the housing from the openings passes through the housing and flows toward the seal member, the rainwater or the like having reached the seal member can be guided to the drainage port along the inclination of the seal member. Accordingly, the rainwater or the like is discharged to the outside of the housing, and can be prevented from entering the gap and the battery pack.
According to the seventh aspect of the present invention, the rainwater or the like is discharged from the openings to the outside of the housing by using the openings without additionally providing the drainage port in the housing. As a result, the rainwater or the like can be prevented from entering a gap between the mounting part for the battery pack and the battery pack, and the battery pack.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other aspects, other advantages and further features of the present invention will become more apparent by describing in detail illustrative, non-limiting embodiments thereof with reference to the accompanying drawings.
FIG. 1 is a lateral cross-sectional view of main parts of an impact driver according to a first embodiment of the present invention.
FIG. 2 is a rear cross-sectional view of the main parts of the impact driver according to the first embodiment of the present invention.
FIG. 3 is an exploded perspective view of left and right half housings and a seal member forming the impact driver according to the first embodiment of the present invention.
FIG. 4 is a lateral cross-sectional view of main parts of an impact driver according to a second embodiment of the present invention.
FIG. 5 is a cross-sectional view taken along the line A-A of FIG. 4 .
FIG. 6 is a cross-sectional view taken along the line B-B of FIG. 4 .
FIG. 7 is a lateral cross-sectional view of main parts of an impact driver according to a third embodiment of the present invention.
FIG. 8 is a cross-sectional view taken along the line C-C of FIG. 7 .
DETAILED DESCRIPTION OF THE EMBODIMENTS
An Illustrative embodiment of the present invention will be described in detail with reference to the drawings.
First Embodiment
A first embodiment of the present invention will be described with reference to FIG. 1 to FIG. 3 . As shown in FIG. 1 , an impact driver 1 includes a main-body housing 10 , a hammer case 20 , a seal member 50 , and the like.
As shown in FIG. 1 and FIG. 2 , a main-body housing 10 is formed by combination of left and right half housings 10 L and 10 R made of resin, and includes a body 11 , a handle part 12 , a battery mounting part 13 , and rear cover R. The body 11 is in a tubular shape and extends in the impact driver 1 in the vertical direction of FIG. 1 . Inside of the body 11 , a motor M is accommodated, and plural inlet ports 14 A and outlet ports 14 B (see FIG. 3 ) are provided at positions near the motor M. Further, the rear cover R formed in a tubular shape that is opened toward the body 11 is attached to a rear end of the body 11 by screwing. Plural inlet ports R 1 (see FIG. 3 ) are provided even at the rear cover R, and these inlet ports 14 A and R 1 are used to draw in cooling air for the motor M in the body 11 . The plural outlet ports 14 B are used to discharge the cooling air to the outside of the body 11 . It should be noted that the main-body housing 10 is an example of a housing of the present invention, the both half housings 10 L and 10 R are examples of two half housings of the present invention, and the inlet ports 14 A and R 1 are examples of openings of the present invention.
As shown in FIG. 1 to FIG. 3 , the handle part 12 is formed by combining a left handle part 12 L of the left-half housing 10 L with a right handle part 12 R of the right-half housing 10 R. The handle part 12 extends from the body 11 so as to form a substantially T-shape when viewed from the lateral side of the impact driver 1 . Inside of the handle part 12 , a box-like switch S having a trigger 15 is accommodated at an upper position relative to the seal member 50 in the vertical direction of the impact driver 1 . In addition, the handle part 12 is provided with a drainage port 17 at the base of the handle part 12 , namely, at a position near a boundary between the handle part 12 and the battery mounting part 13 . The drainage port 17 can be communicated inside of the handle part 12 with the outside thereof. The position where the switch S is accommodated and the position where the drainage port 17 is provided in the handle part 12 correspond to the side where the inlet ports 14 A and R 1 are located with the seal member 50 serving as a boundary. It should be noted that the positions inside of the handle part 12 corresponding to the side where the inlet ports 14 A and R 1 are located are examples in the housing on the opening side of the present invention.
As shown in FIG. 2 and FIG. 3 , a rib 18 L protrudes from an inner surface of the left handle part 12 L, and a rib 18 R protrudes from an inner surface of the right handle part 12 R. Each of the both ribs 18 L and 18 R is formed in a moderate S-shape in accordance with the lateral shape of the seal member 50 . In a state where the left and right half housings 10 L and 10 R are combined with each other, the rib 18 L faces the rib 18 R in the handle part 12 in the vertical direction of FIG. 2 . A cylindrical protrusion 19 A protrudes from the rib 18 R. The protrusion 19 A is provided so as to face a position near a front end of an upper curved part 50 A of the S-shape of the seal member 50 on a surface of the rib 18 R facing the seal member 50 . In addition, a cylindrical protrusion 19 B protrudes from the rib 18 R. The protrusion 19 B is provided so as to face a position near a rear end of a lower curved part 50 B of the S-shape of the seal member 50 on a surface of the rib 18 R facing the seal member 50 .
The battery mounting part 13 is formed by combining a left battery mounting part 13 L of the left-half housing 10 L with a right battery mounting part 13 R of the right-half housing 10 R. This battery mounting part 13 is formed on the lower side relative to the inlet ports 14 A and R 1 in the vertical direction of the impact driver 1 , namely, at a lower end of the handle part 12 . A terminal stage is accommodated in the battery mounting part 13 , and a battery pack 16 formed in a substantially rectangular solid shape is detachably mounted to the terminal stage. The battery pack 16 is a rechargeable electric power source. The trigger 15 is pushed into the inside of the handle part 12 to turn on the switch S, so that the battery pack 16 supplies electricity to the motor M. Further, a hook F (see FIG. 2 ) used to hang the impact driver 1 on a belt of a worker is swingably attached to a left lateral surface of the battery mounting part 13 when viewed from the backside. It should be noted that the impact driver 1 is an example of a rechargeable electric tool of the present invention, and the battery mounting part 13 is an example of a mounting part of the present invention. In addition, the trigger 15 is an example of an operating part of the present invention.
The hammer case 20 is made of metal (for example, aluminum), and is combined with the front side (right direction of FIG. 1 ) of the body 11 . Inside of the hammer case 20 , a hammering mechanism and an anvil 21 are accommodated. The anvil 21 is rotatably supported by a bearing in the hammer case 20 , and projects from a tip-end surface of the hammer case 20 . A chuck 22 is provided at a tip end of the anvil 21 , so that a tip-end tool can be mounted. The hammering mechanism converts the rotation of the motor M into rotational hammering force to be transmitted to the tip-end tool. It should be noted that the anvil 21 is an example of an output shaft of the present invention.
A cover 30 is mounted at a part exposed from the body 11 on the front outer circumference of the hammer case 20 . A bumper 40 is combined with a front end of the cover 30 and is mounted at the exposed part. The cover 30 and the bumper 40 prevent the front outer circumference of the hammer case 20 from being exposed.
The seal member 50 is arranged between the switch S and the battery pack 16 in the handle part 12 . In other words, the seal member 50 is located between the opening s including inlet ports 14 A, R 1 and an opening H used for exposing the trigger 15 from the handle part 12 , and the battery pack 16 . Accordingly, the seal member 50 can seal between the side where the inlet ports 14 A, R 1 and the opening H are located and the side where the battery pack 16 is provided in the handle part 12 . The seal member 50 is made of elastic material such as rubber, has a thickness in the horizontal direction of the handle part 12 , and each of the lateral surfaces of the seal member 50 is formed in a moderate S-shape.
As shown in FIG. 1 and FIG. 3 , the seal member 50 is configured in such a manner that an upper surface of the upper curved part 50 A forming the S-shape serves as an inclined surface (upper inclined surface) S 1 . The inclined surface S 1 is inclined upward in the front direction relative to a bottom surface 16 A of the battery pack 16 mounted to the battery mounting part 13 . A projection 51 is formed at a front end of the upper inclined surface S 1 . The projection 51 projects upward (toward the side where the inlet ports 14 A and R 1 and the opening H are located) from the upper inclined surface S 1 . A lead-line passing hole 52 penetrating the projection 51 and the upper curved part 50 A is formed in the vertical direction of the seal member 50 . In addition, a through-hole 53 A is formed at a position on the upper-end side (a position on the front side) of the upper curved part 50 A in the projection 51 . The through-hole 53 A is formed in the thickness direction of the projection 51 (seal member 50 ), and the protrusion 19 A can be inserted into the through-hole 53 A.
On the other hand, an upper surface of the lower curved part 50 B forming the S-shape serves as an inclined surface (lower inclined surface) S 2 . The inclined surface S 2 is inclined downward in the rear direction relative to the bottom surface 16 A of the battery pack 16 mounted to the battery mounting part 13 . As shown in FIG. 1 , the drainage port 17 is located near a lower end of the lower inclined surface S 2 . In addition, a through-hole 53 B is formed at a position on the rear side of the lower curved part 50 B. The through-hole 53 B is formed in the same direction as the through-hole 53 A, and the protrusion 19 B can be inserted into the through-hole 53 B.
In a state where the left and right half housings 10 L and 10 R are combined with each other as shown in FIG. 2 , the protrusion 19 A is inserted into the through-hole 53 A, and the protrusion 19 B is inserted into the through-hole 53 B, so that the rib 18 L is pressed into a left lateral surface of the seal member 50 , and the rib 18 R is pressed into a right lateral surface of the seal member 50 . Accordingly, the left and right lateral surfaces of the seal member 50 are elastically deformed to be closely attached to the both ribs 18 L and 18 R, respectively. At the same time, the seal member 50 is sandwiched and held between the both ribs 18 L and 18 R in a state where the seal member 50 is fitted into the handle part 12 . In a state where the seal member 50 is held in the handle part 12 , the seal member 50 is inclined downward toward the rear side of the battery pack 16 relative to the bottom surface 16 A of the battery pack 16 . It is due to the presence of the upper inclined surface S 1 and the lower inclined surface S 2 .
As shown in FIG. 1 , an internal connector C 1 is accommodated in the handle part 12 on the battery pack 16 -side. A lead line L connected to the internal connector C 1 is allowed to pass through the lead-line passing hole 52 to extend from the battery pack 16 -side to the side where the inlet ports 14 A and R 1 and the opening H are located in the handle part 12 . The lead line L is electrically connected to the switch S on the side where the inlet ports 14 A and R 1 and the opening H are located in the handle part 12 . A lead line (not shown) for supplying electricity to the motor M is electrically connected between the switch S and the motor M. In addition to the lead line L, a is communication line (not shown) and the like are allowed to pass through the lead-line passing hole 52 without a gap.
An external connector C 2 is accommodated on the battery pack 16 -side in the handle part 12 in a state where the external connector C 2 is coupled to the internal connector C 1 . A lead line (not shown) connected to the external connector C 2 extends toward the lower end side (battery mounting part 13 ) of the handle part 12 to be electrically connected to the terminal stage. In the illustrated impact driver 1 , the switch S and the battery pack 16 are electrically connected to each other through the both connectors C 1 and C 2 , the lead line L, and the like. In the embodiment, non-waterproof connectors are used as the both connectors C 1 and C 2 . Accordingly, the both connectors C 1 and C 2 are small in size as compared to waterproof connectors.
Therefore, the both connectors C 1 and C 2 can be accommodated in a narrow space in the handle part 12 surrounded by the seal member 50 , an inner surface of the handle part 12 on the battery pack 16 -side, and the battery mounting part 13 . It should be noted that the switch S is an example of an electric component of the present invention, and the lead-line passing hole 52 is an example of a passing hole of the present invention.
For example, even if the impact driver 1 of the embodiment is left outside in a standing posture while the bottom surface 16 A of the battery pack 16 is brought into contact with the ground, and rainwater or the like enters from the inlet ports 14 A and R 1 and the opening H (see FIG. 1 ), the rainwater or the like can be prevented from entering the battery pack 16 and the like in the following manner. The rainwater or the like having entered from the inlet ports 14 A and R 1 flows down from the inside of the body 11 . It flows down toward the seal member 50 and the ribs 18 L and 18 R through a gap between an inner surface of the handle part 12 and the switch S. At this time, there is no gap between the side where the inlet ports 14 A and R 1 are located and the battery pack 16 -side in the handle part 12 due to the presence of the seal member 50 . Thus, the rainwater or the like can be prevented from entering the battery pack 16 -side from the side where the inlet ports 14 A and R 1 are located.
In addition, the rainwater or the like having reached the seal member 50 flows down on the upper inclined surface S 1 and the lower inclined surface S 2 to be guided to the drainage port 17 . Further, the rainwater or the like having reached the ribs 18 L and 18 R is guided to the drainage port 17 along upper surfaces of the ribs 18 L and 18 R. Thereafter, the rainwater or the like passes through the drainage port 17 from the inside of the handle part 12 to be discharged to the outside of the handle part 12 . In addition, the rainwater or the like having reached the seal member 50 hardly flows back to the side where the inlet ports 14 A and R 1 are located due to the upward inclination of the upper inclined surface S 1 , and the projection 51 serves as a barrier against backflow. Thus, the rainwater or the like is prevented from flowing into the lead-line passing hole 52 . Further, since the projection 51 projects upward relative to the upper surfaces of the ribs 18 L and 18 R, the rainwater or the like flowing on the upper surfaces of the ribs 18 L and 18 R is prevented from flowing into the lead-line passing hole 52 by the projection 51 serving as a barrier. Therefore, the rainwater or the like can be prevented from entering the battery pack 16 -side in the handle part 12 along the lead line L and the like allowed to pass through the lead-line passing hole 52 . Accordingly, the rainwater or the like is prevented from flowing into the internal connector C 1 and the external connector C 2 connected to the lead line L, and thus the waterproof property of the both connectors C 1 and C 2 is improved.
On the other hand, the rainwater or the like having entered from the opening H is also prevented from entering the battery pack 16 -side from the side where the inlet ports 14 A and R 1 and the opening H are located in the handle part 12 , as similar to that having entered from the inlet ports 14 A and R 1 . In addition, the rainwater or the like having entered from the opening H is guided to the drainage port 17 , as similar to that having entered from the inlet ports 14 A and R 1 . Thereafter, the rainwater or the like is discharged to the outside of the handle part 12 . In addition, the rainwater or the like having entered from the opening H is prevented from flowing into the lead-line passing hole 52 , as similar to that having entered from the inlet ports 14 A and R 1 . Accordingly, the rainwater or the like having entered from the opening H can be prevented from entering the battery pack 16 -side, as similar to that having entered from the inlet ports 14 A and R 1 . It should be noted that the opening H is an example of an opening of the present invention.
Effect of the First Embodiment
In the impact driver 1 of the first embodiment, the seal member 50 seals a portion in the handle part 12 between the inlet ports 14 A and R 1 and the opening H, and the battery pack 16 mounted to the battery mounting part 13 located lower in the vertical direction of the impact driver 1 than the inlet ports 14 A and R 1 and the opening H. Thus, even if the rainwater or the like flows down from the inlet ports 14 A and R 1 toward the handle part 12 through the body 11 , or the rainwater or the like enters from the opening H and flows down along an inner surface of the handle part 12 , the seal member 50 can prevent the rainwater or the like from entering a gap between the battery mounting part 13 and the battery pack 16 , and the battery pack 16 . Accordingly, it is possible to improve the waterproof property of the gap and the battery pack 16 .
Further, even if the rainwater or the like having entered from the inlet ports 14 A and R 1 flows down to the seal member 50 from the inside of the body 11 through a gap between an inner surface of the handle part 12 and the switch S, the projection 51 can prevent the rainwater or the like from flowing back to the side where the inlet ports 14 A and R 1 are located. As a result, the rainwater or the like can be prevented from flowing into the lead-line passing hole 52 . In addition, the rainwater or the like having entered from the opening H can be also prevented from flowing back to the side where the inlet ports 14 A and R 1 and the opening H are located by the projection 51 . As a result, the rainwater or the like can be prevented from flowing toward the lead-line passing hole 52 . Accordingly, the rainwater or the like can be prevented from entering the battery pack 16 -side along the lead line L and the like allowed to pass through the lead-line passing hole 52 .
Further, in a state where the left and right half housings 10 L and 10 R are combined with each other, the seal member 50 is held in the handle part 12 while being sandwiched between the both ribs 18 L and 18 R. Therefore, the seal member 50 is not shaken by being pressed between the both ribs 18 L and 18 R, and the seal member 50 can be prevented from being moved in the handle part 12 . Accordingly, the seal member 50 can be preferably positioned in the handle part 12 .
Furthermore, the drainage port 17 is provided at a position corresponding to the side where the inlet ports 14 A and R 1 and the opening H are located in the handle part 12 . The drainage port 17 is positioned near a lower end of the lower inclined surface S 2 of the seal member 50 . Therefore, even if the rainwater or the like having entered from the inlet ports 14 A and R 1 and the opening H flows down in the handle part 12 , the rainwater or the like having reached the seal member 50 flows down on the upper inclined surface S 1 and the lower inclined surface S 2 to be discharged from the drainage port 17 to the outside of the handle part 12 . Accordingly, the rainwater or the like having entered from the inlet ports 14 A and R 1 and the opening H can be prevented from entering the gap and the battery pack 16 .
Second Embodiment
A second embodiment of the present invention will be described with reference to FIG. 4 to FIG. 6 . In the second embodiment, the same constitutional elements as those in the first embodiment are given the same reference numerals and the explanations thereof will not be repeated. In addition, the same effects as those in the first embodiment will not be repeated. Further, the lead line L is not illustrated in FIG. 4 . However, the lead line L same as that in the first embodiment is also provided in an impact driver 1 A of the second embodiment. The impact driver 1 A includes a heat-shrinkable tube 55 , single-bubble sponges 56 ( 56 A and 56 B), and a seal member 60 . An inner circumferential surface of the heat-shrinkable tube 55 is coated with an adhesive. The heat-shrinkable tube 55 is heated after being mounted to the lead line L and a communication line L 1 , so that the heat-shrinkable tube 55 is shrunk and closely attached to the lead line L and the like. Accordingly, as shown in FIG. 5 and FIG. 6 , the heat-shrinkable tube 55 covers the lead line L and the communication line L 1 . At the same time, the adhesive is melted to flow between the lead line L and the communication line L 1 . Then, the adhesive is hardened after cooling, so that the heat-shrinkable tube 55 , the lead line L and the communication line L 1 are tightly closed to each other.
The single-bubble sponge 56 A includes a concave groove 57 that extends in the vertical direction and is opened on the lateral side. A concave groove 61 extending in the vertical direction of the seal member 60 is formed at a projection 51 of the seal member 60 . The single-bubble sponge 56 A is fitted into the concave groove 61 in a state where tip-ends of the single-bubble sponge 56 A project from the concave groove 61 in the horizontal direction. A concave groove 58 that is opened toward an inner surface of the handle part 12 L is formed at a single-bubble sponge 56 B whose cross-section is U-shaped as shown in FIG. 6 . The single-bubble sponge 56 B is formed in a substantially rectangular shape in planar view, and is fitted into the concave groove 57 from the proximal side of the single-bubble sponge 56 B.
Before combining the left and right half housings 10 L and 10 R with each other, the lead line L and the communication line L 1 covered with the heat-shrinkable tube 55 are allowed to pass through the concave groove 57 of the single-bubble sponge 56 A and to penetrate the seal member 60 , so that the switch S and the internal connector C 1 are electrically connected to each other. As shown in FIG. 5 and FIG. 6 , when the left and right half housings 10 L and 10 R are combined with each other, the rib 18 R is pressed into a right lateral surface of the seal member 60 . At the same time, the rib 18 L presses the single-bubble sponge 56 B into the heat-shrinkable tube 55 in a state where the rib 18 L is fitted into the concave groove 58 of the single-bubble sponge 56 B. At this time, the rib 18 L is closely attached to the single-bubble sponge 56 A while deforming the same. As a result, the single-bubble sponge 56 A and the single-bubble sponge 56 B are pressed into and brought into contact with an outer circumferential surface of the heat-shrinkable tube 55 , so that surfaces of the heat-shrinkable tube 55 facing the single-bubble sponge 56 A and the single-bubble sponge 56 B are sealed. It should be noted that the heat-shrinkable tube 55 is an example of a covering member of the present invention, and the single-bubble sponges 56 A and 56 B are examples of elastic members of the present invention.
In the second embodiment, even if rainwater or the like reaches the lead line L and the communication line L 1 through the inlet ports 14 A and R 1 and the opening H, the rainwater or the like can be prevented from entering the battery pack 16 -side in the following manner. Since there is no gap between the heat-shrinkable tube 55 and the lead line L and the communication line L 1 , the rainwater or the like flowing toward the heat-shrinkable tube 55 along the lead line L and the communication line L 1 neither passes between the heat-shrinkable tube 55 and the lead line L and the like, nor enters the battery pack 16 -side in the handle part 12 . Further, since the surfaces of the heat-shrinkable tube 55 facing the single-bubble sponge 56 A and the single-bubble sponge 56 B are sealed, there is no gap between the heat-shrinkable tube 55 and each of the single-bubble sponges 56 A and 56 B. Thus, the rainwater or the like flowing along the lead line L and the communication line L 1 neither passes between the heat-shrinkable tube 55 and each of the single-bubble sponges 56 A and 56 B, nor enters the battery pack 16 -side in the handle part 12 .
Effect of the Second Embodiment
In the impact driver 1 A of the second embodiment, the heat-shrinkable tube 55 is closely attached to the lead line L and the communication line L 1 to cover the lead line L and the like. As a result, there is no gap between the heat-shrinkable tube 55 and the lead line L and the like. Therefore, the rainwater or the like having entered from the inlet ports 14 A and R 1 and the opening H can be prevented from flowing toward a gap between the battery mounting part 13 and the battery pack 16 , and the battery pack 16 from between the heat-shrinkable tube 55 and the lead line L and the like.
In addition, the surfaces of the heat-shrinkable tube 55 facing the single-bubble sponge 56 A and the single-bubble sponge 56 B are sealed, so that there is no gap between the heat-shrinkable tube 55 and each of the single-bubble sponges 56 A and 56 B. Therefore, the rainwater or the like can be prevented from flowing toward the gap between the battery mounting part 13 and the battery pack 16 or toward the battery pack 16 from between the heat-shrinkable tube 55 and each of the single-bubble sponges 56 A and 56 B.
Third Embodiment
A third embodiment of the present invention will be described with reference to FIG. 7 and FIG. 8 . In the third embodiment, the same constitutional elements as those in the first and second embodiments are given the same reference numerals and the explanations thereof will not be repeated. Unlike the first and second embodiments, an impact driver 1 B of the third embodiment has a body 11 A formed in a tubular shape without providing the rear cover R. The impact driver 1 B is provided with a seal member 70 . The seal member 70 is made of elastic material such as rubber. As shown in FIG. 7 , the seal member 70 is fitted into a position in the handle part 12 between the inlet port 14 A and the opening H, and the battery pack 16 in a state where the seal member 70 is twisted around an outer circumferential surface of the switch S. Accordingly, the seal member 70 seals between the side where the inlet port 14 A and the opening H are located and the battery pack 16 -side in the handle part 12 . The seal member 70 is twisted around the outer circumferential surface in a state where the seal member 70 is inclined downward toward the front side of the battery pack 16 relative to the bottom surface 16 A of the battery pack 16 . A rib guiding grove 71 is provided on the entire circumference of the seal member 70 . Further, as shown in FIG. 8 , a thin-plate rib 18 L 1 protrudes across the entire inner circumference of the left handle part 12 L, and a thin-plate rib 18 R 1 protrudes across the entire inner circumference of the right handle part 12 R. The ribs 18 L 1 and 18 R 1 are arranged on a plane that is inclined downward in the front direction relative to the bottom surface 16 A.
When the left and right half housings 10 L and 10 R are combined with each other, the ribs 18 L 1 and 18 R 1 are engaged with the rib guiding groove 71 while the trigger 15 is exposed from the opening H in a state where the seal member 70 is twisted around the outer circumferential surface of the switch S, so that the switch S is accommodated in the handle part 12 . Accordingly, the seal member 70 is positioned and held in the handle part 12 . At this time, the seal member 70 is arranged in such a manner that its inclined lower end is directed toward the opening H.
In the third embodiment, even if rainwater or the like enters the inside of the handle part 12 through the inlet port 14 A and the opening H, the rainwater or the like can be prevented from entering the battery pack 16 -side in the following manner. Due to the presence of the seal member 70 , there is no gap between the side where the inlet port 14 A and the opening H are located and the battery pack 16 -side in the handle part 12 . Thus, the rainwater or the like cannot enter the battery pack 16 -side from the side where the inlet port 14 A and the opening H are located. In addition, the rainwater or the like having reached the seal member 70 flows down on an upper surface of the seal member 70 to be guided to the opening H. Thereafter, the rainwater or the like passes through the opening H to be discharged to the outside of the handle part 12 . Accordingly, the rainwater or the like cannot enter the battery pack 16 -side in the handle part 12 .
Effect of the Third Embodiment
In the impact driver 1 B of the third embodiment, the seal member 70 is twisted around the outer circumferential surface of the switch S, and the switch S is only accommodated in the handle part 12 while the seal member 70 is engaged with the ribs 18 L 1 and 18 R 1 using the rib guiding groove 71 , so that the seal member 70 can be positioned in the handle part 12 . Accordingly, the seal member 70 can be easily positioned.
Further, unlike the first and second embodiments, the rainwater or the like having entered inside of the handle part 12 through the inlet port 14 A and the opening H is discharged from the opening H to outside of the handle part 12 by using the opening H without additionally providing the drainage port 17 in the handle part 12 . As a result, the rainwater or the like can be prevented from entering a gap between the battery mounting part 13 and the battery pack 16 , and the battery pack 16 .
The present invention is not limited to the above-described embodiments, but can be implemented by appropriately changing a part of the configuration within a range without departing from the scope of the present invention. Unlike the first and second embodiments, the shape of each lateral surface of the seal member is not limited to the S-shape, but may be, for example, a shape that is linearly inclined from side where the inlet ports 14 A and R 1 and the opening H are located toward the battery pack 16 -side.
Further, in the case where the shape of each lateral surface of the seal member is linearly inclined, the shape of each rib protruding from the respective handle parts 12 L and 12 R may be changed to a shape enabling to press each of the linearly inclined lateral surfaces, unlike the above-described embodiments. In addition, the switch S may be accommodated in the handle part 12 by engaging a convex part provided on the entire circumference of the seal member 70 with concave parts provided on the entire circumferences of the both handle parts 12 L and 12 R, unlike the above-described embodiments. Alternatively, the switch S may be accommodated in the handle part 12 by directly engaging the seal member 70 with the concave parts provided on the entire circumferences of the both handle parts 12 L and 12 R without providing the convex part at the seal member 70 . Further, the present invention may be applied to not only the above-described impact drivers 1 , 1 A, and 1 B, but also an electric tool such as a rechargeable hammer drill.
It is explicitly stated that all features disclosed in the description and/or the claims are intended to be disclosed separately and independently from each other for the purpose of original disclosure as well as for the purpose of restricting the claimed invention independent of the composition of the features in the embodiments and/or the claims. | The present invention provides a rechargeable electric tool in which a battery pack detachably mounted to a mounting part, which is formed lower than an opening provided at a housing, wherein a seal member is held in the housing to seal between the opening and the battery pack mounted to the mounting part. A projection projecting toward the opening side is provided at the seal member, and a passing hole that penetrates the projection and the seal member and allows a lead line connecting an electric component accommodated on the opening side in the housing to the battery pack to pass therethrough is formed. | 1 |
This application is related to an application entitled "Random Access Audio/Video Processor with Multiple Outputs," to David Rossmere, Robert Glenn, Jr., William Brown, John Carluci and Robert Duffy, Ser. No. 08.196.018, filed Feb. 14. 1994; and to an application entitled Random Access Audio/Video Processor with Compressed Video Resampling to allow Higher Bandwidth Throughput," by David Rossmere, Robert Glenn, Jr., William Brown, John Carluci and Robert Duffy, Ser. No. 08/196,038, filed Feb. 14, 1994. Both of these applications are hereby incorporated by reference.
BACKGROUND
1. Field of the Invention
This invention relates generally to the field of data compression. More particularly, this invention relates to a method and apparatus for data compression using adaptive bit rate control which is particularly well suited for compression of video data which should be maintained at an approximately constant compressed data size.
2. Background of the Invention
Referring to FIG. 1, a typical field-based video data compression system 10, such as a JPEG (Joint Pictures Expert Group) style system, includes a source data memory 12 which provides data to a video compressor 16. A compressed data counter 20 makes a determination of the size of the compressed data and provides this information to a bit rate controller 24. The bit rate controller makes a determination of a quantizer scale factor and provides this information to the video compressor 16. The compressed data from the video compressor 16 is provided to a compressed data memory 28 which is ultimately used as the source of data for a transport medium 32 (or storage medium).
The source data memory 12 contains the uncompressed video data. The video compressor 16 processes data from the source data memory, reduces its data volume, and stores the compressed video data into the compressed data memory 28. The compressed data counter 20 counts the number of compressed data bytes output by the video compressor 16 during each field. The bit rate controller 24 adjusts the compression parameters to control the volume of data output by the video compressor 16. Compressed video data is moved via the transport medium 32 to other locations.
In a JPEG style video compressor such as 16, compression takes place in three stages: transform 40, quantization 44, and entropy coding 48. In the transform stage, video data is transformed from time domain information into a frequency domain representation using, for example, a discrete cosine transform or fast Fourier transform or the like. This frequency domain information is represented as a matrix. In the quantization stage 44, transformed data is divided by a value from scaled quantizer matrix produced by quantization matrix scaler 52. A large quantizer scale factor at 56 creates larger values in the scaled quantizer matrix at 60, and causes more information to be discarded in the quantization operation of quantizer 44. The compression ratio, defined to be the size of the source video data divided by the size of the compressed video data, is primarily determined by the value of the quantizer scale factor at 56.
Many video compression techniques, such as the JPEG compression standard, produce a compressed data stream that varies in volume depending on the complexity of the source video image. However, in many cases the compressed data stream must then be carried by some medium which has limited data carrying capacity. To prevent overflow of the transport medium, the volume of data produced by the compression technique must be controlled.
Typically, a buffer memory such as 28 is inserted between the output of the variable bit rate video compression circuitry and the input of the constant bit rate transport medium. The buffer memory is used to smooth out variations in the volume of data output by the compression circuitry. Because the buffer memory size is limited, the volume of data produced by the video compression circuitry must still be controlled to prevent buffer overflow.
For most field,based video compression systems, the amount of compression is primarily controlled by the quantization process. In this process, a matrix of transformed video data is divided by a quantization matrix at 44. Because the remainder of the division operation is discarded, information is lost and the number of bits required to represent the source data is reduced. The compressed data volume is controlled at quantization matrix scaler 52 by multiplying the quantization matrix by the quantizer scaling factor at 56. A large quantizer scaling factor increases all of the values in the quantization matrix, which results in more data being discarded in the division operation, and consequently a lower output data volume.
In most applications, the volume of data produced by the video compression circuitry must very closely match the data carrying capacity of the transport medium. To produce this precise control over data volume, an iterative process is used to pick the optimal quantizer scale factor. This iterative process requires each field of data to be compressed multiple times. For a particular field of video data, typically an initial quantizer scale factor is selected, and compression is performed. The volume of data produced is compared to the desired data volume, and the quantizer scale factor is adjusted. If the target data volume was exceeded, the quantizer scale factor is increased, and vice versa. This process is repeated several times until an optimal quantizer scale factor is found for a particular field. The object is to closely match the capacity of the transport medium so that the best quality picture is obtained consistent with the limitations of the transport medium.
Iteration to produce an optimal quantizer scale factor provides precise control over compressed data volume, but can become impractical in real-time systems. In a real-time system, every field must be compressed in a time no longer than one field time. If iteration is used, then a particular field must be compressed several times during one field time, or several compression circuits must be used in parallel. In either case, the system cost can be high due to the need for extremely high speed processing or multiple processors (compressors) are needed to implement the compression.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an improved compression method suitable for use in real time video to produce an approximately constant data rate.
It is a feature that the present invention is simple to implement.
It is an advantage that the present invention provides approximately constant rate output data.
It is a further advantage that one embodiment of the present invention provides detection of scene changes.
These and other objects, advantages and features of the invention will become apparent to those skilled in the art upon consideration of the following description of the invention.
The present invention relates to a one pass adaptive bit rate control method particularly useful for video data. Data from a previous video field is used to calculate a quantizer scale factor for use in compressing a current video field. Large changes in compressed data size is used to detect scene changes. When a scene change is detected, a marker is inserted into the compressed data stream in place of the compressed field. An interpolated field is substituted during decompression for the scene change marker.
To avoid confusion in terminology, for purposes of this discussion:
F n refers to the current frame (number n) being processed;
S n refers to the size of the compressed field F n ;
Q n refers to the quantization factor computed from and used to compress field F n .
In one aspect of the present invention, a method for compressing a sequence of fields of video data F n where n is a field counting number, includes the steps of: (a) establishing a desired data size S desired for fields of compressed data; (b) calculating a quantization factor Q n from the size S n-1 resulting when a field of data F n-1 was compressed; (c) compressing a field of data F n using the quantization factor Q n ; and (d) repeating steps (b) and (c) for each value of n for the sequence of fields of video.
In another aspect of the invention, a method for compressing a sequence of fields of video data F n where n is a field counting number, includes the steps of: establishing a desired data size S desired for fields of compressed data; calculating an initial quantization factor Q 1 as: ##EQU1##
where k is a constant; compressing the field F 1 using an initial quantization factor Q 1 ; for each n>1, calculating a quantization factor Q n using ##EQU2##
and; for n>1, compressing each field of data F n using the quantization factor Q n .
In another aspect of the present invention, a method for compressing a sequence of fields of video data F n where n is a field counting number, includes the steps of: establishing a desired data size S desired for fields of compressed data; calculating an initial quantization factor Q 1 for compressing field F 1 as: ##EQU3##
where k is a constant; compressing the field F 1 using the quantization factor Q 1 ; for n>1, calculating a quantization factor Q n for each field of data F n using ##EQU4##
where c is a constant; and for n>1 , compressing each field of data F n using the quantization factor Q n .
In yet another aspect of the invention, a method for compressing a sequence of fields of video data F n where n is a field counting number, includes the steps of: establishing a desired data size S desired for fields of compressed data; establishing an initial quantization factor Q 1 for compressing field F 1 ; compressing the field F 1 using the quantization factor Q 1 ; for n>1, establishing a quantization factor Q n for each field of data F n ; and for n>1, compressing each field of data F n using the quantization factor Q n calculated using the actual data size S n-1 obtained when field F n-1 was compressed.
A method, according to the invention, for compressing a sequence of fields of video data F n where n is a field counting number, includes the steps of: establishing a desired data size S desired for fields of compressed data; establishing an initial quantization factor Q 1 for compressing field F 1 ; compressing the field F 1 using the quantization factor Q 1 ; for n>1, establishing a quantization factor Q n for each field of data F n ; for n>1, compressing each field of data F n using the quantization factor Q n calculated using an actual data size S n-1 obtained when field F n-1 was compressed; and for n>1, each field's compressed data size S n is compared with the previous field's compressed data size S n-1 and if the difference between S n and S n-1 is greater than a predetermined threshold, then a substitute field or scene change marker is substituted for field F n .
With the present invention, precise control of compressed data volume is not needed because a large buffer memory can absorb data volume fluctuations. This invention uses data from the previous field to calculate a quantizer scale factor for the current field. The calculation is computationally simple, and can be performed very quickly. Adequate control of compressed data volume is achieved with minimum complexity and in a manner suitable for use in a real time system.
The features of the invention believed to be novel are set forth with particularity in the appended claims. The invention itself however, both as to organization and method of operation, together with further objects and advantages thereof, may be best understood by reference to the following description taken in conjunction with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a block diagram of a compression system.
FIG. 2 is a block diagram of a JPEG style compressor.
FIG. 3 is a flow chart of the compression process used in the present invention.
FIG. 4 is a flow chart describing a compression process using scene change detection.
FIG. 5 is a flow chart of a decompression process according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
While this invention is susceptible of embodiment in many different forms, there is shown in the drawings and will herein be described in detail specific embodiments, with the understanding that the present disclosure is to be considered as an example of the principles of the invention and not intended to limit the invention to the specific embodiments shown and described. In the description below, like reference numerals are used to describe the same, similar or corresponding parts in the several views of the drawing.
Referring to FIG. 1, the present invention utilizes a new method of bit rate control within bit rate controller 24. Otherwise, the basic block diagram is similar to that described above. The value of the quantizer scale factor at 56 is set by the bit rate controller 24. While each field is being compressed, the compressed data counter 20 counts the number of bytes of compressed video data that are generated. After the field has been compressed, the bit rate controller 24 uses the field's quantizer scale factor, the compressed video data size generated by using that scale factor, and the desired compressed video data size to calculate a new quantizer scale factor. This new quantizer scale factor is used by the compressor to create a new scaled quantizer matrix in the standard manner, which is used for the next field. That is, the scale factor used for compressing the current field is that calculated from the scale factor which is required for the preceding field. All of this processing is performed in the interval between two fields. Of course, the quantization information may be encoded for transmission to the receiving end to permit proper decoding if the particular compression technique requires such.
The process used in this invention is described with reference to FIG. 3 starting at step 100. In this method of bit rate control, the value of desired data size variable S desired is initially set at step 104 to the desired field compressed data size. Then, an initial value of the quantizer scale factor Q' is calculated at 108, and this value is stored in the compressor at 112. After the entire field has been compressed as determined at step 116, the value of previous field quantizer scale factor variable Q is set to the current value of Q' , and the compressed data size S is retrieved from the compressed data counter at 118. Using these values, a new quantizer scale factor Q' is calculated at 122, and this value is stored into the compressor at 128 and used to compress the next field. The current field is stored at 130 in compressed data memory 28 or otherwise processed. This process repeats indefinitely.
After every field has been compressed, the previous quantizer scale factor and the resulting compressed data size are used to calculate a new quantizer scale factor. The algorithm used for this calculation is very easy to calculate, yet provides good control of compressed data size. This algorithm was empirically derived from observations of the relationship between quantizer scale factor and resulting compressed data size for many different fields of video.
The initial quantization factor used to compress the first field of data is derived empirically. In the preferred embodiment, the formula for initial quantizer scale factor is shown in Equation 1, ##EQU5## where Q' is the initial quantizer scale factor used to compress the first field of data, and S desired is the desired compressed data size. Other initial quantization factors may also be selected if desired or if a good factor is known for the initial field.
The general formula for subsequent quantizer scale factors is shown in Equation 2, ##EQU6## where Q' is the new quantizer scale factor, S desired is the desired compressed data size, Q is the previous quantizer scale factor, and S is the resulting compressed data size.
As a practical matter, it is desirable to limit changes in the quantizer scale factor. For example, a flat black video image contains almost no information, and will naturally result in a very small compressed data size. When compressing a sequence of flat black images, because S desired is larger than S, the value of Q' will become very small. This is not only wasteful of transport medium bandwidth, but will result in an extremely large compressed data size if the scene changes to a complicated image. Therefore, Equation 1 and Equation 2 should, as a practical matter, be modified so that Q' has a floor value, as shown in Equation 3 and Equation 4, ##EQU7## where C is a constant. The value of C depends on the value of S desired . To prevent Q' from becoming too small, we can use Equation 1 to develop a (fairly arbitrary) value for C. The equation shown as Equation 5 has been found suitable for a wide range of images. ##EQU8##
Thus, for a sequence of video fields F n , where n is a field number, the quantization factor Q n which is used for compression of the current field of data F n is calculated as follows to obtain a data size of approximately S desired : ##EQU9## and where S n-1 is the actual size obtained after compression of the previous field of video data F n-1 using quantization factor Q n-1 . The initial field F 1 , is compressed using quantization factor Q 1 as follows: ##EQU10## which could be generalized to: ##EQU11## where k is a constant.
In the case where the bounds are not needed for the quantization factor values, the quantization factor for field F n can be calculated as in EQUATION 2, which would become: ##EQU12##
Note that each field is compressed using a quantizer scale factor calculated from the compressed data size of the previous field of data. Thus, the quantization factor is continuously adjusted to provide a good approximation of the quantization factor needed for the current video information. For video images that are either unchanging or only changing slightly in complexity, this technique provides good compression performance, and approximates the desired compressed data size. This bit rate control method takes advantage of the fact that most video fields are very similar to the temporally previous video field. The present one-pass non-iterative method of bit rate control is advantageous because parallel compressors are unnecessary and compression does not have to be performed faster than real time.
However, a one-pass .bit rate control mechanism cannot generally perfectly control compressed data size if the complexity of consecutive video fields is radically different, such as at scene changes. Because every field is compressed using a quantizer scale factor calculated from the compressed data size of the previous field, the first field of a scene change can be overcompressed or undercompressed. Therefore, this bit rate control mechanism preferably uses a compressed data buffer that is large enough to prohibit a single undercompressed video field from causing a buffer overflow. If a single overcompressed or undercompressed video field is visually objectionable, then corrective measures, such as field replication as discussed below, can be taken to reduce the problem.
This invention uses the compression results from the previous field to calculate a quantizer scale factor for the current field. The desired data volume is achieved because, in general, consecutive fields of video data are similar in complexity. However, consecutive fields of video data can be very different at a "scene change." If the complexity of the current field's video image is higher than that of the previous field, then the volume of compressed data created will be higher than the desired amount. Conversely, if the complexity of the current field's video image is lower than that of the previous field, then the volume of compressed data will be lower than the desired amount. In either case, because this field's compression results will be used to calculate the quantizer scale factor, the volume of compressed data output for the next field will be close to the desired size.
In many video applications, it is desirable to automatically find scene changes. The large deviations of the actual compressed data volume from the expected compressed data volume can be used to detect scene changes as illustrated in FIG. 4. In this figure, which constitutes a modification of FIG. 3, the change in compressed field size is examined at step 138. For every field, the actual compressed data volume is compared to the expected compressed data volume. The expected size is that of the previous compressed field. Thus, if S n , the size of the current field, is much larger or smaller than the previous field S n-1 , so that the absolute value of the difference in size is greater than some threshold value .increment. max , then it can be assumed that the video complexity suddenly changed, and that a scene change has been encountered. When this threshold is exceeded, the process goes to step 144 in which a marker indicating that a scene change has taken place is stored in the compressed data memory 28 in place of the compressed field. When the threshold .increment. max is not exceeded, control passes to step 130 where the compressed field is stored in memory 28.
In FIG. 4, at step 138, the size of the resulting compressed data is compared with the size of the previous data field by subtracting S n-1 from S n and comparing the absolute value of the result with a maximum difference value .increment. max . If the difference is greater than .increment. max , then it can be presumed that a scene change has taken place and the quantization factor for field F n-1 is not appropriate to provide suitable compression. Corrective action is taken in the decoding of the compressed data as shown in FIG. 5.
Referring to FIG. 5, the decoding process for compressed data generated as illustrated above is described. In this arrangement, compressed data is examined at step 200 to see if a scene change marker is present. If not, the data is decompressed in a normal fashion at step 210 to produce output decompressed data. In the event a scene change marker is found at step 200, a substitute field of data is generated at step 220 and provided as an output.
The substitute field of data can be generated in a number of ways. In one embodiment, the previous field of decompressed video can be repeated at step 220. In another embodiment, field interpolation can be used to generate the substitute field. Field interpolation can create an "odd" field from an "even" field or vice versa. It can also be used to reduce image bounce in slow-speed play, and to double vertical resolution under certain circumstances. In the present invention, a vertical averaging filter is used to carry out the interpolation using the following equations: ##EQU13## These equations calculate a synthetic pixel which is spatially midway between the two existing pixels in actual video fields. EQUATION 11 above calculates the spatially higher line while EQUATION 12 above calculates the spatially lower line. Other techniques could also be used to generate the substitute field, including deletion of the field.
The present invention can be implemented in any number of ways without departing from the present invention. For example, a programmed processor can be used to carry out all of the processing described. Alternatively, a hardware implementation using lookup ROMs to store values of the quantization factor corresponding to particular sizes of the compressed data be used. Of course, a hardware implementation using two multipliers and a divider can also be considered.
The invention is preferably implemented using a combination of both hardware and software. All of the compression processing, including quantizer scaling and quantization, is preferably implemented using an application-specific integrated circuit. The quantizer scale factor calculation is preferably performed by a programmed processor such as a microprocessor. The buffer memory is implemented in hardware. Of course, in the alternative, the quantizer scale factor calculation can be performed in hardware, using either special purpose multipliers and dividers, or using lookup tables as suggested above. Other variations will occur to those skilled in the art after consideration of the present invention. Those skilled in the art will also appreciate that a wide range of constants k and c can be expected to be functional in the present invention and that those constant values presented are merely illustrative of values which have been experimentally determined to function reasonably well over a wide range of video input.
Thus it is apparent that in accordance with the present invention, an apparatus that fully satisfies the objectives, aims and advantages is set forth above. While the invention has been described in conjunction with specific embodiments, it is evident that many alternatives, modifications, permutations and variations will become apparent to those skilled in the art in light of the foregoing description. Accordingly, it is intended that the present invention embrace all such alternatives, modifications and variations as fall within the scope of the appended claims. | A one pass adaptive bit rate control method. Data from a previous video field is used to calculate a quantizer scale factor for use in compressing a current video field. Large changes in compressed data size is used to detect scene changes. When a scene change is detected, a marker is inserted into the compressed data stream in place of the compressed field. An interpolated field is substituted during decompression for the scene change marker. | 7 |
FIELD OF THE INVENTION
[0001] The present invention relates to electrical connectors, and more particularly to modular connectors for connecting daughter printed wiring boards to mother printed wiring boards.
BACKGROUND OF THE INVENTION
[0002] In the manufacture of computers and other electronic apparatus, daughter printed wiring boards (PWBs) are commonly connected to mother PWBs by means of modular electrical connectors, typically comprising a receptacle and a header. A daughter card (or PWB) electrically and mechanically connects to a receptacle, which in turn electrically and mechanically connects to a mother card (or backplane).
[0003] Modular electrical connectors of the type mentioned above are used, for example, to connect a large number of signal wires to a PWB. Consequently, a connector is provided with a number of columns of contact holes with contact pins disposed therein. An exemplary connecter is an 8×12 connector which has 12 columns of 8 contact holes with contact pins disposed therein.
[0004] As miniaturization becomes more prevalent, the number of signal wires to be connected to a connector increases, but the dimensions of the connector itself must not increase and preferably should even decrease. This results in an increasing number of signal and ground connections in the limited space of the connector. In high-frequency applications, this results in the risk of cross talk in the signal connections.
[0005] Accordingly, to combat the risk of cross talk due to mutual EMI of the signal connections, electrical connectors are equipped with shielding to attempt to shield each signal from EMI from neighboring and nearby signals. This shielding can be a conventional mechanical shield or an electrical shield in the form of a ground line. With today's electrical connectors, however, the current state of shielding still leaves great risk for cross talk. It is, therefore, desirable to provide an electrical connector that has enhanced shielding capabilities, yet does not significantly reduce signal density.
[0006] Stripline configurations, i.e., arrangements in which conductors in parallel in a dielectric are interposed between ground planes, are known in the art. A need exists for a way to use such configurations to reduce cross.
SUMMARY OF THE INVENTION
[0007] A header for interconnecting electrical components is provided. The header comprises at least one column of conductors interposed between ground planes, wherein the column of conductors comprises at least a first, second and third conductor. The first conductor is a ground line, the second and third conductors are signal lines, and the first conductor is electrically connected to one of the ground planes, wherein the second conductor is positioned in the column in interposed relation between said first and third conductor.
[0008] In alternate embodiments, the header for interconnecting electrical components comprises a plurality of rows and columns of signal lines, wherein at least one column comprises at least one ground line situated between two signal lines so that the ground line is coplanar with the signal lines.
[0009] A ground plane for providing at least one ground line throughout a header for interconnecting electrical components also is provided. The ground plane comprises at least one substantially vertically-oriented metal shield section for separating signal lines of adjacent columns and at least one substantially horizontally-oriented ground shield, through which a ground line that carries a ground current passes.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] [0010]FIG. 1 is a top view of a preferred embodiment of a header of the present invention.
[0011] [0011]FIG. 2 is a schematic of a conventional column of eight signal lines from an 8×12 header.
[0012] [0012]FIG. 3 is a schematic of a column of signal lines of the present invention for an 8×12 header.
[0013] [0013]FIG. 4 is a cross-sectional side view of the header of FIG. 1.
[0014] [0014]FIG. 5 is an inverted rear view of the header of FIG. 1.
[0015] [0015]FIGS. 6 and 7 are the two side isometric views of the ground plane of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0016] A header for connecting a receptacle to a mother printed wiring board (PWB) and having an improved shielding design is provided. A top view of a preferred embodiment of a header of the present invention is shown in FIG. 1. This preferred header is an 8×12 header, having twelve columns of eight contact holes, in which are disposed contact pins 10 , each of which can carry a signal. It will be understood that the terminology 8×12 is used even though the drawings show 9 rows of contacts since only 8 rows of contacts on the header mate with contacts on the receptacle while one row of contacts on the header is grounded to a metallic shield on the receptacle. Alternatively, the 8 rows may be any number of rows of preferably at least 5 rows. Also, the 12 columns may alternatively be any number of columns which is a multiple of 3.
[0017] A schematic of a conventional column of signal lines from an 8×12 header is shown in FIG. 2. The conventional column of FIG. 2 has signal lines 14 , and a vertically-oriented shield 16 separating the columns of signals from each other. This conventional design provides limited protection against cross talk between signal connections.
[0018] A schematic of a column of signal lines of the present invention is shown in FIG. 3. From ground line 12 , there are two signal lines generally A and B (generally at 14 ), followed by a ground line C, two more signal lines D and E, followed by a ground line F, and then two more signal lines G and H. In addition, there are substantially vertically-oriented metal shields 18 adjacent the signal lines 14 and substantially horizontally-oriented metal shields surrounding the ground lines 12 , C and F. This new design provides enhanced protection against cross talk between signal connections. Preferably, these differential pairs of signal lines 14 are used with high speed signals and are offset 180 degrees. As is known in the art, when differential pair signals are offset by 180 degrees, noise in one signal tends to be cancelled by the noise in the other signal. A further explanation of differential pairs is found at pages 267-268 and 319-320 of “High-Speed Digital Design,” by Howard W. Johnson et al. (Prentice Hall, 1993), the contents of which are incorporated herein by reference.
[0019] Still referring to FIG. 3, parallel shield sections 22 and 42 are positioned to opposed sides of the ground and signal line conductors. A tab 21 is also used to contact the shield 22 to ground spring 40 which is also in contact with shield section 42 . It will be appreciated that the ground shield sections 22 and 42 will affect the electromagnetic field around each signal line 14 so as to reduce cross talk between adjacent signal lines 14 . It will also be seen that the ground lines as at lines 12 , C, F and 28 are electrically connected to the shield 22 which will have the effect of further affecting the electromagnetic fields surrounding the signal lines 14 so as to still further enhance cross talk reduction. The tab 44 further enhances grounding and cross talk reduction by allowing ground current from shield section 22 to be further distributed to ground spring 40 and thus other shield sections such as shield section 42 .
[0020] [0020]FIG. 4 shows a cross-sectional side view of the header of FIG. 1. Shown in FIG. 4, there is a column comprised of a ground line 12 , which mates with a grounding shield (not shown) on the receptacle, signal lines A, B, D, E, G and H (generally at 14 ), and ground lines C and F, which mate with contacts on the receptacle. FIG. 4 also shows the metal shield 20 , which comprises shields sections 22 situated between the columns of signal contact pins 10 at the location of the signal lines 14 . Slots 24 also are present between the metal shield sections 22 where the ground lines 12 , C and F are located. FIG. 4 also shows the plastic housing 30 , comprising the three walls 32 , 34 and 36 . FIG. 5 shows an inverted rear view of the header of FIG. 1.
[0021] The metal shield 20 of the present invention, referred to as a ground plane 20 , is shown in FIGS. 6 and 7 in the two side isometric views. FIGS. 6 and 7 depict the metal shield sections 22 , the slots 24 between the shield sections 22 , and ground shields 28 , through which the signal contact pins 10 (or signal lines 10 ) that carry the ground lines 12 , C and F pass. Preferably, a ground plane 20 is one member. For example, the ground plane 20 alternatively may be described as a metal shield plate having slots 24 and ground shields 28 perpendicularly attached to the plate just above the location of the slots 24 .
[0022] The metal shield sections 22 are substantially rectangularly-shaped and are substantially vertically-oriented. The ground shields 28 are substantially rectangularly-shaped and are substantially horizontally-oriented. Preferably, the ground shields 28 are oriented at approximately 90 degrees to the metal shield sections 22 . Each ground shield 28 has four rectangularly-shaped corner tabs 29 that are bent (or curved) upward so that the ground planes 20 can be situated around the signal contact pins 10 without causing damage to the pins 10 . Preferably, the ground shields 28 attach to the pins 10 .
[0023] The header of the present invention is also equipped with springs 40 which are situated on housing wall 32 , as depicted in FIGS. 1, 4 and 5 . These springs 40 have a mechanical function and a grounding function. The springs 40 mechanically receive the connecting receptacle, to which the daughter card connects. The springs 40 also provide an electrical link to the grounding signals 12 of each ground plane 20 by abutting each ground plane 20 . As shown in FIG. 6 and 7 , each ground plane 20 has a connecting tab 21 which, by way of each tab's distal end 41 , electrically connects each ground plane 20 to the series of springs 40 . In the embodiment of FIG. 1, this 8×12 header preferably has 6 springs, as shown in FIGS. 1 and 5.
[0024] The header design of the present invention reduces cross talk between signal lines 14 by providing a 2:1 signal line 14 to ground line 12 , C and F ratio. The header of the present invention also has a conventional footprint that allows it to be used as a header for conventional connectors. The slotted design of the ground shields also allows for more plastic to be present than otherwise be present without the slots 24 , as depicted in FIG. 1. This strengthens the existing electrical insulation provided by the plastic, thereby further reducing the risk of cross talk. It will also be appreciated that the header of the present invention, by making use of ground planes, allows for the use of fewer ground connections to the printed circuit board. Because fewer pins need to be used for grounding, more pins can be used as signal pins, thereby allowing for more signal density.
[0025] 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. Accordingly, changes may be made in detail, especially in matters of shape, size and arrangement of parts within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed. | A header for interconnecting electrical components comprises at least one column of conductors interposed between ground planes, wherein the column of conductors comprises at least a first, second and third conductor. The first conductor is a ground line, the second and third conductors are signal lines, and the first conductor is electrically connected to one of the ground planes, wherein the second conductor is positioned in the column in interposed relation between said first and third conductor. | 7 |
BACKGROUND OF THE INVENTION
1. Field Of The Invention
The present invention relates to windows used in conventional buildings such as houses and particularly to windows that open by pivoting outwardly from their frames.
2. Description Of The Prior Art And Objectives Of The Invention
With the recent increase in the crime rate, in certain populated areas more and more home owners have attempted to secure their dwelling and other buildings from unauthorized intrusions. Various types of security systems and alarms have been have been devised such as shown in the jalousie alarm system of U.S. Pat. No. 4,449,121 whereby a jalousie-type window is connected to an alarm system wherein a deflection of the alarm strut or shaft will cause electrical contact to be made thereby activating an audio alarm. Also, a rotatable saw-bar is included in the alarm strut which will prevent the alarm shaft from being removed or cut by sawing. Other types of securty locks, alarms and devices have been made for a variety of window types. However, such prior art devices usually have certain weakness and problems associated therewith. Also, in recent years changes have been made in building codes for windows to help protect buildings and their contents in adverse weather conditions such as during hurricanes, windstorms and the like.
With the aforesaid problems and conditions understood, the present invention was conceived and one of its objectives is to provide an awning window which can be easily installed by a building contractor and which will provide both burglar and weather protection.
It is another objective of present invention to provide an awning window which include a rotatable transparent panel with a J-shaped lip which will engage a lip receptacle attached to the frame upon closing.
It is yet another objective of the present invention to provide an awning window with an alarm strut having an anti-saw bar and having an alarm switch mechanism therein.
It is also an objective of the invention to provide an awning window with an alarm strut with a panel lip receptacle attached thereto.
It is also an objective of the present invention to provide an awning window having a window sill with a lip receptacle affixed thereto for engagement with the lowermost panel.
Various other objectives and advantages of the invention will become apparent to those skilled in the art as the invention set forth in more detail below.
SUMMARY OF THE INVENTION
The aforesaid and other objectives are achieved by providing an awning window having a rectangular frame consisting of a header, sill and opposingly positioned side jambs. One or more rotatable glass panels are affixed to the frame and a mechanical drive mechanism is provided whereby the panels can be opened or closed as desired. Alarm struts are joined on the inside of the frame behind the panels and include anti-saw bars. Electrical contacts are connected to the alarm strut so if the alarm strut is twisted or bent such as may occur during a burglary attempt, an audible alarm is set off. At the bottom of each of the panels a J-shape lip is provided which will engage a lip receptacle which may be positioned on the alarm strut for the upper panels and for the lower panel may be positioned on the frame sill.
As in the conventional awning windows, as the window is closed the panels rotates inwardly and contacts the frame and upon continued rotation of the drive mechanism handle the panel raises slightly for example one quarter (1/4") of an inch within the frame whereby the lip and receptacle make full engagement and therefore prevent the panel from being pried or forced outwardly as may occur during a burglary attempt or during a severe storm.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts a typical embodiment of the awning window of the invention having three (3) rotatable panels affixed to a rectangular frame;
FIG. 2a provides a cross-sectional view of the closed awning window with certain portions enlarged as shown in FIGS. 2b and 2c;
FIG. 3 demonstrates a side-elevational cross sectional view of the window as shown in FIG. 1 with the panels opened;
FIG. 4 shows a portion of the side jamb and alarm struts as seen at 4--4 in FIG. 3;
FIG. 5 illustrates the mechanical drive mechanism of the window as shown in FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The preferred form of the awning window of the invention includes a rectangular frame formed from extruded aluminum and includes a header, a sill and side jambs. The drive mechanism is positioned in the side jamb and a plurality of rotatable panels formed from glass are rotatably positioned within the frame. Alarm struts are mounted between the side jambs at approximately the lower edge of the upper panels. The alarm struts include an anti-saw bar and lip receptacle. Electrical connections on the struts make contact upon the struts being bent or twisted to activate an audio alarm. On the bottom of the alarm strut is attached a lip receptacle which will engage a J-shaped panel lip on the rotatable panel. A somewhat similar receptacle is provided on the frame sill whereby upon closing, the panel lips engage the lip receptacles to provide additional security and prevent the panels from being forced open as may be attempted by an intruder or by high wind conditions.
DETAILED DESCRIPTION OF THE DRAWINGS AND OPERATION OF THE INVENTION
Turning to the drawings, FIG. 1 demonstrates a typical awning window 10 of the invention having a plurality of three (3) glass panels 11 contained within rectangular frame 12. Panels 11 rotate outwardly as shown in FIG. 1 to allow fresh air to enter the building and by rotating handle 13 in an opposite direction, panels 11 rotate inwardly to frame 12 as shown in FIG. 2. Panels 11 in FIG. 2 are formed from two transparent panes of glass although various other constructions such as single or triple panes of glass or other materials can be used. Frame 12 consists of aluminum extrusions which have been joined together including header 13, side jambs 14 and frame sill 15. Conventional drive mechanism 16 as shown in FIG. 5 is substantially concealed within side jambs 14 and frame sill 15 as is conventional within the trade. As is understood, drive mechanism 16 will rotate panels 11 inwardly and outwardly and upon closing, panels 11 are raised slightly within frame 12.
Rotatable latches (not shown) such as seen in U.S. Pat. No. 2,997,754 may be used on the side jambs to assist in closing the panel within the frame. As is understood, awning window 10 as shown in FIG. 1 includes three (3) transparent rotatable panels 11 although more or fewer panels may be used in particular situations. Also, a series of awning frames 12 can be affixed together to provide a wide awning window for applications needing more window area.
As further seen in FIG. 2, frame sill 15 includes lip receptacle 17 which engages panel lip 18 collectively forming latch means 31 and weep hole 19 allows any accumulated moisture to escape therefrom. Panel lip 18 is somewhat shorter than lip 21 and lip receptacle 17 adequately accomodates the engagement with panel lip 18. As seen in FIG. 2, lip receptacle 17 is positioned forward of lip receptacle 20 and therefore the arc of travel of lip 18 is somewhat different than the travel arc of lip 21. Lip 21 and lip receptacle 20 form latch means 30. Lips 18 and 21 are shown enlarged in FIGS. 2b and 2c and lip receptacle 20 is affixed to alarm strut 22 with lip receptacle 17 being affixed to frame sill 15.
Alarm strut 22 as seen in FIG. 2b includes anti-saw bar 24 with outer frame member 25 and inner strut member 26 connected respectively to electrical conductors 27 and 28 which would actually be inside side jambs 14. Thus, if alarm strut 22 is sufficiently deflected, contact is made between outer frame 25 and inner strut member 26 thereby alarm struts 22 act as a switch and allows electrical current to flow through conductors 27 and 28 to activate an audible alarm (not shown). Horizontal alarm struts 22 are attached to vertical jamb members 14 as shown in FIG. 1 and FIG. 4 and include lip receptacles 20. Thus, awning window 10 includes an alarm strut 22 which acts as a switch for an audible alarm in the event a burgular attempts to enter the window and, during adverse weather conditions or if windows are attempted to be forced outwardly, panel lips 18 and alarm strut receptacle 22, by being engaged, will assist in preventing the window from being opened.
The illustrations and examples provided herein are for explanatory purposes and are not intended to limit the scope of the appended claims. | A security awning window is presented with increased safety factors which grant protection against both adverse weather conditions and unauthorized entry. Alarm struts span the window which, if deflected act as a switch for an audible alarm and also engage the panels to provide increased burglar or adverse weather protection. | 4 |
CROSS REFERENCE TO RELATED APPLICATIONS
Not Applicable
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT
Not Applicable
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to fuel injector spark plugs and particularly to fuel injector spark plugs that vaporize fuel prior to injection.
2. Description of the Prior Art
Spark plugs and fuel injectors have been used in internal combustion engines since the inception of such engines. In recent years, almost all engines use fuel injection in combination with traditional spark plugs in gasoline engines. Although this is a good combination, there are some inefficiencies in delivering the fuel to the cylinder separately from the spark plug. By injecting the fuel right at the source of the spark, it is possible to enhance the power generated and to burn the fuel more completely. To that end, several spark plug-injector patents have been issued. Examples of these are found in U.S. Pat. Nos. 1,310,970, 2,795,214, 3,173,409, 4,095,580, 5,497,744, 4,736,718, and 6,536,405.
In the past, it appears that engine damage was encountered because fuel was inadvertently vaporizing in the cylinder (manifold), ?? thereby causing too much pressure (power). As a result, additives were used to counter the problem.
BRIEF DESCRIPTION OF THE INVENTION
The instant invention is designed to overcome the problem of inadvertent or premature vaporization of fuel. Thus, the intent of the invention is to utilize vaporized fuels in engines currently being used because vaporized fuels produce a superior energy release.
The invention consists of a spark plug and fuel injector combination. The spark plug has a central channel that funnels fuel into the lower portion of the spark plug, where it is vaporized. A solenoid system causes a needle valve to rise up to allow a measured quantity of fuel to be injected into a cylinder through a nozzle. A spring releases the needle valve to close the nozzle. The spark plug also has an ignition ring on the base. The ignition ring produces an encompassing spark, which produces complete combustion of the vaporized fuel. This produces more power and better fuel economy.
It is an object of this invention to produce a fuel injector spark plug that creates and maintains an environment hospitable for vaporized fuels in a compression chamber.
It is another object of this invention to produce a fuel injector spark plug that delivers fuel vapor to cylinder directly to maintain the fuel in vapor form.
It is yet another object of this invention to produce a fuel injector spark plug that eliminates excess fuel use thereby eliminating excess heat.
It is a further object of this invention to produce a fuel injector spark plug that increases mileage and power.
It is a further object of this invention to produce a fuel injector spark plug that saves energy.
It is a further object of this invention to produce a fuel injector spark plug that allows all additives that restrict vaporization to be removed from fuel.
It is a further object of this invention to produce a fuel injector spark plug that allows all additives that are harmful to the environment to be removed from fuel.
It is a further object of this invention to produce a fuel injector spark plug that greatly simplifies engine components accessories, and operation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of the invention.
FIG. 2 is a cross sectional view of the invention showing the placement of the electrical leads.
FIG. 3 is a cross-sectional view of the lower portion of the invention showing the fuel needle and ignition ring.
FIG. 4 is a detail of the ignition ring.
FIG. 5 is a bottom view of the invention showing the ignition ring.
FIG. 6 is a detail view of an internal combustion cylinder showing the invention igniting after the piston reaches top dead center.
DETAILED DESCRIPTION OF THE INVENTION
The instant invention is a spark plug-fuel injector that is designed to vaporize fuel and deliver it into a cylinder and ten ignite it to produce a highly efficient burn. As a result, some changes on engine operation are required. For example, due to the increased speed and efficiency of the fuel burn, the engine timing must change. In most gasoline engines, ignition occurs while the piston is still traveling upward. That means counter opposing force is being applied. The reason for this is that atomized fuel requires a certain amount of time to burn. If the engine timing is advanced, combustion occurs outside the combustion chamber and manifests itself as a backfire through the intake manifold. Moreover, if the timing is retarded, combustion is noted outside the combustion chamber in the form of a backfire into the exhaust manifold.
Using the instant invention, however, vaporized gasoline has far better burn characteristics. It allows timing changes that eliminate the counter opposing forces in the engine, which cause it to take on some of the advantageous features of a rotary engine.
Vaporized gasoline condenses when exposed to ambient air. Thus, it must remain vaporized throughout the combustion process to maintain its highly flammable state. That means it must be introduced to an environment with a high enough temperature to keep the fuel from condensing. The instant invention accomplishes this by injecting super heated fuel, under high pressure, into the compression chamber just as the piston starts its downward motion, and then immediately igniting it.
Referring now to FIG. 1 , a cross-section of the injector spark plug 100 is shown. The plug has an outer shell 1 . At the top of the plug is a formed portion that includes a hex nut portion 2 . The center of the plug is hollow to accommodate a quantity of fuel. At the top of the hex nut portion 2 is an inlet port 4 for a fuel line, which has a screen 5 to filter the fuel. The hex nut portion 2 extends down to a middle portion 6 as shown. An outer shell 1 is used to join the hex nut portion 2 with a threaded lower portion 28 , discussed below. An O-ring 3 is used to make a seal. A solenoid coil 8 is placed about the center of the spark plug as shown. Below the solenoid coil 8 , is a lower portion 28 , which contains the fuel needle 16 , ignition ring 18 and a porcelain insulator 27 (see FIGS. 2 and 3 ).
The hollow center portion acts as a fuel conduit. A flow restrictor 10 is placed in the hollow center as shown. A fuel passage 11 is formed in the center of the flow restrictor 10 as shown. This passage allows fuel 12 to run down the center of the spark plug to the lower portion of the plug. A needle 16 is used as a valve to hold the fuel in the plug until is it ready for use. A spring 13 is positioned below the flow restrictor as shown. The fuel needle 16 is positioned below the spring as shown. To top 17 of the needle 16 acts as a plunger that contacts the spring 13 .
In operation, the lower portion, as discussed below, is designed to hold the needle in position to allow it to move up and down within the spark plug. The top of the needle 17 is made of a ferric metal that is controlled by the solenoid, as discussed below.
On one side of the spark plug is an electrical connector plug 20 . This plug is designed to bring electric power into the spark plug. One conductor 21 brings positive power to the solenoid (the solenoid impulse conductor). Another conductor 22 brings power to the ignition ring 18 . The solenoid impulse conductor sends power to the solenoid, which, when energized, pulls the plunger 17 upwards (as shown in FIG. 1 ). This action lifts the needle upward, which open the tip 15 of the plug, which in turn, allows a measured quantity of fuel 110 to exit the tip 15 . Note that in the preferred embodiment, the needle 16 has flattened surfaces 14 that permit the fuel to flow down past the needle. The operation of the solenoid (which generates heat) and the pressure in the plug creates a situation where the fuel exiting the spark plug is a super heated liquid. This superheated fuel immediately vaporizes upon leaving the tip of the plug. This is discussed further below.
The travel of the needle (and plunger) is controlled by the spring 13 m which causes to needle to be pushed down when the solenoid is de-energized and by a needle valve controller ring 6 , which limits the upward travel of the needle 16 as well as the downward travel of the plunger 17 see FIG. 3 .
FIG. 2 is a cross-section of the device 1 that more clearly shows the routing of the conductors 21 and 22 .
FIG. 3 shows details of the lower portion. Here, the fuel needle 16 is in the “closed” positioned. This figure shows the collar 6 that is designed to hold the needle in position to allow it to move up and down within the spark plug. As mentioned above, the top of the needle 17 is a Ferris metal plug is shown. The lower portion of the needle 16 has a tip 19 that seats in a tapered nozzle 26 . The ignition ring 18 is also shown in this figure. The action of the ignition ring is discussed below. Note that an insulator 27 is positioned between the ignition ring 18 and the nozzle 26 . This insulation prevents flashover inward toward the nozzle. The threaded outer portion 28 of the lower portion of the spark plug is connected to ground to receive the spark 29 when power is sent to the ignition ring. Here, conductor 22 is shown extending down through the body of the plug.
FIG. 4 shows the ring 18 , the insulator 27 , the outer portion 28 and the spark 29 from the bottom of the plug. As is clear in this figure, the ring 18 completely surrounds the center of the plug. Moreover, the outer portion 28 also is a continuous ring. This allows the spark 29 to provide complete ignition of the fuel in as efficient a manner as possible.
FIG. 5 shows a cross-section of the device similar to that of FIG. 1 , except that here, fuel 12 is shown in the lower portion and the needle valve is in the closed position.
FIG. 6 is a detail view of an internal combustion cylinder 120 showing the invention 100 igniting after the piston 130 reaches top dead center. In operation, plug is full of superheated fuel as the piston 130 is rising in the cylinder 120 . Just past top dead center, as the piston 130 begins its downward motion, the solenoid 8 caused the needle 16 to lift, which causes a quantity of fuel 110 to squirt into the cylinder 120 , where it vaporizes immediately. Immediately after, a charge is sent to the ignition ring 18 , which produces a spark 29 that ignites the fuel 110 . Because the piston 130 is already in a downward motion, the firing of the fuel produces a power boost that provides more power to the stroke.
In a conventional engine, sufficient time is needed to allow the fuel to fully burn and produce energy. To accomplish this, the fuel is ignited while the piston is still rising in the cylinder. This procedure is not as efficient as it could be. Ideally, the piston should be moving down upon ignition, as in the case of the instant invention.
The present disclosure should not be construed in any limited sense other than that limited by the scope of the claims having regard to the teachings herein and the prior art being apparent with the preferred form of the invention disclosed herein and which reveals details of structure of a preferred form necessary for a better understanding of the invention and may be subject to change by skilled persons within the scope of the invention without departing from the concept thereof. | A spark plug and fuel injector combination. The spark plug has a central channel that funnels fuel into the lower portion of the spark plug, where it is superheated. A solenoid system causes a needle valve to rise up to allow a measured quantity of fuel to be injected into a cylinder through a nozzle, where it vaporizes upon exiting the spark plug. A spring releases the needle valve to close the nozzle. The spark plug also has an ignition ring on the base. The ignition ring produces an encompassing spark, which produces complete combustion of the vaporized fuel. This produces more power and better fuel economy. | 5 |
This is a division of application Ser. No. 042,452 filed May 25, 1979, abandoned.
BACKGROUND OF IHE INVENTION
This invention relates to heat storage ponds such as solar collectors, and to methods of and means for creating such ponds.
U.S. Pat. No. 4,091,800 discloses construction of a solar collector on the order of several acres in size. Such construction involves lining a large number of shallow trenches about 1-2 feet deep with a water impermeable plastic sheet, adding water to a depth of about one foot to the trenches, and floating a transparent plastic sheet on the surface of the water. The remaining height of each of the trenches is filled with clear water or with a transparent solid such as a gelatinous mass. The lower level of water is heated by its absorption of solar radiation that penetrates the gelatinous mass which serves to prevent heat loss from the water to the ambient medium above the gelatinous mass. There is no disclosure in this patent, however, of the nature of the gel, of a procedure for producing it on the scale contemplated, or of the constituents that will produce a gel that will be transparent to and stable in the presence of solar radiation.
British Provisional patent specification No. 1/9401/77 filed May 9, 1977 discloses a solar collector in which an aqueous gel of cross-linked polyacrylamide floats on a layer of water. The gel is transparent to solar radiation allowing the lower layer of water to be heated to a temperature approaching the boiling point.
The in situ production of an aqueous gel to cover a large-scale solar pond is a formidable task when starting with the monomeric constituents of the gel. The basic problem appears to be the inhibiting effect of atmospheric oxygen on the polymerization process by which the gel structure is formed after the monomeric constituents have been poured out on top of the heat collecting layer of the pond. The adverse effects of the atmospheric oxygen on the polymerization process is conventionally prevented in small-scale laboratory production by carrying out the polymerization process under an inert atmosphere such as a blanket of argon, nitrogen, CO 2 , etc. which excludes atmospheric oxygen during the polymerization process. For obvious reasons, the above described laboratory expedient is impractical when constructing a large-scale solar pond under field conditions. It is therefore, an object of the present invention to provide a new and approved gel, as well as a new and approved method for preparing it under field conditions in the presence of atmospheric oxygen.
BRIEF SUMMARY OF THE INVENTION
In accordance with the present invention, the gel comprises a polymeric cross-linked network formed by co-polymerizing an acrylic monofunctional monomer and an acrylic bifunctional monomer in an aqueous solution in the presence of an atmosphere of oxygen. Preferably, the monofunctional monomer is acrylamide and the bifunctional monomer is methylene-bisacrylamide. Ammonium persulfate may be used as a catalyst, and N,N,N,N tetramethyl-ethylene diamine may be used as an activator.
The invention is practiced under field conditions by floating a transparent, water impervious film upon a heat storage liquid, preparing a gel by dissolving the monomius constituents and optional catalyst and activator in water and depositing the solution on the film. Spontaneous polymerization takes place in an atmosphere containing oxygen after the solution is placed in sunlight or in the dark if the aqueous solution from which the gel is formed contains a dissolved inorganic salt such as magnesium chloride. The gel so formed is transparent to solar radiation; and the presence of the salt also increases the mechanical strength of the gel and its resistance to drying out.
The gel may also include bubbles of such size and distribution as to increase the heat insulating quality of the gel without interferring with its ability to transmit solar radiation. In one form of this aspect of the invention, the bubbles are formed by gas generated during formation of the gel. In another embodiment, the bubbles are constituted by encapsulations imbedded in the gel.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the invention are described below by way of example and with reference to the accompanying drawings we are enclosing:
FIG. 1 is a cross section of solar collector according to the present invention installed in a trench, and a power plant utilizing the same;
FIG. 2 is a cross section of a free-standing solar collector according to the present invention; and
FIGS. 3A-C is a cross section of the gel according to the present invention utilizing the bubbles in the gel for increasing its heat insulation qualities.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawing, FIGS. 1 and 2 are described in detail in U.S. patent application Ser. No. 899,815 filed Apr. 25, 1978, the disclosure of which is hereby incorporated by reference. FIG. 1 shows in schematic form a large scale solar pond whose order of magnitude is in the hectare (10,000 m 2 ) range to utilize the relatively low level energy available from the sun that occurs during daylight hours for heating a large quantity of water to temperatures that approach the boiling point. Layer 14, which is an aqueous gel, must be transparent to solar radiation and stable in the presence of such radiation as well as stable in the presence of heat of the order of magnitude of the boiling point of water. The above identified U.S. patent application describes an aqueous gel meeting these criteria, namely cross-linked polyacrylamide.
The thickness of layer 14 depends on the amount of heat loss that can be tolerated due to conduction through the gel from the relatively hot water beneath the gel to the relatively cool medium (ambient atmosphere) above the gel, particularly during non-daylight hours. If the gel has a thickness of about 50 centermeters, a hectare pond will require about 5,000 cubic meters of gel. The quantity of active ingredients necessary to make such a gel should obviously be minimized in order to reduce the cost of producing the gel as well as to reduce logistic problems in transporting the active ingredients to the location of the pond, particularly if the pond is remotely located. For this reason, the lower limits on the constituents of the gel are considered to be the primary importance together with the ease with which the gel can be created in situ.
From actual experience, it has been found that a suitable aqueous gel includes a polymeric cross-linked network formed by co-polymerization of an acrylic monofunctional monomer and an acrylic bifunctional monomer in a aqueous solution. A suitable monofunctional monomer is acrylamide; and suitable bifunctional monomers are methylene-bisacrylamide or 1, 2-ethylene-bisacrylamide. It is convenient, although not absolutely necessary, with these constituents to utilize a so called redox initiating system of catalyst and activator. Typically, a water soluble radical forming catalyst, such as ammonium persulfate(APS) is used in conjunction with an amine activator, e.g., tetramethylene diamine (TEMED). The preferred type of methylene-bisacrylamide is NN methylene-bisacrylamide; and the preferred form of tetramethylene-diamine is N,N,N,N tetramethylene-diamine. Other types may also be used sucessfully, however.
The preferred constituents of the gel are acrylamide (constituent A), methylene-bisacrylamide or 1,2-ethylene-bisacrylamide (constituent BIS), and amine activator (constituent TEMED) and a water soluble radical forming catalyst (constituent APS). A mixture of a% of A by weight of solution, and b% of BIS by weight of A is termed an a:b gel.
A 2:3 mixture spontaneously gells within about 2-3 hours in the presence of sunlight in an oxygen containing atmosphere at an ambient temperature of 20°-30° C. producing a clear gel that is transparent to solar radiation. This ratio is therefore preferred, although less preferred ratios may also be used. When kept in the dark, a 2:3 mixture does not completely gell even after an extended period of time; and in some cases, only about 60% of the mixture gells, the balance remaining water.
In a most preferred embodiment of the invention, the mixture contains at least about 2% of acrylamide by weight of the mixture so as to ensure complete spontaneous gelling when exposed to sunlight in an oxygen containing atmosphere. Although 2% is a preferred amount of acrylamide, lesser amounts, although yielding less reliable results, may also be used. Thus in a less preferred embodiment, amounts between about 1.5% and 2%, or even less acrylamide can be used. The amount of bis-acrylamide such as methlyene-bisacrylamide used may be as low as about 1% to as much as 10% based upon the weight of acrylamide. In a preferred embodiment, the amount used is about 3% by weight of acrylamide.
It has also been found that the presence of an inorganic salt in the mixture will enhance polymerization, and produce a more transparent and physically stronger gel. The transparency of a gel can be determined by projecting a laser beam through the gel, and measuring the amount of light transmitted. The ratio of incident to transmitted light will be a measure of the efficiency of transmission of the gel. In actual tests, the presence of hydrated magnesium chloride in practically any quantity will permit the mix to gell in the dark and will produce a gel more transparent to solar radiation and more durable in a mechanical sense. The advantages of using an inorganic salt are twofold: a superior gel is produced; and seawater or brackish water rather than fresh water can be used.
Experiments were carried out using MgCl 2 . 6H 2 O, laboratory grade MgCl 2 and Carnalite (KMgCl 3 6H 2 O) as well as mixtures of magnesium chloride, sodium chloride, calcium chloride and potassium chloride. Various quantities of these inorganic salts were used up to a concentration of about 20% by weight; and they all produced clear, transparent gels that polymerized without sunlight. The use of "Dead Sea end brine" produced by the Potash Company of Beersheba, Israel in 2:3 mixtures produced spontaneous polymerization in the dark but produced a yellow but transparent gel. The yellow color is apparently due to the bromines in the "end brine", but it was found that gels so produced lose their yellow color after being in the sun for a relatively short time.
It is believed that the addition of an inorganic salt enhances spontaneous polymerization because the salt displaces atmospheric oxygen during the gelling process.
In a further effort to eliminate atmospheric oxygen, experiments were carried out in which carbon dioxide was generated in the mixture. The presence of sodium bicarbonate and hydrochloric acid in a 2:3 mixture produces spontaneous polymerization in the sun and produced a very transparent gel that contained a small number of very small bubbles (i.e., about 5 bubbles per liter of about 1 mm diameter). By increasing the amount of sodium bicarbonate the density of bubbles is also increased to the point where they appear to be tangent to each other and completely fill the gel. By changing the amount of APS, TEMED, sodium bicarbonate and hydrochloric acid, the number and sizes of the bubbles can be changed.
The presence of such a large density of bubbles gives the gel a cloudy appearance but actual tests for transmission using a laser indicate a reduction of less than 10% in light transmission. Therefore, a gel with a high density of small diameter bubbles will form an insulator of greater efficiency allowing either a thinner gel layer to be used for achieving the same degree of insulation as a thicker non-bubble gel, or for the same thickness of gel to reduce conductive losses.
In addition to the chemical generation of gases during polymerization, bubbles may be introduced into the gel in other ways. For example, they can be mechanically injected, or gas can be bubbled through the gel during polymerization. In such case, nitrogen is a preferred gas rather than carbon dioxide because the latter is soluble in water. Finally, encapsulated bubbles can be embedded in the gel during its formation. Conventional "Blister-Pak" can be used on the top and bottom of the gel as barriers therefor, or embedded in the gel as shown in FIGS. 3A-B at 50. Alternatively, a plurality of transparent plastic balls 51 can be cast in place in the gel. In each case, the trapped bubbles enhance the insulating effect of the gel.
The method of preparing an aqueous gel from the acrylic monomers is exemplified by the following examples which are not considered as limiting:
EXAMPLE No. 1
Mixtures of 2:3 composition were prepared using 20 g of acrylamide, 0.6 g methylene-bisacrylamide, 0.625 g of APS in enough water to make 1 liter. Stirred into the solution is 0.063 ml of TEMED, all the constituents being at ambient temperature 20°-30° C. Each mixture gelled in about 2-3 hours when exposed to sunlight. If kept in the dark, about 60% of the mixture gelled, and the balance remained as water.
EXAMPLE NO. 2
A mixture like that of Example No. 1 was prepared, but 200 g MgCl 2 .6H 2 O were dissolved before the TEMED was added. After two hours at 22° C., the solution gelled in the dark to a clear firm gel.
EXAMPLE NO. 3
A mixture like that of Example No. 1 was prepared, but 5 g magnesium chloride.6H 2 O was dissolved before the TEMED was added. The solution gelled at a temperature of 27° C. but an ungelled layer of 2 millimeters remained on top of the clear and firm gel.
EXAMPLE NO. 4
A mixture like that of Example No. 1 was prepared, but 200 g Carnalite (KMgCl 3 .6H 2 O) was dissolved before the TEMED was added. The solution gelled in the dark in two hours at an ambient temperature of 25° C.
EXAMPLE NO. 5
A mixture like that of Example No. 1 was prepared, but 300 g "Dead Sea end brine" were added before the TEMED was added. The solution gelled in the dark in 2.5 hours to a firm and transparent gel that was yellow in color.
EXAMPLE NO. 6
A 2:3 mixture was prepared using 20 g of A,0.6 g BIS, 10 mg APS and 0.006 ml TEMED in enough water to make 1 liter. To this was added 350 cc of saturated solution of sodium bicarbonate and 70 cc of 32% concentration hydrochloric acid solution. The mixture was placed in the dark over night and the next day placed in the sun where it gelled producing a very transparent gel containing about 5 bubbles of about 1 mm diameter in the liter. The bubbles slowly collapsed after about three weeks so that after about three weeks the bubbles were approximately 1/2 the original size.
EXAMPLE NO. 7
A mixture like that of Example No. 6 was prepared except that the amount of sodium bicarbonate was doubled and 80 cc of 32% concentration hydrochloric acid was used. The gel produced was full of bubbles, tangent to each other, each about 2 mm in diameter.
In view of the experience using sodium bicarbonate, it is preferred to use 2:3 mixture, and it is believed that satisfactory results with bubble size and distribution result when the following constituents are added to each liter of water:
APS in the range 1 mg to 700 mg;
TEMED in the range 0 to 0.06 cc.
NaHCO 3 (saturated solution) in the range 100 cc to 700 cc.
HCl (32% solution) in the range 10 cc to 100 cc.
It is believed that the advantages and improved results furnished by the method and apparatus of the present invention are apparent from the foregoing description of the preferred embodiment of the invention. Various changes and modifications may be made without departing from the spirit and scope of the invention as described in the claims that follow. | A gel is formed by copolymerizing an acrylic monofunctional monomer and an acrylic bifunctional monomer in an aqueous solution exposed to an oxygen containing atmosphere. Spontaneous polymerization takes place in an atmosphere containing oxygen after the solution is placed in sunlight, or in the dark if the solution also contains a dissolved inorganic salt. The gel so formed is transparent to solar radiation, and is stable in the presence of such radiation and of temperatures in the vicinity of the boiling point of water. As a consequence, the gel is suitable for covering a heat storage liquid and thermally insulates the liquid against significant conductive heat loss to an ambient medium above the gel. By providing a myriad of small bubbles trapped in the gel, the insulating efficiency of the gel is increased without significantly interferring with the transmission of solar radiation to the heat storage layer below the gel. A gel having such bubbles is produced by including constituents in the solution from which the gel is formed which produce a gas (i.e., CO 2 ). | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a 35 U.S.C. §§371 national phase conversion of PCT/EP2015/076308, filed Nov. 11, 2015, which claims priority of United Kingdom Patent Application No. 1420965.4, filed Nov. 26, 2014, the contents of which are incorporated by reference herein. The PCT International Application was published in the English language.
TECHNICAL FIELD
[0002] This invention relates to a seal and a method of sealing, in particular for use in cryogenic applications.
TECHNICAL BACKGROUND
[0003] Cryogenic cooling of work rolls requires ways of preventing escape of the cryogen from the area in which it is required to avoid condensation and freezing of parts outside that area.
[0004] WO2012110241 describes an apparatus for cooling a work roll which includes a shielding means to create an essentially closed space within which the cryogenic coolant is sprayed. Various methods of sealing the closed space against the work roll are described including a gas seal and plastic material. A gas seal is preferred across the width of the roll at the top and bottom of the chamber because a plastic seal or other mechanical seal could potentially damage the surface finish of the roll. However, at the sides of the chamber it is more difficult to achieve a good gas seal because the roll diameter changes due to wear.
SUMMARY OF THE INVENTION
[0005] In accordance with a first aspect of the present invention, a sealing device comprises a flexible seal, a source of gas, a gas inlet to the seal, and a gas outlet from the seal, whereby gas flows through the seal. The flexible seal comprises a first sealing member and a second sealing member. The first sealing member comprises a flexible gas chamber and the second sealing member comprises a solid body. The flexible gas chamber is configured and located to apply pressure to the solid body.
[0006] The gas flowing through the seal keeps the seal flexible and applies pressure to maintain the sealing effect. Preferably, the device further comprises a heat supply, whereby the gas is heated at its source before flowing through the seal. A continuous flow of warmed gas through the seal keeps the seal material at an elevated temperature to maintain its flexibility and improve the quality of the seal.
[0007] The flexible seal may comprise a single flexible gas chamber, suitably reinforced where it contacts another surface to form a seal, with gas flowing through.
[0008] The gas flow may be only through the flexible gas chamber, keeping that warm and conducting heat to the solid body. Preferably, the solid body is provided with one or more gas passages therethrough, to receive gas from the flexible gas chamber. The gas supply to the flexible gas chamber presses the seal against the roll, and keeps the seal warm.
[0009] Preferably, at least one of the gas passages exits the solid body where the solid body contacts a work roll in a rolling mill stand. The gas exiting the solid body helps to prevent leakage past the seal.
[0010] Preferably, the source of gas is a cryogenic liquid. Preferably, the gas is nitrogen.
[0011] In accordance with a second aspect of the present invention, a rolling mill stand comprises a pair of work rolls and a cryogenic cooling system. The work rolls are cooled by cryogenic liquid supplied within a cooling chamber of the cooling system. A sealing device according to the first aspect seals a gap between the cooling chamber and the work roll.
[0012] A method of sealing a chamber adjacent to a work roll of a rolling mill stand, during rolling, comprises providing a seal at each edge of the work roll; and supplying a flow of gas through a flexible gas chamber in contact with the seal to apply pressure to the seal. Preferably, the method further comprises heating the gas before supplying it to the flexible gas chamber.
[0013] Preferably, the method further comprises supplying the gas from the flexible gas chamber through passages in the or each seal to exit the seal at an interface between the seal and the work roll. The gas flow between the seal and the work roll surface, significantly reduces or prevents, leakage of cryogenic gas past the seal.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] An example of a seal and a method of sealing according to the present invention will now be described with reference to the accompanying drawings in which:
[0015] FIG. 1A illustrates an example of a gas seal for a rolling mill with a shroud of the type described in WO2012110241;
[0016] FIG. 1B illustrates the effect of change in roll diameter on the gas seal of FIG. 1A ;
[0017] FIG. 2A is a section through one example of a gas seal according to the present invention, for a rolling work roll enclosure;
[0018] FIG. 2B is a section through another example of a gas seal according to the present invention, for a rolling work roll enclosure;
[0019] FIG. 3A illustrates the example of FIG. 2A in place between a work roll and shroud.
[0020] FIG. 3B illustrates the example of FIG. 2A in place between a work roll and another shroud, including reinforcing;
[0021] FIG. 4 illustrates an example of a mechanism to prevent the seal of the present invention from rotating with the work roll, in use; and
[0022] FIG. 5 schematically illustrates a rolling mill stand with a gas seal herein on each roll thereof.
BACKGROUND OF THE INVENTION
[0023] In a rolling mill using cryogenic cooling of the work rolls and/or the strip or product being rolled, a shield, or chamber is provided to contain the coolant in the desired area and prevent it from escaping and causing moisture in the surroundings to condense and damage the strip. This shield is positioned close to, but not in direct contact with, the work roll and typically a gas seal is used to prevent the cryogenic coolant from escaping between the edges of the shield and the work roll surface. FIG. 1A illustrates this arrangement, with a gas seal 3 between a work roll 1 and a shield 2 . Initially, the gap being sealed by the gas seal is substantially constant along the length of the surface of the work roll. Gas seals require a constant and relatively small gap to work effectively.
[0024] After a period of use, the work rolls wear down or the surface finish is damaged and the rolls have to be re-ground. Thus, each work roll diameter changes, relative to the original roll diameter. The problem is that the seal is designed for the original roll diameter and cannot cope with multiple roll diameters. As can be seen from Fig. B, if the edge seal is simply a gas seal, then when the roll diameter changes, the gap for the gas seal changes at the edges and is no longer constant along the arc of the seal. If the gap is bigger along part of the arc, then the whole seal becomes less effective because more of the gas flows through the larger gap and the pressure of the gas seal drops.
[0025] WO2012110241 suggests the use of plastic seals at the edges of the work roll and shield to address the problem of different work roll diameters, but it can be a problem to keep the plastic seal sufficiently flexible to accommodate the different roll diameters. Materials which are sufficiently elastic to accommodate the different roll diameters, such as rubbers, do not generally work very well at cryogenic temperatures, as they lose their elasticity and in some cases become brittle.
DESCRIPTION OF EMBODIMENTS
[0026] The present invention addresses the problems of sealing, and of changing or gradually changing multiple work roll diameters by having a seal in which gas pressure is used to push the seal against the surface of the roll and a flow of gas through the seal keeps the seal warm and hence elastic.
[0027] Examples of seals for a cryogenic application are illustrated in FIGS. 2A, 2B, 3A and 3B . A section through an edge of the chamber 2 shows a seal 7 positioned on a surface 8 of the work roll 1 . A side wall 9 of the chamber 2 is shaped such that a flexible gas chamber 10 may be fitted into a base 11 of the side wall. The side wall is shaped to have an opening 12 in the base, allowing the flexible gas chamber 10 to come into contact with the seal 7 on the work roll. The seal 7 is flexible and may comprise an elastic material, such as rubber, PTFE, plastic or similar. The flexible gas chamber may comprise an inflatable body, having a tubular, or other suitable shape. In the example shown in FIG. 2A , the seal 7 is forced against the surface 11 of the roll 1 by the flexible gas chamber tube 10 . The inflatable tube 10 deforms to take up the shape of the base 11 of the chamber 2 and exerts pressure on the seal 7 . In one embodiment, passages 13 , 14 are provided in the side wall 9 of the chamber for the flow of gas 15 into the inflatable tube 10 . The combination of an inflatable tube and a flexible seal allow the sealing arrangement to easily accommodate different roll sizes. However, the tube and seal may be combined to provide a flexible seal comprising a single flexible gas chamber, suitably reinforced where it contacts another surface to form a seal, with gas flowing through to keep the chamber warm and maintain the flexibility of the sealing part.
[0028] Preferably, the gas is warm nitrogen, above the dew point, which can be obtained by letting the liquid cryogen evaporate to a gas. The liquid cryogen may be allowed to warm to room temperature, or heat may be applied. When the nitrogen is in its gaseous state, it may be further warmed to provide a warm enough gas for keeping the inflatable tube and the plastic seal flexible. Nitrogen is preferred, but any dry gas may be used to inflate the tube. Gases containing water vapor, which could leak into the shroud, should be avoided. The continuous flow of warm gas ensures that the walls of the inflatable tube remain warm and hence, stay flexible. If there was no flow of gas through the inflatable tube (i.e. if the tube was simply pressurized), then the material of the tube on the cold side of the wall would get colder and colder and lose its elastic properties.
[0029] The gas flow may be provided only through the tube 14 to keep the tube warm and flexible and apply pressure to hold the seal 7 against the roll, relying on conduction of heat to the seal to keep the seal flexible. An improvement is to provide passages 16 , 17 in the seal. The passages allow the flow of the gas 17 through the inflatable tube 10 and through the seal 7 . The gas exiting at 18 from a surface of the seal in contact with the surface 11 of the work roll allows a continuous flow of gas.
[0030] FIG. 3A shows the arrangement from an end, with a supply of warm gas 15 through passage 14 into the inflatable tube 10 and then through multiple passages 16 in the seal 7 . The continuous flow of warm gas 15 , 17 ensures that the seal itself stays warm and flexible, rather than becoming too cool and losing its elasticity and hence not sealing properly, or even becoming brittle and failing.
[0031] The continuous flow of warm gas also helps to ensure that no cold gas escapes from the chamber 2 , past the seal 7 . Even if the seal does not create a perfect gas tight seal against the surface 8 of the roll, the flow of warm gas 18 out of the face of the seal 7 ensures that cold gas cannot escape from and that air cannot get into the chamber.
[0032] A further feature which may be provided to increase the volume of flow through the seal passages 16 is to form grooves in the seal surface, or preferably to shape the surface of the seal, for example, as a convex surface where the contact face is in the center and the gas passages are at either side of the contact face, as illustrated in FIG. 2B .
[0033] When the work rolls are rolling a strip or plate, there is friction between the seal surface and the roll surface, and this friction imparts a force to the seal which needs to be counteracted, in order to stop the seal from rotating with the roll. The walls of the inflatable tube may be adapted to restrain the seal from rotating, or the seal may be provided with protrusions which engage with holes, or recesses in the base of the chamber side wall, or connect to the chamber in a similar fashion. FIG. 3B illustrates the tube reinforced with belts 19 so that the tube can hold the seal in place. The back of the tube, away from the seal, is attached to the shroud wall 9 ( FIGS. 2A and 2B ) and the front of the tube is attached to the seal 7 . FIG. 4 illustrates how protrusions 20 and recesses 21 may be provided to prevent rotation.
[0034] The end seals as described above may be used in combination with an air knife, as used in WO2012110241, across the central part of the work roll for the top and bottom work roll to chamber seals. The air knife 22 a , 22 b can be seen in FIG. 3A , with gas supplies 23 , 24 to the top air knife 22 a and bottom air knife 22 b.
[0035] The present invention provides a seal which can accommodate different roll diameters by using a flexible material for the sealing and pressing it in place and which can also handle cryogenic temperatures by keeping that material flexible using the warm gas flow. As mentioned above, prior art systems may use gas or plastic seals, but these both have problems with maintaining an effective seal when the roll changes shape after regrinding, or due to the cryogenic temperatures at which the seal must perform.
[0036] An alternative embodiment would be to dispense with the inflatable tube and simply pressurize the back of the seal itself with gas. To make this work the seal itself would effectively become a piston and it would need seals against the walls within which it moves. This arrangement is more difficult to seal properly than the inflatable tube design and it would need additional guiding and restraints.
[0037] Another solution would be to spring load the seal and use only the gas for keeping the seal warm. If leaf or blade type springs were used, they would restrain the seal from rotation with the roll. The complication with this design is how to get the gas connections to the seal. One possibility is to retain the chamber where the inflatable tube sits. But, then the seal needs piston seals or similar. Another possibility is to have the gas supply via a flexible tube or tubes connected directly to the seal. But, this is more complex than the inflatable tube design.
[0038] The advantage of the inflatable tube arrangement is that it achieves multiple requirements in one easily manufactured and assembled unit. It restrains and guides the seal, it pressurizes the seal against the roll and it provides a simple way of supplying the gas to the seal.
[0039] FIG. 5 shows a two roll rolling mill stand 30 supporting two rolls 1 parallel to each other and rolling a strip, strand, etc. between them. Illustrated are a respective seal 7 , 10 toward an edge of each of the rolls, defining a cryogenic cooling system with a cooling chamber 2 of the cooling system and the seal 7 , 10 , which seals a gap between the cooling chamber and the work roll. | A sealing device includes a flexible seal ( 10 ), a source of gas ( 15 ), a gas inlet ( 14 ) into the seal, and a gas outlet ( 17 ) from the seal 10, 17 whereby gas flows through the seal. A cryogenic source cools the seal and the gas from the cryogen helps seal the seal to the roll and to keep the seal flexible as the gas flows. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This patent application is the national phase of PCT/EP2015/055057 filed Mar. 11, 2015, which claims the benefit of European Patent Application No. 14159263.4 filed Mar. 12, 2014.
TECHNICAL FIELD
[0002] The invention relates to a sawtooth wire for a roll of a carding machine.
BACKGROUND
[0003] Carding machines are used to open (individualize) and align fibres of a fibrous material, e.g. of wool, cotton, synthetic fibres or of a fibre blend, to homogenize them (for fleece production) and/or to parallelize them (for yarn production). The carding process may be used to produce a fibre mat from a fibrous material. The fibre mat consists of a loose collection of ordered individual fibres. A nonwoven, for example, may be produced from a fiber mat of this kind. During carding, the fibre mat is formed by removing the fibres, by way of a removal means, from a large carding roll known as the swift and combining them.
[0004] The carding machine may have various carding rolls, each of which has teeth, serrations or spikes projecting outwards in approximately radial direction. The number and/or size and/or density of the teeth, serrations or spikes, as well as their shape and configuration, may vary.
[0005] Carding rolls are generally provided with all-steel card clothing. This consists of a profiled sawtooth wire wound under tension onto the carding roll in question. The sawtooth wire has a foot segment and a blade segment. The foot segment may have, for example, a rectangular or square cross section. In the operating position, the blade segment projects away from the foot segment at approx. right angles to the curved surface of the carding roll. The blade segment has a sawtooth profile for the formation of teeth or serrations. The sawtooth wire is wound, under longitudinal stress, around the curved surface of the carding roll, and the two ends are attached to the carding roll. Sawtooth wires are known per se. For example, CN 201512617 U describes a sawtooth wire with obliquely slanting teeth on the blade segment.
[0006] In U.S. Pat. No. 5,096,506 A, a sawtooth wire is shown where one side of the blade segment (blade-segment lateral surface) is perpendicular to, and the other blade-segment lateral surface is inclined relative to the base area of the foot segment. The inclined blade-segment lateral surface is flatter on the side further away from the foot segment than on the rest of the surface. Accordingly, the thickness of the blade segment increases faster on the side further away from the foot segment than in the remaining area of the blade segment.
[0007] U.S. Pat. No. 6,185,789 B1, EP 1 408 142 A1 and EP 2 567 010 A1 show sawtooth wires having blade-segment lateral surfaces with a plurality of convexities. One of the advantages listed for these sawtooth wires is that, during the carding process, they are better able to separate non-spinnable fibres and other foreign substances from the spinnable fibres than are conventional sawtooth wires.
[0008] In DE 19 44 251 U and WO 2006/136480 A1, a sawtooth wire is described whose one blade-segment lateral surface has a first, upper area that is very steep. A second planar area adjoins this first portion and is considerably flatter than the first area. The transition between the first and second areas is at a height much less than half the height of the blade-segment lateral surface.
[0009] In practice, it has been found that especially the tips of the teeth are subject to severe wear. Since the tips of the teeth become rounded with time, the quality and efficiency of the carding process decrease. A countermeasure consists in regrinding the carding wires mounted on a drum (carding roll). Rounded teeth tips may be resharpened in this way.
[0010] However, the latter measure, too, is only able to slow down, but not stop, the long-term loss in quality and efficiency.
SUMMARY
[0011] For the reasons cited, the objective of this invention is to create a sawtooth wire which enables optimal homogenization and parallelization of the fibres over a lengthy operating period during production of the fibre mat. The fibres must sustain no or only negligible damage during the carding process.
[0012] Either staple-fibre yarns or nonwovens may be formed from staple-fibre fleeces.
[0013] Among the characteristics of sawtooth wires according to the invention are foot segments, which serve for seating the wire on a carding roll. The foot-segment surface in contact with the carding roll (when the sawtooth wire has been wound onto it) is referred to as the base area. As a rule, the foot segment is the widest segment of the wire. When the wire has been wound on the carding roll, the lateral edges of the foot segments of adjacent wires usually touch each other.
[0014] The base area of the foot segment extends in the wire's longitudinal direction Z (first spatial direction: is defined by the sawtooth wire's longitudinal extension) and in the lateral direction B (second spatial direction: is perpendicular to the wire's longitudinal direction). The third spatial direction is the height direction H, which is perpendicular to the base area of the foot segments and extends towards the exterior surface of the sawtooth wire (i.e. towards the side of the blade segment facing away from the foot segment). Measured from the base area, the height values (i.e. the values in the direction of the height) increase to a maximum blade-segment height. Accordingly, the (height) position of points close to the base area is referred to as being “down” and the position of points close to the exterior surface (of the sawtooth wire) as being “up”.
[0015] The longitudinal, height and lateral directions of the wire are (pairwise) mutually perpendicular. The three directions thus define a Cartesian coordinate system.
[0016] The blade segment running in the height direction tapers as a rule towards the top, i.e. the breadth of the blade segment often decreases steadily with increasing height. The blade segment is confined in the lateral direction by a first and a second blade-segment lateral surface. One of the two blade-segment lateral surfaces frequently (but not always) has a gradient dh(b)/db (henceforth: dh/db) of height as a function of breadth, the value of which is infinitely large, i.e. the blade-segment lateral surface in question is parallel to the perpendicular dropped to the base area of the foot segment. If this is the case, the aforementioned taper is effected in that the other blade-segment lateral surface (in the language of this publication “at least one blade-segment lateral surface”) has a finite gradient dh/db, i.e. the angle between it and the aforementioned perpendicular is not 0°.
[0017] The height value at which the blade segment has its greatest reach in the height direction is referred to as the blade segment's maximum height. The height value at which the blade segment begins (at the bottom thereof) is referred to as the minimum height. The span (in the height direction) between the minimum height and the maximum height is the overall height of the blade segment. The minimum and maximum heights are thus individual height values. The overall height is a distance (a length) in the height direction.
[0018] The manufacture of the sawtooth wire commences with the drawing of a wire. The wire is subsequently rolled, during which process a wire with a broad foot area and a less broad blade area is formed. The cross section of the wire is constant, within the manufacturing tolerances, over its length. In the blade-area parts further away from the base area it is customary to periodically punch out recesses, thereby forming teeth. At least the toothed part of the blade area is hardened. Usually, therefore, at least the toothed part of the blade area is of greater hardness (is harder) than the foot area (this is softer). Sawtooth wires typically have a length of several hundred metres to several kilometres.
[0019] When a sawtooth wire has been wound onto the carding roll, the foot segments form a closed area (except for the narrow gaps between the sawtooth wires). Above the foot segments, carding gaps, as they termed, are formed between adjacent blade segments (the latter being thinner than the foot segments). As the blade segments (usually) taper towards the top, the carding gaps bordered by the blade segments accordingly widen steadily towards the top.
[0020] The foot area may have planar lateral surfaces. Each foot area may, however, have (profiled) elevations and/or recesses on one lateral surface and be provided, on the other lateral surface, with inverse (geometrically corresponding) elevations and/or recesses which, when the sawtooth wire is wound onto a carding roll, engage the lateral surface of the adjacent wire segment (i.e. the wire segments are interlinked/interlocked).
[0021] The foot segment is clearly distinguishable from the blade segment, since, firstly, it has a geometry (greater breadth) that enables the formation of a (largely) closed area when a sawtooth wire is wound onto a roll. By contrast, the geometry of the blade segment is such that (when a sawtooth wire has been wound onto a roll) open carding gaps are formed, i.e. the blade segments are always less broad than than the associated foot segments. Secondly, the blade segments have teeth (i.e. the blade segments end with a serrated outer contour in the height direction), whereas foot segments always end, in respect of height, with a largely planar base area. Thirdly, the blade segments are usually (at least partly) hardened (i.e. they are comparatively hard), whereas the foot segments are less hard.
[0022] In the case of the sawtooth wire according to the invention, the absolute value of the gradient dh/db at least of a first portion at least of one blade-segment lateral surface is greater than the absolute value of the gradient dh/db at least of a second portion of the same blade-segment lateral surface.
[0023] All the height values of the at least one second portion are smaller than all the height values of the at least one first portion, i.e. the at least one second portion is below the at least one first portion. The two portions do not overlap.
[0024] The at least one first portion and the at least one second portion each extend between a smallest height value, which is at the bottom of the portion in question, and a maximum height value, which is at the top of the portion in question.
[0025] The algebraic signs of the gradient dh/db of the at least one first and of the at least one second portion are the same. In other words, a first portion (at least of one blade-segment lateral surface), which is located higher up, is steeper relative to the base area of the sawtooth wire (i.e the gradient of this portion is steeper) than is a portion of the same blade-segment lateral surface located further down. Both portions should either rise or fall (i.e. the gradient sign should be the same for both portions). Whether both portions rise or fall depends on which of the two blade-segment lateral surfaces they are located on.
[0026] According to the invention, the gradients dh/db of those portions on the same blade-segment lateral surfaceside whose height values are in a range extending between the smallest height value of the at least one second portion and a further height value which is, at the most, ⅛ of the overall height of the blade segment below the aforementioned smallest height value of the at least one second portion, have the same sign as the gradients dh/db of the at least one first and of the at least one second portion.
[0027] In other words, there should be no elevations (“humps”) or indentations (“dents”) beneath the lower end of the second portion that cause a change in the sign of the gradient. A change in gradient sign should by all means be ruled out within an height range (below the at least one second portion) whose height dimension is ⅛ of the blade segment's overall height. Preferably, the height range in question is ⅕ of the blade segment's overall height. It is also possible to rule out gradient changes (elevations or indentations) over the entire area of the respective blade-segment lateral surface which is beneath the lower end of the at least one second portion. A further valuable refinement of the invention may consist in that the gradient dh/db of the at least one blade-segment lateral surface also has the same sign everywhere above the at least one first portion (i.e. above the highest height value of the first portion). Alternatively or in addition, provided that the first portion does not border directly on the second portion, the gradient dh/db of the at least one blade-segment lateral surface in the area between the at least one first and the at least one second portion (i.e between the smallest height value of the at least one first portion and the highest height value of the at least one second portion) has the same sign everywhere.
[0028] Elevations/indentations in the flat, rounded transition area between the (comparatively steep) blade segment and the foot segment are irrelevant. Consequently, the term “blade segment” always refers exclusively to the relatively steep area of the blade segment (and not to the flat transition area).
[0029] Changes in gradient sign can also be ignored if they are caused by very small elevations or indentation attributable to manufacturing inaccuracies or manufacturing flaws.
[0030] During the carding process, elevations (indentations) which are sizable and accordingly not attributable to manufacturing flaws/manufacturing tolerances can prevent the fibres from penetrating (in the case of elevations) or penetrating deeper (in the case of indentations) into the carding gaps, thereby impairing the process efficiency.
[0031] If the elevations/indentations have narrow radii or even sharp edges, they can cause substantial damage to the fibres. Such damage leads to quality shortcomings in the end product (e.g. yarns or fleeces) and must by all means be prevented.
[0032] Since, in the case of the sawtooth wire according to the invention, the at least one first portion located further up on the at least one blade segment is steeper (steeper gradient dh/db) and the at least one second portion is flatter (flatter gradient dh/db), the fibres to be carded can enter the carding gaps more easily than with conventional sawtooth wires (whose blade-segment lateral surfaces customarily have a constant gradient). At the level of the smallest height value of the at least one second portion, the carding gaps are usually already very narrow, in particular, substantially narrower than in the height area of the blade-segment lateral surface just beneath its maximum height. Accordingly, elevations/indentations that directly adjoin the at least one second portion or lie only slightly below this very often cause serious damage to the fibres being carded (on account of the narrow carding gap), and usually prevent them from penetrating further into the carding gaps.
[0033] Surprisingly, it was found that elevations/indentations located at a greater height distance (typically at least ⅛ of the blade segment's overall height) below the at least one second portion cause either negligible or no damage to the fibres being carded. It is, furthermore, no longer necessary for the fibres to enter further into the respective carding gap at this point; i.e. even if the elevations/indentations were to prevent further penetration of the fibres there, this would have practically no influence on the carding process.
[0034] Elevations/indentations located above the at least one first portion or between the at least one first and the at least one second portion cause no or only negligible damage to the fibres being carded and do not prevent these fibres from penetrating the carding gaps because they are in an height area in which the the carding gaps are comparatively wide.
[0035] It is advantageous to select precisely the upper end of the blade-segment lateral surface, i.e. the point on the blade-segment lateral surface whose height corresponds to the maximum height of the blade segment, as the maximum height of the at least one first portion. Alternatively, it is also possible to select a point which (in the height direction) lies slightly below the upper end, e.g. at the most 0.2 (preferably at the most 0.1 mm) below the upper end of the blade-segment lateral surface. Or else a point in the upper quarter, preferably in the upper tenth, of the respective blade-segment lateral surface is selected as the maximum height of the at least one first portion. The smallest height value of the at least one first portion is in an area which is 50% to 98%, advantageously 60 to 90%, of the (blade section's) overall height above the blade section's minimum height.
[0036] The at least one first portion is usually positioned longitudinally at a point on the blade-segment lateral surface at which the height (reach in height direction) of the latter is comparatively great. It is advantageous to select, for the at least one first portion, a longitudinal position at which a tooth tip is located.
[0037] For the smallest height value of the at least one second portion, a position is preferably selected in the lower part of the blade segment (nearer the foot segment), e.g. in the bottom tenth of the blade segment. It suffices, however, if the greatest height value of the at least one second portion is less than the smallest height value of the at least one first portion. In a preferred variant, the smallest height value of the at least one first portion borders on the greatest height value of the at least one second portion.
[0038] In the longitudinal direction, a position for the at least one second portion is selected at which the sawtooth wire is existent, i.e. not a position at which the sawtooth wire has a recess (due to the punching out of teeth).
[0039] It should always be assumed that the sawtooth wire runs longitudinally. In particular, the sawtooth wire should not have any deformations in the plane defined by the longitudinal and the lateral directions which could lead to parts of the blade-segment lateral surface being considered as curved which are planar in the case of a longitudinally straight sawtooth wire.
[0040] The at least one first and the at least one second portion are preferably selected such that they are on planar parts of the at least one blade-segment lateral surface. The two portions then run straight in the plane defined by the height and the lateral directions, i.e. the gradient dh/db is constant in each of the two portions and corresponds in each case to the gradient of the secant which runs in the plane defined by the height and lateral directions and through the at least one first or the at least one second portion.
[0041] The at least one blade-segment lateral surface may, however, also be curved in such a way as to preclude the presence, on the blade-segment lateral surface in question, of at least one first and/or at least one second portion located at a “suitable” height (at a height between suitable height values). What is considered as a suitable height has already been explained in earlier sections dealing with the height position of the at least one first and the at least one second portion.
[0042] In a case of this kind, the at least one first portion and/or the at least one second portion may be infinitesimally small (especially in the height direction), i.e. in the case of the infinitesimally small portion concerned, the gradient can no longer be determined in a finite straight/planar portion but at a point. To persons skilled in the art, this situation is known from the introduction to differential calculus, since here the differential quotient for the limit value observation of infinitesimally close arguments (here breadth values) expresses the gradient at a point:
[0000]
lim
Δ
b
→
0
Δ
h
Δ
b
=
h
b
[0043] For this case (infinitesimal portion breadth), the tangent is a special case of the secant through a planar portion, and the value of the secant gradient is the value of the derivative of the function describing the course of the contour of the blade segment in question, or, expressed more simply, the value of the gradient at this point.
[0044] The two portions may (but need not) lie one above the other in the height direction. If one were able to use the starting profile for these sawtooth wires, i.e. the original shape of the sawtooth wire prior to the generation of teeth (e.g. by punching or by a method producing the same effect) as a basis, it would be easy to select the two portions such that they are disposed one above the other in respect of height. However, sawtooth wire teeth are often oblique, i.e. they are shaped like the teeth of a saw, which slope. When determining the tooth's angle of slope, it is customary to use the slope of the tooth face (working angle). The working angle is defined as the angle enclosed between the tooth face and the perpendicular. On account of the tooth's slope, many sawtooth wires have no position at which a complete and gapless cross-section (through the original profile) can be found. It is then necessary not to arrange the portions one above the other in respect of height (i.e. the two portions lie at different points of the sawtooth wire's longitudinal reach).
[0045] A length of 1/100 mm may be preferable as minimum length of the portions (in the lateral direction), although a length of 5/100 or 1/10 mm may also be to advantage.
[0046] The other blade-segment lateral surface (the blade-segment lateral surface opposite the at least one blade-segment lateral surface) is preferably almost completely in a plane defined by the height and longitudinal directions, i.e. its gradient dh/db is infinite. It may, however, have a different geometry, e.g. it could be inclined relative to the height direction by a small angle, e.g. of less than 3° (i.e. its gradient dh/db may have a finite value). Or it could be mirror-symmetric to the at least one blade-segment lateral surface.
[0047] In the case of customarily used sawtooth wires (or in the case of their starting profiles), both blade-segment lateral surfaces (with the exception of curved transition areas) are virtually completely planar, with one blade-segment lateral surface extending in a plane defined by the height and longitudinal directions and the second blade-segment lateral surface extending (likewise in the longitudinal direction but) inclined in respect of height. With sawtooth wires of this kind, the breadth (lateral spread) of the sawtooth wire increases linearly over the entire blade segment.
[0048] By virtue of the blade-segment geometry (of the at least one blade-segment lateral surface) proposed in the invention, the breadth of the blade segment increases more slowly (or not at all) in the upper area (farther away from the foot segment) and then, in the lower area, increases more rapidly (than in the upper area). The transition between the small (or non-existent) increase in breadth and the stronger increase may be continuous or take place in one or more steps, e.g. by way of a succession of several planar portions, e.g. a maximum of 4, preferably 2 to 3. The technical implementation of each of these variants will be explained in more detail below.
[0049] The breadth of the carding gaps formed by a sawtooth wire according to the invention and mounted on a carding roll accordingly decreases—with decreasing height—less quickly (or not at all) in the upper area (nearer the teeth of the sawtooth wire) of the carding gaps, and more quickly in the lower area.
[0050] Surprisingly, it was found that when the sawtooth wire according to the invention is used, the loss in quality and efficiency of the carding process over time (due mainly to necessary regrinding of the teeth) is significantly less than is the case with conventional wires. The sawtooth wire of the invention thus enables optimal homogenization and parallelization of the fibres (during the production of a fibre mat) over a lengthy operating period.
[0051] The sawtooth wire usually has an exterior surface which bounds the sawtooth wire (in the height direction) on the side facing away from the foot segment, and which also extends in the height direction. In so doing, it (often) defines at least one tooth (usually many teeth) of the sawtooth wire. In other words, the blade-segment lateral surface has a serrated contour, at least in its upper area.
[0052] At the tip of the at least one tooth, the exterior surface extends substantially in the longitudinal direction (Z) and the lateral direction (B). The exterior surface of the tooth flanks, by contrast, is inclined in respect of height.
[0053] In one embodiment of the invention, the two portions of the at least one tooth are typically arranged such that they are longitudinally staggered. In this way it is ensured that each of the two portions is located at a point of the sawtooth wire where no material has been removed (by punching during tooth production). This arrangement makes it possible to locate the topmost portion at or near the tip of the at least one tooth and, simultaneously, to locate the at least one second portion at the lower end, or at least in the vicinity of the lower end, of the blade segment (in the area of the respective tooth). The entire (or almost the entire) height of the blade segment can hereby be encompassed by the two portions.
[0054] Arranging the two portions such that are longitudinally staggered, as described above, is unproblematic because sawtooth wires are made from profiled wires the cross-sectional profile of which remains practically the same over their length.
[0055] In principle, the at least one first and the at least one second portion may also be located at a single longitudinal position of the sawtooth wire, i.e. they are arranged one above the other in the height direction, as described above. This is possible in cases where no hollow (punched out) areas exist beneath the tooth tip in question, i.e. if the line connecting the (at least one) first and the (at least one) second portion runs completely within the sawtooth-wire material.
[0056] In a preferred embodiment, at least the part of the blade-segment lateral surface reaching from the blade segment's maximum height to a point which is 2%, preferably 5% or, best of all, 10% of the blade segment's overall height above the minimum height of the blade-segment lateral surface is made up of at least two planar surface portions. Expressed differently, the at least one blade-segment lateral surface (of the sawtooth wire) has at least two planar surface portions, which extend straight in the plane defined by the lateral and height directions. The two surface portions preferably follow each other in succession (adjoin each other) in the height direction and enclose an angle (which does not equal 0°) in the plane defined by the lateral and height directions.
[0057] It is also possible for more than two planar (straight) surface portions to follow each other in succession in the height direction, e.g. three or four straight surface portions. Two or three planar surface portions are preferred. The planar surface portion furthest from the foot segment (the highest surface portion) and the second surface portion bordering thereon (the one nearer the foot segment) preferably adjoin each other at a height in the range between 5/10 and 9/10, preferably ⅖ and ⅘ of the blade segment's overall height.
[0058] The invention is particularly advantageous for (fine) sawtooth wires with comparatively low blade segments, i.e with heights of the blade segments (alternatively: of the teeth) ranging from 0.3 to 1 mm. Sawtooth wires of this kind are customarily used for the manufacture of staple-fibre yarns, e.g. of cotton and/or synthetic fibres.
[0059] For coarser fibres, sawtooth wires are used that may have blade segments with a height of up to 3 (in exceptional cases up to 4) mm.
[0060] In the case of fine sawtooth wires it is to advantage that the portion furthest away from the foot segment (the at least one first portion) usually has a height (reach in h direction) of 0.1 to 0.5 mm, preferably of 0.2 to 0.3 mm. This preferred planar portion preferably begins at a maximum distance of 5/100 mm or 1/10 mm below the tooth tip, i.e. the upper height value of the at least one first portion is, at the most, 5/100 or 1/10 mm smaller than the blade segment's maximum (height) value.
[0061] If the aforementioned ranges are selected, carding quality and efficiency losses due to necessary regrinding of the teeth of the sawtooth wire are significantly less than is the case when conventional wires are used.
[0062] In order to prevent sawtooth wires, i.e. the gaps formed by sawtooth wires, from becoming blocked with fibres (when the wires are in service on a carding roll), at least in a sufficiently large area of the sawtooth-wire the blade segments must taper sufficiently fast in the height direction. Conventional sawtooth wires practically always fulfill this requirement. However, if the area in which the breadth of the sawtooth wire according to the invention only increases slightly or not at all (small angle of slope relative to the height direction) were to extend over the entire blade-segment lateral surface concerned, blocking of the gaps would have to be anticipated. Via suitable selection of the respective height range, the sawtooth wires are prevented from becoming blocked with fibres despite the (at least first) blade-segment lateral surface being very steep in part (correlating with little-pronounced tapering of the blade segment).
[0063] The at least one first portion (the portion in which the breadth of the sawtooth wire increases less) of the at least one blade-segment lateral surface usually makes an angle of less than 5°, preferably 0°-2°, with the perpendicular dropped to the base area of the foot. Accordingly, since 0° are also possible, the (at least one) first portion of the (at least one) blade-segment lateral surface may also be parallel to the perpendicular dropped to the base area of the foot.
[0064] The at least one second portion of the at least one blade-segment lateral surface usually makes an angle of more than 6°, preferably, however, of more than 8°, with the perpendicular dropped to the base area of the foot. This angle is typically less than 15°, preferably less than 12°.
[0065] In an alternative embodiment, the portions of the at least one blade-segment lateral surface may extend curvilinearly in the plane defined by the lateral and height directions. In particular, the entire blade-segment lateral surface may be curved, preferably concave (as seen from the exterior). Curved means the absence of kinks in the portion concerned. Kinks are points at which discontinuities or singular points occur in the gradient (of the portion concerned).
[0066] Ultimately, variants are also conceivable in which the at least one blade-segment lateral surface is formed from a combination of curved surface portions and planar surface portions.
[0067] In this embodiment (curved surface portions), too, it is possible to maintain comparatively high efficiency of the carding process for longer than is possible when conventional sawtooth wires are used. At the same time, it is also possible to prevent the carding gaps formed by the sawtooth wires from becoming blocked with fibres. For this purpose (by analogy with the embodiment having planar portions), a height in the range between 5/10 and 9/10, preferably ⅗ and ⅘, of the blade segment's maximum height is selected for the point at which the surface portion in which the breadth of the sawtooth wire increases faster and the surface portion in which it increases more slowly border on one another. If the entire blade-segment lateral surface is curved, a suitable limiting value (for the maximum breadth increase per unit of height) may be specified for determination of this point.
BRIEF DESCRIPTION OF THE DRAWINGS
[0068] The invention is explained in more detail below on the basis of three embodiments. The drawing in
[0069] FIG. 1 : is a perspective view of a sawtooth wire,
[0070] FIG. 2 : shows a cross section of a sawtooth wire having a blade-segment lateral surface with two planar surface portions; for reasons of clarity, the wire is shown enlarged in the lateral direction.
[0071] FIG. 3 : shows a profile of a sawtooth wire having a blade-segment lateral surface with two planar surface portions;
[0072] FIG. 4 : shows a cross section of a sawtooth wire having a blade-segment lateral surface with four planar surface portions; for reasons of clarity, the wire is shown enlarged in the lateral direction.
[0073] FIG. 5 : shows a profile of a sawtooth wire having a blade-segment lateral surface with four planar surface portions;
[0074] FIG. 6 : shows a cross section of a sawtooth wire the blade-segment lateral surface of which is a concave curve; for reasons of clarity, the wire is shown enlarged in the lateral direction.
[0075] FIG. 7 : shows a profile of a sawtooth wire with a concave blade-segment lateral surface;
[0076] FIG. 8 : shows the determination of contour gradients in the plane extending in the height direction H and lateral direction B;
[0077] FIG. 9 : shows a blade segment and choice of position for the first and second portions on the blade segment;
[0078] FIG. 10 : shows an alternative shape for the foot segment;
[0079] FIG. 11 : shows a first shape for the second blade-segment lateral surface;
[0080] FIG. 12 : shows a second shape for the second blade-segment lateral surface;
[0081] FIG. 13 : shows a further cross section of a sawtooth wire.
DETAILED DESCRIPTION
[0082] The section of sawtooth wire shown in FIG. 1 consists of a foot segment 1 featuring a base area 2 and two lateral surfaces 3 , and a blade segment 4 which adjoins the foot segment 1 and has a first blade-segment lateral surface 5 and a second blade-segment lateral surface 6 . On the side further away from the foot segment 1 (facing upwards), the blade segment 4 is delimited by an exterior surface 7 , which undulates along a serrated path in such a manner as to form teeth 8 .
[0083] The sawtooth wire runs in the longitudinal direction Z; its height extends in the height direction H and its breadth in the lateral direction B (B is perpendicular to both Z and H).
[0084] The height value at which the blade segment 4 has its greatest reach in the height direction H is referred to as the blade segment's maximum height h max . The height value at which the blade segment begins (at the bottom thereof) is referred to as the minimum height h min . The span (in the height direction) between the minimum height h min and the maximum height h max is the overall height H max of the blade segment.
[0085] The second blade-section lateral surface 6 extends (apart from manufacturing tolerances) in a plane spanned by the longitudinal direction Z and the height direction H.
[0086] The first blade-segment lateral surface 5 is made up of a first portion 10 located higher up on the blade segment 4 (further away from the foot segment 1 ) and a second portion 11 located lower down on the blade segment (nearer the foot segment 1 ). As already explained earlier, the comparatively flat, rounded transition area 9 between the foot segment 1 and the blade segment 4 is not part of the blade segment 4 . The first portion 10 is practically parallel to the plane defined by the longitudinal direction Z and the height direction H (accordingly, it is also parallel to the second blade-segment lateral surface 6 ), i.e. its gradient is infinitely large. The first portion 10 may alternatively enclose a small angle not exceeding 2° with the height direction H (i.e. dh/db assumes a finite value) and, except for manufacturing tolerances, run parallel to the longitudinal direction Z.
[0087] The second portion 11 is also parallel to the longitudinal direction Z (except for manufacturing tolerances) but, compared with the first portion 10 , encloses a substantially larger angle of 8° to 12° with the height direction H. In other words, the first portion 10 is steeper than the second portion 11 . A steep run generally means that dh/db is large. For a flat run, dh/db is accordingly small.
[0088] On account of the particular geometry of the blade-segment 4 , its breadth B initially increases very slowly (or not at all) from the top downwards, e.g. starting from one of the tooth tips 12 (technically speaking, the tip is a short edge), as its height decreases (i.e. towards the foot segment). At the transition 13 , at which the first portion 10 merges into the second portion 11 , the breadth of the blade segment 4 then increases faster (or commences to increase) with decreasing height. The sawtooth wire's property of featuring a blade segment 4 the breadth of which, starting from the top, initially increases more slowly and then, towards the bottom, increases more quickly, is essential to the invention and is shown by a multiplicity of advantageous embodiments thereof. Of course, this applies only to those areas of the sawtooth wire in which the material of the original profile is still there, i.e. in which no material was punched out.
[0089] In FIG. 2 the cross section of the sawtooth wire shown in FIG. 1 is illustrated, and in FIG. 3 the associated starting profile (corresponding to the sawtooth wire without teeth). The sectional plane (of the cross section) extends in the lateral direction B and the height direction H. In FIG. 2 —as in FIGS. 4 and 6 —the lateral direction B is shown enlarged (i.e. the overall breadth B max of the sawtooth wire is shown enlarged compared to the overall height H max ,) in order to enable the viewer to recognize the angles and gradients.
[0090] As is apparent from FIG. 2 , the first portion 10 (in the respective sectional plane) is delimited by the end points 14 and 15 and the second portion 11 by the end points 15 and 16 . The first secant 17 , which runs along the first portion 10 (i.e. through the end points 14 , 15 of the first portion 10 ) in the sectional plane defined by the lateral direction B and the height direction H, has a steeper gradient than the second secant 18 , which runs in the same plane and along the second portion 11 (through the end points 15 , 16 of the second portion).
[0091] FIG. 4 shows the cross section (and FIG. 5 the associated profile) of a sawtooth wire the first blade-segment lateral surface 5 of which is made up of four planar surface portions following each other in succession in the height direction H. The uppermost planar surface portion (furthest from the foot segment 1 ), which (in this sectional plane) is delimited by the end points 20 (with the height value h 11 ) and 21 (with the height value h 12 ), has been selected here as the first portion 10 . The second uppermost planar surface portion, which is delimited by the end points 23 (with the height value h 21 ) and 24 (with the height value h 22 ) has been selected as the second portion 11 . The first secant 22 runs through the end points 20 and 21 , the second secant 25 through the end points 23 and 24 . Both secants 22 , 25 run in the plane defined by the lateral direction B and the height direction H. Here too, the secant 22 has a steeper gradient than the secant 25 , i.e. the secant 22 encloses a smaller angle α 1 with the perpendicular 19 dropped to the base area 2 of the foot segment than does the secant 25 (angle α 2 ).
[0092] Beneath the end point 24 , with the height value h 22 of the at least one second portion, is the further height value h 3 . The further height value h 3 is located (at a distance in the height direction H) approximately ⅛ of the overall height H max beneath the lower height value h 22 of the at least one second portion. No change in the sign of the gradient dh/db is allowed in the area between these two height values, i.e. no elevations or indentations are allowed in this area.
[0093] FIG. 6 shows the cross section (and FIG. 7 the associated profile) of a sawtooth wire the first blade-segment lateral surface 5 of which (seen from the outside) is a concave curve (with no kinks). In FIG. 6 —as before in FIGS. 2 and 4 —the lateral direction B is once again shown enlarged so that the viewer is able to recognize different angles between the perpendicular 19 and the tangents 27 and 30 . It remains to be mentioned that in FIGS. 2, 4 and 6 the points 14 , 15 , 16 , 20 , 21 , 23 , 24 , 26 and 29 are represented by horizontal strokes, which intersect the contour of the sawtooth wire 1 . The respective point lies at the intersection between the horizontal stroke and the contour of the sawtooth wire 1 .
[0094] An infinitesimally small surface portion 26 in the height direction H (punctiform relative to the selected sectional plane) has been selected as the first portion 10 . Here, the tangent 27 to the first blade-segment lateral surface 5 at the surface portion/point 26 takes the place of the otherwise customary secant running along a planar portion (in the plane defined by the lateral and height directions). The second portion 11 is formed analogously by the point 29 , with the tangent 30 in place of the secant along a planar portion. Here too (as with the respective secants) the gradients of the tangents correspond in each case to the derivative dh/db at the respective point. As in the two preceding examples, the tangent 27 has a steeper gradient dh/db than the tangent 30 , i.e. the tangent 27 encloses a smaller angle α 1 with the perpendicular 19 dropped to the base area 2 of the foot segment than does the tangent 30 (angle α 2 ).
[0095] FIG. 8 shows the contours of two first blade-segment lateral surfaces 5 in the plane defined by the height direction H and the lateral direction B. The one first blade-segment lateral surface 5 running in the respective plane is entirely curved 31 , the other first blade-segment lateral surface 32 is made up of two planar surface portions 33 , 34 . The lateral direction B is again shown in enlarged form.
[0096] In the case of the blade-segment lateral surface 32 , which comprises two planar surface portions, the first portion 10 may be selected as the surface portion 33 , which extends between the points with the coordinates (b 11 , h 11 ) and (b 12 , h 12 ), and the second portion 11 as the surface portion 34 , which extends between the points with the coordinates (b 21 , h 21 ) and (b 22 , h 22 ). The gradient of the secant through the end points of the first portion 10 is then (h 12 -h 11 )/(b 12 -b 11 ), the gradient of the secant through the end points of the second portion 11 is (h 22 -h 21 )/(b 22 -b 21 ).
[0097] For the blade-segment lateral surface 31 , which is entirely curved, the first portion 10 and the second portion 11 are selected (at least in the viewing plane) to be infinitesimally small (i.e. punctiform). The gradient of the first portion 10 equals the derivative dh/dh at the point b 11 (or at the point b 12 , since the two end points of the infinitesimally small portion 10 coincide), the gradient of the second portion 11 equals the derivative dh/db at the point b 21 (or b 22 ).
[0098] FIG. 9 shows a tooth 8 whose height corresponds to the overall height H max of the blade segment 4 , i.e. the overall height of the tooth 8 equals the overall height H max (=h max −h min ) of the blade segment 4 .
[0099] The tooth has, in the area of the tooth tip 12 , a first planar surface portion 35 , which is steeper, and, further down, a second planar surface portion 36 , which is flatter. The two surface portions 35 , 36 border on each other at the partition line 37 .
[0100] It is possible to select either a first portion 110 b , which extends between the height values h′ 11 and h′ 12 , and a second portion 111 (which extends between the height values h 21 and h 22 ), which have the same reach z 1 in the longitudinal direction Z. Or it is possible to select a first portion 110 a , which extends between the height values h 11 and h 12 , and the second portion 111 , the two portions 110 a and 111 having different reaches z 1 , z 2 in the longitudinal direction Z.
[0101] As is evident from FIG. 10 , the foot segment 1 may be shaped such that adjacent wire sections interlock (linked configuration). The gradients of the side walls 38 of the foot segment are not subject matter of this application.
[0102] In FIGS. 11 and 12 , embodiments of the second blade-segment lateral surface 6 are illustrated. The second blade-segment lateral surface 6 shown in FIG. 11 is approx. mirror-symmetric to the first blade-segment lateral surface 5 . FIG. 12 shows a blade-segment lateral surface 6 which is slightly inclined relative to the height direction H.
[0103] FIG. 13 shows that the at least one blade-segment surface 5 of the sawtooth wire showing the feature essential to the invention may also lie on the “other” side of the sawtooth wire 1 .
LIST OF REFERENCE NUMERALS
[0000]
1 Foot segment
2 Base area of foot segment
3 Lateral surface of foot segment
4 Blade segment
5 First blade-segment lateral surface
6 Second blade-surface lateral surface
7 Exterior surface of blade segment
8 Tooth
9 Rounded transition area between blade segment and foot segment
10 First portion
11 Second portion
12 Tooth tip
13 Transition between first and second portions
14 First end point
15 Second end point
16 Third end point
17 First secant
18 Second secant
19 Perpendicular dropped to the base of the foot
20 First end point
21 Second end point
22 First secant
23 Third end point
24 Fourth endpoint
25 Second secant
26 Infinitesimally small first surface portion/first point
27 Tangent to the first surface portion
29 Infinitesimally small second surface portion/second point
30 Tangent to the second surface portion
31 Curved contour of the blade-segment lateral surface
32 Contour of the blade-segment lateral surface, which is made up of two planar surface portions
33 First planar surface portion
34 Second planar surface portion
35 Steeper planar surface portion
36 Flatter planar surface portion
37 Dividing line between the steeper and the flatter planar surface portions
38 Side walls of the foot
110 a First portion
110 b First portion (alternative)
111 Second portion
Z Longitudinal direction
B Lateral direction
H Height direction
B max Overall breadth of blade segment
b 11 Upper lateral value of first portion
b 12 Lower lateral value of first portion
b′ 11 Upper lateral value of first portion (alternative)
b′ 12 Lower lateral value of first portion (alternative)
b 21 Upper lateral value of second portion
b 22 Lower lateral value of second portion
H max Overall height of blade segment
h max Maximum height of blade segment
h min Minimum height of blade segment
h 11 Upper height value of first portion
h 12 Lower height value of first portion
h′ 11 Upper height value of first portion (alternative)
h′ 12 Lower height value of first portion (alternative)
h 21 Upper height value of second portion
h 22 Lower height value of second portion
h 3 Further height value
z 1 First longitudinal reach value
′z 2 Second longitudinal reach value
α 1 Angle between the first portion and the perpendicular dropped to the base
α 2 Angle between the second portion and the perpendicular dropped to the base
α 3 Angle between the first and second portions | A clothing wire for mounting on a clothing roll of a carding machine has a base section ( 1 ) and a blade section ( 4 ). A gradient dh/db of the height (h) as a function of the width (b) of at least a first section ( 10 ) of at least one blade-section side face ( 5, 6 ) is greater than the gradient dh/db of a second section ( 11 ) of the at least one blade-section side face ( 5, 6 ). The second section ( 11 ) is closer to the base section ( 1 ) than the first section ( 10 ). The sign of the gradients dh/db is the same. In a region which extends to a vertical distance of at most ⅛ of the overall height of the blade section beneath the at least one second portion ( 11 ), there no protrusions or indentations cause a gradient sign change on the at least one blade-section side face ( 5, 6 ). | 3 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to the area of selective protection of identical amino groups in cyclic polyamines, and preferably, relates to an improved process for preparing 1, 1′-[1,4-phenylenebis (methylene)]-bis1,4,8,11-tetraazacyclotetradecane.
[0003] 2. Description of the Prior Art
[0004] J. Med. Chem, Vol. 38, No. 2, pgs. 366-378 (1995) is directed to the synthesis and anti-HIV activity of a series of novel phenylbis(methylene)-linked bis-tetraazamacrocyclic analogs, including 1,1′-[1,4-phenylenebis (methylene)]-bis1,4,8,11-tetraazacyclotetradecane. This compound and its analogs are prepared by: 1) forming the tritosylate of the tetraazamacrocycle; 2) reacting the protected tetraazamacrocycle with an organic dihalide, e.g., dibromo-p-xylene, in acetonitrile in the presence of a base such as potassium carbonate; and 3) de-protecting the bis-tetraazamacrocycle prepared in 2) employing freshly prepared sodium amalgam, concentrated sulfuric acid or an acetic acid/hydrobromic acid mixture to obtain the desired cyclam dimer in the form of a salt.
[0005] U.S. Pat. No. 5,047,527 is directed to a process for preparing a mono-functionalized (e.g., monoalkylated) cyclic tetraamine comprising: 1) reacting the unprotected macrocycle with chrominum hexacarbonyl to obtain a triprotected tetraazacycloalkane compound; 2) reacting the free amine group of the triprotected compound prepared in 1) with an organic halide to obtain a triprotected mono-functionalized tetraazacycloalkane compound; and 3) deprotecting the compound prepared in 2) by simple air oxidation to obtain the desired compound.
[0006] In addition, the reference discloses alternative methods of tri-protection of cyclic tetraamine employing boron and phosphorous derivatives. These tri-protected intermediates are used in the preparation of linked compounds, including the cyclam dimer 1,1′-[1,4-phenylenebis (methylene)]-bis1,4,8,11-tetraazacyclotetradecane, by reacting with an organic dihalide in a molar ratio of 2:1, followed by deprotection.
[0007] Synthetic Communications, 28(15), pgs. 2903-2906, (1998) describes an improved method adopting the above-mentioned phosphorous protection, deprotection sequence to make 1,1′-[1,4-phenylenebis (methylene)]-bis1,4,8,11-tetraazacyclotetradecane.
[0008] U.S. Pat. No. 5,606,053 is directed to a process for preparing cyclam dimer 1,1′-[1,4-phenylenebis (methylene)]bis1,4,8,11-tetraazacyclotetradecane. The compound is prepared by: 1) tosylation of tetraamine starting material to obtain an acyclic ditosyl intermediate and an acyclic tritosyl intermediate; 2) separation of the two different tosylation product from step 1), e.g. the ditosyl tetraamine and the tritosyl tetraamine; 3) alkylation of the ditosyl tetraamine with dibromoxylene, followed by tosylation to make hexatosylated acyclic cyclam dimer; 4) alkylation of the tritosyl tetraamine from 1); 5) cyclization of the compound prepared in steps 3) and 4), i.e., the bridged hexatosyl acyclic dimer, by reacting it with three equivalents of ethylene glycol ditosylate; 6) detosylation of the cyclized cyclam dimer by reacting with a mixture of hydrobromic acid and glacial acetic acid to obtain the product in the form of an HBr salt.
[0009] U.S. Pat. No. 5,801,281 is directed to an improved process for preparing the cyclam dimer 1,1′-[1,4-phenylenebis (methylene)]-bis1,4,8,11-tetraazacyclotetradecane. The compound is prepared by: 1) reacting the acyclic tetraamine with 3 equivalents of ethyl trifluoroacetate; 2) alkylation of the tri-protected acyclic tetraamine with 0.5 equivalents of dibromoxylene, to obtain the 1,4 phenylene bis-methylene bridged acyclic dimer; 3) hydrolysis to remove the six trifluoroacetyl groups of the compound prepared in step 2); 4) tosylation of the compound prepared in step 3) to obtain the hexatosylated bridged tetraamine dimer; 5) cyclization of the compound in step 4) with ethylene glycol ditosylate to obtain the hexatosylated cyclam dimer; 6) detosylation of the compound prepared in step 5) to obtain the cyclam dimer 1,1′-[1,4-phenylenebis (methylene)]-bis1,4,8,11-tetraazacyclotetradecane in the form of a salt using HBr/HOAc mixture.
[0010] U.S. Pat. No. 5,064,956 discloses a process for preparing mono-alkylated polyazamacrocycles by reacting unprotected macrocycle with an electrophile in an aprotic, relatively non-polar solvent in the absence of a base. No example resembling the synthesis of cyclam dimer was provided.
[0011] Although the current approaches to 1,1′-[1,4-phenylenebis (methylene)]-bis1,4,8,11-tetraazacyclotetradecane via tri-protection of cyclam or starting from acyclic tetraamine as demonstrated previously are suitable to prepare the compound (supra), they both suffer from the fact that the key step in each process is low yielding. The average yield of tri-protection reported is rarely over 50%. The macrocyclizations are also frequently suffering from lower yields. In addition, the deprotection of tosyl groups is time consuming and requires relatively harsh conditions.
[0012] It is known to those skilled in the art that the direct N-1 protection of N-ring nitrogen containing cyclic polyamines, where “N-1 protection” refers to the protection of all but one nitrogen in a cyclic polyamine containing N amines and N equals the number of protectable primary or secondary amines, e.g. cyclam and cyclen (N=4 in both cases), are generally problematic. Protecting groups such as tosyl, mesyl, Boc etc have been tested and vigorously optimized. Nevertheless, the drawbacks of these existing methods are obvious in several general aspects: 1) the low to moderate yield (frequently less than 50%) during the N-1 protection pursued due to the concurrent formation, with relatively great amount, of from N-M (M<N) to N substituted derivatives; 2) the difficulty in the isolation of the N-1 protected intermediate from the mixture; and 3) in several cases, such as tosyl, the harsh conditions required in the removal of these protecting groups at certain stage of the application.
[0013] In particular, the chemistry related to the tri-protection of tetraazamacrocycles such as 1,4,8,11-tetraazacyclotetradecane (cyclam), 1,4,7,10-tetraazacyclododecane (cyclen) and the di-protection of 1,4,7-triazacyclononane are currently under active development in the field. It will be obvious to those skilled in the art that these N-1 protected cyclic polyamines are useful intermediates that will lead to, after necessary manipulation, mono-substituted cyclic amines. Hence these are key intermediates having great potential in the preparation of MRI diagnostic agents (U.S. Pat. No. 5,994,536; U.S. Pat. No. 5,919,431; U.S. Pat. No. 5,871,709; U.S. Pat. No. 5,410,043; U.S. Pat. No. 5,277,895; U.S. Pat. No. 5,132,409; U.S. Pat. No. 4,885,363.) or for the preparation of anti-HIV compounds (U.S. Pat. No. 5,583,131; U.S. Pat. No. 5,698,546; U.S. Pat. No. 5,021,409; and U.S. Pat. No. 6,001,826), or for the preparation of compounds disclosed in PCT WO 2000/45814.
[0014] More recently, U.S. Pat. No. 5,705,637 discloses a process for preparing tri-benzylated macrocycles following a macrocyclization/amide reduction sequence. The three benzyl groups are removed eventually to afford mono-substituted cyclen.
[0015] For those skilled in the art it will also be obvious that the N-1 protected cyclic macrocyclic polyamines of the present invention are useful, after necessary additional protection deprotection steps, for the preparation of N-1 substituted cyclic polyamines.
[0016] Certain unique nitrogen protecting groups other than those described above have been reported and offer from low to excellent selectivity among primary and secondary amines and between two secondary amines.
[0017] Tetrahedron Letters Vol. 36. No. 20, pgs 3451-3452, (1995) reported reactions using ethyl trifluoroacetate to selectively protect primary amine in the presence of secondary amine in several linear polyamine compounds.
[0018] Tetrahedron Letters Vol. 36. No. 41, pgs 7357-7360, (1995) relates to examples using single equivalent ethyl trifluoroacetate to selectively protect di-primary amines and di-secondary amines. One case involving a six-membered diamine piperazine demonstrated a moderate selectivity of 5.8:1 when one equivalent of ethyl trifluoroacetate is used per equivalent of piperazine. It is noted that treatment of piperazine with excess ethyl trifluoroacetate readily produces more double (full) protected product, thus significantly reduced selectivity.
[0019] U.S. Pat. No. 6,080,785 relates to new mono-functionalized ethylenediaminetetraacetic acid, diethylenetriaminepentaacetic acid and triethylenetetraaminehexaacetic acid derivatives. A linear 1,4,7-triazaheptane was treated with 1.1 equivalents of ethyl trifluoroacetate and produced a mixture of monoamide and diamide at a ratio of 9:1. This mixture was carried further to the next step.
[0020] The present invention is based on the discovery that, when certain protecting agents are used to protect cyclic polyamines containing N ring nitrogen (N≧3) with each nitrogen being separated by 2 or more carbon atoms , the rate of reaction will slow down sharply once N-1 nitrogens are protected, even when all of the nitrogens in the cyclic polyamine are originally chemically equivalent. These controlled reactions thus afford, in an excellent yield, the important N-1 protected polyazamacrocycles at high selectivity.
SUMMARY OF THE INVENTION
[0021] The present invention relates, for example, to efficient high yielding N-1 protection of cyclic polyamines containing a total of N amine nitrogens, where the ring has from 9 to 20 ring members and N is from 3 to 6 amine nitrogens spaced by 2 or more carbon atoms, using fluroronated acid esters and other structurally related protecting agents (formula III). The resultant protected amines prepared by this method are useful intermediates for the preparation of selectively N-substituted protected cyclic polyamines. The protected selectively N-substituted cyclic polyamine is readily deprotected under mild conditions to form selectively N-substituted cyclic polyamines.
[0022] More particularly, the current invention discloses, inter alia, the high yielding tri-protection of 1,4,8,11-tetraazacyclotetradecane (cyclam), 1,4,7,10-tetraazacyclododecane (cyclen) and di-protection of 1,4,7-triazacyclononane using agents such as those represented by formula III.
[0023] In addition, the present invention provides an extremely efficient and economic process for preparing 1,1′-[1,4-phenylenebis (methylene)]-bis1,4,8,11-tetraazacyclotetradecane from cyclam, by using protecting groups such as, but not limited to, trifluoroacetyl, following a reaction sequence of tri-protection, alkylation and deprotection.
[0024] Other aspects of the invention are described throughout the specification and in particular the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] [0025]FIG. 1 depicts the 13 C NMR of Tri-trifluoroacetyl cyclam.
[0026] [0026]FIG. 2 depicts the 1 H NMR of Tri-trifluoroacetyl cyclam.
[0027] [0027]FIG. 3 depicts the 19 F NMR of Tri-trifluoroacetyl cyclam.
DETAILED DESCRIPTION OF THE INVENTION
[0028] The present invention relates to N-1 (i.e. all but one) protection of cyclic polyamines containing a total of N amine nitrogens on the ring system, where the ring has from 9 to 20 ring members and contains from 3 to 6 amine nitrogens spaced by 2 or more carbon atoms, using trifluoroacetyl and other structurally related protecting agents as represented by formula III.
[0029] Preferably, applicable cyclic polyamine may be represented by formulas I and II, where m and m′ represent from 0 to 2 inclusive, preferably from 0 to 1 inclusive carbons; n, n′ and n″ represent from 1 to 3 inclusive, preferably from 1 to 2 inclusive carbons; m, m′, n, n′ and n″ may be identical or different for any specific compound.
[0030] Even more preferable examples are cyclam (formula I, m=m′=n=n′=1), cyclen (formula I, m=m′=0, n=n′=1) and 1,4,7-triazacyclononane (formula II, n=n′=n″=1).
[0031] In another embodiment, one or more carbon atoms on the ring (formula I and II) may also be substituted with one or more atoms such as oxygen and/or sulfur.
[0032] The protecting agents are represented by formula III, where X is a fluoro-substituted, preferably perfluoro substituted aromatic, heteroaromatic, alkyl, alkenyl and/or alkynyl group, more preferably perfluoro substituted linear or branched alkyl group, most preferably perfluoro substituted saturated linear alkyl group containing 1-5 carbons, and further wherein X is preferably CyHpFz, wherein y is from 1 to 10 inclusive, p is from 0 to 20 inclusive, preferably 0 to 5, more preferably 0 to 2, and z is from 1 to 21 inclusive, preferably 1 to 9, more preferably 1 to 5; Lv is a moderately reactive nitrogen, oxygen, or sulfur containing leaving group such as, but not limited to, alkoxy, phenoxy, mercaptyl, imidazoyl, N-hydroxysuccinyl or other nitrogen or oxygen containing group preferably alkoxy containing 1-6 carbons, more preferably C1-C4. As would be well understood by someone skilled in the field, where u is the total number of rings and pi (double) bonds in the group, and t is the number of nitrogen atoms in the group, z=1 to 2y+1−2u+t, and p=2y+1−z−2u+t. These and similar reagents can also be in the form of polymer-bound derivatives, such as those described by P. Suirskaya and L. Letnoff, J. Org. chem (1987) 52:1362-1364.
[0033] Compounds represented by formulas VIII and IX shown below are prepared, according to conditions detailed elsewhere herein, from reactions of I and II with III, respectively. In formulas VIII and IX, CyHpFz is as described above; m, m′ are from 0 to 2 inclusive, n, n′ and n″ are from 1 to 3 inclusive carbons, and m, m′, n, n′ and n″ may be identical or different for any specific compound.
[0034] This N-1 protection is carried out using 1 to more than 100 equivalents, preferably N-1 to 3×N equivalents, most preferably N-1 to 2×N equivalents, of alkyl trifluoroacetate and/or other reagents with similar reactivity as defined by formula III per mole of cyclic polyamine where N=the number of ring nitrogens in the cyclic polyamine.
[0035] This N-1 protection reaction may be carried out in the presence of a diluting agent or a combination of diluting agents, such as: a C1-C12, preferably C1-C4, straight chain or branched chain alkanol, or a mixture of any other non-aqueous solvents with any alkanol described, including but not limited to methanol, ethanol, or low molecular weight (less than 5 carbon) alkanol such as butanol, or propanol; and/or pure alkyl trifluoroacetate, preferably methyl trifluoroacetate or ethyl trifluoroacetate, or other protecting agents adopted as defined by formula III.
[0036] Solvent or solvents used may contain certain levels of water without very serious product formation problem; however, it is preferable to exclude water. This may be accomplished by using additives that will sequester water.
[0037] The quantity of diluting agent employed may range from 0 to 100 liters per mole of the cyclic polyamine, preferably from 0 to 5 liter, most preferably from 2 to 3 liters, per mole of the cyclic polyamine.
[0038] Additives that will keep the reaction system acid free may be used such as carbonates, bicarbonates, phosphates, oxides, aluminates, aliphatic or aromatic amines, or polymer supported basic resins. Examples of amines includes aliphatic or aromatic amines that contain up to 24 carbons and preferably 3 to 12 carbons. Example of inorganic bases include alkali carbonates preferably sodium or potassium carbonate. The amount of this additive can range from 0 to a large excess, such as 0 to 10 equivalents, preferably 0 to 1 equivalents, more preferably 0.1 to 1 equivalents, per equivalent of the cyclic polyamine.
[0039] Alternatively, the N-1 protection operation may be advantageously carried out at temperatures from −78° C. to 120° C., preferably from −20° C. to 100° C., most preferably from 0° C. to 60° C.
[0040] The duration of the N-1 protection is generally on the order of 10 minutes to 72 hours, preferably from 1 hour to 24 hours, more preferably from 2 to 10 hours.
[0041] The product obtained from the reaction medium may be purified by methods such as, but not limited to, silica gel chromatography, recrystallization, acid wash and any other commonly practiced purification techniques. The product can also be isolated by treatment with salt forming acid in the form of amine salt, such as, but not limited to, the hydrogen chloride salt. Alternatively, the product may be used for further modification as crude without further purification.
[0042] The N-1 protected cyclic polyamine can be used in further reactions where the single unmasked amine nitrogen will take part. These reactions, which are known art of the field, will lead to mono-functionalized, N-1 differently protected cyclic polyamines. Commonly and conveniently, the N-1 protection groups such as trifluoroacetyl, maybe removed, under various standard and mild conditions, to give mono-functionalized cyclic polyamines (T. W. Greene and P. G. M. Wuts, Protective Groups in Organic Synthesis, 3 rd edition, 1999, Wiley & Sons.). These are important intermediates and useful in the preparation of many known and potential cyclic polyamine based MRI chelating agents.
[0043] The aforementioned reactions may be used to synthesize compounds XIV and XVII as described herein, wherein CyHpFz is a fluoro-substituted alkyl, alkenyl, alkynyl, cycloalkyl, aromatic, or heteroaromatic group, wherein y is from 1 to 10, p is from 0 to 20, and z is from 1 to 21; wherein m and m′ are from 0 to 2 and n, n′ and n″ are from 1 to 3; and wherein m, m′, n, n′ and n″ may be the same or different; and wherein E is an alkyl, acyl, alkenyl, alkynl, hydroxyalkyl, cycloalkyl, aromatic, heteroaromatic, carboxamide, thiocarboxamide, carboxyl, phosphoryl or sulphato group.
[0044] In compounds XIV and XVII, E may also form a linker group, E″, which is attached to one macrocyclic nitrogen of each macrocyclic polyamine and is preferably a phenylene ring optionally substituted with an electron donating or withdrawing group consisting of alkyl, aryl, amino, alkoxy, hydroxy, halogen, carboxyl or carboxamido.
[0045] In a more general sense, the final compound may be represented by compound XX:
Q-E″-Q′ XX
[0046] where Q and Q′ may be the same or different and are macrocyclic polyamines represented by formulas I or II that are linked via E″.
[0047] For instance, when E is an aromatic ring, it may function to link two compound XIV groups together to form the compound according to formula XXI, wherein CyHpFz is a fluoro-substituted alkyl, alkenyl, alkynyl, cycloalkyl, aromatic, or heteroaromatic group, wherein y is from 1 to 10, p is from 0 to 20, and z is from 1 to 21; and wherein m and m′ are from 0 to 2 and n and n′ are from 1 to 3, and wherein m, m′, n and n′ may be the same or different, and wherein Ar is a phenylene ring, optionally substituted with an electron donating or withdrawing group such as alkyl, aryl, amino, alkoxy, hydroxy, halogen, carboxyl or carboxamido.
[0048] Preferably, linker Ar is formed from compound XI, wherein Lx and Lx′ are the same or different and are moieties that can be displaced by an unprotected amine nitrogen. Preferably, Lx and Lx′ are selected from Cl, Br, I, aryl sulfonate and alkyl sulfonate (e.g., 4-tolylsulfonate, methanesulfonate and trifluoromethane sulfonate).
[0049] By way of example, the following description pertains to a process for preparing 1,1′[1,4-phenylenebis (methylene)]-bis 1,4,8,11-tetraazacyclotetradecane, which is a representative process according to the present invention, with the protecting step described above given by step 1 .
[0050] Thus, the present invention is exemplified by the process for preparing 1,1′-[1,4-phenylenebis (methylene)]-bis1,4,8,11-tetraazacyclotetradecane via a three step sequence as depicted above. As shown, R in formula V and VI is the protecting moiety that is represented by formula III, where Lv is removed, preferably when X in Formula III is CyHpFz, and is a perfluoro substituted alkyl group containing 1 to 6 carbons, more preferably CyHpFz═CF 3 .
[0051] Step 1
[0052] With respect to the individual steps, the first step involves the reaction of cyclam IV with a reagent represented by formula III. The reaction may use from 3 to 100 equivalents, preferably 3 to 10 equivalents of protecting agent III, in a non-aqueous solvent or a mixture of solvents suitable to dissolve the materials, preferably methanol, ethanol and/or other low molecular alcohol solvent or solvent mixture containing these polar solvents, at a temperature between −78° C. to 120° C., preferably between 20° C. to 60° C.
[0053] The reaction may take from 30 minutes to 72 hours , depending on the yield pursued, preferably from 2 hours to 10 hours. Other than the solvent system described above, suitable protecting agents such as depicted by formula III, preferably alkyl trifluoroacetate, more preferably methyl and/or ethyl trifluoroacetate can also serve as solvent for this reaction.
[0054] Additives that will keep the reaction system acid free may be used such as carbonates, bicarbonates, phosphates, oxides, aluminates, aliphatic or aromatic amines, or polymer supported basic resins. Examples of amines includes aliphatic or aromatic amines that contain up to 24 carbons and preferably 3 to 12 carbons. Example of inorganic bases include alkali carbonates preferably sodium or potassium carbonate. The amount of this additive can range from 0 to 10 equivalents, preferably from 0.1 to 1 equivalent, per equivalent of cyclam.
[0055] The product of Step 1, such as the tri-protected cyclam V, can be used as crude for the next step, or can be purified by silica gel column or using other common practice in the field such as, but not limited to, aqueous extraction work-up or recrystallization.
[0056] Step 2
[0057] The second step concerns functionalizing the remaining secondary amine from step 1 with a mono-reactive or di-reactive electrophile. For example, compound V obtained from step 1 can be alkylated using 1,4-dibromoxylene, 1,4-dichloroxylene, the ditosylate analogue or other similar alkylating agents. A wide range of organic solvents are suitable as diluting agents including acetonitrile, toluene, THF, DMF, 2-propanol and any other solvent or combination of solvents desirable for amine alkylation. The reaction may be carried out at a temperature from 20° C. to 150° C., preferably from 60° C. to 120° C. Further, any single or mixture of iodide anion containing compounds may be used as additives, including but not limited to KI, NaI, Bu 4 NI, preferably KI. Additives that will keep the reaction system acid free may be used such as carbonates, bicarbonates, phosphates, oxides, aluminates, aliphatic or aromatic amines, or polymer supported basic resins. Examples of amines includes aliphatic or aromatic amines that contain up to 24 carbons and preferably 3 to 12 carbons. Example of inorganic bases include alkali carbonates preferably sodium or potassium carbonate.
[0058] Alternatively, reductive amination methods may be used. For example, terephthaldehyde may be reductively aminated with compound V using a reducing agent such as sodium cyanoborohydride or other borohydride reducing agents, or via catalytic hydrogenation. Additionally, the product from step 1 can also react with terephthaloyl chloride to obtain the corresponding diamide, followed by reduction to give the hexa-trifluoroacetyl cyclam dimer. The product VI from these alkylation reactions may be used as crude for the next step, or preferably, recrystallized from common solvents and/or mixture of solvents. These solvent systems include, but are not limited to, ethyl acetate, methanol, ethanol, methanol-water mixture etc.
[0059] In one embodiment of the invention, step two comprises reaction of compound VIII given above with the alkylating agent compound XI given above to form compound X.
[0060] Step 3
[0061] The third step of the process is deprotection (e.g. by saponification) of all the protecting groups in compound VI. Reagents that are useful for this saponification include, but are not limited to, alkoxides, hydroxides, amines, hydrazines, thiolates or other nucleophiles or reagents that generate nucleophiles such as metal carbonates in wet alcohols or water.
[0062] Alternatively, hydrolysis of the nitrogen protecting group in compound VI may be effected using acidic conditions such as those described in T. W. Greene and P. G. M. Wuts, Protective Groups in Organic Synthesis, 3 rd edition, 1999, Wiley & Sons. A variety of other deprotection methods are also known to those skilled in the art. See T. W. Greene and P. G. M. Wuts, Protective Groups in Organic Synthesis, 3 rd edition, 1999, Wiley & Sons. The final product VII can be obtained and purified by common methods such as, but not limited to, recrystallization, salt formation and chromatography.
[0063] In one embodiment of the present invention, step 2 is used to form the intermediate given by formula VIII above, which is reacted with a suitable electrophile selected from the group consisting of organic halides, tosylates, triflates, epoxides, thiocyanates and isocyanates to form a compound given by formula XIV above, wherein E is a functional group bonded to the nitrogen as described above. Then, step 3 consists of removing the (C═O)CyHpFz groups from the formula XIV compound using a method compatible with E to form a compound given by the formula XV.
[0064] In another embodiment, step 3 comprises removing the (C═O)CyHpFz groups from a compound given by formula XVII above using a method compatible with E to form a compound given by the formula XVIII.
[0065] In yet another embodiment, when compound X as described above is deprotected in step three, this results in formation of compound XII.
[0066] Step 4
[0067] Optional step 4 involves functionalizing all of the secondary amines released in the third step with an electrophile that includes but is not limited to an alkylating, acylating, sulphonylating or phosphorylating agent.
[0068] In one embodiment, step 4 comprises reacting the compound given by formula XV above with an electrophile, E′, which is different from E, to form the compound according to the formula XVI
[0069] wherein E′ is selected from the group consisting of organic halide, tosylates, triflate, epoxide, thiocyanate, and isocyanate.
[0070] In another embodiment, step 4 comprises reacting the compound given by formula XVIII given above with an electrophile as described above to form the compound according to the formula XIX.
EXAMPLES
[0071] Having now generally described the invention, the same will be more readily understood by way of reference to the following examples which are provided and illustrated, and are not intended to be limiting of the present invention, unless specified.
Example 1
Preparation of 1,4,7-tris-(trifluoroacetyl)-1,4,7,10-tetraazacyclododecane
[0072] [0072]
[0073] Cyclen (2.13 g, 12.35 mmol) was dissolved in MeOH (20 mL). To the clear solution was added NEt 3 (1.70 mL, 12.35 mmol) in one portion, followed by slow addition of ethyl trifluoroacetate (7.35 mL, 61.76 mmol) during a period of 5 minutes. The reaction may be chilled to keep temperature under 25° C. Stirring was continued under N 2 for 15 hours. Volatiles were then removed under vacuum. The residue was dissolved in the minimum amount of CH 2 Cl 2 (˜2.0mL) and passed through a short silica gel pad, eluted with 100% EtOAc. The eluent was concentrated to give the product as a white semi solid (5.25 g, 92.5%). 1 H NMR (300 MHz, CDCl 3 ): δ3.90-3.76 (broad multiplet, 4 H, 3.68-3.20 (multiplet, 8 H), 3.10-2.65 (multiplet, 4 H), 1.40-1.25 (multiplet, 1 H). Mass C 14 H 17 F 9 N 4 O 3 requires C 36.53, H 3.72, N 12.17, O 10.43, found C 36.49, H 3.71, N 12.11, O 10.59.
Example 2
Preparation of 1,4-bis (trifluoroacetyl)-1,4,7-triazacyclononane
[0074] [0074]
[0075] 1,4,7-triazacyclononane (115.0 mg, 0.89 mmol) was dissolved in MeOH (2.0mL). To this clear solution was added NEt 3 (0.13 mL, 0.89 mmol) in one portion, followed by ethyl trifluoroacetate (0.43 mL, 13.56 mmol) during a period of 5 minutes. Stirring was continued under N 2 for 15 hours. Volatiles were then removed by rotavapor. The residue was dissolved in the minimum amount of CH 2 Cl 2 (˜2.0mL) and passed through a short silica gel pad, eluted with 100% EtOAc. The eluent was concentrated to give the product as a white solid (267.0 mg, 94%). 1 H NMR (300 MHz, CDCl 3 ): δ4.04-3.95 (multiplet, 2 H), 3.80-3.72 (multiplet, 2 H), 3.50-3.40 (multiplet, 4 H), 3.0-2.90 (multiplet, 4 H), 1.59 (singlet, 1 H). Mass calculated for C 10 H 13 F 6 N 3 O 2 321.2, found M+1 322.1.
Example 3
Preparation of 1,4,8-tris (trifluoroacetyl)-1,4,8,11-tetraazacyclotetradecane
[0076] [0076]
[0077] Cyclam (7.53 g, 37.58 mmol) was dissolved in bench MeOH (30 mL). To this clear solution was added NEt 3 (5.20 mL, 37.58 mmol) in one portion, followed by portional addition of ethyl trifluoroacetate (18.0 mL, 150.3 mmol) during a period of 5 minutes. The reaction may be chilled to keep temperature under 25° C. Stirring was continued under N 2 for 5 h. Volatiles were then removed under vacuum. The residue was dissolved in minimum amount of CH 2 Cl 2 (˜2.0mL) and passed through a short silica gel pad (˜25 g), eluted with 100% EtOAc. The eluent was concentrated to give the product as a white semi solid (17.05 g, 92.5%), 1 H NMR (200 MHz, CDCl 3 ): δ3.85-3.25 (multiplet, 12 H), 2.80 (broad singlet, 2 H), 2.74-2.50 (broad singlet, 2H), 2.30-1.90 (multiplet, 2 H), 1.85-1.63 (multiplet, 2 H), 1.25-0.60 (multiplet, 1 H). 13 C NMR (75.5 MHz, CDCl 3 ): δ158.74-157.31 (multiplet, C═O, muitiplets due to existence of conformers), 122.84-11.32 (quartet, CF 3 , due to C—F coupling, J C—F ˜264 Hz, further split due to existence of conformers), 51.2-46.2 (multiplet, CH 2 next to N), 29.4-27.8 (multiplet, CH 2 ); Mass of C 16 H 21 F 9 N 4 O 3 requires: C 39.35; H 4.33; N 11.47; O 9.83; found: C 39.19; H 4.36; N 11.33; O 10.04.
Example 4
Preparation of 1,1′-[1,4-phenylenebis (methylene)]-bis-tris-(trifluoroacetyl)-1,4,8,11-azatetradecane
[0078] [0078]
[0079] To a round bottom flask was charged 1,4,8-tris (trifluoroacetyl)-1,4,8,11-tetraazacyclotetradecane (3.70 g, 7.57 mmol) and anhydrous CH 3 CN (20 mL). The mixture was stirred at rt. until a solution was obtained (˜10 min). To this solution was then added K 2 CO 3 (98%, 1.57 g, 11.35 mmol), KI (62.8mg, 0.38 mmol) and Dichloro-xylene (663.0 mg, 3.78 mmol). The mixture was refluxed under N 2 . TLC (1:1 EtOAc/Hexane) was used to monitor the reaction progress, which was completed after ˜16 h. The mixture was cooled to rt. and filtered through a sintered glass filter to remove insoluble salt (washed with 20mL CH 3 CN). The solution was then concentrated to give a slightly yellowish solid. The solid was recrystallized using 4/1 EtOH/H 2 O to give the purified product (3.47 g, 85%) as an off white solid. 1 H NMR (300 MHz, CDCl 3 ): δ7.25-7.06 (multiplet, 5 H), 3.80-3.20 (multiplet, 28 H), 2.75 (broad singlet, 4 H), 2.45-2.20 (multiplet, 8 H), 1.90-1.60 (multiplet, 4 H); 13 C NMR (75.5 MHz, CDCl 3 ): a 155.6-154.5 (multiplet, C═O, multiplet due to conformers), 135.9-134.0 (multiplet, aromatic C), 127.9-126.7 (multiplet, aromatic C—H), 118.0 (quartet, J C—F ˜287 Hz), 58.3-57.7 (multiplet), 55.0-52.0 (multiplet), 50.4-42.7 (multiplet due to conformers), 26.5-21.8 (multiplets due to conformers). Elemental analysis for C 40 H 48 F 18 N 8 O 6 calculated C 44.53, H 4.48, N 10.39, O 8.90, found C 44.46, H 4.40, N 10.26, O 9.11.
Example 5
Preparation of 1,1′-[1,4-phenylenebis (methylene)]bis1,4,8,11-tetraazacyclotetradecane, compound XII:
[0080] [0080]
[0081] 1,1′-[1,4-phenylenebis (methylene)]-bis-tris-(trifluoroacetyl)-1,4,8,11-azatetradecane (3.30 g, 3.05 mmol) was dissolved in MeOH (6.0mL). K 2 CO 3 (1.27 g, 9.1 mmol) was added in one portion. The suspension was heated at reflux for 3 h. Toluene (30 mL) was then added to the cooled mixture. MeOH was removed by forming an azeotrope with toluene. After all MeOH was removed, the hot toluene solution suspended with inorganic salt was filtered and concentrated to give AMD3100 free base (1.32 g, 86%) as a white solid. All characteristics of this product are in good agreement with an authentic sample prepared according to reported methods.
Example 6
Preparation of 1,4,7-triazacyclononane-1-acetamide
[0082] [0082]
[0083] Bis-TFA 1,4,7-triazacyclononane (261.4 mg, 0.81 mmol) was dissolved in acetonitrile (5.0 mL), bromoacetamide (168.1 mg, 1.22 mmol) and K 2 CO 3 (225.0 mg, 1.62 mmol) were added sequentially. The mixture was refluxed for 15 hours. Filtration and chromatography of the residue after removal of all volatiles gave the desired product as an oil (214.0 mg, 70%).
Example 7
Preparation of 1,4,8-tris (pentafluoropropionyl)-1,4,8,11-tetraazacyclotetradecane
[0084] [0084]
[0085] Cyclam (618.9 mg, 3.08 mmol) was dissolved in methanol (5.0 mL). NEt 3 (0.43 ml, 3.08 mmol) and methyl pentafluoropropionate (2.0 mL, 15.44 mmol) were added sequentially. The reaction was continued at room temperature for 15 h. After removal of volatiles, the residue was chromatographed to give 1,4,8-tris (pentafluoropropionyl)-1,4,8,11-tetraazacyclotetradecane (660.0 mg, 34%) as a white foam. 1 H NMR (CDCl 3 , 200MHz): δ4.0-3.28 (multiplet, 10 H), 2.86 (broad multiplet, 2 H), 2.64-2.59 (multiplet, 2 H), 2.48-1.99 (multiplet, 2H), 1.8-1.7(multiplet, 2H), 1.1 (s, 1H); 13 C NMR (75.5 MHz, CDCl 3 ): δ159.4-157.7 (multiplet, C═O), 123.9-111.8 (triplet of quartet, J C—F =249 Hz, 34 Hz, CF 3 CF 2 ), 112.6-104.6 (multiplet of triplet, J C—F= 308 Hz, CF 2 CF 3 ), 50.3-44.4 (multiplet, CH 2 next to N), 28.9-27.8 (multiplet, CH 2 ); C 19 H 21 N 4 F 15 O 3 requires: C 35.75, H 3.32, N 8.78, O 7.52, found C 35.81, H 3.37, N 8.55, O 7.74.
Example 8
Preparation of urea derivative of 1,4,7-tris (trifluoroacetyl)-1,4,7,10-tetraazacyclododecane
[0086] [0086]
[0087] 1,4,7-tris (trifluoroacetyl)-1,4,7,10-tetraazacyclododecane (303.5 mg, 0.658 mmol) was dissolved in CH 2 Cl 2 (5.0 mL). Phenyl isocyanate (0.14 mL, 1.32 mmol) was added in one portion. The reaction was continued at room temperature for 15 hours. After removal of all volatiles, the residue was chromatographed to give the desired urea derivative (301.0 mg, 79%). 1 H NMR (CDCl 3 , 200 MHz): δ7.38-7.26 (multiplet, 5H), 7.08-7.03 (multiplet, 1H), 4.03-3.28 (multiplet, 16 H); MS calculated for C 21 H 22 N 5 F 9 O 4 579.4, found M+Na: 602.5.
Example 9
Preparation of mono-Cbz-tris-(trifluoroacetyl) cyclam
[0088] [0088]
[0089] Tri-TFA cyclam was dissolved in CH 2 Cl 2 (10 mL) at room temperature. Na 2 CO 3 (566 mg, 5.34 mmol) was added in one portion, followed by slow addition of Cbz chloride. The reaction was monitored by TLC (1:1 ethyl acetate: hexane). The reaction was stopped after 15 hours. Usual work up followed by column chromatography using silica gel afforded the product (1.30 g, 94%) as a white foam. 1 H NMR (CDCl 3 , 200 MHz): δ7.31 (broad multiplet, 5 H), 5.02 (s, 2H), 3.54-3.10 (multiplet, 16 H), 2.04-1.54 (multiplet, 4 H); Mass for C 24 H 27 F 9 N 4 O 4 , calculated: 622.5, found M+1 623.2.
Example 10
Preparation of mono-tosyl-tris-(trifluoroacetyl) cyclam
[0090] [0090]
[0091] Tri-TFA cyclam (3.31 g, 6.77 mmol) was dissolved in CH 2 Cl 2 (30 mL). Triethyl amine (1.40 mL, 8.12 mmol) was added in one portion. The solution was cooled in an ice water bath. TsCl (1.55 g, 8.12 mmol) was added in small portions during a period of 5 minutes. The reaction was continued at room temperature for 8 hours. Usual work up and column chromatography afforded the desired the product (3.47 g, 80%). 1 H NMR (300 MHz, CDCl 3 ): δ7.5-7.48 (multiplet, 2H), 7.26-7.20 (multiplet, 2 H), 3.67-3.30 (multiplet, 12 H), 3.21 (broad multiplet, 2 H), 2.95 (broad multiplet, 2 H), 2.32 (s, 3 H), 2.20-1.70 (multiplet, 4 H). 3 C NMR (75.5 MHz, CDCl 13 ): δ158.4-156.4 (multiplet, C═O), 144.8-144.7 ( two singlet due to conformers), 134.2-133.8 ( four singlet due to ring conformers), 133.8, 127.7-127.5 ( two singlet due to conformers), 122.3-110.8 (four singlet, due to C—F coupling, J C—F ˜287 Hz), 51.8-45.0 (multiplet due to conformers), 28.4-27.2 (multiplet due to conformers), 21.6.
Example 11
Preparation of mono-Cbz cyclam
[0092] [0092]
[0093] Mono-Cbz-tris-(trifluoroacetyl) cyclam (4.0 g, 6.4 mmol) was dissolved in bench MeOH (50 mL). K 2 CO 3 (2.0 g, 14.5 mmol) was added in one portion. The mixture was refluxed for 15 h. Most of the volatiles was removed under vacuum and the residue was taken into CHCl 3 (100mL). The solid was filtered off and the solution was concentrated to give mono-Cbz cyclam (1.82 g, 85%). 1 H NMR (CDCl 3 , 200 MHz): δ7.21-7.14 (multiplet, 5 H), 4.98 (singlet, 2 H), 3.33 (triplet, 2 H), 3.26 (triplet, 2 H), 2.67 (triplet, 2 H), 2.60-2.51 (multiplet, 10 H), 1.68 (broad singlet, 3 H), 1.68-1.49 (multiplet, 4 H).
[0094] Citation of documents herein is not intended as an admission that any of the document is prior art. All statements as to the date or representation as to the contents of these documents is based on the information available to the applicants and does not constitute any admission of the correctness of the dates or contents of these documents. Further, all publications and patents mentioned in the above specification are herein incorporated by reference. Various modifications and variations of the described method and system of the invention will be apparent to those skilled in the art without departing from the scope and spirit of the invention. Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. Indeed, various modifications of the described modes for carrying out the invention which are obvious to those skilled in the same or any related fields are intended to be within the scope of the following claims. | Cyclic polyamines containing N nitrogens on the ring are protected with high yields in a N-1 manner, e.g. all protected but one amino group, by using certain fluoro-containing agents that offer easy deprotection. Preferably, a new process for preparing 1,1′-[1,4-phenylenebis (methylene)]-bis1,4,8,11-tetraazacyclotetradecane is disclosed. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 11/415,025, filed May 1, 2006, now U.S. Pat. No. 7,450,647 entitled Method and Apparatus for Inserting Digital Media Advertisements into Statistical Multiplexed Streams, which is a division of U.S. Appl. No. 09/694,848 now U.S. Pat. No. 7,068,724, filed Oct. 20, 2000, entitled Method and Apparatus for Inserting Digital Media Advertisements into Statistical Multiplexed Streams, the entire disclosure of which is incorporated herein by reference.
This application claims the benefit of U.S. Provisional Patent Application No. 60/160,549, filed Oct. 20, 1999.
BACKGROUND OF THE INVENTION
The transition to digital video allows video programming to be transmitted in a digital format through satellite systems, cable systems, and over the air broadcast systems. Digital compression, and in particular, the Motion Pictures Expert Group (MPEG) Standard allows for multiple digital programs to be carried in a section of spectrum which previously could only carry one analog program. Typically, the 6 MHz wide channel which carried one analog program can carry six to ten digitally encoded and compressed programs.
As part of the digital transmission process, multiple programs are statistically multiplexed such that the bit rate requirements for each program are met and when programs do not have a high bit rate requirement, other programs can use the available bandwidth. As an example, when a football game is statistically multiplexed with a talk show, the football game will be allocated sufficient bandwidth to permit accurate representation of the play on the field and the motion of the players. The talk show program will be allocated a minimum amount of bandwidth such that the people appearing on the program can be seen clearly. However, in an instance when there is motion in the talk show program as may be the case when the participants on the talk show begin to hurl chairs at one another, the multiplexing process will allocate additional bandwidth to the talk show and in the event that there is a minimum bandwidth requirement in the football game, that bandwidth will be allocated from the football game to the talk show. Clearly, when there are multiple programs, bandwidth can be allocated among all the programs such that the motion can be accurately represented in each program and the overall statistically multiplexed stream optimized.
Several problems arise in statistically multiplexed programs including the difficulty in separating programs and substituting provisional programming. As an example, at a re-transmission point such as a cable television local head end it becomes difficult to remove one program from the statistically multiplexed stream and insert another program. This difficulty arises from the fact that the bandwidth of the program is varying constantly according to the bandwidth tradeoffs achieved by the statistical multiplexing equipment at the origin point.
Another difficulty is the insertion of advertisements into the statistically multiplexed streams. Because the bandwidth of each program is varying, an original advertisement inserted into the program stream at the origin point will have a time varying bandwidth. Inserting another advertisement at the re-transmission point is not readily facilitated in existing systems and equipment because the bandwidth is varying and in some cases not easily discernible by the equipment at the re-transmission point. Because local advertisement insertion is an important part of many broadcast services and generates significant revenue, it is necessary to be able to remove the initial advertisements, which are part of the program stream and substitute new advertisements.
U.S. Pat. No. 5,715,018 entitled “Digital Advertisement Insertion system” issued on Feb. 3, 1998, provides means for digitizing, compressing and storing analog/audio video source information; and decompressing the information to regenerate an analog signal. A method based on this patent includes receiving motion video information from an analog source; digitizing, compressing and storing the received motion video information in a computer data file such that upon decompression, broadcast quality motion video information is obtained; selecting and editing at least a portion of the stored motion video information; decompressing the selected and edited portion of the stored motion video information to obtain broadcast quality motion; and regenerating an analog signal from the selected and edited portion of the stored motion video information; inserting the regenerated analog signal in place of a broadcast signal on a channel at a predetermined time; and providing synchronization of the regenerated analog signal to the broadcast signal.
An apparatus based on this patent includes means for inserting a signal representing motion video information in place of a broadcast signal on a broadcast channel at a predetermined time, and wherein the broadcast channel transmits the motion video information at a field per second rate; means for providing synchronization of the signal representing motion video information to the broadcast signal; a randomly-accessible computer-readable medium for digitally storing in a data file compressed image data for a sequence of digital still images, including an image corresponding to each field of the motion video information to be transmitted in the broadcast channel, such that upon decompression, broadcast quality motion video information is obtained; and a computer including means for editing the sequence of digital still images, means for accessing the sequence at the predetermined time, for decompressing the sequence to obtain broadcast quality motion video information and for generating the signal to be inserted into the broadcast channel from the accessed sequence.
U.S. Pat. No. 5,600,366 entitled “Methods and Apparatus for Digital Advertisement Insertion in Video Programming”, issued on Feb. 4, 1997 permits timely and correct switchovers from network programming to local advertising in ways which occur smoothly without disruption in perception to the viewer. Switchovers occur at packet or frame boundaries and are designed to occur upon detection of idle information from a network source. An apparatus based on this patent includes means for receiving externally supplied programming comprising analog video information and embedded tone cues including a pre-roll cue and a roll cue, detecting said tone cues and converting the analog video information to digital video information; means for activating digital video storage in response to one of said tone cues preparatory to initiating playback; and means for initiating playback from said storage in response to detecting an idle condition from said digital video information.
Another apparatus based on this patent includes means for receiving externally supplied programming from a plurality of sources, each source providing programming comprising analog video information and embedded tone cues, and for converting the analog video information to digital video information; storage means for storing a plurality of local programs; common means for monitoring all of said sources to detect one or more tone cues from a source and for preparing said storage means for playback of respective one or more of said local programs to be substituted for said externally supplied programming from a source sending at least one of said one or more tone cues; and means for initiating playback from said storage means of respective one or more of said local programs to be substituted for said externally supplied programming from a source in response to detecting an idle condition from said digital video information of said source.
A method based on this patent includes receiving externally supplied programming comprising analog video information and embedded tone cues including a pre-roll cue and a roll cue, detecting said tone cues and converting the analog video information to digital video information; activating video storage in response to one of said tone cues preparatory to initiating playback; and initiating playback from said recorder in response to detecting an idle condition from said digital video information.
Another method based on this patent includes receiving local digital video programming and providing it to a user; receiving externally supplied analog video programming and embedded tone cues including a return to network cue, detecting said return to network cue; converting said analog video programming to digital video information upon receipt of said return to network cue; and terminating operation of video storage in response to detection of an idle condition in said local digital video programming.
U.S. Pat. No. 5,956,088 entitled “Method and Apparatus for Modifying Encoded Digital Video for Improved Channel Utilization” issued on Sep. 21, 1999 and U.S. Pat. No. 5,862,140 entitled “Method and Apparatus for multiplexing Video Programs for Improved Channel Utilization” issued on Jan. 19, 1999 both provide a method (and apparatus) for increasing channel utilization for a data channel transmitting a multiplex of a set of one or more encoded program streams. Each program stream in said set being decodable by a corresponding decoder. Each corresponding decoder including a corresponding decoder buffer, the decoder buffers having a maximum allowable size. The method comprising selecting encoded pictures to be modified, said selecting according to a criterion, which includes preventing any underflow of any decoder buffer, modifying each said selected encoded picture to form a corresponding modified encoded picture, said modified encoded picture having less data than said selected encoded picture, and transmitting the corresponding modified encoded pictures through the channel in place of the selected encoded pictures. In one embodiment of these patents, modifying deletes each selected encoded picture. In another embodiment of the patents, where the encoded program streams include predictively encoded pictures, selecting selects predictively encoded pictures that are not anchor pictures, and modifying deletes the prediction error data from each said selected encoded picture.
In a further embodiment of these patents, one or more additional data channels are used to send augmentation information. The augmentation information can be used by specially equipped receivers to correct the impairments that would normally occur when decoding the modified signal received from the data channel. In yet another embodiment of the patent, augmentation information is sent using the same data channel that is used to transmit the modified pictures. In this case, the information that is removed by modifying is transmitted before it is needed for decoding and at a time when the data channel is not fully utilized. Certain receivers equipped with sufficient storage can receive and store the augmentation information until it is needed. Alternatively, if the additional storage is used to insert additional delay between the time that data is received and the time that data is decoded, then the augmentation information can be sent after it would be needed by a conventional receiver.
A system of these patents comprise primary and overflow demodulators configured to demodulate data from the primary and overflow channels, respectively; a first demultiplexer, coupled to the primary demodulator, configured to extract a primary packet stream from an output of the primary demodulator; a second demultiplexer, coupled to the overflow demodulator, configured to extract an overflow packet stream from an output of the overflow demodulator; a buffer coupled to the second demultiplexer; a time stamp comparator, coupled to the first demultiplexer and the buffer, configured to compare a time stamp associated with a next packet from the primary packet stream with a time stamp associated with a next packet from the overflow packet stream; and a packet multiplexer, coupled to the first demultiplexer, the buffer and the time stamp comparator, configured to select one of the next packets from the primary packet stream and the overflow packet stream in response to a comparison made by the time stamp comparator.
U.S. Pat. No. 5,029,014 entitled “Ad Insertion System and Method for Broadcasting Spot Messages Out of Recorded Sequence”, issued on Jul. 2, 1991, provides an advertisement insertion system and method transmit spot messages during intervals in a broadcast transmission and provide immediate access to stored spot messages, in any sequential order, with a single video source. Custom spot messages can be created by superimposing graphics over selected video signals and simultaneously transmitting those signals with appropriate audio signals.
A system of this patent comprises a first playing means for playing spot messages stored in a recorded sequence on a video source, and control means for switching a broadcast system from program signals of a scheduled broadcast, selecting and causing said first playing means to play into said broadcast system in immediate succession a plurality of spot messages out of said recorded sequence without intervening material from another playing means, and switching said broadcast system back to program signals of a scheduled broadcast.
A method of this patent comprises selecting video, audio and/or graphic signals to form custom spot messages; accessing the selected video signals on a laser disk; accessing selected audio signals which are to be simultaneously broadcast with said accessed video signals; and switching from broadcast transmission to spot message transmission to co-broadcast said accessed video and audio signals as said spot messages with an audio component according to a programmed time schedule and out of a pre-recorded sequence of spot messages on said laser disk.
U.S. Pat. No. 5,966,120, entitled “Method and Apparatus for Combining and Distributing Data with Pre-formatted Real-time Video”, issued on Oct. 12, 1999, relates to providing constant bit rate distribution of variable bit rate-encoded video programs, along with Auxiliary Data of a general character, to one or more receivers. At a particular receiver, a customized augmented video program is created by inserting selected portions of the Auxiliary Data into a selected encoded video program. The encoded video portion of the augmented video program can be transmitted, decoded and displayed in real time, while the Auxiliary Data need not be transmitted in real time but can be stored locally at the receiver for real-time presentation at a later time. Real time presentation might include insertion into the video program while non real-time presentation might include insertion into non-video applications separate from the video program.
A method of this patent comprises the steps of receiving the primary data stream; detecting fill data in the primary data stream; inserting an auxiliary data stream in place of the fill data; and adding location data for the programs and for the auxiliary data; to form a modified data stream for distribution to a plurality of receivers configured for individually extracting selected portions of the modified data stream in accordance with the location data.
Another method of this patent comprises the steps of statistically multiplexing a plurality of encoded video programs; monitoring the statistically multiplexed encoded video programs for the occurrence of a fill packet; maintaining a buffer of auxiliary data segments; replacing the fill packet with at least one segment of the auxiliary data stream from the buffer if the segment is smaller than the size of the fill packet; adding location data for the encoded video programs and for the auxiliary data; to form a modified data stream for distribution to a plurality of receivers configured for individually extracting selected portions of the modified data stream in accordance with the location data.
A system of this patent comprises a program multiplexer for statistically multiplexing a plurality of encoded video programs to the modified data stream; a data insertion controller coupled to receive a multiplexed program stream from the program multiplexer and for inserting auxiliary data therein to yield a modified data stream; and a program map insertion controller coupled to receive the modified data stream for adding location data for the encoded video programs and for the auxiliary data to the modified data stream. Another system comprises a multiplexer for statistically multiplexing a plurality of encoded video programs; a first controller for adding auxiliary data to the output of the multiplexer; a second controller for adding location data for the encoded video programs and for the auxiliary data to the output of the first controller, thereby forming a modified data stream; a distribution channel for distributing the modified data stream to at least one receiver; a processor for determining location data from the distributed modified data stream; a first demultiplexer for selecting an encoded video program from the modified data stream in accordance with a first predetermined characteristic of the processor and the location data; a second demultiplexer for selecting local auxiliary data from the modified data stream in accordance with a second predetermined characteristic of the processor and the location data; a storage device for storing the local auxiliary data from the second demultiplexer; and an augmentation unit for associating the encoded video program and the stored local auxiliary data to form a receiver-specific augmented video program for decoding and display.
SUMMARY OF THE INVENTION
The present invention provides a system and method for computing rate profiles associated with the multiplexed program streams. The rate profiles may be used for inserting local advertisements and allowing substitution of original advertisements or other programming with inserted advertisements. In one embodiment, a predetermined bit rate profile is specified for the compression of an advertisement with the specification extending from the start point of the advertisement to the end point. The digital media advertisement is compressed according to the specified profile and inserted into the advertising opportunity.
The predetermined bit profile may comprise a maximum bit rate, a maximum bit rate and a minimum bit rate, a minimum or maximum number of bits over the avail or a subset or portion of the avail, or a time varying profile defined from the start point to the end point. The profile may be modeled as a piece-wise linear model, allowing bandwidth to change at specified moments during the advertisement.
The specified predetermined bit rate profile may comprise only a minimum bit rate and null packets may be inserted to make up the difference between the minimum bit rate and the actual bit rate which occurs in the statistically multiplexed stream.
In a statistically multiplexed stream where there are multiple programs with varying bit rates for each program, multiple bit rate profiles may be defined such that each advertising opportunity has a specific bit rate profile defined for it. The individual rate profiles may be defined such that the sum of all the profiles is equal to the maximum allowed bit rate in the statistically multiplexed stream during the advertisement. The predetermined bit rate profile for the stream may specify the instantaneous sum of the first bit rate profile and the second bit rate profile or may simply define the total number of bits from the start point to the end point of the first bit rate profile summed with the second bit rate profile.
In inserting advertisements in various multiplexed program streams, it is possible to create the bit rate profiles for the individual advertisements such that they are complementary. That is, the high bandwidth portions of the first bit rate profile correspond to the low bandwidth portions of the second bit rate profile. This method can be extended across multiple profiles such that high bandwidth portions of an advertisement correspond with at least one low bandwidth portion in another program stream, thus allowing for multiple simultaneous high bandwidth portions of advertisements. Alternatively, high bandwidth portions of advertisements may be staggered in a predetermined manner such that ads are allowed to have sections of high motion or other high bandwidth requirements but that these portions do not occur simultaneously.
These and other features and objects of the invention will be more fully understood from the following detailed description of the preferred embodiments, which should be read in light of the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and form a part of the specification, illustrate the embodiments of the present invention and, together with the description serve to explain the principles of the invention.
In the drawings:
FIG. 1 is a block diagram illustrating an exemplary processing associated with the generation of statistically multiplexed streams;
FIGS. 2A and 2B illustrate the time varying bit rates for an incoming program stream and an outgoing stream with inserts respectively;
FIGS. 3A and 3B illustrate the time varying bit rates for two statistically multiplexed streams having complementary advertisement avails;
FIGS. 4A-4C illustrate staggered avail profiles for three simultaneous multiplexed streams;
FIG. 5 illustrates two profiles having coarse granularity and fine granularity respectively; and
FIG. 6 illustrates monitoring of the total number of bits during the avails.
DETAILED DESCRIPTION
In describing a preferred embodiment of the invention illustrated in the drawings, specific terminology will be used for the sake of clarity. However, the invention is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes all technical equivalents which operate in a similar manner to accomplish a similar purpose.
With reference to the drawings, in general, and FIGS. 1 through 6 in particular, the system and method of the present invention is disclosed.
FIG. 1 illustrates an exemplary processing associated with the generation of statistically multiplexed program streams. As illustrated, each video encoder 110 produces a video programming stream 117 which is received by the statmux 130 . The statmux 130 includes a rate control unit 120 , which provides a rate control signal 115 to each video encoder 110 . This rate control signal 115 is used by the video encoder 110 to compress the programming according to the requirements of the statmux 130 . The statmux 130 acts to control the total bandwidth utilized by the multiple video encoders 110 . The actual number of video encoders will be determined by the amount of bandwidth available to the statistical multiplexer 130 .
The origin point 100 for the video may be a studio location, a satellite uplink location, a cable centralized transmission point, in-home server, or other video origin point.
Once the statmux 130 creates a statistical multiplexed stream 135 , it is transmitted to the re-transmission point 155 . Rate control information may be transmitted as part of the statistically multiplexed stream 135 through use of an inserted rate control signal 140 which is combined with the programming. Alternatively, the rate control information may be transmitted as a separate rate control signal 150 that may be reinserted through use of a rate control reinsertion signal 145 . In another embodiment, rate control information may be transmitted only as MPEG video rate parameters.
The re-transmission point 155 may comprise a cable television head end, a satellite downlink receiver, or can even be home equipment such as a television set top, personal computer, or other equipment, which receives the statistically multiplexed stream 135 .
At the re-transmission point 155 , a program inserter 160 works in conjunction with an insertion server 165 to reform the program streams with substituted advertisements. This new program stream comprises the outgoing program stream multiplex 170 . The outgoing program stream multiplex 170 is received by a decoding point 175 that includes a program decoder 180 , which decodes the digital video stream and presents it to a display unit 190 . In one embodiment, the program decoder comprises an MPEG decoder and is coupled to a television which acts as display 190 . In another embodiment, the program decoder 180 comprises another type of digital video decompression system and is coupled to a personal computer or other display device.
From a business perspective, the fact that advertisements have been inserted into what are termed “ad avails” creates difficulty at the re-transmission point 155 because the advertisement may not be suitable for the viewers in that geographic area, the service provider may be able to receive more revenue by substituting the original advertisement with a new advertisement. As an example, it may be desirable for a cable operator to replace a nationally broadcast advertisement with a local advertisement for a restaurant, car dealership, or other locally provided service. If the cable operator had permission to substitute the ads, they will want to remove the original advertisement from the programming stream and substitute the local advertisement. The term “ad avail” refers to any available spot for advertising which may be filled with an original advertisement or a blank spot in the programming. Alternatively, it may be possible to interrupt the program stream and insert an advertisement where there was no original advertisement. In this case, the “ad avail” becomes created although it did not originally exist.
The rate control signal 115 may contain rate control information as well as insertion timing information to enable program and advertisement insertion at re-transmission points 155 . The information which may be included consists of the minimum or actual rate during the avails as determined by predefined rate profiles, or the actual rate profile of the upcoming avail in predefined or specified time units. The rate control signal 115 may indicate a fixed minimum rate which may be different during each ad avail and/or the total number of bits, bites, packets, or other measurable units in the ad avail.
The separate rate control signal 150 as illustrated in FIG. 1 serves as a means of delivery for rate information and can include prearrangement by any means including e-mail, written or verbal specifications, or templates designated by a standards body, or an actual out-of-band or out-of-multiplex transmission which represents the specific rate control information.
FIG. 2A illustrates time varying bits associated with an incoming program stream. Incoming program rate 205 is drawn on Y axis and time 207 is drawn on X axis. The illustration of the incoming program rate 205 as compared to function of the time 207 , illustrates that a defined minimum 230 over a pre-determined period of time may be determined. The predetermined time period may have an associated avail start 210 , avail end 220 , and an example rate 240 . Thus, the incoming program stream has a bit rate which varies and exceeds the defined minimum 230 for the avail having avail start 210 and avail end 220 . Thus, the underlined program may actually utilize more bandwidth than the avail, but the avail will be assigned the minimum defined bandwidth 230 .
FIG. 2B illustrates the time varying bit rates for an outgoing stream. FIG. 2B further illustrates an avail committed information rate (CIR) 260 which is the minimum bit rate that will be guaranteed for use for the insertion of the advertisement in the avail. As shown in FIG. 2B , one or more null packets 250 can be inserted to make up the difference between the CIR 260 and the actual bit rate as defined by the example stream 240 .
For exemplary purposes, FIGS. 3A and 3B illustrate exemplary statistically multiplexed streams having predefined avail rate profiles. FIG. 3A represents a first stream in a multiplex, and FIG. 3B represents a second and simultaneous stream in the same multiplex. As illustrated in FIGS. 3A and 3B , a number of avail profiles are specified including avail profile # 1 ( 310 ); avail profile # 2 ( 320 ); avail profile # 3 ( 330 ); avail profile # 4 ( 340 ); avail profile # 5 ( 350 ); avail profile # 6 ( 360 ); avail profile # 7 ( 370 ); and avail profile # 8 ( 380 ). As illustrated, avail profile # 1 ( 310 ) may be complementary to avail profile # 5 ( 350 ) in that these avail profiles occur simultaneously in the multiplexed stream. This may be the case when the advertisements are synchronous such that the start times are equal or nearly equal and the end times are equal or nearly equal. In such a case it is possible to define the avail profiles such that they complement each other to allow for a defined rate for multiple simultaneous profiles in a single multiplex wherein high bandwidth requirements are permitted at a time in avail profile # 1 ( 310 ) which is complementary to the high bandwidth requirement time in avail profile # 5 ( 350 ).
FIGS. 4A-4C represent avails in three program streams in a multiplexed signal. As shown, several avails are defined including avail 1 A 410 , avail 2 A 420 , avail 1 B 430 , avail 2 B 440 , avail 1 C 450 and avail 2 C 460 . The profiles for these avails are defined such that the high bandwidth times are staggered.
FIG. 5 illustrates custom profiles including avail 1 A 510 and avail 2 A 520 with profiles defined such that avail 1 A has a coarse custom profile with the bit rate varying over time substantially. Avail 2 A 520 has a fine time granularity for definition of the rate such that the defined bit rate may vary dramatically over a period as short as a second or several milliseconds. This method allows for the bandwidth in the statistically multiplexed stream to be utilized optimally such that when the initial advertisement is removed the inserted advertisement has a bit rate which matches that of the original advertisement closely.
FIG. 6 illustrates monitoring of avail 1 A 610 and avail 2 A 620 such that the total number of bits, packets, or other digital measurement is calculated. This can be visualized as the area under the rate curve. By specifying the total number of bits, short avails can be defined and streams can be defined for decoders with large buffers.
It is to be noted that a typical MPEG buffer has a latency of less than 1 second. Thus, the sections of video must be delivered and used within that time. However, the decoders with larger buffers, as may be included in equipment with large amounts of memory, such as set top devices, may define a 30 second latency and allow bits to be delivered at any time in the 30 second window. Such large buffers can provide additional flexibility in advertisement insertion. One way in which a large buffer can be used is by using the memory to buffer the video stream of the avail, allowing low bit rate delivery of high bit rate ads, and inserting the ads at the appropriate moment. Thus, although the statistically multiplexed video stream may not be capable of transporting a high bit rate advertisement for real time display, the system may receive the advertisement over a period of several seconds and subsequently display the high bit rate advertisement.
The extensions of the techniques disclosed herein can be utilized and include concepts such as profiling of avails which includes profiling of portions of the pre-advertisement and post-advertisement content. For example, by profiling the start/end of television shows it becomes possible to allow higher bit rate and/or higher quality advertisements, based on the occurrence of low bit rate segments of television programming in adjacent channels. When the start/end of programming in an adjacent channel results in a low bit rate and the avail overlaps this start/end segment, the bandwidth from the programming can be used for the avail. For example, ads on channel 2 can benefit from rolling credits on channel 3 at the end of the show on channel 3 when the end time of the programs on channels 2 and 3 are staggered, as frequently occurs.
Another technique which can be utilized as part of the present invention is blind profiling, in which no external rate information other than the MPEG rate values in the video stream is transmitted to the insertion point, which in one embodiment, is the statistical multiplexer 130 . At the insertion point, the insertion device optimizes use of the avail bits, and profiles are created based on the ads which originate from off-line encoders, with the statistical multiplexing process allowing optimal use of bits for the highest quality and full control over the images. The resulting profiles can be transmitted in the inserted rate control signal 140 or through use of the separate rate control signal 150 .
In the blind profiling technique, the secondary insertion point 155 , which in one embodiment is the retransmission point, utilizes the profiles of the original ads as the basis for compressing or re-compressing replacement ads, which will be forced to match the profiles of the original ads. One advantage of this technique is that it allows for the coexistence of both profiled and unconstrained ads in which the statistical multiplexer 130 accommodates the advertisement in its original form, using traditional statistical multiplexing techniques for compression. The profiles created by the first instance of compression can be piecewise linear profiles with the linear segments extending periods of one second or longer, minimum or maximum bit rate profiles, high granularity profiles which track the bandwidth allocated to the avail in increments ranging from a few milliseconds to one second or more, or total bit rate profiles.
Another advantage of blind profiling is that at the initial insertion point, the profile of the avail is only constrained by the statistical multiplexing process and not by a predetermined profile. Using this technique, it is possible for content providers to sell avails and insert the advertiser's material while insuring a high quality advertisement. The local broadcaster, using the profile generated by the initial insertion, can substitute the original advertisement with another advertisement which matches the profile. The substituted advertisement may have a profile which approximates that of the original advertisement, or may be compressed or re-compressed to match or approximate the profile of the original advertisement.
Although this invention has been illustrated by reference to specific embodiments, it will be apparent to those skilled in the art that various changes and modifications may be made which clearly fall within the scope of the invention. The invention is intended to be protected broadly within the spirit and scope of the appended claims. | A method and system for the insertion of local signals, including digital media advertisements, into statistically multiplexed streams is presented. The rate control and timing information is computed and is used to specify the insertion time and rate parameters for digital advertisements. In one embodiment, a maximum bit rate over the advertisement duration is specified. The maximum bit rate may be constant or may vary in time, such that high bit rate portions of the advertisement are supported. High bit rate portions of the advertisements in different program streams may be staggered, such that the total bandwidth required does not exceed a maximum, but allowing for high bit rate portions of advertisements. Custom bit rate profiles for advertisements may also be defined, with the profiles being defined at a high granularity or a low granularity. | 7 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to fluid mixing devices and fluid—solid separating devices. More particularly, the present invention relates to fluid mixing devices and fluid—solid separating devices which include a static material mixing apparatus and a cap. The present invention also relates to methods of using same.
[0003] 2. Description of the Related Art
[0004] Static mixers are known in the art as devices that provide a way to mix materials without a motor (or rotor) and the energy required to power the motor (typically by spinning) and/or provide a swirling and/or agitating action to cause the materials to mix without requiring an energy source for the mixing action to occur.
[0005] One such type of static mixer includes a number of vanes arranged sequentially within a conduit. Whereas it is normally desirable for a fluid to have a laminar (smooth) flow, the vanes are arranged to create a turbulent flow by having the material strike the vanes on its path through a conduit (e.g., a pipe or barrel) by dividing the flow into a series of sub-streams, and then causing the sub-streams to recombine with a swirling action when exiting a particular vane, only to strike a successive vane and subdivide again, followed by recombination. The action of the material dividing and recombining as it passes through the conduit results in a completely homogeneous mixture being discharged from the conduit.
[0006] In the aforementioned mixer, the vanes are often constructed of complicated geometric configurations that are not only expensive to manufacture, but have been known at times to cause large variations in the pressure of the materials as they are being mixed by their passage through the conduit. The large drops of pressure at some portions of the configuration of the vanes are particularly undesirable, as the difference in the pressure at different points may cause the acceleration of the fluid in the pipe to reach undesirable levels.
[0007] U.S. Pat. No. 4,511,258 to Federighi et al. (herein after “Federighi '258”) incorporated herein by reference discloses a mixing element that is simpler to manufacture than the vanes and in many ways, more effective because there are no large drops in pressure. Federighi '258 discloses a symmetrically formed mixing element to eliminate precision alignment with the conduit that was often necessary when using vanes. The mixing element includes two substantially identical segments having a sinuous cross-section between opposite ends.
[0008] In U.S. Pat. No. 4,936,689 to Federighi (hereinafter “Federighi '689”) incorporated herein by reference, the inventor admits that certain prior art static mixers, which included those described in a previous patent (Federighi '258), had a shortcoming that becomes evident when mixing liquids that contain solids; such mixers are prone to clogging. In order to keep the mixer from staying unclogged, repeated maintenance at constant intervals is required, but there also needs to be a monitoring system in place to make sure there is no clogging. Not only is the use of the prior art system inefficient and costly, but the unclogging can be unpleasant when the mixer is used to mix sanitation items, such as sewage.
[0009] In addition, Federighi '689 discloses at column 3, lines 34-40 that a primary benefit of the invention is that solids suspended within the fluids can pass through an internal chamber 16 of the conduit 12 via a gap 21 between the radially spaced segments 14 a , 14 b.
[0010] However, there are still clogging problems and varying drops in pressure within the conduit that are associated with prior art static mixers. Thus, there is a need in the art for an improved static mixer.
[0011] There is also a need for improved gas-liquid contacting and liquid-liquid contacting to enhance water treatment, e.g., water chlorination or water treatment with ozone, because the simple use of an in-line mixer is insufficient for efficient contacting in a small space.
[0012] There is also a need for improved compact sand filters.
SUMMARY OF THE INVENTION
[0013] The invention provides a static mixer including a tank and a mixing tube inside the tank. The mixing tube is made of an upper/first and lower/second mixing chambers, with the two mixing chambers being separated by a swirl chamber. Each mixing chamber provided with baffles to be a static mixer. The upper mixing chamber is arranged at an upper end of the mixing tube where materials would initially begin passage there through, and the lower mixing chamber is arranged at a lower end of the mixing tube and receives materials that may have to some degree been mixed by their passage through the upper mixing chamber. The downwardly directed mixed stream then reverses direction by passage into an inverted cap, which includes a diverting plate, at a lower end of the tube which discharges the fluid stream such that the discharged fluid stream continues to swirl and mix in the tank with the other fluid in the tank.
[0014] In particular, the mixing tube is typically a conduit comprising an upper mixing chamber, a swirl chamber, a lower mixing chamber and diverter valve (also termed a “diverter chamber”). The upper mixing chamber has a first inlet and a first outlet and an axial centerline in a longitudinal direction of main stream flow. The swirl chamber has a second inlet and a second outlet, the second inlet being in fluid communication with the first outlet of the upper mixing chamber. The lower mixing chamber has a third inlet and a downwardly directed third outlet and an axial centerline in the longitudinal direction of main stream flow, the third inlet of the lower mixing chamber being in fluid communication with the second outlet of the swirl chamber. A plurality of baffles are arranged within the upper mixing chamber and the lower mixing chamber, wherein the plurality of baffles are shaped and arranged for subdividing a flow of an additive material against a plurality of portions of an internal perimeter of the upper mixing chamber and the lower mixing chamber, and for redirecting the subdivided flow of the additive material to the axial centerline of the upper and lower mixing chambers to form a single direction mixing vortex axial to the centerline of the upper mixing chamber and the lower mixing chamber. The diverter chamber has sidewalls provided at a lower end of the conduit below the lower mixing chamber, the diverter chamber having a fourth inlet and a fourth outlet, the fourth inlet being in fluid communication with the third outlet of the lower mixing chamber and arranged in the longitudinal direction of the main stream flow of the lower mixing chamber, and the fourth outlet comprising a plurality of slits in the diverter chamber sidewalls, the slits being radially arranged relative to the axial direction of the lower mixing chamber. A cap is provided having a bottom wall and one or more cap sidewalls, the cap being connected to a lower portion of the diverter chamber, and the cap sidewalls spaced from the diverter chamber and having a height that extends upwardly at least approximately to a height of the plurality of slits to overlap the slits and define an annular region between inner surfaces of the cap sidewalls of the cap and outer walls of the diverter chamber. A diffuser plate is spaced from an upper edge of the cap to define a discharge area, the diffuser plate extending radially from the conduit to define a surface which overlaps the entire annular opening defined by an upper edge of the cap and the conduit, the diffuser plate being generally parallel to the upper edge of the cap.
[0015] The invention permits the mixing of liquid additives or gaseous additives to a liquid stream with increased efficiency than known heretofore in a static mixer. The internal design of the mixer turns a drop of water into hundreds of micro bubbles, which allows the chemicals to mix and react as much five times faster than a prior art static mixer. The micro bubbles increase the available surface area that can react with the other chemicals.
[0016] For purposes of illustration and not intended to limit the scope of the invention in any way, some of the multitude of materials that can be mixed using the present invention includes air, chlorine, ozone, fertilizer, phosphates, potassium, peroxide. The micro bubbles can be used to boost the effectiveness of air, chlorine, ozone, or anything else that is required to be mixed thoroughly.
[0017] The swirl chamber is formed by spacing the upper mixing from the lower mixing chamber by the desired length and circumference of the swirl chamber. The swirl chamber may optionally include a rotational passageway to assist in causing the liquid to continue to rotate (swirl) as it passes through the swirl chamber.
[0018] Moreover, the swirl chamber provides an advantage in that the materials to be mixed continue to spin while traveling downwardly toward the second/lower mixing chamber. The lower mixing chamber is optionally formed such that there are baffles arranged to cause fluid rotation in a direction that is opposite to the upper mixing chamber.
[0019] In one particular embodiment of the invention, the static mixer has first and second longitudinally elongated baffles. Each baffle has a plurality of attached segments forming a series of peaks and valleys resulting in a saw-tooth or sine curve longitudinal cross-section. Each segment extends from one peak of the respective baffle to an adjacent valley of the respective baffle. The peaks and valleys of the longitudinal cross-section of the first baffle alternate with the peaks and valleys of the longitudinal cross-section of the second baffle.
[0020] A method for mixing a first liquid material and an additive material in the static comprises the steps of:
[0021] passing a first liquid material and an additive material through an upper mixing chamber, a swirl chamber, a lower mixing chamber and a diverter chamber of a conduit in a tank;
[0022] the upper mixing chamber having a first inlet and a first outlet and an axial centerline in a longitudinal direction of main stream flow;
[0023] the swirl chamber having a second inlet and a second outlet, the second inlet being in fluid communication with the first outlet of the upper mixing chamber;
[0024] the lower mixing chamber having a third inlet and a downwardly directed third outlet and an axial centerline in the longitudinal direction of main stream flow, the third inlet of the lower mixing chamber being in fluid communication with the second outlet of the swirl chamber;
[0025] a plurality of baffles arranged within the upper mixing chamber and the lower mixing chamber, wherein the plurality of baffles are shaped and arranged for subdividing a flow of the first material and the additive material against a plurality of portions of an internal perimeter of the upper mixing chamber and the lower mixing chamber, and for redirecting the subdivided flow of the first material and the additive material to the axial centerline of the upper and lower mixing chambers to form a single direction mixing vortex axial to the centerline of the upper mixing chamber and the lower mixing chamber to form a mixed stream;
[0026] discharging the mixed stream from the lower mixing chamber downwardly into the diverter chamber;
[0027] discharging the mixed stream from the diverter chamber laterally through slits, radially arranged in sidewalls of the diverter chamber relative to the axial direction of the lower mixing chamber, into an annular region defined between outer walls of the diverter chamber and inner sidewalls of a cap and passing the mixed stream upwardly through the annular region, the cap having a bottom wall and the cap sidewalls, the cap being connected to a lower portion of the diverter chamber, and the cap sidewalls spaced from the diverter chamber and having a height that extends upwardly at least approximately to a height of the plurality of slits to overlap the slits and define an annular region between inner surfaces of the cap sidewalls of the cap and outer walls of the diverter chamber;
[0028] the mixed stream discharging from the annular region and being diverted by a diffuser plate spaced from an upper edge of the cap to define a discharge area, the diffuser plate extending radially from the conduit to define a surface which overlaps the entire annular opening defined by an upper edge of the cap and the conduit, the diffuser plate being generally parallel to the upper edge of the cap;
[0029] discharging the mixed stream from the discharge area such that the mixed stream has centrifugal motion when the mixed stream discharges from the discharge area and contacts the material in the tank; and
[0030] receiving the mixed material from an exit port of the tank arranged to receive the mixed stream as the mixed stream rotates upward in the tank.
[0031] In a second embodiment of the present invention, a sand trap having an internal swirl chamber permits water to pass the internal swirl chamber and into a diverting plate, to permit heavier particles to settle to the bottom of the tank for blow down.
[0032] In particular, the present invention provides a sandtrap device comprising:
[0033] a tank; a fluid outlet port arranged at an upper portion of the tank; a drain port arranged at a lower portion of the tank; a conduit comprising a mixing chamber and a diverter chamber inserted into the tank; a cap; and a diffuser plate. The mixing chamber has a first inlet and a first outlet and an axial centerline in a longitudinal direction of main stream flow. A plurality of baffles are arranged within the mixing chamber, wherein the plurality of baffles are shaped and arranged for subdividing a flow of an additive material against a plurality of portions of an internal perimeter of the upper mixing chamber and the lower mixing chamber, and for redirecting the subdivided flow of the additive material to the axial centerline of the upper and lower mixing chambers to form a single direction mixing vortex axial to the centerline of the upper mixing chamber and the lower mixing chamber. The diverter chamber has sidewalls provided at a lower end of the conduit below the mixing chamber, the diverter chamber having a second inlet and a second outlet, the second inlet being in fluid communication with the first outlet of the mixing chamber and arranged in the longitudinal direction of the main stream flow of the mixing chamber, and the second outlet comprising a plurality of slits in the diverter chamber sidewalls, the slits being radially arranged relative to the axial direction of the mixing chamber. The cap has a bottom wall and one or more cap sidewalls, the cap being connected to a lower portion of the diverter chamber, and the cap sidewalls spaced from the diverter chamber and having a height that extends upwardly at least approximately to a height of the plurality of slits to overlap the slits and define an annular region between inner surfaces of the cap sidewalls of the cap and outer walls of the diverter chamber. The diffuser plate is spaced from an upper edge of the cap to define a discharge area, the diffuser plate extending radially from the conduit to define a surface which overlaps the entire annular opening defined by an upper edge of the cap and the conduit, the diffuser plate being generally parallel to the upper edge of the cap. A length of the conduit within the tank chamber is approximately one-half to two thirds of a height of the tank.
[0034] In its method respects, the present invention provides a method for separating solids from liquid in the sandtrap device of the present invention, comprises: passing a feed stream comprising liquid and solids through a conduit comprising a mixing chamber and a diverter chamber inserted into a tank, the mixing chamber having a first inlet and a first outlet and an axial centerline in a longitudinal direction of main stream flow; passing the feed stream through a plurality of baffles arranged within the mixing chamber, wherein the plurality of baffles are shaped and arranged for subdividing a flow of the feed stream against a plurality of portions of an internal perimeter of the mixing chamber, and for redirecting the subdivided flow of the feed stream to the axial centerline of the mixing chamber to form a single direction mixing vortex axial to the centerline of the mixing chamber; downwardly discharging the feed stream into a diverter chamber having sidewalls provided at a lower end of the conduit below the mixing chamber, the diverter chamber being in fluid communication with the mixing chamber and arranged in the longitudinal direction of the main stream flow of the mixing chamber, discharging the feed fluid from the diverter chamber laterally through slits, radially arranged in sidewalls of the diverter chamber relative to the axial direction of the lower mixing chamber, into an annular region defined between outer walls of the diverter chamber and inner sidewalls of a cap and passing the mixed stream upwardly through the annular region, the cap having a bottom wall and the cap sidewalls, the cap being connected to a lower portion of the diverter chamber, and the cap sidewalls spaced from the diverter chamber and having a height that extends upwardly at least approximately to a height of the slits to overlap the slits and define an annular region between inner surfaces of the cap sidewalls of the cap and outer walls of the diverter chamber; the feed stream discharging from the annular region and being diverted by a diffuser plate spaced from an upper edge of the cap to define a discharge area, the diffuser plate extending radially from the conduit to define a surface which overlaps the entire annular opening defined by an upper edge of the cap and the conduit, the diffuser plate being generally parallel to the upper edge of the cap; discharging the feed stream from the discharge area such that the feed stream has centrifugal motion to separate at least a portion of the solids from the liquid in the feed stream when the feed stream discharges from the discharge area and contacts the material in the tank to produce a liquid product stream; receiving the liquid product stream from a fluid outlet port of the tank arranged at an upper portion of the tank to receive the liquid product stream as the liquid product stream rotates upward in the tank; and receiving the separated solids from a drain port arranged at a lower portion of the tank; wherein a length of the conduit within the tank chamber is approximately one-half to two thirds of a height of the tank.
BRIEF DESCRIPTION OF THE DRAWINGS
[0035] These and other characteristics of the invention will be clear from the following description of a preferred form of the embodiments, given as non-restrictive example, with reference to the attached drawings wherein:
[0036] FIG. 1 is a schematic of a tank including a mixing device according to the present invention.
[0037] FIG. 2 is a cross section of an assembly of the diverter plate, diverter valve and cap of FIG. 1 .
[0038] FIG. 3 is an exploded view of the components shown in FIG. 2 .
[0039] FIG. 4 is a photograph of a static mixing device suitable for being employed in the embodiment of FIG. 1 with portions of tube removed to show the internal baffles of the upper and lower mixing chambers.
[0040] FIG. 5 is a photograph of the upper mixing chamber of the embodiment of FIG. 4 with a portion of the tube removed to better show the baffles.
[0041] FIG. 6 is a photograph of the lower mixing chamber of the embodiment of FIG. 4 with a portion of the tube and the deflecting plate removed to better show the baffles.
[0042] FIG. 7 is a close up photograph of the end cap of the lower mixing chamber of FIG. 4 with a portion of the tube and the deflecting plate removed to better show the baffles.
[0043] FIG. 8 is a perspective view of a pair of baffles having a small washer at one end and a larger washer at the other end.
[0044] FIG. 9 is a side view of a pair of baffles having a small washer at both ends.
[0045] FIG. 10 illustrates a single drop of additive.
[0046] FIG. 11 illustrates a single drop of additive subdivided into a plurality of micro bubbles to enhance mixing saturation.
[0047] FIG. 12 is a schematic drawing of a sand trap according to another embodiment of the present invention, wherein the sand trap separates solid particles from liquids without using a filter.
[0048] FIG. 13 illustrates an embodiment of the sand trap consistent with the embodiment of FIG. 12 .
[0049] FIG. 14 is a photograph of an upper section of the embodiment of the sand trap of FIG. 14 .
[0050] FIG. 15 is a close up photograph of an end cap suitable for the mixing section of FIG. 14 with a portion of the tube and the deflecting plate removed to better show the baffles.
DETAILED DESCRIPTION OF THE INVENTION
[0051] It is understood by a person of ordinary skill in the art that the drawings are presented for purposes of illustration and not for limitation. The embodiments shown and described herein do not encompass all possible variations of the arrangement of structure, and an artisan appreciates that many modifications can be made within the spirit of the invention and the scope of the appended claims.
[0052] FIG. 1 is an illustration of a first embodiment 10 of the present invention having a tank 12 and a static mixing device 11 according to the present invention located within the tank 12 . The tank 12 has an outlet or drain valve 14 near a lowermost portion to facilitate drainage by gravity. The tank 12 may be filled with a first material 15 , which may or may not be a fluid material. A feed stream 2 including water and an additive feeds an upper end of the static mixing device 11 . In the mixing device 111 the water and additive are mixed to form a mixed stream 17 . Then in the tank 11 the mixed stream 17 mixes with the contents of the tank 11 and then exits the tank through discharge conduit 42 as a discharge stream 4 .
[0053] Still referring to FIG. 1 , the mixing device 11 has an upper mixing chamber 16 and a lower mixing chamber 18 separated by a swirl chamber 20 , with an upside down cap 22 at the end of the lower mixing chamber 18 . The upper mixing chamber 16 , lower mixing chamber 18 and the swirl chamber 20 may have a conduit (or pipe or tube) 24 as an external housing. There can be a common conduit 24 or a series of connected conduits arranged to house the upper and lower mixing chambers 16 , 18 and the swirl chamber 20 . Inside the conduit 24 is a passageway. The diameter of the conduit passageway can be either the same throughout or varied in size. At the end of the lower mixing chamber 18 there is a diffuser plate 46 , followed by a diverter valve 28 (also termed a diverter chamber), which provides an annular space between the lower mixing chamber 18 and the cap 22 .
[0054] As shown in FIG. 1 , the diverter valve 28 (also termed a “diverter chamber”) has sidewalls 13 provided at a lower end of the conduit below the lower mixing chamber 18 , the diverter valve 28 has an inlet 15 and an outlet 28 a . The inlet 15 being in fluid communication with an outlet 17 of the lower mixing chamber 18 and arranged in the longitudinal direction of the main stream flow of the lower mixing chamber 18 . The diverter valve outlet 28 a comprising a plurality of slits 28 a in the diverter valve sidewalls 9 . The slits 28 a being radially arranged relative to the axial direction of the lower mixing chamber 18 . The cap 22 has a bottom wall 6 and one or more cap sidewalls 13 , the cap 22 being connected to a lower portion of the diverter valve 28 , and the cap sidewalls 13 spaced from the diverter valve 28 . The cap 22 has a height L 1 that extends upwardly at least approximately to a height L 2 of the plurality of slits to overlap the slits and define an annular region between inner surfaces of the cap sidewalls of the cap and outer walls of the diverter chamber. Typical heights L 1 of the cap 22 range from about 1 to 3 inches. The diffuser plate 46 is separated from an upper edge of the cap 22 a distance “L 3 ”. Typically the diffuser plate 28 is located about 0.25 to about 2 inches, for example from about 0.5 to 1.5 inches, above the upper edge of the cap 22 . Typically the diffuser plate 46 has an annular shape. However, other shapes are also suitable.
[0055] FIG. 2 and FIG. 3 illustrate the construction of the lower portion of the end cap of the mixing device according to the present invention. FIG. 2 , which is a cross section of a cap such as shown in FIG. 7 , is comprised of three parts that are preferably connected using an adhesive. However, an artisan appreciates there are other techniques to assembly the structure of the lower assembly.
[0056] For example, as shown in FIG. 2 , the diverter plate 26 , which has an outer diameter “D 1 ” that is approximately the same size as the outer diameter “D” of the cap 22 , also has a stepped portion 465 complementary to a stepped portion 225 of cap 22 . The extension 46 A of the diffuser plate 46 is preferably bonded to the cap 22 at the meeting of the steps 225 , 465 , but an artisan appreciates there are other way to connect these pieces to each other. In turn, the lower end of conduit 24 is inserted into the diffuser plate 46 to be seated in a central portion of the cap 22 , with the diverter valve shaft having an outer diameter D 2 . The central portion of the cap 22 can be sized to receive the conduit 24 as a type of friction fit, but an adhesive is preferably used to attach the conduit to the cap diffuser pale extension 46 A and the extension 22 A of the cap 22 . Adhesive may also be applied between the steps 225 , 464 .
[0057] The diffuser plate 26 being spaced a distance “L 3 ” from an upper edge of the cap 22 to define a discharge area, the diffuser plate 46 extending radially from the conduit of the mixing device 11 to define a surface which overlaps the entire annular opening defined by the upper edge of the cap 22 . The diffuser plate 46 is generally parallel to the upper edge of the cap 22 .
[0058] An annular area (AA) is defined between the upper edge of the cap 22 and the walls 13 of the diverter valve 28 and a discharge area (DA) is defined by phantom cylindrical sidewall in the space from the upper portion of the inner sidewalls 13 of the cap 22 to the diffuser plate 46 . Typically a ratio of an annular area (AA) to the discharge area (DA) ranges from about 1: 0.7-3, or from about 1:0.8-2, or from about 1: 1-1.5.
[0059] For example, if hypothetically the annular area has an outer diameter of about 2.5 inches (radius of about 1.25 inches) and an inner diameter is about 1 inch (radius of about 0.5 inches), the annular area (AA) is calculated as follows:
AA=π[r o 2 −r i 2 ]=[(1.25 inches) 2 −(0.5 inches) 2 ]=4.1 s q. in.
and if the phantom cylinder discharge area (DA) has the diameter of about 2.5 inches and a height of about 0.6 inches, the discharge area (DA) is calculated as follows:
DA=π× d×h =3.14×2.5 inches×0.6 inches=4.7 sq. in.
[0060] Thus, the ratio of AA:DA is 1: 1.14
[0061] FIG. 4 is a photograph of a static mixing device suitable for being employed in the embodiment of FIG. 1 with portions of tube removed to show the internal baffles of the upper and lower mixing chambers. FIG. 2 shows an elongated pair of baffles for each of the upper and lower mixing chambers.
[0062] FIG. 5 is a photograph of the upper mixing chamber 16 of the embodiment of FIG. 4 with a portion of the tube removed to better show the baffles 26 .
[0063] FIG. 6 is a photograph of the lower mixing section of the embodiment of FIG. 4 with a portion of the tube and the deflecting plate removed to better show the baffles 26 .
[0064] FIG. 7 is a close up photograph of the end cap 22 of the lower mixing chamber of FIG. 4 with a portion of the tube and the deflecting plate removed to better show the baffles.
[0065] FIG. 8 is a perspective view of the set of baffles 26 having a small washer 38 at one end and a larger washer 39 at the other end. The larger washer 39 of an upper set of baffles 26 is provided to contact the upper edge of the swirl chamber 20 to force flow from the upper chamber 16 through the center hole of the washer 39 into the swirl chamber 20 . The larger washer 39 of a lower set of baffles 26 is provided to contact the lower edge of the swirl chamber 20 to force flow from the swirl chamber 20 through the center hole of the washer 39 into the lower chamber 16 . The large washer is also useful to center the baffles 26 in the event a series of baffles are employed in either mixing chamber 16 , 18 .
[0066] FIG. 8 shows the elongated baffles 26 are each made up of a series of segments 32 forming a series of peaks and valleys. The peaks and valleys generally follow a sinusoidal or saw-tooth pattern. This pattern of segments causes the fluid to disburse/splatter and lends itself to causing droplets to break up into a plurality of micro bubbles.
[0067] FIG. 9 illustrates the pair of baffles 30 a , 30 b removed from the conduit. FIG. 9 is a perspective view of a pair of baffles 30 a , 30 b which differ from baffles 26 of FIG. 6 in that the baffles 30 a , 30 b of FIG. 9 have a small washer 38 at both ends. FIG. 8 is a side view of the pair of baffles 30 a , 30 b of FIG. 9 . FIG. 9 shows the peaks and valleys of the longitudinal cross-section of first baffle 30 a alternate with the peaks and valleys of the longitudinal cross-section of the second baffle 30 b referring to FIG. 9 , each of the baffles 30 a , 30 b has an inside edge 31 a and an outside edge 31 b . The segments of the first baffle 30 a define a first crossing location 34 on a portion of the inside edge between the peak and the valley of the first battle segment. Each segment of the second baffle 30 b defines a second crossing location 36 on a portion of its inside edge between the peak and valley of the second baffle segment. The first crossing location 34 crosses, and typically is attached to, a respective second crossing location 36 .
[0068] Still referring to FIG. 9 , each baffle width narrows in a direction transverse to each peak and value by anywhere from approximately 40% to 80%. Circular ends 38 are arranged at respective longitudinal edges of baffles 30 a , 30 b . The circular ends are positioned substantially perpendicular to the longitudinal direction of the segments that comprise the baffle pair 30 a , 30 b , and define respective axial holes at each end.
[0069] Typically, the circular ends 38 provide a uniform support structure as a base for the baffle pair 30 a , 30 b . The diameter of each circular end 38 is usually less than an internal diameter of the conduit 24 in which it is arranged. The circular ends may also be constructed of different size diameters. For example, a first circular end can have a diameter that is large enough to extend to the internal diameter of the conduit 24 . In such a case, the second circular end can be made to be somewhat smaller in diameter than the first circular end so as to facilitate seating of the second circular end in another component of the device. It is also possible that the diameter of the second circular end can be larger than the first circular end.
[0070] Optionally, the baffles in the lower mixing chamber 18 can be arranged so as to be opposite of those arranged in the upper mixing chamber 16 . The arrangement of the baffles in the upper mixing chamber and lower mixing chamber can be designed to reverse the rotation of the fluid as it passes through the lower portion of the conduit after passage through the upper portion.
[0071] Referring to FIG. 1 , the diffuser plate 46 extends radially from at least a lower portion of the conduit 24 housing the lower mixing chamber. The diffuser plate 46 has an annular area defined by its diameter, and is spaced from the upper portion of the cap 22 to define a discharge area. The ratio of the annular area to the discharge area ranges from 1: about 0.75 to 2, typically 1: about 1 to 1.5. This ratio assists to maintain a high flow rate out of the discharge area when desired to enhance the mixing in the tank outside of the tube.
[0072] A typical maximum flow rate through a mixing chamber of the embodiment of FIG. 1 is 24 gallons per minute for a 12 inch inside diameter tank with a mixing chamber conduit having about a 1 inch inside diameter.
[0073] Still referring to FIG. 1 , the directional diverter valve 28 has an upper end in fluid communication with an axial hole of the circumferential end of the pair of baffles in the lower mixing chamber. The cap 22 has substantially concentric sidewalls having a diameter larger than at least a portion of the diverter valve 28 , so as to define a channel there between. A series of openings 28 a (e.g., slits) are provided in at least a sidewall of the diverter 28 . The sidewalls of the cap typically extend at least as high as a top of the openings 28 a.
[0074] FIG. 10 shows an illustration of one drop 60 of an additive, e.g. chlorine containing additive. FIG. 11 shows this drop 60 transformed into a plurality of micro bubbles of the additive because of the design of the static mixer according to the present invention. As a result of the creation of micro bubbles, the present invention is faster and provides more efficient mixing of the additive to the liquid in the tank.
[0075] In operation, while referring to the embodiment shown in FIG. 1 , where two materials are about to be mixed together, such as, for example an additive such as chlorine and a liquid 15 (such a water in the tank 10 ), the chlorine can be poured into the inlet 40 . The interior of the tank 12 typically contains the second material/liquid 15 . Once the material (in this case chlorine) is poured into the inlet 40 , the material flows downward through the mixing chambers.
[0076] While passing through the upper mixing chamber 16 , the baffle pair 30 a , 30 b divides the flow into two downwardly flowing streams that subsequently recombine. In other words, the design of the baffles force the path of the streams to opposite outside walls of the conduit and then redirect the separated streams to the axial center to form a single direction mixing vortex axial to the centerline (longitudinal axis) of the mixing chambers.
[0077] As the liquid flows past the location where the two baffles cross, the mixing vortex is sheared and the main stream is divided again, but now flows in an opposite directional rotation. After exiting the upper chamber, the fluid enters the swirl chamber 20 prior to entering the lower chamber 18 .
[0078] In both the upper and the lower mixing chambers, the mixing is being performed around the axial centerline and in the direction of the main stream flow, having considerably less back pressure realized with better mixing than conventional static mixers.
[0079] The baffles in the lower mixing chamber 18 terminate in the lower mixing chamber 18 , and the fluid enters into the diverter valve 28 . The fluid flows through the slits 28 a in the sidewalls of the diverter valve 28 with a centrifugal force causing it to rotate about a centerline of the diverter valve. Then the liquid is redirected upwardly (due to the cap) while still retaining its spinning motion through the annular space between the cap 22 and the diffuser plate 46 . The diffuser plate 46 redirects the upwardly spinning liquid to travel laterally with a spinning motion.
[0080] The diffuser plate 46 essentially turns the tank into a big mixing tank because the spinning motion of the liquid discharged from the diverter valve 28 causes the liquid 15 in the tank to rotate. The liquid mixed with the first material (in this case chlorine) then travels upwardly and discharges through a port 27 in an upper portion of the mixing tank typically alongside the top inlet.
[0081] Sand Trap
[0082] A second embodiment of the present invention is suitable for another use, namely to separate solids from liquids, typically to separate sand (or other solids) from water.
[0083] FIG. 12 is a schematic drawing of a sand trap 100 according to the second embodiment of the present invention.
[0084] The sand trap 100 contains a tank 120 , having an outlet or drain valve 140 near a lowermost portion to facilitate drainage by gravity. The sand trap 100 contains the at least one mixing chamber 200 , the cap 22 , the diffuser plate 26 and diverter valve 280 (also termed a “diverter chamber”)
[0085] Still referring to FIG. 12 , the in-line mixer extends a distance “L” to be shorter than the mixer shown in FIG. 1 , so as to leave a significant distance “H 1 ” above the bottom of the tank 120 . This distance “H 1 ” is approximately from about one-half to two-thirds of the height “H 2 ” of the tank 120 .
[0086] In operation, the sand trap 100 has water containing sand or other fine particles running through the swirl chamber 200 that exits via the diverting valve 280 . The water exiting the diverting valve has centrifugal movement. As the cap 220 redirects the spinning water upward and the diffuser plate 260 directs the spinning water laterally, the heavier particles, such as sand, shale, etc. will settle in the bottom of the tank for a blow-down via the drain 140 . Thus the sediment can be separated from the liquid without using any moving parts, and without requiring filter cartridges, electricity, or backwashing. Typical particle size of separated sand is that of “sugar sand.” A typical particle that can be separated by the present invention for example has a particle size such as 5 to 400 microns or 20 to 200 microns. Additional chemicals such as alum can be added if desired to the water to enhance separation.
[0087] The sand trap 100 separates solid particles from liquids without using a filter. As shown in FIG. 12 , a feed stream 102 feeds the mixing device 200 located in a tank 120 provided as the conduit 202 containing a mixing chamber 206 employing a pair of baffles 223 ( FIG. 15 , baffles 223 shown in white) as a static mixer. The typical maximum flow rate through the mixing chamber 206 is 24 gallons per minute for a tank having an inside diameter of about 10 inches and a conduit 202 having an inside diameter of about 1 inch.
[0088] The tank 120 shown in FIG. 10 is approximately 12 inches in diameter, but this size can be varied according to need.
[0089] The pair of baffles 223 is the same as or similar to the pair of baffles (see FIG. 6 ) in the lower chamber 18 of the first embodiment. The mixing chamber 200 terminates into the diverter chamber 280 (also termed a “diverter valve”). The feed stream 102 discharges from the mixing chamber 200 into the diverter chamber 280 . The stream 102 then discharges through slits 216 provided in sidewalls of the diverter chamber 280 into an annular region defined between the outer walls of the diverter chamber 280 and the inner sidewalls 230 of an upside down cap 220 . The feed stream then exits from the annular region and is deflected by the diffuser plate 260 as stream 231 which enters the surrounding liquid in the tank 198 . Stream 231 has a centrifugal motion as it discharges from between the upper edge of the cap 220 and the diffuser plate 260 such that the solids travel radially and then downwardly while the liquids travel upwardly and discharge as product stream 250 through outlet conduit 252 which extends below the upper liquid surface 253 .
[0090] The diverter chamber 280 has sidewalls provided at a lower end of the conduit 202 below the mixing chamber 200 . The diverter chamber 280 has an inlet 214 and an outlet 216 . The inlet 214 being in fluid communication with the outlet 208 of the mixing chamber 200 and arranged in the longitudinal direction of the main stream flow of the mixing chamber 200 , and the outlet 216 comprising a plurality of slits 216 in the diverter chamber sidewalls. The slits 216 are radially arranged relative to the axial direction of the mixing chamber 200 . Typically, there are six slits arranged in the diverter chamber sidewalls, but this number can be increased or decreased according to need. About 30-70% of the wall space should have slits 216 therein, with about 50% being a typical construction. These percentages are provided as guidance but an artisan appreciates that it is within the spirit of the invention and the scope of the appended claims to use percentages outside of those disclosed above. An artisan may consider the viscosity of the fluids and in the case of the sand trap, the size of the particles, when selecting the number of slits and the amount of wall space in which they are arranged.
[0091] The cap 220 has a bottom wall 222 and one or more cap sidewalls 230 , the cap 220 being connected to a lower portion of the diverter valve 280 , and the cap sidewalls 230 spaced from the diverter valve 280 .
[0092] The cap 220 , conduit 202 and diffuser plate are typically assembled as described in more detail above for the cap 22 , conduit 24 and diffuser plate 46 of the water filtration device of FIGS. 2 and 3 . Thus, a channel extends downwardly from the diffuser plate 260 and has a stepped portion (not shown) which interlocks with a complimentary stepped portion (not shown) of a channel extending upwardly from the lower inner wall of the cap 220 . Then the lower end of the conduit 202 is slid through the channel extending downwardly from the diffuser plate 260 into the channel extending upwardly from the cap 220 and glued in place to not entirely block the slits 216 .
[0093] An embodiment of the diverter valve 280 shown in FIG. 12 typically has an outer diameter of about 1 inch. The outer diameter of the diffuser plate 26 is at least as large as the outer diameter of the cap 220 . A typical embodiment of the cap 220 shown in FIG. 12 has an outer diameter of about 2.6 inches, and the outer diameter of the diffuser plate 26 is also about 2.6 inches. The cap 220 has a height “L 1 ” that extends upwardly at least about to a height “L 2 ” of the plurality of slits 216 to overlap the slits 216 and define an annular region between inner surfaces of the cap sidewalls 230 and outer walls of the diverter chamber 280 . Typical heights LI of the cap 220 range from about 1 to 3 inches, for example about 2 inches.
[0094] The slits 216 are typically about 0.9 to 1.6 inches high (L 2 ), and about 0.4 inches wide. A typical height (L 4 ) of the inner sidewalls 230 of the cap 220 is about 1.8 inches high measured from the upper surface of the floor of the cap 220 to the upper edge of the cap 220 , (with the floor of the cap being approximately 0.25 inches thick). Thus, “L 4 ” identifies the height of the annular region, which is taller than the slits 216 , and the highest portion of the slits 216 should be arranged below the upper portion of the sidewalls 230 so that the liquid exiting the slits travels upward to exit the annular region and strike the diffuser plate 260 . The diffuser plate 260 is separated from an upper edge of the cap 220 by a distance “L 3 ” of typically about 0.25 to about 2 inches, e.g., from about 0.5 to 1.5 inches. Typically the diffuser plate 260 has an annular shape. However, other shapes are also suitable.
[0095] The diffuser plate 260 is spaced a distance “L 3 ” from an upper edge of the cap 220 to define a discharge area. In an embodiment of FIG. 10 , the height “L 3 ” is approximately 0.6 inches from the upper edge of cap 220 to the lower edge of the diffuser plate 260 . The diffuser plate 260 extends radially from the conduit 202 of the mixing device 200 to define a surface which overlaps the entire annular opening defined by the upper edge of the cap 202 . The diffuser plate 260 is generally parallel to the upper edge of the cap 220 .
[0096] Typically, the above-described ratios of the annular area of flow through the cap and the discharge area between the cap and diffuser plate of the embodiment of FIG. 1 also apply to this sand trap embodiment.
[0097] FIG. 13 illustrates an embodiment of the sand trap 100 consistent with the embodiment of FIG. 12 .
[0098] FIG. 14 is a photograph of an upper section of the embodiment of the sand trap 100 of FIG. 13 .
[0099] FIG. 15 is a close up photograph of a white end cap suitable for substituting for the black end cap of the sand trap 100 of FIG. 14 with a portion of the tube and the deflecting plate removed to better show the baffles 223 .
[0100] One significant advantage of the present invention is that is there is a low liquid usage rate, and thus a low flow rate through the mixing chambers and the tank, there is sufficient time for the liquid and the additive to achieve saturation.
[0101] In contrast, another advantage of the present invention is that if there is a high liquid usage rate, and thus a high flow rate through the tube and the tank, then there is increased mixing of the liquid and the additive to achieve saturation.
[0102] It is also clear that, although the invention has been described with reference to a specific example, a person of skill will certainly be able to achieve many other equivalent forms, all of which will come within the field and scope of the invention. | A static mixer tank includes upper/first and lower/second mixing chambers, with the two mixing chambers being separated by a swirl chamber. The upper mixing chamber is arranged at an upper end of the mixing tube where materials would initial begin passage there through, and the lower mixing chamber is arranged at a lower end of the mixing tube and receives materials that may have to some degree been mixed by their passage through the upper mixing chamber. A series of baffles in the mixing chamber are arranged in sinusoidal or saw-tooth pairs that can be oppositely arranged, so that the mixer turns a drop of water into hundreds of micro-bubbles of rotating fluid, which allows the chemicals to exit the mixer and react with fluid in a storage tank as much five times faster than previously known. A variation includes a sand trap using the swirl chamber, cap, diverter chamber, and diffusing plate to separate sediment from a liquid without using a filter of moving parts. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority from provisional application Ser. No. 61/733,438, filed Dec. 5, 2012, which is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
The invention relates to a process for preparing phosphonic acid monomers.
Polymers containing phosphorus acid groups are useful in many applications including coatings and adhesives. The phosphorus acid groups provide improved adhesion of the polymer to metal substrates, form crosslinks in the presence of divalent metal ions, and promote adsorption of the polymer to pigment particles, such as titanium dioxide, to form composite particles. However, such monomers generally contain many undesirable impurities and/or by-products.
U.S. Pat. No. 6,710,161 discloses a phosphorous acid-containing monomer composition that is substantially free of certain phosphorus acid compounds. However, the monomer must be treated prior to use in order to remove the unwanted phosphorus acid compounds, and only then can it be polymerized with a comonomer to produce a polymer that can be used to prepare coatings.
It would be desirable to have a simple, direct process for the preparation of phosphonic acid monomers.
SUMMARY OF THE INVENTION
The invention is such a process comprising contacting methacrylic acid (MAA) with a phosphorus reactant of the formula:
wherein n is a number having an average value of from 1 to 3, under reaction conditions sufficient to produce a product comprising a phosphonic acid compound of the formula:
Surprisingly, the product monomer can be produced such that it is substantially free of inorganic phosphorous acid(s) and substantially free of diester cross-linkers, thereby avoiding the need for expensive and time-consuming purification steps for the removal of such compounds.
DETAILED DESCRIPTION OF THE INVENTION
As used herein, “a,” “an,” “the,” “at least one,” and “one or more” are used interchangeably. The terms “comprises,” “includes,” and variations thereof do not have a limiting meaning where these terms appear in the description and claims. Thus, for example, an aqueous composition that includes particles of “a” hydrophobic polymer can be interpreted to mean that the composition includes particles of “one or more” hydrophobic polymers.
Also herein, the recitations of numerical ranges by endpoints include all numbers subsumed in that range (e.g., 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4, 5, etc.). For the purposes of the invention, it is to be understood, consistent with what one of ordinary skill in the art would understand, that a numerical range is intended to include and support all possible subranges that are included in that range. For example, the range from 1 to 100 is intended to convey from 1.01 to 100, from 1 to 99.99, from 1.01 to 99.99, from 40 to 60, from 1 to 55, etc.
Also herein, the recitations of numerical ranges and/or numerical values, including such recitations in the claims, can be read to include the term “about.” In such instances the term “about” refers to numerical ranges and/or numerical values that are substantially the same as those recited herein.
Unless stated to the contrary, or implicit from the context, all parts and percentages are based on weight and all test methods are current as of the filing date of this application. For purposes of United States patent practice, the contents of any referenced patent, patent application or publication are incorporated by reference in their entirety (or its equivalent U.S. version is so incorporated by reference) especially with respect to the disclosure of definitions (to the extent not inconsistent with any definitions specifically provided in this disclosure) and general knowledge in the art.
Methacrylic acid (MAA) is well-known and widely commercially available.
In the process of the invention, MAA is reacted with a phosphorus reactant of formula I:
wherein n is a number having an average value of from 1 to 3. The amount of MAA employed advantageously is from 0.5 to 10 moles per mole of phosphorus reactant. In various embodiments of the invention, the amount of MAA employed is from 1 to 3 moles per mole of phosphorus reactant, or from 1.5 to 2 moles per mole of phosphorus reactant. Mixtures of phosphorus reactant can be employed.
The MAA and phosphorus reactant are contacted under reaction conditions sufficient to produce a phosphonic acid monomer of formula II:
In one embodiment of the invention, the reactants are contacted under reduced pressure at elevated temperature for a time sufficient to produce the desired monomer. Advantageously, the temperature is from 70 to 170° C. and will depend, as known to those skilled in the art, on the pressure employed, the stage of the process, and the composition of the reaction mixture. Preferably the process temperature is from 90 to 150° C., and more preferably is from 120 to 140° C. Water is a by-product of the reaction and advantageously is removed as it vaporizes or boils out of the reaction mixture. The pressure advantageously is from 0 to 760 mmHg, and preferably is from 200 to 600 mmHg and more preferably is from 450 to 550 mmHg.
A polymerization inhibitor advantageously is employed in the process. The inhibitor is employed in an amount sufficient to prevent unwanted polymerization. Many inhibitors, and methods of their use, are known to those skilled in the art, and many inhibitors are commercially available. Examples of inhibitors include phenothiazine (PTZ), 4-hydroxy-TEMPO (4-HT), methoxy hydroquinone (MeHQ) and hydroquinone (HQ).
Advantageously, the reaction requires no additional solvent or catalyst, and produces the desired product in high yield. The process does not require expensive reagents, such as (CH 3 ) 3 SiBr.
SPECIFIC EMBODIMENTS OF THE INVENTION
Example 1
Preparation of (methacroyloxy)ethyl phosphonic acid
A four-neck, 1000 ml round bottom flask equipped with an overhead stirrer, thermocouple and 10-tray distillation column is charged with 2-hydroxyethylphosphonic acid (125 g, 0.991 mol), methacrylic acid (180 g, 2.1 mol) and 45 mg of phenothiazine. The stirrer is turned on and set at 200 rpm, and the pressure of the reactor is set at 488 mmHg. Contents of the flask are heated to 130° C. over 45 minutes. Distillate begins to come off when the pot temperature reaches 125° C. and the vapor temperature stays between 80 to 90° C. After an hour, the vapor temperature begins to drop. The heat is turned off, and the vacuum is released. A sample is taken and analyzed by 1 H-NMR and 31 P-NMR spectroscopy. The NMR results indicate that 16% of the starting alcohol remains in the sample. The pressure of the reactor is reduced to 490 mmHg again and the contents are heated to 140° C. Distillate is collected at the vapor temperature range of 60-85° C. for an additional hour.
The remaining MAA is removed under full vacuum (<10 mmHg) at a pot temperature of 100 to 120° C. The product weighs 174 g (89% of the theoretical yield) and is analyzed by 1 H, 13 C, 31 P-NMR spectroscopy. The results are consistent with the expected structure of a monomer with formula III, (methacroyloxy)ethyl phosphonic acid.
For some applications, it is not necessary to remove the remaining MAA, as the unseparated mixture can be used for polymerization.
Example 2
Preparation of (methacroyloxy)methyl phosphonic acid
A four-neck, 250 ml round bottom flask equipped with an overhead stirrer, thermocouple and 10-tray distillation column is charged with 2-hydroxymethylphosphonic acid (42 g, 0.38 mol), methacrylic acid (93 g, 1.1 mol) and 45 mg of phenothiazine. The stirrer is turned on and set at 200 rpm, and the pressure of the reactor is set at 497 mmHg. The contents of the flask are heated to 130° C. over 45 minutes. Distillate begins to come off when the pot temperature reaches 125° C. and the vapor temperature stays between 80 to 90° C. After two hours, the pressure is reduced to full vacuum (<10 mmHg), and the remaining MAA is removed at a pot temperature of 100 to 120° C. The product weighs 57 g (84% of the theoretical yield) and is analyzed by 1 H, 31 P-NMR spectroscopy. The results are consistent with the expected structure of a monomer with formula IV, (methacroyloxy)methyl phosphonic acid. | A simple, commercially viable process for the preparation of phosphonic acid monomers containing essentially no diester or inorganic phosphorous acid compounds is disclosed. | 2 |
BACKGROUND OF THE INVENTION
This invention relates to the packaging of liquid or powder products, such as fruit juices, milk, sugar, salt, soap powders and the like and more particularly to a carton construction having a flanged pour spout.
Aside from a required barrier layer on the carton interior surfaces for packaging certain product types, such as potables, known methods and apparatus for bonding a pour spout to a paperboard container or blank, such as a gable top container or blank therefor, yield only relatively modest bonding or welding rates.
In copending patent application Ser. No. 07/551,818 filed July 12, 1990 (commonly assigned and incorporated by reference) a similar pour spout/carton construction and method is disclosed. There, an annular ultrasonic sealing horn is provided with radially spaced, concentric ridges. The ridges engage the flange of a flanged plastic pour spout and bond the flange to a plastic coated carton upon actuation of the horn.
SUMMARY OF THE INVENTION
This invention permits relatively high rates of sealing speeds to bond pour spouts to gable top type paperboard containers. A specific knurled ring sonic horn surface configuration yields superior pour spout bonding to the carton. The sonic head is provided with a zone or annulus of knurls on its working surface to rapidly and efficiently heat bond the spout flange to the usual polyethylene coating or to a specific barrier layer on the carton exterior.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial end elevational view of a typical gable top container provided with the pour spout construction of this invention.
FIG. 2 is a plan view of the upper portion of a typical paperboard blank from which the gable top container of FIG. 1 is fashioned.
FIG. 3 is a view taken in the direction of 3--3 of FIG. 1 and illustrates the pour spout construction of this invention.
FIG. 4 is a view similar to FIG. 3 and illustrates the method of assembly of the pour spout in conjunction with the knurled ultrasonic horn of this invention.
FIG. 4a is an enlarged view of that portion within the dashed circle of FIG. 4.
FIG. 5 is a plan view of the spout flange after its attachment to the paperboard blank of FIG. 2.
FIG. 6 is a view similar to FIG. 4 and illustrates another embodiment.
FIG. 7 is a chart illustrating certain differences in flange ultrasonic seals.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 1, the upper portion of an otherwise conventional gable top container 10 having the usual upper fin 12 and slanting gable walls 14 is illustrated. A plastic pour spout fitment and cap assembly is denoted generally as 16. The container partially illustrated at FIG. 1 is similar to that shown at FIG. 1 of U.S. Pat. No. 4,813,578 issued to Robert L. Gordon et al.
FIG. 2 illustrates the upper portion 20 of a conventional paperboard blank for forming a gable top carton. One of the gable forming panels 14 of the blank is provided with a die cut dispensing opening 24.
FIG. 3 illustrates the construction of the pour spout attachment of this invention. The paperboard from which blank 20 is fashioned is denoted as 21. The usual polyethylene layer or coating on the exterior of the blank is designated as 30, with an internal barrier layer 32 covering the entire surface of one side of the blank, and hence of the completed carton. External polyethylene layer 30 and carton internal barrier layer 32 extend to the edge of dispensing opening 24. The pour spout is denoted by 40 and includes a short cylindrical spout section provided on its exterior with threads 42. The lower portion of the spout carries a flange 44. The spout is fashioned of a plastic material. The pour spout cap includes an upper disk portion 48 having an annular skirt 50 and internal threads 52 on the skirt. Threads 52 and 42 are adapted to become engaged and effect full closure with only one turn of the closure cap.
The radially outermost portion of flange 44 is denoted as 66 and is see to be of lesser thickness than the remainder of the flange. Its upper surface is knurled by male knurlings denoted as 74 (see FIGS. 4a and 5).
The material of the spout is a critical factor. It has to be of a polymer dissimilar to the spout. Upon sonic sealing of the spout flange to the container blank 20 (to be described) the vibration induced heat generated would fuse the spout and cap together if they were of similar materials. The cap material used is polypropylene while the spout material is low density or linear low density polyethylene.
The spout material, LDPE or LLDPE, serves two important functions. First is the above non-fusing relationship to the cap. Secondly, and most important, is the compatibility of this material to the outer surface of the container which is LDPE. When sonic (vibration creating heat) power is applied to the top surface of the flange, the flange material and polymer coating 30 on the paperboard fuse, creating a permanent bond between the spout and carton surface. The flange sealing area from the view point of bonding/sealing rates is critical. If the flange were thinner, holes or stress points would be created. If it were thicker, or the seal surface area covered the entire flange area, a longer dwell time to seal the flange would be required. The 0.020" flange thickness permits the sealing of the fitment to the container at form fill seal rates of 90/min. The combined cap and spout are circular in shape. Thus, there is no concern about alignment or orientation. The top of the spout has a flat uninterrupted surface that acts as a pour lip and a platform to seal the tamper evident membrane. This surface is 0.035" wide which allows for an adequate sealing. On the interior of the spout wall are four vertical ribs. These ribs are used in the molding process to grasp the spout while unscrewing them from the mold and are conventional.
FIG. 4 illustrates the method of bonding the pour spout to the carton shown at FIG. 3. An annular ultrasonic horn 60, the flange and cap pour fitment assembly, the paperboard blank 20 with both layers 30 and 32 and a backup mandrel 68, are all assembled as indicated. The ultrasonic horn 60 has a flat annular end surface 62, modified by this invention so as to include a female knurled outer, annular zone defined by female knurlings 70 of about 0.002 to 0.003 inches in depth. The knurled zone 72 of the horn rests on a radially outermost zone 66 of flange 44. Backup mandrel 68 has a flat upper surface. Application of sonic energy is transmitted by horn 60 to flange 44. The female knurlings and the downward force of the horn, together with the horn vibrations, give rise to male knurlings 74 on the radially outermost zone of the plastic flange, and also cause a lessing of flange thickness 66 at the zone of the knurlings. The movement or flow of plastic from the top surface of the flange into the female knurlings 70 helps resist lateral sliding movement of the flange relative to the horn face and the backup mandrel. As shown at FIG. 4a, an annular recess 73 is provided on the outer, lower edge of the horn. This inhibits plastic material from the flange from creeping radially outwardly and up the sides of the horn.
FIG. 5 illustrates the annular, outermost knurled zone of female knurlings 74 on flange 44. A corresponding view of the working face of horn 60 would be similar, but the knurlings would be female as indicated at FIG. 4a.
FIG. 6 illustrates a carton/pour spout construction when raw edge protection is required. The dispensing opening 24 is wider and layers 30 and 32 are sealed together by upstanding rim 76 on backup mandrel 68, rim 76 squeezing layers 30 and 32 together through flange 44 by the flat face portion of horn 60. This produces a continuous annular seal around the raw paperboard edge of opening 24. The layers 30 and 32 extend radially inwardly of opening 24, and define a different dispensing opening 26.
Table I shows the improvement in ultrasonic sealing integrity with carton blanks having less than optimum seal surfaces to accept the flange of the pour spout.
TABLE I______________________________________ % FIBER TEAR ON PRINTEDHORN WELD CARTONSPATTERN TIME, MS LITHO ROTO______________________________________3-ring 210 75 72 190 58 53Knurled Face 210 94 95 190 88 --______________________________________
Most carton blanks, such as those shown at FIG. 2, are printed prior to spout attachment. Carton blanks manufactured for use with pour spouts have a no print and no varnish area specified in the spout flange sealing area. Due to variability in print process control, contamination of the no print/no varnish area is a critical manufacturing issue. Since the printing press operates at very high speeds, significant quantities of contaminated cartons can be produced before the press operator can take corrective action. The ultrasonic horn referenced in the copending application Ser. No. 07/551,818 is particularly sensitive to carton seal area contamination with ink and/or varnish particles. This sensitivity requires both exceedingly tight process control and strict post-production quality control. The improved sealing embodied here produces excellent spout flange to carton bonds despite the presence of contamination in the seal area. The first line of Table I sets out weld time in milliseconds and the seal integrity for two types of printed carton blanks, for a sonic horn working face configuration having three concentric ridges, as shown in noted copending application Ser. No. 07/551,818. The two types of preprinting were offered lithography (LITHO) and rotogravure (ROTO). A (conventional) 1:2 booster was used in conjunction with the ultrasonic horn. The second row sets out the same ultrasonic weld times and type of preprinting, but with the knurled sonic horn working face of this invention. The higher the percent fiber tear when the spout is forcibly removed, the better the seal. It is seen that the seals produced by the knurlings of this invention are superior to those produced by a three ridge sonic horn configuration.
FIG. 7 is a bar type graph showing the variation in seal integrity, as measured in percent fiber tear, for several weld times, for both the three ridge horn face described in noted copending application Ser. No. 07/551,818 and the knurled horn face of this invention. In both cases, the horn was provided with a conventional 1:2 booster. For corresponding weld times (measured in milliseconds, MS) it is seen that the knurled horn face produces a better flange to carton weld/seal. The better results are even more pronounced with shorter weld times. For both Table I and FIG. 7, the thickness of flange 44 was 0.020 inches and the parameter "% fiber tear" refers to the percentage of paperboard torn when the flange is forcibly removed from the paperboard. When this parameter is 100% for paperboard 21, no plastic 30 remains on the torn area of the paperboard upon the forced removal of the pour spout.
As may be seen at FIG. 4a, radially inner zone 62 of the horn working face is preferably tapered upwardly about 2 to 3 degrees, the taper running upwardly from left to right. | A pour spout carton for extended shelf life paperboard containers, such as those of the gable top type. A dispensing opening is formed, as by die cutting, in a panel of the carton. A pour spout carries a flange extending from the edge of the dispensing hole to a location radically beyond the dispensing opening, the flange sonically bonded to the outer barrier layer along an annular outermost knurled zone. The knurled zone sonic horn configuration yields pour spout attachment times and spout attachment integrity superior to known prior spout attachment methods and spout constructions. | 1 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates, in general, to testing techniques and, more particularly, to a method for testing a plurality of functional circuit blocks, wherein each of the functional circuit blocks is designed as an existing semiconductor integrated circuit.
[0003] This claims priority under 35 USC §119 to Japanese patent application Serial Number 371925/2001, filed Dec. 5, 2001, the subject matter of which is incorporated herein by reference in its entirely for all purposes.
DESCRIPTION OF THE RELATED ART
[0004] In recent years, a system LSI comprises many functional circuit blocks. The functional circuit block which is a core of the system LSI, is called as intellectual property (IP), macro cell or so on. The IP is a block which is designed in the state of hardware or software and executes a specific operation.
[0005] A conventional method for testing the functional circuit blocks in the system LSI sets a plurality of test groups each comprising a plurality of the functional circuit blocks to be tested simultaneously, using a combination of a parallel access method and a serial access method. The conventional method tests the test groups in turn. The concept of the parallel access method is shown in FIG. 14. As shown in FIG. 14, each of the input and output terminals of each of IP 1401 and 1402 connects with the outer terminals of the system LSI 1400 with one-one relation. The parallel access method tests a plurality of IP parallel using the outer terminals of the system LSI, by inputting a signal to IP from the outer terminals directly and observing an output signal output by the outer terminals directly. The concept of the serial access method is shown in FIG. 15. As shown in FIG. 15, there are a serial-parallel converter 1501 and a parallel-serial converter 1502 between the outer terminals of the system LSI 1500 and the input and output terminals of IP 1503 and 1504 . The serial access method tests a plurality of IP serially using the outer terminals of the system LSI, by inputting a signal to IP from the outer terminals through the serial-parallel converter 1501 and observing an output signal output by the outer terminals through the parallel-serial converter 1502 .
[0006] An operation of the conventional method for testing the functional circuits in the system LSI will be described with reference to FIG. 16. The vertical axis shows the range of the number of pins of the system LSI necessary for testing. The horizontal axis shows test time necessary for testing. Six functional circuit blocks IP(A)-IP(F) are shown in FIG. 16. A vertical length of each functional circuit block is indicative of the number of pins of the system LSI necessary for testing. A horizontal length of each functional circuit block is indicative of test time necessary for testing.
[0007] The conventional test method divides the functional circuit blocks into a plurality of test groups. In FIG. 16, the functional circuit blocks are divided into four test groups. A first test group comprises the functional circuit blocks IP(A) and IP(B). A second test group comprises the functional circuit blocks IP(C) and IP(D). A third test group comprises the functional circuit block IP(E). A fourth test group comprises the functional circuit block IP(F).
[0008] The conventional test method tests the functional circuit blocks by test groups. First, the first test group is tested. Next, the second test group is tested, after the test in the first test group is finished. Correspondingly, the third test group is tested, after the test in the second test group is finished. The fourth test group is tested, after the test in the third test group is finished.
[0009] However, each of the functional circuit blocks in each test group does not always have the same test time as the other functional circuit blocks in the corresponding test group. The test time of the functional circuit block IP(A) is longer than that of the functional circuit block IP(B). The non-used pins of the system LSI for testing exist uselessly, from the time of finishing the test in the functional circuit block IP(A) until finishing the test in the functional circuit block IP(B). The testing of the second test group can not start immediately after the test of the functional circuit block IP(B) is finished, because the test in the functional circuit block IP(A) has not been finished yet. Therefore, the conventional test method does not use the non-used pins of the system LSI effectively.
SUMMARY OF THE INVENTION
[0010] According to one aspect of the present invention, there is provided a method for testing a plurality of the functional circuit blocks in the system LSI, the method comprising dividing a plurality of the functional circuit blocks into at least a first test group and a second test group, wherein the first test group is tested before the second test group, and starting testing of one functional circuit block in the second test group immediately after one functional circuit block in the first test group is finished being tested.
[0011] The novel features of the invention will more fully appear from the following detailed description, appended claims and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] [0012]FIG. 1 is an operational diagram showing a method for testing functional circuit blocks according to a first preferred embodiment of the present invention.
[0013] [0013]FIG. 2 is a block diagram showing the number of LSI pins and testing time according to the first preferred embodiment of the present invention.
[0014] [0014]FIG. 3 is a block diagram showing a test circuit according to the first preferred embodiment of the present invention.
[0015] [0015]FIG. 4 is a timing chart showing necessary time for testing each functional circuit block shown in FIG. 2.
[0016] [0016]FIG. 5 is an operational diagram showing a method for testing functional circuit blocks according to a second preferred embodiment of the present invention.
[0017] [0017]FIG. 6 is a block diagram showing the number of LSI pins and testing time according to the second preferred embodiment of the present invention.
[0018] [0018]FIG. 7 is a block diagram showing a test circuit according to the second preferred embodiment of the present invention.
[0019] [0019]FIG. 8 is a timing chart showing necessary time for testing each functional circuit block shown in FIG. 6.
[0020] [0020]FIG. 9 is an operational diagram showing a method for testing functional circuit blocks according to a third preferred embodiment of the present invention.
[0021] [0021]FIG. 10 is a block diagram showing the number of LSI pins and testing time according to the third preferred embodiment of the present invention.
[0022] [0022]FIG. 11 is a block diagram showing a test circuit according to the third preferred embodiment of the present invention.
[0023] [0023]FIG. 12 is a timing chart showing necessary time for testing each functional circuit block shown in FIG. 10.
[0024] [0024]FIG. 13 is an operational diagram showing a method for testing functional circuit blocks according to a fourth preferred embodiment of the present invention.
[0025] [0025]FIG. 14 is a block diagram for describing a parallel access method.
[0026] [0026]FIG. 15 is a block diagram for describing a serial access method.
[0027] [0027]FIG. 16 is a block diagram showing the number of LSI pins and testing time according to a conventional method for testing functional circuit blocks.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0028] A method for testing functional circuit blocks of the present invention will be explained with reference to the preferred embodiments of the present invention. Moreover, not all the combinations of the characteristics of the present invention described in the embodiments are essential to the problem solving means of the present invention.
[0029] A method for testing the functional circuit blocks according to a first preferred embodiment of the present invention will be described with reference to FIGS. 1 - 4 . FIG. 1 is an operational diagram showing the method for testing the functional circuit blocks according to the first preferred embodiment of the present invention. FIG. 2 is a block diagram showing the number of LSI pins and testing time according to the first preferred embodiment of the present invention. FIG. 3 is a block diagram showing a test circuit according to the first preferred embodiment of the present invention. FIG. 4 is a timing chart showing time necessary for testing each functional circuit block shown in FIG. 2.
[0030] First, an operation of the method for testing the functional circuit blocks according to the first preferred embodiment of the present invention will be explained with reference to FIGS. 1 and 2. In FIG. 2, the vertical axis P shows the range of the number of pins of the system LSI which are available for testing the functional circuit blocks. The horizontal axis T shows test time to finish testing in the functional circuit blocks. The functional circuit blocks are shown as IP(i). IP(i)t shows test time necessary for testing the functional circuit block IP(i) and IP(i)p shows the number of pins of the system LSI necessary for testing.
[0031] In step S 101 , each test time necessary for testing each functional circuit block and each of the number of pins of the system LSI necessary for testing each functional circuit blocks, are determined. In FIG. 2, each test time IP(A)t-IP(F)t and each of the number of pins IP(A)p-IP(F)p are determined. In addition, in step S 101 , the functional circuit block having the longest test time among the functional circuit blocks, is selected. In FIG. 2, the functional circuit block IP(A) having test time IP(A)t is selected. As shown in FIG. 2, test time IP(A)t has the longest horizontal length.
[0032] In step S 102 , one of the functional circuit blocks is selected from among the non-selected functional circuit blocks of step S 101 in consideration of the number of pins of the system LSI which are available for starting testing in parallel with the functional circuit block selected in step S 101 . In FIG. 2, the functional circuit block IP(B) is selected. The following relationship is considered:
P=IP ( A ) p+IP ( B ) p+ΔP 1 [1],
[0033] wherein ΔP1 is the number of unused pins of the LSI when the functional circuit blocks IP(A) and IP(B) are simultaneously tested. The smaller the value ΔP1 is, the more efficient the method for testing becomes. The other functional circuit blocks IP(C)-IP(F) are not selected, because testing of the other functional circuit blocks IP(C)-IP(F) can not be started with the functional circuit block IP(A) at the same time out of consideration of the number of pins of the system LSI. Also, if for the example the functional circuit block IP(D) is selected instead of the functional circuit block IP(B), ΔP2 (=P−IP(A)p−IP(D)p) is larger than ΔP1. The method for testing becomes inefficient if the functional circuit block IP(D) is selected in step S 102 instead of functional circuit block IP(B).
[0034] In step S 103 , the functional circuit blocks selected in steps S 102 and S 103 are set as one test group. These set functional circuit blocks can be tested by the parallel access method at the same time. In FIG. 2, the functional circuit blocks IP(A) and IP(B) are set as one test group (1st test group).
[0035] In step S 104 , it is determined whether there is the non-selected functional circuit block or not. If there is a non-selected functional circuit block, steps S 101 -S 103 are repeated. If not, step S 105 is executed. In FIG. 2, the functional circuit blocks IP(C) and IP(D) are set as one test group (2nd test group). The functional circuit block IP(E) is set as one test group (3rd test group) and the functional circuit block IP(F) is set as one test group (4th test group). In FIG. 2, there are four test groups.
[0036] By the way, in the 1st test group, test time IP(B)t is shorter than test time IP(A)t. So, the test process for the functional circuit block IP(B) is finished faster than the test process for the functional circuit block IP(A). When the test process for the functional circuit block IP(B) is finished, the number of non-used pins ΔP3 (=P−IP(A)p)>ΔP1 exists until the test process for the functional circuit block IP(A) is finished.
[0037] So, in step S 105 , it is determined whether there is a functional circuit block among the next test group which is available as a pretest group for starting to test using the non-used pins of the system LSI during the test process of the first test group. If such a functional circuit block is determined as available in step S 105 , step S 106 is executed, and if not, step S 107 is executed. In more detail with reference to FIG. 2, according to the relationship between the 1 st test group and the 2nd test group, the functional circuit block IP(D) in the 2nd test group is available for starting to test using the non-used pins of the system LSI during the test process for the 1st test group. So, the functional circuit block IP(D) is selected out of consideration for the test time. Usually, the functional circuit block having the longest test time is selected.
[0038] In step S 106 , the functional circuit block which is selected in step S 105 , is added to the pre-test-group. Therefore, immediately after the test process for one functional circuit block in the first test group is finished, the test process for the functional circuit block which is selected in step S 105 in the pretest group is started. In FIG. 2, the functional circuit block IP(D) is selected as in the pretest group and is thus added to the 1st test group. Therefore, immediately after the test process for the functional circuit block IP(B) is finished, the test process for the functional circuit block IP(D) is started.
[0039] In step S 107 , it is determined whether there is the non-selected test group or not. If there is a non-selected test group, steps S 105 and S 106 are executed. If not, step S 108 is executed. In FIG. 2, there are 3rd test group and 4th test group. Steps S 105 and S 106 are executed for the 3rd test group and 4th test group.
[0040] In step S 108 , a test circuit is provided for each test group as shown in FIG. 3 . The test circuit has a test control circuit 310 and the functional circuit blocks 320 - 370 . The test control circuit 310 and the functional circuit blocks 320 - 370 are connected to each other by the control bus. Each of the functional circuit blocks 320 - 370 is controlled through the control bus by the test control circuit 310 . In addition, the test control circuit 310 has a test access circuit and so on. As shown in FIG. 3, each functional circuit block is tested by the parallel access method. Returning to FIG. 3, the test process for the functional circuit blocks is executed.
[0041] In FIG. 4, each wave form shows the testing status of each functional circuit block. The rising part of the wave form shows the status of being tested. The falling part of the wave shows the status of not being tested. As shown in FIG. 4, the test process for the functional circuit blocks IP(A) and IP(B) are started at the same time. Next, immediately after the test process for the functional circuit block IP(B) is finished, the test process for the functional circuit block IP(D) is started. Next, immediately after the test process for the functional circuit block IP(A) is finished, the test process for the functional circuit block IP(C) is started. Next, immediately after the test process for the functional circuit blocks IP(C) and IP(D) is finished, the test process for the functional circuit block IP(E) is started. Next, immediately after the test process for the functional circuit block IP(E) is finished, the test process for the functional circuit block IP(F) is started. Therefore, total test time is the sum of IP(B)t, IP(D)t, IP(E)t and IP(F)t. On the other hand, total test time of the conventional test method is the sum of IP(A)t, IP(D)t, IP(E)t and IP(F)t. Thus, total test time of the first preferred embodiment of the present invention is shorter than total test time of the conventional test method by the difference between IP(A)t and IP(B)t.
[0042] The method for testing the functional circuit blocks according to the first preferred embodiment of the present invention starts to test next test group without waiting for finishing all of test processes of the previous test group. The method for testing the functional circuit blocks according to the first preferred embodiment of the present invention saves the time necessary for finishing all of the test processes of the previous test group. Therefore, the method for testing the functional circuit blocks according to the first preferred embodiment of the present invention reduces test time for the functional circuit blocks of the system LSI in comparison with the conventional method.
[0043] A method for testing the functional circuit blocks according to a second preferred embodiment of the present invention will be described with reference to FIGS. 5 - 8 . FIG. 5 is an operational diagram showing the method for testing the functional circuit blocks according to the second preferred embodiment of the present invention. FIG. 6 is a block diagram showing the number of LSI pins and testing time according to the second preferred embodiment of the present invention. FIG. 7 is a block diagram showing a test circuit according to the second preferred embodiment of the present invention. FIG. 8 is a timing chart showing necessary time for testing each functional circuit block shown in FIG. 6. Like elements are given like or corresponding reference numerals in the first and second preferred embodiments. Thus, dual explanations of the same elements are avoided.
[0044] First, an operation of the method for testing the functional circuit blocks according to the second preferred embodiment of the present invention will be explained with reference to FIG. 5. The steps S 501 -S 505 shown in FIG. 5 are added between step S 107 and step S 108 shown in FIG. 1.
[0045] In step S 501 , it is determined whether the test group comprises only one functional circuit block or not. If the test group comprises only one functional circuit block, step S 502 is executed, and if not, step S 505 is executed.
[0046] In step S 502 , whether or not the functional circuit block can be tested in parallel with test processes of another test group by the serial access method is determined, based on consideration of the number of pins of the system LSI. If it can be tested, step S 503 is executed. If not, step S 505 is executed.
[0047] In step S 503 , it is determined whether test time of the functional circuit block to be tested by the serial access method is shorter than total test time of the other test groups or not. If it is, step S 504 is executed. If not, step S 505 is executed. In step S 504 , the functional circuit block is added to another test group. Then, step S 505 is executed.
[0048] In step S 505 , it is determined whether additional test groups exist or not. If it is, step S 501 is executed again. If not, step S 108 is executed.
[0049] Next, an operation of the method for testing the functional circuit blocks according to the second preferred embodiment of the present invention will be explained with reference to FIG. 6 concretely.
[0050] In step S 501 , first, the 1st test group is checked. The 1st test group comprises two functional circuit blocks IP(A) and IP(B), so step S 505 is executed. In step S 505 , additional test groups (2nd, 3rd, 4th test groups) exist, so step S 501 is executed again. The process of the 2nd test group is omitted for the same reason as the 1st test group. In step S 501 again, the 3rd test group is checked. The 3rd test group comprises only one functional circuit block IP(E), so step S 502 is executed. It is determined that the 3rd test group can be tested by the serial access method in parallel with other test groups, so step S 503 is executed. Test time of the functional circuit block IP(E) of the 3rd test group to be tested by the serial access method is shorter than total test time of the other test groups, so step S 504 is executed. In step S 504 , the functional circuit block IP(E) of the 3rd test group is added to other test groups (1st, 2nd and 4th test groups) and is shown as IP(E 1 ) in FIG. 6. In step S 505 , the 4th test group is checked, the 4th test group is checked in step S 501 again. The 4th test group comprises only one functional circuit block IP(F), so step S 502 is executed. In step S 502 , it is determined that the 4th test group can not be tested in parallel with another test groups, so step S 505 is executed. In step S 505 , additional test group do not exist, so step S 108 is executed.
[0051] In step S 108 , a test circuit is provided for each test group as shown in FIG. 7. The test circuit has a test control circuit 710 and the functional circuit blocks 720 - 770 . The test control circuit 710 and the functional circuit blocks 720 - 770 are connected to each other by the control bus. Each functional circuit block 720 - 770 is controlled through the control bus by the test control circuit 710 . In addition, the test control circuit 710 has a test access circuit and so on. As shown in FIG. 7, all functional circuit blocks except for the functional circuit block IP(E 1 ) are tested by the parallel access method, the functional circuit block IP(E 1 ) is tested by the serial access method. Returning to FIG. 7, the test process for the functional circuit blocks is executed.
[0052] In FIG. 8, each wave form shows the testing status of each functional circuit block. The rising part of the wave form shows the status of being tested. The falling part of the wave shows the status of not being tested. As shown in FIG. 8, the test process for the functional circuit blocks IP(A), IP(B) and IP(E 1 ) are started at the same time. Next, immediately after the test process for the functional circuit block IP(B) is finished, the test process for the functional circuit block IP(D) is started. Next, immediately after the test process for the functional circuit block IP(A) is finished, the test process for the functional circuit block IP(C) is started. Next, immediately after the test process for the functional circuit blocks IP(C) and IP(D) is finished, the test process for the functional circuit block IP(F) is started. Therefore, total test time is the sum of IP(B)t, IP(D)t and IP(F)t. On the other hand, total test time of the conventional test method is the sum of IP(A)t, IP(D)t, IP(E)t and IP(F)t. Thus, total test time of the second preferred embodiment of the present invention is shorter than total test time of the conventional test method by the difference IP(A)t+IP(E)t−IP(B)t. In addition, total test time of the first preferred embodiment of the present invention is the sum of IP(B)t, IP(D)t, IP(E)t and IP(F)t. Therefore, total test time of the second preferred embodiment of the present invention is shorter than total test time of the first preferred embodiment by the difference IP(E)t.
[0053] As the method for testing the functional circuit blocks according the first preferred embodiment of the present invention, the method for testing the functional circuit blocks according to the second preferred embodiment of the present invention can start to test next test group without waiting for finishing all of test processes of previous test group. The method for testing the functional circuit blocks according to the second preferred embodiment of the present invention saves the time necessary for finishing all of the test processes of the previous test group. Therefore, the method for testing the functional circuit blocks according to the second preferred embodiment of the present invention reduces test time for the functional circuit blocks of the system LSI in comparison with the conventional method.
[0054] Furthermore, the method for testing the functional circuit blocks according to the second preferred embodiment of the present invention tests the functional circuit blocks using a combination of the parallel access method and the serial access method. Therefore, the method for testing the functional circuit blocks according to the second preferred embodiment of the present invention reduces test time for the functional circuit blocks of the system LSI in comparison with the method according to the first preferred embodiment of the present invention.
[0055] A method for testing the functional circuit blocks according to a third preferred embodiment of the present invention will be described with reference to FIGS. 9 - 12 . FIG. 9 is an operational diagram showing the method for testing the functional circuit blocks according to the third preferred embodiment of the present invention. FIG. 10 is a block diagram showing the number of LSI pins and testing time according to the third preferred embodiment of the present invention. FIG. 11 is a block diagram showing a test circuit according to the third preferred embodiment of the present invention. FIG. 12 is a timing chart showing necessary time for testing each functional circuit block shown in FIG. 10. Like elements are given like or corresponding reference numerals in the above preferred embodiments. Thus, dual explanations of the same elements are avoided.
[0056] First, an operation of the method for testing the functional circuit blocks according to the third preferred embodiment of the present invention will be explained with reference to FIG. 9. The steps S 901 -S 905 shown in FIG. 9 are added between step S 505 and step S 108 shown in FIG. 5.
[0057] In step S 901 , it is determined whether the test group comprises only one functional circuit block or not. If the test group has only one functional circuit block, step S 902 is executed. If not, step S 905 is executed.
[0058] In step S 902 , whether or not the functional circuit block can be tested in parallel with test processes of another test group by a parallel/serial combination access method is determined, based on consideration of the number of pins of the system LSI. If it can be tested, step S 903 is executed. If not, step S 905 is executed.
[0059] In step S 903 , it is determined whether or not test time of the functional circuit block to be tested by the parallel/serial combination access method is shorter than total test time of the other test groups. If it is, step S 904 is executed. If not, step S 905 is executed. In step S 904 , the functional circuit block is added to other test groups. Then, step S 905 is executed.
[0060] In step S 905 , it is determined whether additional test groups exist or not. If additional test groups exist, step S 901 is executed again. If not, step S 108 is executed.
[0061] Next, an operation of the method for testing the functional circuit blocks according to the third preferred embodiment of the present invention will be explained with reference to FIG. 10 concretely.
[0062] In step S 901 , first, the 1st test group is checked. The 1st test group is comprised with two functional circuit blocks IP(A) and IP(B), so step S 905 is executed. In step S 905 , the additional test groups (2nd, 3rd, 4th test groups) exist, so step S 901 is executed again. The process of the 2nd test group is omitted for the same reason as the 1st test group. In step S 901 again, the 3rd test group is checked. The 3rd test group is comprised with only one functional circuit block IP(E 1 ), so step S 902 is executed. As explained above in the preferred embodiment, the 3rd test group is decided to be tested by the serial access method, so step S 905 is executed. After step S 905 , in step S 901 again, the 4th test group is checked. The 4th test group is comprised with only one functional circuit block IP(F), so step S 902 is executed. It is determined that the 4th test group can be tested by the parallel/serial combination access method in parallel with other test groups, so step S 903 is executed. Test time of the functional circuit block IP(F) of 4th test group to be tested by the parallel/serial combination access method is shorter than total test time of the other test groups, so step S 904 is executed. In step S 904 , the functional circuit block IP(F) of 4th test group is added to other test groups (1st, 2nd and 3rd test groups) and is shown as IP(F 1 ) in FIG. 10. In step S 905 , the additional test groups do not exist, so step S 108 is executed.
[0063] In step S 108 , a test circuit is provided for each test group as shown in FIG. 11. The test circuit has a test control circuit 1101 and the functional circuit blocks 1102 - 1107 . The test control circuit 1101 and the functional circuit blocks 1102 - 1107 are connected with the control bus to each other. Each functional circuit block 1102 - 1107 is controlled through the control bus by the test control circuit 1101 . In addition, the test control circuit 1101 has a test access circuit and so on. As shown in FIG. 11, the functional circuit blocks IP(A)-IP(D) are tested by the parallel access method, the functional circuit block IP(E 1 ) is tested by the serial access method and the functional circuit block IP(F 1 ) is tested by the parallel/serial combination method. Then, the test process for the functional circuit blocks is executed.
[0064] In FIG. 12, each wave form shows the testing status of each functional circuit block. The rising part of the wave form shows the status of being tested. The falling part of the wave shows the status of not being tested. As shown in FIG. 12, the test process for the functional circuit blocks IP(A), IP(B), IP(E 1 ) and IP(F 1 ) are started at the same time. Next, immediately after the test process for the functional circuit block IP(B) is finished, the test process for the functional circuit block IP(D) is started. Next, immediately after the test process for the functional circuit block IP(A) is finished, the test process for the functional circuit block IP(C) is started. Therefore, total test time is the sum IP(E 1 )t of IP(B)t, IP(D) and Δα. On the other hand, total test time of the conventional test method is the sum of IP(A)t, IP(D)t, IP(E)t and IP(F)t. Thus, total test time of the third preferred embodiment of the present invention is shorter than total test time of the conventional test method by the difference IP(A)t+IP(E)t+IP(F)t−IP(B)−Δα. In addition, total test time of the first preferred embodiment of the present invention is the sum of IP(B)t, IP(D)t, IP(E)t and IP(F)t. Therefore, total test time of the third preferred embodiment of the present invention is shorter than total test time of the first preferred embodiment by the difference IP(E)t+IP(F)t−Δα. Furthermore, total test time of the second preferred embodiment of the present invention is the sum of IP(B)t, IP(D)t and IP(F)t. Therefore, total test time of the third preferred embodiment of the present invention is shorter than total test time of the second preferred embodiment by the difference IP(F)t−Δα.
[0065] As the method for testing the functional circuit blocks according the first and second preferred embodiments of the present invention, the method for testing the functional circuit blocks according to the third preferred embodiment of the present invention starts to test next test group without waiting for finishing all of test processes of previous test group. The method for testing the functional circuit blocks according to the third preferred embodiment of the present invention saves the time needed to wait for finishing all of test processes of previous test group. Therefore, the method for testing the functional circuit blocks according to the third preferred embodiment of the present invention reduces test time for the functional circuit blocks of the system LSI in comparison with the conventional method.
[0066] Furthermore, the method for the method for testing the functional circuit blocks according to the third preferred embodiment of the present invention tests the functional circuit blocks using a combination of the parallel access method, the serial access method and parallel/serial combination access method. Therefore, the method for testing the functional circuit blocks according to the third preferred embodiment of the present invention reduces test time for the functional circuit blocks of the system LSI in comparison with the method according to the first and second preferred embodiments of the present invention.
[0067] A method for testing the functional circuit blocks according to a fourth preferred embodiment of the present invention will be described with reference to FIG. 13. FIG. 13 is an operational diagram showing the method for testing the functional circuit blocks according to the fourth preferred embodiment of the present invention. The method for testing the functional circuit blocks according to the fourth preferred embodiment of the present invention provides an improvement of the first preferred embodiment. The method for testing the functional circuit blocks according to the first preferred embodiment of the present invention decides all test groups and then adjusts the relationship among the test groups. However, the method for testing the functional circuit blocks according to the fourth preferred embodiment of the present invention adjusts the relationship between predecided test group and newly decided test groups every newly decided test group.
[0068] An operation of the method for testing the functional circuit blocks according to the fourth preferred embodiment of the present invention will be explained with reference to FIG. 13.
[0069] In step S 1301 , test time necessary for testing each functional circuit block and the number of pins of the system LSI necessary for testing each functional circuit block are calculated.
[0070] In step S 1302 , the functional circuit block of which test time is the longest test time among all functional circuit blocks, is selected.
[0071] In step S 1303 , it is determined whether or not there is the functional circuit block which can be tested in parallel with the functional circuit block selected in step S 1302 among the non-selected functional circuit blocks out of consideration for the number of pins of the system LSI. If there is, step S 1304 is executed, and the functional circuit block is selected. Steps S 1303 and S 1304 are repeated until there is no functional circuit block which can be tested in parallel with the functional circuit block selected in step S 1302 . If the decision in step S 1303 is no, step S 1305 is executed and the functional circuit blocks selected in steps S 1302 -S 1304 are set as one test group. Next, step S 1306 is executed.
[0072] In step S 1306 , it is determined whether or not there is the non-selected functional circuit block. If there is, step S 1307 is executed. If not, step S 1309 is executed.
[0073] In step S 1307 , it is determined whether or not there is a functional circuit block among the non-selected functional circuit blocks which is available for starting to test using the non-used pins of the system LSI at test process for a predecided test group. If there is, step S 1308 is executed. If not, step S 1302 is executed.
[0074] In step S 1308 , the functional circuit block is added to the predecided test group. Therefore, immediately after the test process for one functional circuit block in the predecided test group is finished, the test process for the added functional circuit block is started. Next, step S 1306 is executed.
[0075] Step S 1309 is equal to step S 108 . In step S 1309 , a test circuit is provided for each test group.
[0076] As the method for testing the functional circuit blocks according the first preferred embodiments of the present invention, a method for testing the functional circuit blocks according to a fourth preferred embodiment of the present invention starts to test a next test group without waiting for finishing all of test processes of previous test group. The method for testing the functional circuit blocks according to the fourth preferred embodiment of the present invention saves the time needed to wait for finishing all of test processes of previous test group. Therefore, the method for testing the functional circuit blocks according to the fourth preferred embodiment of the present invention reduces test time for the functional circuit blocks of the system LSI in comparison with the conventional method.
[0077] Furthermore, the method for testing the functional circuit blocks according to the fourth preferred embodiment of the present invention adjusts the relationship between predecided test group and newly decided test group for every newly decided test group.
[0078] While the preferred form of the present invention has been described, it is to be understood that modifications will be apparent to those skilled in the art without departing from the spirit of the invention.
[0079] The scope of the invention, therefore, is to be determined solely by the following claims. | A method for testing a plurality of functional circuit blocks of a system LSI, including dividing the plurality of functional circuit blocks into at least a first test group and a second test group, wherein the first test group is tested before the second test group and wherein testing of a functional circuit block in the second test group is started immediately after testing of a functional circuit block in the first test group is finished. | 6 |
BACKGROUND OF THE INVENTION
The present invention generally relates to a mobile winching system whereby a motorized winch and power source are mounted to a metal plate that is secured inside a carrying bag or other similarly bag-shaped enclosure. This mobile winch in a bag system provides a way to easily transport and operate a winch in areas that are otherwise inaccessible by traditional vehicle-mounted winches and situations where carrying multiple separate components would be inconvenient.
A winch is a mechanical device commonly used for lifting or pulling loads by means of a rope or cable that is wound around a cylinder turned by an engine, a motor, or by hand. A winch is typically comprised of a bi-directional motor, which drives a cable drum around which a cable is wrapped. One end of the cable is secured to the drum while the free end of the cable includes a hook or other hook-like device. A typical winch has a cable made of wound metal strands, rope, chain, or other similar material having high tensile strength wound around the drum. Thus when the motor turns in one direction, the cable can be fed outwardly, and conversely, while the motor turns in the opposite direction, the cable is pulled inwardly, creating a pulling force on the cable and the hook.
A winch may be used in situations where a pulling force on an item is required and the winch is relatively fixed with respect to another object. Typically, a winch can be attached to a vehicle such as all terrain vehicle (ATV), snowmobile, four-wheel drive vehicle and the like. The winch can be used in a variety of ways to provide assistance to the vehicle driver. For example, one end of the cable may be attached to a stationary object and the winch used to help move or extricate the vehicle from a stuck position. Additionally, one end of the cable may be attached to an object in order to hoist or haul it, or to remove an obstacle from the road in order for the vehicle to pass. Additionally, a winch may be used in tree rigging and removal whereby the winch is attached to a tree to facilitate pulling the tree in the desired direction in which to fall.
While the vehicle mounted winch has multiple attributes, the shortcoming is that the winch is permanently coupled to the vehicle, and the winch can only be used in conjunction with the vehicle, or where the vehicle may maneuver. Moreover, as the winches are hardwired and powered by the vehicle's battery, extended use of the winch can reduce vehicle battery voltage to below starting requirements and may strand the operator without sufficient battery power.
While a person could transport a winch and power source separately to a location where a wench is necessary but inconvenient to take a vehicle mounted winch, the shortcoming is that transporting, assembling, using, and disassembling such a system is an inconvenience. Moreover, even if all of these components were transported together in an enclosure, they would require removal and setup before use.
Therefore, it would be desirable to provide a convenient, portable system and method of operating a winch in areas inaccessible by current vehicle-mounted winches that reduces the inconvenience of separate transport or setup of the components. Additionally, having an independent power source operating the winch avoids the problem of draining a vehicle battery. Further, it would be desirable to provide a small winch system that may be easily moved and handled by a single person, and which would be particularly useful for logging operations and other types of jobs that are necessarily located in remote places that provide challenges for positioning a vehicle with a mounted winch.
SUMMARY OF THE INVENTION
In accordance with one aspect of the invention, a mobile winch system in a bag shaped enclosure is provided. The winch system, in a preferred embodiment, generally comprises a metal plate; an anchor component affixed to the plate which is used to anchor the system in a fixed position; a battery power source mounted on or affixed to the plate; a switch and/or controller optionally mounted to the plate; and a motorized winch operatively coupled to the battery, switch, and/or controller and mounted on the plate, the winch comprising a motor or engine; a drum or winding mechanism; and a cable, rope, or the like, all positioned within an encloseable bag.
The metal plate is preferably rectangular in shape, fits inside the bag, and has attachment points for an anchor component, which protrude outside of the bag. The attachment points, in one embodiment, may take the form of a pair of protrusions, integrally formed with the metal plate, that extend outwardly through slits in the bag. The protrusions may define a hole therein, which may be used to attach a strap, cable, or the like, in order to secure the apparatus to a fixed object (such as a tree or stump, for instance). In a preferred embodiment, the metal plate is attached to the bag so that it serves as the floor of the bag for easy transport of the winch system. The winch and controller are preferably bolted to the metal plate to prevent movement and the battery is removably attached to the metal plate to allow for the interchangeability of batteries. An anchor component, such as a strap, and a switch may also be transported and stored within the bag. The bag may also define pockets for a switch, anchor strap, or other desired objects or accessories. The bag may also have handles to allow the winch system to be comfortably carried and a zipper or other means for closing the bag in order to enclose and protect the winch system. The winch system may be used independently of any additional vehicle or motorized transportation means, by a single person. The winch comprises a spool or drum around which a cable may be wrapped; a winding mechanism to wind the cable inward or feed the cable outward; and a motor that is coupled to and powered by battery. The free end of the cable may include a hook or similar attachment device for securing the cable to the item that is to be winched. Numerous winches are commercially available, and it should be understood that any suitable winch may be used as preferred by the user.
The mobile winch in a bag system further comprises a means for anchoring the system in a fixed position. This means preferably includes an anchor component such as a cable, strap, rope, or the like that may be removably affixed to the aforementioned protrusions extending from the metal plate in a location best suited for the winching operation; preferably such that the anchoring means provides a securing force that is opposite the pulling direction of the winch. This anchor component may be wrapped around or secured to a fixed object and secured to the present apparatus to stabilize the winch and maximize pulling force. In one embodiment, a heavy duty nylon strap may be removably attached to the metal plate, and may further wrap around or attach to a fixed object, like a large rock, stump or tree, in order to secure the winch system in place for a winching operation. This anchor component may be removably affixed to the metal plate with a clevis fastener, U-bolt(s), or any other suitable device.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:
FIG. 1 is a top view of one embodiment of the mobile winch system in accordance with one aspect of the present invention;
FIG. 2 is a front view of one embodiment of the mobile winch system in accordance with one aspect of the present invention;
FIG. 3 is an back view of one embodiment of the mobile winch system in accordance with one aspect of the present invention; and
FIG. 4 is a cross sectional view at line 4 - 4 of the embodiment of the mobile winch system of FIG. 1 .
FIG. 5 is perspective view showing one embodiment of the mobile winch system in use during a winching operation, in accordance with one aspect of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates one embodiment of a mobile winch in a bag system 10 generally comprising an anchor component 18 for anchoring the system 10 in a fixed position and a bag 12 enclosing the components of the winch system 14 , preferably comprising a metal plate 16 attached to the floor of the bag 12 , a battery 22 mounted on or affixed to the metal plate 16 , a motorized winch 28 mounted on the metal plate 16 , and a controller 24 mounted on the metal plate 16 .
FIG. 1 shows a generally rectangular shaped metal plate 16 inside a bag 12 , the metal plate 16 acting as a base for the winch 28 , a controller 24 , and a battery 22 . The metal plate 16 may also define attachment points 20 that protrude through slits or openings in the bag, and extend outside the bag 12 . These attachment points 20 may allow connection of the anchor component 18 to the apparatus. A single person can easily move the mobile winch in a bag system 10 to any physical location required by simply transporting the bag 12 . To aid in transport of the bag 12 , the bag 12 may have handles, wheels, straps, or other useful items. The bag may also have zippers, buttons, or other features to aid in enclosing and securing the winch system 14 within.
In a preferred embodiment, the battery 22 , controller 24 , and winch 28 may be mounted to the metal plate 16 inside the bag 12 . In a preferred arrangement, the winch 28 may be operatively connected to the battery 22 , a controller 24 , and mounted to the metal plate 16 . The winch 28 may be comprised of a motor 30 , winch drum 32 , and winch cable 34 . The winch drum 32 may be facing in an opposite direction from the attachment points 20 on the metal plate 16 such that the free end of the winch cable 34 may be pulled or extended in an outward direction relatively straight away from the winch 28 and attachment points 20 . The drum 32 may have a release mechanism, so that a user can simply release the drum 32 from the gears for unspooling the cable 34 therefrom. In that case, the drum 32 must be re-engaged with the gears (taken out of “neutral”) after the cable 34 has been spooled out as desired, and before commencing a winching operation.
Additionally, the bag 12 may feature an opening on the side closest to the winch drum 32 so that the winch cable 34 can be pulled through the side of the bag 12 . The cable slit in the side of the bag 12 allows the winch 28 to be utilized without removal of the winch 28 or the metal plate 16 it is mounted on from the bag 12 . The winch 28 , controller 24 , and battery 22 may be mounted or affixed to the metal plate 16 with bolts or the like. In a preferred embodiment, the battery 22 may be removably mounted to the metal plate 16 to allow the battery 22 to be replaced as necessary. Alternatively, a battery mount may be affixed to the metal plate, and the battery may be removably secured to the battery mount.
As shown in FIG. 1 , the winch 28 may include an electric motor 30 , a drum/axle 32 coupled to and driven by the motor 30 , and a winch cable 34 wound around the drum/axle 32 . The motor 30 is electrically coupled to the battery 22 . The motor 30 drives the drum/axle 32 in either direction, as desired by the user. The winch cable 34 is wound about the drum/axle 32 such that rotation of the drum/axle 32 either retracts or extends the winch cable 32 thereon, as necessary. The free end of winch cable 34 may preferably include a hook attached thereto for attaching to an object to be winched in any suitable manner. When not in use, the free end of winch cable 34 may be pulled inside of the bag 12 to prevent uncontrolled movement of the cable 34 . Additionally, as in FIG. 2 , a fairlead 36 may be attached to the bag 12 or to the metal plate 16 , over the opening in the side of the bag 12 from which the winch cable 34 exits, in order to preserve the life of the winch cable 34 by reducing the friction of winching operations, particularly between the opening in the side of the bag 12 and the winch cable 34 . As in FIG. 1 , the winch 28 may be operated by a controller 24 . The controller 24 may be operatively connected to a switch 26 . The switch 26 may be physically attached to the controller 24 , as by a cable, or may be remotely attached. The winch 28 may be any suitable winch, many of which are commercially available, such as the Badland Winches 2500 LB Capacity ATV/UTV Winch or the Rugged Ridge Extreme HD ATV/UTV Winch, for example.
As in FIGS. 3-5 , the metal plate 16 may also preferably include attachment points 20 that protrude through the bag 12 and allow attachment of an anchor component 18 for anchoring the system 10 in a fixed position. In a preferred embodiment, as shown in FIGS. 1-5 , the anchor component 18 may be a tree trunk protector strap made of tough, high quality nylon, removably affixed to each lateral edge of the metal plate 16 at the attachment points 20 through the use of a clevis fastener and cotter pin. The attachment points 20 may be heavy duty metal rings welded to the metal plate 16 or may be holes defined by metal strips extending from the metal plate 16 either welded, bolted in place, integrally formed with the metal plate 16 , or affixed in any suitable manner, wherein the clevis fastener 16 may be removably attached to the metal ring 18 or holes defined by the metal strips. As shown in FIGS. 3 and 5 , this arrangement provides that one end of the attachment component 18 may be released from the attachment points 20 allowing the attachment component 18 to be wrapped around a fixed object and re-attached to the attachment points 20 . It should be understood that other suitable removable attachment components may be utilized for anchoring the system 10 in a fixed position, as desired. Additionally, the anchor component 18 may be stored and transported within the bag 12 when not in use.
FIG. 5 illustrates the mobile winch in a bag system 10 as it may be used during operation. The system 10 may be manually transported by carrying of the bag 12 to a desired location. An important aspect of this invention is the ability to transport the winch system 10 over terrain and to locations inaccessible by current vehicle-mounted winches. During a winching operation, the anchor component 18 (strap) may be secured to a fixed object, such as a tree or stump, and the winch cable 34 may be extended outwardly and attached to the target object to be winched, as shown in FIG. 5 . During the winching operation, it is noted that the system 10 may be raised from the ground as the winch cable 34 tightens. This placement depends upon the position and orientation of the end of the winch cable 34 and the anchor component 18 .
It is contemplated that the winch cable 34 may also be directed upwardly, toward the top of a tree that is being cut, for instance, and then the force exerted by the winch 28 is at a downward angle toward the winch 28 . In most cases, it will be necessary to use the anchor component 18 to prevent the winch 28 from moving, because otherwise, the winching operation is likely to simply move the winch system 10 toward the target object, rather than moving the target object toward the winch system 10 .
Although the present invention has been described in considerable detail with reference to certain preferred versions thereof, other versions are possible. Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred versions contained herein. All features disclosed in this specification may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features. | A mobile winching system is provided, whereby a motorized winch, battery, and controller are mounted on a metal plate that is attached to and may be enclosed within a bag, wherein the metal plate has attachment points for coupling an anchor component to fix the winch system in position during a winching operation. The mobile winch in a bag system provides a way to transport and operate a winch in areas that are otherwise inaccessible by traditional vehicle mounted winches without the necessity of separately transporting the components of the system and with reduced setup of the components for use. | 1 |
BACKGROUND OF THE INVENTION
In shuttleless looms, that is, those looms in which weft yarn is supplied from a stationary source location outside the lateral limits of the warp yarns, it is customary to insert each pick of weft by means of a reciprocating inserter or inserters. In the most common shuttleless loom operation a supply of weft is located adjacent the right hand side of the loom and each pick of weft is drawn from the source and inserted into the shed formed between the warp yarns. The insertion itself is effected by means of an inserter carrier which is moved into and from the shed by means of a reciprocating inserter. In this usual form the inserter carrier is met at approximately the center of the warp shed by an extending carrier which grasps the weft being inserted and draws it to the other side of the loom. The extending carrier is moved into and out of the shed by means of a reciprocating inserter in the same manner in which the inserter carrier is moved.
There are two basic weft insertion methods that are used in connection with looms of the type mentioned above. These weft insertion methods are the Gabler and Dewas methods and are frequently referred to as the "hair pin" and "gripper" methods respectively. In the Gabler insertion method a weft yarn end is held clamped outside of the selvedge after cutting and the inserting carrier then pulls a quantity of yarn from the yarn package so that a loop of yarn is initially formed in the warp shed. After a predetermined length of time, the clamped end is releasaed so that the extending carrier can continue to draw the looped yarn to the other side of the loom. By way of contrast the Dewas system utilizes inserting and extending carriers in which the end of the yarn is gripped by the inserting carrier and then this same gripped end is transferred to the extending carrier and drawn on to the other side of the warp.
In the gripper system for inserting weft yarns it is often necessary, or desirable, to be able to insert yarns of different qualities and thicknesses, as it is in the hair pin system. However in the gripper method it is extremely vital that the clamping elements be brought into very accurate, aligned contact so that yarn ends are not lost during a pick and thus result in interruption of loom operation. For example if a loom is working with both a coarse and a fine yarn, that is with yarns of grossly different diameters, it is obvious that a gripper inserter must be able to accommodate and positively grip the yarn of lesser diameter as well as the yarn of larger diameter. Thus it is necessary to result to complex, time consuming and, therefore, expensive machining or other costly manufacturing methods for insuring that extremely close tolerances are obtained between the clamping elements.
SUMMARY AND OBJECTS OF THE INVENTION
It is a present object of this invention to provide an improved gripper inserter element which can accommodate, conveniently, yarns of different characteristics and sizes.
Another object of this invention is to provide an improved gripper inserter element in which one of the yarn gripping elements can have its axis of rotation spatially adjusted to insure evenness of contact between the inserter gripper surfaces.
An additional object of this invention is to provide an improved yarn gripping inserter which provides a novel means for adjusting the gripping tension.
A further object of this invention is to provide an improved gripper inserter apparatus in which the tensioning means for varying gripping tension has greater life and flexibility of operation.
Other objects and advantages of this invention will be in part explained by reference to the accompanying specification and drawings in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded perspective view of an improved gripper weft inserter according to this invention;
FIG. 2 is a side elevation of an improved gripper looking toward the front wall thereof;
FIG. 3 is a top elevation of the improved gripper showing the positioning of a gripped yarn.
FIG. 4 is a side elevational similar to FIG. 2 with the carrier moved into the position where the gripping surfaces are opened;
FIG. 5 is a somewhat enlarged fragmentary side elevation showing the gripper adjusting cam in the position that causes alignment between gripping surfaces;
FIG. 6 is a view similar to FIG. 5 showing the cam in a position causing disalignment between gripping surfaces; and
FIG. 7 is an enlarged perspective view of the gripper cam.
DESCRIPTION OF THE PREFERRED EMBODIMENT
As was previously mentioned it is extremely important in the gripper type of shuttleless loom that the gripping surfaces by accurately aligned so that yarns of various sizes can be gripped positively to avoid shutdown of the loom. Heretofore, to achieve accuracy of the type that is delivered by the apparatus of this invention it would have been necessary to result to time consuming and expensive machining operations. In order to better understand the construction and method of operation by which the shortcomings of the prior art are obviated, reference is made to the drawings, and specifically to FIG. 1. In this Figure numeral 10 indicates the general carrier assembly which is attached to the leading end of a reciprocating inserter 11. In this case reciprocating inserter 11 is shown as a flat flexible tape which can be wound and unwound about a tape wheel located outside of the warp shed, all in a well known manner. Other type of reciprocating inserters may also be used since the particular reciprocating inserter used is not relevent the present invention.
The improved gripper carrier 10 is comprised of a main body portion 12, which in turn includes a shank portion 12 that can be attached to the forward end of tape 11 by any suitable means, such as silver soldering, braising, etc. Main body portion 12 also includes a back wall 14 which extends outwardly from shank portion 13, at substantially right angles with respect to the upper surface of the shank portion 13. It can also be seen that back wall 14 includes means which define a yarn guide 15 that is in the form of a rearwardly sloped slot. Specifically the upper wall 16 and lower wall 17 define the limits of the yarn guide 15. This particular type of guide is normally used when it is desired to operate a loom when using yarn from a plurality of sources, as opposed to a single source. These type of yarn guides are also well known in the prior art.
A further part of main body portion 12 is an upper wall 20 that begins at the uppermost limit of back wall 14 and extends forwardly in a substantially horizontal plane from the back wall 14. This upper wall 20 is also located outwardly from the shank portion 13 and is substantially parallel with the upper surface of the shank portion. Upper wall 20 terminates in a front wall 25 that extends downwardly from the forwardmost limit of upper wall 20.
From wall 25 extends downwardly from upper wall 20 a distance less that the height of back wall 14, as best seen in FIGS. 2 and 4 of the drawings. The lower terminus of front wall 25 defines a yarn gripping surface 26. That is, the bottom surface 26 defines a surface which combines with a gripper element, to be subsequently described, to engage the yarn and hold it firmly during the inserting operation.
As clearly shown in FIG. 1 of the drawings there is provided a yarn guide finger 30 that is secured at one end to the shank portion 13. Yarn guide finger 30 is attached to shank portion 13 by means of the Allen Reed screws 31 that extend through holes 32 in the yarn guide finger and on into the interiorly threaded openings 33 in the side of shank portion 13. The yarn guide finger 30 also includes a generally rectangularly shaped opening 34 in the upper surface of that portion which extends outwardly from shank portion 13 in the same direction as front wall 20. When assembled into position, the finger 30, and consequently the opening 34, are located in underlying relationship with respect to the gripping surface 26 of front wall 25.
An element essential to the yarn gripping functioning of the present improved carrier is identified in the figures by the numeral 35. This element 35 is the yarn gripper finger which has a gripper surface 36 that is adapted to cooperate with the lower yarn gripping surface 26 of front wall 25. It is these two surfaces that must be placed in accurate cooperating relationship throughout the lengths thereof if the carrier is to be capable of operating simultaneously with different varieties and sizes of yarns.
To achieve the necessary relationship between gripping surfaces 26 and 36, the gripper finger 35 is assembled onto the front wall 25 and provision is made for the finger 35 to pivot about an effective pivot axis which can be adjusted to be located in various spatial locations. As shown in the drawings this mounting means comprises a pivot shaft 40 that is inserted into a hole 41 in front wall 20 of main carrier body 12 and also through a larger opening 42 which extends through gripper finger 35. The location of the gripper finger 35 with respect to the front wall 25 is such that the openings 41 and 42 are in communication to permit pivot shaft 40 to extend through each of the openings. An additional element included as part of this overall mounting means is a cam 45 which is made up of a main body 46 and an outwardly extending finger 47. The main body 46 of cam 45 includes a shoulder 48 (FIG. 7) that is so proportioned as to be rotatably received into the opening 42 of the gripper finger 35. It also includes means defining an opening 49 that is located on an axis generally parallel to the axis of rotation of cam 45, but which is not concentric therewith. The final element of the assembly mechanism is a fastening member 50, which is here shown as a nut that is assembled on the threaded outer end of a pivot shaft 40.
In order that the gripper finger 35 will be biased in a direction that causes gripper surface 36 to be urged against gripper surface 26, there is provided adjacent that end of the gripper finger 35 nearest to shank portion 13 a biasing means that is operatively connected to the gripper finger. The biasing means has been indicated generally by the numeral 55 and comprises a biasing element which is here shown as a coil spring 56, the coil spring having one end secured to the back wall 14 by inserting it into the opening 58. The other end, 59, of spring 56 is secured to the gripper finger 35 by inserting it into the opening 60.
The pressure that is present to urge the gripping surface 36 of gripper finger 35 toward the yarn gripping surface 26 of front wall 25 can be varied by means of an arrangement whereby tension in the coil spring 56 can be altered. Referring to the drawings there is provided a clamp 65 which has a rounded or generally arcuately shaped portion that receives a portion of the body of spring 56. Clamp 65 is held in position on the shank portion 13 of main body 12 by means of a bolt 66 that extends upwardly through an opening 67 in the shank portion 13. The upper end of bolt 66 extends through the slotted opening 68 in clamp 65 so that the nut 70 can be threaded thereon. Thus after spring 56 is secured to the back wall 14 and to the gripper finger 35 the clamp 65 is drawn down to exert more or less pressure against the coiled body portion of the spring, as desired. This pressure exerted against the body varies the tension exerted against it and thus, in turn results in a change in the amount of pressure that finger 35 can exert against the gripping surface of front wall 25.
To explain the general functioning or operation of the present invention, a gripper carrier is assembled in accordance with the preceeding discussion. The tension exerted against spring 56 can be roughly approximated from knowledge of the type of weft yarn that is to be inserted into the warp shed. Obviously this tension can be adjusted to be either greater or smaller circumstances require. The operator then determines whether or not there is continuous, unbroken contact between the surface 36 and 26 (as for example shown in FIG. 5) or whether there exists a gap, as indicated by the numeral 75 in FIG. 6. If these surfaces are not completely mating then the operator loosens the fastener 50 on pivot shaft 40 and rotates the cam 45 in the direction necessary to bring surfaces 26 and 36 into the mating engagement illustrated in FIG. 5. Since the axis of pivot shaft 40 is parallel to the axis of rotation of cam 45, but is not concentric therewith, rotation of the cam will cause a spatial relocation of the axis of rotation of the gripper finger 35. It is this change of location of the pivot axis of gripper finger 35 that makes possible the relative alignment between gripping surfaces 26 and 36. After alignment of the gripping surface has been accomplished the carrier is ready for use.
Although the present invention has been described in connection with preferred embodiments, it is to be understood that modifications and variations may be resorted to without departing from the spirit and scope of the invention as those skilled in the art will readily understand. Such modifications and variations are considered to be within the purview and scope of the invention and the appended claims. | An improved carrier for use on a shuttleless loom of the type in which yarn is inserted into the warp shed from a stationary source located outside of the warp and in which a free end of the previously cut warp is gripped by the inserter carrier between biased gripper finger and a yarn guide finger to carry the end to approximately the mid point between the two sides of the loom, in which the improved inserter carrier has a yarn gripping element whose axis of rotation can be spatially varied to assure accurate and uniform contact between the gripping surfaces of the pivotable gripper element and the yarn guide element. | 3 |
CROSS REFERENCE TO RELATED APPLICATIONS
This is a non-provisional application of application No. 60/141,628 filed Jun. 30, 1999.
FIELD OF THE INVENTION
This invention relates to the field of video projection display and in particular to the use of a photo transistor for measurement of projected illumination.
BACKGROUND OF THE INVENTION
In a projection video display, geometrical raster distortions result from the physical placement of the cathode ray display tubes. Such raster distortions are exacerbated by the use of cathode ray tubes with curved, concave display surfaces and the inherent magnification in the optical projection path. The projected image is composed of three scanning rasters which are required to be in register one with the other on a viewing screen. The precise overlay of the three projected images requires the adjustment of multiple waveforms to compensate for geometrical distortion and facilitate the superimposition of the three projected images. However, manual alignment of multiple waveforms is labor intensive during manufacturing, and without the use of sophisticated test equipment may preclude setup at a user location. Thus an automated convergence system is disclosed which simplifies manufacturing alignment and facilitates user location adjustment. An automated alignment system may employ raster edge measurement at peripheral display screen locations in order to determine raster size and convergence. Such raster edge measurement may be facilitated with a plurality of photo transistors.
SUMMARY OF THE INVENTION
A projection television display apparatus with an automated alignment system may advantageously employ raster edge measurement at peripheral display screen locations with a plurality of photo transistors. A method for determining raster positioning in a video projection display apparatus comprises the steps of detecting illumination by a first edge of a measurement image moving in a first direction. Detecting illumination by a second edge of the measurement image moving in a second direction, and averaging movement values related to the first and second edge illuminations of the detecting steps.
In a parallel sensor arrangement differences in image edge determination are advantageously precluded by sensing and detecting marker image edges with a marker that reverses sensing direction. In simple terms, motion direction of the marker block image is reversed relative to the sensor, which consequently reverses the leading and trailing marker image edges. Thus dissimilar edge determination is precluded. In more general terms, edge dissimilarities are obviated and accurate image edge sensing is obtained when image edges cause the sensor to transition from an unlit to lit condition.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a simplified front view of a projection video display.
FIG. 2 is a simplified block diagram of a video image projection display apparatus including inventive features.
FIG. 3A depicts in detail, part of screen 700 of FIG. 1, and illustrates an inventive sensing sequence.
FIG. 3B depicts in greater detail, movement of marker M relative to photo transistor sensor S 1 .
FIG. 4A is a simplified schematic drawing of a photo transistor sensor S 1 .
FIG. 4B illustrates the voltage waveform at the collector of photo transistor S 1 .
DETAILED DESCRIPTION
FIG. 1 illustrates a front view of a video projection display apparatus. The projection display comprises a plurality of cathode ray tubes with raster scanned images which are projected on to screen 700 . A cabinet supports and surrounds screen 700 and provides a picture display area 800 which is slightly smaller than the screen. Screen 700 is depicted with a broken line to indicate an edge area which is concealed within cabinet C and which may be illuminated with raster scanned images when operated in an overscan mode as indicated by area OS. Photo transistor sensors are located adjacent to the periphery of screen 700 within the concealed edge area and outside viewed area 800 . Eight photo transistor sensors, depicted as shaded circles, are shown in FIG. 1, positioned at the corners and at the centers of the screen edges. Thus with these sensor positions it is possible to detect and measure an image formed by an electronically generated test pattern, for example a non-peak video value block M. By sensing illumination of sensor S by block M determination of picture width and height and certain geometric errors, for example, rotation, bow, trapezium, pincushion etc. is achieved. Hence the displayed images are aligned to be superimposed one with the other over the whole of the screen area. Measurements are performed in both horizontal and vertical directions in each of the three projected color images thus yielding at least forty eight measured values.
Operation of the measurement and alignment system will be explained with reference to FIG. 2 which depicts in block diagram form, part of a raster scanned video projection display. In FIG. 2 three cathode ray tubes, R, G and B form raster scanned monochromatic color images which are directed through individual lens systems to converge and form a single display image 800 on screen 700 . Each cathode ray tube is depicted with four coil sets which provide horizontal and vertical deflection and horizontal and vertical convergence. The horizontal deflection coil sets are driven by a horizontal deflection amplifier 600 and vertical deflection coil sets are driven by a vertical deflection amplifier 650 . Both horizontal and vertical deflection amplifiers are driven with deflection waveform signals that are controlled in amplitude and waveshape via data bus 951 and synchronized with the signal source selected for display. Exemplary green channel horizontal and vertical convergence coils 615 and 665 respectively, are driven by amplifiers 610 and 660 respectively, which are supplied with convergence correction waveform signals. The correction waveform signals GHC and GVC may be considered representative of DC and AC convergence signals, for example static and dynamic convergence respectively. However, these functional attributes may be facilitated as follows. An apparent static convergence or centering effect, for example, can be acheived by modifying all measurement location addresses by the same value or offset to move the complete raster. Similarly, a dynamic convergence effect may be produced by modification of the location address of a specific measurement location. Correction waveform signals GHC and GVC for the green channel are generated by exemplary digital to analog converters 311 and 312 which convert digital values read from memory 550 into deflection currents ihc and ivc respectively. Similarly, red and blue correction waveform signals are generated by digital to analog conversion of digital values read from memory 550 .
An input display signal selector selects, by means of bus 951 , between two signal sources IP 1 and IP 2 , for example a broadcast video signal and an SVGA computer generated display signal. Video display signals RGB, are derived from the display video selector and electronically generated message information, for example; user control information, display setup and alignment signals and messages generated responsive to commands from controllers 301 , 900 and 950 , are coupled via buses 302 and 951 , and may be combined by on screen display generator 500 . During automated sensitivity calibration or convergence alignment, controller 900 sends commands via a data bus 302 to controller 301 which instructs video generator 310 to generate an exemplary green channel calibration video test signal AV comprising an exemplary black level signal with a rectangular block M having a predetermined video amplitude value. Controllers 900 and 301 also control the generation of block M to illuminate exemplary sensor S 1 by determining horizontal and vertical timing to position block M within the scanned display raster. Alternatively, controllers 900 and 301 can move the scanned raster, or a part of the scanned raster containing the marker block M to achieve sensor lighting. Advantageously, both methods of marker motion control are employed to facilitate precision adjustment of the marker image relative to the sensor.
A green channel test signal AV is output from IC 300 and combined at amplifier 510 with the green channel output signal from on screen display generator 500 . Thus, the output signal from amplifier 510 is coupled to exemplary green cathode ray tube GCRT, and may include display source video and or an OSD generated signal, for example a set up message, and or an IC 300 generated calibration video test signals AV.
Controller 301 also executes a program stored in program memory 308 which comprises various algorithms. To facilitate an initial setup adjustment, controller 301 outputs a digital word D on data bus 303 , which is coupled to a controllable current source 250 . The digital word D represents a specific current to be generated by current source 250 and supplied to sensors S 1 - 8 and sensor detector 275 .
To facilitate adjustment and alignment of the three color images, setup block M is generated as described previously and coupled to exemplary green CRT. In FIG. 1 an image of test pattern, block M is shown approaching photo transistor S 1 . As previously mentioned, each sensor may be illuminated by the marker block having a precise generated timing within a video signal projected with an overscanned raster. Alternatively the marker block may cause illumination by positioning, or shifting the scanned raster such that marker block M lights sensor S 1 , or with a combination of both. With certain display signal inputs, for example computer display format signals, substantially all of the scanned area can be utilized for signal display thus the raster is not overscanned. During operation with computer display format signals, raster overscan is limited to a nominal few percent, for example 1%. Hence under these substantially zero overscan conditions exemplary sensor S 1 may be illuminated by raster positioning of block M. Clearly, individual sensor illumination may be facilitated with a combination of both video signal timing and raster positioning.
In each photo transistor, photon generated carriers enable transistor conduction in a substantially linear relationship to the intensity of the illumination incident thereon. However, the intensity of illumination at each individual sensor may vary greatly for a number of reasons, for example, the phosphor brightness of each individual CRT may be different, and there may be lens and optical path differences between the three monochromatic color images. As each CRT ages the phosphor brightness declines, furthermore with the passage of time, dust may accumulate within the optical projection path to reduce the intensity of illumination at the sensor. A further source of sensor current variability results from variations in sensitivity between individual sensors and their inherent spectral sensitivity. For example, in a silicon sensor, sensitivity is low for blue light and increases through the green and red spectrum to reach a maximum in the near infra red region. Thus, it may be appreciated that each individual sensor may conduct widely differing photo generated currents. Hence, to facilitate stable, repeatable measurements, it is essential that these sensor current variations are individually measured and a detection threshold set for each sensor and illuminating color. Thus, having determined the peak sensor current, which is directly proportional to the intensity of illumination, individual sensor detection threshold values may be stored to permit the subsequent detection of a lit or unlit sensor to occur at a consistent amplitude point of each sensor current.
With reference to FIG. 2, video generator 310 is instructed by control logic 301 to generate an exemplary green video block M having an initial non-peak video value and positioned on a substantially black or black level background. Similar video blocks with non-peak video values may be generated in each color channel, which when generated simultaneously and superimposed at the screen produce a white image block on a substantially black background. Thus, an exemplary green block M is generated by video generator 310 and coupled via amplifier 510 to the green CRT. The video generator 310 is controlled by the micro controller 301 to generate the green block M at a horizontal and vertical screen position such that a specific sensor, for example, sensor S 1 , is illuminated by green light from the image of block M. Illumination of the sensor results in photo generated charge PC, depicted in FIG. 4A, which results in photo transistor conduction of current Isen, shown in FIG. 2 .
The widely differing photo generated sensor currents described previously are advantageously compensated, calibrated and measured by means of control loop 100 depicted in FIG. 2 . Sensor detector 275 is depicted in circuit block 200 of FIG. 2 . In simple terms, a reference current Iref is generated by a digitally controlled current source 250 . The reference current is supplied to both exemplary photo transistor S 1 and sensor detector 275 . In the absence of illumination, photo transistor S 1 , represents a high impedance and consequently diverts an insignificant current, Isen, from reference current Iref. Thus the majority of reference current Iref, is coupled to sensor detector 275 as current Isw. Current Isw biases detector 275 such that the output state is low, which is chosen to represent an unlit or un-illuminated sensor. When photo transistor S 1 is illuminated, photo generated charge PC causes the transistor to turn on and conduct current Isen from reference current Iref. Since the reference current is generated by a constant current source 250 , sensor current Isen is diverted from sensor detector 275 current Isw. At a particular illumination level, photo transistor S 1 diverts sufficient current from sensor detector 275 to cause it to switch off and assume a high, nominally supply voltage potential, which is chosen to be indicative of a lit or illuminated sensor. The output from sensor detector 275 is positive going pulse signal 202 which is a coupled to an input of digital convergence IC STV2050. The rising edge of pulse signal 202 is sampled which causes horizontal and vertical counters to stop thus providing counts which determine where in the measurement matrix the lit sensor occurred.
The photo transistor current is measured by controllably increasing reference current Iref until sensor detector 275 switches to indicate loss of sensor illumination. The value of reference current that caused detector 275 to indicate loss of sensor illumination is representative of the level of illumination incident on the sensor. Thus this current may be processed and stored as a sensor and color specific threshold value. The stored reference current value differs between sensors and from color to color, but detector switching is equalized to occur for illumination values reduced by approximately half of the measured Isen switching value.
FIG. 3A depicts part of the display screen 700 of FIG. 1, in the vicinity of exemplary photo transistor sensor S 1 . The screen is illuminated with a projected measurement image formed by a signal which is largely black level with a monochrome measurement signal block M which has a significant video signal amplitude. Thus screen 700 is substantially black with a bright monochrome block M of duration W. The raster generating the projected image has a size such that exemplary photo transistor sensor S 1 is within the projected image area.
In FIG. 3A the image of measurement block M is shown in various exemplary horizontal positions. A similar sequence of vertical positions can be employed for edge measurement in the vertical scan direction. Various block positions are illustrated representing different time periods, for example periods t 0 -t 7 . Although the exemplary horizontal block positions are depicted during a sequence of time periods, the actual block position, or image on the screen, is determined by controlled current steps applied to exemplary coils GHC or GVC of FIG. 2 . The exemplary horizontal movement sequence is shown with reference to the fixed position of sensor S 1 and is depicted at various time periods by repetition in the vertical drawing direction.
At time period t 0 , the image of measurement block M is located on the display screen such that sensor S 1 is not illuminated by the bright monochrome image of block M. Thus, at time t 0 , photo transistor S 1 is not illuminated, hence no photon generated base current is produced and photo transistor S 1 is off. FIG. 4B shows the voltage waveform at the collector of photo transistor sensor S 1 occurring at the various time periods. At time period t 0 , photo transistor S 1 is non-conductive and FIG. 4B shows the sensor collector waveform voltage to be substantially equal to the supply voltage Vcc.
At time period t 1 the image of block M is moved in a direction which causes the leading edge LE of the of image block M to illuminate sensor S 1 . The illuminating photons generate base current in the photo transistor S 1 which causes the photo transistor S 1 to become conductive. Some short time after period t 1 , the illumination has generated sufficient base charge to cause the photo transistor to be saturated. The saturated state is depicted in FIG. 4B at period t 2 , where the collector has a nominally voltage of zero volts or Vcesat.
The collector signal voltage Vout, from photo transistor S 1 is coupled to a detector 275 which determines the presence or absence of marker block illumination. Both the leading or trailing edge position of the displayed image block are depicted relative to the fixed photo transistor S 1 . However, as shown in FIG. 4B, the collector voltage waveform Vout may, for a number of differing reasons, not accurately portray the duration and or intensity of the illuminating marker block image. During period t 2 of FIG. 4B, the collector voltage occurring due to the leading edge of block M is depicted with a sloping, rounded falling edge to illustrate that establishing the saturated sensor state depends upon the intensity of the incident illumination. At time t 3 and beyond, illumination of transistor S 1 ceases because the image of block M has moved beyond the sensor and photo charge generation terminates in the photo transistor base. However, during period t 3 -t 3 d of FIG. 4B, the transistor collector potential remains low, indicating continued transistor conduction, for example, as a consequence of excess photo generated charge PC, or carriers remaining in the base region of the transistor. These photo generated carriers continue to sustain the conductive state of transistor S 1 , and only when dissipated will the transistor resume the off, or unlit condition. Thus it can be appreciated that the sustained sensor conduction following light termination at period t 3 -t 3 d will result in an erroneous measurement of block length Ws, if the leading and trailing edges of marker block are measured sequentially with unidirectional motion. The sensor response delay in returning to the unlit condition is obviated by an inventive sequence where the motion direction of measurement block M is reversed to permit the leading and trailing edges of block M to be measured by sensor S 1 only when transitioning from an unlit to a lit condition. Thus by ensuring that measurements are performed as the sensor is illuminated eliminates erroneous measurement due to turn off delay. FIG. 4B depicts the slow rise time of the collector voltage waveform occurring during unlit period t 3 .
In FIG. 3A at period t 3 , the forward and reverse block motion for leading and trailing edge detection is depicted by the curved arrows where SD LE indicates the search direction for leading edge detection and arrow SD TE indicates the reversed direction for measurement of the trailing image edge. As described previously, by reversing the search direction, the trailing edge becomes the leading edge thus precise block measurement is achieved by ensuring that the measurement is performed only when the sensor transitions between unlit and lit conditions.
In FIG. 4B at time t 5 , the reverse direction leading edge of image block M starts to illuminate photo transistor S 1 causing photo generated carriers PC to accumulate in the base region. These photo generated carriers turn on the photo transistor causing the collector potential to drop as depicted in period t 5 . At time t 7 the trailing edge of the reverse motion image ceases to light photo transistor S 1 , and as previously described the transistor begins to turnoff. At some time after period t 6 d the sensor finally ceases conduction and at time t 7 the image block is displaced from the sensor such that it is no longer lit.
The slow rise of the photo transistor collector voltage during turn off shown in FIG. 4B, may result from a number of different causes. For example, as described previously, excess photo generated charge in the photo transistor base region may sustain transistor conduction following the extinguishment of illumination. FIG. 4A, period t 0 , depicts a parallel configuration of photo transistors S 1 -Sn, in the absence of image block illumination with photo transistor base regions exaggerated and devoid of photo generated charge PC. At period t 2 of FIG. 4A, image block M, depicted as a broken arrow, generates charge PC, shown by shading in the exaggerated base region of photo transistor S 1 . At period t 3 d of FIG. 4A, the image of block M is absent and photo generated charging ceases. However, photo generated charge PC, depicted by the shaded base region, remains and will sustain transistor conduction until dissipated. Thus the trailing edge TE of marker M is stretched and an erroneous duration Ws may be measured.
Another cause of slow collector voltage rise time results from capacitance C shown in FIG. 4 A. The capacitance may result from a number of different sources, for example, the parallel connection of photo transistors S 1 -Sn results in the summation of both circuit and device parasitic capacitance. Furthermore any additional capacitance, for example, to reduce spurious signal pickup or provide low pass filtering of the photo transistor output signal will further slow the rate of collector voltage rise when transistor conduction ceases. In simple terms the photo transistor turn on may discharge capacitance C rapidly, but at transistor turnoff, charging current Ich is determined by the value of supply Vcc and resistor R.
A further source of poor trailing edge detection may result from CRT display phosphor persistence, decay time or after glow, following a lit to unlit image transition. Phosphor persistence is depicted in FIG. 3B by the graded shading following the trailing edge TE of the marker block image. To aid identification, the leading LE and trailing TE edges of the marker block image are depicted with horizontal shading. Phosphor persistence differs for different display colors, for example in a typical projection CRT, a blue phosphor may be described to have a short decay time, approximately in the order of 20 to 30 micro seconds. The green and red phosphor may be described as having a longer short decay time in the range of 1-2 mille seconds.
From the preceding descriptions of trailing edge image artifacts it can be deduced that determination of the cessation of marker illumination occurring at the trailing image edge may suffer distortion or delaying artifacts which erroneously increase detected block duration Ws. Such distortions are illustrated in FIG. 4B by the rising edges of exemplary collector voltage waveforms 10 , 20 and 30 . Collector voltage waveform 5 depicts an ideal, rapid rise of collector voltage. Clearly an inability to accurately sense marker block edges renders determination of the block duration, and thus marker center value invalid.
The consequence of slow sensor turn off and the slow rise in collector potential with light cessation may be advantageously precluded by sensing and detecting the marker trailing edge TE, with a reversed motion direction. In simple terms, the marker block motion is reversed relative to the sensor, thus the leading and trailing edges of the image block are also reversed. Hence, although the measurement of light cessation at the trailing edge remains ill-defined, by advantageously reversing the sensing direction, an accurate determination may be obtained for each edge of the marker block. Furthermore, inspection of FIGS. 3A and 4B indicates that accurate edge sensing is obtained when image edges cause the sensor to transition from an unlit to lit condition. Hence accurate edge measurements may be obtained at periods t 1 and t 5 of FIG. 3A, with the horizontal center of the marker image determined by calculation. For example the center of marker block can be determined from the average of the current values required to position the marker block at periods t 1 and t 5 , the averaged block center being represented by [ihc(t 1 )+ihc(t 5 )]/2. | A method for determining raster positioning in a video projection display apparatus comprises the steps of detecting illumination by a first edge of a measurement image moving in a first direction. Detecting illumination by a second edge of the measurement image moving in a second direction, and averaging movement values related to the first and second edge illuminations of the detecting steps. | 7 |
FIELD OF THE INVENTION
[0001] This invention relates to a method of thermal insulation of a pool, in particular to a method of thermal insulation of a swimming pool, and to a pool that is thermally insulated by such a method.
BACKGROUND TO THE INVENTION
[0002] Various methods of thermal insulation of pools are known.
[0003] In one of the known methods, hollow modular expanded polystyrene formers sold under the registered trade mark BECO are assembled into a pool wall and concrete is poured into the formers. Once the concrete has set, the formers are left in place to give a concrete pool wall the interior and exterior surfaces of which are provided with a layer of expanded polystyrene.
[0004] This method is not suitable for construction of a floor of a pool and can only be used for construction of the walls of new pools.
[0005] In another of the known methods, shown in International Patent Application Publication No. WO 01/44601, modular wall members comprising a pair of steel sheets enclosing a layer of polyurethane insulation are assembled into a pool wall inside a hole. The modular wall members are braced against the edges of the hole by brace rods so as to leave a gap between the edges of the hole and the exterior surface of the pool wall. The gap is then filled with a suitable backfill material such as pea shingle.
[0006] Again this method is not suitable for construction of a floor of a pool and can only be used for the construction of the walls of new pools.
[0007] In yet another of the known methods, a hole is excavated and a steel skeleton is erected against the walls of the hole. Insulation boards are attached to the steel skeleton to line the walls of the hole. Cement is then sprayed onto the insulation board and floor of the hole in layers to form a pool wall and floor.
[0008] This method is also not suitable for construction of a floor of a pool, because the weight of the pool would have to be supported on insulation board. It also can be used only for the construction of new pools.
[0009] In this specification, “pool” includes any container that will hold more than 200 litres of a liquid, for example a swimming pool, exercise pool, or a hot tub.
SUMMARY OF THE INVENTION
[0010] According to a first aspect of the invention there is provided a method of thermal insulation of a pool, the method comprising the steps of preparing a pool structure, and attaching a layer of thermal insulation material to an interior surface of the pool structure.
[0011] The step of preparing the pool structure may advantageously comprise building a new pool structure.
[0012] However, the step of preparing the pool structure may advantageously alternatively comprise preparing an existing pool structure, to enable the layer of thermal insulation material to be attached thereto.
[0013] The invention therefore provides a method that is more versatile than known methods, because it can be carried out on both new and existing pools, and can be used on both the walls and the floors of such pools.
[0014] Where the step of preparing the pool structure comprises building a new pool structure, the step of building the new pool structure may advantageously include attaching a further layer of thermal insulation material, said further layer being attached to an exterior surface of the pool structure.
[0015] In this way not only can heat transfer from a liquid in the pool to the pool structure be reduced, but also heat transfer from the pool structure to the environment of the pool structure can be reduced.
[0016] The step of preparing the existing pool structure may advantageously simply comprise draining the existing pool structure.
[0017] Preferably, however, the step of preparing the existing pool structure comprises draining the existing pool structure and preparing an interior surface of the existing pool structure for attachment of the layer of thermal insulation material.
[0018] The step of attaching the layer of thermal insulation material to the interior surface of the pool structure may advantageously comprise applying an adhesive to the layer and/or to the surface.
[0019] Alternatively or additionally, the step of attaching the layer of thermal insulation material to the interior surface of the pool structure may advantageously comprise fastening the layer of thermal insulation to the surface by means of a mechanical fastener.
[0020] The layer of thermal insulation material may advantageously comprise an impermeable material. Use of an impermeable material prevents a liquid in the pool from being absorbed into the material, which would adversely affect the thermal insulation property of the material.
[0021] The layer of thermal insulation material preferably comprises at least one insulation board.
[0022] Where the layer of thermal insulation material comprises at least one insulation board, the at least one insulation board is preferably coated on all of its surfaces with a sealant layer.
[0023] The sealant layer prevents a liquid in the pool from being absorbed into the insulation board. This is important because if a liquid is absorbed into the board and then freezes, it can damage the structure of the board. Also, the insulation board insulates by maintaining an air gap between a liquid in the pool and the environment of the pool structure. If the liquid is absorbed into the insulation board, the air gap is, in effect, removed from between the liquid and the environment of the pool structure.
[0024] Preferably the at least one insulation board is a phenolic insulation board, and more preferably still, a cellular glass insulation board, such as is sold under the registered trade mark FOAMGLAS.
[0025] The step of attaching the layer of thermal insulation material to the internal surface of the pool structure may advantageously comprise attaching the layer to at least one of a wall or walls and a floor of the pool structure.
[0026] Preferably the step of attaching the layer of thermal insulation material to the internal surface of the pool structure comprises attaching the layer to both the wall or walls and the floor of the pool structure.
[0027] Where the layer of thermal insulation material is attached to both the wall or walls and the floor of the pool structure, the layer is preferably continuous.
[0028] The invention therefore further provides a method that is more effective than known methods, because heat transfer from a liquid in the pool to both the wall or walls and floor of the pool structure is reduced.
[0029] The method preferably comprises the further step of applying a finish to the layer of thermal insulation material and said further step may advantageously comprise tiling the layer.
[0030] Alternatively, the step of applying the finish may advantageously comprise laying a waterproof liner over the layer.
[0031] Where a waterproof liner is laid over the layer of thermal insulation material, the layer is preferably provided with apertures arranged to permit a liquid between the liner and the layer to escape from the pool structure.
[0032] This is useful where a liquid in the pool is splashed over the top edge of the waterproof liner and flows between the exterior surface of the liner and the layer of thermal insulation material.
[0033] Where the layer of thermal insulation material comprises a plurality of insulation boards and all of the surfaces of the insulation boards are coated with a sealant layer, the method may advantageously include the step of sliding the edges of neighbouring boards against one another so as to trap a sealant layer between the edges of the plurality of boards.
[0034] In this way the need to use a liner or to apply a waterproof render to the insulation boards to retain a liquid in the pool can be avoided, because the insulation boards themselves form a liner.
[0035] The method may advantageously further comprise the step of bevelling the upper edges of the layer of thermal insulation material attached to the wall or walls of the pool structure and/or the edges of an aperture formed in the layer of thermal insulation material.
[0036] In this way, a waterproof liner laid over the layer of thermal insulation material does not have to be laid over any sharp edges that would otherwise be present at the upper edges of the layer of thermal insulation material attached to the wall or walls of the pool structure and/or the edges of any apertures formed in the layer. In addition, the bevelling makes it easier to stretch the liner to fit the pool structure without tearing the liner.
[0037] Preferably the pool is a swimming pool.
[0038] According to a second aspect of the invention there is provided a pool constructed according to the method of the first aspect of the invention.
[0039] Preferably the pool is a swimming pool.
[0040] According to a third aspect of the invention there is provided a pool comprising a pool structure and a layer of thermal insulation material attached to an interior surface of a floor of the pool structure.
[0041] Preferably the pool further comprises a layer of thermal insulation material attached to an interior surface of a wall or walls of the pool structure.
[0042] Preferably the pool is a swimming pool.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
[0043] The invention will now be described by way of illustrative example and with reference to the accompanying drawing figures in which:
[0044] FIG. 1 is a sectional view of a portion of a wall of a first swimming pool in accordance with the second aspect of the invention;
[0045] FIG. 2 is a sectional view of a portion of a wall of a second swimming pool in accordance with the second aspect of the invention;
[0046] FIG. 3 is a sectional view of a portion of a wall of a third swimming pool in accordance with the second aspect of the invention;
[0047] FIG. 4 is a sectional view of a filter inlet (through which water flows from the pool to a filter) in a wall of the swimming pool of FIG. 3 ; and
[0048] FIG. 5 is a sectional view of a filter outlet (through which water flows from a filter to the pool) in a floor of the swimming pool of FIG. 3 .
DETAILED DESCRIPTION OF EMBODIMENTS
[0049] A first swimming pool 100 is built by excavating a rectangular hole in the earth and lining the hole with a wire mesh screen to restrain the earthen banks that form the walls of the hole. One such bank is shown in FIG. 1 , denoted by reference numeral 9 . The wire mesh screen is not shown in FIG. 1 .
[0050] Gunnite is sprayed in layers against the banks and wire mesh screen and the floor of the hole to a thickness of 350 mm, to form the walls and floor of the pool structure. One such wall is shown in FIG. 1 , denoted by reference numeral 10 .
[0051] As shown in FIG. 1 , a coating 14 of S-2625 E epoxy adhesive, available from Structural Adhesives Limited of Leicester, UK, is applied to the walls 10 and floor and 80 mm thickness phenolic insulation boards 11 are attached to the walls 10 and floor of the pool structure.
[0052] The attachment of the phenolic insulation boards 11 to the walls 10 and floor is strengthened by means of Termofix S8 110 mm length hammerset fixings, available from Knauf Marmorit GmbH of Germany. Such a fixing is shown in FIG. 1 , denoted by reference numeral 15 .
[0053] A finish in the form of a coating 12 of between 5 and 10 mm thickness of MR ST1 composite mortar is applied to the phenolic insulation boards 11 and MR scrim is embedded in the coating 12 . The scrim is not shown in FIG. 1 . Both the composite mortar and scrim are available from Alumsac Exteriors Building Products Limited of Merseyside, UK. The attachment of the coating 12 to the phenolic insulation boards 11 is strengthened by means of Termofix S8 110 mm length hammerset fixings. Another such fixing is shown in FIG. 1 passing through the coating 12 , and is also denoted by reference numeral 15 .
[0054] A render 13 of waterproofed sand and cement is applied to the coat 12 of composite mortar. Two coats of pool paint are applied to the render 13 , and once dry, the pool structure is filled with water, denoted in FIG. 1 by reference numeral 17 .
[0055] Turning to FIG. 2 , a second swimming pool 200 is also built by excavating a rectangular hole, lining the hole with a wire mesh screen, spraying gunnite against the banks and floor of the hole and applying a coating of epoxy adhesive to the walls and floor formed by the gunnite as described in relation to FIG. 1 , and these components (where shown) are denoted by the same reference numerals in FIG. 2 as in FIG. 1 .
[0056] Phenolic insulation boards 18 of 80 mm thickness are attached to the walls and floor of the pool structure and the attachment of the phenolic insulation boards 18 to the walls 10 and floor is strengthened as described above in relation to FIG. 1 by hammerset fixings 15 .
[0057] A polyvinyl chloride (PVC) liner 19 is laid over the phenolic insulation boards 18 and the pool structure filled with water 17 .
[0058] Turning to FIG. 3 , this shows a third swimming pool 300 that is built by excavating a rectangular hole and lining the earthen banks 9 of the hole with walls 20 constructed of breeze blocks 22 . A concrete floor is laid upon suitable foundations formed in the bottom of the hole.
[0059] Cellular glass insulation boards 24 are coated on a first face and their edges with a layer 26 of S-2625 E epoxy adhesive. The layer 26 of epoxy adhesive on the first face of each board is used to attach the boards to the walls 20 and floor of the pool structure. To attach each board to the wall or floor the board is placed against the wall or floor and then slid relative to the wall or floor to abut one or more neighbouring boards, so that a layer of epoxy adhesive is trapped between the edges of each board and its neighbouring boards.
[0060] The second, opposite faces of the boards are levelled and a layer 28 of epoxy adhesive is applied to the opposite faces of the boards so as to form an even surface. In this way, the boards 24 form a continuous surface over the walls 20 and floor of the pool structure.
[0061] Coating all of the surfaces of the boards with epoxy adhesive prevents water from entering the boards. This is important for two reasons, namely that water entering the cells at the surfaces of the cellular glass boards would freeze in winter and destroy those cells, eventually breaking down the structure of the cellular glass boards, and if absorbent insulation boards were used instead of cellular glass boards, for example phenolic insulation boards, in the absence of the coating the boards would become waterlogged and lose their thermal insulation property, acting as thermal bridges between the water in the pool and the environment of the pool structure.
[0062] A coating 30 of a waterproof sealant is applied to the sealed even surface formed by the levelled boards 24 . Tiles 32 are attached to the coating 30 using a mixture of grout and a waterproof adhesive. Instead of tiling, it is possible to lay a PVC liner (not shown in FIG. 3 ) over the coating 30 .
[0063] Where an existing pool is to be insulated by the method of the invention, the filing of the existing pool is removed and sealed cellular glass insulation boards are bonded to the existing pool structure beneath the tiling using a layer of S-2625 E epoxy adhesive as described above in relation to FIG. 3 . If a suitable adhesive can be found for use instead of S-2625 epoxy adhesive, it may be possible to bond the sealed cellular glass insulation boards to the tiling itself, thus avoiding the need to remove the tiling of the existing pool.
[0064] Where an existing pool has a PVC liner and is to be insulated by the method of the invention, the PVC liner is removed and sealed cellular glass insulation boards are bonded to the existing pool structure beneath the PVC liner as described in relation to FIG. 3 . The steps described above of trapping a layer of epoxy adhesive between the cellular glass insulation boards, levelling the exposed second faces of the boards, applying the layer 28 of epoxy adhesive and applying the coating 30 of waterproof sealant to the sealed even surface remove the need for the PVC liner. Nevertheless, if it is not wished to tile over the insulation boards, a PVC liner may instead be laid over the boards. In that case it is desirable to provide small drainage holes in the boards 24 at the corners and along the lower edges of the wall 20 , at intervals of one to two metres, to enable water between the boards and the liner to escape from the pool structure.
[0065] Turning finally to FIGS. 4 and 5 , these show bevelling of the edges of the cellular glass insulation boards 24 where apertures have been formed in the boards to permit water 17 to flow, respectively, between the pool and a filter inlet 38 and a filter outlet 40 . The bevelling, in addition to being more aesthetically pleasing and safer than an abrupt edge to the insulation boards, ensures that a PVC liner, if used, is not subjected to a sharp edge, which might tear the liner. If tiling is used instead of a PVC liner, as shown in FIG. 3 , the tiles would be laid to follow the bevelled edges of the insulation boards, so as to avoid subjecting users of the swimming pool to sharp edges.
[0066] It is desirable when building the pool structure to recess fittings such as the filter inlet 38 and filter outlet 40 less deeply into the pool structure than would be the case with a conventional pool, because once the insulation boards 24 have been fitted to the pool structure, such fittings are, in effect, recessed by the thickness of the insulation boards.
[0067] It is believed that the method of thermal insulation of the invention is more effective than known methods because, if used on both the wall or walls and floor of a swimming pool, heat transfer between water in the pool and the pool structure is very much reduced and any thermal bridge between the water in the pool and the environment surrounding the pool structure, be it air or earth, is very much reduced. Pools insulated using the known methods can at best reduce only the thermal bridge between the water in the pool and the walls of the pool structure, not the thermal bridge between the water and the floor of the pool structure, which conducts heat directly into the earth beneath the pool structure.
[0068] It is estimated that, while it is possible using known methods of thermal insulation to reduce heat transfer through a pool structure to the environment by up to 40 percent, using the method of the invention with cellular glass insulating boards of 100 mm thickness on a pool of 10 m length, 5 m width and 1.5 m depth, it is possible to reduce heat transfer through a pool structure to the environment by 80 percent or more.
[0069] It will be apparent that the above description relates only to three embodiments of the invention, and that the invention encompasses other embodiments as defined by the claims set out hereafter. In particular, it will be apparent to those skilled in the art that the method of the invention can be carried out on pools made of materials, and made in shapes, other than those mentioned in relation to the three embodiments described above using materials other than those mentioned above. The method can also be carried out on pools that are constructed above ground level, as opposed to constructed in holes excavated in the earth. | A method of thermal insulation of a pool ( 300 ) is provided, the method comprising the steps of preparing a pool structure ( 20, 22 ), and attaching a layer ( 24 ) of thermal insulation material to an interior surface of the pool structure ( 20, 22 ). Also provided are a pool constructed according to such a method and a pool comprising a pool structure and a layer of thermal insulation material attached to an interior surface of a floor of the pool structure. | 4 |
BACKGROUND OF THE INVENTION
The present invention relates to a device for displacing a switch blade between a position on a stock rail and a position at a distance from the stock rail.
Railroad switches are fitted with locking devices for the purpose of securing switch blades, as disclosed for instance in European patent application EP 0 885 795 A1. This European patent application discloses the function of a modern locking device (latching closure CKA). Said document discloses not only the locking and unlocking but also the displacement of the switch blades, which in the case of a latching closure take place with the aid of a locking rod and a locking catch. The switch blade connected to the locking catch via a locking bearing is brought into contact with the associated stock rail during the locking procedure of the locking rod, during which the locking catch is guided under the stock rail and pressed upward against the foot of the stock rail, that is, against the locking support arranged at the foot of the stock rail, by the locking rod for locking the switch blade.
Particularly in the case of switch blades which are quite long, as they need to be for the larger radiuses, undesirable oscillations occur during use. These switch blades are furthermore at increased risk of torsion, as a result of which the switch blade can lift clear of the stock rail. It is known that document EP 0 624 508 A1 discloses a locking device which seeks to achieve a tight connection between the switch blade and the stock rail. This is achieved by providing the locking bearing connected to the switch blade with an elongation which presses against a locking support firmly connected to the stock rail when the locking device locks, as a result of which the switch blade pivots about the locking bearing and is pressed tightly against the stock rail.
Moreover German patent application DE 43 15 200 A1 discloses a locking device according to the document EP 0 624 508 A1 mentioned above. Said device is integrated into a hollow-section cross-tie, enabling automatic tamping of the track ballast in the region of the switch displacement device, that is, especially in the region of the tips of the switch blades.
It is common to all the above-mentioned reference documents that the locking support at the foot of the stock rail is held by gripping the foot of the stock rail on both sides and/or the locking catch is held in the locking bearing which is directly fastened to the switch blade. It is therefore easy to understand that, particularly in countries such as the USA, the UK and Japan, which have a great plurality of track and switch blade profiles, a correspondingly large number of different locking supports and/or locking bearings needs to be held in inventory and used in line with demand. It is thus expensive and time-consuming to store and use such items in this way in view of the plurality of profiles which exist. Even with only slight differences between one profile and another there is a risk that the construction team, which as a rule installs switches when the line is open to traffic, and is therefore always working under a certain amount of time pressure, might get the profiles mixed up. Such mistakes however can lead to premature wear or even to a serious malfunction.
SUMMARY OF THE INVENTION
The object of the invention is thus to specify a displacement and locking device for switch blades which manages with a particularly small number of parts despite the presence of a diversity of rail and switch profiles, at the same time making the work of the construction team efficient and to a large extent eliminating sources of error.
This object is achieved in a first variant of the previously mentioned displacement and locking device to which the invention relates, in that the device has the following components:
a) a locking bearing which is coupled to the switch blade and connected to a locking catch by means of an axle, and b) a locking rod that guides the locking catch against a locking support coupled to the stock rail, locks the locking catch to the support and then unlocks the same and guides it away from said locking support, c) the locking support being positioned on the side of the stock rail opposed to the switch blade, and being connected to a thrust bearing that is arranged on a fixed superstructure component.
By this means the locking support is successfully fastened to the stock rail without the need to fix fastening elements to the stock rail on the side of the stock rail facing toward the switch blade. This results in a “clear” inner profile against which the widest range of switch blade profiles can press. The fixed superstructure component, being a component which already exists in the track area and/or in the area of a switch, can therefore be utilized for -fastening the locking support and meets the requirement to leave the above-mentioned inner profile clear.
A particularly appropriate solution proposes using a component for supporting the switch blade as the fixed superstructure component. Such a component is designed to be very stable and is therefore suitable for holding the fastening of the locking support onto the inner side of the stock rail, if necessary even by tensioning the locking support. A switch blade slide chair proves to be particularly suitable for this purpose. This slide chair can also take the form of a switch blade slide bearing or a switch blade roller bearing.
As already disclosed in German patent application 43 15 200, a switch displacement device can also be integrated into a hollow-section cross-tie. In such a case it is particularly advantageous in an embodiment of the invention if the fixed superstructure component is arranged on a rising edge of a cross-tie member having a U-shaped profile.
In principle however, virtually any flange attached to a cross-tie member is suitable as a fixed superstructure component. This flange merely needs to be stable enough to act as a thrust bearing for the locking support fastening. The flange can obviously therefore be strengthened with the aid of supporting bridge pieces or the like.
A particularly appropriate fastening for the locking support occurs on the outer side of the stock rail (the side of the stock rail facing away from the switch blades) if the locking support is tightly coupled in the foot area of the stock rail. The locking support can then enclose the foot of the rail like a clamp on the outer side and thus be tensioned in a direction which is mainly vertical to the longitudinal extent of the stock rail.
The object mentioned above is further achieved in a second variant of the previously mentioned displacement and locking device to which the invention relates, in that the device has the following components:
a) a locking bearing which is coupled to the switch blade and connected to a locking catch by means of an axle, and b) a locking rod that guides the locking catch against a locking support coupled to the stock rail, locks the locking catch to the support and then unlocks the same and guides it away from said locking support, c) the locking bearing being arranged on a component that at least partially follows the displacement and the displacement motion being transferred from the locking bearing to the switch blade by means of a displaceable push rod.
This method avoids any direct connection between the locking bearing and the switch blade without having to give up the advantages of the locking bearing whereby the locking catch is supported so that it can rotate about an axle that is mainly parallel to the longitudinal extent of the stock rail. The push rod deals with the adaptation to different switch blade profiles, and is accordingly designed to be displaceable. A locking component that follows the displacement of the locking rod is for example the locking rod itself, the push rod or a component which is itself an element in the system linking the push rod to the locking rod. Such a component can also be an additional supporting element or slide member or the like which is fastened to one or more of the above-mentioned components and therefore supports the locking bearing.
A preferred variant in an embodiment of the invention proposes connecting the push rod firmly to the switch blade and holding it in the locking bearing so that it is movable. As a rule this variant requires a drill hole in the switch blade so that the push rod can be bolted to the switch blade. However, a solution in which the push rod has no drill hole but is held on the switch blade by clamping or tensioning or the like is also conceivable.
As an alternative the push rod can be held in the locking bearing so that it is movable and the two switch blades can be connected by means of a coupling rod. Then in the event of displacement, one switch blade is pushed as far as the stock rail by the push rod and the other switch blades are pulled away by the stock rail with the aid of the coupling rod in each case. In this case also, virtually any number of different switch blade profiles can be accommodated thanks to the mobility of the push rod in the locking bearing.
In a further embodiment of the invention the push rod can be held in the locking bearing and prevented from moving by means of a defined tractive power. Thus the switch blades can be forced open in a way that is non-destructive for the switch displacement mechanism, the alternative solution having been for example to install components in which the desired breaking points are predefined. According to this variant, instead of broken components having to be replaced when the switch blades have been forced open, the push rod need only be moved back to its original position and once more fastened with the predefined tractive power. In this case said tractive power can be provided by a spring-loaded catch. Embodiments are therefore conceivable in which a sphere or a cylinder is pressed into a bulge in the push rod by means of a spring. Thanks to this bulge it is also possible to return the push rod to the correct position (after the switch blades have been forced open) without any special adjustment tools or the like, because the best and thus the correct final position of the push rod can be found almost automatically due to the force of the spring.
Lastly the object mentioned above is achieved in yet a third variant according to the invention. This third variant is a combination of the first and second variants, and has the following features: Device for displacing a switch blade between a position on a stock rail and a position at a distance from the stock rail, having:
a) a locking bearing which is coupled to the switch blade and connected to a locking catch by means of an axle, and b) a locking rod that guides the locking catch against a locking support coupled to the stock rail, locks the locking catch to the support and then unlocks the same and guides it away from said locking support, c) the locking support being positioned on the side of the stock rail opposed to the switch blade, and being connected to a thrust bearing that is arranged on a fixed superstructure component; and d) the locking bearing being arranged on a component that at least partially follows the displacement and the displacement motion being transferred from the locking bearing to the switch blade by means of a displaceable push rod.
Further advantageous embodiments of the invention are to be found in the remaining sub-claims.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
Exemplary embodiments of the invention will be explained in greater detail with the aid of the attached drawings. These show the following:
FIG. 1 a side view of a first displacement device for a switch blade;
FIG. 2 a side view of a second displacement device for a switch blade; and
FIG. 3 a locking device known from document EP 0 624 508 Al.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 3 shows a locking device 2 which is known from document EP 0 624 508 A1 and which has a locking catch 10 connected by means of an axle 4 and a locking bearing 6 to a switch blade 8 ; after closing, said locking catch presses tightly against a surface 12 of a locking support 16 connected to a stock rail 14 and is firmly blocked in that position by a locking rod 18 . The locking bearing 6 is provided underneath with an extension (not shown in greater detail) which when the locking device is closed abuts against the locking support 16 , transmitting a force F 1 to the locking bearing 6 and causing a head 20 of the switch blade 8 to be pressed against the head 22 of the stock rail 14 . The locking bearing 6 is connected by a bolted connection 24 to the foot 26 of the switch blade 8 , said switch blade being designed in such a way that its foot 26 rests on the foot 28 of the stock rail 14 when the head 20 of the switch blade 8 is pressed against the head 22 of the stock rail 14 . It is therefore easy to see that the locking bearing 6 can readily be fastened to the foot 26 of the switch blade 8 . Similarly the locking support 16 can also be tensioned against the foot 28 of the stock rail 14 by means of a clamping screw 30 and a clamping hook 32 .
However, this embodiment of the locking device 2 cannot be used if for example the switch blade 8 has a different profile so that there is no room available at the foot 28 of the stock rail 14 for the fastening of the clamping hook 32 . This embodiment is also problematical if there is a great plurality of different profiles for the stock rails and switch blades in a rail network. In this case a separate locking bearing and a separate locking support must be used for each profile.
FIG. 1 is a diagram showing a side view of a first locking device 100 according to the invention, in which support is provided for a locking support 102 and a locking bearing 104 in a way that is independent of the respective profiles of the stock rail 14 and of a switch blade 106 that has been changed in comparison with FIG. 3 .
As in FIG. 3 , the locking support 102 is fastened on the side 108 facing away from the switch blade 106 , by virtue of its tight grip on the foot 28 of the stock rail 14 . At the same time, however, a thrust bearing is created in the form of a bolt 110 , so that the locking support 102 can be tensioned by means of a clamping screw 112 and a hooked rod 114 . The bolt 110 is attached in a manner not shown here to a superstructure component, for instance on the inner side of a hollow-section cross-tie or on the underside of a slide bearing for the switch blade 106 . For the sake of a clearer main illustration, this figure shows the bolt 110 to be arranged below the foot 26 of the switch blade 106 . It is clear that when the arrangement is this low, the tensioning could give rise to outwardly directed torque which could have a generally undesirable effect on the stock rail 14 . The bolt 110 , or in general terms, a thrust bearing for fastening the locking support 102 , is therefore as a rule arranged at a level which will avoid giving rise to outwardly directed torque (except of course in cases where such outwardly directed torque may be expressly desired).
Due to this method of support using the concept of a thrust bearing arranged on a superstructure component which as a rule already exists, enough clear space remains in the interior space 116 facing toward the switch blade 106 for switch blades 106 that are milled from the profile of the stock rail 14 also to be brought into play on the stock rail 14 .
The locking bearing 104 has likewise been mounted in a way which enables completely different switch blade profiles to be used. The locking bearing 104 is hence supported with the aid of a slide plate 118 which closely engages with a superstructure component by means of a sliding fit. In the present example the superstructure component is a cover plate 119 (partially shown) which closes the space in a hollow cross-tie or a cross-tie compartment in an upward direction. Arranged on this cover plate 119 are L-shaped guides 121 having a part 123 running horizontally on which the slide plate 118 slides. By this means the displacement is transmitted from the locking rod 18 via the locking catch 10 to the locking bearing 104 fastened to the slide plate 118 . When the switch blade 106 is displaced, the slide plate 118 is moved forward and back between the two end-positions of its travel. As an alternative to a sliding support for the slide plate 118 a roller bearing or the like can also be used. The slide plate 118 is thus supported on the guides 121 , 123 , which also act as slide bearings. The guides 121 , 123 therefore bear the weight of the locking bearing 104 . The locking catch 10 is supported, as mentioned, on the axle 4 in the locking bearing 104 . In the upper part of the locking bearing 104 a push rod 120 is supported in a drill hole in such a way that it can move. The push rod 120 is locked in each final position, enabling the front end 122 of the push rod 120 to press accurately against the switch blade 106 . When the switch is displaced the push rod 120 abuts against the switch blade 106 in the position shown in FIG. 1 . By means of a coupling rod (not shown) for the two switch blades 106 , the push rod 120 affects the other side of the locking device 100 opposite the split pin 124 in the axially symmetrical drive rod 126 , so that the opposite switch blade abuts against the opposite stock rail and the switch blade 106 shown in FIG. 1 is then guided away from the stock rail 14 . The previously mentioned coupling rod between the two switch blades 106 , also known as a tie rod, can also be achieved by means of a continuous slide plate 118 which either itself has elements coupled to the switch blades 106 or is part of an arrangement in which the push rods 120 are able not only to push a switch blade into a desired position but also to pull a switch blade into a desired position. It can then be an advantage, particularly in the last mentioned case, to design the slide plate 118 separately for each locking bearing 104 . This results in the ability to force open the switch without the slide plate 118 being damaged, as would be the case with a continuous slide plate 118 , because when the switch is forced the second of the two switch blades 106 is forced into a position away from the stock rail 14 in each case.
FIG. 2 is a diagram showing a side view of a second locking device 130 . For the most part only the mountings for a locking support 132 and for a locking bearing 134 are shown for the sake of clarity. The whole locking device 130 is integrated in a hollow-section cross-tie 136 , open in the upward direction, having a U-shaped profile and outward facing flanges 138 . Mounted on these flanges 138 and secured by means of bolted connections 139 is a slide chair 140 for a switch blade 142 . A stock rail 144 , modified in profile compared to the previously described stock rails 14 , is also fastened on the flanges 138 by means of bolted connections 146 .
A bolt 148 which projects sideways is provided on the inward facing sides of the slide chairs 140 in each case, and acts as a thrust bearing for the fastening of the locking support 132 . Due to the way it is mounted, the locking support encloses the foot 150 of the stock rail 144 on its outer side 152 and is fastened by means of a clamping screw 154 , which tensions a hooked rod 156 gripping the bolt 148 . This fastening is provided on both the slide chairs 140 fastened on the flanges 138 . In view of the profiles of stock rail 144 and switch blades 142 present at this point it is easy to understand that at the foot 150 of the stock rail 144 no room would be available on its inner side for the fastening of the locking support 132 . The fastening of the locking support 132 can however be achieved in a way previously described without a drill hole in the stock rail, as is often required by rail infrastructure operators.
The locking bearing 134 is also fastened in a correspondingly flexible manner. The locking bearing 134 is fastened to a slide member 135 which itself rolls (idlers 137 indicated by broken lines) in a guideway 141 arranged on the inward facing lateral surfaces of the slide chairs 140 . In the locking bearing 134 , the locking catch (not shown) is supported as before so that it can rotate about the axle 4 and is held in an eccentric bush 5 (cf. FIG. 1 ). Moreover the locking bearing 134 has a mainly horizontal drill hole in which a push rod 156 is held in such a way that it can move. The push rod 156 can be connected firmly to the switch blade 142 by means of a threaded connector arranged on said push rod 156 .
Additionally the push rod 156 has a cylindrical recess 158 into which a roll body 162 is pressed by a spring 160 . The spring 160 is tensioned by means of a bolt 164 which is screwed into a vertical spring casing 166 . A predefined tractive power can be exerted on the push rod 156 by selecting a particular thickness for a washer 168 . The tractive power is chosen so as to enable the switch to be forced open in the direction of travel when traffic passes over it. When a wheel rim penetrates the locked switch blade 142 a force is exerted on the switch blade 142 in the direction of an arrow 170 . When the tractive power exerted by the spring 160 is overcome, the push rod 156 is moved in the direction 170 . It is true that an adjustment to the push rod 156 has become necessary as a result, but total destruction of the displacement device due to the forcing can be reliably avoided in this way.
The second locking device 130 therefore also shows the desired advantages of easy adaptability to different profiles of the stock rail 144 and of the switch blades 142 , as was also demonstrated with the first locking device 100 .
KEY TO REFERENCE CHARACTERS
2 Known locking device
4 Axle
5 Eccentric bush
6 Locking bearing
8 Switch blade
10 Locking catch
12 Surface
14 Stock rail
16 Locking support
18 Locking rod
20 Head of the switch blade 8
22 Head of the stock rail 14
24 Bolted connection
26 Foot of the switch blade 8
28 Foot of the stock rail 14
30 Clamping screw
32 Clamping hook
F 1 Force
100 First locking device according to the invention
102 Locking support
104 Locking bearing
106 Switch blade
108 Side facing away from the switch blade 106
110 Bolt
112 Clamping screw
114 Hooked rod
116 Interior space
118 Slide plate
119 Cover plate
120 Push rod
121 L-shaped guide
122 Front end of the push rod 120
123 Horizontal part of the L-shaped guide 121
124 Split pin
126 Drive rod
130 Second displacement device according to the invention
132 Locking support
134 Locking bearing
135 Slide member
136 Hollow-section cross-tie
137 Idlers
138 Flanges
139 Bolted connection
140 Slide chair
141 Guideway
142 Switch blade
144 Stock rail
146 Bolted connection
147 Hooked rod
148 Bolt
150 Foot of the stock rail 144
152 Side facing away from the switch blade 142
154 Clamping screw
156 Push rod
158 Cylindrical recess
160 Spring
162 Roll body
164 Bolt
166 Spring casing
168 Washer
170 Arrow | The invention is a device for displacing a switch blade between a position on a stock rail and a position at a distance from the stock rail. The device has: a locking bearing coupled to the switch blade and connected to a locking catch via an axle; and a locking rod that guides the locking catch against a locking support coupled to the stock rail, locks the locking catch to the support, and then unlocks and guides it away from the locking support. The locking support is positioned on the side of the stock rail opposed to the switch blade and is connected to a thrust bearing that is arranged on a fixed superstructure component. The locking bearing is arranged on a component that at least partially follows the displacement, and the displacement motion is transferred from the locking bearing to the switch blade via a displaceable push rod. | 1 |
BACKGROUND
This invention relates to a linear motor-actuated flow control valve assembly having an electromagnetically actuated and controlled moving-coil linear motor, and valve means for controlling the degree of communication between an inlet port and outlet port in accordance with the operation of the linear motor. More particularly, the invention relates to a valve assembly of the type described in which the flow rate between the two ports can be controlled in proportion to the electric current applied.
In general, a linear motor-actuated flow control valve of the aforementioned type includes a moving-coil linear motor which is arranged within a casing having an inlet port and outlet port. The moving-coil linear motor comprises a hollow, ferromagnetic core which delimits valve chambers and which is provided with a valve hole for communicating the two ports, a bobbin, having an electromagnetic coil wound thereon, slidably disposed on the core for controlling the opening degree of the valve hole, permanent magnets so arranged as to produce a magnetic flux axially of the electromagnetic coil, and a ferromagnetic body for forming, together with the core, a magnetic circuit for the permanent magnets. The arrangement is such that passing an energizing current through the electromagnetic coil causes the bobbin to regulate the opening of the valve hole by moving the bobbin against a biasing force applied to the bobbin by spring means.
In the conventional linear motor-actuated flow control valve of the above kind, the bobbin is biased in a given direction (ordinarily the fully-closed direction) by the spring means. By passing an energizing current through the electromagnetic coil, a repulsive force is produced to drive the bobbin against the biasing force applied by the spring means, whereby the valve hole may be regulated to a predetermined opening degree between the fully-closed and fully-open positions as a function of the magnitude of the energizing current. One example of the relationship between the current i and the flow rate Q in such case is illustrated in FIG. 4, which shows the flow rate characteristic of a proportional relation. This type of linear motor-actuated flow control valve is frequently employed to control the air-fuel ratio in the internal combustion engine of an automotive vehicle. In such case the flow control valve operates with the valve hole open approximately mid-way while the vehicle is travelling, with control being effected either toward the fully-open or fully-closed positions from the mid-way position. Accordingly, it has been necessary to hold the excitation current at a fixed magnitude constantly under predetermined control conditions while the vehicle is running, also to apply allowable maximum current in order to open the valve hole fully when so desired. Moreover, in order to achieve stable control characteristics despite the vibration which acts upon the system, conventional practice has been to employ spring means having a considerably large spring modulus for the purpose of biasing the bobbin, and this has in turn required that the elctromagnetic coil be energized to a greater degree to be able to drive the bobbin against the force of the spring means. This makes it difficult to achieve a low level of power consumption because regulating the valve when the vehicle is running requires the expenditure of considerable excitation current.
The following is counted as additional disadvantage in the prior art:
The above-described control valve which is normally biased closed during non-excitation of the electromagnetic coil is employed as an air-fuel ratio control valve in the carburetor by-pass of a vehicle engine during engine idling. However, this can lead to a problem wherein engine starting cannot be achieved when ice forms adjacent the throttle valve of the carburetor in a cold environment since ice forms at the control valve closed.
Therefore, there has been much to be desired in the prior art.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a novel and improved linear motor-actuated flow control valve.
It is another object of the present invention to provide a linear motor-actuated flow control valve actuatable with reduced power consumption.
Other objects of the present invention will be apparent in the entire disclosure in the application.
To this end, a flow control valve actuated by a linear motor in accordance with the present invention is provided with spring means for biasing the bobbin in mutually opposing directions in such fashion that the valve holes are held open to a predetermined degree when the electromagnetic coil is in the de-energized state, wherein, when an energizing current is passed through the electromagnetic coil, the opening degree of the valve holes is regulated from the predetermined opening degree toward either the fully-open or fully-closed state depending upon whether the energizing current is positive or negative.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a longitudinal section view illustrating an embodiment of a linear motor-actuated flow control valve assembly according to the present invention;
FIG. 2 is a graph of a control characteristic according to the present invention, in which flow rate Q(1/min) is plotted against current (A);
FIGS. 3a and 3b show examples of valve holes according to the present invention; and
FIG. 4 is a graph showing a flow rate-current characteristic curve according to the prior art.
In the following, preferred embodiments of the present invention will be described with reference to the accompanying drawing which serves to better illustration of the embodiments of the invention and not to limitation thereof.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
An embodiment of the present invention will now be described in conjunction with the accompanying drawings.
In the embodiment illustrated in FIG. 1, a linear motor-actuated flow control valve assembly is shown generally at numeral 10. The valve assembly 10 includes a cylindrical casing 14 which comprises a casing section 14a of a non-magnetic material (such as an aluminum alloy) having an inlet port 11 and an outlet port 12, and defining a valve chamber 13b on the inlet port side, and a casing section 14b, also made of a non-magnetic material such as an aluminum alloy, hermetically fit in the casing section 14a through a sealing member 33. A hollow, ferromagnetic core 16 is disposed coaxially within the casing 14 in such fashion as to form a valve chamber 13a which communicates with the outlet port 12. Thus the hollow, ferromagnetic core 16 forms a partition between the two valve chambers 13a and 13b. Communication is established between these two valve chambers 13a and 13b by means of valve holes 21 and 22 formed in the wall of the core 16. The valve holes 21 are located at a portion of the ferromagnetic core 16 that lies within a magnetic circuit formed by permanent magnets 19a and 19b, as will be described below. The valve holes 22 are disposed at the other end of the core 16, namely at that portion thereof that does not lie within the magnetic circuit.
The valve assembly further includes a bobbin 17 consisting of a non-magnetic material, such as a synthetic resin or a metal sleeve encased with a synthetic resin. The bobbin 17 is slidably disposed on the core 16 so as to be capable of sliding axially thereof, and has an electromagnetic coil 18 wound on the central portion thereof. A pair of permanent magnets 19a and 19b are affixed to the inner side of an inner casing 15 comprising a magnetic material. The permanent magnets 19a and 19b are spaced away from the coil 18 to form an intervening clearance 23, and are so arranged that the magnetic flux produced thereby passes through the coil 18 at a right angle to the windings thereof. The inner casing 15, which has a compartment 15c formed internally thereof, is provided with a communicating hole 15a for communicating the internal compartment 15 with the valve chamber 13b on the inlet port side, and with a communicating hole 15b for communicating a compartment 14c, formed internally of the casing section 14b, with the valve chamber 13b. The end portion 15d of the casing 15 facing the outlet port 12 is provided with a flange for retaining the corresponding end of the ferromagnetic core 16 within the compartment 15c to fix the core 16 against movement. A magnetic circuit for the magnetic flux produced by the permanent magnets 19a and 19b extends from the inner surface of each permanent magnet, through the clearance 23 between each magnet and the coil 18, and further through the longitudinally extending wall of the core 16 before returning to the outer surface of each permanent magnet via the inner casing 15. Thus the magnetic flux crosses the windings of the coil 18 at a right angle.
The bobbin 17 slidably disposed on the core 16 is elongated at both ends to form lands which control the opening degree of the valve holes 21 and 22, and is provided with communicating holes 17a at the right-hand side of the coil 18 in order to communicate the compartment 14c with the valve holes 22. Thus the communicating holes 17a are adapted to open the valve holes 22. A cylindrical body 20 comprising an insulator (preferably a synthetic resin) is affixed to the bobbin 17 on the outer surface thereof to the right of the coil 18. The cylindrical insulator 20 has a flange 20a at the right-hand side thereof for affixing the two terminal leads 27 of the coil 18.
An annular spring holder 28, also comprising an insulator, is affixed to the interior of the casing section 14b at the right-hand end thereof, opposite the flange 20a of the cylindrical insulator 20, which is affixed to the bobbin 17. Coil springs 25 and 26 are disposed and compressed between the flange 20a and the spring holder 28. The coil springs 25 and 26 are connected at one end to respective ones of the coil terminal leads 27a and 27b, and at the other end to external connection terminals, only one of which, denoted at numeral 29, is shown. Thus the coil springs 25 and 26 serve to connect an external power supply to the electromagnetic coil 18.
A pair of small flanges 17b and 17c are provided on the outer periphery of the bobbin 17 to the left and right of the electromagnetic coil 18 to fix the coil windings axially of the bobbin. A coil spring 34 is disposed in a compressed state between the left-hand flange 17b and the end portion 15d of the inner casing 15. Thus the springs 25 and 26 acting upon the bobbin 17 from the right and the spring 34 acting upon it from the left urge the bobbin in mutually opposing directions. These springs 25, 26 and 34 are so chosen that the opposing forces acting upon the bobbin 17 balance each other in such a manner that the bobbin 17 opens the valve holes 21 approximately mid-way when the electromagnetic coil 18 is in the de-energized state. Furthermore, the arrangement is such that the valve holes 22 are fully closed under such balance conditions by the bobbin 17.
The hollow, ferromagnetic core 16 terminates at its right-hand end at a point beyond the sliding range of the bobbin 17, and has said end fixedly supported on an inwardly projecting cylinder 30 formed on the non-magnetic casing section 14b. A sealing member 31 is interposed between the core 16 and projecting cylinder 30 to hermetically seal the joint between them. A spring 32 is disposed between the right-hand end of the core 16 and the spring holder 28 to urge the core 16 to the left. Thus the core 16 is supported centrally of the casing and is held against movement, its left end being retained by the flange of the inner casing 15, its right end being supported on the projecting cylinder 30.
A slit 17d preferably is provided at the left-hand extremity of the bobbin 17 in order to assure an equivalence in pressure on the inner and outer sides of the bobbin when the valve holes 21 and 22 are fully closed. The valve holes 21 and 22 may have the shapes shown in the sectional views of FIGS. 3a and 3b. The number of these valve holes formed in the wall of the core 16 will be based on the particular operating conditions.
The flow control valve 10 having the foregoing construction operates in the following manner. In FIG. 1 the valve assembly is shown under quiescent conditions, that is, when the electromagnetic coil 18 is in the de-energized state. Under such conditions the opposing forces which the springs 25, 26 and 33 apply to the bobbin 17 are in balance, so that the bobbin 17 is at rest at what will be reffered to hereinafter as the "reference" position, corresponding to the point Q 0 in FIG. 2. Also, as described above, the valve holes 21 are opened approximately mid-way under these conditions, permitting a flow rate Q 0 of a predetermined magnitude.
Assume now that a positive energizing current is applied to the electromagnetic coil 18 to produce a repulsive force with respect to the permanent magnets 19a and 19b. The repulsive force slides the bobbin 17 toward the right by a distance which is a function of the magnitude of the energizing current. Increasing the energizing current therefore causes the bobbin 17 to open the valve holes 21 to a greater degree, and to begin opening the valve holes 22. When the current reaches a given magnitude, both sets of valve holes 21 and 22 will be fully open. The foregoing process is depicted by the curve I extending to the right of the reference point Q 0 in FIG. 2. Reducing the magnitude of the energizing current causes the bobbin 17 to return to the reference position.
Next, assume that a negative energizing current is applied to the coil 18. Owing to the change in polarity, the repulsive force produced in this case will be directed opposite to that of the former repulsive force. As a result, the bobbin 17 is slid to the left in FIG. 1, thereby closing valve holes 21 to a greater degree, while valve holes 22 remain closed. As the negative energizing current is increased, the bobbin 17 closes the valve holes 21 fully and abuts against the end portion 15d of the inner casing 15, so that no further leftward movement of the bobbin is possible. Restoring the negative energizing current to zero causes the bobbin 17 to return to the reference position Q 0 . This process corresponds to curve I extending to the left of the reference point Q 0 in FIG. 2.
According to the present invention, the flow control valve assembly 10 is arranged so that the valve will be open approximately mid-way when the bobbin 17 is at the reference position. Accordingly, if the reference position is taken as the center of mean bobbin movement when the vehicle is runhing, control can be effected over the necessary range with only a small energizing current.
The effect of the present invention will be obvious from a review of the flow control characteristics of the invention, as shown in FIG. 2, in comparison with the characteristics encountered in the prior art, as depicted in FIG. 4. It will be seen that an energizing current, indicated at the vertical line H in FIG. 4, is required to obtain the same opening degree, or flow rate, indicated at Q 0 in FIG. 2, where no energizing current is necessary.
In FIG. 3a and 3b, each one example of the valve holes 21 and 22 is illustrated, respectively.
A suitable number of the valve holes 21 and 22, respectively, may be provided in the wall of the ferromagnetic core 16. For instance, the overall opening area of the valve holes 22 can be increased to a suitable degree. This permits the flow rate characteristics indicated by curve II in FIG. 2 to be obtained. In other words, the slope of the flow rate characteristic curve can be set or changed at will, as a function of the overall opening area of the valve holes 22, for a given range of energizing currents (negative to positive) centered on the reference position.
By disposing the valve holes 22 at positions where they may communicate with the corresponding communicating holes 17a located in the bobbin 17 to the right of coil 18, as shown in FIG. 2, it is possible to achieve greater control of flow rate with less excitation current, or to obtain control characteristics which are much less susceptible to vibration. The foregoing can be accomplished since the valve holes 22 can be provided with the necessary opening area without affecting the magnetic characteristics of the system due to the fact that the valve holes 22 are not disposed in the flux produced by the permanent magnets 19a and 19b.
The valve assembly ordinarily is employed with the inlet port 11 connected to the atmosphere and the outlet port 12 connected to the negative pressure side of the intake system (i.e., to a source of negative pressure). The valve holes 21 and 22 may have shapes other than those illustrated, this being decided upon the particular requirements.
Since the control valve assembly of the present invention is in the half-open state when the electromagnetic coil 18 is de-energized, the assembly is particularly well suited for use as an air-fuel ratio control valve, which forms the by-pass of a throttle valve, for the purpose of controlling the idling speed of an internal combustion engine. In such case the valve assembly may serve as a fast idle mechanism to facilitate engine starting even under ice forming in the throttle valve region.
The inventive valve assembly is useful also as an air-fuel ratio control valve or EGR control valve for an internal combustion engine. Further, although the reference position in the foregoing embodiment is set at a point where the valve holes 22 begin to be opened by the bobbin 17 as the bobbin starts to move to the right, the reference position can be taken as one where the valve holes 22 are in the half-open state, or one where the valve holes 22 remain closed for a predetermined period of time even after the bobbin 17 has started to move to the right.
According to the present invention as described hereinabove, the power consumed to obtain a given flow rate control characteristic can be reduced to a fraction of that required in the prior art. Moreover, it is possible to obtain good stability against vibration, large flow rates with the same level of noise, and optional flow rate control characteristics. Furthermore, when the valve assembly is employed as a valve for controlling idling speed, a predetermined feed of air and fuel can be achieved even if ice forms in the throttle valve region.
The principles, preferred embodiments and modes of operation of the present invention have been described in the foregoing specification. However, the invention which is intended to be protected is not to be construed as limited to the particular embodiments disclosed. The embodiments are to be regarded as illustrative rather than restrictive. Variations and changes may be made by others without departing from the spirit of the present invention. Accordingly, it is expressly intended that all such variations and changes which fall within the spirit and scope of the present invention as defined in the claims be embraced thereby. | A linear motor-actuated flow control valve includes spring means for biasing a bobbin controlling valve hole opening degree in mutually opposing directions, to hold the bobbin at a middle opened position when an electromagnetic coil wound on the bobbin is deenergized. The bobbin is driven against spring means force in any opposing directions to increase or decrease the opening degree by applying a positive or negative energizing current to the coil. | 8 |
This application is a divisional application of Ser. No. 07/000,857, filed on Jan. 06, 1987, to issue to U.S. Pat. No. 4,780,218, on Oct. 25, 1988, and for which there has been maintained a continuous chain of copendency.
BACKGROUND OF THE INVENTION
The instant invention relates generally to the perchlorethylene recovery process for dry cleaning equipment, and more specifically on an improvement in both conventional equipment and the method for the dry cleaning of fabric. The instant invention to be described is more efficient and recovers a larger percentage of perchlorethylene dry cleaning fluid (which hereinafter will be referred to sometimes as perc in this application).
Numerous dry cleaning systems with solvent recovery have been provided in the prior art that are adapted to recover their cleaning solvent. For example, U.S. Pat. Nos. 3,738,074 to Victor, 3,775,053 to Wisdom, and 4,086,706 to Wehr all are illustrative of such prior art. While these units may be suitable for the particular purpose to which they address, they are not the same, and are not be suitable for the purpose of the present instant invention as hereafter described.
SUMMARY OF THE INVENTION
A primary object of the present invention is to provide a perchlorethylene recovery process for dry cleaning equipment that will overcome the shortcomings of the prior art devices.
Another object is to provide a perchlorethylene recovery process for dry cleaning equipment in which virtually all of the perc is recovered from the process.
An additional object is to provide a perchlorethylene recovery process for dry cleaning equipment in which the operator does not breath nor is exposed to perc fumes or even other wise exposed to the perc in almost any way.
A further object is to provide a perchlorethylene recovery process for dry cleaning equipment which eliminates all odors from the fabric being cleaned and does not compromise but rather enhances the quality of the cleaning process and the degree to of cleanliness of the fabric.
A yet further object is to provide a perchlorethylene recovery process for dry cleaning equipment in which the normal dry cleaning filtering cartridges are left so entirely free of perc that these cartridges can be discarded with regular trash without any health to the general public at large etcetera.
A yet still further object is to provide a perchlorethylene recovery process for dry cleaning equipment which utilizes a same steam sweep system for stripping both the still and filtering cartridges.
Yet still further additional object is to provide a perchlorethylene recovery process for dry cleaning equipment which typically improves the ratio of perc to fabric cleaned from typically 20,000 lbs of fabric to about 70,000 lbs of fabric per 50 gallon drum of perc.
Yet another object is to provide a perchlorethylene recovery process for dry cleaning equipment that is simple and easy to use for those skilled in the art.
A still additional further object is to provide a perchlorethylene recovery process for dry cleaning equipment that is economical in cost to manufacture.
Further objects of the invention will appear as the description proceeds.
To the accomplishment of the above and related objects, this invention may be embodied in the form illustrated in the accompanying drawings, attention being called to the fact, however, that the drawings are illustrative only and that changes may be made in the specific construction illustrated and described within the scope of the appended claims.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
The figure in the drawing is briefly described as follows:
The figure is a block diagram of a typical dry cleaning fabric processing system with the added components to improve the process shown enclosed in dotted lines.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In order that the instant invention be more clearly understood a description of parts of the conventional portion of the process will be explained but as a precursor to the understanding of the instant invention, and before examining the instant invention it is desirable to review what is involved in the ordinary dry cleaning cycle.
To start with the objective is to separate the dirt from the the fabric textiles and or garments to be cleaned. To do this the fabric or clothes are tumbled in the dry cleaning solvent perc much in the same way that clothes are washed in a conventional washing machine. However perc is a relatively expensive commodity, and is injurious to both the environment and the health of the operator. It is therefore desirable to reclaim or recycle as much dirty contaminated perc as possible and keep it as a permanent working fluid within the dry cleaning processing system and equipment for use over and over again and again.
To re-process the dirty contaminated perc there are several processes which are performed in a conventional system and generally in the following order:
1. Water is separated from the perc;
2. The perc is distilled; and
3. The perc is filtered in a cartridge.
The system conventionally includes the required valves, sight glasses, pumps, etcetera so that perc in various stages of cleanliness can be diverted back into the cleaning cycle as may be reasonably required at a particular point in a cycle. For example it would be very poor economy to use absolutely clean perc to begin or even continue a cycle wherein the cloth or fabric were quite dirty. Conventionally clean perc would most likely be saved for final rinses.
However there are two places in the perc reclaiming process in which perc is not salvaged in the conventional scheme of the cycle, which are as follows:
1. It seems that after the perc has been recycle several times there is a small amount of perc (approximately 1 lb.) which must be discarded from the water separator, or else the fabric or clothes take on an unpleasant odor.
2. When the filter cartridges are to be discarded because they are completely spent and can not accept any more contaminate there is always a certain amount of perc (approximately 2 lbs.) left in each cartridge at the time the cartridge is discarded.
It is at these two points in the cycle wherein the instant invention corrects the situation and recovers entirely the perc which is otherwise lost in the conventional dry cleaning process and equipment.
Having thus described substantially the nature of the of the loss involved in reclaiming perc in a conventional system a more detailed description of the instant invention will follow.
Turning now descriptively to the drawing is seen a figure which represents a block diagram of a typical dry cleaning process system with the addition of extra components enclosed in dotted contours 10 and 12 so as to create the more efficient perchlorethylene recovery process of the instant invention.
A conventional rotating drum tumbling mechanism 14 is shown in which fabric quite often which is in the form of conventional street clothes or other dry good which might be around a house of the general public, is present and available for the operator to place such items which are to be cleaned. Dry cleaning solvent fluid perc may be caused to be transferred into the drum 14 by pump 20, and valve set 22, 24, & 26, from work tank 16, or rinse tank 18 as may be required at a particular point in a cleaning cycle.
A circulated portion of the volatile fluids (water, perc & air) may be removed from the cycle by fan motor and duct assembly 28 to heat pump and condenser 30, some of which is caused to flow into a water separator 32, where it is freed from water and allowed to flow back to rinse tank 18 via path 42, along with clean perc from condenser 34. At a point in the cycle when the perc is too contaminated to be used for cleaning purposes, it is caused to flow into still 36 so that it can be returned to the cleaning cycle via paths 38, 44 and condenser 34 previously mentioned. Perc which is some what contaminated but is still useable for cleaning may be returned to work tank via path 40.
Perc which is contaminated to such a sufficient degree may be pumped directly to filter cartridges 46, via path 48, valve 50, and pump 20 previously mentioned, and then returned either directly to the drum 14 via path 52, and valve 54, or to still 36 via path 56, and valve 58 as a particular cleaning cycle may require.
After perc has been recycle several times that is so many gallons per so many kilo pounds of clothes cleaned separator 32 is drained of perc which is collected in container 60, but instead of discarding as is normally done in a conventional dry cleaning system this slightly contaminated perc is returned to still 36 either by a optional pump 62 via path 64, or by physically taking container 60 and dumping the contents therein into funnel 66, while opening valve 68. In any case the important consideration is that the perc is returned to the system at a point where it will be distilled again by still 36.
Because the conventional operation of the still component 36 has not been discussed it is appropriate to do so at this point in the examination of the scheme of things.
Normally contaminated perc enters the still 36 from path 56, and in the instant invention also from path 64, and is boiled of to a high degree in a conventional manner by heat supplied by hot steam from boiler 721, to heat exchanger 70. The boiled off perc leaves the still 36 and is returned to the cleaning cycle via path 38 as previously described. At some point in this portion of the perc reclaiming cycle the still will become sufficiently loaded with muck/high concentrated contaminate and perc mixed together wherein the concentration of muck is so high that the distillation process is no longer effective or efficient.
In order to efficiently reclaim the perc from this highly contaminated state live steam is normally allowed to enter the still 36 via path 74 and valve 76, dissolve and mix with the perc and re-condense in perc condenser 34, while excessive water is dumped in sewer or bucket 80. This portion of the process is commonly referred to in the art as sweeping the still and must be regularly carry out by the operator of the system.
When the filtering cartridges are determined to be filled to capacity with contaminate so as to longer be useful in the conventional system they are removed, discarded, and replaced with fresh cartridges. It is to be noted that every time the cartridges are replaced a significant amount of perc remains left in each cartridge, and is there by lost from the system. It might also be noted that there are laws which require that these cartridges be returned to a depot where they may be correctly and properly disposed of so as to not damage the environment or be so hazardous to the operator's health.
A feature of the instant invention is that the same steam that is used to sweep the still 36, on particular occasions when it is required to discard a set of filter cartridges 82 or 46, can be first diverted to flow through a set of filter cartridges 82 or 46 and then to the still 36. What occurs is that the live steam dissolves and mixes with all of the perc which would otherwise remain in a discarded filter cartridge and transfers this otherwise lost perc back into the still sweep reclamation cycle previously described, leaving the spent cartridges 82 or 46 as the case might be completely stripped and void of any measurable amount of perc whatsoever, and all without even any hint of extra cost in operating this system. An optional steam restricting element 88 appears to make both stripping process more efficient.
A set of valves 84a, 84b, 84c & 84d are ganged together by linkage 86 so that two separate set of filter cartridges 82 and 46 may be kept connected to the system so that a fresh set may be immediately switched into a cleaning cycle while a spent set is being stripped of any perc.
While certain novel features of this invention have been shown and described and are pointed out in the annexed claims, it will be understood that various omissions, substitutions and changes in the forms and details of the device illustrated and in its operation can be made by those skilled in the art without departing from the spirit of the invention. | A method for a perchlorethylene recovery process for dry cleaning equipment in which virtually all of the perchorethylene is recovered from the process so as to increase the economic efficiency of the system while at the same time reducing the hazardous to both environment and the operator's health. | 3 |
The present application is a continuation of U.S. patent application Ser. No. 13/681,746, with a filing date of Nov. 20, 2012, which is a continuation of U.S. patent application Ser. No. 13/017,016, with a filing date of Jan. 30, 2011, all of which are hereby incorporated by reference.
TECHNICAL FIELD OF THE INVENTION
The present invention relates generally to focused charged particle beam systems and, in particular, to systems used to excite and localize fluorescent markers in a sample.
BACKGROUND OF THE INVENTION
Biological research today is increasingly focusing on determining the positions within the cell of various cellular components to ever higher spatial resolutions. This involves many different techniques for enhancing resolution and contrast in images, both for electron microscopes (TEMs, STEMs, SEMs, etc.), as well as all types of light microscopes, including the latest super-resolution techniques. One powerful technique that has gained wide acceptance for research into cellular structure, transport, metabolism, and motility is the application of recombinant genetic techniques to link “reporter” genes to “genes of interest” (GoIs). Thus, when a particular GoI is expressed during normal genetic transcription/translation processes, the reporter gene will also be expressed, producing a small protein which ends up attached to the “protein of interest” (PoI) encoded for by the GoI. One widely-accepted reporter gene is that encoding for a green fluorescent protein (GFP), these reporter genes being available in wild and genetically-modified versions, and the expressed GFPs having fluorescence that extends from blue to yellow in emission wavelengths. The GFP is relatively small (29.6 kDa, 3 nm in diameter by 4 nm long) with its chromophore well protected inside and not requiring any co-factors for light emission. All that is needed to “light up” a GFP is illumination by a laser with a slightly shorter wavelength than the GFP emission wavelength. GFPs appear to be essentially “inert” to the proper functioning of their attached PoI—this is ensured in some cases by connecting the GFP to the PoI with a short flexible polypeptide “linker” which enables the GFP to swing around free from the protein, which may be part of some intracellular structure or mechanism that must not be interfered with in order to preserve the cellular functions being studied by the researcher.
Clearly, if the X-Y-Z location of the GFP can be determined precisely within a cell (say, to 10 nm accuracy) then the location of the PoI would be known to a similar accuracy. The fluorescing GFP can be observed through a light microscope and so the location of the PoI can be seen in the microscope relative to observable structures in the sample. Several techniques in the prior art have been proposed and, in some cases, demonstrated, for achieving high positional information from various fluorescent markers (FMs) such as GFPs and also quantum dots. In one technique, a green laser is used to excite a small portion of the fluorescent markers (FMs) in a sample, and the sample is then imaged. Using Gaussian curve fitting, the locations of the FMs may be determined within a FWHM of 20 nm, substantially smaller than the diffraction limit of the imaging system. Using multiple green laser flashes, alternating with red laser flashes which extinguish the fluorescence, the locations of a larger number of FMs may be determined in a process which may typically take tens of minutes. In another technique, described in U.S. Pat. No. 7,317,515 to Buijsse et al. for “Method of Localizing Fluorescent Markers,” which is assigned to the assignee of the present application and which is hereby incorporated by reference, a charged particle beam scans the surface of the sample, damaging the markers and extinguishing the fluorescence when the beam hits the FM. The location of the FM corresponds to the position of the charged particle beam when the fluorescence is extinguished. Because the charged particle beam can be focused to a much smaller point than the laser that illuminates the marker, and the position of the charged particle beam at any time during its scan can be determined with great accuracy, the position of the FM, and therefore the position of the PoI, can be determined with similar accuracy.
Throughout all descriptions herein of the present invention, the term GFP will be used to represent the larger class of FMs which can be damaged by a charged particle beam (comprising electrons or ions), including GFPs, organic dyes, as well as inorganic markers such as quantum dots (which may typically be functionalized to enable selective attachment to particular intracellular components such as proteins, nucleic acids, etc.).
Many of the prior art methods for localization of FMs within biological samples work only for relatively small numbers of FMs, from which a small subset are activated at any one time—thus imaging times can be many minutes and still suffer from some of the limitations of light optical imaging. Prior art methods employing charged particle beams to selectively damage FMs within samples have utilized image processing methods capable of dealing only with relatively small numbers of FMs—for these methods, the statistical signal-to-noise ratio limits their application to FMs which do not inherently appear in large densities. For GFPs, in particular, this may be a hindrance, since any type of expressible tag (as opposed to a functionalized tag such as a quantum dot) can be created in very large numbers through normal cellular process of gene transcription to mRNA, followed by translation to proteins (GoI+linker+GFP). Thus, there is a need for a fast method for localization of very large numbers (≧10000) of FMs such as GFPs within cells, or sections of cells, in time frames, for example, of the order of a minute.
SUMMARY OF THE INVENTION
An object of the invention is to provide an improved method and apparatus for locating proteins of interest in a sample.
A preferred embodiment includes a charged particle apparatus and method capable of imaging samples containing fluorescent markers (FMs), such as green fluorescent proteins (GFPs) or quantum dots, using standard electron microscopic signals such as secondary electrons (SEs) or transmitted electrons (unscattered, elastically-scattered, and/or inelastically-scattered), while simultaneously exciting the FMs with a laser and collecting emitted light from the excited FMs.
One embodiment comprises a detector optics configuration which presents a very large collection solid angle for both secondary electrons and emitted light, without interference between the two types of detectors which would tend to reduce the respective collection solid angles for both SEs and light.
Some embodiments of the present invention comprise an exemplary image processing method potentially enabling larger (e.g., >10000) numbers of FMs to be simultaneously localized (during a single imaging scan of roughly a minute duration) than was possible with simpler image processing schemes in the prior art.
The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter. It should be appreciated by those skilled in the art that the conception and specific embodiments disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more thorough understanding of the present invention, and advantages thereof, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:
FIG. 1 shows a schematic diagram of a protein of interest (PoI), with a green fluorescent protein (GFP) attached by a linker.
FIG. 2 is a schematic diagram of an X-Y scan raster, illustrating pixels containing GFPs and pixels without GFPs.
FIG. 3 is a schematic diagram of a first embodiment of the present invention comprising detector optics above the sample.
FIG. 4A is a side view of both light and secondary electron trajectories for the detector optics in FIG. 3 .
FIG. 4B is a cutaway isometric view of the detector optics in FIGS. 3 and 4A .
FIG. 5 is a schematic diagram of a second embodiment of the present invention comprising detector optics below the sample.
FIG. 6 is a schematic diagram of a third embodiment of the present invention comprising detector optics both above and below the sample.
FIG. 7 is a graph of the signal as a function of the time during a raster scan for a scan field containing 100 GFPs.
FIG. 8 is a graph showing a close-up of the beginning of the graph in FIG. 7 , showing damage to the first eight GFPs out of the total of 100.
FIG. 9 is a graph of the signal as a function of the time during a raster scan for a scan field containing 10000 GFPs.
FIG. 10 is a graph showing a close-up of the beginning of the graph in FIG. 9 , showing damage to the first eight GFPs out of the total of 10000.
FIG. 11 is a graph showing a raw signal with statistical noise and a smoothed signal as a function of the time during a raster scan, showing damage to the first three GFPs out of a total of 100.
FIG. 12 is a graph showing the smoothing function and the derivative function.
FIG. 13 is a graph showing the raw signal with statistical noise, the smoothed signal, and the smoothed derivative as a function of the time during a raster scan, showing damage to the first three GFPs out of a total of 100.
FIG. 14 is a graph showing a raw signal with statistical noise and a smoothed signal as a function of the time during a raster scan, showing damage to the first three GFPs out of a total of 10000.
FIG. 15 is a graph showing the raw signal with statistical noise, the smoothed signal, and the smoothed derivative as a function of the time during a raster scan, showing damage to the first three GFPs out of a total of 10000.
FIG. 16 is a histogram showing the performance of an image processing method for locating GFPs within the scan signal in the presence of large amounts of statistical noise during the detection of the first three GFPs out of a total of 10000 GFPs in the scan field.
FIG. 17 is a graph of the optimization results for the image processing method.
FIG. 18 is a flow chart for the method of the present invention for localizing expressible tags such as GFPs within a sample.
FIG. 19 is a flow chart for the method of the present invention for localizing functionalized tags such as quantum dots within a sample.
FIG. 20 is a schematic diagram of a combined secondary electron and fluorescent marker image.
FIG. 21 is a flow chart for an image processing method for localizing fluorescent markers.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Some embodiments of the present invention provide charged particle systems comprising detector optics systems optimized for very high collection efficiencies for both secondary electrons and light simultaneously, without spatial interference between the two types of detectors. This is accomplished in some embodiments by at least one mirror, preferably a paraboloidal mirror, above and/or below the sample, such that the point on the sample surface impacted by the charged particle beam is at or in proximity to the focal point of the paraboloid(s) (either one or two). By the focal point being “in proximity to” the charged particle is meant that the area illuminated by the light reflected from the mirror includes, and is larger than, the area impacted by the charged particle beam.
In addition, a conducting surface, typically metallic, of the paraboloidal light mirror is electrically biased (typically a few hundred volts negative) to provide an electric field between the sample and the mirror to deflect secondary electrons so that they do not impact the mirror and to reflect the secondary electrons to a detector. Thus, both the photons and secondary electrons (SEs) emitted from the sample may be collected into large solid angles, preferably greater than π/4 steradians, more preferably greater than π/2 steradians, and even more preferably greater than π steradians, providing efficiencies (and resultant higher signal-to-noise ratios) previously unattainable for detector systems in which the light and SE solid angles are spatially separated and mutually interfere. The secondary electron detector is preferably positioned below the point at which the charged particle beam exits mirror 314 in FIGS. 3, 4A and 4B .
In addition to these highly efficient light detection systems, issues of statistical (stochastic) noise in the light signal are addressed in some embodiments. This noise arises because the imaging mode of the present invention utilizes selective damage of single FMs such as GFPs due to the energetic charged particle (electron or ion) beam to localize each FM. Damaging a single FM results in an incremental loss in total light emission from the sample, e.g., if one FM out of a total of 10000 FMs is damaged, then the emitted light will decrease by roughly 0.01%. To detect such a small decrease in light emission, it is necessary that the stochastic noise due to fluctuations in light emission averaged over the pixel dwell time not be substantially larger than 0.01% in this example. Similar methods have been described in the prior art for smaller numbers of FMs, as in U.S. Pat. No. 7,317,515, assigned to the assignee of the present invention. In all these cases, the numbers of FMs which could be localized were limited.
The benefits of this improved signal-to-noise ratio in the light optical signal arising due to fluorescent emission from markers (such as GFPs, organic dyes, or quantum dots) in the sample are further amplified by another aspect of the present invention—an image processing method enabling the timing (and thus the locations) of FM damage events to be determined, even in the case of very large stochastic noise in the raw imaging signal.
Fluorescent Markers as Expressible Tags
FIG. 1 shows a schematic diagram 100 of a protein of interest (PoI) 102 , with a green fluorescent protein (GFP) 104 attached by a linker peptide 110 . A typical GFP has a diameter 106 of 3 nm and a length 108 of 4 nm—details of the “beta barrel” structure of the GFP 104 are omitted here. In general, the PoI 102 will be larger than the GFP 104 , as shown. One key consideration in the use of expressible tags is that the tag does not interfere with the proper functioning of the PoI 102 within the cell, whether that function is metabolic, transport, structural, etc. Thus, a short peptide linker 110 is often used to attach the fairly rigid GFP 104 to the PoI 102 , enabling the GFP 104 to swing around on an arc 112 of radius 114 , as shown. Note that this radius 114 determines the maximum precision at which the GFP 104 can be located since GFP 104 is free to occupy any position on circle 112 . Thus, it is likely that locating the GFP 104 to within 5 to 8 nm is sufficient for any position-determining methodology, as in the present invention, as well as in the prior art such as described in U.S. Pat. No. 7,317,515 assigned to the assignee of the present invention and incorporated herein by reference.
Methods for recombinantly-linking genes for reporter genes, such as for various versions of the “green fluorescent proteins” (GFPs) originating from the hydrozoan jellyfish species Aequorea victoria are well known. Since the original discovery of GFPs in the 1950s, a number of genetic variants have been developed with improved fluorescence spectra spanning an emission range from blue to yellow light, with simplified spectral absorption distributions. GFPs are relatively small cylinders (“beta barrels”, 3 nm diameter by 4 nm long) comprising 238 amino acids (26.9 kDa), which appear to be essentially “inert” to the overall cellular mechanisms of species which can be far removed from jellyfish. Because of this, the use of GFPs is widely accepted in the biological community. What is particularly important is that the wide acceptance of GFPs as expressible markers makes the present invention potentially highly useful for the biological community in applications where current GFP localization methodologies are insufficiently precise. Throughout the descriptions of the operation of the three embodiments below, the GFPs should be understood to comprise a multiplicity of GFP variants, representing multiple recombinant reporter genes being expressed simultaneously in the biological samples being examined. Similarly, the light detectors in the three embodiments should be understood to comprise multiple detectors operating independently, and in parallel, each detecting light from a particular GFP type within the multiplicity of GFP types in the sample.
The present invention is applicable both to cases where a smaller number (10 to several 100) of GFPs are within the imaging field of view, as well as cases where there are many more (up to at least 10000) GFPs. The improved image processing method of the invention is applicable to both cases. Each GFP variant has its own unique spectral absorption and emission characteristics. An example is for the original “wild-type” GFPs (wtGFP) which has an absorption peak at 395 nm and an emission peak at 509 nm. Because the wtGFP has an undesirable second absorption peak at 475 nm, efforts were made to develop improved versions, such as the S65T mutation, having an absorption peak at 484 nm and an emission peak at 507 nm, with no secondary absorption peak. A key aspect in employing GFPs as expressible tags is that they may be present in very high numbers within the sample, necessitating the efficient light detection and image processing of the present invention.
Imaging Methodology for Fluorescent Markers in a Charged Particle System
FIG. 2 is a schematic diagram of a 32×32 X-Y scan raster 200 , illustrating pixels containing GFPs 208 and pixels without GFPs 206 . The fast scan axis 202 is along the X-direction, while the slow scan axis 204 is along the Y-direction. For normal raster scanning, the beam would first be positioned at the upper left and then moved to the upper right along the top row. Next, the beam would “retrace” back to the left side and move down one row, followed by scanning horizontally to the right again. This process is repeated until all 32×32=1024 pixels have been imaged. In the example here, white pixels 206 represent those not containing a GFP, while black pixels 208 contain a single GFP. It is assumed that the GFP density is low enough that Poisson statistics apply and we can make the approximation that no pixels contain more than one GFP. Since the GFPs are expressible tags representing the locations within a cell (or slice of a cell) of a particular Protein of Interest (PoI), the distribution of GFPs will often be non-uniform, representing the non-uniform distribution of PoIs due to their required locations within the cell for proper functioning.
Three exemplary system configurations are presented below: a first configuration which is applicable to thick samples and collects all signals from the front surface of the sample (i.e., operating in SEM mode); a second configuration with the detector optics for electrons and light below the sample (i.e., operating in a TEM or STEM mode); and a third configuration with a combined detector system both above and below the sample to give the maximum possible collection efficiency for light emitted from excited FMs within the sample.
First Embodiment
Detector Optics Above the Sample
FIG. 3 is a schematic diagram of a first embodiment 300 of the present invention comprising detector optics above the sample 306 . Sample 306 may include a biological sample including fluorescent markers that are expressed by genes linked to genes of interest or including inorganic markers that selectively attach to particular intracellular components. Sample 306 may also include a biological sample including dyes or other inorganic markers, such as quantum dots, that are functionalized to enable selective attachment to particular intracellular components. Sample 306 sits on a sample stage at a sample position that defines a sample plane.
A charged particle column 302 , such as an electron beam column or a focused ion beam column, generates a beam 304 of charged particles that is focused by column 302 onto the surface of a sample 306 at a location 308 . Electrons in the beam typically have energies of between 1,000 eV and 25,000 eV. Ions typically have energies of between 5,000 eV and 50,000 eV. An X-Y beam deflector 310 , which may comprise magnetic coils, electrostatic multipoles, or a combination of both magnetic coils and electrostatic multipoles, is configured to move the beam 304 around on the surface of the sample 306 , typically in an X-Y raster pattern for imaging, as in FIG. 2 .
In this first embodiment 300 of the invention, the sample 306 is assumed to be thick enough to prevent penetration of the beam 304 through the sample 306 , thus all imaging signals (both light and charged particles) are collected above the sample surface as shown. A paraboloidal mirror 314 is positioned between the deflector 310 and the sample 306 . A hole 312 in mirror 314 allows passage of beam 304 downwards to the sample 306 . Below the mirror 314 is a flat shield plate 316 , typically biased to the same voltage as the sample 306 . In order to achieve maximum collection efficiency for light, mirror 314 is configured to subtend the largest possible solid angle, preferably greater than π steradians, at location 308 . Then the maximum possible amount of light emitted from the fluorescent markers (FMs) at location 308 will be collected and transmitted through the beam splitter 326 , then through color filter 372 , and finally to detector 360 —this maximizes the achievable signal-to-noise ratio in the optical signal.
The fluorescent markers (FMs) are excited by light 324 from laser 322 , which is emitted upwards, reflected first off beam splitter 326 and then reflected and focused by the paraboloidal mirror 314 onto the surface of sample 306 at location 308 . Note that it is desirable to have the largest possible transmission of emitted light from the FMs through beam splitter 326 in order to increase the amount of light reaching detector 360 . If the transmission of beam splitter 326 is 50%, then half the signal light 327 from location 308 will get to the detector 360 , and half of the excitation light 324 from laser 322 will reach location 308 . Thus, to focus 3 mW from laser 322 onto location 308 would require a 6 mW laser output 324 (ignoring other reflective losses). If ample laser power is available, it may be preferred to increase the transmission (and thus reduce the reflectivity) of beam splitter 326 , for example to 80%. Then 80% of the light from location 308 (again, ignoring reflective losses) will pass through the beam splitter 326 , while only 20% of the light 324 from laser 322 will reach location 308 —thus, to focus 3 mW at location 308 , a 15 mW laser output power 324 would be required (12 mW would pass through beam splitter 326 , to be absorbed in a beam dump (not shown) above splitter 326 ). In this embodiment, the light from laser 322 is reflected by mirror 314 onto the top surface of sample 306 , that is, the light does not first pass through sample 306 before being reflected by mirror 314 and the light from the source illuminates the sample initially from above the sample. Similarly, light emitted by fluorescent markers within sample 306 are emitted through the top surface of sample 306 , collected by mirror 314 above sample 306 , and reflected to light detector 360 without passing completely through sample 306 and being collected on the opposite side of the mirror, as in U.S. Pat. No. 7,317,515.
The second function of paraboloidal mirror 314 is to provide a conductor that can be electrically biased to provide an electric field that prevents secondary electrons from impacting mirror 314 by reflecting secondary electrons (SEs) 332 emitted from location 308 due to the impact of the primary charged particle beam 304 . This is shown in more detail in FIGS. 4A and 4B . SEs 332 are deflected by a several hundred volt negative potential applied to the (conducting) mirror surface. Note that the SEs do not reflect the same way that the light 328 does, because the SEs are reflected by the electrostatic field created by the voltage applied to the mirror 314 or other conductor, and this field extends throughout the entire volume of the paraboloidal mirror 314 (see FIG. 4B for an isometric view of mirror 314 ). The SEs 332 are deflected toward a detector 320 and collected by the detector 320 as shown to the side of the sample 306 . Thus, both the light and secondary electrons are collected from location 308 with high efficiencies since there is no conflict between the collection solid angles for light and SEs. The size of hole 312 is preferably kept to a minimum to reduce both loss in light reflection and any perturbations to the electrostatic field deflecting the secondary electrons. The focal point of the paraboloidal mirror 314 is approximately at location 308 on the surface of sample 306 —thus light emitted from the vicinity of location 308 will be focused into roughly parallel light beams 328 , directed towards the right of FIG. 3 . While it is preferred that the electric field that directs the SEs away from the mirror be produced by the conductive mirror, the electric field can be produced by a conductor that is separate from the mirror. An electrical bias can also be applied to the entrance of the charged particle detector 320 .
A system controller 362 is electrically connected to column 302 through cable 370 , to X-Y deflector 310 through cable 368 , to mirror 314 through cable 366 , to shield plate 316 through cable 376 , to sample 306 through cable 378 , to SE detector 320 through cable 380 , and to laser 322 through cable 374 . The system controller 362 coordinates the scanning of beam 304 by the X-Y deflector 310 with the display of an image on a monitor (not shown), as well as performing the image processing calculations described below to locate FMs on the sample surface.
Charged particle beams typically must travel in a vacuum, thus a vacuum enclosure 334 contains the exit of column 302 , X-Y deflector 310 , mirror 314 , shield plate 316 , and sample 306 , as shown. Typically, it is much easier to locate as much of the light optical instrumentation outside the vacuum as possible, thus a viewport 356 allows the light 327 from laser 322 (reflected off beam splitter 326 ) to pass into enclosure 334 , while the light emitted from FMs at location 308 is allowed to pass out from enclosure 334 , through beam splitter 326 , then through color filter 372 and into detector 360 . Color filter 372 serves to reduce the amount of laser excitation light 324 which can pass into detector 360 . Since the excitation light always has a shorter wavelength than the emitted light from the FMs, it is possible to tune the passband of filter 372 to transmit most of the light from the FMs, while blocking most of the laser light. In some cases, additional light filtering may take place within detector 360 . Electrical feedthrough 354 allows the passage of cables 366 , 368 and 370 into and out of enclosure 334 , while feedthrough 352 allows the passage of cables 376 , 378 and 380 into and out of enclosure 334 .
Detector Optics for High Efficiency Collection of Light and Secondary Electrons
FIG. 4A is a side cross-sectional view 400 generated using the SIMION ray-tracing program showing both light and secondary electron trajectories for the detector optics in FIG. 3 . The primary beam 304 can be seen passing downwards through hole 312 in the paraboloidal mirror 314 . Impact of beam 304 with sample 306 at location 308 induces the emission of secondary electrons 332 into a cosine (Lambert Law) distribution. Shield plate 316 and sample 306 generally have the same voltage applied by system controller 362 (see FIG. 3 ). Several hundred volts negative bias is applied to the conductive mirror surface 314 to repel the (0 to 50 eV) secondary electrons 332 as shown. This reflection differs from that of the light reflecting specularly off mirror 314 , thus the SEs are collected on detector 320 to the side of sample 306 . The collection solid angle at location 308 is very high, preferably greater than π steradians, in this configuration, giving a good signal-to-noise SE image. Light emitted from the fluorescent markers (FMs) in the sample 306 is also emitted into a cosine distribution, a large fraction of which is directed towards mirror 314 , as shown. Since location 308 on sample 306 is the focal point of paraboloidal mirror 314 , light 328 reflecting off mirror 314 is generally parallel passing to the right of the FIG. 4A . It will be understood that the benefits of the mirror 314 can be used in other applications in which light is directed toward a sample or detected from a sample in a charged particle beam system. Such systems that would benefit from mirror 314 include systems that collect light for an optical microscope that is coaxial with a charged particle beam, such as the system described in U.S. Pat. No. 6,373,070 to Rasmussen for “Method apparatus for a coaxial optical microscope with focused ion beam,” and systems that collect light from photo luminescence caused by the charged particle beam, or luminescence.
FIG. 4B is a cutaway isometric view of the detector optics in FIG. 4A , also generated using SIMION. In addition, the beam splitter 326 is shown at the lower right. The elliptical pattern of SE 332 impacts at detector 320 can be seen, thus the area of detector 320 need not be excessively large—smaller detector areas may increase the detector bandwidth (at least for solid-state detectors) and thus are generally preferred.
Second Embodiment
Detector Optics Below the Sample
FIG. 5 is a schematic diagram of a second embodiment 500 of the present invention comprising detector optics below a sample 506 . A charged particle column 502 , such as an electron beam column or a focused ion beam column, generates a beam 504 of charged particles which is focused by column 502 onto the surface of the sample 506 at a location 508 . Beam 504 typically includes electrons having energies between about 50 keV and 300 keV. An X-Y beam deflector 510 , which may comprise magnetic coils, electrostatic multipoles, or a combination of both magnetic coils and electrostatic multipoles, is configured to move the beam 504 around on the surface of the sample 506 , typically in an X-Y raster pattern for imaging. In this second embodiment 500 of the invention, the sample 506 is assumed to be thin enough to permit penetration of the beam 504 through the sample 506 , thus all imaging signals (both light and charged particles) are collected below the sample surface as shown. A paraboloidal mirror 580 is positioned below the sample 506 . A hole 582 in mirror 580 allows the travel of transmitted charged particle beam 584 downwards after passage through sample 506 . Beam 584 may typically comprise unscattered particles from the primary beam 504 , elastically-scattered particles, inelastically-scattered particles, secondary electrons and/or ions, and particles which have scattered both elastically and inelastically in the sample 506 . After passing through hole 582 , beam 584 enters detector 586 which may comprise energy filters to differentiate between transmitted particles of the various types cited above, and possibly multiple detectors operating in parallel.
In order to achieve maximum collection efficiency for light, mirror 580 is configured to subtend the largest possible solid angle (typically >π steradians) at location 508 . Thus, the maximum possible amount of light emitted from the fluorescent markers (FMs) at location 508 will be collected and transmitted through beam splitter 596 , then through color filter 598 , and finally to light detector 590 —this maximizes the achievable signal-to-noise ratio in the optical signal. The FMs are excited by light 594 from laser 522 , which is emitted upwards, reflected first off beam splitter 596 and then reflected and focused by paraboloidal mirror 580 through sample 506 at location 508 . Note that it is desirable to have the largest possible transmission of light through beam splitter 596 in order to increase the amount of light reaching detector 590 —the same percentage transmission considerations apply here as for FIG. 3 , above. It is important that the size of hole 582 be kept to a minimum to reduce loss in light reflection, while remaining large enough to accommodate the elastically-scattered electrons within beam 584 . The focal point of the paraboloid 580 is at approximately location 508 on sample 506 —thus light emitted from the vicinity of location 508 will be focused into roughly parallel light beams 587 , directed towards the right of the figure.
A system controller 562 is electrically connected to column 502 through cable 570 , to X-Y deflector 510 through cable 568 , to sample 506 through cable 566 , to laser 522 through cable 574 , to detector 590 through cable 564 , and to detector 586 through cable 588 . System controller 562 coordinates the scanning of beam 504 by X-Y deflector 510 with the display of an image on a monitor (not shown), as well as performing the image processing calculations described below to locate FMs on the sample surface.
Charged particle beams typically must travel in a vacuum, thus a vacuum enclosure 534 contains the exit of column 502 , X-Y deflector 510 , sample 506 , mirror 580 , and detector 586 , as shown. Viewport 556 allows the light 587 from laser 522 (reflected off beam splitter 596 ) to pass into enclosure 534 , while the light emitted from FMs at location 508 is allowed to pass out of enclosure 534 , through beam splitter 596 , then through color filter 598 , and into detector 590 . Color filter 598 serves to reduce the amount of laser excitation light 594 which can pass into detector 590 , as for the first embodiment in FIG. 3 . The same reflectivity considerations apply here for beam splitter 596 as for beam splitter 326 in FIG. 3 . Electrical feedthrough 554 allows the passage of cables 566 , 568 and 570 into and out of enclosure 534 , while feedthrough 552 allows the passage of cable 588 into and out of enclosure 534 .
Third Embodiment
Detector Optics Both Above and Below the Sample
FIG. 6 is a schematic diagram of a third embodiment 600 of the present invention comprising detector optics both above and below the sample 606 . A charged particle column 602 , such as an electron beam column or a focused ion beam column, generates a beam 604 of charged particles which is focused by column 602 onto the surface of a sample 606 at a location 608 . An X-Y beam deflector 610 , which may comprise magnetic coils, electrostatic multipoles, or a combination of both magnetic coils and electrostatic multipoles, is configured to move the beam 604 around on the surface of the sample 606 , typically in an X-Y raster pattern for imaging. In this third embodiment 600 of the invention, the sample 606 is assumed to be thin enough to permit penetration of the beam 604 through the sample 606 . To achieve larger collection efficiencies for light, two paraboloidal mirrors 614 and 680 are positioned above and below the sample 606 , respectively. A hole 612 in mirror 614 allows passage of beam 604 to the sample 606 . A hole 682 in mirror 680 allows passage of transmitted charged particle beam 684 downwards after passage through sample 606 . Beam 684 may typically comprise unscattered particles from primary beam 604 , elastically-scattered particles, inelastically-scattered particles, secondary electrons and/or ions, and particles which have scattered both elastically and inelastically in sample 606 . After passing through hole 682 , beam 684 enters detector 686 which may comprise energy filters to differentiate between transmitted particles of the various types cited above, and possibly multiple detectors operating in parallel. The considerations for collection of SEs 632 emitted from location 608 due to the impact of primary beam 604 into detector 620 are the same as in FIGS. 3, 4A and 4B .
In order to achieve maximum collection efficiency for light, both mirrors 614 and 680 are configured to subtend the largest possible solid angles (typically >π steradians for each of mirrors 614 and 680 , giving a total >2π steradians) at location 608 . The maximum possible amount of upwards-emitted light emitted from the fluorescent markers (FMs) at location 608 will be collected and transmitted through the beam splitter 626 , then through color filter 672 , and into detector 660 —this maximizes the achievable signal-to-noise ratio in the optical signal. Similarly, the maximum possible amount of downwards-emitted light from the FMs at location 608 will be collected and transmitted through color filter 698 and then to detector 690 . The FMs are excited by light 624 from laser 622 , which is emitted upwards, reflected first off beam splitter 626 and then reflected and focused by paraboloidal mirror 614 onto sample 606 at location 608 . Note that it is desirable to have the largest possible transmission of light through beam splitter 626 in order to increase the amount of light reaching detector 660 —the same percentage transmission considerations apply here as for FIGS. 3 and 5 , above. It is important that the size of holes 612 and 682 be kept to a minimum to reduce loss in light reflection. The focal points of paraboloids 614 and 680 are at approximately location 608 on sample 606 —thus light emitted from the vicinity of location 608 will be focused into roughly parallel light beams 628 and 687 , respectively, directed towards the right of the figure.
A system controller 662 is electrically connected to column 602 through cable 670 , to X-Y deflector 610 through cable 668 , to mirror 614 through cable 666 , to detectors 660 and 690 through cable 664 , to shield plate 616 through cable 676 , to sample 606 through cable 678 , to detector 686 through cable 688 , and to laser 622 through cable 674 . Detectors 690 and 660 are shown interconnected through cable 699 , however, an alternative configuration would have separate cables to system controller 662 . System controller 662 coordinates the scanning of beam 604 by the X-Y deflector 610 with the display of an image on a monitor (not shown), as well as performing the image processing calculations described below to locate FMs on the sample surface.
Charged particle beams typically must travel in a vacuum, thus a vacuum enclosure 634 contains the exit of column 602 , X-Y deflector 610 , mirror 614 , shield plate 616 , sample 506 , mirror 680 , and detector 686 , as shown. It is much easier to locate as much of the light optical instrumentation outside the vacuum as possible, thus a viewport 656 allows the light 624 from laser 622 (reflected off beam splitter 626 ) to pass into enclosure 634 , while the upwards-emitted light from FMs at location 608 is allowed to pass out of enclosure 634 , through beam splitter 626 , then through color filter 672 and into detector 660 . The downwards-emitted light from FMs at location 608 passes out of enclosure 634 through viewport 656 , through color filter 698 , and then into detector 690 . Color filters 672 and 698 serve to reduce the amount of laser excitation light 624 which can pass into detectors 660 and 690 , respectively, as for the first embodiment in FIGS. 3 and 5 . Electrical feedthrough 654 allows the passage of cables 666 , 668 and 670 into and out of enclosure 334 , while feedthrough 652 allows the passage of cables 676 , 678 , 688 , and 680 into and out of enclosure 634 . Note that in this dual paraboloidal mirror configuration, light from laser 622 which passes through sample 606 unabsorbed will reflect off mirror 680 towards detector 690 —thus color filter 698 must be configured to withstand a potentially high level of laser illumination, higher than would be the case in FIGS. 3 and 5 .
Imaging of Smaller Numbers of Fluorescent Markers in the Scan Field
FIG. 7 is a graph 700 of the signal 704 (number of photons collected per pixel) as a function of the time 702 during a raster scan for a scan field containing 100 GFPs. The overall scan time is 60 s, distributed over 512×512 (256 k) pixels, with a pixel dwell time of 229 μs. Curve 706 represents the number of photons collected per pixel for all the undamaged GFPs within the illuminated area. At the far left, all 100 GFPs are assumed to be emitting light in response to laser excitation. As curve 706 descends towards the lower right, the number of damaged GFPs is gradually increasing from 0 to 100, with eventually all GFPs damaged at the end of the 60 s raster. Because the GFPs are randomly located, curve 706 has some irregularities while following an overall descent from 0 s to 60 s. The laser power of 3 mW is distributed over a 28 μm 2 area at the sample—in this example, the raster is assumed to have this same area, thus at the end of the scan, no GFPs remain undamaged. In general, the illuminated area may be larger than the raster, thus some GFPs would remain undamaged at the end of the scan at 60 s.
FIG. 8 is a graph 800 showing a close-up of the beginning of the graph 700 in FIG. 7 , showing damage to the first eight GFPs out of the total of 100. The most difficult point in the localization of the GFPs within the area illuminated by the laser is at the beginning when there is the maximum number of GFPs emitting (and the minimum number of GFPs already damaged). This is because with the largest number of undamaged GFPs emitting light, the statistical fluctuations in the total collected light from all GFPs will be the largest (calculated as the square root of the number of photons collected in the pixel dwell time). Graphs 700 and 800 were made with the assumptions listed in Table I. Curve 806 represents the mean number of photons collected from all the undamaged GFPs in the illuminated area as a function of time into the scan—only the first 8 s are shown, during which time eight GFPs are struck and damaged by the charged particle beam (electrons or ions). Each of these damage events is represented by a vertical drop in the signal, such as drop 812 at the upper left. Above curve 806 is the +3 σ curve 808 (long dashes), representing expected signal fluctuations three standard deviations above the mean signal level 806 —a relatively unlikely event. Similarly, below curve 806 is the −3 σ curve 810 (short dashes), representing expected signal fluctuations three standard deviations below the mean signal level 806 —also a relatively unlikely event. The key thing to note here is that at jump 812 , representing the loss (due to damage) of one GFP, curve 810 at the left of jump 812 is well above curve 808 at the right of jump 812 —in other words, it is extremely unlikely that the inherent statistical signal-to-noise arising from the number of photons collected from all the undamaged GFPs will make it difficult to detect a single GFP damage event, in the case where there are only 100 GFPs being illuminated (and thus emitting) within the laser focused area.
TABLE I Assumptions for Graphs 700 and 800 in FIGS. 7 and 8. Total Imaging time 60.00 s Image dimension 512 # pixels/side Total # pixels 262144 Pixel time 228.9 us Laser power at substrate 0.0030 W = J/s Wavelength 550.00 nm Energy/photon 2.25 eV = (in J) Incident photons/s 8.306E+15 /s Diameter of illuminated area 6.00 um Area of illuminated area 28.27 um{circumflex over ( )}2 Diameter of GFP 3.00 nm Area of GFP 7.07 nm{circumflex over ( )}2 Incident photons/s/GFP 2.077E+09 /s quantum efficiency estimate 0.50 collection efficiency estimate 0.25 photons collected/s/GFP 2.596E+08 /s/GFP photons collected/pixel/GFP 59410.21 statistical fluctuation in #photons/pixel/GFP 243.74 Number of GFP in illuminated area 100 photons collected/pixel time/ilium. area 5.941E+06 statistical fluctuation in #photons/illum. area 2437.42 Signal/Noise estimate 24.37
Imaging of Larger Numbers of Fluorescent Markers in the Scan Field
FIG. 9 is a graph 900 of the signal 904 (number of photons collected per pixel) as a function of the time 902 during a raster scan for a scan field containing 10000 GFPs. The overall scan time is 60 s, distributed over 512×512 (256 k) pixels, with a pixel dwell time of 229 μs, as in FIG. 7 . Curve 906 represents the number of photons collected per pixel for all the undamaged GFPs within the illuminated area. At the far left, all 10000 GFPs are assumed to be emitting light in response to laser excitation. As curve 906 descends almost linearly towards the lower right, the number of damaged GFPs is gradually increasing from 0 to 10000, with eventually all GFPs damaged at the end of the 60 s raster. Because 10000 is such a large number, even though the GFPs were randomly distributed in the field of view, curve 906 is approximately a straight line. The laser power of 3 mW is distributed over a 28 μm 2 area at the sample—in this example, the raster is assumed to have this same area, thus at the end of the scan, no GFPs remain undamaged. In general, the illuminated area may be larger than the scan raster, thus some GFPs would remain undamaged at the end of the raster.
FIG. 10 is a graph 1000 showing a close-up of the beginning of the graph 900 in FIG. 9 , showing damage to the first eight GFPs out of the total of 10000. As was the case for graph 700 in FIG. 7 , the most difficult point in the localization of the GFPs within the area illuminated by the laser is at the beginning when there is the maximum number of GFPs emitting (and the minimum number of GFPs already damaged). Graphs 900 and 1000 represent a hundred times more GFPs in the area illuminated by the laser than was the case in FIGS. 7 and 8 —thus the total light collected (see the three alternative detector geometries in FIGS. 3, 5, and 6 ) will be a hundred times higher, with √100=10 times higher absolute statistical fluctuations. Since the light emitted by a single GFP is independent of the total number of illuminated GFPs, this means that the change in total light collected (from all the undamaged GFPs) whenever a single GFP is damaged by the charged particle beam will be 10 times smaller in comparison with the statistical fluctuations than was the case for 100 GFPs total ( FIGS. 7 and 8 ). This can be seen from the qualitative differences between graphs 800 and 1000 .
Graphs 900 and 1000 were made with the assumptions listed in Table II. Curve 1006 represents the mean number of photons collected from all the undamaged GFPs in the illuminated area as a function of time into the scan—only the first 0.09 s are shown, during which time eight GFPs are struck and damaged by the charged particle beam (electrons or ions). Each of these damage events is represented by a vertical drop in the signal, such as drop 1012 at the upper left. Above curve 1006 is the +3 σ curve 1008 (long dashes), representing expected signal fluctuations three standard deviations above the mean signal level 1006 —a relatively unlikely event. Similarly, below curve 1006 is the −3 σ curve 1010 (short dashes), representing expected signal fluctuations three standard deviations below the mean signal level 1006 —also a relatively unlikely event. The key thing to note here is that at the jump 1012 , representing the loss (due to damage) of one GFP, curve 1010 at the left of jump 1012 is now below curve 1008 at the right of jump 1012 —this situation differs qualitatively from that shown in FIG. 8 where there was no overlap. Although ±3 σ is a fairly stringent criterion, it is clear that distinguishing individual GFP damage events from out of the overall statistical noise in the light signal (such as from detector 360 in FIG. 3 ) will be more difficult in this case.
TABLE II Assumptions for Graphs 900 and 1000 in FIGS. 9 and 10. Total Imaging time 60.00 s Image dimension 512 # pixels/side Total # pixels 262144 Pixel time 228.9 us Laser power at substrate 0.0030 W = J/s Wavelength 550.00 nm Energy/photon 2.25 eV= Incident photons/s 8.306E+15 /s Diameter of illuminated area 6.00 um Area of illuminated area 28.27 um{circumflex over ( )}2 Diameter of GFP 3.00 nm Area of GFP 7.07 nm{circumflex over ( )}2 Incident photons/s/GFP 2.077E+09 /s quantum efficiency estimate 0.50 collection efficiency estimate 0.25 photons collected/s/GFP 2.596E+08 /s/Qdot photons collected/pixel/GFP 59410.21 statistical fluctuation in #photons/pixel/GFP 243.74 Number of GFP in illuminated area 10000 photons collected/pixel time/ilium. area 5.941E+08 statistical fluctuation in #photons/illum. area 24374.21 Signal/Noise estimate 2.44
Image Processing to Improve FM Localization for Smaller Numbers of FMs
In this section, we will examine further the localization of fluorescent markers (FMs) such as green fluorescent proteins (GFPs), as first discussed in FIGS. 7 and 8 , above, for the case of 100 GFPs in the laser illumination area. FIG. 11 is a graph 1100 showing a raw signal 1106 with statistical noise and a smoothed signal 1108 as a function of the time 1102 during a raster scan, showing damage to the first three GFPs out of the total of 100. Both curves 1106 and 1108 are plotted against a vertical axis 1104 representing the numbers of photons collected from all GFPs per pixel. The noise is assumed to be entirely stochastic, i.e., fluctuations in the signals per pixel will have a standard deviation equal to the square root of the number of photons collected during the pixel time, in this example, 229 μs. With only 100 GFPs being illuminated by the laser, as was discussed for FIG. 8 , curves 808 and 810 were close to the mean number of photons curve 806 , meaning that for very few pixels will there be enough noise to make it hard to distinguish a GFP damage event. This is further illustrated here, where the small plus and minus signal noise fluctuations cause no problems is locating the GFP damage events at 1110 , 1112 , and 1114 . An image processing method comprising a smoothing step, followed by a differentiation step, is illustrated in FIGS. 11-13 . In FIG. 11 , curve 1108 is a smoothed version of the raw data curve 1106 —the downward steps at each of the three GFP damage events 1110 , 1112 , and 1114 can clearly be seen. The smoothing function (kernel) 1206 is shown in FIG. 12 .
FIG. 12 is a graph 1200 showing a Gaussian smoothing function 1206 centered at 1208 and the derivative function 1210 centered at 1212 , plotted against the time 1202 from the center (i.e., the particular pixel data being smoothed) in units of pixels (229 μs dwell time in this example)—the vertical axis 1204 is the values of the two functions (unitless). The sum of the 13 weights (solid squares) in curve 1206 is 1.000, with a maximum value at the center of approximately 0.11. Although in this embodiment, a Gaussian smoothing function 1206 is shown, other smoothing functions are also within the scope of the invention, including, but not limited to, binomial distributions and bell curves. After the raw signal data has been convolved or combined with curve 1206 , the resultant smoothed data, such as curve 1108 in FIG. 11 , is then autocorrelated with a second, “derivative function” curve 1210 , which is the derivative of curve 1206 in this example. Although in this embodiment, curve 1210 is the derivative of a Gaussian curve, other types of “derivative function” curves are possible, including, but not limited to, the derivatives of binomial distributions or bell curves. The full-width half-maximum (FWHM) of Gaussian curve 1206 is a parameter to be optimized, as discussed in FIG. 16 , below, and is 10.0 pixels in this example. A simplification of this process would be to first convolve curves 1206 and 1210 , which is allowed since both convolution and autocorrelation are associative, and then convolve this resultant curve with the raw image data. Curves 1206 and 1210 are kept separate here to clarify the process.
FIG. 13 is a graph 1300 showing the raw signal 1106 and the smoothed signal 1108 (both from FIG. 11 ), and the smoothed derivative 1306 as a function of the time 1302 during a raster scan, showing damage to the first three GFPs out of the total of 100. The vertical axis 1304 at the left is for curves 1106 and 1108 in units of photons per pixel from all undamaged GFPs, while the vertical axis 1305 at the right is for the derivative 1306 , also in units of the numbers of photons per pixel from all undamaged GFPs. The derivative curve 1306 has three deep downward-going peaks: a first at 1310 corresponding to GFP damage event 1110 , a second at 1312 corresponding to GFP damage event 1112 , and a third at 1314 corresponding to GFP damage event 1114 —note the excellent locational agreement along the time axis. Thus, for small numbers of GFPs being excited by the laser, the image processing routine can easily locate GFP damage events from the raw imaging signal 1106 , as shown. The threshold line 1320 defines the maximum height for peaks in the derivative curve 1306 which are counted as GFP damage events. There are thus two parameters in the image processing method of the invention: the FWHM of the smoothing curve (such as curve 1206 in FIG. 12 ), and the threshold value 1320 . Choices for these two parameters are discussed in FIG. 17 , below.
Image Processing to Improve FM Localization for Larger Numbers of FMs
In this section, we will examine further the localization of fluorescent markers (FMs) such as green fluorescent proteins (GFPs), as first discussed in FIGS. 9 and 10 , above, for the case of a hundred times as many GFPs (i.e., now 10000) in the laser illumination area. FIG. 14 for the 10000 GFP case corresponds to FIG. 11 for the 100 GFP case—graph 1400 shows a raw signal 1406 with statistical noise and a smoothed signal 1408 as a function of the time 1402 during a raster scan, showing damage to the first three GFPs out of the total of 10000. Both graphs are plotted against a vertical axis 1404 representing the numbers of photons collected from all undamaged GFPs per pixel. As for the 100 GFP example, the noise is assumed to be entirely stochastic, i.e., fluctuations in the signals per pixel will have a standard deviation equal to the square root of the number of photons collected during the pixel time, in this example, 229 μs. With such a large number of GFPs being illuminated by the laser, as was discussed for FIG. 10 , curves 1008 and 1010 were much farther from the mean number of photons curve 1006 , meaning that it may potentially be difficult to distinguish individual GFP damage events from the general noise background—for this reason, the image processing method discussed herein was developed. This method is exemplary and is included here to illustrate that, with sufficient image processing of the proper type, the locations of most GFPs, even from a large number within a sample, should be fairly accurate, thus extending the techniques first described in U.S. Pat. No. 7,317,515 to the much higher fluorescent marker densities which may be typical for expressible tags such as GFPs. The same image processing routine illustrated in FIGS. 11-13 was used here. In FIG. 14 , curve 1408 is a smoothed version of the raw data curve 1406 , calculated using a smoothing curve 1206 having a FWHM of 10.0 pixels—the exact locations of the downward steps at each of the three GFP damage events 1410 , 1412 , 1414 are difficult to see in the raw data curve 1406 . The smoothing function (kernel) 1206 is shown in FIG. 12 , generating the smoothed curve 1408 , in which the GFP damage events are more apparent.
FIG. 15 is a graph 1500 showing the raw signal 1406 and the smoothed signal 1408 (both from FIG. 14 ), and the smoothed derivative 1506 as a function of the time 1502 during a raster scan, showing damage to the first three GFPs out of the total of 10000. The vertical axis 1504 at the left is for curves 1406 and 1408 in units of photons per pixel, while the vertical axis at the right 1505 is for the derivative, also in units of the numbers of photons per pixel. The derivative curve 1506 has three deep downward-going peaks: a first at 1510 corresponding to GFP damage event 1410 , a second at 1512 corresponding to GFP damage event 1412 , and a third at 1514 corresponding to GFP damage event 1414 —note the excellent agreement, in spite of the relatively noisy raw signal data 1406 in this example, compared with curve 1106 in FIG. 11 . The threshold line 1520 defines the maximum height for peaks in the derivative curve 1506 which are counted as GFP damage events (compare with threshold 1320 in FIG. 13 ). There are thus two parameters in the image processing method of the invention for 10000 GFPs, as for 100 GFPs: the FWHM of the smoothing curve (such as curve 1206 in FIG. 12 ), and the threshold value 1520 . Choices for these two parameters are discussed in FIG. 17 , below. Thus, for larger numbers of GFPs being illuminated by the laser, the image processing routine can still locate GFP damage events by processing the raw imaging signal 1406 , as shown.
Optimization of the Image processing Method
We now discuss the optimal choice of FWHM and threshold parameters for the image processing method. This analysis is for exemplary purposes only since it uses simulated noisy data—for actual experimental data, the FWHM and threshold values may be determined empirically from samples with known quantities of FMs (using a regular array of quantum dots or GFPs, for example) by adjusting the FWHM and threshold values to make the detected number of FMs match the actual number of FMs. FIG. 16 is a histogram 1600 showing the performance of an image processing method for locating the first three GFPs in the presence of large amounts of statistical noise and large numbers of GFPs (10000) being illuminated in the scan field. For an example in which there are exactly three GFPs (as in FIGS. 11, 13-15 ), histogram 1600 shows that for a FWHM of 10.0 pixels and a threshold of −3625, that 94% of the time 1608 , the routine will locate exactly the correct number of transitions, with no false positives (i.e., extraneous GFPs) and no false negatives (i.e., no missed GFPs). In 3% of the cases 1606 , one out of the three GFPs is missed, while in another 3% of the cases 1610 , an extraneous GFP is recorded (3 actual+1 extraneous=4 total).
FIG. 17 is a graph 1700 of the optimization results for the image processing method, illustrating the GFPs found 1706 as a function of the FWHM (in pixels) 1702 . The left axis 1704 corresponds to curve 1706 in percent. Curve 1708 illustrates the percentage of false negatives (i.e., the missed GFPs) using axis 1704 magnified by 10×. The sum of curves 1706 and 1708 always equals 100%. Curve 1710 illustrates the percentage of false positives (i.e., extraneous GFP locations not corresponding to real GFPs), also using axis 1704 magnified by 10×. The right axis 1720 corresponds to the curve 1712 of the optimized threshold level for the derivative (i.e., the values for line 1320 in FIG. 13 and line 1520 in FIG. 15 ). An extensive series of modeling calculations was performed, varying both the FWHM and threshold to determine the optimum values to maximize the level of curve 1706 while reducing and equalizing the percentages of false negatives and false positives. The results are shown in Table III, below. The threshold curve 1712 continues to rise as the FWHM is increased—this is intuitively reasonable, since clearly as the amount of smoothing is increased (with larger FWHM values), the peaks in the derivative will be “blunted” and will not extend as far downwards, requiring smaller thresholds (i.e., higher on the graph) to avoid cutting off those peaks which correspond to actual GFPs.
The four columns in Table III listing the “% of Times Each Number of GFPs Detected” show that in all cases, either two, three or four peaks were detected (never more or less), although in all cases the correct number of peaks was three. When two peaks were detected, it was found that both locations corresponded to actual GFPs, but the peak for the third GFP location did not extend below the threshold and was lost. Thus, for FWHM=6.0 pixels, a 9.50% rate of detection of two peaks corresponds to (9.50%)/3=3.17% rate of false negatives (i.e., missed GFPs), and a (9.50%) 2/3=6.37% rate of correctly detecting GFPs, which adds to the 78.25% rate of detecting the correct number of GFPs (at the correct locations). Similarly, when four peaks were detected, it was found that three locations corresponded to actual GFPs, but an additional peak due to smoothed noise fell below the threshold and was counted as an extraneous GFP. Thus, the 12.25% rate of detecting four peaks corresponds to (12.25%)/4=3.06% rate of false positives, and a (12.25%) 3/4=9.19% rate of correctly detecting GFPs, which adds to the 78.25% rate. Thus the total percent of GFPs found correctly is: 3.17%+78.25%+9.19%=96.83%, as shown in Table III.
From this analysis, it appears that a FWHM of 10 pixels with a threshold of −3625 provides a good balance of a minimum number of false positives (0.75%) and false negatives (1.00%), while giving a high rate (99%) of correct GFP localization. In general, it is preferable to use the smallest possible FWHM for smoothing, subject to the constraint of minimizing the error rate, since larger FWHM values may cause the loss of data in the rare cases where GFPs are very close together along the scan line (i.e., only a few pixels apart)—thus a FWHM of 10.0 pixels was chosen, instead of a FWHM of 13.0 pixels which would give the same error rate. Hundreds of simulations with random noise have shown surprising consistency in the results shown in FIG. 17 and Table III. Clearly, the optimum value for the FWHM may be a function of various characteristics of the image. It is expected that this optimization process will be integral to the overall charged particle beam system used to acquire the raw imaging signal and to perform subsequent image processing to produce the final image containing the coordinates of the GFPs in the sample. For actual biological samples, with variations in light emittance from GFPs, and many other issues, theoretical errors rates as demonstrated here are almost certainly more than adequate.
Flowchart of Method for Localizing Expressible Tags Such as GFPs
FIG. 18 is a flow chart 1800 for the method of the present invention for localizing expressible tags such as GFPs within a biological sample. In block 1802 , the reporter gene for GFP is attached to the regulatory sequence of a particular gene of interest (GoI) in an animal, plant or cell culture which is the subject of research interest, thus whenever the GoI is expressed within the cell (consistent with the cell's need for the protein encoded for by that GoI), the GFP (and the peptide linker, if present) will also be expressed and will remain attached to the protein of interest (PoI). In block 1804 , the cell is allowed to express the GFP genes (producing the PoI+linker+GFP amino acid sequence, with the normal secondary, tertiary, and possibly quaternary structures for the PoI). The sample is then prepared for charged particle microscopy in block 1806 in a manner familiar to those skilled in the art—since the GFPs are typical proteins, no special treatment should be necessary to preserve the optical emission properties of the GFPs within the sample. In parallel with blocks 1802 - 1806 , in block 1808 , a charged particle beam system is configured for both the laser illumination of the sample (with the required excitation wavelength based on the choice of mutant or wild-type GFP), as well as the efficient collection of emitted fluorescence from the excited GFPs. The three embodiments of the invention illustrated in FIGS. 3, 5 and 6 are exemplary of systems having this required capability, however other systems also having this capability are also possible for implementation of the present invention.
Once the sample has been prepared in block 1806 , and the charged particle system has been properly configured in block 1808 , the sample can be inserted into the charged particle beam system in block 1810 and positioned under the charged particle beam. The efficient dual imaging capability enabled by the detector optics illustrated in FIGS. 4A and 4B may enable this process to be performed with low levels of damage to the specimen (because imaging doses can be minimized). Now, in block 1812 , the sample is illuminated by a laser beam tuned to optimally excite the GFPs within the sample. Preferably almost immediately, rastering of the charged particle beam (comprising either electrons or ions) is started in block 1814 while the light signal from the excited GFPs is collected and stored in an image storage device, such as a frame grabber. Block 1818 represents the operator selecting image processing parameters, such as the FWHM for smoothing and the threshold, as discussed above. This step is optional, and if skipped, block 1816 will use previously-defined image processing parameters. In block 1816 , the raw noisy signal data from the sample are processed to determine the locations of GFPs in the sample, and thus the locations of the PoIs encoded for by the GoIs.
Flowchart of Method for Localizing Functionalized Tags Such as Quantum Dots
FIG. 19 is a flow chart 1900 for the method of the present invention for localizing functionalized tags such as quantum dots within a sample. In block 1902 , the sample is prepared for attachment of functionalized quantum dots or other types of functionalized fluorescent markers or dyes to the intracellular components of interest to the researcher. In block 1904 , the sample is exposed to a solution of functionalized fluorescent markers (FMs), such as quantum dots (Q-dots). The sample is then prepared for charged particle microscopy in block 1906 in a manner familiar to those skilled in the art. In parallel with blocks 1902 - 1906 , in block 1908 , a charged particle beam system is configured for both the laser illumination of the sample [with the required wavelength(s) based on the choice of Q-dot(s)], as well as the efficient collection of emitted fluorescence from the excited Q-dots. The three embodiments of the invention illustrated in FIGS. 3, 5 and 6 are exemplary of systems having this required capability, however other systems also having this capability are also possible for implementation of the present invention.
Once the sample has been prepared in block 1906 , and the charged particle system has been properly configured in block 1908 , the sample can be inserted into the charged particle beam system in block 1910 and positioned under the charged particle beam. The efficient dual imaging capability enabled by the detector optics illustrated in FIGS. 4A and 4B may enable this process to be performed with low levels of damage to the specimen (because imaging doses can be minimized). Now, in block 1912 , the sample is illuminated by a laser beam tuned to optimally excite the Q-dots within the sample. Preferably almost immediately, rastering of the charged particle beam (comprising either electrons or ions) is started in block 1914 while the light signal from the excited Q-dots is collected and stored in an image storage device, such as a frame grabber. Block 1918 represents the operator selecting image processing parameters, such as the FWHM for smoothing and the threshold, as discussed above. This step is optional, and if skipped, block 1916 will use previously-defined image processing parameters. In block 1916 , the raw noisy signal data from the sample are processed to determine the locations of Q-dots in the sample, and thus the locations of the PoIs compatible with the Q-dot functionalization.
Combined Secondary Electron and FM Damage Event Imaging
FIG. 20 is a schematic diagram 2000 of a combined secondary electron and fluorescent marker image 2002 . During the scanning in a pattern of the charged particle beam across the sample surface by the beam deflector, two images may be simultaneously acquired: a secondary electron (SE) image and a light optical image arising from emitted fluorescent light from the sample containing expressible fluorescent markers (FMs), such as GFPs, or functionalized fluorescent markers, such as Q-dots. The charged particle beam irradiates an area generally somewhat smaller than the area of the light or other radiation beam that causes the FMs to fluoresce—it is preferred that the illumination area not be substantially larger than the area irradiated by the charged particle beam so that the decreases in light collected for each FM damage event may be maximized relative to the overall light background from all the undamaged FMs. The secondary electron image is composed of image pixels, the brightness of each corresponds to the signal from the SE detector while the charged particle beam is on the corresponding point on the sample, the signal from the SE typically being related to the number of SEs detected. Such an image is referred to as a “charged particle beam image” and can be generated by a primary beam of electrons or ions, using detected secondary electrons, backscattered electrons, secondary ions, or other types of signal. In FIG. 20 , the SE image corresponds to the various lines 2008 , circles 2006 , ovals, and shaded areas 2004 , corresponding to various intracellular components of the cell being imaged, e.g., nuclei, cell membranes, smooth and rough endoplasmic reticula, mitochodria, vesicles, etc. Superimposed on the SE image are indicators of the locations of the multiplicity of FMs, indicated by small black circles in the figure. As the charged particle beam is scanned across the sample, the position of the charged particle beam is registered at the instant that a reduction or extinguishment of fluorescence of a FM is detected. The extinguishment is determined by the image processing method in FIG. 21 —these data are stored in the FM Location File generated by block 2122 of FIG. 21 . The benefits of the high collection efficiency combined SE and light detection enabled by the detector optics illustrated in FIGS. 4A and 4B are apparent here—high SE collection efficiency improves the image quality of the various intracellular structures, while the efficient collection of light from the sample enables a high percentage of the FMs in the sample to be precisely located, with the location being stored and superimposed onto the SE image. Since the SE and light data both arise from the same raster scan, superposition of the FM locations on the SE image can be very precise. Alternatively, the locations of FMs within the sample can be superimposed on typical TEM images (elastic, inelastic, energy-filtered inelastic, etc.) created using signals from detector 586 in FIG. 5 , or detector 686 in FIG. 6 .
Exemplary Image Processing Method
FIG. 21 is a flow chart 2100 for an image processing method for localizing fluorescent markers (FMs) within a sample. This method assumes that a full raster scan of the sample by the charged particle beam has been completed—during this scan, a set of raw image data for the set of pixels comprising the raster has been acquired and stored in a first image memory. Each pixel datum is a number proportional to the emitted fluorescent light intensity from all the undamaged fluorescent markers (FMs), such as GFPs or Q-dots, in the sample averaged over the pixel dwell time. An image processor may be comprised in the system controller such as 362 , 562 , and 662 in FIGS. 3, 5, and 6 , respectively. Alternatively, an image processor may be comprised in a separate off-line processing computer (not shown). In block 2102 , the image processor convolves the raw image data (such as curve 1106 in FIG. 11 , or curve 1406 in FIG. 14 ) with a pre-determined smoothing function from block 2104 (such as curve 1206 in FIG. 12 ) to generate smoothed image data which is stored in a second image memory. In block 2106 , the smoothed image data (such as curve 1108 in FIG. 11 , or curve 1408 in FIG. 14 ) from block 2102 is autocorrelated with a pre-determined derivative function from block 2108 (such as curve 1210 in FIG. 12 ) to generate derivative data which is stored in a third image memory.
Next, in block 2110 , the image processor scans the derivative data for all local minima—both the values and locations of all local minima are stored in a Derivative Minimum Location File (DMLF). Examples of local minima include peaks 1310 , 1312 , and 1314 in FIG. 13 , or peaks 1510 , 1512 , and 1514 in FIG. 15 . A loop comprising decision block 2112 and blocks 2114 , 2122 , and 2124 is then executed for each of the local minima in the DMLF. The value of each local minimum is compared with a predetermined maximum threshold level from block 2114 , such as level 1320 in FIG. 13 , or level 1520 in FIG. 15 . In general, many of the local minima will correspond to random noise fluctuations in the data, and not to true locations of FMs in the sample—with the proper selection of the maximum threshold level in block 2114 , most of the local minima which do not correspond to actual FMs will be eliminated by decision block 2112 (thereby reducing the number of false positives). Also, it is preferred that most of the local minima which do correspond to actual FMs will fall below the maximum threshold level (thereby reducing the number of false negatives). The success of the image processing method in localizing a large fraction of actual FMs, while excluding a large fraction of minima not corresponding to actual FMs relies on the fact that when an actual FM is damaged, there is a permanent reduction in the light from the sample, while for random noise the light from the sample goes up and down, but remains the same on average. Thus, by smoothing the data and using a derivative function, the up and down fluctuations due to noise will be smoothed out, while step reductions in light from the sample will still be detectable. Path 2120 from decision block 2112 corresponds to all local minima falling below the maximum threshold level—the locations of these local minima are saved in the FM Location File (FMLF) in block 2122 , and the loop then proceeds to block 2124 . All local minima having values above the maximum threshold level follow path 2118 to block 2124 and are not stored in the FMLF since these data are, by definition, assumed not to correspond to actual FM locations (this is the purpose of the threshold). In block 2124 , the loop increments to the next local minimum in the DMLF until all stored local minima have been analyzed in decision block 2112 . At the conclusion of the image processing method, the FMLF will preferably contain the locations of the majority of the FMs within the sample, and a minimum number of extraneous (non FM) locations—thus the levels of false negatives (missed FMs) and false positives (erroneous extra FMs) will both be minimized, as discussed in FIGS. 16 and 17 .
The above discussion has used the term “green fluorescent protein”, or “GFP”, to represent any type of expressible biological fluorescent marker, or tag, all being within the scope of the invention. The term “Q-dot” has been used to represent any type of functionalized fluorescent marker as commonly used in the art, all being within the scope of the invention. Although three embodiments of charged particle systems for implementing the present invention are presented, it is understood that other system configurations are also possible within the scope if the invention. The term secondary electron may include not only low energy secondary electrons, but also Auger electrons and backscattered electrons.
TABLE III
Image Processing Routine Optimization Results. For each set of FWHM
and threshold values, 300 simulation runs (each with exactly three initial
GFP damage events) were run to get good statistics on the performance of
the image processing routine.
% of Times Each No. of
GFPs
False
False
FWHM
GFPs Detected
Found
Neg.
Pos.
(pixels)
Threshold
2.0
3.0
4.0
5.0
(%)
(%)
(%)
6.0
−8000
9.50
78.25
12.25
0.00
96.83
3.17
3.06
7.0
−6600
12.50
75.00
12.5
0.00
95.83
4.17
3.13
8.0
−5000
0.00
85.00
15.00
0.00
100.00
0.00
3.75
9.0
−4300
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3.17
0.00
98.94
1.06
0.79
10.0
−3625
3.00
94.00
3.00
0.00
99.00
1.00
0.75
11.0
−3100
3.25
93.50
3.25
0.00
98.92
1.08
0.81
12.0
−2500
0.00
94.00
6.00
0.00
100.00
0.00
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93.00
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1.75
Computer programs can be applied to input data to perform the functions described herein and thereby transform the input data to generate output data. The output information is applied to one or more output devices such as a display monitor. In preferred embodiments of the present invention, the transformed data represents physical and tangible objects, including producing a particular visual depiction of the physical and tangible objects on a display.
Preferred embodiments of the present invention also make use of a particle beam apparatus, such as a FIB or SEM, in order to image a sample using a beam of particles. Such particles used to image a sample inherently interact with the sample resulting in some degree of physical transformation. Further, throughout the present specification, discussions utilizing terms such as “calculating,” “determining,” “measuring,” “generating,” “detecting,” “forming,” or the like, also refer to the action and processes of a computer system, or similar electronic device, that manipulates and transforms data represented as physical quantities within the computer system into other data similarly represented as physical quantities within the computer system or other information storage, transmission or display devices.
Although embodiments of the present invention and their advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made to the embodiments described herein without departing from the spirit and scope of the invention as defined by the appended claims. The invention includes several novel and inventive aspects which may be used together or separately in different embodiments. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. For example, the novel image processing method can be used with other types of systems, including prior art systems and yet-to-be developed systems. As one of ordinary skill in the art will readily appreciate from the disclosure of the present invention, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the present invention. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps. | A method and system for the imaging and localization of fluorescent markers such as fluorescent proteins or quantum dots within biological samples is disclosed. The use of recombinant genetics technology to insert “reporter” genes into many species is well established. In particular, green fluorescent proteins (GFPs) and their genetically-modified variants ranging from blue to yellow, are easily spliced into many genomes at the sites of genes of interest (GoIs), where the GFPs are expressed with no apparent effect on the functioning of the proteins of interest (PoIs) coded for by the GoIs. One goal of biologists is more precise localization of PoIs within cells. The invention is a method and system for enabling more rapid and precise PoI localization using charged particle beam-induced damage to GFPs. Multiple embodiments of systems for implementing the method are presented, along with an image processing method relatively immune to high statistical noise levels. | 7 |
CROSS REFERENCE TO RELATED APPLICATION
This application is a divisional of U.S. patent application Ser. No. 10/156,580, filed on May 24, 2002, now U.S. Pat. 6,843,880.
BACKGROUND OF THE INVENTION
As Integrated circuit devices increase in device density and the size of wafers used in integrated circuit manufacturing increase in size, there is a continued need for more precise manufacturing process control.
In wet processes (e.g., wet etching) used in some stages of integrated circuit manufacture, process endpoint control has been achieved by monitoring one or more electrical properties (e.g., impedance) in the liquid bath medium in which the wet process is conducted. The change of such electrical property (ies) is correlated with the actual state of the wafer(s) being processed such that the process can be terminated or altered when a target electrical property value and/or rate of change is achieved. Examples of such processes are described in U.S. Pat. Nos. 5,338,390; 5,445,705; 5,456,788; 5,501,766; 5,516,399; and 5,788,801, the disclosures of which are incorporated herein by reference.
While the known techniques provide some process control, there can be difficulty in interpretation of the electrical signal corresponding to the monitored electrical property. For example, noise or scatter may be present in the signal such that the actual value of the electrical property and/or the rate of change (slope) are difficult to determine accurately. This problem can lead to operator and/or machine error in interpreting when to stop the wet process of interest such that the ideal manufacturing result is not achieved.
Thus, there is a need for improved monitoring techniques and apparatus to provide better electrical properly monitoring to enable consistent selection of the desired process endpoint.
SUMMARY OF THE INVENTION
The invention provides apparatus and methods for detecting changes in wet processes. The apparatus and methods of the invention are especially useful where noise otherwise makes electrical property monitoring problematic. The apparatus and methods of the invention are characterized by the use of a capacitor to adjust the phase angle of the electrical circuit used to monitor an electrical property (especially impedance) of the liquid medium used in the wet process. The apparatus and methods of the invention are especially useful where the effective phase angle of the circuit can be set at or close to zero at the start of the wet process of interest.
In one aspect, the invention provides an apparatus for detecting a change in impedance in a liquid medium, the apparatus comprising an electrical circuit having a capacitor, at least two electrodes for placement in the liquid medium, a source of alternating electrical current, and a detector for measurement of impedance across the electrodes as a function of time. The capacitor is preferably a variable capacitor which enables adjustment of the phase angle of the circuit relative to the frequency of the applied current. The adjustable capacitor preferably can be adjusted to provide a circuit phase angle of zero at the start of a wet process where the apparatus of the invention is used for process control. The apparatus of the invention enables improved methods of controlling wet processes, especially wet etch processes.
In another aspect, the invention encompasses a method of controlling a process for wet etching a wafer, the method comprising:
(a) providing a container with a liquid etch medium,
(b) providing an apparatus for detecting a change in impedance in the liquid medium, the apparatus comprising an electrical circuit having a variable capacitor, at least two electrodes placed in the liquid medium, a source of alternating electrical current, and a detector for measurement of impedance across the electrodes as a function of time,
(c) applying an alternating current to the circuit and adjusting the variable capacitor until the circuit exhibits a desired phase angle,
(d) immersing at least one wafer in the liquid medium whereby the etching process is initiated, a surface of the immersed wafer being proximate to the electrodes, and
(e) monitoring the detected impedance as a function of time.
The capacitor adjustment preferably results in a phase angle of about zero at the beginning of the wet process. The method of the invention is especially useful for monitoring wet etching processes such as wet etching of TiW.
The invention further encompasses a method of patterning a material layer on a substrate, the method comprising:
(a) providing a substrate having a partially masked material layer,
(b) providing a liquid etchant medium in a container,
(c) providing apparatus for detecting a change in impedance in the liquid medium, the apparatus comprising an electrical circuit having a variable capacitor, at least two electrodes for placement in the liquid medium, a source of alternating electrical current, and a detector for measurement of impedance across the electrodes as a function of time,
(d) contacting the electrodes with the liquid medium,
(e) adjusting the variable capacitor to change a phase angle of the circuit of at a provided frequency of alternating electrical current,
(f) positioning a surface of the substrate proximate to the electrodes in the liquid etchant medium, and
(g) etching the substrate until a desired impedance condition is achieved in the circuit.
The invention also encompasses computer programs in a computer or computer-readable medium for carrying out the endpoint determination and process control aspects of the invention.
These and other aspects of the invention are discussed in further detail below.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic layout of an apparatus according to an embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
The invention provides apparatus and methods for detecting changes in wet processes. The apparatus and methods of the invention are especially useful where noise otherwise makes electrical property monitoring problematic. The apparatus and methods of the invention are characterized by the use of a capacitor to adjust the phase angle of the electrical circuit used to monitor an electrical property (especially impedance) of the liquid medium used in the wet process. The apparatus and methods of the invention are especially useful where the phase angle of the circuit can be set at or close to zero at the start of the wet process of interest.
Referring to FIG. 1 , the apparatus of the invention generally comprises an electrical circuit 10 which is driven by an alternating current source 20 (e.g., an impedance (LCR) meter). The circuit 10 further includes at least two electrodes 30 for immersion in a liquid medium 40 (preferably an aqueous etch medium) in a container 50 . The apparatus of the invention may be used with any suitable workpiece to be etched, however, the apparatus is preferably adapted for use in wafer etch processes. In FIG. 1 , wafer 60 is held in holder 70 which is immersed in liquid medium 40 . The electrodes 30 are preferably in close proximity to, but not touching, the wafer 60 .
The circuit 10 is preferably further characterized by the presence of a variable capacitor 80 ; more preferably the capacitor 80 is in parallel with the path formed by electrodes 30 through the liquid medium 40 . The variable capacitor 80 may be adjusted directly at the capacitor and/or control may be integrated with another control device such as a programmed controller or a computer 90 interfaced through a general purpose interface bus (GPIB) 95 or through other suitable device configurations. The adjustment of variable capacitor 80 may be done manually, e.g., where the LCR meter 20 contains an oscilloscope function 25 (or other frequency comparison function) that permits determination of the phase relationship between the applied current to the detected current. Typically, LCR meter 20 would also contain circuitry adapted to analyze the detected current to determine the impedance values as a function of time during the process of interest.
The impedance values can then be processed, preferably using an endpoint program of the invention which preferably resides in computer 90 . The program acquires the impedance data (total amplitude and phase angle). The program processes the impedance data to determine when an endpoint reference (e.g., a turning point of the impedance values with respect to time) is achieved. Once the endpoint reference is detected, the program preferably adds an appropriate amount of over-etch time to determine when to send a stop signal (e.g., through control signals 99 sent from GPIB 95 ) to remove the wafer from contact with the liquid medium or otherwise stop and/or change the process as desired.
In order to reduce noise in the impedance data, the program preferably makes the endpoint determination using a moving array average of impedance values, more preferably a double moving array average. In a single moving array, each impedance value used in the endpoint determination is actually a moving average N 1 of the n 1 most recent impedance values where n 1 is an integer value selected to provide noise reduction (curve smoothing) while minimizing loss of transient response. Preferably, n 1 is typically about 3–50, more typically about 5–10. In a moving array, the N 1 data value at time t is the average of the n 1 most recent values including the raw data value at time t. In the case of a double moving array, the N 1 data values are themselves averaged in a second moving array N 2 of the n 2 most recent N 1 values where n 2 is an integer, preferably about 3–50, more typically about 5–10. The use of double moving array average generally provides a better combination of noise reduction and transient response.
In some instances, especially where greater sensitivity is needed, a derivative of the impedance values may be used for endpoint determination. In such instances, preferably the a first derivative (with respect to time) of the N 2 impedance values is used, more preferably, a single or double moving array average of the N 2 values is used in calculation of the derivative.
The invention may be employed in wet processes where wafers are processed individually and/or where multiple wafers are processed simultaneously in the same bath. The apparatus configuration should have the allow for the electrodes of the electrical circuit to be in proximity to the surface of the wafer to be etched (i.e., sufficiently close that changes in the electrical characteristics of the liquid medium at the wafer surface can be monitored), the invention is not limited to any specific wafer or wafer-holder configuration. Similarly, the invention is not limited to any specific electrode configuration apart from meeting the position criteria mentioned above. An example wafer holder 70 is shown where slot 100 is present to facilitate handling and recesses 110 are present to facilitate loading and unloading of the wafer(s) to be processed.
The invention encompasses a method of controlling a process for wet etching a wafer, the method comprising:
(a) providing a container with a liquid etch medium,
(b) providing an apparatus for detecting a change in impedance in the liquid medium, the apparatus comprising an electrical circuit having a variable capacitor, at least two electrodes placed in the liquid medium, a source of alternating electrical current, and a detector for measurement of impedance across the electrodes as a function of time,
(c) applying an alternating current to the circuit and adjusting the variable capacitor until the circuit exhibits a desired phase angle,
(d) immersing at least one wafer in the liquid medium whereby the etching process is initiated, a surface of the immersed wafer being proximate to the electrodes, and
(e) monitoring the detected impedance as a function of time.
This method of the invention preferably involves using the apparatus and averaging described above. The liquid medium is preferably a wet etch medium adapted to etch a material on a wafer surface. Examples of wet etch processes are those used for TiW etch (see U.S. Pat. No. 6,293,457 the disclosure of which is incorporated herein by reference). The method is not limited to any specific liquid medium or processing step as long as an impedance change occurs which can be correlated to a control point of the process. In the method, the variable capacitor is preferably adjusted achieve a phase angle for the circuit of less than about 0.25 radians (approx. 15°), more preferably less than 0.1 radians, most preferably about zero radians. This adjustment is preferably done around the start of the process to be controlled. The method preferably further comprises removing the wafer from contact with the liquid medium in response to a behavior of the monitored impedance.
The invention also encompasses a method of patterning a material layer on a substrate, the method comprising:
(a) providing a substrate having a partially masked material layer,
(b) providing a liquid etchant medium in a container,
(c) providing apparatus for detecting a change in impedance in the liquid medium, the apparatus comprising an electrical circuit having a variable capacitor, at least two electrodes for placement in the liquid medium, a source of alternating electrical current, and a detector for measurement of impedance across the electrodes as a function of time,
(d) contacting the electrodes with the liquid medium,
(e) adjusting the variable capacitor to change a phase angle of the circuit of at a provided frequency of alternating electrical current,
(f) positioning a surface of the substrate proximate to the electrodes in the liquid etchant medium, and
(g) etching the substrate until a desired impedance condition is achieved in the circuit.
This method preferably uses the apparatus and techniques described above relative to the method of controlling wet etch. The partially masked material layer on the substrate may be a TiW layer such as described in the above mentioned U.S. Pat. No. 6,293,457. Alternatively, the layer may be of another material of interest (e.g., ceramic, metal or semiconductor) or may be the substrate material itself. The invention is especially useful where the material layer of interest is a metal. The masking may be provided by photoresist, hard mask or other patterned layers as is known in the art. The liquid etchant medium may be one of those described in the above mentioned patent or may be another composition suitable for etching the material layer of interest. See for example wet etch processes described in “Fundamentals of Semiconductor Processing Technologies” by Badih El-Kareh, Kluwer Academic Publishers, (1995), pages 272–281.
The computer programs of the invention preferably are embodied in a computer-readable medium. The programs are capable of at least the following steps: acquiring the impedance data as a function of time, calculating double moving array averages of the impedance data, determining whether the impedance data based on the double moving array averages meets an endpoint condition, and causing a control signal to be sent to apparatus performing the process of interest. The program is also preferably capable of performing the derivative calculations described above and determining whether the derivative data meets an endpoint condition, and on that basis, causing a control signal to be sent to apparatus performing the process of interest. | Improved endpoint detection is obtained for wet etch and/or other chemical processes involving in situ measurement of bath impedance. The endpoint detection uses a measurement apparatus having a measurement circuit with a capacitor designed to alter the phase angle of the circuit. The capacitor is preferably a variable capacitor which is used to set the initial phase angle of the measurement circuit to about zero. The methods using the improved detection enable etch to be more precisely controlled even under conditions where noise would otherwise adversely impact determination of the endpoint. | 2 |
SCOPE OF THE INVENTION
[0001] The invention is encompassed within the technical field of lung cancer treatment with antitumor drugs and, specifically, develops a diagnostic device which allows for treating each patient with the most effective drug according to the polymorphism they show for the XPD gene.
STATE OF THE ART
[0002] Different antitumor drugs damage DNA in a manner similar to that carried out by carcinogens. The covalent bond of the carcinogen or of a cytotoxic antitumor drug provides the formation of a DNA base which is chemically altered, which is known with the term adduct (Philips, 2002). Cisplatin causes bonds between DNA strands, and such adducts provide the cytotoxic action of cisplatin (Siddik, 2062). DNA repair systems are essential for eliminating cisplatin adducts. Nucleotide Excision Repair (NER) is the main pathway for protecting the host from developing lung cancer, and at the same time it is the generating principle of resistance to cisplatin. In fact, both the benzopyrene diol epoxide (BPDE) adducts and also the cisplatin adducts effectively block RNA polymerase II and thus void transcription (Hanawalt, 2001). These DNA lesions are eliminated by the NER system, which in turn is subdivided into two metabolic pathways: Transcription Coupled Repair (TCR) and Global Genomic Repair (GGR) (Diagram 1). TCR (or TC-NER) significantly repairs the lesions blocking transcription in the strand transcribing the DNA of active genes, whereas GGR (or GG-NER) repairs the lesions in the strand which does not transcribe in the active genes and also in the genome without transcription function (Cullinane et al., 1999; May et al., 1993; McKay et al., 1998).
[0003] Diagram 1: Representation of the Nucleotide Excision Repair (NER) Pathways.
[0004] In human beings, NER is a fundamental defense mechanism against the carcinogenic effects of sunlight, and certain genetic defects in the repair pathways produce severe consequences on autosomal recessive hereditary disorders, such as xeroderma pigmentosum (XP). In fact, patients with this disease are hypersensitive to sunlight with an extraordinary susceptibility to and high frequency of suffering from skin cancer. In XP, there are seven complementary groups which can be deficient in the NER pathways. These genes are enumerated from XPA to XPG. In XP disease, these genes are defective in both NER pathways (Conforti et al., 2000). In ovarian cancer and, less frequently, in colon cancer and lung cancer, losses of heterozygosity have been observed in different XP genes (Takebayashi et al., 2001). The loss of heterozygosity is related to the loss of transcription, and the deficiency of these genes entails an increase in sensitivity to cisplatin, as has been observed in ovarian cancer. Cockayne Syndrome (CS) is another photosensitive disease which is linked to a deficiency in the NER system. Two genes have been identified, CSA and CSB. The alterations of said genes disrupt the functions in which they are involved in the TCR pathway (Conforti et al., 2000).
[0005] The left portion of Diagram 1 (modified from Rajewsky and Müller, 2002) shows the TCR pathway which is the essential pathway for detecting the damage caused by cisplatin (Cullinane et al., 1999). In the moment of transcription, when the RNA polymerase II detects the lesion, the specific CSA and CSB transcription factors are activated in the molecular NER pathway (Furuta et al., 2002; McKay et al., 2001). The XP genes are also involved in the TCR pathway, as shown in the box in Diagram 1. Essentially, different molecular deficiencies in both pathways (GGR and TCR) in fibroblasts confer an increase in the sensitivity to the cytotoxic effect of cisplatin in comparison to what occurs in normal fibroblasts. What is important is that any deficiency in any of the XPA, XPD, XPF or XPG genes confers a substantial increase of the activity of cisplatin (Furuta et al., 2002).
[0006] As a common principle, the repertoire of cytotoxins used in cancer treatment, particularly in lung cancer, are centered around the use of cisplatin or carboplatin in association with another drug, such as gemcitabine, docetaxel, paclitaxel or vinorelbine as the most important ones and of standard clinical use. However, chemotherapy results in metastatic lung cancer are very limited, with a median time to progression which does not pass five months, and a median survival which does not exceed eight or ten months. No type of combination stands out in improving such survival expectancies. However, on an individual level, as a clinical verification, it is noted that individual cases have significantly longer survivals. Polymorphisms, which are simple nucleotide changes, confer interindividual differences which alter gene expression or function. Such polymorphisms existing in a very high proportion in the genome are still under study. It is possible that more than 3,000 polymorphisms will be characterized in the future which will be useful for determining susceptibility to cancer, the prognostic value of the disease and the predictive value of response to treatment. At the level of messenger RNA expression, it has been verified that the overexpression of the ERCC1 gene acting in the GGR pathway causes resistance to cisplatin in gastric, ovarian and lung cancer (Lord et al., 2002; Metzger et al., 1998; Shirota et al., 2001).
[0007] XPD polymorphisms have been linked to a decrease in DNA repair capacity in different studies (Spitz et al., 2001). In fact, about half the population has the Lys751Lys genotype, and they also have the normal, homozygote Asp312Asp genotype. Such patients or persons with normal homozygote genotype have a very good repair capacity and, therefore, can be resistant to cisplatin (Bosken et al., 2002). The increase of the repair capacity, which can be measured by means of functional assays, has been associated with the resistance to cisplatin in non small cell lung cancer (NSCLC) (Zeng-Rong et al., 1995). Repair capacity has also been studied by means of measuring the reactivation of a gene damaged by exposure to BPDE, and repair capacity levels are significantly lower in lung cancer patients than in control patients (Wei et al., 1996, 2000). Multiple studies indicate that the decline of the repair capacity and the increase in the DNA adduct levels increases the risk of lung cancer. Therefore, the basal expression of critical genes in the NER pathway is related to the risk of lung cancer. By RT-PCR, the ERCC1, XPB, XPG, CSB and XPC transcript levels were measured in lymphocytes of 75 lung cancer patients and 95 control patients. The results showed a significant decrease in the XPG and CSB expression levels in the cases of lung cancer in comparison with the controls (Cheng et al., 2000). What is very important is that the lymphocyte messenger RNA levels of the XPA, XPB, XPC, XPD, XPF, XPG, ERCC1 and CSB genes showed a very significant correlation in the messenger RNA levels between ERCC1 and XPD, in turn, the expression of both genes is correlated to DNA repair capacity (Vogel et al., 2000).
[0008] There are patents (WO 97/25442) relating to lung cancer diagnosis methods, as well as to diagnosis methods for other types of tumors (WO 97/38125, WO 95/16739) based on the detection of other polymorphisms different from those herein described. Other patents have also been located which also use the detection of polymorphisms in other genes to know the response of certain patients to other drugs (statins); but this applicant is not aware of patents determining which patients with lung cancer are more prone to one antitumor treatment or another.
LITERATURE
[0000]
1. Aloyz R, Xu Z Y, Bello V, et al. Regulation of cisplatin resistance and homologous recombinational repair by the TFIIH subunit XPD. Cancer Res 2002; 62:5457-5462
2. Bosken C H, Wei Q, Amos C I, Spitz M R: An analysis of DNA repair as a determinant of survival in patients with non-small-cell lung cancer. J Natl Cancer Inst 2002; 94:1091-1099
3. Cheng L, Guan Y, Li L, et al. Expression in normal human tissues of five nucleotide excision repair genes measured simultaneously by multiplex reverse transcription-polymerase chain reaction. Cancer, epidemiology biomarkers & prevention 1999; 8:801-807
4. Cheng L, Guan Y, Li L, et al. Expression in normal human tissues of five nucleotide excision repair genes measured simultaneously by multiplex reverse transcription-polymerase chain reaction. Cancer, Epidemiol Biomark Prev 8:801-807, 1999
5. Cheng L, Sptiz M R, K Hong W, Wei K. Reduced expression levels of nucleotide excision repair genes in lung cancer: a case-control analysis. Carcinogenesis 2000; 21: 1527-1530
6. Cheng L, Sptiz M R, K Hong W, Wei K. Reduced expression levels of nucleotide excision repair genes in lung cancer: a case-control analysis. Carcinogenesis 21: 1527-1530, 2000
7. Cheng L, Sturgis E M, Eicher S A, Sptiz M R, Wei Q. Expression of nucleotide excision repair genes and the risk for squamous cell carcinoma of the head and neck. Cancer 2002; 94:393-397
8. Conforti G, Nardo T, D'Incalci M, Stefanini M: Proneness to UV-induced apoptosis in human fibroblasts defective in transcription coupled repair is associated with the lack of Mdm2 transactivation. Oncogene 2000; 19:2714-2720
9. Cullinane C, Mazur S J, Essigmann J M, et al: Inhibition of RNA polymerase II transcription in human cell extracts by cisplatin DNA damage. Biochemistry 1999; 38: 6204-6212
10. Furuta T, Ueda T, Aune G, et al. Transcription-coupled nucleotide excision repair as a determinant of cisplatin sensitivity of human cells. Cancer Res. 62:4809-4902, 2002
11. Furuta T, Ueda T, Aune G, et al: Transcription-coupled nucleotide excision repair as a determinant of cisplatin sensitivity of human cells. Cancer Res 2002; 62:4899-4902
12. Hanawalt P C: Controlling the efficiency of excision repair. Mut Res 2001; 485:3-13
13. Hou S-M, Fält S, Angelini S, et al: The XPD variant alleles are associated with increased aromatic DNA adduct level and lung cancer risk. Carcinogenesis 2002; 23:599-603
14. Lord R V N, Brabender J, Gandara D, et al: Low ERCC1 expression correlates with prolonged survival after cisplatin plus gemcitabine chemotherapy in non-small-cell lung cancer. Clin Cancer Res 2002; 8: 2286-2291
15. May A, Naim R S, Okumoto D S, et al: Repair of individual DNA strands in the hamster dihydrofolate reductase gene after treatment with ultraviolet light, alkylating agents, and cisplatin J Biol Chem 1993; 268:1650-1657
16. McKay B C, Becerril C, Ljungman M: p53 plays a protective role against UV- and cisplatin-induced apoptosis in transcription-coupled repair proficient fibroblasts. Oncogene 2001; 20:6805-6808
17. McKay B C, Ljungman M, Rainbow A J: Persistent DNA damage induced by ultraviolet light inhibits p21 wafl and bax expression: implications for DNA repair, UV sensitivity and the induction of apoptosis. Oncogene 1998; 17:545-555
18. Metzger R, Leichman C G, Danenberg K D, et al: ERCC1 mRNA levels complement thymidylate synthase mRNA levels in predicting response and survival for gastric cancer patients receiving combination cisplatin and fluorouracil chemotherapy. J Clin Oncol 1998; 16:309-316
19. Phillips D H: The formation of DNA adducts. In: Alison M R, ed. The Cancer Handbook. London: Nature Publishing Group; 2002:293-307
20. Rajewsky M F, Müller R. DNA repair and the cell cycle as targets in cancer therapy. In: Alison M R, d. The Cancer Handbook. London: Nature Publishing Group 2002; 1507-1519
21. Shirota Y, Stoehlmacher J, Brabender J, et al: ERCC1 and thymidylate synthase mRNA-levels predict survival for colorectal cancer patients receiving combination oxaliplatin and fluorouracil chemotherapy. J Clin Oncol 2001; 19:4298-4304
22. Siddik Z H: Mechanisms of action of cancer chemotherapeutic agents: DNA-interactive alkylating agents and antitumour platinum-based drugs. In: Alison M R, ed. The Cancer Handbook London: Nature Publishing Group; 2002:1295-1313
23. Spitz M R, Wu X, Wang Y, et al. Modulation of nucleotide excision repair capacity by XPD polymorphisms in lung cancer patients. Cancer Res 61:1354-1357, 2001
24. Spitz M R, Wu X, Wang Y, et al: Modulation of nucleotide excision repair capacity by XPD polymorphisms in lung cancer patients. Cancer Res 2001; 61:1354-1357
25. Takebayashi Y, Nakayama K, Kanzaki A, et al: Loss of heterozygosity of nucleotide excision repair factors in sporadic ovarian, colon and lung carcinomas: implication for their roles of carcinogenesis in human solid tumors. Cancer Letters 2001; 174:115-125
26. Vogel U, Dybdahl M, Frentz G, et al. DNA repair capacity: inconsistency between effect of over-expression of five NER genes and the correlation to mRNA levels in primary lymphocytes. Mutat Res. 461:197-210, 2000
27. Wei Q, Cheng L, Amos C I, et al. Repair of tobacco carcinogen-induced DNA adducts and lung cancer risk: a molecular epidemiologic study. J Natl Cancer Inst 2000; 92: 1764-1772
28. Wei Q, Cheng L, Ki Hong W, Spitz M R. Reduced DNA repair capacity in lung cancer patients. Cancer Res 1996; 56:4103-4107
29. Zeng-Rong N, Paterson J, Alpert P, et al. Elevated DNA Capacity is associated with intrinsic resistance of lung cancer to chemotherapy. Cancer Res 1995; 55:4760-4764.
BRIEF DESCRIPTION OF THE INVENTION
[0038] In the research carried out, the pharmacogenetic predictive value of XP gene polymorphic variants have been discovered. The XPD gene polymorphisms at exon 23 (A-C, Lys751Gln) and at exon 10 (G-A, Asp312Ans) have been studied. FIGS. 1 and 2 show two examples of identification of the XPD polymorphisms at condons 312 and 751, respectively, carried out by automatic sequencing. Diagram 2 shows the different DNA repair metabolic pathways and the position occupied by the XPD gene in said pathways. The clinical interest in examining XPD polymorphism is strengthened, given that a screening of a panel of cell lines of different tumors of the National Cancer Institute reveals that among XPA, XPB, XPD and ERCC1, only the overexpression of XPD is correlated with resistance to alkylating agents (Aloyz et al., 2002).
[0039] Diagram 2. DNA Repair Systems
DETAILED DESCRIPTION OF THE INVENTION
[0000] Classification of the Lys751Gln and Asp312Asn polymorphisms of the Human XPD/ERCC2 Gene.
[0000] 1. —Gene Information of the ERCC2/XPD Locus
[0040] Information of the sequence of DNA, RNA and protein corresponding to this gene is detailed on the web page www.ncbi.nlm.nih.gov/locuslink/refseq.html, with Locus ID number 2068, and which is summarized below:
[0000] ERCC2/XPD—excision repair cross-complementing rodent repair deficiency complementation group 2 (xeroderma pigmentosum D)
[0000] NCBI Reference Sequences (RefSeq):
[0000]
mRNA: NM — 000400
Protein: NP — 000391
GenBank Source: X52221, X52222
mRNA: NM — 000400
Protein: NP — 000391
GenBank Nucleotide Sequences:
Nucleotide: L47234 (type g), BC008346 (type m) X52221 (type m), X52222 (type m)
Other Links:
OMIM: 126340
UniGene: Hs 99987
2. —Biological Samples for Obtaining DNA
[0049] The DNA used for the classification of the two Lys751Gln and Asp312Asn polymorphisms has been obtained from nucleated cells from peripheral blood.
[0050] It is worth pointing out that to obtain the DNA and the subsequent classification, any other nucleated cell type of the human organism can be used.
[0000] 3. —Blood Extraction
[0051] Peripheral blood is collected in vacutainer-type tubes containing K 3 /EDTA (Becton Dickinson Systems; reference number 36752 or 368457). Then it is centrifuged for 15 minutes at 2,500 rpm at room temperature, and the plasma fraction is discarded. Two volumes of erythrocyte lysing solution (155 mM NH 4 Cl, 0.1 mM EDTA, 10 mM Hepes, pH=7.4) are added to the cell fraction and is incubated at room temperature for 30 minutes on a rotating platform. Then the sample is centrifuged for 10 minutes at 3,000 rpm at room temperature, the supernatant is discarded and the cellular precipitate obtained is re-suspended in 1 ml of erythrocyte lysing solution. The 10-minute, 3,000 rpm centrifugation at room temperature is repeated and the supernatant is discarded. The obtained precipitate corresponds to the erythrocyte-free cell fraction.
[0000] 4. —DNA Extraction
[0052] The DNA is extracted from the peripheral blood nucleated cells and purified by means of the commercial kit QIAmp® DNA blood Mini-kit (Qiagen; reference 51104 or 51106) following the manufacturer instructions.
[0000] 5. —Classification of the Lys751Gln and Asp312Asn Polymorphisms
[0053] The following PCR conditions were used to classify the Asp312Asn polymorphism of exon 10 (final reaction volume of 25 μl): 900 nM of primer SEQ ID NO. 1: ACGCCCACCTGGCCA, 900 nM of primer SEQ ID NO 2: GGCGGGAAAGGGACTGG, 300 nM of TaqMan MGB™ VIC probe SEQ ID NO 3: CCGTGCTGCCCGACGAAGT TAMRA, 300 nM of TaqMan MGB™ 6-FAM probe SEQ ID NO 4: CCCGTGCTGCCCAACGAAG TAMRA, 12.5 μl of TaqMan Universal PCR Master Mix (Applied Biosystems; reference 4304437) and 200 ng of DNA. The PCR cycles (50° C. for 2 minutes, 95° C. for 10 minutes, [92° C. for 15 seconds, 60° C. for 1 minute] for 40 cycles) and the polymorphism analysis were carried out in an ABI Prism 7000 Sequence Detection System equipment (Applied Biosystems) using the Allelic Discrimination program (Applied Biosystems).
[0054] The following PCR conditions were used to classify the Lys751Gln polymorphism of exon 23 (final reaction volume of 25 μl): 900 nM of primer SEQ ID NO. 5: GCCTGGAGCAGCTAGAATCAGA, goo nM of primer SEQ ID NO 6: CACTCAGAGCTGCTGAGCAATC, 300 nM of TaqMan MGB™ VIC probe SEQ. ID NO 7: TATCCTCTGCAGCGTC TAMRA, 300 nM of TaqMan MGB™ 6-FAM probe SEQ ID NO 8: CTATCCTCTTCAGCGTC TAMRA, 12.5 μl of TaqMan Universal PCR Master Mix (Applied Biosystems; reference 4304437) and 200 ng of DNA. The PCR cycles (50° C. for 2 minutes, 95° C. for 10 minutes, [92° C. for 15 seconds, 60° C. for 1 minute] for 40 cycles) and the polymorphism analysis were carried out in an ABI Prism 7000 Sequence Detection System equipment (Applied Biosystems) using the Allelic Discrimination program (Applied Biosystems).
[0055] In both cases, the design of the primers and probes was carried out by means of the PrimerExpress™ computer program (Applied Biosystems), following the supplier instructions and using the previously described reference DNA sequence. The specificity of the primers and of the probes was previously tested by means of the BLAST computer program (www.ncbi.nlm.nih.gov/blast). In all cases, both the primers and the probes showed unique specificity on each one of the two regions to be studied of the ERCC2/XPD gene.
[0000] 6. —Validation of the Analysis by Means of Automatic DNA Sequencing
[0056] As validation of the obtained results, the DNA fragments corresponding to the Lys751Gln and Asp312Asn polymorphisms in 100 samples of DNA which had previously been analyzed (see previous sections) were sequenced.
[0057] In the first place, the exon 10 fragment of the XPD/ERCC2 gene where the Asp312Asn polymorphism is mapped was amplified by means of the PCR technique. The PCR reaction conditions were the following (final volume of 50 μl): 0.25 μM of primer SEQ ID NO: 1, 0.25 μM of primer SEQ ID NO: 2, 5 μl of PCR buffer (67 mM Tris-HCl, 16.6 mM (NH 4 ) 2 SO 4 , 0.1% Tween 20) (Ecogen; reference ETAQ-500), 1 mM MgCl 2 (Ecogen; reference ETAQ-500), 0.12 mM of PCR Nucleotide Mix (Roche; reference 1581295), 1 unit of EcoTaq DNA Polymerase (Ecogen; reference ETAQ-500) and 200 ng of DNA. The PCR cycles used were: 95° C. for 5 minutes, [94° C. for 30 seconds, 60° C. for 45 seconds, 72° C. for 1 minute] for 35 cycles, 74° C. for 7 minutes.
[0058] In the second place, the exon 23 fragment of the XPD/ERCC2 gene where the Lys751Gln polymorphism is mapped was amplified by means of the PCR technique. The PCR reaction conditions were the following (final volume of 50 μl): 0.25 μM of primer SEQ ID NO: 6, 0.25 μM of primer SEQ ID NO: 7, 5 μl of PCR buffer (67 mM Tris-HCl, 16.6 mM (NH 4 ) 2 SO 4 , 0.1% Tween 20) (Ecogen; reference ETAQ-500), 1 mM MgCl 2 (Ecogen; reference ETAQ-500), 0.12 mM PCR Nucleotide Mix (Roche; reference 1581295), 1 unit of EcoTaq DNA Polymerase (Ecogen; reference ETAQ-500) and 200 ng of DNA. The PCR cycles used were: 95° C. for 5 minutes, [94° C. for 30 seconds, 64° C. for 45 seconds, 72° C. for 1 minute] for 35 cycles, 74° C. for 7 minutes.
[0059] The integrity of the PCR products was analyzed after electrophoresis in a 1.5%-TBE agarose gel and subsequent staining with 1% ethidium bromide in a UV transilluminator.
[0060] The obtained PCR products were used for the sequencing reaction as detailed as follows: in the first place, the products were purified by means of adding 4 μl of ExoSap-IT (USB; reference 7820) to 10 μl of the corresponding PCR product and was sequentially incubated at 37° C. for 45 minutes and at 80° C. for 15 minutes. Four μl of BigDye Terminator solution, version 3.0 (Applied Biosystems; reference 439024801024) and 3.2 pmoles of the corresponding primer (in this case, the same primers as those used in the PCR amplification, both forward and reverse, were used in separate reactions) were added to 500-600 ng of purified PCR product. The PCR cycles for this sequencing reaction were: 94° C. for 5 minutes, [96° C. for 10 seconds, 50° C. for 5 seconds, 60° C. for 4 minutes] for 32 cycles.
[0061] Once the sequencing reaction concluded, the products precipitated by means of adding 62.5 μl of 96% ethanol, 3 μl of 3 M sodium acetate buffer pH=4.6 and 24.5 μl of double-distilled water. After an incubation of 30 minutes at room temperature, they were centrifuged for 30 minutes at 14,000 rpm at room temperature, the supernatant is discarded and a washing is carried out with 250 μl of 70% ethanol. Then the samples were centrifuged for 5 minutes at 14,000 rpm at room temperature, the ethanol remains are discarded (leaving the precipitates to completely dry), and 15 μl of TSR loading buffer (Applied Biosystems; reference 401674) are added. They are finally incubated at 95° C. for 3 minutes prior to their injection in the ABI Prism 310 Sequence Detection System automatic capillary equipment (Applied Biosystems). The automatic sequencing results were analyzed with the Sequencing Analysis 4.3.1 program (Applied Biosystems).
[0062] In all the analyzed cases, the two polymorphisms of each one of the samples were sequenced both with the forward primer and with the reverse primer, the results in all cases being coincident between one another and also with the results obtained by quantitative real time PCR analysis.
[0000] Results
[0063] Three studies in metastatic lung cancer patients commenced in August of 2001 for the purpose of confirming that the allelic variants of XPD could affect survival after treatment with chemotherapy in metastatic lung cancer. These three different studies are: the first one with gemcitabine and cisplatin, the second one with vinorelbine and cisplatin and the third one with docetaxel and cisplatin. One-hundred patients with locally advanced lung cancer who underwent neoadjuvant chemotherapy and then surgery were also retrospectively analyzed. About 150 patients in initial stages who received treatment either with surgery alone or with pre-operative or post-operative chemotherapy, and whose summary is also included in the appendix, were also analyzed.
[0064] The most significant data to date are those obtained from the study of patients with stage IV lung cancer who received treatment with gemcitabine and cisplatin. Between August of 2001 and July of 2002, 250 patients were included, out of which patients final data on 109 of them is available. Attached Table 1 describes the clinical characteristics of these patients which are the normal characteristics in relation to age, general condition, histology, metastases. Table II shows the frequencies of the different polymorphisms. The polymorphism of the ERCC1 gene at position 118 was also analyzed. It can be seen that the frequencies of the XPD polymorphisms at exons 23 and 10 show that the normal homozygote genotypes constitute 50%, whereas the heterozygote variants are 40% (Table II). In the following figures, the overall survival of the 109 patients with a median survival time of 10.7 months in a range of 8.9-12.5 ( FIG. 3 ) is presented in a serial manner. The differences according to the polymorphism of the ERCC1 gene are not significant ( FIG. 4 ). However, when survival time is analyzed on the basis of the XPD polymorphism at codon 751, it is shown that the median survival time for 59 patients with the Lys/Lys genotype is 10.7 months, whereas it is much higher and the median has not yet been reached in 40 Lys/Gln heterozygote patients ( FIG. 5 ). It has also been discovered that a minority group of patients (10) are homozygotes for the Gln/Gln variant, the median survival time is 2.1 (p=0.0009) ( FIG. 5 ). The same significant differences are observed for codon 312, see the corresponding figure (p=0.003) ( FIG. 6 ). In the same manner, when the time to progression is analyzed, overall, the median time to progression is 4 months in a range of 3.2-4.8 ( FIG. 7 ). There are no differences according to the ERCC1 genotype ( FIG. 8 ). However, on the basis of the genotype, large differences are observed at codon 751, such that in the 59 patients who are Lys/Lys, the median is 2.9 months, whereas in the 40 Lys/Gln patients, the median increases to 7.4 months. The difference is very significant (p=0.03) ( FIG. 9 ). The time to progression of the XPD polymorphism at codon 312 is also shown, where the difference in survival time is not significant ( FIG. 10 ). The conclusions of this study are revealing as they differentiate two patient subgroups, some patients with a response and survival time far exceeding the overall response and survival time in which gemcitabine and cisplatin obtain great results, whereas in the other group of patients, said treatment would clearly be contraindicated in light of such meager results, far below the normally accepted median survival times.
TABLE I Clinical Characteristics of Patients Treated with Gem/Cis No. of Patients 109 Age, years 61 (Medicine, range) 35-82 Clinical condition (Performance Status) 0-1 89(81.7) 2 20(18.3) Histology Adenocarcinoma 52(47.7) SCC 37(33.9) LCUC 5(4.6) Others 15(13.8) Phase IIIb 29(26.6) IV 80(73.4) Pleural Effusion 19(17.4) Surgery 10(9.2) Radiotherapy 11(10.1) Metastasis Liver 9(8.3) Lung 43(39.4) Bone 21(19.3) CNS 16(14.7) Adrenal 18(16.5) Foot 7(6.4) Lymphatic nodes 23(21.1) Others 13(11.9)
[0065]
TABLE II
ERCC1 and XPD Genotypes and Response
Response
Complete response
5(5.3)
Partial response
29(30.9)
Complete response +
34(36.2)
Partial response
Stable disease
14(14.9)
Progressive disease
46(48.9)
Cannot be evaluated
15
ERCC1
T/T
14(12.8)
C/T
52(47.7)
C/C
43(39.4)
XPD23
Lys/Lys
59(54.1)
Lys/Gln
40(36.7)
Gln/Gln
10(9.2)
XPD10
Asp/Asp
51(46.8)
Asp/Asn
48(44)
Asn/Asn
10(9.2)
[0066] In a second stage IV lung cancer study, which also commenced in August of 2001, about 100 patients treated with cisplatin and vinorelbine were analyzed, and of which patients preliminary results are available. The effect of vinorelbine according to the XPD genotype shows that when Lys/Lys patients with a poor prognosis are treated with gemcitabine and cisplatin, in this case, when vinorelbine is used, the opposite occurs and a time to progression of 10 months is obtained in the Lys/Lys patient group when they are treated in the study with gemcitabine and cisplatin, said median time to progression is only 2.9 months. See the corresponding Graphs 11 and 12.
[0067] Finally, the results of the XPD polymorphism in locally advanced, stage III lung cancer patients, where once again survival time varies according to the genotype, are also shown. By adding docetaxel to the gemcitabine and cisplatin combination, the time to progression is significantly greater in Lys/Lys plus Asp/Asp or Lys/Lys homozygote patients. See corresponding FIGS. 13 and 14 .
[0000] Clinical Application
[0068] These results unequivocally signal the individual pharmacogenetic prediction of lung cancer for the first time. First, the Lys751Gln XPD genotype predicts an effect and a survival time substantially greater than normal when treated with gemcitabine and cisplatin. Secondly, said combination is clearly contraindicated in the other Lys751Lys and Gln751Gln genotypes. Clinical results also show that Lys751Lys patients respond very favorably to the combination of vinorelbine and cisplatin or docetaxel and cisplatin. Finally and in the third place, it is identified that a minority patient group with the Gln751Gln genotype have a very poor survival time with any combination of chemotherapy with cisplatin, and therefore they should be treated with combinations without cisplatin.
[0069] The XPD polymorphism genetic test is absolutely necessary for the appropriate selection of drugs prior to administering chemotherapy in cancer patients, and very particularly in lung cancer patients.
DESCRIPTION OF THE FIGURES
[0070] FIG. 1 : XPD 312 polymorphism with G→A substitution causing an amino acid change of Asp→Asn at codon 312.
[0071] FIG. 2 : XPD 751 polymorphism with A→C substitution causing an amino acid change of Lys→Gln at codon 751.
[0072] FIG. 3 : Abscissa: months; Ordinate: Probability. Overall survival time with Gem/Cis.
[0073] FIG. 4 : Abscissa: months; Ordinate: Probability. Survival time according to ERCC1 genotype.
[0074] FIG. 5 : Abscissa: months; Ordinate: Probability. Survival time according to XPD 751.
[0075] FIG. 6 : Abscissa: months; Ordinate: Probability. Survival time according to XPD 312.
[0076] FIG. 7 : Abscissa: months; Ordinate: Probability. Time to progression.
[0077] FIG. 8 : Abscissa: months; Ordinate: Probability. Progression according to ERCC1 genotype.
[0078] FIG. 9 : Abscissa: months; Ordinate: Probability. Progression according to XPD 751 genotype.
[0079] FIG. 10 : Abscissa: months; Ordinate: Probability. Progression according to XPD 312 genotype.
[0080] FIG. 11 : Abscissa: months; Ordinate: Probability. Progression according to XPD 751 genotype for vinorelbine/cisplatin.
[0081] FIG. 12 : Abscissa: months; Ordinate: Probability. Progression according to XPD 751 genotype for gemcitabine/cisplatin.
[0082] FIG. 13 : Abscissa: weeks; Ordinate: Probability. Progression according to XPD 751 genotype for Gem/Cis/Docetaxel.
[0083] FIG. 14 : Abscissa: weeks; Ordinate: Probability. Progression according to XPD 751 and 312 genotypes. | The invention is encompassed in the technical sector of lung cancer treatment with antitumor drugs, and it specifically develops a diagnostic device which allows treating each patient with the most effective drug according to the polymorphism they show for the XPD gene. The assay device of the invention is, based on the polymorphic variants of the XPD gene at exon 23 (A-C, Lys 751 Gln) and at exon 10 (G-A, Asp312Asn) and on the development of specific primers which allow detecting said polymorphisms by PCR or by means of automatic DNA sequencing. | 2 |
This is a continuation of copending application Ser. No. 846,336 filed on 3-31-86 now U.S. Pat. No. 4,708,318.
FIELD
This invention relates generally to display monitor positioning apparatus, and more particularly to an apparatus for a video display monitor unit which allows the unit to be inclined or tilted readily by manual movement.
BACKGROUND
With the widespread use of computers and word processing systems in the workplace, there has been an increased concern over the ergonomics of these devices. Where an operator must spend long periods of time viewing a video display monitor, often without relief, it is paramount that the monitor be designed to provide a high level of operator comfort and convenience in its use. Most notably, it has been recognized that display monitors should provide for the ergonomical differences between operators and for differences in the environments in which these devices are used. Since one standard cannot suit all, display monitors must be adjustable to suit the needs of the individual operator in his individual working environment.
More specifically, for an operator using a video display monitor, varying lighting conditions in the workplace produce light reflections and glare which may in turn cause eyestrain and other detriments. To solve this problem it is desirable that the individual operator be able to adjust the tilt angle of the display monitor a few degrees forward and back in order to control glare from the screen and to achieve an optimum viewing angle. It is further desirable that the tilt angle be quickly and easily changed and that the new tilt angle be maintained with a minimum of hand operated locking devices. The prior art has addressed these problems in numerous ways.
One solution has been the tilt and rotate ball. An example of this apparatus is disclosed in U.S. Pat. No. 4,365,779 issued to Bates et al. The display monitor is supported on a stationary base by means of a spherical ball and socket joint which permits tilting and rotating of the monitor with respect to the base.
A very different design for a tilting monitor is disclosed in U.S. Pat. No. 4,368,867 issued to Pendleton et al. a display monitor has two pairs of elongated feet suspended from its bottom. The feet rest on the inclined surfaces of a pair of parallel, trapezoidal shaped base members joined together by a horizontal plate. The trapezoidal base members have step like indentations on their inclined surfaces, for holding the elongated feet, which correspond to the desired viewing angles. To change viewing angles, the monitor is moved incrementally up the step like indententation, basically in an arc.
Still another approach for varying the tilt angle of a display monitor is disclosed in U.S. Pat. No. 4,372,515 issued to Noonan. In this patent, a display monitor housing is mounted to a stationary pedestal base by means of a rack and spur gear arrangement, which allows a tilting movement of the monitor with respect to the pedestal base. This apparently allows the center of gravity of the monitor to be co located with its contact point on the pedestal base to thereby balance the monitor on the base.
Devices such as those discussed above are basically effective, although they suffer from certain disadvantages. All devices of this type generally include a base or pedestal support and some complex mechanism for mounting the display monitor thereon. This often results in a very expensive assembly which is bulky on an operator's desk. Some of the devices include detents which allow a tilt adjustment only in predefined increments or steps, rather than continuously throughout a tilt range, as would be more desirable. Many of the devices require the movement of the entire weight of the monitor to accomplish tilting. Still others require locking devices to keep the display monitor stationary once the tilt angle is set.
SUMMARY
In accordance with the present invention, a novel tilt apparatus is provided for a video display monitor whereby tilting of the monitor is obtained through a continuously variable tilt range of a few degrees forward and a few degrees backward. The tilt apparatus provides the operator with the simplest, fastest, most direct way of changing the tilt angle of a display monitor, and it requires no locking devices. Furthermore, it is extremely inexpensive and simple to manufacture, primarily because it requires no pedestal or base members to support the monitor.
The display monitor used with the present invention rests on a horizontal supporting surface, such as a desktop. The display monitor housing is provided with a pair of support legs on its bottom surface toward the front of the housing, which together function as a pivot point, so that the monitor is capable of pivoting through the desired range of tilt angles. The center of gravity of the display monitor is rearward of this pivot point. During tilting of the display monitor, the location of the center of gravity shifts, but it is always rearward of the pivot point.
The tilt apparatus of the present invention mounts to the display monitor housing at a point rearward of the pivot point and center of gravity and supports the rear end of the housing.
The tilt apparatus includes a tubular housing, a piston, a counterbalance spring and a frictional drag device, which act together as a counterbalancing mechanism. The tubular housing has an aperture on one end and is closed on the other end by an end cap. The piston is disposed for reciprocable movement within the tubular housing and has a shaft which extends through the aperture. The tubular housing is positioned vertically on the support surface, and the piston shaft, extending upwardly, connects by an attachment means to the display monitor housing.
The counterbalance spring is positioned within the tubular housing between the piston and the closed end such that downward movement of the piston compresses the spring. The spring has a predetermined length and spring constant for counterbalancing the weight of the display monitor throughout a predefined tilt range.
The frictional drag device within the tubular housing counteracts movement of the piston and spring due to nonlinear shifting of the center of gravity of the monitor at extreme tilt angles.
In operation, the tilt apparatus supports the rear end of the display monitor and counterbalances the moments of force about the pivot point from the shifting center of gravity of the monitor. The display monitor is thereby maintained in a state of static balance throughout its predefined tilt range.
In another aspect of the present invention, the tilt apparatus can be easily detached from the display monitor housing or almost fully retracted within it to allow the display monitor to be mounted on an auxiliary support device, such as a display monitor support arm. In this embodiment the tilt apparatus performs a locking function to securely hold the display monitor on the auxiliary device.
The tilt apparatus of the present invention can accommodate display monitors having different weights and dimensions, simply by changing the spring constant of the counterbalance spring, the stroke of the piston, and the frictional drag force to meet the various center of gravity characteristics of those monitors. Also, the tilt apparatus is a complete subassembly by itself, and it can be attached to many existing display monitors with no change in their basic design.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects, features and advantages of the invention will be apparent from the following more particular description of a preferred embodiment of the invention, in conjunction with the accompanying drawings. In the drawings:
FIG. 1 is a perspective view of a display monitor using the tilt apparatus of the present invention;
FIG. 2 is a side elevational view of the display monitor using the tilt apparatus of the present invention;
FIG. 3 is a cross sectional view of the tubular housing and end cap of the tilt assembly;
FIG. 4 is a side elevational view of the piston;
FIG. 5 is a partially sectional, elevational view showing the interior arrangement of components of the tilt apparatus;
FIG. 6 is an exploded view of the tilt apparatus, showing its method of assembly;
FIG. 7 is a front view of the interior of the display monitor housing, with electronic components removed, showing the mounting of the tilt apparatus therein;
FIG. 8 is a functional diagram illustrating the shift in center of gravity of the display monitor housing with changes in tilt;
FIG. 9 is a perspective view of an alternative embodiment of the present invention, showing the tilt apparatus functioning as a locking device on a display monitor support arm; and
FIG. 10 is another view of the alternative embodiment shown in FIG. 9, illustrating how the tilt apparatus inserts through a display monitor support arm base to function as a locking device.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1 and FIG. 2, a display monitor 10 is shown which uses a tilt apparatus in accordance with the present invention. The display monitor 10 includes a monitor housing 12, a screen 14 for viewing by an operator, and a combined power switch and brightness control 16. Screen 14 consists of a twelve inch cathode ray tube, for what is customarily referred to as a half-page display.
The display monitor 10 is designed to rest on a desktop or other horizontal surface 18 with the screen 14 facing toward an operator. The display monitor 10 is used with a keyboard, not shown, which may be located in various positions in front of the monitor housing, as an operator may desire.
The internal electronic components of the display monitor 10 form no part of this invention and will not be disclosed herein, except as they pertain to the location of the center of gravity of the monitor 10.
Support legs 20 and 22 extend from the bottom of the housing 12 and have the function of supporting most of the display monitor s weight. The support legs 20 and 22 also function as a pivot point for tilting the monitor forward and backward, as desired. This relationship is most clearly illustrated in FIG. 2, which shows a side view of display monitor 10 in its normal, perpendicular screen position.
The display monitor housing 12 has a tilt range of twenty degrees, or five degrees forward from its normal, perpendicular screen position and fifteen degrees backward from the normal position. This optimum tilt range was determined by human factors engineering studies on the ergonomics of monitor displays, and can be considered somewhat standard for the industry, giving the operator the most desirable range of viewing angles.
In FIG. 2, the bottom surface of the monitor housing 12 is shown to slope gradually upward from the support legs 20 and 22 to the rearward end of the monitor housing 12. This slope allows the monitor to be tilted backward at least fifteen degrees from the normal position without the housing 14 contacting the horizontal surface 18 upon which it is placed. In a like manner, the housing 12 is sloped upward in front of the supports 20 and 22 to allow the monitor 10 to be tilted forward at least five degrees forward without contacting the horizontal surface 18.
The center of gravity (C.G.) 24 for display monitor 10 is located generally toward the front of the unit because most of the weight of the display monitor resides in the cathode ray tube and printed circuit boards, which are physically located toward the front. However, as shown in FIG. 2, the location of the C.G. 24 is above and slightly to the rear of the pivot point established by the support legs 20 and 22.
A tilt apparatus 26 is shown extending from the bottom surface of the monitor housing 12 toward the rear of the housing. Its function is to counterbalance rotational forces due to the shift in the location of the C.G. of the display monitor 10 as it pivots forwardly and backwardly on the support legs 20 and 22.
In FIG. 3 through 6, the tilt apparatus of the present invention is shown in more detail. The tilt apparatus includes a tubular housing 28, a piston 30, a end cap 32, a counterbalance spring 34, drag washers 36, and a retainer ring 38.
Referring to FIG. 3, it will be seen that the tubular housing 28 is a hollow cylinder with a near constant inner diameter, or zero draft. It is molded in medium impact styrene, chosen because of its durability. One end of housing 28 is an open end 40. The open end 40 has a slightly decreased outside diameter to allow for the fitting of the end cap 32 thereon. A circular lip 42 is provided to coact with a similar circular lip 44 on the inside of end cap 32 to provide a snap fit. The other end of tubular housing 28 contains has an aperture 46 having a diameter appropriate for receiving the shaft of piston 30.
Referring now to FIG. 4, the piston 30 consists of a shaft 48 with a molded-in shoulder 50, a chamfered piston tip 52, and a shaft extension 54. The piston 30 is disposed for reciprocable movement within tubular housing 28 with the shaft 48 extending through the aperture 46. The diameter of the shoulder 50 is slightly less than the inside diameter of the housing 28 to allow the piston 30 to slide within the housing. The piston 30 itself is made of acetyl plastic, a material which has very good lubricity characteristics and allows the piston 30 to slide smoothly within the styrene housing without the need for lubricants of any kind.
The shaft extension 54 is provided for the mounting of the drag washers 36. Once secured to the piston 30, the drag washers 36 act upon housing 28 to produce frictional drag. Chamfered piston tip 52 engages a molded in spring clip in the monitor housing 12, to providing anchoring of the piston shaft 48 as will be explained below. During operation of tilt apparatus 26, the piston 30 remains stationary with respect to the monitor housing 12.
The counterbalance spring 34, shown in FIG. 5 and FIG. 6, is a standard steel compression spring made of music wire, having a spring constant (k) of 1.55 pounds/inch. The spring 34 has a coil diameter slightly less than the inside diameter of tubular housing 28. It is inserted in the housing 28, with its ends bearing against the drag washers 36 on one end and the end cap 32 on the other.
In its normal, uncompressed state, the counterbalance spring 34 is one inch longer than the inside length of tubular housing 28 with the piston 30 and drag washers 36 already installed. Therefore, when the tilt apparatus is assembled and the end cap 32 installed, the counterbalance spring 34 is initially compressed one inch. This gives the spring 34 an initial or preloading force of 1.55 pounds. When the display monitor 10 tilts forward, the preloading of spring 34 acts to extend the tilt apparatus fully, forcing the piston all the way out against the stop.
As the display monitor tilts backward, spring 34 is compressed a maximum of 3.25 inches, and the spring force on the piston increases from the initial 1.55 pounds to a maximum of approximately 6.6 pounds. The spring force on the piston for any position of the display monitor may be calculated by the following formula:
F.sub.TA =kx+F.sub.i
where
F TAt =Total spring force of Tilt Apparatus (lbs)
k=spring constant (1.55 lb/in)
x=deflection distance of spring (inch)
F i =initial loading force (1.55 lbs.)
This force range (1.55-6.6) for spring 34 corresponds to the required force needed to counterbalance the display monitor through the tilt range of five degrees forward of normal to fifteen degrees back.
The counterbalance spring 34 has a normal length that falls within the constraints imposed by the length of tubular housing 28 (to support the monitor), the required stroke of piston 30 (to provide the monitor with a twenty degree tilt range), and the required counterbalancing force. Within the constraints imposed, the normal length of the spring (6.75 inches) has been maximized in order to provide the most linear change in force obtainable. This, in turn, provides smoothest possible operation of the tilt apparatus.
During assembly of the tilt apparatus, just prior to installing the counterbalance spring 34 in the housing 28, four spring dampers 56 are centered within the coils of spring 34. The spring dampers 56 are balls of soft rayon. Rayon has the sound dampening properties of cotton and is more durable under varying environmental conditions. The dampers 56 eliminate noises or squeeks from spring 34 resonating on the inside wall of the housing 28 by insulating the spring 34 from the housing and absorbing the spring resonance. The rayon balls dampen the sound, while not affecting the spring rate.
Counterbalance spring 34 has a linear force range which counterbalances the C.G. shift of the display monitor 10, except at the most rearward tilt angles, where the C.G. shift becomes slightly nonlinear. This slight nonlinearity of the C.G. shift will affect the static balance. Other factors may affect the static balance by altering the C.G. of monitor 10. For example, the desktop upon which the display monitor rests might be non level, or tolerances in the assembly of the display monitor could alter the monitor's C.G. characteristics.
To counteract these undesirable effects, drag washers 36 are provided on shaft extension 54 to provide a frictional load against the inside wall of the housing 28 and thereby aid in holding the display monitor 10 at the desired tilt angle.
The drag washers 36 are composed of a woven fabric of polyester fiber, which has very good wear and drag characteristics in addition to low cost. A suitable material for use in this application is Style No. XT863792R Polyester manufactured by Tex Tech Industries of Auburn, Me. Drag washers made of this material have been tested to over 50,000 cycles with no perceptable wear.
The drag washers 36 are cut on a multiple drill press with a specially designed cutter which makes concentric washers having a diameter slightly greater than the inside diameter of housing 26 and a center hole with a diameter slightly greater than the diameter of the shaft extension 54.
A metal push-on retainer ring 38 holds the drag washers 36 against shoulder 50 on the shaft extension 54. This relationship can best be seen in FIG. 5. The amount of drag force is controlled by adjusting the amount of compression applied to the drag washers 36 by means of the retainer ring 38. As the drag washers 36 are compressed by retainer ring 38, their diameter increases slightly, providing greater drag against the inside wall of housing 28. In the preferred embodiment, between 1.0 and 1.25 pounds of drag was found to be desirable throughout the full tilt range of the monitor. To simplify assembly, a tool may be used to set the retainer ring 38 against the drag washers 36 at the proper height for the desired compression.
The end cap 32 snap fits over the open end 40 of the tubular housing 28. Use of the end cap 32 greatly simplifies assembly procedures for the tilt apparatus 26, as can be appreciated by consideration of FIG. 6. The piston 30, with drag washers 36 and retainer ring 38 already installed, is inserted into the open end 40 of tubular housing 28, followed by the counterbalance spring 34 with spring dampers 56. The end cap is then snap fit over the tubular housing 28.
The circular lip 42 on the housing 26 engages a similar lip 44 on the inside of the end cap 32 to ensure a tight grip, as can best be seen in FIG. 2. The force required to remove the end cap 32 must be greater than the axial force developed in the counterbalance spring 34 during maximum compression, so that the end cap 32 will not pop off. In the preferred embodiment, to prevent any possible operator injury from the end cap 32 inadvertently coming off, the end cap 32 is designed to withstand 25 pounds of axial force, a safety factor in the three to four range.
The tilt apparatus 26 contacts a desktop or other horizontal surface with end cap 32. A rubber pad 58 is attached by means of an pressure sensitive adhesive to the end cap 32 to prevent sliding on a table surface. As the monitor is moved throughout its tilt range, the tilt apparatus 26 pivots on the desktop, and rubber pad 58 provides a pivot surface producing increased friction, so that the tilt apparatus 26 does not skid on the desktop. The surface of the rubber pad 58 includes a slight curvature with a three inch spherical radius 60 to accommodate the pivoting; so that, for example, when the display monitor 10 is tilted from a normal position to a backward position, the contact point of the rubber pad 58 on the desktop rotates from dead center of the rubber pad 58 to a position further back.
Locking tabs 61 on end cap 32 are provided so that the display monitor 10 may be mounted on an alternative support means. This will be described in more detail further on.
Referring now to FIG. 7, there is shown the means by which the tilt apparatus 26 is anchored to the display monitor housing 12. This figure views the interior of the display housing 12 with the CRT all electronic components removed. The tilt apparatus 26 extends through a generally circular access port and collar 62 which is molded into the bottom of monitor housing 12 against rear wall 64. The collar has a diameter such that the tubular housing 28 may slide loosely within it, without adding significant frictional drag to the tubular housing 28. Located on the rear wall 64 of housing 12 are guides 66, 68, which serve to hold the tubular housing 28 parallel to the rear wall 64, with the piston shaft 48 extending upwardly. The chamfered piston tip 52 engages a spring clip 70 that is molded into the top wall 72 of the display housing 12 and holds the tilt apparatus 26 securely in the display housing 12. The guides 66, 68 reduce the amount of play in collar 62 so that, during installation, the chamfered piston tip 52 will line up more easily with the spring clip 70. During operation of the tilt apparatus 26, the tubular housing 28 moves upwardly or downwardly, and the piston 30 remains stationary with respect to the display housing 12.
The tilt 26 apparatus can be removed simply by grasping the tubular housing 28 and gently pulling downwardly until the chamfered piston tip 52 disengages from spring clip 70, and it can be reinstalled by reversing the procedure. This simple installation and removal is accomplished without the use of tools.
FIG. 8 illustrates in more detail the relationship between tilt angle, C.G., and counterbalance force.
As will be well known to those skilled in the art, the C.G. is, most simply, that point at which the sum of the rotational forces acting on a rigid body is equal to zero. In the preferred embodiment, the C.G. of display monitor 10 is always located at a point to the rear of the pivot point defined by the support legs 20 and 22. As the display monitor 10 tilts forward, its C.G. also moves forward; as display monitor 10 tilts backward, its C.G. also moves backwards. In FIG. 8, dotted line representations show the display monitor 10 in the five degrees forward position 73, and the fifteen degrees backward position 74. For each tilt angle, the location of the associated C.G. is also represented.
The C.G. of the display monitor 10 was determined in the three positions experimentally by placing the display monitor on a horizontal surface and using a pivot rod to determine the points at which the display monitor balanced, first on the front surface and then on the bottom surface at the three tilt angles. Perpendicular lines were drawn from the front surface and bottom surface for each angle. The C.G. for each tilt position is the point at which the lines intersected.
If the C.G. of display monitor 10 were concentrated directly above the pivot point, the sum of rotational forces would equal zero, and the monitor would be balanced over supports 20 and 22. In the preferred embodiment, however, a moment of force always exists, having a magnitude defined by the weight of the display monitor times the horizontal distance between from the pivot point to a perpendicular line drawn from the location of the C.G.
By referring to FIG. 8, it will be appreciated that the C.G. creates a clockwise rotating force around the pivot point and must be counterbalanced by an equal counterclockwise rotating force from the tilt apparatus 26. Static balance is normally achieved when the sum of the forces balance out to zero. However, because of the frictional force applied by the drag washers 36, the plus and minus moments need not balance precisely. Static balance will be achieved as long as the absolute value of the moments about the pivot point is less than or equal to the absolute value of the moment due to the drag washers 36.
The formula governing the static balance is as follows:
M.sub.A =[-WT(X.sub.CG)+F.sub.TA (X.sub.TA)]=FR(X.sub.FR)
where:
M A =Sum of the moment around pivot point (inch lb)
X CG =Distance from pivot point to the C.G. (inch)
X TA =Distance from pivot point to Tilt Apparatus (8.83 inch)
X FR =Distance from pivot point to drag washers (8.83 inch)
F TA =Total spring force of Tilt Apparatus (lbs)
F=Spring force of counterbalance spring (lbs)
FR=Friction force of drag washers in tilt apparatus (lbs)
WT=Weight of display monitor (16.5 lbs)
When it becomes desirable for the operator to adjust his viewing angle, the display monitor 10 may be tilted to any angle within the predefined continuous tilt range simply by placing a hand on the top front portion of the display monitor housing 12 and applying a slight forward or backward pressure to the housing. The display monitor 10 will remain at the tilt angle chosen without any locking devices. The display monitor 10 can also be swiveled on the support legs 20, 22 and tilt apparatus 26 to achieve the optimum viewing orientation for the operator.
Referring now to FIG. 9 and FIG. 10, the tilt apparatus 26 is shown to be functioning as a locking pin for mounting the display monitor 10 on an auxiliary support device, such as a display monitor support arm 76.
Conventionally, display monitors are mounted on display monitor support arms by means of mounting hardware which is often cumbersome for an operator to install or remove. Here, the present invention simplifies this mounting and adds greatly to the versatility of display monitor 10, which may now function on a desktop or on a support arm, as the operator may desire.
Installation of the display monitor 10 on the display monitor support arm 76 is accomplished by removing the tilt apparatus 26 from the housing 12, sliding the display monitor housing 12 onto the support arm base 78 which contains an aperture therein, and then reinserting the tilt apparatus. The tilt apparatus is manually pushed into the display monitor housing 12 until it is in its fully retracted position, as shown in FIG. 9. The tilt apparatus is then rotated forty five degrees, which engages locking tabs 61 of end cap 32 in recessed slots 80 (one of two shown in FIG. 10). The display monitor 10 is now securely fastened to the display monitor support arm 76. The display monitor 10 can easily be removed from the display monitor support arm 76 by removing the tilt apparatus 26, where it could easily be converted to a desktop unit once again.
In view of the above, it will be seen that the several objects of the present invention are readily achieved and other advantageous results attained.
Obviously many modifications and variations of the present invention are possible in light of the above teachings, without departing from the spirit and scope of the invention. For example, the counterbalance principle of the present invention might be accomplished by a more expensive gas piston, rather than by the means disclosed in the preferred embodiment above. It is also within the scope of the present teaching to provide brackets and the like to attach the tilt apparatus of the present invention to existing display monitors. It is also contemplated that, in the place of drag washers 36, an externally adjustable, spring loaded device could be used to provide frictional drag to the piston 30.
In view of this, it is understood that the above description is illustrative rather than limiting. | A tilt apparatus allows an operator to readily change the tilt angle of a display monitor and retain the angle after it is changed. The tilt apparatus mounts vertically to the display monitor housing at the rear of the monitor's pivot point and center of gravity. The apparatus includes a piston and spring assembly which counterbalances shifting in the monitor's center of gravity during the manual tilting of the monitor to provide continuously variable adjustment throughout a predefined tilt range. The apparatus also includes frictional drag means to compensate for nonlinear changes in the center of gravity of the monitor. | 5 |
[0001] This application is a continuation application under 37 CFR §1.53(b) of copending application Ser. No. 09/536,578, filed Mar. 28, 2000 and assigned to the same assignee, which is hereby incorporated by reference in its entirety.
1. FIELD OF THE INVENTION
[0002] The present invention relates to an integrated controller for the detecting and operating one or more expansion cards. More specifically, the present invention relates to an integrated controller for detecting and controlling PC Cards (16-bit PCMCIA cards and 32 bit-CardBus cards), and smart cards. Particular utility of the present invention is to provide an integrated controller for mobile computing devices, e.g., laptop computers, etc, although other utilities are contemplated herein.
2. DESCRIPTION OF RELATED ART
[0003] The need for security and enhanced privacy is increasing as electronic forms of identification replace face-to-face and paper-based ones. The emergence of the global Internet, and the expansion of the corporate network to include access by customers and suppliers from outside the firewall, have accelerated the demand for solutions based on public-key technology. A few examples of the kinds of services that public key technologies enable are secure channel communications over a public network, digital signatures to ensure image integrity and confidentiality, and authentication of a client to a server (and visa-versa).
[0004] Smart cards are a key component of the public-key infrastructure that Microsoft is integrating into the Windows platform because smart cards enhance software-only solutions such as client authentication, logon, and secure e-mail. Smart cards are essentially a convergence point for public key certificates and associated keys because they provide tamper-resistant storage for protecting private keys and other forms of personal information; isolate security-critical computations involving authentication, digital signatures, and key exchange from other parts of the system that do not have a “need to know”; and enable portability of credentials and other private information between computers at work, home, or on the road.
[0005] It is estimated that the smart card will become an integral part of the Windows platform because smart cards will enable new breeds of applications in the same manner that the mouse and CD-ROM did when they were first integrated with the Personal Computer (PC). Incompatibility among applications, cards, and readers has been a major reason for the slow adoption of smart cards outside of Europe. Interoperability among different vendors' products is a necessary requirement to enable broad consumer acceptance of smart cards, and for corporations to deploy smart cards for use within the enterprise.
[0006] ISO 7816, EMV and GSM
[0007] In order to promote interoperability among smart cards and readers, the International Standards Organization (ISO) developed the ISO 7816 standards for integrated circuit cards with contacts. These specifications focused on interoperability at the physical, electrical, and data-link protocol levels. In 1996, Europay, MasterCard, and VISA (EMV) defined an industry-specific smart card specification that adopted the ISO 7816 standards and defined some additional data types and encoding rules for use by the financial services industry. The European telecommunications industry also embraced the ISO 7816 standards for their Global System for Mobile communications (GSM) smart card specification to enable identification and authentication of mobile phone users.
[0008] While all of these specifications (ISO 7816, EMV, and GSM) were a step in the right direction, each was either too low-level or application-specific to gain broad industry support. Application interoperability issues such as device-independent APIs, developer tools, and resource sharing were not addressed by any of these specifications.
[0009] PC/SC Workgroup
[0010] The PC/SC (Personal Computer/Smart Card) Workgroup was formed in May 1996 in partnership with major PC and smart card companies: Groupe Bull, Hewlett-Packard, Microsoft, Schlumberger, and Siemens Nixdorf. The main focus of the workgroup has been to develop specifications that solve the previously mentioned interoperability problems. The PC/SC specifications are based on the ISO 7816 standards and are compatible with both the EMV and GSM industry-specific specifications. By virtue of the companies involved in the PC/SC Workgroup, there is broad industry support for the specifications and a strong desire to move them onto an independent-standards tract in the future.
[0011] Since its founding and initial publication of the specifications, additional members have joined the PC/SC Workgroup. New members include Gemplus, TBM, Sun Microsystems, Toshiba, and Verifone.
[0012] Microsoft's Approach
[0013] Microsoft's approach consists of the following:
[0014] A standard model for interfacing smart card readers and cards with PCs
[0015] Device-independent APIs for enabling smart card-aware applications
[0016] Familiar tools for software development
[0017] Integration with Windows and Windows NT platforms
[0018] Having a standard model for how readers and cards interface with the PC enforces interoperability among cards and readers from different manufacturers. Device-independent APIs serves to insulate application developers from differences between current and future implementations. Device-independence also preserves software development costs by avoiding application obsolescence due to underlying hardware changes.
[0019] The most popular method currently being used to interface a smart card with a notebook computer is to use a PCMCIA Type II smart card reader/writer (FIG. 1). PCMCIA smart card readers are currently available from companies such as Gemplus, SCM Microsystems and Tritheim Technologies, to name a few. The end user cost for these smart card readers is typically around $150. The cost of the reader is a major portion to the cost of the overall security solution. The adapter card 104 in FIG. 1 depicts the major functional blocks of a conventional smart card reader. The PCIC Host Interface block of the smart card reader provides the electrical interface to the PC Card connector ( 106 which in turn connects to the PC Card controller 102 . Additional logic is provided to control the interaction between the smart card and the software application. However, as noted above, this solution carries a significant per unit cost, and thus, is an unattractive alternative to large-scale migration to smart card compatibility.
[0020] Thus, there exists a need to provide an integrated host controller that provides PC Card, smart card, and Passive smart card adapter operability. Moreover, there exists a need to provide an integrated controller that can replace existing motherboard-mounted PC Card host controllers, without having to retool or redesign the motherboard.
SUMMARY OF THE INVENTION
[0021] Accordingly, one object of the present invention is to provide an integrated PC Card and Smart card controller suitable to replace conventional PC Card controllers for integration into current PC motherboard technology.
[0022] It is another object to provide a controller as above that is simultaneously fully compatible with PC Card specifications.
[0023] It is still another object to provide a Smart card controller, as above, that has an identical pinout arrangement as existing PC Card controllers, thereby permitting the controller to be directly integrated onto a PC motherboard without redesigning and/or retooling costs.
[0024] It is another object of the present invention to provide logic and methodology to detect the presence of a smart card or a Passive smart card adapter utilizing existing PC Card specified signals.
[0025] In one aspect, the present invention provides a method of detecting the presence of an expansion card using conventional PC Card specification signal lines, during the initial card detection sequence. The method comprising the steps of determining the signal state of a first and second card detection signal lines; determining the signal state of a first and second voltage select signal lines; determining if said first and/or second card detection signal lines, or said first and/or second voltage select signal lines, comprise a signal state that is reserved by a PC Card signal specification; and determining the signal state of a predetermined unused PC Card signal line, relative to said reserved signal state. During the card detection sequence the status change signal (STSCHG) is used to detect a smart card or a smart card adapter. After the detection sequence is completed the STSCHG signal has the original uses based on the PC Card specification for signal defination. Also, in the preferred embodiment, this process determines the presence of a smart card or a Passive smart card adapter by determining whether said first card detection signal and said second voltage select signals are tied together.
[0026] In logic form, the present invention provides a device to detect the presence of an expansion card using conventional PC Card specification signal lines, comprising a state machine including a lookup table and a plurality of logic sets, each said logic sets operable to interface with a certain predefined expansion card type, said state machine accepting as input signals a plurality of predetermined card detection and voltage selection signals, and an additional signal, and coupling an appropriate one of said logic sets to an appropriate one of said expansion cards based on a match between said input signals and said lookup table.
[0027] In another aspect, the present invention provides an integrated circuit for the detection and operation of a plurality of expansion cards, comprising, a first logic set for detecting and operating a plurality of expansion card types, said first logic set having predetermined signal lines and a pinout arrangement defined by PC Card specifications, and a second logic set for detecting and operating a smart card, wherein said first and second logic being incorporated into a single controller without requiring additional pinouts. In the preferred embodiment, the second logic set is adapted to reassign certain ones of said predetermined signal lines to detect and operate said smart card, so that additional pins are not required.
[0028] It will be appreciated by those skilled in the art that although the following Detailed Description will proceed with reference being made to preferred embodiments and methods of use, the present invention is not intended to be limited to these preferred embodiments and methods of use. Rather, the present invention is of broad scope and is intended to be limited as only set forth in the accompanying claims.
[0029] Other features and advantages of the present invention will become apparent as the following Detailed Description proceeds, and upon reference to the Drawings, wherein like numerals depict like parts, and wherein:
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] [0030]FIG. 1 depicts a block diagram of a conventional solution to incorporate smart card operability for PC applications;
[0031] [0031]FIG. 2 is a system-level block diagram of the integrated smart card reader of the present invention;
[0032] [0032]FIG. 3 is a detailed block diagram of the integrated Smart card reader of the present invention;
[0033] [0033]FIG. 4 is a state machine block diagram of the integrated Smart card reader of the present invention;
[0034] [0034]FIG. 5 is a table of conventional PC Card detection and voltage sensing pin arrangements, and an example of the use of a pin arrangement for smart card detection employed by the controller of the present invention;
[0035] [0035]FIG. 6 is a flowchart of an exemplary smart card and passive smart card adapter detection scheme of the present invention; and
[0036] [0036]FIGS. 7A and 7B depict tables showing conventional PCMCIA assigned functional pins and their use for Smart Card interface and detection, respectively.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0037] [0037]FIG. 2 depicts a system-level block diagram of how the passive smart card adapter and a smart card interface with a host controller. The controller 10 is integrated into a PC platform, for example, laptop PC. As an example, the PC may be configured as shown, with the controller 10 operating to detect and control one or more expansion device cards that are inserted into Socket A 12 and/or Socket B 14 . It will be understood that the controller 10 of present invention is adapted with the appropriate logic to drive PC Cards as well as smart cards. The PC system typically includes a processor 26 and a data bus 20 . “North Bridge” logic 24 provides communication between the processor 26 and the bus 20 . The controller 10 , of the present invention is likewise adapted to communicate with the bus 20 . In this example, the bus 20 is a PCI bus, however, any bus technology can be incorporated into the controller's logic. To complete the picture, “South Bridge” logic is provided for external bus communications, for example, legacy devices (ISA bus architecture), etc. South Bridge and North Bridge logic are well known in the art. Power IC chip 28 supplies the correct voltages (as determined by the card type inserted into Socket A or B) to the pins of the PC Card connector. Once the type of card is detected (based on the PC Card definitional table of FIG. 5, discussed below), chip 28 supplies the appropriate voltage for that card type.
[0038] In one embodiment, the present invention provides a passive smartcard adapter 18 which is configured to be inserted into either Socket A 12 or Socket B 14 , which are in turn configured as either PC Card type I/II/III-type socket interface. The passive adapter 18 of this embodiment includes appropriate connector 84 and passive circuit 86 . The smart card 16 inserted into the passive smart card adapter 18 also includes physical contacts 88 to interface with the physical connector 84 of the adapter. Pinout arrangements 84 and 88 of the adapter and smart card are dictated by the smart card specification, for example PC/SC compliant Smart card specification that meets ISO 7816 electrical specifications and T-0, T-1 protocols. In this embodiment the use of an adapter 18 permits smart card readability and operability without retooling the PC case to include a specific smart card socket. Alternatively, the PC can include a smart card slot 14 ′ as shown in FIG. 2. In this alternative embodiment, the logic 86 and connector 84 are, of course, provided internally within socket 14 .
[0039] Referring now to FIG. 3, a more detailed block diagram of the integrated controller 10 is depicted, showing those logic portions directed to smart card detection and operability. In this example, the controller 10 includes smart card sensing logic 30 A and 30 B, Smart card multiplexer (MUX) logic 32 A and 32 B, Smart card reader logic 34 A and 34 B and interface logic 36 A and 36 B.
[0040] It should be noted at the outset that FIG. 3 depicts only the logic associated with smartcard and Passive smart card adapter detection and operability, and it should be understood that controller 10 includes additional logic (not shown) to permit detection and operation of conventional PC Card's. Conventional PC Card controllers detect the type of card inserted into a slot using a set of card detection pins, CD 1 and CD 2 , and a set of voltage sense pins VS 1 and V 52 . The coupling combinations between these pins (with reference to ground) indicate to the appropriate logic which type of card has been inserted into the socket. For example, as shown in the table of FIG. 5, the coupling combination of CD 1 , CD 2 , VS 1 and V 52 determine whether the PC Card inserted is a 16-bit PCMCIA card or a 32-bit CardBus card. Moreover, a sis shown in the table, this combination also determines the driving voltage for the particular type of card. For example, 3.3 V, 5 V, X.X V and Y.Y V. In the last two rows of the table of FIG. 5, it is to be noted that the listed combinations of CD 1 , CD 2 , VS 1 and V 52 are reserved in the PC Card specification. The present invention utilizes one of these reserved combinations of CD 1 , CD 2 , VS 1 and VS 2 , and additionally uses a status change signal, STSCHG, to indicate whether a smart card has been inserted into the slot (either directly, or via an adapter). The status change signal is preferably used in the present invention since this signal is not utilized during the detection process for conventional PC Card cards, and is only used once the card type is known.
[0041] Thus, in one sense, the smart card sensing logic 30 A shown in FIG. 3 can be viewed as a state machine that determines the type of card inserted into a socket. To that end, and referring to FIG. 4, a state machine representation of the card sensing logic 30 A of FIG. 3 is depicted. As is shown, the card sensing logic 30 A accepts as inputs CD 1 , CD 2 , VS 1 , V 52 and status change (labeled 40 , 42 , 44 , 46 and 48 , respectively). In accordance with the reserved arrangement of CD 1 , CD 2 , VS 1 , V 52 as shown in FIG. 5, and the addition of the status change signal, the state machine 30 A determines the appropriate logic 32 A for communicating with the 4 given type of card. For example, certain combinations of CD 1 , CD 2 , VS 1 , V 52 (as indicated in FIG. 5) will dictate that the card inserted into the socket is either a 16-bit PC card or a 32-bit CardBus PC card. Accordingly, the state machine 30 A will activate the appropriate logic 50 or 52 for the given card type. It should also be noted that the particular voltage of the inserted card is also determined using the combination of these four pins. Extending the capabilities of conventional PC Card controllers, the present invention also monitors the 575 CHG pin to determine if a smart card or a passive smart card adapter has been inserted into the socket, and likewise activates the appropriate logic 54 to communicate with the smart card, for example, logic 32 A as shown in FIG. 3. To determine the states of CD 1 , CD 2 , VS 1 , V 52 and STSCHG, the card sensing logic 30 A can produce, for example, a pulse train signal on selected ones of these pinouts, and by monitoring the signal on one or more of the other pins (with respect to ground), it can then be determined the card type inserted into the socket.
[0042] The smart card sensing logic 30 A and 30 B operate to detect both a smart card or a passive smart card adapter and PC Cards, based on the Table in FIG. 5. The pin assignments shown in FIG. 5 are designated by the PC Card specification, and are conventional pin assignments for these signal lines. The identity of the card is determined by the values of the voltages of columns 1-4, i.e., CD 2 , CD 1 , V 52 and VS 1 . Both smart card and passive smart card adapter detection operates by utilizing the reserved combinations of these pins, plus the use of an additional pin, for example, STSCHG signal line. The concept is summarized in the Table of FIG. 7B. This table shows the pins used to detect PC Cards, smart cards and Passive smart card adapter cards. The signal column for a smart card or passive smart card adapter detection includes one of the reserved areas for CD 1 , CD 2 , VS 1 and V 52 , as shown in the last two rows of Table of FIG. 5. It should be noted that although the figures depict the use of signal line STSCHG (which is provided by the conventional PC Card specification), the present invention, generally, could use any pin in the PC Card specification that is unused during the card detection sequence. In other words, from a timing perspective, certain signal lines in the PC Card specification remain unused during the card detection process. The present invention utilizes one (or more) of these signal lines, in conjunction with the reserved combination of CD 1 , CD 2 , VS 1 , and V 52 , to effectuate smart card or passive smart card adapter detection. Thus, the figures represent only one of many examples for the use of an additional signal pin that could be used for smart card detection.
[0043] A flow chart 60 of the card-type detection process is depicted in FIG. 6. For clarity, the corresponding reference numerals of the logic to detect and operate PC Card, smart card and passive smart card adapter cards (as shown in FIGS. 2 and 3) are omitted. Initially, the detection logic seeks the presence of CD 1 , CD 2 , VS 1 , V 52 , and STSCHG 62 . If not present, or otherwise unavailable, it is assumed the no card has been inserted into a socket, and thus the card detection signals (CD 1 and CD 2 ) are blocked 64 . Once a card is inserted, the detection logic monitors the falling edge of CD 1 or CD 2 66 . This is dictated by the PC Card specification for determining the presence of a card. Once a card is detected, the detection logic of the present invention toggles CD 1 , CD 2 , VS 1 , V 52 , and STSCHG to determine the type of card inserted 68 . Toggling, as cited above, can be in the form of a pulse train signal, or other toggling signal. The detection logic proceeds by polling CD 1 , CD 2 , VS 1 , V 52 , and STSCHG in the following manner. First, the logic determines if VS 1 and CD 2 are tied to ground 70 . If not, it is known that a 16-Bit PCMCIA Card or 32-bit CardBus card is inserted 72 , as indicated by the table of FIG. 5 . If yes, the logic determines if V 52 and CD 1 are tied together 74 . If this is not the case, again it is known that a 16-Bit Card or 32-bit CardBus card is inserted 76 , as indicated by the table of FIG. 5. If it is determined that CD 1 and STSCHG are tied together 78 , then it is determined that a smart card or a passive smart card adapter is present. Either the passive smart card adapter is inserted into the socket, or a smart card is inserted directly into a smart card socket 82 .
[0044] Another feature of the present invention is to provide an integrated controller circuit 10 , which can be directly integrated with current PC Card controller logic. Conventional PC Card controller logic is an IC package that is mounted directly on the motherboard, which has 208 pins, and each of these pins is assigned by the PC Card specification. Another feature is to provide a controller 10 that can directly replace conventional controllers, without having to reconfigure pin assignments, add additional pin configurations, alter the motherboard, or change the tooling required. To that end, and referring to the table of FIG. 7A, the controller 10 of present invention includes both conventional, legacy interface card signals and smart card signals. As is shown in this table, the same pins (leftmost column) used to interface with conventional 16 and 32 cards are likewise used to interface with the smart card. Thus, no additional pins are required. Referring again to FIG. 3, if a smart card is detected into a socket, logic 30 A or 30 B communicates with and enables logic 34 A or 34 B, to enable smart card readability. Logic 34 A and 34 B enable the socket MUX logic 32 A or 32 B, so that the socket (A or B) can communicate with the cardbus/PCI controller logic 36 A or 36 B, which communicate with the PCI bus 20 (via PCI interface 38 ). As should be understood, the smart card logic 30 A, 30 B, 34 A and 34 B of the present invention directly interfaces with the MUX logic 32 A and 32 B and communicates with bus interface controllers 36 A and 36 B using conventional PC Card 2 communication protocols. If a conventional card is inserted into a socket (socket A or B), then conventional logic (not shown) incorporated into the controller 10 activates MUX 32 A and 32 B and communicates with bus interface controllers 36 A and 36 B using conventional PC Card communication protocols.
[0045] To facilitate direct integration with conventional PC Card logic sets, the present invention controls a predetermined number of pre-assigned pins to effectuate smart card communication. For example, as shown in FIG. 7A, pins 17 , 51 , 58 , 47 , 32 , GND, 18 , 16 and 40 , as specified by the PC Card standard, are utilized by the present invention to operate both smart cards and PC cards. Therefore, no extra pins are required by the controller 10 to effectuate Smart card operability. In operation, once the smart card has been detected (as described above with reference to FIGS. 3 - 6 ), logic 34 A or 34 B reassigns the operability of the PC Card pins noted in FIG. 7A to effectuate Smart card readability. The signal assignments, set forth under the smart card Signal column of FIG. 7A, are the required signals to read smart Cards.
[0046] The table and FIG. 7A is included as a lookup table in the controller 10 of the present invention to operate PC Cards. Likewise, the tables of FIG. 5 and FIG. 7B are included as lookup tables in the controller 10 for the detection of PC Cards and smart Cards. To this end, and view the logic sets 30 A and 30 B as a state machine (shown in FIG. 4), the state machine compares the input signals to the lookup tables of FIGS. 5 and 7B to couple the appropriate logic to the card.
[0047] Those skilled in the art will recognize that CD 1 , CD 2 , VS 1 and V 52 comprise card detect and voltage select signals, respectively, as specified by the conventional PC Card signal specification. In the tables of FIGS. 5, 7A and 7 B, and the flowchart of FIG. 6, the nomenclature used for these signal lines includes, for example, CDI#, CD 2 #, VS 1 #, V 52 #, etc., which are the formal names for these conventional signal lines. However, it should be apparent that the use of CD 1 , CD 2 , VS 1 and V 52 are shorthand versions of these formal names, and may be used interchangeably.
[0048] Thus, it is evident that there has been provided an integrated Smart card controller and Smart card detection process that satisfies the aims and objectives stated herein. It will be apparent to those skilled in the art that modifications are possible. For example, although the present invention has been described with reference to detection and operation of smart Cards, the present invention is equally adapted for the detection and operation of any type of expansion cards, in addition to conventional PC Cards. Other modifications are possible. For example, it may be desirable to include a software lock on the operability of the smart card logic shown herein. Accordingly, the logic depicted in FIG. 3 can include an enable bit, which selectively turns on and off smart card detectability and operability. To that end, and referring to FIG. 6, the smart card detection process may alternatively include the step of determining if an enable bit is enabled, and if CD 1 and STSCHG are tied together 84 . If this is not the case, the smart card the logic will not detect the presence of a smart card. This feature of the present invention permits, for example, manufacturers to offer smart card compatibility as an upgrade option, while still integrating the core logic of the controller 10 . Those skilled in the art will recognize additional modifications, and all such modifications are deemed within the scope of the present invention, only as limited by the appended claims. | An integrated controller for the detection and operation of both PC Cards, smart cards and passive smart card adapter cards. In one aspect, the invention detects the presence of standard expansion cards or passive smart card adapters by utilizing the reserved detection and voltage selection signal area defined by the PC Card specification. In another aspect, the invention provides an integrated controller that includes logic to operate either a standard expansion card or a passive smart card adapter by reassigning certain PC Card signal lines to operate a standard expansion card or a passive smart card adapter, thereby eliminating the need to provide pins in addition to those defined by the PC Card specification. | 8 |
This application is a continuation-in-part to U.S. patent application Ser. No. 11/131,726 filed May 18, 2005.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates generally to methods and devices for cleaning and remediating a subsurface safety valve or other downhole tool having a sliding flow tube member.
2. Description of the Related Art
Flapper-type valves are often used as safety valves within wells to selectively close off production. The usual flapper valve uses a torsion spring to bias the valve member toward a closed position. During normal operation, however, the flapper member is retained in an open position by an axially moveable flow tube. When the flow tube is moved upwardly within the production tubing, the flapper member is permitted to close under influence of the spring. To reopen the valve, the flow tube is moved downwardly within the production tubing to urge the valve back towards its open position.
One problem that has traditionally been faced by valves of this type is that scale, dirt, and other debris will often build up within the production tubing during typical production operations. This build up can render the safety valve partially or completely inoperable. The most deleterious build up will be that which occurs on and around the flow tube that is used to open the valve, making the flow tube difficult to physically move upwardly and downwardly. Additionally, the flapper mechanism may be encrusted with scale and other debris making it less likely to fully close when necessary. This means that the valve will be unable to function well in the event of an emergency requiring production flow to be closed off.
U.S. Pat. No. 6,273,187, entitled “Method and Apparatus for Downhole Safety Valve Remediation,” describes a technique for removing scale and debris build up using explosive charges. The use of explosives, however, carries with it risks of damage to wellbore valve components as well as the potential for a breach of the production tubing string.
The harmful effects of scale and debris build up can be prevented and reduced by exercising the safety valve, through operation of its components, before the build up has reached a point where the safety valve is no longer fully operational. In the past, this has been accomplished using a gripping tool having mechanical slips that are set against the inside of the flow tube. Once the slips are set, the gripping tool can be pulled upwardly to move the flow tube upwardly or jarred downwardly to move the flow tube downwardly. Unfortunately, tools of this type tend to physically damage the flow tube and other wellbore components, due to the use of the slips.
The parent application to this one describes a flow tube exercising tool that is used in conjunction with the hydraulic controller of a safety valve to move the flow tube axially upwardly and downwardly in order to remove build ups of scale and debris from the safety valve and ensure proper operation. This exercising tool provides an engagement portion that underlies the lower end of the safety valve flow tube so that upward movement of the exercising tool will move the flow tube upwardly. Hydraulic fluid is provided to the hydraulic controller to move the flow tube downwardly. This exercising tool represents a significant improvement over the prior art. However, there may be instances wherein this type of flow tube exerciser is not practical. One example would be an instance where the flow tube of the safety valve is not controllable hydraulically.
The present invention addresses the problems of the prior art.
SUMMARY OF THE INVENTION
The invention provides an improved flow tube exercising tool and method of use. An exemplary flow tube exercising tool is described that features a mandrel having upper and lower engagement portions that will overlie and underlie the upper and lower ends of the flow tube, respectively. The flow tube exercising tool is run into a production tubing string using a running tool. The tool is landed onto a safety valve within the tubing string. Further downward force upon the exercising tool will cause the upper and lower engagement portions to engage the upper and lower ends, respectively, of the flow tube of the safety valve.
In a currently preferred embodiment, the flow tube exercising tool includes an inner mandrel and an outer mandrel that are axially moveable with respect to one another, and initially releasably affixed to one another via a shear member. The outer mandrel carries a stop shoulder that is shaped and sized to abut a landing shoulder within the tubing string that is associated with the safety valve. After the tool is landed in this manner, fluid pressure is increased above the tool within the tubing string to shear the shear member. Further increase in fluid pressure will urge the inner mandrel axially downwardly with respect to the outer mandrel. Downward movement of the inner mandrel will cause the lower engagement portion of the exercising tool to become aligned with the lower end of the flow tube and the upper engagement portion to become aligned with the upper end of the flow tube. The upper and lower engagement portions are shaped and sized to overlie and underlie, respectively, the upper and lower ends of the flow tube. In a currently preferred embodiment, the upper and lower engagement portions are provided by collets.
The flow tube of the safety valve is exercised by moving it axially upwardly and downwardly with respect to the safety valve housing. The flow tube can be moved upwardly by pulling upwardly on the running arrangement for the exercising tool. The flow tube can also be moved downwardly by increasing fluid pressure within the tubing string. An increase of fluid pressure within the production tubing string will exert fluid pressure upon a fluid pressure receiving area of the tool to urge the flow tube axially downwardly. The flow tube may be repeatedly moved up and down to clean scales and other debris from it.
The flow tube exercising tool of the present invention provides a number of advantages over conventional systems. The flow tube of the safety valve may be exercised (i.e., moved axially with respect to the safety valve housing) without the risk of damage from the setting of slips. Only a single trip of the flow tube exercising tool is necessary to accomplish multiple upward and downward movements of the flow tube. Additionally, the flow tube is exercised without the need to operate the hydraulic actuator of the safety valve.
BRIEF DESCRIPTION OF THE DRAWINGS
For a thorough understanding of the present invention, reference is made to the following detailed description of the preferred embodiments, taken in conjunction with the accompanying drawings in which like reference characters designate like or similar elements throughout the several figures of the drawing.
FIGS. 1A , 1 B and 1 C present a side, cross sectional view of an exemplary flow tube exercising tool constructed in accordance with the present invention in a position for being run into production tubing.
FIGS. 2A , 2 B and 2 C are a side, cross-sectional view of the exercising tool shown in FIGS. 1A-1C , now with the lower engagement portion of the exercising tool engaging the lower end of the safety valve flow tube and the upper engagement portion of the exercising tool engaging the upper end of the flow tube.
FIGS. 3A , 3 B and 3 C are a side, cross-sectional view of the exercising tool shown in FIGS. 1A-1C , now with the safety valve flow tube having been raised to an upper position.
FIG. 4 is a side, cross-sectional view of the upper portion of the exercising tool now with the emergency release feature activated.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1A , 1 B and 1 C illustrate a section of portion of a string of production tubing 10 , of a type known in the art that defines a production flowbore 12 along its length. A safety valve, generally indicated at 14 is integrated into the production tubing string 10 . The safety valve 14 is a flapper valve, of a type that is well known in the art and described in, for example, U.S. Pat. No. 4,415,036 issued to Carmody. U.S. Pat. No. 4,415,036 is owned by the assignee of the present invention and is incorporated herein by reference. In the safety valve 14 , a flapper valve member 16 rotates in a pivoting manner about a hinge 18 and is biased toward a closed position by a spring (not shown), in a manner well known in the art. The flapper member 16 is opened and retained in an open position (as illustrated in FIG. 1C ) by an axially moveable flow tube 20 which, in turn, is actuated by a hydraulic piston-type controller (not shown) of a type known in the art.
At its upper end, the safety valve 14 includes a nipple adapter 22 that is secured by threaded connection 24 to the production tubing string 10 . The nipple adapter 22 defines an interior axial flowbore 26 along its length, and an annular dog recess 28 is located within the flowbore 26 . An upwardly directed stop shoulder 30 is also located within the flowbore 26 .
The body of the safety valve 14 defines a piston chamber 32 that houses actuation piston 34 . The actuation piston 34 is secured to the flow tube 20 and presents an upper pressure receiving end 36 with fluid seals 38 to form a fluid tight seal within the piston chamber 32 . A hydraulic controller (not shown) of a type known in the art is interconnected with the nipple adapter 22 , as is know, to provide fluid pressure to the interior of the chamber 32 in order to actuate the flapper valve 14 to an open position by axial movement of the flow tube 20 . The upper pressure receiving end 36 of the piston 34 is adapted to receive increased fluid pressure. The lower end of the nipple adapter 22 is secured to a flapper valve housing 40 that encloses the flapper valve member 16 and compression spring 42 .
Also shown in FIGS. 1A , 1 B and 1 C is a flow tube exercising tool 50 that is run into the flowbore 12 of the production tubing string 10 at the lower end of a wireline “GS” type running tool (not shown) or other suitable running arrangement of a type known in the art. Beginning at its upper end, the flow tube exercising tool 50 includes a fishing neck sub 52 having a fishing neck 54 at its upper end. The lower end of the fishing neck sub 52 is secured by threading to a fishing neck extension 56 . An abutment shoulder 58 is also formed at the lower end of the fishing neck sub 52 . The fishing neck extension 56 has a radially reduced body portion 60 and an enlarged body portion 62 . A fluid seal 64 surrounds the enlarged body portion 62 .
Radially surrounding the fishing neck extension 56 is a tubular sealing mandrel 66 . The sealing mandrel 66 includes a body 68 that defines an axial passage 70 along its length. The axial passage 70 contains a reduced-diameter flow portion 71 and an enlarged diameter portion 72 . The upper end of the body 68 presents a landing shoulder 74 within the passage 70 while the lower end of the body 68 presents an exterior landing shoulder 76 .
The sealing mandrel 66 is releasably affixed by shear members 78 to an inner mandrel 80 . The inner mandrel 80 features an enlarged head portion 82 and an exterior dog recess 83 . The inner mandrel 80 is affixed at its lower end to an inner sleeve 84 . The inner sleeve 84 features a set of collet windows 86 in its body.
The lower end of the inner sleeve 84 is secured to a lower collet sub 88 . The lower collet sub 88 presents a number of axially extending collets 90 having latch end portions 92 that are shaped and sized to underlie the lower end 94 of the flow tube 20 . The lower collet sub 88 also includes a plurality of slots 96 , 98 above the collets 90 . In a currently preferred embodiment, there are four slots 96 , 98 , which are spaced about the circumference of the lower collet sub 88 at approximate 90 degree angles from each other. Pins 100 extend through each slot 96 , 98 and are secured to a ring 102 retained within the lower collet sub 88 and a lower outer sleeve 104 that radially surrounds the lower collet sub 88 .
The lower outer sleeve 104 is releasably affixed by shear screws 106 to an upper outer sleeve 108 . The upper outer sleeve 108 includes a set of outer collet windows 110 and a set of locking dog windows 112 . The upper outer sleeve 108 terminates in an upper end 114 . The upper outer sleeve 108 is releasably secured by shearable pin members 116 to the inner mandrel 80 . Additionally, the upper outer sleeve 108 presents an outward and downwardly directed landing shoulder 117 that is shaped and sized to land within and contact the shoulder 30 in the nipple adapter 22 . During run in, the locking dogs 118 initially reside within the locking dog slots 112 and partially within the dog recess 83 of the inner mandrel 80 , as depicted in FIG. 1B .
A set of upper collets 118 are disposed generally within the radial space 120 between the inner sleeve 84 and the upper outer sleeve 108 . Each of the upper collets 118 has a prong-type end portion 122 that is shaped and sized to overlie and engage the upper end 124 of the flow tube 20 . The upper and lower collets 118 , 90 collectively provide a mandrel body that is shaped and sized to reside within the flow tube 20 of the safety valve 14 and, as will be described, are capable of moving the flow tube 20 axially upwardly and downwardly with respect to the safety valve 14 .
Both sets of collets 90 and 118 are biased radially outwardly due to shape memory, and, in the initial run-in configuration depicted by FIGS. 1A , 1 B and 1 C, are restrained radially inwardly by a surrounding member. In the case of the upper collets 118 , the upper prong portion 122 is contacted by sloped side surfaces 126 on the upper outer sleeve 108 , which cam the collets 118 radially inwardly. The lower collets 90 are retained radially inwardly by the surrounding lower end of the lower outer sleeve 104 .
In operation, the flow tube exercising tool 50 is run down into the flowbore 12 of the production string 10 , in the initial condition shown in FIGS. 1A , 1 B, and 1 C. FIGS. 2A , 2 B and 2 C illustrate the exercising tool 50 now having been landed within the nipple adapter 22 of the safety valve 14 . The landing shoulder 117 of the upper outer sleeve 108 has been landed into the shoulder 30 of the nipple adapter 22 . Further downward force is then applied to the upper fishing neck sub portion of the tool 50 via fluid pressure, a jarring tool, weight, or otherwise to cause the shear members 78 to shear. This will release the inner mandrel 80 from the surrounding upper outer sleeve 108 . Downward movement of the inner mandrel 80 with respect to the upper outer sleeve 108 will cause the locking dogs 118 to be cammed out of the dog recess 83 of the inner mandrel and into the dog recess 28 of the nipple adapter 22 , thereby securely locking the exercising tool 50 to the nipple adapter 22 . The inner mandrel 80 continues to move downwardly with respect to the upper outer sleeve 108 until the enlarged head portion 82 of the inner mandrel 80 shoulders out against the upper end 114 of the upper outer sleeve 108 , as depicted in FIG. 2B . In this position, the lower collets 90 will be moved to a position wherein they are not restrained by the lower outer sleeve 104 . The prong ends 92 of each lower collet 90 will then underlie the lower end 94 of the flow tube 20 .
Downward movement of the inner mandrel 80 with respect to the upper outer sleeve 108 will also cause the upper collets 118 to slide downwardly within outer collet windows 110 . The prong portions 122 of each upper collet 118 will enter the recessed area 130 above the upper end 124 of the flow tube 20 . Thus, the prong ends 122 will overlie the upper end 124 .
It is further noted that, as the inner mandrel 80 is moved downwardly, the enlarged body portion 62 of the fishing neck extension 56 is moved out of the enlarged diameter portion 72 of the axial passage 70 of the sealing mandrel 66 so that the fluid seal 64 surrounding the enlarged body portion 62 will create a fluid seal against the side of the axial passage 70 (see FIG. 2B ). Downward movement of the fishing neck extension 56 within the sealing mandrel 66 is limited by the landing of shoulder 58 against shoulder 74 , as shown in FIG. 2B .
Once the exercising tool 50 has been landed into the nipple adapter 22 and safety valve 14 in the manner described above, the flow tube 20 may then be exercised by the tool 50 to move the flow tube 20 axially upwardly and downwardly with respect to the safety valve 14 , thereby removing scales, paraffins, debris and other build up that might tend to preclude proper operation of the safety valve 14 . To raise the flow tube 20 with respect to the safety valve 14 , an operator at the surface of the well (not shown) will pull up on the running arrangement (not shown) for the exercising tool 50 which, in turn, will cause the fishing neck sub 52 and affixed fishing neck extension 56 to be raised. The enlarged body potion 62 will shoulder against the upper reduced diameter flow portion 71 of the axial passage 70 of the surrounding sealing mandrel 66 and cause the sealing mandrel 66 to be moved upwardly as well. Because the sealing mandrel 66 is affixed by pins 78 to the inner mandrel 80 , the inner mandrel 80 and affixed inner sleeve 84 and lower collet sub 88 are raised as well. FIGS. 3A-3C illustrate the configuration of the exercising tool 50 with the flow tube 20 now having been raised to an upper position with respect to the safety valve 14 by virtue of the underlying relation of the prong portions 92 of lower collets 90 beneath the lower end 94 of the flow tube 20 .
To return the flow tube 20 to its downward position (as depicted in FIGS. 2A-2C ), fluid pressure is increased in the flowbore 12 above the exercising tool 50 . The fluid pressure increase will exert force upon the upper axial ends of the fishing neck sub 52 , the sealing mandrel 66 , and the inner mandrel 80 . By virtue of fluid seals 64 and 132 (between the inner mandrel 80 and the sealing mandrel 66 ), a substantially uniform pressure receiving area is created. The inner mandrel 80 , sealing mandrel 66 , and fishing neck sub 52 and extension 56 and upper collets 118 are all moved radially downwardly within the surrounding upper and lower outer sleeves 108 , 104 . It should be noted that the upper and lower outer sleeves 108 , 104 collectively form a unitary outer sleeve that surrounds the inner mandrel 80 and associated components. This downward axial movement will cause the upper collets 118 , whose flange portions overlie the upper end 124 of the flow tube 20 , to urge the flow tube 20 axially downwardly. The upper collets 118 are capable of movement within the collet windows 110 for movement of the flow tube 20 while the outer sleeves 104 , 108 remain securely locked to the nipple adapter 22 .
The procedures described above for movement of the flow tube 20 upwardly and downwardly with respect to the safety valve 14 may be repeated as necessary in an alternating manner to remove scale and other debris and ensure proper operation of the safety valve 14 . Movement of the flow tube 20 may be exercised in this manner using only a single trip of the exercising tool 50 into the production tubing 10 . However, the exercising tool 50 may also be run into the production tubing 10 on several separate occasions during the life of the wellbore to ensure continued proper operation of the safety valve 14 throughout.
Normally, the exercising tool 50 may be detached from the flow tube 20 by merely pulling upwardly on the running arrangement with sufficient force that the lower collets 90 are deflected radially inwardly and thus released from the lower end 94 of the flow tube 20 . Further upward pulling of the running arrangement will cause the fishing neck sub 52 , fishing neck extension 56 , sealing sub 66 , inner mandrel 80 , inner sleeve 84 and lower collet sub 88 and affixed outer sleeves 104 , 108 to be moved axially upwardly. The locking dogs 112 will retract back into the dog recess 83 of the inner mandrel 80 , thereby freeing the exercising tool 50 from locking engagement with the safety valve 14 . At this point, the exercising tool 50 is withdrawn from the safety valve 14 and from the tubing string 10 .
If, however, the exercising tool 50 cannot be detached in this manner, the tool 50 may be released using a technique for emergency disengagement of portions of the tool 50 from the safety valve 14 . An operator at the surface (not shown) will apply an upward pull on the fishing neck sub 52 that is sufficient to shear the pins 78 that are securing the sealing mandrel 66 to the inner mandrel 80 . Further upward pulling will remove the fishing neck sub 52 , fishing neck extension 54 and sealing mandrel 66 from the exercising tool 50 and then from the production tubing 10 (see FIG. 4 ). With these components removed, a fishing tool (not shown) of a type known in the art may be inserted into the production tubing 10 and used to engage the enlarged head portion 82 of the inner mandrel 80 and remove it from the valve 14 and tubing string 10 as well. A further release tool (not shown), such as a standard sinker bar or weight, may subsequently be run into the tubing string 10 and used to contact the ring 102 to urge these additional components out of engagement with the surrounding valve 14 . The release tool will be effective to release the lower collets 90 from the lower end 94 of the flow tube 20 because downward urging of the ring 102 will cause shifting members, or pins, 100 to slide downwardly within slots 96 , 98 in the lower collet sub 88 . The shifting members 100 are affixed to the lower outer sleeve 104 and will cause the lower end 130 of the lower outer sleeve 104 to wedge between the lower collets 90 and the flow tube 20 , thereby forcing disengagement.
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 flow tube exercising tool and method for use are described for actuating the flow tube of a downhole safety valve in order to remove build ups of scale and debris from the safety valve and ensure proper operation. The exercising tool provides a lower engagement portion that underlies the lower end of the safety valve flow tube so that upward movement of portions of the exercising tool will move the flow tube upwardly. An upper engagement portion overlies the upper end of the flow tube so that downward movement of portions of the exercising tool will move the flow tube downwardly. Only a single trip of the flow tube exercising tool is necessary to accomplish multiple upward and downward movements of the flow tube. | 4 |
BACKGROUND OF THE INVENTION
The present invention relates generally to toy blocks and more specifically to a toy block connector that forms a flush and secure yet releasable connection that conceals the coupling mechanism.
A number of toy blocks and construction sets have been developed that simulate structures such as skyscrapers, houses, and castles. Columns, beams, panels, and preformed building components such as roofs and walls are among the structural elements used to build the various toys. There are a variety of connectors that can be used to join each type of structural element to suit the particular needs and materials of the structural elements.
SUMMARY OF THE INVENTION
A connector in accordance with the present invention provides a novel alternative to the connectors previously developed. The connector comprises male and female connector assemblies. The female connector assemblies have alternating recesses and female snaps, and are joined to toy structural elements including, but not limited to, beams, columns, panels, bases, foundations and roofs. They are adapted to engage the male connector assemblies which have alternating tongues and male snaps and which are joined to another toy structural element. When assembled, the male and female connector assemblies form a secure flush connection between structural elements that conceals the male and female connecting assemblies when viewed from the outside of the adjoined structural elements. The connector is resilient enough for children to assemble and disassemble in a variety of configurations which enhances the play value of the toy.
In use, the tongues are adapted to align with and frictionally engage the female recesses. The male and female snaps are also adapted to align and snap engage one another. To make the connection, a first structural element having a female assembly is aligned adjacent to a second structural element having a male assembly so that the tongues of the male engage the recesses of the female and the female snaps engage the male snaps.
In one embodiment, the female connector assemblies are joined to, or essentially make up, couplings that engage one or more male connector assemblies which are in turn joined to the edges of panels. It is noted that male and female connector assemblies may be joined to any structural element of a toy construction set.
The female recesses may comprise a web and a flange both extending outwardly from the structural element and spaced apart from one another, defining the recess therebetween. The female snaps can be a resilient web extending outwardly from the structural element between the recesses. A lug may be formed on a distal portion of the web to engage the male snap. The web for both the recesses and the female snaps may be continuous, running the length of the structural element.
The male snaps may also be resilient and may be in the form of a tab extending outwardly from another structural element. The snap may further comprise a lug formed on a distal portion of the tab to engage a female snap.
When both the male and female snaps have lugs adapted to engage one another the connector operates by bringing the two structural elements together and inserting the tongues into the recesses causing them to frictionally engage. The lugs of the male and female snaps should be in the same plane so that when they engage they can only pass over one another due to the resilient deformation of the webs and tabs and the restraining force of the engagement of the tongues and recesses. Once the lugs have passed over one another the web and tab return to their original shapes. The connection is secure due to the frictional engagement between the tongues and recesses and the relative positions of the lugs.
One or more stops may be joined to the recesses which engage one or more tongues and restrain their lateral movement out of the recesses. A stop may join the recess web and flange to close one end of the recess thereby blocking a tongue inserted in the recess from moving laterally out of the recess.
One or more female connector assemblies may be joined to an edge or edges of a panel, coupling or other structural element so long as they are adapted to engage complimentary male connector assemblies on another panel, coupling or other structural element. A single structural element may have both male and female connector assemblies joined to it which are adapted to engage complimentary connector assemblies on other structural elements. It may be desirable to join structural elements shaped like various building components such as roofs or foundations using the connector of the present invention.
Other features and advantages are inherent in the connector claimed and disclosed or will become apparent to those skilled in the art from the following detailed description in conjunction with the accompanying diagrammatic drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a coupling member having two contiguous female assemblies joined at their edges, one female connector assembly is engaging a male connector assembly joined to a panel while the other female assembly is unengaged but in alignment with another panel having a male connector assembly;
FIG. 2 is a cross sectional view taken along line 2--2 in FIG. 1;
FIG. 3 is a perspective view of a panel in the shape of a toy house exterior wall having a plurality of male connector assemblies, and toy house foundation having formed in it a plurality of female connector assemblies;
FIG. 4 is an exploded view of a toy building having panels and couplings themselves having a plurality of the male and female connector assemblies of the present invention; and
FIG. 5 is a perspective view of a completed toy structure constructed with the connector of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, indicated generally at 10 is a coupling comprising a first female connector assembly 12 contiguous with a second female connector assembly 14. Each female connector assembly has two recesses 16 and a female snap 18. In the illustrated embodiment, the recesses 16 and female snap 18 share a common web 20. Together with web 20, the recesses 16 each comprise a flange 22 parallel to and spaced apart from web 20. A partition 24 separates the recesses 16 of first female connector assembly 12 from the recesses 16 of second female connector assembly 14. The female snaps 18 each have an upwardly extending lug 30 joined to web 20 near a distal edge 32 of web 20. Finally, the recesses illustrated include stops means 34 which close one end of the recesses and restrain lateral movement of engaged tongues out of the recesses.
A panel 40 has joined to it a male connector assembly 38 complimentary to female assembly 12. Male assembly 38 has alternating tongues 42 joined to and extending outwardly from a panel edge 44. Tongues 42 are adapted to frictionally engage recesses 12. In between tongues 42 is a male snap 46 which is also joined to and extends outwardly from panel edge 44. Male snap 46 comprises a resilient tab 48 and a downwardly extending lug 50 joined near a distal edge 52 of tab 48. Male snap 46 is adapted to engage female snap 18.
In operation, coupling 10 and panel 40 are aligned and brought adjacent one another until tongues 42 frictionally engage female recesses 16 and female snap 18 and male snap 46 resiliently engage one another at their respective lugs 30 and 50 which are positioned in a predetermined plane, as illustrated, which is selected to ensure their contact. When the lugs engage, web 20 bends downwardly and tab 48 bends upwardly until the lugs pass one another and the web 20 and tab 48 snap back to their original shapes. A complete connection is illustrated in FIGS. 1 and 2 between female coupling 10 and a second panel 60 having a male assembly 58 joined thereto.
While web 20 and tab 48 are described as resilient, certain plastics or other materials may be used to form coupling 10 and panel 40 (or any other structural element) which permit the connector to operate by flexing coupling member 10 along substantially its entire length and panel 40 along its entire edge 44. The snap mechanism operates in substantially the same way as described above except that as lugs 30 and 50 pass over one another, coupling 10 and panel 40 are bowed along some, if not all, of their length but snap back to their original shape when the lugs completely pass one another.
Second panel 60 has joined to its edge 62 male connector assembly 58 having outwardly extending tongues 64 which are frictionally engaging recesses 16 of second female connector assembly 14. Between tongues 64 is a male snap 66 joined to and extending outwardly from edge 62 and which is illustrated as engaging female snap 18. Male snap 66 comprises a resilient tab 68 and a downwardly extending lug 70 joined to tab 68 near its distal edge 72.
FIG. 2 illustrates a sectional view of the complete panel connection between second female connector assembly 14 of coupling 10 and male connector assembly 58 taken along line 2--2 in FIG. 1. Female snap 18 is engaged with male snap element 66 extending outwardly from panel 60 edge 62. Male snap element 66 comprises tab 68 and downwardly extending lug 70 joined near the distal edge 72 of tab 68.
FIG. 3 illustrates substantially similar male and female connector assemblies as those illustrated in FIGS. 1 and 2 except that the assemblies are joined to different toy structural elements. A house foundation 80 has formed in it a plurality of female connector assemblies 82. A continuous web 84 is used for all female assemblies 82 on one side of the foundation. A plurality of flanges 86 are shown which are formed in foundation 80, parallel to and spaced apart from web 84 to define a plurality of recesses 88. A plurality of female snaps 90 comprise web 84 and lugs 92.
A simulated wall panel 100 has a plurality of male connector assemblies 102 joined to its edges 104. Each male connector assembly 102 comprises two tongues 106 separated by a male snap 108. Tongues 106 are adapted to frictionally engage recesses 88. Male snaps 108 comprise resilient tabs 110 and lugs 112 adapted to engage female snaps 90 in the manner described above.
Also illustrated in FIG. 3 is a porch 120 formed together with foundation 80. When foundation 80 and wall panel 100 are snapped together, they simulate part of an actual frame house having a porch 120. Other building elements, not illustrated, include other wall panels, doors and at least one roof section. The completed toy structure may resemble a house.
FIG. 4 illustrates an exploded view of the garagetype structure 130 illustrated in FIG. 5. In this structure, garage 130 comprises a number of wall panels 132 joined together by couplings 134 comprising contiguous female connector assemblies. End walls 136 are fitted with female connector assemblies 138 which are adapted to engage male connector assemblies 140 joined to panels 132.
Roof structure 146 comprises two angled panels 148 and 150, respectively, joined by coupling 152. Roof panels 148 and 150 are fitted with male connector assemblies 154 (not visible on panel 148) which are adapted to engage contiguous female connector assemblies of coupling 152. Alternatively, roof panel 148 could be fitted with female connector assemblies adapted to engage male connector assemblies 154 fitted on roof panel 150, thereby obviating the need for coupling 152. (Embodiment not illustrated). Both roof panels 148 and 150 are fitted with female connector assemblies (not visible) which are adapted to engage male connector assemblies 156 joined to the tops of wall panels 132.
The foregoing detailed description has been given for clearness of understanding only, and no unnecessary limitations should be understood therefrom, as modifications will be obvious to those skilled in the art. | A toy connector in accordance with the present invention joins first and second structural elements which are aligned adjacent one another and engaged to form a flush, secure connection having a female connector assembly joined to the first structural element having at least two recess elements and at least one female snap element disposed between the recess elements, and a male connector assembly joined to the second structural element having at least one tongue adapted to engage each of the recess elements, and at least one male snap element adapted to engage the female snap element. | 0 |
[0001] This application is a United States non-provisional application which claims the benefit of U.S. Provisional Application Ser. No. 60/274,846 filed on Mar. 9, 2001, the teachings of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to the design and synthesis of a new class of stabilized peptide structures that are useful as mimics of the alpha helical structure ubiquitous in proteins.
[0004] 2. Description of the Related Art
[0005] Steroids, along with other lipophilic hormones such as the retinoids and vitamins, bind to members of the nuclear-receptor superfamily. These ligands modify the DNA-binding and transcriptional properties of these receptors, resulting in the activation or repression of target genes. Ligand binding induces conformational changes in nuclear receptors and promotes their association with a diverse group of nuclear proteins, including SRC-1/p160, TIF-2/GRIP-1 and CBP/p300 which function as co-activators of transcription. A short sequence motif LXXLL (where L is leucine and X is any amino acid) present in RIP-140, SRC-1 and CBP is necessary and sufficient to mediate the binding of these proteins to liganded nuclear receptors. The ability of coactivators to bind the estrogen receptor and enhance its transcriptional activity is dependent upon the integrity of the LXXLL motifs and on key hydrophobic residues in a conserved helix (helix 12) of the estrogen receptor that are required for its ligand-induced activation function. Thus the LXXLL motif is a signature sequence that facilitates the interaction of different proteins with nuclear receptors, and is thus a defining feature of a new family of nuclear proteins (Heery, 1997).
[0006] These compounds are intended as protein mimics and thus could find numerous applications, and especially for inhibition of protein-protein interactions where at least one of the proteins displays a helical segment as a prominent feature in terms of its tight binding to another protein. Where the protein-protein interaction is critical to a biological function, as is often the case, then by retarding or preventing this interaction through the intervention of the helicomimetic (helix protein mimic), this compound can serve as a useful drug candidate in the event of a pathologic process such as cancer or stroke, or other instances such as transcription mediated by nuclear receptors and their cognate macromolecules.
SUMMARY OF THE INVENTION
[0007] This invention includes helix stabilized compounds that contain the so-called NR Box, found in a large number of Nuclear Receptor Coactivator Proteins. The NR Box sequence, consisting of Leu-Xxx-Yyy-Leu-Leu within a longer peptide, is found in both coactivator proteins and also in certain nuclear receptors themselves. In the case of the Androgen Receptor, this sequence is varied to include Phe-Xxx-Yyy-Leu-Phe and Phe-Xxx-Yyy-Leu-Trp, where Xxx and Yyy typically consist of two out of a rather large and diverse choice among the 20 common or natural amino acids.
[0008] By preparing synthetic variants of relatively short peptides and peptide mimics that contain the crucial hydrophobic amino acids, e.g., leucines, that maintain contact with the nuclear receptor, it is possible to prevent binding of the coactivator proteins to the nuclear receptors. This intervention prevents the receptor from its normal subsequent step of binding to DNA and thus also prevents the transcription of the DNA segment known os the Estrogen Response Element. This intervention has a similar pattern with respect to the other types of nuclear receptors, such as the androgen, progestin, glucocorticoid, mineralocorticoid, and the growing number of orphan receptors that have been shown to function in a biochemically equivalent manner. Thus, by the prevention of the normal receptor-coactivator interactions, we will be able to control such effects as DNA transcription and the related downstream events that are affected, such as cell growth and division. Thus these molecules represent a novel approach to the control of such diseases as breast cancer and prostate cancer. These forms of cancer are currently treated with such agents as tamoxifen and raloxifene that function as estrogen antagonists. But tamoxifen and raloxifene have been shown to bind to the normal steroid binding site, and not to the site occupied by the helical peptide LXXLL. Thus our peptides represent a novel and distinct approach toward the treatment of cancer through a new form of inhibition of nuclear receptor action.
[0009] In order for LXXLL peptides to bind to the receptor, it is believed essential that they do so in the form of an alpha helix conformation. Shorter linear peptides tend to adont random or β-sheet structures rather than helices. Various strategies have been used to induce helix folding including incorporation of α-alkyl amino acid residues such as Aib (aminoisobutyric acid) or Deg (diethylglycine). This approach may lead to unacceptably high hydrophobic character when matched with an LXXLL sequence. Other options include helix end capping and dipole stabilization, primarily useful for longer sequences.
[0010] The peptides of the instant invention are preferable to LXXLL linear sequences for several reasons. The first is that we and others have shown that short, linear peptides are not able to inhibit coactivator binding, at least to the extent our bioassays reflect this activity. Second, by including pairs of cysteine residues within the sequence, we are able to enhance the helical character of these peptides. The preferred method for doing so involves the incorporation of one D-cysteine in the sequence and one L-cysteine. It is important to note that other workers have generally found that this type of side chain to side chain cyclization does not yield a strongly helical sequence. Our studies have also demonstrated this trend. But our work also demonstrates that the cysteine bridges do in fact help stabilize this helical tendency when the cyclic peptide comes into contact with the nuclear receptor. This has been shown most clearly by a study of the interaction of one of our peptides (that one known as PERM-1 for peptidomimetic estrogen receptor modulator −1) with the ligand binding domain of the estrogen receptor (see the Figure showing the X-ray crystal structure by N. Chirgadze and coworkers). This finding is significant since it shows the ability of our synthetic peptide to adopt a clear helical conformation in the presence of its partner and to form a strong and stable interaction with the receptor.
[0011] Additionally, our peptides can easily be made selective to one or another of the multiple nuclear receptors by changing the structure of the amino acids in the flanking regions. Thus, as seen in Table I entitled “Peptide Analogs and their Ki values against ER alpha and ER beta”, it is apparent that by changes in amino acid composition, we are able to increase the binding toward ER alpha to a significant degree. Furthermore, this selectivity in preferred binding to a receptor is in most cases predictable through an examination of both the sequences of amino acids found in various naturally occurring coactivator proteins as well as by an examination of the receptor residues found in close proximity to the LXXLL binding sites. This is an important attribute of our cyclic peptide analogs since it means that we may retain the preferred small, cyclic helix-forming nature of our peptides and yet still embody the selectivity and specificity important to any useful drug.
[0012] For instance a preferred embodiment of a compound of the present invention comprises of the structure R1-(Xn)-D-Cys-Y-Y-L-Cys-(Xn)-R2, where R1 consists of H, an alkyl, aryl, acetyl, formyl, or other blocking or solubilizing group such as a polyethylene glycol (PEG) or other polyether moiety, linked to the N-terminal nitrogen through a carbon-nitrogen bond. Moreover, X consists of one or more natural or unusual amino acids, linked together in a chain from 0 to n in length, and Y consists of any natural or unnatural amino acid, usually of the L-configuration, and with two such amino acids that need not be identical, separating the pairs of cysteines to form an i to i+3 type of disulfide bridged unit. R2 consists of an OH, NH2, NHR, OR, or other blocking or solubilizing group such as polyethylene glycol (PEG) or other polyether moiety linked to the C-terminal carbonyl through an oxygen or carbon or nitrogen linkage, such as an amide group.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] A better understanding of the present invention will be had upon reference to the following description in conjunction with the accompanying drawings in which like numerals refer to like parts throughout the several views and wherein:
[0014] FIG. 1 is a structure of a side chain linked amide (a) and disulfide (b) bridges at (i,i+4) and (i, i+3) positions, respectively;
[0015] FIG. 2 is color a molecular modeling rendition of the structure of a helicomimetic peptide bound to a nuclear receptor; and
[0016] FIG. 3 is a black and white photocopy of FIG. 2 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0017] The preferred compound of this invention involves a cyclic peptide containing the LXXLL sequence. The cycle is formed through a side chain to side chain ring involving a monosulfide or disulfide bridge between pairs of cysteines, penicillamines, homocysteines, combinations of the foregoing, or other pairs of amino acids in which the side chains are linked with either one or two sulfur atoms. In a preferred embodiment, the peptide cycle is formed with a D-cysteine at the −2 position and an L-cysteine at the first Xxx residue to produce an i to i+3 ring. With this partial structure, such as -D-Cys-Ile-Leu-Cys-Arg-Leu-Leu-, the flanking residues attached at the N-terminal side of the D-Cys and at the C-terminal side of the Leu provide selectivity as inhibitors against one of several nuclear receptors. For example, in the case of the compound known as PERM-1, the Ki value against ER beta is approximately 390 nM, while its value against ER alpha is 25 nM. Thus this compound exhibits selectivity against the ER alpha receptor.
[0018] The compounds may also be modified by the attachment of elements designed to stabilize the structure, and to enhance bioavailability. For example, the N- and/or C-termini may be attached to polyethylene glycol (PEG) fragments, designed to enhance penetration through lipid membranes. Alternatively, other types of solubility enhancing bioconjugates may be used to assist in membrane permeability. Other modifiers can also be attached. For example, the TAT and related hydrophilic peptide sequences, derived originally from the HIV virus, have been demonstrated to assist in the delivery of peptides and other therapeutic agents into cells. These sequences, along with those known as antennapedia peptides, would be expected to provide a similar benefit for the delivery of these nuclear receptor antagonists into the cell and eventually to the nuclear compartment.
[0019] Another approach that has shown promise in enhancing peptide bioavailability is the replacement of one or more amide bonds with various backbone replacements. These may include pseudopeptides, with CH2S, CH2NH. CH═(CH, or N-methyl amide bond modifications, or can involve the substitution of an amino acid with more conformationally constrained variants such as alpha methyl and beta methyl substitutions. The replacement of cysteine by penicillamine (beta, beta-dimethyl cysteine) has been previously mentioned. This modification is able to reduce the flexibility of the disulfide ring and can enhance stability, potency, and selectivity, as has been documented in the case of the mu selective opioid analog known as DPDPE.
[0020] The major therapeutic benefit gained by the design and synthesis of coactivator antagonists is a more effective control of steroid receptor mediated transcriptional processes. Thus in diseases such as breast cancer or prostate cancer, certain hormone dependent tumors grow through the uncontrolled steroid-mediated transcription within the malignant cells. Effective therapeutics may me used in the assessment, treatment, and prevention of cancer. It is also important that these agents be selective so that undesired cell proliferation is prevented but such other benefits of estrogenic agonists such as prevention of osteoporosis should not be compromised. Control of transcription may be desired in order to help overcome one or more genetic malfunctions in an individual. It may also be anticipated that these novel antagonists can serve as diagnostic agents and as effective inhibitors in the case of various types of orphan nuclear receptors, whose functions have yet to be determined (Burris and McCabe, 2000).
[heading-0021] Experimental (Peptide Synthesis)
[0022] The linear and cyclic peptides were synthesized using Boc-based Merrifield solid phase peptide synthesis using a anhydrous hydrogen fluoride for cleavage from the methylbenzhydryamine resin support to provide the targeted peptide amides. Scheme 1 summarizes the approach used for two cyclic variants. A lactam bridge between Glu, Lys was formed on the resin following base-mediated cleavage of the fluorenylmethyl-class protecting groups. In contrast, disulfide bridge formation was performed off-resin, with Tam's DMSO oxidation procedure providing the best results when using heated sulfoxide reagent.
[0023] Products were analyzed by CD, NMR spectroscopy, reversed phase high pressure liquid chromatography, and thin layer chromatography, and the expected structures confirmed with MALDI-TOF mass spectrometry.
Biological Activity Data
[0024] The synthetic helicormimetic peptides designed as antagonists of the estrogen receptor-coactivator interactions were tested in a competition binding assay (Lilly Research Labs) against a model linear peptide sequence. Activities are reported in the Table below in Ki values, with two of the best analogs labeled as PERM-1 and PERM-2, or Peptidomimetic Estrogen Receptor Modulators.
TABLE I Peptide Analogs and their Ki values against ER alpha and ER beta ER α ER β Title Sequence MW μM μM AML-I-22 H-Leu-Glu-Gln-Leu-Leu-OH 614.3 N/A 201.2 AML-I-31 Mannosylacetvl-Leu-Glu-Gln-Leu-Leu-OH 818 N/A 339.4 AML-I-48/4 H-Lys-cyclo (D-Cys-Ile-Leu-Cys)-Arg-Leu-Leu-Gln-NH 2 PERM-1 1085 0.025 0.39 AML-I-61/2 H-Lys-Lys-Ile-Leu-His-Arg-Leu-Leu-Gln-NH 2 1147 0.17 2.8 AML-I-59/6 K-Lys-cyclo(Glu-Ile-Leu-Arg-Lys)-Leu-Leu-Gln-NH 2 1120.7 0.22 4.8 AML-I-71/2 Ac-Lys-cyclo(D-Cys-Ile-Leu-Cys)-Arg-Leu-Leu-Gln-NH 2 1127 0.12 7.7 AML-I-86/1 Gu-Lys-cyclo-(D-Cys-Ile-Leu-Cys)-Arg-Leu-Leu-Gln-NH 2 1183 0.14 0.6 AML-I-83/4 Aib-Lys-cyclo(D-Cys-Ile-Leu-Cys)-Arg-Leu-Leu-Gln-NH 2 1172 0.13 1.4 AML-I-89/2 H-Lys-His-Lys-Ile-Leu-His-Arg-Leu-Leu-Gln-Asp-Ser-Ser-OH 1573.9 0.38 6.9 AKG-I-28 H-D-Lys-cyclo (D-Cys-Ile-Leu-Cys)-Arg-Leu-Leu-Gln-NH 2 1085 0.22 1.9 AKG-I-39 H-Lys-cyclo (Ala-Ile-Leu-Ala)- Arg-Leu-Leu-Gln-NH 2 , 1053 1.18 15.4 Lanthionine AKG-I-40 H-D-Lys-cyclo (AIa-Ile-Leu-Ala)- Arg-Leu-Leu-Gln-NH 2 , 1053 3.95 13.5 Lanthionine AKG-I-46 H-Lys-Leu-Leu-cyclo(D-Cys-Ile-Leu-Cys)-Arg-Leu-Leu-Gln- 1311 0.398 2.0 NH 2 AKG-I-48 K-Lys-cyclo(Cys-Ile-Leu-Cys)-Arg-Leu-Leu-Gln-NH 2 1085 0.416 1.8 AKG-I-50 H-Arg-cyclo(D-Cys-Ile-Leu-Cys)-Arg-Leu-Leu-Gln-NH 2 PERM-2 1113 0.011 0.077 AKG-I-59 H-Lys-cyclo(Cys-Leu-Ile-D-Cys)-Arg-Leu-Leu-Gln-NH 2 1085 2.1 17.0 AKG-I-60 H-Lys-cyclo(Cys-Ile-Leu-D-Cys)-Arg-Leu-Leu-Gln-NH 2 1085 2.4 7.2 AKG-I-61 H-Lys-cyclo(D-Cys-Ile-Leu-D-Cys)-Arg-Leu-Leu-Gln-NH 2 1085 0.928 3.9 AKG-I-63 H-Lys-cyclo(Cys-Leu-D-Cys)-Arg-Leu-Leu-Gln-NH 2 972 2.2 7.9 AKG-I-64 H-Lys-cyclo(D-Cys-Leu-D-Cys)-Arg-Leu-Leu-Gln-NH 2 972 1.8 5.2 AKG-II-1 H-Arg-cyclo (D-Cys-Leu-Ile-Cys)-Arg-Leu-Leu-Gln-NH 2 1113 .013 .216 AKG-II-3 H-Arg-cyclo (D-Cys-Ile-Leu-HomoCys)-Arg-Leu-Leu-Gln-NH 2 1127 .013 .214 AKG-II-4 H-Arg-cyclo (DHomoCys-lIe-Leu-Cys)- Arg-Leu-Leu-Gln-NH 2 1127 .035 .591 AKG-II-8 H-Arg-cyclo (Cys-Ile-Leu-Arg-Cys)-Leu-Leu-Gln-NH 2 1113 .174 1.16 AKG-II-9 H-Arg-cyclo (D-Pen-Ile-Leu-Cys)-Arg-Leu-Leu-Gln-NH 2 1141 .168 .933 AKG-II-10 H-Arg-cyclo (D-Cys-Ile-Leu-Pen)-Arg-Leu-Leu-Gln-NH 2 1141 .088 1.91 AKG-II-11 H-Arg-cyclo(D-Pen-Ile-Leu-Pen)-Arg-Leu-Leu-Gln-NH 2 1169 .078 3.97 SRC-1 NR2 LTERHKILHRLLQEGSPSD 0.39 —
[0025] Short linear peptides that contain the LXXLL sequence, such as Leu-Asn-Gln-Leu-Leu, do not display any inhibitory activity with respect to the desired effect of inhibiting the binding of the estrogen receptors to the helical segment of coactivator proteins.
[0026] As seen in the Table, compounds that contain a D-Cys, L-Cys pairing are especially active with respect to binding inhibition.
[0027] A report by Geistlinger ad Guy teaches of the inhibition of the interaction between thyroid hormone and its interaction using side chain to side chain linked peptides. The ring in this example is formed through an amide linkage between a lysine residue and a glutamic acid residue. But this report does not include any examples of disulfide bridges nor of the preference for a D-cysteine and L-cysteine pairing, nor does it include any examples of receptors other than the thyroid nuclear receptor.
[0028] X-Ray Structure of a Helicomimetic Peptide Bound to the Estrogen Receptor Dimer Ligand Binding Domain (LBD)
[0029] The conditions for the cyrstallization of the peptide protein complex as shown in FIG. 1 are describes as follows:
[0030] Cloning of the Gene Expression and Purification of Human ER LBD.
[0031] The ER LBD gene was overexpressed in E. coli and purified by Pan Vera, Inc.
[0032] Crystallization.
[0033] Diffraction-quality crystals of the ER LBD complex were grown by the vapor diffusion technique at 294K using a Hampton (Hampton Research Inc.,) crystallization screen. Crystals belong to orthorhombic space group C222 1 , with unit cell parameters a=53.8 Å, b=102.4 Å, c=195.3 Å. There are two molecules of the complex per asymmetric unit, with a V m value (Matthews 1968) of 2.28 Å 3 /Da that corresponds to a solvent content of approximately 46% in both cases. The 17-estradiol and PERM-1 (peptide) in 2-3 fold of excess of the protein were used for co-crystallization.
[0034] Data Collection, Structure Solution, and Crystallographic Refinement.
[0035] The diffraction data resolution of (resolution of 2.7 Å; R merge =0.114, and completeness of 95%) were collected using a MarCCD (refmar) detector on IMCA (Industrial Macromolecular Crystallography Association) beam line BM-17 at the APS (Advanced Photon Source, Argonne National Laboratories) at 100K, using 15-20% glycerol as a cryoprotectant. The diffraction data were reduced using HKL2000 (Otwinowski and Minor 1997) and the intensities were scaled with SCALEPACK. Crystal structure was determined by the method of molecular replacement using the AMORE program suite (CCP4; Collaborative Computing Project #4 1994). The crystal structure was refined against data between 20-2.7 Å using a maximum likely-hood algorithm as incorporated in the program CNX2000 (Badger et al., 1999) (R work =0.203, R free =0.258, RMS=0.007 Å) (Brünger 1992). The program suite QUANTA 98 (Molecular Simulation Inc., San Diego, Calif.) was used for visual inspection and manual corrections between rounds of refinement. An analysis of the geometry showed all parameters were within the values expected for a model at this resolution. All residues were found in the most favorable and additionally allowed regions of a Ramachandran plot.
[0036] The omitted unbiased electron density map was used for positioning 17β-estradiol and the PERM-1 peptide.
[0037] Specific compositions, methods, or embodiments discussed are intended to be only illustrative of the invention disclosed by this specification. Variation on these compositions, methods, or embodiments are readily apparent to a person of skill in the art based upon the teachings of this specification and are therefore intended to be included as part of the inventions disclosed herein.
[0038] Reference to documents made in the specification is intended to result in such patents or literature cited are expressly incorporated herein by reference, including any patents or other literature references cited within such documents as if fully set forth in this specification.
[0039] The foregoing detailed description is given primarily for clearness of understanding and no unnecessary limitations are to be understood therefrom, for modification will become obvious to those skilled in the art upon reading this disclosure and may be made upon departing from the spirit of the invention and scope of the appended claims. Accordingly, this invention is not intended to be limited by the specific exemplifications presented hereinabove. Rather, what is intended to be covered is within the spirit and scope of the appended claims. | This invention pertains to the design and synthesis of molecules that can act as protein mimics. In particular this disclosure teaches the preparation of short, cyclic peptide sequences that can adopt a helical conformation and display a particular arrangement of amino acid side chains oriented in a specific arrangement to serve as a pharmacophore. A ring, formed by a disulfide bridge between pairs of cysteine residues, maintains the helical structure. When the cysteines are arranged in a pattern of i to i+3 as illustrated in FIG. 1 , and when the first cysteine is of the D-configuration, and the second cysteine is of the L-configuration, the helical arrangement is especially stabilized. A preferred version of this invention involves a pentapeptide sequence of general structure known as the NR Box, stabilized by a side chain to side chain disulfide bridge formed from the two cysteines. | 2 |
FIELD OF THE INVENTION
The present invention relates to the connection of ribbon cables to printed circuit boards. More particularly, the present invention relates to a plug-in connector assembly for ribbon cables.
BACKGROUND OF THE INVENTION
Ribbon cables often have a series of electrical conductors embedded next to each other in an insulation material. These conductors can be round with a circular cross section and/or flat with a rectangular cross section. Conventional plug-in connector housings have a cable plug-in opening to accept an end portion of a ribbon cable. Conductor contacts, in the form of conductor contact receptacles, electrically contact ribbon cable conductors when the cable is inserted into a plug-in connector housing. The conductor contacts are electrically connected to terminal contacts that can be electrically connected, for example, to the strip conductors of a printed circuit board.
In order to permit electrical contacting between the ribbon cable conductors and conductor contacts of the plug-in connector, the ribbon cable conductors are often exposed on one ribbon cable end, on a broad side of the ribbon cable, by stripping the insulation down to the ribbon cable conductors. However, the ribbon cable end loses its bending rigidity when the insulation on the ribbon cable end is stripped. A loss of rigidity hampers the inserting of the ribbon cable end into the cable plug-in opening of the plug-in connector and complicates problem-free electrical contacting between the exposed ribbon cable conductors and the conductor contacts.
To overcome this shortcoming, in the past a reinforcement layer, preferably in the form of a reinforcement sheet, has been applied on the broad side of the ribbon cable end on which the ribbon cable conductors are not exposed, i.e., no insulation has been removed. This has increased the bending rigidity of the ribbon cable end which was reduced by the stripping of the insulation. A material with a relatively high intrinsic bending rigidity has been used for the reinforcement sheet. Notwithstanding such an attempt to increase the rigidity of the stripped ribbon cable, this design suffers from shortcomings which detract from its usefulness.
A conventional ribbon cable has a sheet structure with a thickness of about 0.4 mm. The plug-in connectors commonly used for the connection of such a ribbon cable have a limited design height of about 10 mm. From the beginning of the cable plug-in opening, to the spring contacts of a conductor contact, a lateral guide for the thin ribbon cable exists only over a short zone of about 7 mm. Additionally, common plug-in connectors for connection of such ribbon cables have significant manufacturing tolerances. This means that the ribbon cable end must be plugged into the cable plug-in opening of the plug-in connector with only limited guide depth and unreliable lateral guiding. The ribbon cable end is likely to be plugged into the plug-in connector obliquely or with kinks. Misalignment of the ribbon cable with respect to the plug-in connector may cause the ribbon cable conductors to not properly contact corresponding conductor contacts.
In particular, such a problem arises in shielding flat conductor ribbon cables that have a shielding sheet situated above a layer of insulation material on each broad side of the cable, and in which a flat conductor situated on a longitudinal edge of the cable is in contact with both shielding sheets. The shielding sheets lie on this flat conductor without interposition of insulation material. Since insulation is lacking in this longitudinal edge region of the flat conductor ribbon cable, this longitudinal edge region is particularly labile.
The force with which the contact spring arms of the conductor contacts engage the ribbon cable conductors is limited given the very small size of the conductor contacts. Therefore, the ribbon cable conductors may loosen from the conductor contacts even if a small tensile force is exerted on the ribbon cable. However, such loosening is not acceptable in applications which demand a particularly high reliability of the plug-in connection between the ribbon cable end and the plug-in connector.
Additionally, ribbon cables often have an electrical shield in the form of a shielding sheet situated between an insulation material surrounding the ribbon cable conductors and an insulation material sheath of the ribbon cable. This shielding sheet needs to be electrically grounded. One way of providing this ground is by using an additional wire to connect the ribbon cable shield to either the plug-in connector shield or the ground conductor of a printed circuit board. Shielding quality, as is desired in high-grade applications, is not possible with this design.
The foregoing illustrates limitations known to exist in present plug-in connectors for ribbon cables. Thus, it is apparent that it would be advantageous to provide an improved plug-in connector directed to overcoming one or more of the limitations set forth above. Accordingly, a suitable alternative is provided including features more fully disclosed hereinafter.
SUMMARY OF THE INVENTION
The present invention advances the art of electrical connectors beyond which is known to date. In one embodiment of the present invention, a plug-in connector assembly for ribbon cables comprises a ribbon cable, a plug-in connector, a locking spring and a locking spring housing. The ribbon cable may be configured with a recess for spring-actuated engagement to provide strain relieving locking of the ribbon cable and to provide a region of electrical contact with the locking spring to enhance shielding contact. The locking spring may also engage the ribbon cable in a shape-mated fashion to provide lateral guidance of the cable.
The locking spring housing may also be designed to accept existing plug-in connectors by providing an opening in which an existing connector may be inserted and secured to the locking spring housing.
Additionally, the locking spring housing and the locking spring can form a single shield housing. The connector can be designed in one piece with this shielding housing, for example, by cutting and bending a section out from a side wall of the shielding housing.
In the present invention, the improved plug-in connector assembly provides an improved design height that provides improved contacting of the ribbon cable conductors with the conductor contacts of the plug-in connector, thereby preventing lateral pivoting and oblique insertion of the ribbon cable end. The housing also prevents inadvertent removal of the ribbon cable and produces reliable shield contacting with very low contact resistance.
Accordingly, it is a purpose of the present invention to provide an improved plug-in connector assembly for ribbon cables that prevents inadvertent removal of the ribbon cable from the plug-in connector.
It is another purpose of the present invention to provide an improved plug-in connector assembly for ribbon cables that provides improved contacting of the ribbon cable conductors with the conductor contacts of the plug-in connector.
It is another purpose of the present invention to provide an improved plug-in connector assembly for ribbon cables that prevents lateral pivoting and oblique insertion of the ribbon cable end.
It is another purpose of the present invention to provide an improved plug-in connector assembly for ribbon cables that produces reliable shield contacting with very low contact resistance.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing summary, as well as the following detailed description of a preferred embodiment of the invention, will be better understood when read in conjunction with the appended drawings. For purposes of illustrating the invention, there is shown in the drawings an embodiment which is presently preferred. It should be understood, however, that the invention is not limited to the precise arrangement and instrumentality shown. In the drawings:
FIG. 1 shows a ribbon cable plug-in connector according to one embodiment of the present invention having a separate locking spring housing disposable about an ordinary plug-in connector;
FIG. 2 shows a plug-in connector according to FIG. 1 with two alternatively applicable locking spring devices;
FIGS. 3-5 show cross sections of three different ribbon cable configurations along a line running across the longitudinal extent of the corresponding ribbon cable;
FIG. 6 shows a variant of a locking spring device according to the present invention;
FIG. 7 shows a partial detailed view of the embodiment depicted in FIG. 1 of a locking spring device and locking spring housing;
FIG. 8 shows a cross section of a plug-in connector according to the present invention;
FIG. 9 shows a detailed view of the plug-in connector depicted in FIG. 8;
FIG. 10 is a schematic side view of the plug-in connector depicted in FIG. 8;
FIG. 11 is a side view of the plug-in connector depicted in FIG. 10 with a printed circuit board;
FIG. 12 shows a variant of a plug-in connector according to the invention with shielding housing;
FIG. 13 shows a schematic representation of a ribbon cable end with flat connectors exposed on one side;
FIG. 14 shows a schematic view of an ordinary plug-in connector before insertion into the soldering holes of a printed circuit board;
FIG. 15 shows a schematic view of a ribbon cable suitable for use with the present invention;
FIG. 16 shows a schematic side view of the embodiment depicted in FIG. 15;
FIG. 17 shows an example of a covering suitable for use in the embodiment according to FIGS. 15 and 16;
FIG. 18 shows a locking spring suitable for use in the embodiment of FIGS. 15 to 18; and
FIG. 19 shows a schematic view of another embodiment of a ribbon cable suitable for use with the present invention and applicable together with the locking spring depicted in FIG. 18.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings, wherein similar reference characters designate corresponding parts throughout the several views, the present invention is generally illustrated at 33 in the figures. The present invention generally comprises a ribbon cable, a plug-in connector, a locking spring and a locking spring housing.
FIG. 13 shows a ribbon cable 11 in a schematic view with flat conductors 13 that are embedded on all sides in an insulation material 15. Ribbon cable 11 may have any number of flat conductors 13. Sheets of insulation material are applied on both sides of the flat conductors 13. Insulation material 15 can be expanded polytetrafluoroethylene (ePTFE), polyester or other plastics. Enough insulation material is removed in one end region 17 of the ribbon cable 11 to expose flat conductors 13 on one side to facilitate electrical contact. A reinforcement sheet 19, such as polyester, is applied to the insulation material 15 on the back of the ribbon cable end 17 on which the flat conductors 13 are still covered with insulation material 15. The reinforcement sheet 19 increases the bending rigidity of the ribbon cable end, which was reduced by exposure of flat conductors 13, and brings the ribbon cable end to the dimensions of the plug-in connector contacts. Without a reinforcement sheet 19, the ribbon cable end 17, which has a width of 15 mm and a thickness of 0.4 mm, for example, would become unstable due to removal of insulation 15 to expose flat conductors 13, and insertion thereof into the plug-in connector would be difficult.
FIG. 14 shows an ordinary plug-in connector 21 for acceptance of the ribbon cable end 17 and a printed circuit board 23 having soldering holes 25 for insertion and soldering of connection posts 27. The plug-in connector 21 is provided with a cable plug-in opening 29 on the side opposite the connection posts 27. The cable plug-in opening 29 is dimensioned so that ribbon cable end 17 can be inserted.
Conductor contacts of plug-in connector 21 (not visible in FIG. 14) extend into the cable plug-in opening 29, to electrically connect ribbon cable conductors 13 of the ribbon cable end 17 and strip conductors of printed circuit board 23.
A plug-in connection between a ribbon cable end 17 and a plug-in connector 21, according to FIG. 14, is known in the art but is replete with shortcomings which have detracted from its usefulness.
Such known plug-in connectors 21 have a design height of about 10 mm and an insertion depth of only about 6 mm. The ribbon cable end 17 is, therefore, guided during insertion into the cable plug-in opening 29 only over a very short length so that there is a considerable hazard that the ribbon cable end 17 will be inserted obliquely into the cable plug-in opening 29, which can lead to incorrect contacting between the flat conductors 13 and the conductor contacts (not shown) arranged in the plug-in connector 21.
FIG. 1 shows an embodiment of the present invention in which the ribbon cable end 17 is inserted into the cable plug-in opening 29 of an ordinary plug-in connector 21, not directly, but rather after passing through a cable plug-through opening 31 of an additional housing 33 forming a locking spring housing, in which a locking spring 35 is arranged. Use of the invention with plug-in connector 21 provides good lateral guidance of the ribbon cable end 17 during insertion, reliable attachment in the plug-in position and easy and reliable shield contacting of a ribbon cable shield.
If the ordinary plug-in connector 21 is not used, the plug-in connector housing and the locking spring housing can be designed as a one piece construction. The conductor contacts may be provided in the lower region of the plug-in connector and the locking spring in the upper region.
The additional housing 33 of FIG. 1 has a plug-in opening 37 on its lower end into which the plug-in connector 21 can be inserted. The plug-in opening 37 is open on the bottom to prevent collision with the connection posts 27 of the plug-in connector 21. Clamping ribs 39 extend laterally from the sidewalls of the lower end of plug-in opening 37. The side walls of plug-in opening 37 are each provided with a locking spring arm 41 cut out from a corresponding side wall. Each locking spring arm 41 has a locking hook 43 on its free end with a locking shoulder 45 and a leading slope 47. During insertion of plug-in connector 21 into plug-in opening 37, the locking spring arms 41 widen elastically when the plug-in connector 21 reaches the leading slope 47 if the plug-in connector 21 is pushed sufficiently deep into plug-in opening 37, the locking spring arms 41 spring back, whereupon their locking shoulders 45 snap behind plug-in connector 21 and secure it within plug-in opening 37.
The plug-in opening 37 and the locking spring arms 41 are dimensioned relative to the dimensions of the plug-in connector 21 so that when plug-in connector 21 is locked into plug-in opening 37, its cable plug-in opening 29 is aligned with the cable plug-through opening 31 of the additional housing 33. The ribbon cable end 17 can then be inserted through the cable plug-through opening 31 of additional housing 33 into the cable plug-in opening 29 of plug-in connector 21 guided by the cable plug-through opening 31. The additional housing 33 and locking spring 35 facilitate the alignment of the flat conductors 13 and the conductor contacts in plug-in connector 21, and prevent inadvertent withdrawal of the ribbon cable end 17 from the cable plug-in opening 29. The invention also provides correct alignment and prevention of withdrawal when an ordinary plug-in connector 21 is used.
The additional housing 33 may also be disposed about a plug-in connector 21 that has already been soldered to a printed circuit board by pushing it onto the soldered plug-in connector 21 and inserting the ribbon cable end 17 through the cable plug-through opening 31 and into the cable plug-in opening 29.
Three exemplary ribbon cable configurations, which are illustrated in FIGS. 3 to 5, are suitable for plug-in connection with the plug-in connector according to the present invention. FIGS. 3 and 4 show ribbon cable designs with shielding sheets, whereas FIG. 5 shows a ribbon cable design without a shielding sheet.
A first ribbon cable configuration 49, which is depicted in FIG. 3, contains four flat conductors 13 that are embedded in an insulation material 15. The upper longitudinal outside of the ribbon cable 49 is formed by an upper insulation sheath 51, and the lower longitudinal outside is formed by a lower insulation sheath 53. An upper shielding sheet 55 is situated in FIG. 3 between the insulation material 15 and the upper insulation sheath 51, and a lower shielding sheet 57 is situated between the insulation material 15 and the lower insulation sheath 53. The two shielding sheets 55 and 57 are separated from the three right most disposed flat conductors 13 by the insulation material 15, as seen in FIG. 3, while the two shielding sheets 55 and 57 contact the left most disposed flat conductor 13. Therefore its two shielding sheets 55 and 57 are electrically connected via the left flat conductor 13.
In one of the two insulation sheaths 51 and 53 (in the upper insulation sheath 51 in FIG. 3) a locking recess 59 is punched, in which the upper shielding sheet 55 is exposed.
A second ribbon cable configuration 61, which is depicted in FIG. 4, is substantially similar to the first ribbon cable configuration 49. In the second ribbon cable configuration 61, the two shielding sheets 55 and 57 are electrically insulated from all of the flat conductors 13 and from each other over their entire width. In order to be able to produce electrical contact to the two shielding sheets 55 and 57, a locking recess is situated in each of the two insulation sheaths 51 and 53, namely an upper locking recess 63 and a lower locking recess 65.
A third ribbon cable configuration 67, which is depicted in FIG. 5, shows an unshielded ribbon cable that has flat conductors 13 and an insulation material 15 disposed about the flat conductors. Since no shielding sheets are present, this ribbon cable configuration requires no locking recess. If a shape-mated locking is to be created between this ribbon cable configuration 67 and the locking spring device, an upper locking recess 63 and/or a lower locking recess 65, can be provided in the insulation material 15 of ribbon cable configuration 67.
In the embodiment depicted in FIG. 1, a locking spring 35 is arranged as a flat spring in the additional housing 33 that serves as locking spring housing. The locking spring 35 is mounted to pivot around a pivot axis 69 that runs parallel to the transverse direction of additional housing 33. The locking spring 35 has a roughly plate-like locking region 71 that extends obliquely downward in the direction of the plug-in opening 37 of the additional housing 33 from the region of the pivot axis 69. The locking spring 35 has a locking tab 73 cut from the plate-like body of locking spring 35 and bent out obliquely upward on the side of locking spring 35 facing away from the plug-in opening 37.
FIG. 2 shows a variant of the additional housing 33 in which either a locking spring 35 or a locking spring 35' can be arranged. The locking spring 35 corresponds to the locking spring depicted in FIG. 1 and is designed primarily for shape-mated engagement in a respective locking recess of one of the ribbon cable configurations 49, 61 or 67 depicted in FIGS. 3 to 5. The locking spring 35' is primarily designed for spring-actuated engagement of a ribbon cable which need not have any locking recess, like the ribbon cable configuration 67 depicted in FIG. 5. A locking region 71' of locking spring 35' is provided with blocking ribs 77' in order to improve spring-actuated engagement on the longitudinal outside of the ribbon cable. The locking spring 35' has pivot axis stubs 79' on its pivot axis 69' that can be locked into pivot axis holes 81 (open on one side) of the additional housing 33.
More particularly, if the locking spring 35 is used for electrical contacting of an exposed ribbon cable sheet shield 55 or 57, it consists of metal or an electrically conducting material in order to produce electrical contacting of the sheet shield 55 or 57. If the locking spring 35 is not to be used for spring-actuated engagement on a shielding sheet, but rather on the insulation material 15 of ribbon cable configuration 67, or on one of the insulation sheaths 51 or 53, the locking spring 35 can consist of a resilient non-conductive material.
A pivotable support of locking spring 35 within additional housing 33 is further explained with reference to FIG. 7. The additional housing 33 serves as a locking spring housing at top 83, on the cable plug-in side, and on the upper end of its rear wall 85. A support post 89, with a support shoulder 91 displaced downward in one piece from top 83, is situated on the inside of two transverse side walls 87 of the additional housing. One or two convex support arcs 93 are formed on both sides of the locking region 71 of locking spring 35. The convexity of each support arc 93 facing locking region 71 is also supported on one of the two support shoulders 91 and on the wall region of the corresponding support post 89 situated above the support shoulder 91 in pivotable fashion.
In the variant of locking spring 35 depicted in FIGS. 1 and 2, the locking region 71 is cut out from the plate of locking spring 35. The plate remainders 97, left after cutting on both sides of locking region 71, extend into an intermediate space between the rear wall 85 and the corresponding support post 89. The locking spring 35, on its upper end in FIG. 2, has an upper edge 101 bent away from the locking region 71.
The locking spring 35, on the lower edge in FIG. 2, is provided with two protrusions 103 that can be plugged into correspondingly shaped printed circuit board holes and electrically connected there to ground conductors.
The locking spring 35 is employed to contact the upper shielding sheet 55 or the lower shielding sheet 57, depending on the rotational position in which the ribbon cable is plugged into the cable plug-through opening 31. The locking spring 35 is suitable, in particular, for shielding sheet contacting of the ribbon cable configuration 49 depicted in FIG. 3. When the ribbon cable configuration 61 depicted in FIG. 4 is used, electrical contacting of both the upper shielding sheet 55 and the lower shielding sheet 57 is prescribed. For this type of two-sided contacting, a locking spring 105, as shown in FIG. 6, is suitable. This has the same design as the locking spring depicted in FIG. 2 with regards to the locking region 71, the support arc 93, the plate remainder 97, the locking tab 73, the upper edge 101 and the protrusions 103. In addition to the locking spring 35 depicted in FIG. 2, the locking spring 105 depicted in FIG. 6 has an angle bridge 107 that protrudes at right angles from the plate remainder 97 and has an additional locking region 111 on its angled free end 109. When a ribbon cable, with a ribbon cable configuration 61 depicted in FIG. 4, is plugged into the cable plug-through opening 31 of additional housing 33, it is guided between the oblique locking regions 71 and 111 until it has reached its final plug-in position. The additional locking region 111 may also be directed obliquely to locking region 71. This would result in stronger attachment of the ribbon cable, but may hamper release of the ribbon cable from locking.
When a ribbon cable configuration is used in which only one shielding sheet or no shielding sheet must be contacted, the locking spring 105, according to FIG. 6, can also be advantageous. In this case an easily definable plug-through gap between locking region 71 and 111 is formed for the ribbon cable by the locking spring 105 so that the ribbon cable can be fastened particularly well during use of locking spring 105.
The positioning and method of operation of the locking spring 35 are shown in FIGS. 8 and 9. In the cutaway view of FIG. 8, the plug-in connector 21 is shown in the inserted position in the plug-in opening 37 of the additional housing 33. The cutaway view shows conductor contacts 113 with connection posts 27, which are soldered into the solder holes 25 of the printed circuit board 23. A ribbon cable end is inserted into the cable plug-through opening 31 of additional housing 33 and the cable plug-in opening 29 of plug-in connector 21. The flat conductors 13, as in FIG. 13, are exposed on at least one side so that they can be electrically contacted by at least one conductor contact of the conductor contact pair 113. Ordinarily the flat conductors 13 are only exposed on one side so that only one conductor contact 13 of the oppositely lying conductor contact pair produces electrical contact with the corresponding flat conductor 13, whereas the other conductor contact 113 of the corresponding contact conductor pair exerts only a counterpressure. In the depiction of FIG. 8, the ribbon cable end has a reinforcement sheet 19 on the side facing locking spring 35. The upper end 115 of reinforcement sheet 19 forms an engagement shoulder for the free end of locking region 71. If the ribbon cable has shielding sheets that are to be electrically contacted by means of locking spring 35, the insulation sheath 55 or 57 facing the locking spring 35 is provided with a locking recess 59, 63 or 65 so that the free end of the locking region 71 can make electrical contact with this shielding sheet. In this case the locking spring 35 consists of metal or another electrically conducting material and at least one of the protrusions 103 is connected to a ground conductor of the printed circuit board 23. In this fashion the shielding sheet is electrically connected to the ground conductor of the printed circuit board 23 via the locking spring 35.
The plate part of locking spring 35, situated next to and below locking region 71, is arranged between the support post 89 and the rear wall 85 of the additional housing 33 with limited play between the support post 89 and the rear wall 85 so that the locking spring 35 is held between the locking tab 73 in a complementary locking shoulder 74 of rear wall 85. The locking spring 35 remains locked in additional housing 33. As is in FIG. 9, a front edge 117 of support shoulder 91 forms a stop for the lower end 119 of support arc 93 of locking spring 35. The center of curvature of the support arc 93 then forms the pivot axis 69 of locking spring 35. In the resting state of locking spring 35 its locking part 71 is prestressed on the ribbon cable so that locking of the free end of the locking region 71 with the ribbon cable occurs in shape-mated fashion.
The locking spring 35 forms a free-wheeling mechanism with its locking region 71 so that, when the ribbon cable is inserted into the cable plug-through opening 31, the locking region 71 expands elastically and does not prevent insertion of the ribbon cable, whereas withdrawal of the ribbon cable from the cable plug-through opening 31 initiates locking between the locking region 71 and the shoulder, which is formed by the upper reinforcement sheet end 115 and/or the limitation of the locking recess 59, 63 or 65. If locking between the ribbon cable and locking region 71 is to be released, pressure is exerted with the finger or a tool against the upper edge 101 of the locking spring 35 in the direction of arrow "A" shown in FIG. 8 so that pivoting of the angular region 71 around the pivot axis 69 releases the ribbon cable. Release of locking between the ribbon cable and the locking region 71 can also occur by moving the upper edge 101 of the locking spring 35 in the direction of arrow "B" depicted in FIG. 8 so far from the ribbon cable that the locking region 71 disengages from the ribbon cable. The ribbon cable can then be easily removed from the cable plug-in opening 29 and the cable plug-through opening 31.
Views similar to FIG. 8 are shown in FIGS. 10 and 11. In the embodiments depicted in FIGS. 10 and 11, the insulation material 15 is not cut on the lower ribbon cable end where the flat conductors 13 are exposed, but instead is turned upward in the form of a wrapping 121 and acts there as a support on the inside of a front wall 123 of additional housing 33. The wrapping 121 supports reliable positioning of the ribbon cable for reliable engagement between the locking region 71 and the locking recess 59, 63 or 65, and optionally the upper reinforcement sheet end 115.
FIG. 12 shows an embodiment in which the arrangement of plug-in connector 21, additional housing 33, locking spring 35 and the ribbon cable end is accommodated within a shielding housing made of an electrically conducting material. This is connected by means of lower protrusions 127 to ground conductors (not shown) of a printed circuit board 23, either by soldering or by a solder-free clamp connection, as shown in region 129 of the printed circuit board. The shielded housing 125 is provided with an additional locking spring 131 that can be cut and bent out from a side wall of the shielded housing 125. The locking spring 35, only partially visible in FIG. 12, can be used for contact of a shielding sheet 55 or 57, while the additional locking spring 131 can assume contacting of the other shielding sheet 57 or 55 of the ribbon cable configuration 61 in FIG. 4.
If a ribbon cable configuration 61 is used, that is a configuration having two shielding sheets 55, 57 that are not connected to each other electrically via one of the flat conductors 13, electrical contacting of both shielding sheets 55, 57 by means of an electrically conducting locking spring is recommended, for example, by means of the two locking regions 71 and 111 of the locking spring 105 depicted in FIG. 6, or by means of the two locking springs 35 and 131 depicted in FIG. 12. Since in this type of ribbon cable configuration only one of the two shielding sheets would be connected by means of a locking spring during one-sided electrical contacting, as shown in FIG. 8, an additional wire will be required as before for electrical contacting of the other shielding sheet.
Ribbon cables of the considered type have very thin thicknesses, for example, of only about 0.4 mm. This means that the shielding sheets 55,57 are also very thin and can break, especially on contact with locking region 71. This problem is solved by the embodiments of the invention depicted in FIGS. 15 to 19.
In the embodiment depicted in FIG. 15, when the ribbon cable configuration 49 depicted in FIG. 3 is used, the locking recess 59 is protected with a reinforcing cover 133. When the ribbon cable configuration 61 depicted in FIG. 4 is used, the upper locking recess 63 and the lower locking recess 65 are protected with a reinforcing cover. The reinforcing cover 133 consists of a plastic strip folded around a long edge of the ribbon cable 11 forming arms 135 and 137, both of which lie on different flat sides of ribbon cable 11 so that they cover the locking recesses 59, or 63 and 65. In the regions lying above the locking recesses 59, or 63 and 65, the arms 135 and 137 are provided with penetration openings 139. Penetration protrusions 141 on locking regions 71 of the modification of locking spring 35 (depicted in FIG. 18) pass through the penetration openings 139 when the ribbon cable 11 is situated in the locking position in locking spring housing 33. In this embodiment, with appropriate relative dimensioning of the penetration openings 139 and penetration protrusions 141, the engagement force of the locking region 71 is essentially taken up by the cover 133 so that the shielding sheets 55, 57 remain essentially unloaded and the hazard of their breaking is reduced very sharply.
Alternatively, the cover 133 can be made from two individual plates, one of which is arranged on one flat side and the other on the opposite flat side of ribbon cable 11. In contrast to the embodiment depicted in FIGS. 15 and 17, the two arms 135 and 137 are not joined together in one piece, but represent separate parts.
FIG. 16 shows a cross section with a cover 133 either of the one-piece, folded embodiment depicted in FIG. 15, or of the embodiment with two separate arms 135 and 137.
If the ribbon cable 11 is to be reinforced, as shown in FIGS. 8 and 13, a reinforcement sheet 19 can be applied to the arm of the cover 133 that is situated on the side whose flat conductors 13 are not exposed in the end region 17 of ribbon cable 11. The reinforcement sheet 19 is then situated on the inside of arm 137 facing the ribbon cable. The reinforcement sheet can be designed either in one piece with cover 133, or as a separate reinforcement sheet that is adhered to the inside of arm 137. In the latter instance, the penetration openings 139 of arm 137 are punched through the reinforcement sheet 19.
In the embodiments with a cover 133, the corresponding shielding sheet or shielding sheets can be exposed over the entire width of the ribbon cable and covered with cover 133 instead of the locking recesses 59, or 63 and 65.
Both reinforcement of ribbon cable 11 in its region weakened by locking recesses 59, 63, 65 and protection of the shielding sheets 55, 57 can be achieved with cover 133.
In the embodiment depicted in FIG. 19, no reinforcing cover 133 is provided, but penetration openings 143 are provided in insulation sheath 51 and/or 53 instead of the locking recesses 59, or 63 and 65. In this case the penetration protrusions 141 penetrate directly through the penetration openings 143 in the insulation sheath of ribbon cable 11 to the shielding sheet 55 and/or 57 on the locking region 71 of the locking spring 35 depicted in FIG. 18. In this case, the relative dimensions of the penetration openings 143 and the penetration protrusions 141 are chosen so that the engagement force of the locking region 71 is taken up by the region of the insulation sheath 51 and/or 53 surrounding the penetration openings 143.
Although a few exemplary embodiments of the present invention have been described in detail above, those skilled in the art readily appreciate that many modifications are possible without materially departing from the novel teachings and advantages which are described herein. Accordingly, all such modifications are intended to be included within the scope of the present invention, as defined by the following claims. | A plug-in connector assembly for ribbon cables comprises a ribbon cable, a plug-in connector, a locking spring and a locking spring housing. The locking spring may engage the ribbon cable in a shape-mated fashion to provide lateral guidance of the ribbon cable. The ribbon cable may be configured with a recess for spring-actuated engagement to provide strain relieving locking of the ribbon cable and to provide a region of electrical contact with the locking spring to enhance shielding contact. | 7 |
FIELD OF THE INVENTION
The present invention relates to a double tang design articulating hub assembly used as a connector among tubular rod elements comprising the frame matrix for collapsible self-supporting prefabricated structures requiring clear span interiors with no supporting columns.
BACKGROUND OF THE INVENTION
Hub assemblies have been used in the construction of exhibit display stands and dome-like structures such as geodesic domes. For maximum utility, designs which minimize the number of small parts, minimize part count, minimize the number of free components when disassembled, and maximize the stiffness are particularly valuable.
U.S. Pat. No. 3,968,808 discloses a collapsible self-supporting dome-like structure with a network of pivotal rods interconnected with linking joints. The linking joint holds six rods, each connected to a six-sided metal ring. Each rod is connected onto the ring and is capable of rotating. The rod is a permanent attachment and thus cannot be disconnected nor replaced. There does not appear any way to attach a cover to the dome-like structure such as is found in the “keeper” component in the articulating hub assembly of the present invention.
U.S. Pat. No. 4,026,313 also discloses a collapsible self-supporting dome-like structure with a network of pivotal rods interconnected with linking joints. The pivotal device linking the rods together forming the structure is a circular joint. Each joint has only four rods. Each rod contains a plug ending with a small cylinder. This small cylinder is nested inside the joint and allows the rod to rotate. It appears that none of the components is easily interchanged. The top and bottom sections of the hubs in the reference appear to be permanently joined by an adhesive so that none of the rods or plugs can be replaced.
U.S. Pat. No. 4,512,097 discloses a display panel mounting clip. The clip body is used to connect display panels together. The clip assembly disclosed requires a spring mechanism to create tension and hold the panels together. The present invention requires no springs. The clip disclosed in the reference must be snapped into an opening joining the rods in a circular joint. In the present invention, the keeper is screwed into the hub body so it is threadedly secured.
U.S. Pat. No. 4,280,521 discloses a hub assembly for collapsible structures. The hub assembly disclosed in the reference requires a circular retaining ring to hold the “column like elements” or tubes in place. Each tube must be threaded onto a circular retaining ring prior to insertion into the hub section. The hub sections are secured in place by use of an adhesive to fuse the two hub sections together permanently. The tube members within the structure, therefore, are not easily replaceable since the hub sections cannot be replaced without destroying them. The reference design uses a three piece clamping device to hold or attach a skin or cover to the structure. One piece is a plug that is incorporated inside the hub section and is fused into the hub sections. The second piece is a flat disc. The third piece is an element which is a screw. The screw is threaded into the plug and holds the clamp down. A screw driver would obviously be required to remove the clamp if the cover, the skin or the tubes have to be replaced.
In the present invention no circular ring is present or required to hold the rods together inside the hub, reducing the number of components. In addition, a screwdriver is not required to disassemble the present invention. Further, the design taught by '521utilizes a single tang design. Single tang designs are inherently flexible, an issue addressed by the present invention. Further, the reference design does not provide a means to restrict rotation of the tubes that connect to the hub assembly without the use of an adhesive or other welding method. In the present invention an adhesive is not required.
U.S. Pat. No. 5,797,695 also discloses a hub assembly for collapsible structures. The hub assembly disclosed in the reference employs a design comprised of a single tang connected to a separate plug. This design secures the tube to the body of the hub assembly with an assembly consisting of a plug, tang, roll pin and rivet, presenting the user with four small, easily misplaced, and damaged parts at each tube position. The reference assembly provides for eight positions, thus users must account for 32 such parts in total when repairing to assembling the assembly or structure.
The single tang design also permits the plug and attached tube to bend in the direction perpendicular to the plane of the tang, an undesirable feature when the hub assembly is used in collapsible structures. Lateral weakness results because a single tang design requires the tang to resist bending forces in its weakest direction, making the tang susceptible to forming a permanent bend or fracture, an undesirable failure mode addressed by the present invention. Also, in the '695 design, the position of the tang along the roll pin is not fixed, resulting in bending when mispositioning of the tang on the roll pin occurs, an issue addressed in the present invention. Finally, the hub assembly disclosed in the reference employs a rivet in the side wall at the end of each tube to secure the tang's tail to the plug and tube. The rivet is a small, easily misplaced part that requires special tools for removal and replacement in the event repair is required and holes in the side wall of the ends of the tubes must be provided to accept the rivet. The hole in the side wall of the tube weakens the tube, making the tube more susceptible to failure than tubes used with the present invention. Provision of said holes requires the availability of additional special tooling to effect a field repair or the availability of application-specific tubing with holes provided.
SUMMARY OF THE INVENTION
The present invention relates to an articulating hub assembly suitable for use in collapsible structures. The hub assembly consists of a hub body having a periphery, a central threaded opening therethrough and a plurality of paired radial slots extending inwardly from the periphery of the hub body, each pair of said radial slots in the hub body having a discontinuous groove located perpendicular thereto. The hub body also possesses a series of openings extending through the hub body, with the openings being positioned radially between each of the radial slots and between the periphery and the central opening of said hub body.
The assembly also has a hub cover having a periphery, a central opening therethrough, a plurality of paired radial slots and a series of openings extending through the hub cover, the hub body and the hub cover being assembled contiguously so that at the central opening, the paired radial slots and the openings of the hub cover are in registry with the central opening, the paired radial slots and the openings of the hub body.
Also in the assembly, there is an integrally formed keeper element having a top and a shaft extending downwardly therefrom, wherein the shaft is capable of being inserted through the hub cover, and the shaft is capable of being secured to the hub body.
The assembly possesses a plurality of forked plugs, each of the forked plugs having a first end and a second end, the first end having a pair of tangs joined by a post, the pair of tangs being positioned in one pair of the radial slots of the hub body and the hub cover in registry therewith, and the post being positioned in the discontinuous groove, the second end having a cylindrical plug comprised of a crown and ribs wherein at least one such rib has at least one shoulder and a structural element is secured to the plug.
Objects and features as well as additional details of the present invention will become apparent from the following detailed description and annexed drawings of the presently preferred embodiments thereof, when considered in conjunction with the associated drawings. The hub assembly of the present invention is a substantial improvement over prior art reference assemblies.
The present invention employs a one piece “forked-plug” comprised of a cylindrical plug with two tangs and an integral post connecting the tangs that allows the forked plug to rotate. The integral post between the tangs also results in a structure that provides unexpectedly high lateral stiffness, a feature particularly desirable for application in collapsible structures. Further the cylindrical plug is ribbed. The ribbed plug enables the plug to grip the inside of the tubes, enabling assemblies that do not employ the adhesives or rivets used in prior art, but still provide secure, non-rotating fastening of the tube to the ribbed plug while allowing disassembly and repair without tools.
The present invention requires no mechanical devices, such as a screwdriver, to disassemble or assemble the hub assembly, and adhesives are not required.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described in greater detail in the following description of the preferred embodiments taken in conjunction with the accompanying drawings.
FIG. 1 is a plan view of the of the hub body of the present invention.
FIG. 2 is a plan view of the hub cover of the present invention.
FIG. 3 is a side view of the articulating hub assembly of the present invention.
FIG. 4 is a side view of the forked-plug.
FIG. 5 is a plan view of a forked-plug.
FIG. 6 is an end view of the hub (inner) end of the forked-plug.
FIG. 7 . is an end view of the tube (peripheral) end of the forked-plug.
FIG. 8 is a plan view of the articulating hub assembly of the present invention.
FIG. 9 is a perspective view of the articulating hub assembly of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The articulating hub assembly of the present invention comprises a novel means for pivotally joining a network of tubes forming the matrix for a collapsible deployable structure. Multiple assemblies are used as pivotal devices for the movement of tubes to allow the quick erection and striking of a tubular frame supported structures.
A first significant feature of the present invention is to allow the tubes to articulate or move when either upward, i.e., vertical, or opposing side, i.e., horizontal, forces are applied.
More specifically, with respect to a collapsed network of tubes, assemblies, etc. laid out prior to erection, when manual upward pressure is applied at 90°.(i.e., perpendicular) to the ground at specific locations on the network, multiple hub assemblies are displaced from positions physically contacting the ground to specific elevated positions above the ground. The upward vertical force creates an action that moves the articulating hub assemblies of the present invention from static positions to tension positions and forms a structure of interconnected tubes and articulating hub assemblies that is self supporting. The resultant structure has five physical sides; the two ends, two sides and the top. The size and the shape of the structure can vary based upon the length of the tubes and the location of the scissor points.
To collapse the frame to its original position on the ground, simultaneous and opposing forces are applied on each of the four sides of the structure, (to the ends and to the sides) 180° to each other and 90° to the vertical (along the 0 or X-axis), to specific articulating hub assemblies.
This action allows the tubular frame to move from a tension position with the assemblies above ground, back to a static position and collapse down to the original location on the ground.
A second significant feature of the articulating hub assembly of the present invention is the ability to secure a fabric cover (covering the tubular frame network) to the hub body and allow the cover to move simultaneously with the tubular frame. The mushroom shaped threaded “keeper” component is inserted through an opening in the cover and screws into the hub body. This arrangement semi-permanently fixes and secures the fabric cover to the tubular frame. In this manner the frame and cover produce a quickly-erected fabric-covered shelter.
The third significant feature of the present invention is that all components are interchangeable.
A fourth significant feature of the present invention is its ability to grip the ends of tubes without the use of an additional fastener thereby avoiding the need for a hole or other feature in the side wall of the tube to accept a fastener while permitting repair of tubes.
A fifth significant feature of the present invention is that the forked-plug is one piece, facilitating handling in the field and mitigating the risk small parts may be lost during a field repair.
A sixth significant feature of the present invention is that the forked-plug provides high lateral stiffness enabling lighter weight, more robust or lower production cost for the collapsible structures.
A seventh significant feature of the present invention is that it grips the tubes such that they cannot rotate freely, resulting in stiffer collapsible structures.
The body of the hub assembly is depicted in FIG. 1 . The hub body 1 is a disc-like unit having a central opening 2 therethrough and a series of radial slots 3 extending inwardly from the periphery of disc 1 having a series of openings 4 extending through disc 1 and positioned radially between each of the radial slots 3 and between periphery 5 and central opening 2 , the surface of which is threaded. A groove 3 A is located perpendicular to each of radial slots 3 .
The cover of the hub assembly is depicted in FIG. 2 . The hub cover 6 is a disc like unit having a central opening 7 , radial slots 8 , and openings 9 . The hub body 1 and hub cover 6 are assembled contiguously so that central openings 2 and 7 , radial slots 3 and 8 , and openings 4 and 9 are in registry.
FIG. 3 is a side view of the articulating hub, assembly. Mechanically captured by the hub body and hub cover are the forked-plugs 13 . The assembly is threadedly secured by keeper 12 wherein the shaft of the keeper is threaded and has a diameter and thread that coincides with the diameter and thread present in central opening 2 , and possesses a diameter less than that of central opening 7 , enabling the shaft of the keeper to pass through the hub cover and threadedly engage the hub body, thereby securing the assembly. The keeper is large enough that it can be turned by hand, without the use of tools. It is a mushroom-shaped element such that the exposed top of the keeper 24 is contoured to match the contoured shape of the hub cover. Keepers of any shape may be used. Also shown in FIG. 3 is boss 20 which provides additional strength to the hub body.
FIG. 4 is a side view of forked-plug 13 , showing post 14 , tang 15 , crown 16 , and ten retaining ribs 17 . Tang 15 is designed to fit within radial slots 3 and 8 and post 14 is designed to fit within groove 3 A. Tang 15 possesses substantially the same thickness as the width of slots 3 and 8 and post 14 possesses an exterior dimensions substantially the same as the interior dimensions of groove 3 A. Further the distance between post 14 and crown 16 is greater than the dimension between groove 3 A and the periphery of the hub body ensuring the forked-plug may pivot freely within the hub-assembly. Also shown in FIG. 4 is central rib 18 which is provided with four shoulders 19 .
FIG. 5 is a plan view of the forked-plug showing the arrangement of the tangs 15 and integral post 14 . The arrangement of the tangs and post are further depicted in FIG. 6 . The one-piece double-tang and post design of the forked-plug is substantially different than the prior art and provides lateral stiffness greater than a simple multiple of the single tang designs taught in the prior art. The dramatic improvement in lateral stiffness is possible through the use of the integral post 14 which connects the two tangs of the forked-plug. The one-piece design of the forked plug has the additional benefits of reducing part count and eliminating the need for small parts, such as pins, as is practiced in the prior art.
FIG. 5 also depicts ribs 17 and shoulders 19 which enable forked-plug to reversibly grip the tubes of a collapsible structure without the use of an adhesive or other fastener, a marked improvement over prior art. The prior art practice of fastener fixed tubes requires the user to also have the requisite tools to operate the fastener, tools that may not be readily available in the field. Alternatively, the prior art practice of fixing tubes with adhesive precludes repair of tubes. Further, the ribs and shoulder prevent the tubes from rotating on the forked-plug, imparting additional stiffness to the resulting structure.
FIG. 7 . depicts an end view of the peripheral end of the forked-plug, including the ribs 17 and shoulders 19 . The cross-sectional dimensions of ribs 17 form a cylindrical shape that is substantially the same as the inner diameter of the tube of a collapsible structure. When a tube is slid over the ribs, its travel is stopped by crown 16 . Further, the ribs deform slightly, enabling them to accommodate small changes in the inner diameter of the tubes, such as may result from manufacturing inconsistency of the tubes, and allowing the shoulders and ribs to grip the inner surface of the tubes.
FIG. 8 depicts a plan view of the articulating hub assembly, including the keeper, hub cover and forked-plug as described above. In the preferred embodiment the hub assembly is provided with eight forked-plug, as shown in FIG. 8 . The keeper is provided with a central well 21 and two peripheral wells 22 for application of torque by means of a tool for the purpose of making the assembly operable by those without sufficient manual dexterity to operate the hub assembly without tools. The hub cover has openings 9 which coincide with registered openings in the hub body.
FIG. 9 is a perspective view of the articulating hub assembly of the present invention depicting openings 4 in the hub body and threads on the inner surface of central opening 2 . This view does not include the fabric which would cover the collapsible structure. The fabric may be captured by the keeper by inserting the keeper's captured shaft through a hole in the fabric before inserting the keeper's shaft through the hub cover and threading the keeper into the hub body.
All of the components described above are interchangeable. Further, assembly or disassembly of the hub assembly does not require any tools, unlike prior art which required a screwdriver to remove screws that joined hub sections. In addition, tubes may be individually replaced without having to remove the entire collection of tubes before the individual tube in the collection is replaced. As noted above the forked-plug design provides improved stiffness while the ribs and shoulder enable the invention to reversibly grasp tubes while not allowing them to rotate.
Thus while there have been shown, described and pointed out fundamental features of the invention as applied to currently preferred embodiments thereof, it will be understood that various omissions and substitutions and changes in form and details of the method and apparatus illustrated, and in their operation, may be made by those skilled in the art without departing from the spirit of the invention. In addition it is to be understood that the drawings are not necessarily drawn to scale but that the are merely conceptual in nature. It is the intention, therefore, to be limited only by the scope of the claims appended herewith. | A double tang articulating hub assembly used in combination with a collapsible self-supporting structure. The double tang articulating hub assembly is used as a connector among tubular rod elements which together provide a generally tubular frame matrix used to erect a collapsible self-supporting prefabricated deployable structure where a clear span interior without supporting columns is required. The hub employs a plurality of one piece “forked plugs” each containing a cylindrical plug with two tangs and an integral post connecting the tangs allowing the forked plug to rotate. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method for forming a zener diode and, more particularly, to a method of forming a zener diode in a npn and pnp bipolar process flow that requires no additional steps to set the reverse breakdown voltage of the zener diode to any voltage within a range of voltages.
2. Description of the Related Art
A zener diode is a p-n junction device that allows substantially no current flow through the diode when the diode is reverse biased (when the voltage on the n region of the diode is greater than the voltage on the p region of the diode.) However, when the n-to-p voltage difference is positive and exceeds a reverse breakdown voltage, a large breakdown current flows through the diode.
The magnitude of the reverse breakdown voltage, in turn, is a function of the relative doping concentrations of the n and p regions of the diode. Thus, by varying the relative doping concentrations, the reverse breakdown voltage can be set to any voltage within a range of voltages.
Zener diodes are commonly formed in a semiconductor process that utilizes a separate doping step to define the relative doping concentrations. The separate doping step typically forms the n or the p region of the diode, or adds a predefined amount of dopant to an existing n or p region, to thereby define the reverse breakdown voltage of the diode.
Zener diodes have a number of uses in semiconductor integrated circuits, including in an electrostatic discharge (ESD) protection circuit that provides ESD protection for variable power supply lines. FIG. 1 shows a circuit diagram that illustrates a conventional ESD protection circuit 100 .
As shown in FIG. 1, circuit 100 includes a zener clamp diode 110 , a npn transistor 112 , and a resistor 114 . Transistor 112 has a collector connected to a power supply line 116 , a base connected to diode 110 and resistor 114 , and an emitter connected to ground. Diode 110 also has a connection to power supply line 116 , while resistor 114 also has a connection to ground.
In operation, when the voltage on power supply line 116 is less than the reverse breakdown voltage, essentially no current flows through diode 110 . As a result, ground is on the base of transistor 112 , thereby turning off transistor 112 . When the voltage on power supply line 116 exceeds the reverse breakdown voltage, such as when a human body model (HBM) pulse is applied to line 116 , a current flows through diode 110 and resistor 114 , thereby placing a voltage on the base of transistor 112 . The voltage on the base of transistor 112 , in turn, turns on transistor 112 , thereby allowing a collector current IC to flow into the collector, and an emitter current IE to flow out of the emitter, of transistor 112 .
Although the separate doping step described above is conventionally utilized to form a zener diode, the need for a separate doping step increases the cost and complexity of the fabrication process. Thus, there is a need for a method of forming a zener diode that allows the reverse breakdown voltage to be set to any voltage within a range of voltages without requiring a separate doping step.
SUMMARY OF THE INVENTION
The present invention provides a method of forming a zener diode. The method allows the reverse breakdown voltage of the diode to be set by modifying the existing steps in a bipolar or BiCMOS fabrication process. The present method provides both a high tunable breakdown voltage range and a simple realization.
The method of the present invention begins with the step of forming a first zener region of a first conductivity type in a semiconductor material. The method also includes the steps of forming a second zener region of a second conductivity type in the substrate in the first zener region, and forming a layer of epitaxial material on the semiconductor material. The layer of epitaxial material has a surface, a first region that extends from the surface to the first zener region, and a second region that extends from the surface to the second zener region. The method also includes the step of doping the layer of epitaxial material so that the first region has the first conductivity type and the second region has the second conductivity type.
The method can also include the step of forming first and second transistor buried regions of the first and second conductivity types, respectively, in the semiconductor material. In addition, the method can form a third region of the first conductivity type in the epitaxial layer that extends from the surface to the first transistor buried region.
Further, a fourth region of the second conductivity type is formed in the epitaxial layer to extend from the surface to the second transistor buried region. The method can also form a first base of a second conductivity type that contacts the third region of the epitaxial layer; and a second base of a first conductivity type that contacts the fourth region of the epitaxial layer.
The present invention also provides a semiconductor device that includes a first zener region of a first conductivity type that is formed in a substrate, and a second zener region of the second conductivity type that is formed in the substrate in the first zener region. The semiconductor device also includes an epitaxial layer that is formed on the substrate. The epitaxial layer has a surface, a first region of the first conductivity type that extends from the surface to the first zener region, and a second region of the second conductivity type that extends from the surface to the second zener region.
The semiconductor device can also include a first isolation region of the first conductivity type that is formed in the substrate apart from the zener region. The semiconductor device can further include a first buried region of the first conductivity type that is formed in the substrate in the first isolation region, and a second buried region of the second conductivity type that is formed in the substrate.
The semiconductor device can additionally include, in the epitaxial layer, a third region of the first conductivity type that extends from the surface to the first buried region, and a fourth region of the second conductivity type that extends from the surface to the second buried region. In addition, a first base region of the second conductivity type contacts the third region of the epitaxial layer, and a second base region of the first conductivity type contacts the fourth region of the epitaxial layer.
A better understanding of the features and advantages of the present invention will be obtained by reference to the following detailed description and accompanying drawings that set forth an illustrative embodiment in which the principles of the invention are utilized.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a circuit diagram illustrating a conventional ESD protection circuit 100 .
FIG. 2 is a cross-sectional diagram illustrating an example of a semiconductor device 200 in accordance with the present invention.
FIGS. 3A-3M are cross-sectional drawings illustrating an example of a method of forming a semiconductor device in accordance with the present invention.
FIGS. 4A and 4B are plan views illustrating two of a number of shapes that zener opening 314 can have after mask 312 has been formed and patterned in accordance with the present invention.
FIG. 5 is a graph illustrating the reverse breakdown voltage of zener diode 430 vs. the current through zener diode 430 for four sizes of zener area 410 in accordance with the present invention.
FIG. 6 is a graph illustrating the reverse breakdown voltage of zener diode 430 vs. the size of opening 314 with and without deep zener trench in accordance with the present invention.
DETAILED DESCRIPTION
FIG. 2 shows a cross-sectional diagram that illustrates an example of a semiconductor device 200 in accordance with the present invention.
As shown in FIG. 2, device 200 , which is formed on a conventionally-formed substrate 216 , includes a n-type zener region 220 that is formed in substrate 216 , a p-type isolation region 222 that is optionally formed in substrate 216 , and a n-type isolation region 224 that is formed in substrate 216 . (If substrate 216 has a p conductivity type of a sufficient dopant concentration, substrate 216 and region 222 can be considered the same.) As described in greater detail below, zener region 220 and isolation region 224 are formed at the same time and, therefore, have substantially the same dopant concentrations.
Device 200 additionally includes a p+ zener region 230 that is formed in n-type zener region 220 , and an optional n+ zener region 232 that is formed in zener region 220 . Device 200 further includes a n+ buried region 234 that is formed in p-type isolation region 222 (or substrate 216 ), and a p+ buried region 236 that is formed in n-type isolation region 224 . As described in greater detail below, p+ zener region 230 and p+ buried region 236 are formed at the same time and, therefore, have substantially the same dopant concentrations.
Device 200 also includes a n-type region 240 that is formed on substrate 216 over zener region 220 (or optional n+ region 232 ) and buried region 234 , and a p-type region 242 that is formed on substrate 216 over zener region 230 and buried region 236 . Region 240 over buried region 234 forms the collector of transistor 212 , while region 242 over buried region 236 forms the collector of transistor 214 . Device 200 further includes a p− base region 244 that contacts n-type collector region 240 over buried region 234 , and a n− base region 246 that contacts p-type collector region 242 over buried region 236 .
Device 200 additionally includes a n+ emitter region 250 that is formed in p− base region 244 , and a p+ emitter region 252 that is formed in a n− base region 246 . In addition, a n+ zener sinker 254 is optionally formed in region 240 to contact n-type zener region 220 or optional n+ region 232 , and a p+ zener sinker 256 is optionally formed in region 242 to contact p+ region 230 . Further, a n+ sinker 260 is formed in region 240 to contact n+ buried layer 234 , and a p+ sinker 262 is formed in region 242 to contact p+ buried layer 236 .
Sinkers 254 , 256 , 260 , and 262 reduce the series resistance to n-type zener region 220 (or n+ region 232 ), p+ region 230 , n+ buried region 234 , and p+ buried region 236 , respectively. Further, deep trench isolators 270 are formed between devices, shallow trench isolators 272 are formed in regions 240 and 242 over buried layers 234 and 236 , respectively, to define collector surface areas 274 and base/emitter surface areas 276 . In addition, a zener isolator 278 is optionally formed in the center of n-type zener region 220 .
FIGS. 3A-3M show cross-sectional drawings that illustrate an example of a method of forming a semiconductor device in accordance with the present invention.
Following this, a n-iso mask 304 is formed and patterned on oxide layer 302 . Mask 304 is patterned to have a zener opening 306 that exposes a zener surface 308 of substrate 300 (under oxide layer 302 ), and a pnp opening 310 that exposes a pnp surface 312 of substrate 300 . Zener opening 306 , in turn, has a zener area measured on the surface of a plane that passes through substantially all of the surface of mask 304 .
FIGS. 4A and 4B show plan views that illustrate two of a number of shapes that zener opening 306 can have after mask 304 has been formed and patterned in accordance with the present invention. As shown in FIG. 4A, mask 304 can be formed such that zener opening 306 has a square shape. In this case, a zener area 410 is defined by squaring a side-length L of opening 306 .
As shown in FIG. 4B, mask 304 can alternately be formed such that opening 306 has a multi-fingered shape. In this case, a zener area 412 is defined by the sum of the areas of each of the fingers. (A 5% breakdown voltage increase results for a square mask (represents a multiple cell layout) in comparison with a multiple finger layout.)
Once mask 304 has been patterned, zener surface 308 and pnp surface 312 in FIG. 3A are implanted with a dopant, such as phosphorous or arsenic, through overlying oxide layer 302 . The implant forms a first n-type zener implanted region in substrate 300 below zener opening 306 , and a first pnp implanted region in substrate 300 below opening 310 . Mask 304 is then stripped.
Following this, as shown in FIG. 3B, a p-iso mask 314 is optionally formed and patterned on oxide layer 302 (p-iso mask 314 and the subsequent boron implant are unnecessary if substrate 300 is formed with a p conductivity type and a sufficient dopant concentration). Mask 314 is patterned to have a npn opening 316 that exposes a npn surface 318 of substrate 300 (under oxide layer 302 ), and to protect zener surface 308 and pnp surface 312 . Once p-iso mask 314 has been patterned, npn surface 318 is implanted with a dopant, such as boron, through overlying oxide layer 302 . The implant forms a first npn implanted region in substrate 300 below opening 316 . P-iso mask 314 is then stripped.
After the implanted regions have been formed, as shown in FIG. 3C, substrate 300 is annealed in a neutral ambient, such as nitrogen. (Other ambients may alternately be used.) The annealing causes the dopants in the zener implanted region to diffuse and form an n-type zener region 320 -Z, the first npn implanted region to diffuse and form a p-type isolation region 320 -P, and the first pnp implanted region to diffuse and form a n-type isolation region 320 -N.
In accordance with the present invention, by varying the area of opening 306 in mask 304 (FIG. 3 A), the amount of dopant that is introduced into substrate 300 can be varied. By varying the amount of dopant that is introduced into substrate 300 , the doping profile in the center of n-type zener region 320 -Z can be varied.
Bipolar and BiCMOS fabrication processes typically include a number of long high-temperature cycles that cause dopant diffusion. The doping profile that results is a function of the total amount of dopant that is available for diffusion which, in turn, is a function of the area of opening 306 in mask 304 .
Thus, when the area of opening 306 is relatively small, a first doping profile results, and when the area of opening 306 is relatively large, a second doping profile results. Thus, varying the area of opening 306 varies the amount of dopant available for diffusion which, in turn, varies the doping profile.
Varying the doping profile allows the breakdown voltage of the diode to be varied. As described in greater detail below, a p-type region with a known dopant concentration is subsequently formed to define a p-n junction. Since the p-type region has a known dopant concentration, the reverse breakdown voltage of the diode can be set to any voltage within a range of voltages by varying the doping profile of the n-type region.
Returning to FIG. 3C, a first buried layer mask 322 is next formed on oxide layer 302 . Mask 322 is patterned to expose npn surface 318 under oxide layer 302 . Following this, npn surface 318 is implanted with a dopant, such as phosphorous or arsenic, through overlying oxide layer 302 . The implant forms a second npn implanted region at the surface of isolation region 320 -P (or in substrate 300 if region 320 -P is not formed).
Mask 322 can also be patterned to expose a first surface portion 324 -A of zener surface 308 . When mask 322 is patterned to expose portion 324 -A, the implant also forms a second zener implanted region at the surface of zener region 320 -Z. Mask 322 is then stripped.
As shown in FIG. 3D, a second buried layer mask 326 is formed on oxide layer 302 after mask 322 has been removed. Mask 326 is patterned to expose a second portion 324 -B of zener surface 308 and pnp surface 312 under oxide layer 302 , and protect first portion 324 -A of zener surface 308 and npn surface 318 .
Following this, second portion 324 -B of zener surface 308 and pnp surface 312 are implanted with a dopant, such as boron, through oxide layer 302 . The implant forms a third zener implanted region at the surface of zener region 320 -Z, and a second pnp implanted region at the surface of isolation region 320 -N. Mask 326 is then stripped.
After the implanted regions have been formed, as shown in FIG. 3E, substrate 300 is again annealed in a neutral ambient. (Other ambients may also be used.) This annealing step causes the dopants in the third zener implanted region to diffuse and form a p+ region 328 -A in zener region 320 -Z. In addition, if a second zener implanted region was formed at the surface of zener region 320 -Z, then the anneal causes the dopants in the second zener implanted region to diffuse and form a n+ region 328 -B in zener region 320 -Z.
The step also causes the dopants in the second npn implanted region to diffuse and form a n+ buried region 330 in isolation region 320 -P (or substrate 300 if region 320 -P is not present), and the second pnp implanted region to diffuse and form a p+ buried region 332 in isolation region 320 -N. This annealing step is shorter than the prior annealing step and, as a result, causes less diffusion.
Following this, sacrificial oxide layer 302 is removed, and a n-type epitaxial layer 334 is grown on substrate 300 using conventional epitaxial preparation and growth steps. After region 334 has been formed, a layer of sacrificial oxide 336 is formed on n− region 334 . Next, a mask 338 is formed and patterned on oxide layer 336 .
Mask 338 is patterned to expose the area of n− region 334 (under oxide layer 336 ) that overlies pnp surface 312 , and protect the areas of region 334 that overlie zener surface 308 and npn surface 318 . Mask 338 can also be patterned to expose the area of region 334 (under oxide layer 336 ) that overlies p+ region 328 -A. The area overlying pnp surface 312 is then implanted with a dopant, such as boron, through oxide layer 336 to form a p-type implanted region.
When mask 338 is also patterned to expose the area of region 334 that overlies p+ region 328 -A, the area overlying the surface of p+ region 328 -A is also implanted to form a p-type implanted region. Mask 338 is then removed. Substrate 300 is then annealed in a neutral ambient (other ambients may also be used), thereby causing the dopants in the p-type implanted regions to diffuse and form a p− region 340 . The area of region 334 formed over n+ buried region 330 forms the collector of transistor 212 , while the area of region 340 formed over p+ buried region 332 forms the collector of transistor 214 .
Next, as shown in FIG. 3F, a layer of nitride 342 is formed on oxide layer 336 . After this, a deep trench mask 344 is formed and patterned on nitride layer 342 . Mask 344 is patterned to expose a trench surface 346 on n− collector region 334 . In addition, mask 344 can also be patterned to expose a zener surface region 348 over the surface junction of p+ region 328 -A, and zener surface 308 or n+ region 328 -B when formed.
As shown in FIG. 3G, once mask 344 has been patterned, the exposed regions of nitride layer 342 and the underlying oxide layer 336 and substrate 300 are etched for a predetermined period of time to form deep trenches 350 . When mask 344 is patterned to expose the surface junction, the etch also forms deep zener trench 352 . Mask 344 is then stripped.
After this, as shown in FIG. 3H, a shallow trench mask 354 is formed and patterned on nitride layer 342 . Mask 354 is patterned to expose shallow trench regions over deep trenches 350 , a shallow trench region over n− collector region 334 , and a shallow trench region over p-type collector region 340 . Mask 354 can also be patterned to expose a shallow trench region over deep zener trench 352 . Once mask 354 has been patterned, the exposed regions are etched for a predetermined period of time to form shallow trenches 356 and, when the pattern is present, a shallow zener trench 358 over deep zener trench 352 . (The etch also enlarges the size of trenches 350 and 352 .) Mask 354 is then stripped.
Following this, as shown in FIG. 3I, a layer of liner oxide 360 is grown in trenches 350 , 352 , 356 , and 358 . Next, a layer of oxide is formed on nitride layer 342 to fill up trenches 350 , 352 , 356 , and 358 . The oxide layer is then planarized using conventional techniques, such as chemical-mechanical-polishing, to remove the oxide layer from the surface of nitride layer 342 , and form deep isolation regions 362 and shallow isolation regions 364 . If zener trenches 352 and 358 were formed, the planarization also forms zener isolation region 368 .
As shown in FIG. 3J, after the planarization, nitride layer 342 is removed. Next, a n+ sinker mask 370 is formed and patterned on oxide layer 366 . Mask 370 is patterned to expose the area of collector region 334 that is formed over a collector surface 372 between deep isolation region 362 and shallow isolation region 364 over n+ buried layer 330 . Mask 370 is also patterned to expose the area of collector region 334 formed over zener surface 308 or n+ region 328 -B if formed.
Once mask 370 has been patterned, the exposed regions of oxide layer 336 are implanted with a dopant, such as phosphorous or arsenic, to form a first collector implanted region in n-type region 334 over n+ buried layer 330 . The implant also forms a first zener implanted region in n− region 334 over zener surface 308 , or n+ region 328 -B if formed. Mask 370 is then removed.
As shown in FIG. 3K, a p+ sinker mask 374 is formed and patterned on oxide layer 336 . Mask 374 is patterned to expose the area of region 340 that is formed over a collector surface 376 between deep isolation region 362 and shallow isolation region 364 over p+ buried layer 332 . Mask 374 is also patterned to expose the area of region 340 that is formed over p+ region 328 -A.
Once mask 374 has been patterned, the exposed regions of oxide layer 336 are implanted with a dopant, such as boron, to form a second collector implanted region in p-type region 340 over p+ buried layer 332 . The implant also forms a second zener implanted region in p-type region 340 over p+ region 328 -A. Mask 374 is then removed.
After the implanted regions have been formed, as shown in FIG. 3L, substrate 300 is annealed in a neutral ambient, such as nitrogen. (Other ambients can also be used.) The annealing causes the dopants in the first zener implanted region to diffuse and form a n+ zener sinker region 378 , and the second zener implanted region to diffuse and form a p+ zener sinker region 380 . The annealing also causes the first collector implanted region to diffuse and form a n+ bipolar sinker region 382 , and the second collector implanted region to diffuse and form a p+ bipolar sinker region 384 .
Following this, the process continues with conventional steps. As shown in FIG. 3M, these steps include the formation of a p− base region 386 in collector region 334 over n+ buried layer 330 , and a n− base region 388 in collector region 340 over p+ buried layer 332 . Although FIG. 3M shows base regions 386 and 388 formed in collector region 334 and collector region 340 , respectively, the present method applies equally well to other base structures, including reduced-size base structures, grown base structures, and extrinsic base structures.
These conventional steps also include the formation of a n+ emitter region 390 in p− base region 386 , and a p+ emitter region 392 in n− base region 388 . Although FIG. 3L shows emitter regions 390 and 392 formed in base layers 386 and 388 , respectively, the present method applies equally well to other emitter structures, including single and double poly extrinsic emitter structures.
Thus, a method has been shown for forming a zener diode 394 , such as diode 210 , a npn bipolar transistor 396 , such as transistor 212 , and a pnp bipolar transistor 398 , such as transistor 214 . Zener diode 394 includes zener region 320 -Z, p+ region 328 -A, n+ region 328 -B, n+region 378 , and p+ region 380 .
Npn bipolar transistor 396 includes isolation region 320 -P, n+ buried region 330 , collector region 334 , sinker 382 , p− base 386 , and n+ emitter 390 . Pnp bipolar transistor 398 includes isolation region 320 -N, p+ buried region 332 , collector region 340 , sinker 384 , n− base 388 , and p+ emitter 392 .
In accordance with the present invention, the reverse breakdown voltage of zener diode 394 is set by varying the size of the zener area, such as zener area 410 or 412 . FIG. 5 shows a graph that illustrates the reverse breakdown voltage of zener diode 394 vs. the current through zener diode 394 for four sizes of zener area 410 in accordance with the present invention.
As shown in FIG. 5, a 5 um by 5 um opening 306 in n-iso mask 304 , represented by line A, has a breakdown voltage of approximately 28V, while a 4 um by 4 um opening 306 , represented by line B, has a breakdown voltage of approximately 30V. In addition, a 1.5 um by 1.5 um opening 306 in mask 312 , represented by line C, has a breakdown voltage of approximately 55V, while a 1 um by 1 um opening 306 , represented by line D, has a breakdown voltage of approximately 75V.
FIG. 6 shows a graph that illustrates the reverse breakdown voltage of zener diode 394 vs. the size of opening 306 with and without deep zener isolation 368 in accordance with the present invention. As shown in FIG. 6, the breakdown voltage of varies from approximately 80V down to 20V based on the area of the mask opening, and then becomes substantially constant when the size of opening 306 exceeds a 10 um by 10 um sized opening.
In addition, the value of the breakdown voltage is largely independent of the presence of zener trench isolation 368 . As further shown in FIG. 6, with trench isolation 368 , a 10 um by 10 um sized opening 306 produces a reverse breakdown voltage of approximately 27V while a 30 um by 30 um sized opening 306 produces a reverse breakdown voltage of the same 27V.
On the other hand, when zener trench isolation 368 is absent, a 10 um by 10 um sized opening 306 produces a reverse breakdown voltage of approximately 27V while a 30 um by 30 um sized opening 306 produces a reverse breakdown voltage of approximately 22V. Overall, a square-shaped opening 306 with a side length ranging from 100 um to 1 um has a reverse breakdown voltage range from approximately 20V to 80V.
In the present invention, after regions 332 , 334 , and 336 have been formed, each subsequent high temperature step, including the formation of collector region 334 and collector region 340 , causes the dopants in isolation regions 320 -N and 320 -P to further diffuse into substrate 300 . For example, in a 0.18-micron fabrication process, regions 320 -N and 320 -P can have depths D of approximately 12 um when the fabrication process is complete.
It should be understood that various alternatives to the method of the invention described herein may be employed in practicing the invention. For example, rather than continuing to reuse a layer of gate oxide, the layer can be removed and replaced by a new layer. Further, the present method can also be incorporated into a BiCMOS process.
Thus, it is intended that the following claims define the scope of the invention and that methods and structures within the scope of these claims and their equivalents be covered thereby. | A zener diode is formed in a bipolar or BiCMOS fabrication process by modifying the existing masks that are used in the bipolar or BiCMOS fabrication process, thereby eliminating the need for a separate doping step. In addition, the reverse breakdown voltage of the zener diode is set to a desired value within a range of values by modifying the area of a new opening in one of existing masks. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
This is a continuation of U.S. application Ser. No. 10/250,251 entitled, “Optical Storage Device Rotation Speed Control Apparatus and Method”, which was filed on 2003 Jun. 18 now U.S. Pat No. 7,116,622 and is included herein by reference.
BACKGROUND
The present invention relates to a method and apparatus to control an optical storage device, and more particularly to a method and apparatus to control the spindle motor rotation speed of the optical storage device by detecting the armature currents of the spindle motor.
In the realm of optical storage devices there exists two major types of spindle motors. The first type is a three-phase motor, typically installed with a Hall sensor. Such motor can provide FG signal to indicate the rotation speed of the motor. Therefore the optical storage device can use the FG signal to know the current angular velocity of the motor and perform constant angular velocity (CAV) control to the motor. In addition, three-phase motors can rotate at very high speeds, so they are very popular in high-speed CD-ROM, CD-RW, and DVD-ROM applications. However, a major weakness of three-phase motors is that the motor itself, and its corresponding driving circuits, are rather expensive. Therefore, in most low-speed optical storage devices, such as DVD players and CD players, a DC motor is used as a spindle motor, so as to reduce the cost.
For optical storage devices using DC motors, there's no FG signal provided. The optical storage devices can only perform low speed constant linear velocity (CLV) control. Furthermore, because there is no easy way to sense the current angular velocity of the DC motor, it is difficult to control the deceleration rate and time before ejecting the optical medium from the optical storage device. Traditional control methods include using the optical pick-up of the optical storage device to read the timing information recorded on the optical medium, and calculating the DC motor rotation speed before performing the braking operation on the DC motor. Then, according to the calculated angular velocity of the DC motor, the system implements a constant deceleration for the corresponding period of time, causing the motor to stop spinning. Finally, the deceleration is stopped, and the ejection of the optical medium is performed. Under normal operation, this type of control method is capable of braking the medium-loaded optical storage device in a stable fashion. However, in some cases, the method will start ejection of the optical medium prior to complete deceleration of the DC motor, and cause damages to the surface of the medium. Such cases include:
1.) Erroneous calculation of the angular velocity of the DC motor. If the optical medium contains pre-existing and heavy damaged surface, the timing information recorded on the medium can not be properly read. The deceleration begins while the angular velocity of the DC motor is still unstable. 2.) Inconsistent loading of the spindle motor. For example, an 8 cm or a 12 cm optical disc, or optical discs of different thicknesses. 3.) Inherent inconsistent characteristics of the spindle motors. Same control currents applied to different spindle motors may lead to different deceleration operations.
SUMMARY
It is therefore an objective of the present invention to provide an apparatus and method that senses the armature current of the spindle motor to estimate the current angular velocity of the motor. The present invention calculates the angular velocity of the motor from the armature current, and then accurately controls the DC motor to a halt through a simple motor control circuit.
Briefly, the present invention provides a method for controlling angular velocity of a spindle motor, the method comprising generating a first control signal while in a first control mode, and generating a second control signal while in a second control mode; when receiving the first control signal in the first control mode, sending a first control voltage and a second control voltage to the spindle motor, causing the spindle motor to produce a first armature current upon reception of the first pulse and produce a second armature current upon reception of the second pulse; when receiving the second control signal in the second control mode, sending a third DC signal with a third control voltage to the spindle motor, causing the spindle motor to produce a third armature current upon reception of the DC signal; outputting a first, a second, and a third test voltage corresponding to the first, the second, and the third armature currents; using the first control voltage, the second control voltage and the third control voltage with the first, the second and the third test voltages to obtain a motor coefficient and a relative angular velocity of the spindle motor for controlling the angular velocity of the spindle motor.
The present invention further provides an apparatus for reproducing information on a medium, comprising a spindle motor for rotating the medium; a motor driving circuit for generating with a first control voltage to a spindle motor and causing the spindle motor to produce a first armature current, generating with a second control voltage to the spindle motor and causing the spindle motor to produce a second armature current, and generating a DC signal with a third voltage to the spindle motor and causing the spindle motor to produce a third armature current; a sensor circuit for sensing the first, the second, and the third armature currents, and generating a first, a second, and a third test voltage corresponding to the first, the second, and the third armature currents, respectively; wherein the first and the second test voltages are calculated to obtain a motor coefficient of the spindle motor; and wherein the third control voltage, the motor coefficient, and the third test voltage are calculated to obtain a relative angular velocity of the spindle motor for controlling the angular velocity of the spindle motor.
The present invention further provides a method for controlling angular velocity of a spindle motor to rotate a disc in a disc reproduction apparatus, the method comprising generating with a first control voltage and with a second control voltage to the spindle motor, causing the spindle motor to produce a first armature current upon reception of the first pulse and produce a second armature current upon reception of the second pulse; generating a third control voltage to the spindle motor, causing the spindle motor to produce a third armature current; sensing the first, the second, and the third armature currents, and outputting a first, a second, and a third test voltage corresponding to the first, the second, and the third armature currents; using the first and the second control voltages and the first and second test voltages to obtain a motor coefficient of the spindle motor; using the third control voltage, the motor coefficient, and the third test voltage to obtain a relative angular velocity of the spindle motor for controlling the angular velocity of the spindle motor.
It is an advantage of the present invention that it measures the armature current of a spindle motor to find an angular velocity of the spindle motor. By calculating a counter-electromotive force, and thus the angular velocity of the motor, according to the size of the armature current, and then using a simple motor control circuit, the present invention allows a deceleration control process to proceed in a closed-loop circuit, allowing for precise control of the DC motor to a complete stop.
These and other objectives of the present invention will no doubt become obvious to those of ordinary skill in the art after reading the following detailed description of the preferred embodiment that is illustrated in the various figures and drawings.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 shows a simplified model of a DC motor.
FIG. 2 shows a circuit block diagram of an optical storage device angular velocity control apparatus according to the present invention.
FIG. 3 shows an armature current sensor circuit according to the present invention.
FIG. 4 shows a flow chart of an optical storage device angular velocity control method according to the present invention.
DETAILED DESCRIPTION
FIG. 1 shows a simplified model of a DC motor. From the simplified model, the following equalities can be obtained:
ⅆ i a ( t ) ⅆ t = 1 L a e a ( t ) - R a L a i a ( t ) - 1 L a e b ( t ) ( 1 ) T m (t)=K i i a (t) (2) e b (t)=K b w m (t) (3)
where i a (t) is the armature current, R a is the armature resistance, e a (t) is the armature voltage, L a is the armature inductance, e b (t) is the counter-electromotive force (CEMF), K i is the torque coefficient, T m (t) is the motor torque, K b is the CEMF constant, w m (t) is the armature angular velocity, and T L (t) is the load torque.
From equation (3), it can be seen that the armature angular velocity w m (t) is directly proportional to the CEMF e b (t). According to equation (1), if the armature voltage e a (t) is known, the relative value of the current motor armature angular velocity w m (t) can be obtained via the armature current i a (t).
FIG. 3 shows an armature current sensor circuit according to one preferred embodiment of the present invention. The sensor circuit comprises five resistors (R 1 , R 2 , R 3 , R 4 , R 5 ), and an operational amplifier (OPAMP) 32 . The circuit is used to measure the armature current i a produced by the spindle motor 31 . Resistor R 1 and the spindle motor 31 are connected in series. Resistors R 2 and R 3 are connected at one end to either end of resistor R 1 , and at another end to the non-inverting input and inverting input of the OPAMP 32 , respectively. Resistor R 4 is connected from the non-inverting input of the OPAMP 32 to a reference voltage V ref . Resistor R 5 acts as a negative feedback and is connected from the output of the OPAMP 32 to the inverting input of the OPAMP 32 . The output of the OPAMP 32 is a test voltage V ia .
In this embodiment, the resistance of resistors R 2 and R 3 is much larger than the resistance of resistor R 1 . Therefore, the current through resistor R 1 is approximately equal to the current through the spindle motor 31 , and is thus treated as i a (t). Due to the armature current sensor circuit described above, we can derive the following relation:
V
ia
=
V
ref
R
2
R
2
+
R
4
R
3
+
R
5
R
3
+
V
+
R
4
R
4
+
R
2
R
3
+
R
5
R
3
-
(
V
+
-
i
a
R
1
)
R
5
R
3
where V + is the voltage at the node connecting R 1 and R 2 . With R 2 =R 3 =K 1 and R 4 =R 5 =K 2 , the relationship between V ia and i a can be simplified as:
V
ia
=
V
ref
+
K
2
K
1
(
i
a
R
1
)
Therefore, we can find the armature current from the magnitude of V ia .
Here, the value of V ref can be modified such that the output voltage V ia falls within the input voltage range of the analog-to-digital converter in the angular velocity control circuit (explained below) that receives the output voltage V ia .
Additionally, in the armature current sensor circuit described above, generally speaking, because the inductance of the spindle motor is not large, the armature current can settle very quickly, so in practical use, equation (1) can be simplified as:
e b ( t )= e a ( t )− R a i a ( t ) (4)
Knowing that the motor armature angular velocity w m (t) is directly proportional to the CEMF e b , in practical use, we need not measure the actual armature voltage and current. Instead, we can use the control voltage (DMOLVL) of the motor driving circuit (explained below) in substitute for the armature voltage, and use the test voltage V ia outputted by the armature current sensor circuit in substitute for the armature current, and enter a motor coefficient K ia to get the following relationship:
w m ( t )∝( DMOLVL−K ia V ia ( t )) (5)
The motor coefficient K ia used here is related to the internal resistance of the motor and special characteristics involved in producing the armature current. So, we must measure the motor coefficient either before velocity measurement begins, or directly after turning on the power supply. The method of finding the motor coefficient K ia is to send two pulses of voltages V 1 and −V 2 to the motor in a very short period of time. Because the duration of the pulses is very short, we can assume that in this time, the angular velocity of the motor does not change, and can therefore derive the following relationship:
V 1 −K ia V ia1 =−V 2 −K ia V ia2 (6)
where V ia1 and V ia2 represent the voltages outputted by the armature current sensor circuit when producing pulses V 1 and −V 2 , respectively.
From equation (6), we can find the following equation for the motor coefficient:
K
ia
=
V
1
+
V
2
V
ia
1
-
V
ia
2
(
7
)
Therefore, substituting the motor coefficient found from equation (7) and the known control voltage DMOLVL into equation (5), we can find the relative value of the motor armature angular velocity w m (t).
FIG. 2 shows a circuit block diagram of an optical medium angular velocity control apparatus according to the preferred embodiment. This apparatus uses the principles and the armature current sensor circuit described above. This apparatus is used to control the actual angular velocity of the spindle motor 22 . The spindle motor 22 spins an optical medium 21 , and uses optical pick-up to read information stored in the medium 21 . The apparatus comprises an armature current sensor circuit 23 , an angular velocity control circuit 24 , and a motor driving circuit 25 .
The angular velocity control circuit 24 produces a first control signal while in a first control mode, and a second control signal while in a second control mode. The first control mode can find the motor coefficient, according to the principle described above in equation (7), when the power is turned on or right before deceleration begins. The second control mode is used to perform deceleration.
In the first control mode, the motor driving circuit 25 receives a first control signal and sends the first pulse of the first control voltage V 1 and the second pulse of the second control voltage −V 2 to the spindle motor 22 , causing the spindle motor 22 to produce the first armature current and the second armature current upon receiving the first pulse and the second pulse, respectively. In the second control mode, the motor control circuit 25 receives a second control signal and produces a DC signal of the voltage DMOLVL, causing the spindle motor 22 to produce the third armature current upon reception of the DC signal.
The armature current sensor circuit 23 measures the first, second, and third armature currents, mentioned above, and outputs the proportional first test voltage V ia1 , the second test voltage V ia2 , and the third test voltage V ia3 , respectively.
In this manner, the angular velocity control circuit 24 , according to equation (7), uses the ratio of the sum of the control voltages V 1 and V 2 to the difference of the test voltages V ia1 , and V ia2 to find the motor coefficient K ia of the spindle motor. The control circuit 24 then, according to equation (5), takes the difference of the control voltage DMOLVL and the product of the motor coefficient K ia and the third test voltage V ia3 to find the relative armature angular velocity w m (t) of the spindle motor 22 . In the second control mode, the angular voltage control circuit 24 uses the relative value of the spindle motor armature angular velocity w m (t) to change the third control signal and adjust the control voltage DMOLVL, changing the actual speed of the spindle motor 22 .
FIG. 4 shows a flow chart of a method of controlling an angular velocity of an optical medium, according to the preferred embodiment. First, in step 41 , in a first control mode, produce a first control signal, and in a second control mode, produce a second control signal.
Then in step 42 , in the first control mode, according to the first control signal, send a first pulse of a first control voltage, and a second pulse of a second control voltage to the spindle motor, to cause the spindle motor to produce a first armature current and a second armature current when receiving the first pulse and the second pulse, respectively. In the second control mode, according to the second control signal, produce a DC signal of a third control voltage to cause the spindle motor, upon reception of the DC signal, to produce a third armature current.
Then, in step 43 , use an armature current sensor circuit, such as the one shown in FIG. 3 , to sense the first, second and third armature currents, and output respective the first, second and third test voltages relative to the armature currents.
In step 44 , take the ratio of sum of the first and second control votages to the difference of the first and second test voltages to find the motor coefficient of the spindle motor.
In step 45 , proceed to take the difference of the third control voltage and the product of the motor coefficient and the third test voltage to find the relative armature angular velocity of the spindle motor.
In conclusion, the present invention provides a control apparatus and method that uses an armature current of a spindle motor to find the angular velocity of the spindle motor. According to the magnitude of the armature current, calculation of the CEMF, approximation of the motor angular velocity, and through use of a simple motor control circuit, the present invention can perform motor deceleration control in a closed loop, efficiently bringing the DC motor to a complete stop.
Those skilled in the art will readily observe that numerous modifications and alterations of the device may be made while retaining the teachings of the invention. Accordingly, the above disclosure should be construed as limited only by the metes and bounds of the appended claims. | A method for controlling the rotation speed of an optical storage device. In the first mode, a first signal is produced, and in the second mode, a second signal is produced. In one mode, a first pulse of a first voltage and a second pulse of a second voltage are sent to the motor, which causes the motor to produce a first armature current and a second armature current. In another mode, a DC signal of a third voltage is produced, which causes the motor to produce a third armature current. The armature currents are detected, and test voltages are outputted. The first and second voltages, and the first and second test voltages are used to find a motor coefficient. The third voltage, the motor coefficient, and the third test voltage are used to calculate a motor rotation speed. The calculated speed is used to control the real motor speed. | 6 |
TECHNICAL FIELD
[0001] The invention relates generally to the field of dental products and more particularly to such products supplemented so that they are useful in treating skeletal diseases.
BACKGROUND OF THE INVENTION
[0002] A wide range of dental products including toothpastes, mouthwashes and dental floss are used. These products are generally intended to reduce dental diseases. However, it is well-documented that disorders of skeletal tissues and mineral metabolism cause numerous significant health problems and such can be specific to dental problems.
[0003] In humans, the maximum bone mass occurs between the age of 15 and 40 and is referred to as “peak bone mass.” After such peak bone mass age, bone mass begins declining gradually and the mechanical strength of the bone is accordingly reduced. Consequently, when mechanical strength declines to a certain level, the individual is at greater risk of bone fracture. This natural occurrence is called osteoporosis if severe enough to be pathogenic.
[0004] The speed at which bone loss occurs differs among individuals, and especially with respect to gender. In females, the speed of bone loss accelerates immediately after menopause (See FIG. 1 ) because of a significant decline in available estrogen, a hormone which plays a critical role in maintaining healthy bone metabolism. Postmenopausal osteoporosis constitutes an important clinical problem because it afflicts significant numbers of women. Notably, the ratio of female to male osteoporosis patients is 3:1.
[0005] The majority of bone diseases are characterized by loss of bone minerals, weakening of bones and consequently, an increase of the frequency and severity of bone fractures, which are called “pathological fracture.” In the elderly population, this has significant social ramifications as well, as many of those with bone fractures have difficulty with mobility, which often leads to the deterioration of other mental and physical functions, resulting in dementia, muscular weakness and/or fatigue. In addition, morbidity and pain are significantly increased by thrombotic events, such as pulmonary embolism which occur as a result of hip or pelvic fractures.
[0006] In the United States alone, it is said that 52 million women over age of 45 will suffer from osteoporosis by 2000. Current worldwide osteoporosis population is around 200 million. Annual incidence of pathological fracture in the United States alone is approximately 1.5 million. It is estimated that annual medical costs for those osteoporosis patients in the United States and world are $14 billion and $60 billion, respectively.
[0007] Renal failure is also a significant health problem related to mineral metabolism and skeletal formation, and the number of its patients is increasing rapidly. Renal function is declining gradually over several to ten years period in these patients. When the renal function becomes approximately a quarter (¼) of the healthy level, the patients are classified to chronic renal failure. When it becomes approximately one sixth (⅙) thereof, they need to start dialysis and are called end stage renal disease (ESRD). In patients with chronic renal failure, serum levels of important minerals such as calcium and phosphate lose their normal homeostasis, which results in malformation of skeleton. It is called renal osteodystropny (ROD), which is a secondary osteoporosis from renal failure. ROD can also cause pathological fracture like osteoporosis. The prevalence of end stage renal disease (ESRD) in the United States is rapidly increasing and about to reach 300 thousand in 2000. As ESRD is a part of chronic renal failure, there should be much higher number of ROD patients.
[0008] There are several other diseases of skeletal tissues and mineral metabolism such as Paget's Disease, rikets, osteopetrosis, hyperparathyroidism, and so forth and number of patients are affected by these diseases.
[0009] Metabolically, bone is a highly active organ with bone resorption and formation occurring continuously (remodeling). Bone resorption is facilitated by osteoclasts which are differentiated from monocyte/macrophage lineage cells. Osteoclasts adhere to the surface of bone and degrade bone tissue by secreting acids and enzymes. Osteoblasts facilitate bone formation by adhering to degraded bone tissue and secreting bone matrix proteins, which are mineralized mostly by calcium and phosphate. Osteoblasts differentiate into bone cells (osteocytes), and become a part of bone tissue.
[0010] Numerous experimental approaches have been attempted to either accelerate bone formation or diminish bone resorption. For example, growth factors such as BMPs (bone morphogenetic proteins), TGFβ (transforming growth factor β), IGF (insulin-like growth factor), fibroblast growth factor (FGF) are known to have potent biological activities in bone formation. In particular, a few subfamily molecules of BMP such as BMP-2 are regarded one of the most potent growth factors for hard tissue. However, these factors have not been developed as therapeutic agents for systemic bone diseases. It is because none of them can be delivered to the bone selectively and some of these factors such as BMPs convert soft tissue into hard tissue. It is called ectopic calcification and a critical adverse effect for them when they are used systemically. Further, the processes of bone formation and resorption are so closely connected and that makes selective increase of bone formation or selective inhibition of bone resorption extremely difficult.
[0011] Currently, there is a need for an effective treatment for bone loss. Therapeutic agents such as estrogen, calcitonin, vitamin D, fluoride, Iprifravon, bisphosphonates, and a few others have failed to provide a satisfactory means of treatment. (Gennari et al., Drug Saf . (1994) 11(3):179-95).
[0012] Estrogen and its analogues are frequently administered to patients with postmenopausal osteoporosis. Estrogen replacement therapy involves administration of estrogen just prior to or after the onset of menopause. However, as is often the case with steroid hormones, the long term use of estrogen has significant adverse effects such as breast and other gynecological cancers (Schneider et al., Int. J. Fertil. Menopausal Study (1995) 40(1):40-53).
[0013] Calcitonin, an endogenous hormone produced by the thyroid, binds selectively to osteoclasts, via its receptor, and inactivates them. Since the osteoclast is the only cell which can dissolve bone tissue, calcitonin binding can block or slow down bone degradation caused by the osteoclast. However, this biological mechanism is very short-lived, as the osteoclasts become tolerant to this drug relatively quickly. Therefore, the use of calcitonin does not provide an effective therapeutic option.
[0014] Fluoride has been shown to increase bone mass when it is administered to humans. However, while bone mass is increased, mechanical strength is not. Therefore, despite the increase in apparent bone mass, the risk of fracture remains (Fratzl et al., J. Bone Mineral Res . (1994) 9(10):1541-1549). In addition, fluoride administration has significant health risks.
[0015] Iprifravon has been used to treat osteoporosis in limited areas in the world. However, the actual efficacy of this compound is questionable and it is not widely accepted as a useful therapeutic agent for bone diseases.
[0016] Bisphosphonates are compounds derivatized from pyrophosphate. Synthesis involves replacing an oxygen atom situated between two phosphorus atoms with carbon and modifying the carbon with various substituents. While bisphosphonates are known to suppress bone resorption, they have little effect on bone formation. Furthermore, bisphosphonates adhere to the bone surface and remain there for very long time causing a long-term decrease in bone tissue turnover. As bone tissue needs to be turned over continuously, this decrease in turnover ultimately results in bone deterioration (Lufkin et al., Osteoporos. Int . (1994) 4(6):320-322; Chapparel et al., J. Bone Miner. Res . (1995) 10(1):112-118).
[0017] Another significant problem with the agents described above is that with the exception of fluoride and iprifravon, they are unsuitable for oral administration, and thus, must be given parenterally. Since bone disorders are often chronic and require long-term therapy, it is important that therapeutic agents be suitable for oral administration.
[0018] In summary, a significant need exists for a therapeutic agent which can prevent or treat bone loss. In particular, a new drug that can selectively increase bone formation and/or number of osteoblast without affecting bone resorption or soft tissue is highly desired.
[0019] Another major health problem relating to skeleton and mineral metabolism is that with teeth. In the United States alone, it is estimated that 67 million people are affected by periodontal disease and that the annual cost of its treatment is approximately $6.0 billion in 2000. It is said 90% of the entire population experience dental caries in their lives. The annual cost to treat them is over $50 billion per year in the United States alone.
[0020] Dental caries is a universal disease and affects children and adults. Periodontal disease, on the other hand, affects mostly adults, and in particular, the aged. In many cases, the patient's gum is inflamed and destroyed, the alveolar bone that supports the teeth is deteriorated. Cement that composes the core of the root is also damaged, and subsequently, teeth fall out. One of the most common treatments for tooth loss involves the use of a dental implant. An artificial implant (osseointegrated dental implants) is placed in the space where the tooth was lost. In severe cases, an entire denture is replaced by implants. However, implants frequently loosen, or fall out because their fixation on the alveolar bone is not always successful. Since alveolar bone is somehow damaged in these patients, the implant can not always be supported well by alveolar bone. When alveolar bone is severely damaged, autogenous bone grafting is made. In this case, a bone graft taken from another skeletal tissue of the same patient is grafted in the damaged alveolar area so that the hard tissue is regenerated and sinus is elevated there. Since these treatments require expensive bio-compatible materials and/or highly skilled techniques, the cost of treatment is usually very high.
[0021] It is believed that dental caries is caused by acidic condition in the oral cavity. For instance, sugars are converted to acid and dissolve the surface of the teeth. Although only enamel and a part of dentin is affected in many cases, the damage can reach the pulp cavity in severe cases that cause significant pain. The most typical treatment is filling the caries lesion with undegradable materials such as metals or metal oxide. Treatment of dental caries mostly depends upon those materials and the techniques by the dentists, which is often expensive.
[0022] Although a few therapeutic agents have been developed and used in dental area, they are generally only anti-inflammatory drugs, analgesics, and antibiotics. No generally effective therapeutic agent that directly improves periodontal hard tissues has been developed. Obviously, there is a significant demand for a therapeutic agent that promotes regeneration of alveolar bone and/or teeth, and increases the number and activity of odontoblasts/osteoblasts that help form of dental tissues.
SUMMARY OF THE INVENTION
[0023] Dental products including toothpaste, mouthwash, and dental floss are disclosed which products are comprised of a compound which enhance bone growth. The compound is any of a class of compounds which are useful in treating or preventing a condition associated with skeletal loss or weakness. The compounds are peptides or analogs thereof which comprise between 10 and 50 monomer (e.g. amino acids) units. The amino acid sequence comprises an integrin binding motif sequence which may be in the D- or L-conformation. The remaining monomer units (the sequence other than the integrin binding motif) in the compound may be amino acid analogs but are preferably naturally occurring amino acids having a sequence which is substantially the same as an amino acid sequence contiguous with the RGD sequence in the naturally occurring protein, matrix extracellular phosphoglycoprotein (Rowe et. al., Genomics (2000) 67:56-68).
[0024] An aspect of the invention is a set of peptides and/or peptide analogs.
[0025] Another aspect of the invention is to provide toothpaste which comprises a sufficient concentration of a compound of the invention to enhance tooth and/or alveolar bone growth on areas where deterioration has occurred.
[0026] Yet another aspect of the invention is to provide a mouthwash which comprises a sufficient concentration of a compound of the invention to enhance tooth and/or alveolar bone growth on areas where deterioration has occurred.
[0027] Still another aspect of the invention is a dental floss having coated thereon and/or embedded therein a compound of the invention in an amount such that repeated application to teeth and/or alveolar bone results in enhanced tooth and/or alveolar bone growth on areas where deterioration has occurred.
[0028] A feature of the invention is that a compound of the invention comprised an integrin binding motif sequence in a D or L conformation.
[0029] An advantage of the invention is that a compound of the invention enhances skeletal growth.
[0030] Another advantage of the invention is that a compound of the invention enhances the amount of osteoblast and possibly odontoblast cells on the surface of new skeletal growth.
[0031] Another aspect of the invention is to provide a formulation for therapeutic use which comprises a sufficient concentration of a compound of the invention and can be injected into the pulp of teeth, the space between the root of teeth and gum, or alveolar bone to prevent the damage on teeth and/or alveolar bone or regenerate the hard tissue in the damaged teeth and/or alveolar bone.
[0032] An object of the invention is to provide a method of treating skeletal loss by the administration/application of any formulation/composition of the invention.
[0033] These and other objects, aspects, features and advantages will become apparent to those skilled in the art upon reading this disclosure.
BRIEF DESCRIPTION OF THE FIGURES
[0034] FIG. 1 is a graph showing the relationship between bone mass and age in humans.
[0035] FIG. 2 is a schematic drawing of a matrix extracellular phosphoglycoprotein wherein the area designated as “A” includes sequences which match peptides of the present invention and the area designated as “B” is a highly homologous motif to a group of bone-tooth matrix phosphoglycoproteins such as osteopontin (OPN), dentin sialophosphoprotein (DSPP), dentin matrix protein 1 (DMP1), and bone sialoprotein II (IBSP).
[0036] FIGS. 3A, 3B , 3 C, and 3 D are actual photographs of bone cross-sections (from a seven day mouse calvaria organ culture study) showing the effects of a control ( FIG. 3A ), fibroblast growth factor-1 (FGF-1) ( FIG. 3B ), and two peptides of the invention designated D-00004 and D-00006 ( FIGS. 3C and 3D , respectively).
[0037] FIG. 4 is a graph comparing the effects of different compounds on calvaria.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0038] Before the toothpastes, mouthwashes, dental floss products, peptides, analogs, formulations, and methodology of the present invention are described, it is to be understood that this invention is not limited to any particular embodiment described, as such may, of course, vary. It is also to be understood that the terminology used herein is with the purpose of describing particular embodiments only, and is not intended to limit the scope of the present invention which will be limited only by the appended claims.
[0039] Where a range of values is provided, it is understood that each intervening value, to the tenth of the unit of the lower limit unless the context clearly dictates otherwise, between the upper and lower limits of that range is also specifically disclosed. Each smaller range between any stated value or intervening value in a stated range and any other stated or intervening value in that stated range is encompassed within the invention. The upper and lower limits of these smaller ranges may independently be included or excluded in the range, and each range where either, neither or both limits are included in the smaller ranges is also encompassed within the invention, subject to any specifically excluded limit in the stated range. Where the stated range includes one or both of the limits, ranges excluding either or both of those included limits are also included in the invention
[0040] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although any methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, the preferred methods and materials are now described. All publications mentioned herein are incorporated herein by reference to disclose and describe the methods and/or materials in connection with which the publications are cited.
[0041] It must be noted that as used herein and in the appended claims, the singular forms “a”, “and”, and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a peptide” includes a plurality of such peptides and reference to “the method” includes reference to one or more methods and equivalents thereof known to those skilled in the art, and so forth.
[0042] The publications discussed herein are provided solely for their disclosure prior to the filing date of the present application. Nothing herein is to be construed as an admission that the present invention is not entitled to antedate such publication by virtue of prior invention. Further, the dates of publication provided may be different from the actual publication dates which may need to be independently confirmed.
Definitions
[0043] The term “dental product” refers to all and any product used in the mouth. Preferably the product is used on a regular basis by consumers such as toothpaste, mouthwash and dental floss. However, the term includes products used solely by oral surgeons and dentists such as dental implants and materials used to fill dental cavities.
[0044] The terms “treat”, “treating”, “treatment” and the like are used interchangeably herein and mean obtaining a desired pharmacological and/or physiological effect. The effect may be prophylactic in terms of completely or partially preventing a disease or symptom thereof and/or may be therapeutic in terms of partially or completely curing a disease and/or adverse effect attributed the disease such as enhancing the effect of vitamin D. “Treating” as used herein covers treating a disease in a vertebrate and particularly a mammal and most particularly a human, and includes:
[0045] (a) preventing the disease from occurring in a subject which may be predisposed to the disease but has not yet been diagnosed as having it;
[0046] (b) inhibiting the disease, i.e. arresting its development; or
[0047] (c) relieving the disease, i.e. causing regression of the disease.
[0048] The invention is particularly directed towards peptides which make it possible to treat patient's which have experienced bone loss or which would be expected to experience bone loss and thus is particularly directed towards preventing, inhibiting or relieving the effects of bone loss. A subject is “treated” provided the subject experiences a therapeutically detectable and beneficial effect which may be measured based on a variety of different criteria including increased bone growth, increased bone strength or other characteristics generally understood by those skilled in the art to be desirable with respect to the treatment of diseases related to bone.
[0049] The term “antibody” is meant an immunoglobulin protein capable of binding an antigen. The term “antibody” as used herein is intended to include antibody fragments (e.g. F(ab′) 2 , Fab′, and Fab) capable of binding an antigen or antigenic fragment of interest.
[0050] The term “binds specifically” is meant high avidity and/or high affinity binding of an antibody to a specific peptide—specifically a peptide of the invention. Antibody binding to its specific target epitope is stronger than the binding of the antibody to other epitopes on the peptide or to other epitopes on other peptides. Antibodies which bind specifically to a peptide of interest may be capable of binding to other peptides at a weak, yet detectable level (e.g. 10% or less of the binding shown to the peptide of interest). Such weak binding or background binding, is readily discernable from the specific antibody binding to the peptide of interest, e.g. by the use of appropriate controls.
[0051] The term “skeletal loss” refers to any situation in which skeletal mass, substance or matrix or any component of the skeleton, such as calcium and phosphate, is decreased or the bone is weakened such as in terms of its ability to resist being broken.
[0052] The term “skeleton” includes both bone and teeth. In the same manner, the term “skeletal” means both bone and teeth.
[0053] The term “osteoporosis” is intended to refer to any condition involving bone loss, i.e. involving a reduction in the amount of bone mass or substance resulting from any cause. The term particularly results in a bone loss resulting from demineralization of the bone, post menopausal or peri-menopausal estrogen decrease or nerve damage.
[0054] The term “subject” refers to any vertebrate, particularly any mammal and most particularly including human subjects.
Invention in General
[0055] In general the invention comprises any dental product comprising a compound which enhances bone growth. The product is preferably a toothpaste, mouthwash or dental floss. The compound is preferably a peptide comprising from 10 to 50 amino acids. The amino acids are preferably one of the twenty naturally occurring L-amino acids. However, D-amino acids may be present as may amino acid analogs. A sequence of the invention will comprise an integrin binding motif such as RGD sequence in either the L- or D-form but preferably in the L-conformation. The peptide of the invention can be amidated or non-amidated on its C-terminus, or carboxylated or non-carboxylated on its N-terminus. The peptide of the invention may or may not contain a glycosaminoglycan binding motif such as SGDG sequence in L- or D-isomer form. A compound of the invention is still further characterized by biological activity i.e. it enhances skeletal growth as well as the growth or recruiting of osteoblast or odontoblast cells on surface of the new skeletal growth.
Specific Dental Products
[0056] The present invention is broadly applicable to all types of dental products and is particularly useful in connection with products used by consumers on a regular basis such as toothpaste, mouthwash and dental floss.
[0057] Specific examples of toothpastes which could be modified by having a compound of the invention dissolved, suspended or mixed therein include those toothpaste compositions disclosed and described in U.S. Pat. Nos. 6,045,780; 5,951,966; 5,932,193; 5,932,191; and 5,876,701. These patents as well as the patents and publications cited in these patents are incorporated herein by reference for the purpose of disclosing and describing various toothpaste compositions which can be used in connection with the present invention.
[0058] Compounds of the invention can also be used in combination with all types of mouthwashes. The various compounds including specific peptides disclosed herein can be dissolved or dispersed within a wide range of different compositions including the mouthwash compositions disclosed and described within U.S. Pat. Nos. 5,993,785; 5,817,295; 5,723,106; 5,707,610; 5,549,885; 5,470,561; 5,466,437; 5,455,023; 5,407,664; 5,328,682; and 5,256,401 all of which are incorporated herein by reference along with the patents and publications cited therein in order to disclose and describe various mouthwash compositions useful in connection with the present invention.
[0059] Compounds of the invention can also be coated on or absorbed into various types of filament materials used as dental flosses. Specific examples of dental floss materials which can be used in combination with the present invention include those disclosed and described within U.S. Pat. Nos. 6,102,050; 6,080,481; 6,027,592; 6,026,829; 6,016,816; 5,967,155; 5,937,874; 5,915,392; 5,904,152; 5,875,797; and 5,845,652 all of which are incorporated herein by reference along with the patents and publications cited therein in order to disclose and describe dental floss filament materials which can be used in combination with the present invention.
Specific Peptides
[0060] Specific examples of peptides of the invention comprise seven to forty-seven amino acids on either side of the RGD sequence of the naturally occurring sequence of matrix extracellular phosphoglycoprotein. Thus, examples of peptides of the invention comprising sequences taken from the following sequence and including the RGD sequence shown in bold:
(SEQ ID NO: 1) DSQAQKSPVKSKSTHRIQHNIDYLKHLSKVKKIPSDFEGSGYTDLQE RGD NDISPFSGDGQPFKDIPGKGEATGPDLEGKDIQTGFAGPSEAESTHL
[0061] Specific examples of peptides of the invention which comprise the RGD sequence as the terminal sequence include the following:
AQKSPVKSKSTHRIQHNIDYLKHLSKVKKIPSDFEGSGYTDLQE RGD (SEQ ID NO:2) RGD AQKSPVKSKSTHRIQHNIDYLKHLSKVKKIPSDFEGSGYTDLQE (SEQ ID NO:3) DSQAQKSPVKSKSTHRIQHNIDYLKHLSKVKKIPSDFEGSGYTD RGD (SEQ ID NO:4) RGD SPVKSKSTHRIQHNIDYLKHLSKVKKIPSDFEGSGYTDLQE (SEQ ID NO:5) DSQAQKSPVKSKSTHRIQHNIDYLKHLSKVKKIPSDFEGSG RGD (SEQ ID NO:6) RGD THRIQHNIDYLKHLSKVKKIPSDFEGSGYTDLQE (SEQ ID NO:7) DSQAQKSPVKSKSTHRIQHNIDYLKHLSKVKKIPSDFE RGD (SEQ ID NO:8) RGD LKHLSKVKKIPSDFEGSGYTDLQE (SEQ ID NO:9) DSQAQKSPVKSKSTHRIQHNIDYLKHLSKVKKIPSRGD (SEQ ID NO:10) RGD LSKVKKIPSDFEGSGYTDLQE (SEQ ID NO:11) DSQAQKSPVKSKSTHRIQHNIDYLKHLSK RGD (SEQ ID NO:12) RGD VKKIPSDFEGSGYTDLQE (SEQ ID NO:13) DSQAQKSPVKSKSTHRIQHNIDYLK RGD (SEQ ID NO:14) RGD IPSDFEGSGYTDLQE (SEQ ID NO:15) DSQAQKSPVKSKSTHRIQHNID RGD (SEQ ID NO:16) RGD DFEGSGYTDLQE (SEQ ID NO:17) DSQAQKSPVKSKSTHR RGD (SEQ ID NO:18) RGD GSGYTDLQE (SEQ ID NO:19) DSQAQKSPVK RGD (SEQ ID NO:20) RGD GYTDLQE (SEQ ID NO:21) DSQAQKS RGD (SEQ ID NO:22) RGD NDISPFSGDGQPFKDIPGKGEATGPDLEGKDIQTGFA (SEQ ID NO:23)
[0062] Specific examples of the peptides of the invention which comprise the RGD internally include the following:
NDI RGD SPFSGDGQPFKDIPGKGEATGPDLEGKDIQTGFA (SEQ ID NO:24) NDISPF RGD SGDGQPFKDIPGKGEATGPDLEGKDI (SEQ ID NO:25) NDISPFSGD RGD GQPFKDIPGKGEATGPDL (SEQ ID NO:26) FSGDGQPFKDIPGKGEATGPDLEGKDIQTGFAGPSEAES RGD THL (SEQ ID NO:27) IPGKGEATGPDLEGKDIQTGFAGPSE RGD AESTHL (SEQ ID NO:28) EATGPDLEGKDIQTGFAG RGD PSEAESTHL (SEQ ID NO:29) NDISPFSGDGQPFKD RGD IPGKGEATGPDLEGK (SEQ ID NO:30) GKGEATGPDLEGKDI RGD QTGFAGPSEAESTHL (SEQ ID NO:31) FSGDGQPFKDIPGKGEATG RGD PDLEGKDIQTGFAGPSEA (SEQ ID NQ:32) DGQPFKDIPGKGEATG RGD PDLEGKDIQTGF (SEQ ID NO:33) PFKDIPGKGEATG RGD PDLEGKDIQ (SEQ ID NO:34) DIPGKGEATG RGD PDLEGKDIQTGFAGP (SEQ ID NO:35) DGQPFKDIPGKGEATG RGD PDLEGKDIQTGF (SEQ ID NO:36) GKGEATG RGD PDLEGKDIQTGFAGPSEA (SEQ ID NO:37) EATG RGD PDLEGKDIQTGF (SEQ ID NO:38) EATG RGD PDLEGK (SEQ ID NO:39) EATG RGD PDL (SEQ ID NO:40)
[0063] All or any of the amino acids in the above sequences may be in the D- or L-conformation and may be substituted with equivalent analogs. The preferred embodiments comprise naturally occurring amino acids in the L-conformation.
[0064] All or any of the above sequences may be amidated or no-amidated on their C-terminus, or carboxylated or non-carboxylated on their N-terminus.
[0065] Matrix extracellular phosphoglycoprotein was cloned and characterized from a human tumor that caused osteomalacia in the patients. This extremely rare type of tumor called Oncogenic Hypophosphatemic Osteomalacia (OHO) tumor has been known to cause renal phosphate leak, hypophosphatemia (low serum phosphate levels), low serum calcitriol (1,25-vitamin D3), and abnormalities in skeletal mineralization (Osteomalacia). In the patients of OHO tumor, resection of the tumors results in remission of all of the above symptoms and it has been proposed that a circulating phosphaturic factor secreted from OHO tumor plays a role in osteomalacia. Matrix extracellular phosphoglycoprotein was proposed as a candidate of this phosphaturic factor phosphoglycoprotein (Rowe et. al., Genomics (2000) 67:56-68).
[0066] Phosphate plays a central role in many of the basic processes essential to the cell and the mineralization of skeleton. In particular, skeletal mineralization is dependent on the regulation of phosphate and calcium in the body and any disturbances in phosphate-calcium homeostasis can have severe repercussions on the integrity of bone. In the kidney, phosphate is lost passively into the glomerular filtrate and is actively reabsorbed via a sodium (Na+) dependent phosphate cotransporter. In the intestine, phosphate is absorbed from foods. A sodium (Na+) dependent phosphate cotransporter was found to be expressed in the intestine and recently cloned (Hilfiker, PNAS 95(24) (1998), 14564-14569). The liver, skin and kidney are involved in the conversion of vitamin D3 to its active metabolite, calcitriol, which plays an active role in the maintenance of phosphate balance and skeletal mineralization.
[0067] Vitamin D deficiency causes rickets in children and osteomalacia in adults. Both conditions are characterized by failure of calcification of osteoid, which is the matrix of skeleton.
[0068] Thus, all of the humoral functions by matrix extracellular phosphoglycoprotein, namely, renal phosphate leak, hypophosphatemia (low serum phosphate levels), low serum calcitriol (1,25-vitamin D3), are harmful to healthy skeletal formation.
[0069] Matrix extracellular phosphoglycoprotein is a large polypeptide with 525 amino acid with short N-terminus signal sequence. Therefore, it is highly probable that this molecule is secreted from its producing cells into the body fluid and circulation. Out of its 525 amino acid sequence, 23 amino acid motif on the C-terminus showed high similarities to a group of bone-tooth mineral matrix phosphoglycoproteins such as osteopontin (OPN), dentin sialophosphoprotein (DSPP), dentin matrix protein 1 (DMP1), and bone sialoprotein II (IBSP). It has been proposed that these bone-tooth mineral matrix phosphoproteins may play important roles in skeletal mineralization.
[0070] Notwithstanding the above observations about matrix extracellular phosphoglycoprotein, smaller peptide sequence containing integrin binding motif that is located within the amino acid sequence and far from its C-terminus sequence with a high degree of similarity to other bone-tooth mineral matrix phosphoglycoproteins demonstrated a very potent skeletal formation activity and increased the number of osteoblasts on such skeletal formation surface. The potency of such activities was equivalent to fibroblast growth factor (FGF). It was surprising in that small motifs within a large protein which protein has destructive functions on the skeleton demonstrated potent bone formation activity, and that such motifs were located far from the sequence which showed homology to other known bone-tooth matrix proteins.
[0071] Another surprising fact was that potent skeletal formation motifs of the invention contained an integrin binding motif, in particular, RGD sequence. It has been reported that a synthetic peptide containing the RGD sequence inhibited bone formation and resorption in a mineralizing organ culture system of fetal rat skeleton (Gronowicz et. al. Journal of Bone and Mineral Research 9(2):193-201 (1994)), that is a very similar experimental method used to test the subject of the present invention.
[0072] Further, the skeletal formation activity provided by the small peptides of the invention was as potent as that of an intact growth factor such as FGF.
EXAMPLES
[0073] The following examples are put forth so as to provide those of ordinary skill in the art with a complete disclosure and description of how to make and use the present invention, and are not intended to limit the scope of what the inventors regard as their invention nor are they intended to represent that the experiments below are all or the only experiments performed. Efforts have been made to ensure accuracy with respect to numbers used (e.g. amounts, temperature, etc.) but some experimental errors and deviations should be accounted for. Unless indicated otherwise, parts are parts by weight, molecular weight is weight average molecular weight, temperature is in degrees Centigrade, and pressure is at or near atmospheric.
Example 1
Synthesis of D-00001, etc
[0074] Six different peptides were manually synthesized by the 9-fluorenylmethoxycarbonyl (Fmoc) strategy and prepared in the C-terminal amide form. The six peptides are as follows:
D-00001: IPSDFEGSGYTDLQE (SEQ ID NO:41) D-00002: DFEGSGYTDLQE RGD (SEQ ID NO:42) D-00003: YTDLQE RGD NDISPF (SEQ ID NO:43) D-00004: E RGD NDISPFSGDGQ (SEQ ID NO:44) D-00005: NDISPFSGDGQPFKD (SEQ ID NO:45) D-00006: TDLQE RGD NDISPFSGDGQPFKD (SEQ ID NO:46) (C-terminus amidated)
Amino acid derivatives and resins were purchased from Bachem, Inc., Torrance, Calif., and Novabiochem, La Jolla, Calif. The respective amino acids were condensed manually in a stepwise manner using 4-(2′,4′-dimethoxyphenyl-Fmoc-aminomethyl)-phenoxy resin. N-methyl pyrrolidone was used during the synthesis as a solvent. For condensation, diisopropylcarbodiimide/N-hydroxybenzotriazole was employed, and for deprotection of N α -Fmoc groups, 20% piperidine in N-methylpyrrolidone was employed. The following side chain protecting groups were used: Asn and Gln, trityl; Asp, Glu, Ser, and Thr, t-butyl; Arg, 2,2,5,7,8-pentamethylchroman-6-sulfonyl; and Lys, t-butoxycarbonyl. Resulting protected peptide resins were deprotected and cleaved from the resin using a trifluoroacetic acid-thioanisole-m-cresol-ethanedithiol-H 2 O (80:5:5:5:5, v/v) at 20° C. for 2 h. Resulting crude peptides were precipitated and washed with ethyl ether then purified by reverse-phase high performance liquid chromatography (using Vydac 5C18 column and a gradient of water/acetonitrile containing 0.1% trifluoroacetic acid). All peptides were obtained with 5-20% yield (from the starting resin). Purity of the peptides was confirmed by analytical high performance liquid chromatography. Identity of the peptides was confirmed by a Sciex API IIE triple quadrupole ion spray mass spectrometer.
Example 2
Fetal Mouse Calvarial Assay
[0000] Reagents
[0000] FGF-1 was purchased from Peprotech Inc. (Rocky Hill, N.J.). RGD-1, 2, 3, 4, 5 and 6 (referred to here as D-00001, D-00002, D-00003, D-00004, D-00005 and D-00006) were provided by Dr. Nomizu (Hokkaido University, Japan).
[0000] Mice
[0000] Pregnant ICR mice were purchased from SLC Japan Co. Ltd. (Shizuoka, Japan).
[0000] Mouse Calvarial Organ Culture
[0075] Mouse calvarial organ culture was performed as described in Mundy G et al. Science 286: 1946-1949, 1999 and Traisnedes K et al. Endocrinoloy 139: 3178-3184, 1998. The calvaria from 4-days-old mice were excised and cut in half along the sagittal suture. Each half of the calvaria was placed on a stainless steel grid in a 12-well tissue culture dish (Asahi Glass Techno Corp., Funabashi, Japan). Each well contained 1.5 ml of BGj medium (Sigma, St. Louis, Mo.) supplemented with 0.1% bovine serum albumin (Sigma) and each compound. FGF-1 was used as a positive control as described by Mundy et al. The medium was changed at day 1 and 4, and the assay was terminated at day 7.
[0000] Histomorphometrical Analysis
[0076] Calvaria was fixed with 10% neutral-buffered formalin, decalcified with 4.13% EDTA and embedded in paraffin. 4 mm-thickness sections were made and stained with hematoxylin and eosin. New bone area was measured using Inage-Pro Plus (Media Cybernetics, Silver Spring, Md.).
[0077] The six peptides of Example 1 were tested for their ability to enhance bone growth with the tests being carried out as described above in Example 2. The peptides which did not include the RGD sequence did not show positive results. The other four peptides showed positive results with the best results being obtained with the sequences
D-00004: E RGD NDISPFSGDGQ, (SEQ ID NO:44) and D-00006: TDLQE RGD NDISPFSGDGQPFKD. (SEQ ID NO:46)
The best results are in FIG. 3 (specifically FIGS. 3C and 3D ). Data from these results are graphically shown in FIG. 4 .
[0078] While the present invention has been described with reference to the specific embodiments thereof, it should be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the true spirit and scope of the invention. In addition, many modifications may be made to adapt a particular situation, material, composition of matter, process, process step or steps, to the objective, spirit and scope of the present invention. All such modifications are intended to be within the scope of the claims appended hereto. | Dental products such as toothpastes, mouthwash and dental floss are disclosed which products are enhanced by having dissolved, dispersed or coated thereon a compound which promoted bone growth. Preferred compounds are peptide sequences comprising 10 to 50 amino acids are disclosed. The sequences are characterized by containing an integrin binding motif such as RGD sequence and the remainder of amino acids contiguous with the RGD sequence in matrix extracellular phosphoglycoprotein. The sequences may be formulated for dispersed in toothpaste or a mouthwash and administered to enhance bone/tooth growth. When the dental products are used repeatedly over time they enhance good dental health. | 8 |
RELATED APPLICATIONS
This application is a divisional of U.S. application Ser. No. 11/010,598 filed on Dec. 13, 2004, now U.S. Pat. No. 7,712,637 which claims the benefit of U.S. Provisional Application No. 60/528,565 filed Dec. 11, 2003, the entire teachings of these applications being incorporated herein by reference.
BACKGROUND OF THE INVENTION
Field of Invention
This invention relates generally to the dispensing or extracting of fluids from within containers and finds particular utility in the dispensing and preservation of wine.
SUMMARY OF THE INVENTION
The field of the invention includes devices and methods for extracting fluids from within containers.
An object of one or more embodiments of the invention is to allow a user to withdraw a volume of liquid from within a container that is sealed by a cork, plug or elastomeric septum without removing the cork, septum or closure device. It is a further object of one or more embodiments of the invention to allow removal of liquid from such a container repeatedly without causing enough damage to the cork that either gas or fluid exchange through the cork is possible under standard storage conditions. It is a further object of one or more embodiments of the invention to ensure that no gas which is reactive with the liquid passes into the container either during or after extraction of fluid from within the container.
Various embodiments of the invention enables the user to withdraw wine from within a wine bottle without removal of, or damage to the cork that would allow undesired gaseous or liquid egress or ingress during or after extraction of wine.
One embodiment of the invention involves a needle, a valve, and a source of pressurized gas. The needle is connected to the valve which is in turn connected to the source of pressurized gas. The needle is passed through the cork or between the cork and an interior wall of the bottle until it makes contact, at a minimum, with the interior of the bottle beyond the cork. Prior to or following insertion of the needle, the bottle is positioned such that the liquid content of the bottle can contact at least a portion of the needle. The valve is then opened such that pressurized gas can pass through the needle into the interior of the bottle. The valve is then switched to a position preventing further ingress of gas while allowing the liquid contents of the bottle to be expelled from the bottle through the needle by the pressurized gas now within the bottle. Once a desired amount of liquid content has been removed from the bottle, the bottle is then repositioned such that the pressurized gas content of the bottle is in contact with at least a portion of the needle so that the gas may be expelled from the bottle until there is no or an acceptably low pressure differential between the bottle and atmosphere. The needle is then removed from the cork.
In a preferred embodiment, the needle is a smooth exterior walled, cylindrical needle with a non-coring tip that can be passed through the cork without removing any material from the cork. The preferred non-coring tip is a pencil-tip that dilates a passageway through the cork, although deflected-tip and stylet needles have also been found to work and could be used in alternative embodiments. The pencil-tip needle preferably has at least one lumen extending along its length from at least one inlet on the end opposite the pencil-tip and at least one outlet proximal to the pencil-tip. The preferred outlet is through the side-wall of the needle.
With the correct needle gauge, it has been found that the passageway that remains following removal of such a needle self-seals against egress or ingress of fluids and gasses under normal storage conditions. While multiple needle gauges can work, preferred needle gauges range from 16 to 22 gauge, with the optimal needle gauge being between 17 and 20 gauge. These needles gauges offer optimal fluid flow with minimal pressures while doing an acceptably low level of damage to the cork even after repeated insertions and extractions.
Multiple needle lengths can be adapted to work within the scope of the present invention, however it has been found that a minimum needle length of 1.5 inches is required to pass through standard corks. Needles as long as 9 inches could be employed, but the optimal range of length has been found to be between 2 and 2.6 inches. The needle may be connected to the valve directly through any standard fitting (e.g. NPT, RPT, Leur, quick-connect or standard thread) or alternatively may be connected to the valve through an additional means such as a flexible or rigid tube.
While many standard valves could be employed, two are of particular utility for this application. The first is a three-way trumpet or spool valve. Such valves have a piston which slides within a cylinder. The piston is moved downward into the cylinder by the user depressing a button connected to or integral to the piston. The piston is moved upward by a return spring in contact with the piston. When the piston is depressed by the user, a first passageway through the cylinder allows passage of gas from a pressurized gas source connected to the valve at the “gas connection” into the needle connected to the valve at the “needle connection”. Gas is allowed to enter the bottle through the needle until the user decides to release the piston. When the piston is released by the user, the spring pushes the cylinder upward exposing a second passageway through the cylinder which allows passage of the pressurized content in connection with the needle to pass through the cylinder to a “valve exit”. This valve exit may, for example be a simple hole positioned above a glass or may be a tube leading to a secondary container. This process may be repeated until a desired amount of liquid is removed, from the bottle. The user then positions the bottle such that pressurized gas within the bottle is in contact with at least one outlet of the needle. With the valve cylinder released, pressurized gas can then vent from the bottle through the needle connection and out of the valve exit until a desired final pressure is reached. The needle is then removed from the cork.
The second advantageous valve is an automatic, pressure regulated valve. The primary function of this valve is to maximize the rate of liquid content egress through the needle by automatically maintaining an optimal pressure range within the bottle. A secondary function of such a valve is to control the final pressure within the bottle just prior to removal of the needle from the cork. Such a valve could be operated by a user through the use of a toggle between two valve positions—extract and vent. In the extract position a passage between the pressurized gas source and the needle would be opened by the valve until a desired maximum pressure limit is achieved within the bottle. The valve would then automatically switch to the vent position wherein a passageway is opened between the needle and a valve exit so that contents of the bottle can be expelled. The valve would then automatically switch back to the extract position when a lower pressure limit was reached. This process, continues until a desired amount of the liquid content of the bottle is extracted. The bottle is then positioned such that the gaseous contents of the bottle are in contact with at least a portion of the needle allowing gas to exit in the vent position prior to extraction of the needle. The lower pressure limit could be changed for this gas-venting procedure to allow a final/controlled pressure within the bottle. This changing of the lower pressure limit could be achieved automatically through the use of a switch that is activated by the tilting of the bottle (e.g. when the bottle is standing upward the switch would be activate the lower pressure while when the bottle is on its side the switch would activate the higher pressure.)
Other valves that could be used include, but are not limited to ball, solenoid, pivoted-armature, rotating cylinder, and toggle valves. Additional valves could further be added to the system. For example, a simple two-way check valve placed at the wine exit could be employed to maintain pressure within the bottle without flow of wine. In this way, wine can be released from the bottle at the users discretion after pressurization.
It has been found that the maximum value for the upper pressure limit is between around 40 and 50 PSI but is optimally between around 15 and 30 PSI. These pressures are well tolerated by even the weakest of cork-to-bottle seals. The lower pressure limit during wine extraction could be between 1 and 20 PSI lower than the upper pressure limit. For example, selecting an upper pressure limit of 30 PSI, it has been found that a lower limit of 15-20 PSI maintains an adequate pressure gradient to ensure rapid expulsion of wine through a 17 to 20 gauge needle. The final/controlled pressure (the lower of the lower pressure limits) can be between 0 and 15 PSI, with an optimal range of 0 to 5 PSI.
The source of pressurized gas can be any of a variety of regulated or unregulated pressurized gas containers filled with a variety of non-reactive gasses. In a preferred embodiment, the source consists of a container of gas with the gas at an elevated initial pressure (2000-3000 psi). This container is then regulated to the desired outlet pressure by either a fixed or variable regulator. This regulator can be any of a variety of single or two stage regulators available on the market. This configuration allows the use of conveniently small bottles of compressed gas that contain relatively large quantities of gas capable of emptying many bottles of wine. It further insures that the outlet pressure of the valve is maintained as the pressure within the container of gas changes during use. Multiple gasses have been tested successfully over extended periods of time, but the preferred gasses are nitrogen and argon. Preferably the gas is non-reactive with the fluid within the subject vessel such as wine and can otherwise protect the fluid from the deleterious effect of air infiltration or exposure. Nitrogen has the advantage of being very inexpensive and readily available in a variety of container sizes and initial pressures. Argon has the advantage of being a completely inert, noble gas as well as being heavier-than-air. By being heavier-than-air, argon minimizes the risk of inadvertent ingress of reactive atmospheric gasses during the final venting of the pressurized gas from within the container. Other non or minimally reactive gases or mixtures thereof also work, for example helium and neon. Preferably, the gas used should be equal to or greater in weight than air to preventingress of unwanted gasses and should have a low permeability through cork and/or glass, all resulting in helium being less preferred. Mixtures of gas are also possible. For example, a mixture of argon and another lighter gas would blanket the wine in argon while the lighter gas would occupy volume within the bottle and perhaps reduce the overall cost of the gas. Preferred embodiments use disposable membrane cylinders of nitrogen or argon at storage pressures equal to or greater than 2500 psi and a simple regulator set at a fixed outlet pressure between 15 and 30 PSI.
An alternative source of gas that allows greater volumes to be stored in smaller containers is a liquid that changes phase to gas and expands once released from its container.
In one exemplary embodiment a device is provided that has a hollow needle having an inlet at one end and an outlet at a second end and wherein the needle is adapted to penetrate beyond a closure device (such as a cork, plug, or septum) sealing a container; a pressurized source of gas; a pressure regulator capable of reducing the pressure of the gas from the pressurized source to a lower pressure at a regulator outlet wherein the regulator is connected to the pressurized source at a regulator inlet; a valve secured at a first valve inlet to the regulator outlet, secured at a first valve outlet to the needle inlet, and having a second valve outlet for the passage of gas or fluids from within the container; and wherein the valve controls the flow of gas from the pressurized source into the container through the needle and the flow of gas or fluid from within the container through the needle and out of said valve outlet.
In one exemplary method fluid can be extracted from within a container sealed by a closure device by inserting the outlet of a single lumen, non-coring needle with a smooth exterior wall beyond the closure device and into the container; injecting a pressurized non-reactive gas into the container through the hollow needle thereby causing an increase of pressure within the container to a level higher than the surrounding atmospheric pressure; allowing the fluid within the container to be forced out of the container by this pressure through the needle until a desired amount of fluid is extracted; and then removing the needle from the closure device thereby allowing the closure device to reseal.
Other components can be added to the system to increase its functionality or durability. Of particular utility include a linear drive mechanism, a container attachment mechanism, a sealing member retention means, and an anti-buckling mechanism.
A linear drive mechanism is any mechanism that forces the needle to be inserted into and through the closure device or between the closure device and container in a linear path. This can help to prevent buckling of the needle due to side loads or bending moments. This system could be as simple as a single keyed rod passing through a matching keyed hole wherein the rod's travel through the hole is along a line co-linear with the desired needle path. This rod can be connected directly to the needle or to an intervening device. Further embodiments could include multiple cylindrical rods that pass through multiple closely matching round holes or tubes that are co-linear with the desired needle path, among others.
A container attachment mechanism is any mechanism capable of securing or stabilizing at least a portion of the device to the container. This can serve the purpose of again reducing the risk of buckling of the needle by ensuring that the needle path stays fixedly relative to the container. It can also aid in preventing inadvertent withdrawal of the needle from the container. It can further be used in concert with a cork or sealing member retention means to prevent expulsion of the sealing member from the container during pressurization. An attachment mechanism can provide an anchoring location that would give such a sealing member retention means the stability necessary to hold the sealing member in place during pressurization. For example, such a retention means could comprise a surface of the device that contacts a surface of a sealing member outside of the container and, when secured to the container by an attachment mechanism, could obstruct the path that the sealing member must travel to be expelled from the container. Suitable attachment mechanisms can include, but are not limited to, two clamping arms that close about a portion of the container. For example, in the case of a wine bottle, these two clamp arms could close about the neck of the bottle. An attachment mechanism could alternatively involve glue, Velcro, threaded attachments that are driven into a wall of the container, suction cups, tape, and the like. The attachment mechanism could additionally have a releasable lock that acts to releaseably secure the device to the container. In the case of the clamp arms, such a lock could include a simple threaded bolt that passes through both arms and has a nut on one end that can be threaded down the bolt to apply varying clamping force to the container and then be unthreaded to release the container.
An anti-buckling mechanism is any mechanism that acts to reduce the risk of the needle buckling during insertion and withdrawal of the needle. Apposing arms that contact the sides of the needle's length are one possible embodiment of such a mechanism. The arms could have a slot running through a surface of the arm. This slot could be as wide and deep as the needle diameter. As the needle is advanced into the sealing device, these slots would act to resist buckling of the needle by restraining bending of the needle due to contact between the needle length and the walls of the slot, giving the needle the opportunity to bend only toward the opening of the slot. Apposing arms could meet at an angle to create unlikely buckling paths offset by this angle. 90 degrees has been found to be a particularly effective angle. Other anti-buckling mechanisms are possible and include, but are not limited to, telescoping cylinders along the needle's length, a collapsible sleeve or bellows that supports the needle at various points along its length, a stiff coiled spring that contacts the needle along its inner diameter, or a single sliding cylinder that contacts the needle at the mid-point of the needle's exposed length outside of the sealing means during insertion and withdrawal.
Various exemplary embodiments of the device are further depicted and described below.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts an embodiment comprising a pencil tip needle connected to a 3-way toggle valve which is in turn connected to a variable regulator connected to a compressed gas cylinder. A wine bottle that has been accessed by the device is also shown in the Figure. Note that the foil 742 covering the corked opening of the bottle is still intact and has not been removed but that small needle hole perforation at an insertion point 740 is shown.
FIG. 2 depicts a cross section of a preferred embodiment of the present invention. The embodiment consists of a cylinder of compressed gas, a fixed pressure regulator, a valve, a needle, and a linear drive mechanism. Details of this embodiment and its use are depicted in FIGS. 2A-E .
FIG. 2A is an exploded view of the three-way spool valve used in this embodiment.
FIG. 2B depicts the valve in its normal position which allows flow between the valve exit and the needle.
FIG. 2C depicts the valve in its activated position which allows flow between the needle and the regulator.
FIG. 2D depicts the linear drive mechanism attached to the needle with the linear drive mechanism at its upward most position.
FIG. 2E depicts the linear drive mechanism attached to the needle with the linear drive mechanism at its downward most position.
FIG. 3A depicts the embodiment positioned on the bottle with the needle positioned over the wine bottle cork and the linear drive mechanism at its upward most position.
FIG. 3B depicts the linear drive mechanism at its downward most position with the needle tip driven through the cork and into the interior of the bottle.
FIG. 3C depicts the system shown in 3 B with the bottle tilted on its side causing the needle tip to come in contact with the liquid contents of the bottle.
FIG. 3D depicts the system of 3 C with the valve activated causing gas at a pressure regulated by the fixed regulator to enter the bottle through the needle, increasing the pressure within the bottle.
FIG. 3E depicts the system of 3 D with the valve returned to its normal position, enabling the increased pressure within the bottle to drive wine through the needle and out of the valve exit.
FIG. 3F depicts the bottle returned to an upright position allowing excess gas from within the bottle to contact the needle tip and vent through the valve exit until the pressure equilibrates with atmospheric pressure.
FIG. 3G depicts the system shown in FIG. 3F with the needle withdrawn from the bottle and the linear drive mechanism at its upward most position.
FIG. 4 is a side view of an alternative embodiment further comprising an anti-buckling mechanism that resists buckling of the needle as it is advanced into the bottle. It further employs a trumpet valve, a linear drive mechanism comprising a linear drive shaft and gear, and a container attachment or bottle clamping mechanism.
FIG. 5A and FIG. 5B depict detail of a preferred embodiment of the anti-buckling mechanism. FIG. 5A shows a front view of a swing arm and indicates a swing arm slot which fits over a section of the needle length to resist buckling. FIG. 5B depicts two swing arms and their relationship to each of two swing arm axes and the needle.
DETAILED DESCRIPTION OF THE INVENTION
An embodiment of the present invention is shown in FIG. 1 . This system uses a pressurized source of gas 100 regulated by a variable regulator 600 . The cylinder 100 is secured to the pressure regulator 600 by a simple threaded connection. This embodiment employs a 3-way toggle valve 300 allowing both extract and vent positions described above. This system also uses a pencil-tip non-coring needle 200 with a needle outlet along the side of the needle length near the needle tip. The connection between the valve 300 either the regulator 600 or needle is shown to be rigid. Alternatively these connections could be flexible if desired.
Additional components of a preferred embodiment of the present invention may include:
a bottle attachment or clamping mechanism securing the needle to the bottle,
a linear needle drive system to facilitate insertion of the needle into the bottle along a linear path,
a needle guide that allows insertion of the needle through a particular region of the cork,
an anti-buckling means to minimize the risk of the needle buckling during insertion,
a cork retention means that acts to prevent cork expulsion during pressurization,
a bottle stand that facilitates holding and/or tilting of the bottle during the extraction and venting phases,
a pressure meter that allows the user to know the pressure within the bottle and/or the exit pressure of the gas source,
a needle protection means or lock preventing inadvertent injury of the user by the needle once it is withdrawn from the bottle.
Multiples of these components could be combined into single parts or components serving multiple functions. For example, the anti-budding means could also serve as a needle protection means, the cork retention means and the needle guide could be combined into a single unit secured to the bottle at the exterior of the cork, and this needle guide/cork retainer could further be a part of the bottle clamping means that may be further combined with the linear needle drive.
FIG. 2 depicts a cross section of a preferred embodiment of the present invention. The embodiment consists of a cylinder of gas 100 connected to a regulator 600 which is in turn connected to a valve 300 . This valve 300 is then secured to a needle 200 . The needle 200 and/or the valve 300 are secured to a linear drive mechanism 400 . The pressure within cylinder 100 is preferably considerably higher than the outlet pressure of the regulator 600 . Regulator 600 is shown without detail, but can be any of a variety of commercially available single or two stage pressure regulators capable of regulating gas pressures to a pre-set or variable outlet pressure. The connection of the various components is not depicted in detail, but can be achieved through either rigid (threaded, welded, taper lock etc.) means or flexible (tubing, o-ring seal, gasket seal) means. The length of such a connection can be varied depending upon the specifics of the desired application.
FIGS. 2A-C detail a preferred embodiment of a three-way, spool valve 300 that has been found particularly useful to control the flow of wine and gas. The valve 300 consists of a piston 310 and a valve body 305 . The piston 310 employs three o-rings—an upper 312 , middle 313 , and lower 314 —to control the flow of fluids and gasses through the valve cylinder 301 .
In FIG. 2B , the upper 312 and lower 314 o-rings are sealing against the inner walls of the valve cylinder 301 , allowing flow between the needle attachment site 303 and the wine exit 304 . In this position, flow between the gas entrance 302 and the other two ports is prevented by the lower o-ring 314 . This is the normal state of the valve with the return spring 311 holding the cylinder in this position. This is the “vent” position described above which, for convenience, will be referred to as B-C.
In FIG. 2C , the upper 312 and middle 313 o-rings are sealing against the inner walls of the valve cylinder 301 , allowing flow between the gas entrance 302 and the needle attachment site 303 . Flow between the wine exit 304 and the other two ports is prevented by o-ring 313 in this position. This is the “extract” position described above which, for convenience, will be referred to as A-B. The user achieves this valve position by pushing down on piston 310 compressing the return spring 311 . Once the user stops depressing the valve piston 310 , the return spring 311 causes the piston to return to position B-C depicted in FIG. 2B .
FIGS. 2D and 2E detail an embodiment of a linear drive mechanism 400 . In this embodiment, two cylindrical rods (front rod 410 and back rod 420 ) pass through two closely matching rod holes (front rod hole 460 and back rod hole 470 ). These two rods are securely attached to upper piece 430 which is also secured to needle 200 . The offset of the two rods creates a resistance to angulations of or side loads on needle 200 by providing a resistive moment. This insures that the needle 200 can travel into and out of a cork only along a line co-linear with the rods.
A flat has further been cut onto the front surface of front rod 410 . This flat acts in concert with rod stop 450 to restrict the upward travel of the needle 200 relative to the bottom piece 440 when stop surface 415 on front rod 410 engages rod stop 450 . This method could also be used to limit downward travel of the needle 200 relative to bottom piece 440 . FIG. 2D illustrates the needle 200 at full upward travel while FIG. 2E illustrates the needle 200 at full downward travel relative to bottom piece 440 .
During use, the needle guide 480 and its through hole 485 are positioned above the cork of a wine bottle and are secured to or part of bottom piece 440 . In this embodiment, the needle guide 480 could be used as a cork retainer if a bottle clamping mechanism is incorporated into bottom piece 440 . Such a bottle clamping mechanism has been left out of this embodiment to detail the other components of the system, but could readily be added. Various embodiments of such a clamping mechanism are described below in alternate embodiments.
FIGS. 3A-3G illustrate the use of the embodiment depicted in FIG. 2 and detailed in FIGS. 2A-E . In FIG. 3A , the bottom piece 440 has been placed on top of wine bottle 700 with the upper piece 430 at full upward travel. The valve is in its normal position B-C. The wine 710 and gas 720 within the bottle 700 are in their undisturbed state as bottled by the vintner. FIG. 3B depicts the needle outlet 220 beyond cork 730 and within bottle 700 with the upper piece 430 at full downward travel. This position is achieved by simply pushing downward on valve 300 or upper piece 430 . The valve 300 is still in its normal B-C position.
In FIG. 3C , the bottle has been tilted on its side, causing wine 710 to contact the needle outlet 220 . In FIG. 3D , the valve has been moved by the user into its A-B position, allowing pressurized gas 120 from within cylinder 100 to pass through the regulator 600 at its upper pressure setting, through gas entrance 302 , through needle attachment 303 , out of needle outlet 220 into wine 710 within the bottle 700 . This gas 120 increases the pressure within the bottle until it reaches equilibrium with the gas pressure determined by the regulator 600 . In FIG. 3E , the valve 300 has been allowed to return to its normal state B-C, opening a path between the needle outlet 220 and the wine exit 304 . The wine 710 is now driven by the elevated pressure of the gasses 720 and 120 within the bottle through the needle outlet 220 and out of valve 300 . This flow will continue until pressure within the bottle equilibrates with atmospheric pressure if the user wishes. However, excess pressure can be allowed to vent by simply standing the bottle upright, as depicted in FIG. 3F . Once the bottle is upright, the gasses 720 and 120 within the bottle are in contact with the needle outlet 220 and can vent from valve 300 with the valve in its normal position B-C. Once the pressure has reached a desired level, the needle can be withdrawn from the cork 730 by pulling upward on the upper piece 430 or valve 300 until the upper piece reaches its upward most travel. The bottom piece 440 and the rest of the system can then be removed from bottle 700 .
It has been found that corks accessed by such a system, particularly with a smooth walled exterior, pencil point or Huber point needle of 16 gauge or higher, seal effectively and prevent the ingress or egress of gases or fluids and can be stored in the same way as an un-accessed bottle for years without abnormal alteration of the wines flavor. Other needle profiles and gauges are also usable with the system.
In the above described embodiment, the needle guide through hole 485 is depicted over the center of the cork 730 . Alternatively, the through hole 485 could be offset from the center of cork 730 to decrease the potential that multiple uses of the system will allow the needle to pass through the same site in the cork.
An alternative embodiment is depicted in FIG. 4 . This embodiment employs an alternate linear drive system, a bottle clamping mechanism, a different configuration of 3-way spool or trumpet valve, and an anti-bucking mechanism.
FIG. 4 illustrates a side view of this exemplary embodiment in a multi-component, assembled fashion. On the upper left the figure is a cylinder of compressed gas 100 attached to a regulator 600 . Below the regulator 600 is a trumpet valve 300 . Below valve 300 are the needle 200 , anti-buckling assembly 800 , linear drive mechanism 400 , needle guide and cork retention means 480 , and bottle clamp 500 . The regulator 600 of this embodiment is a variable regulator. It has a simple threaded attachment to the compressed gas cylinder 100 . The trumpet valve 300 is attached to the regulator 600 through a simple Luer connector. The valve 300 is actuated by depressing the piston 310 shown in FIG. 4 . This valve 300 is a simple trumpet or spool valve. With the piston 310 in the un-depressed position, the valve 300 is opened such that fluid can flow from the needle 200 and out of the valve exit 304 (position B-C or vent position). When the piston 310 is depressed, gas can flow from the regulator 600 through the needle 200 (position A-B or extract position).
The linear drive mechanism 400 of this embodiment consists of a steel shaft or front rod 410 and gear 490 toward the bottom of the figure. The front rod 410 passes through a closely matching hole 460 in lower piece 440 . Gear 490 is a rack and pinion system wherein when the circular gear turns, the gear teeth mesh causing the needle to be driven downward into the cork or upward out of the cork depending upon the rotational direction of the circular gear.
The clamp mechanism 500 and the anti-buckling mechanism 800 . The anti-buckling system 800 comprises two steel rods 810 and seven swing arms 820 pivoting about rods 810 . Each swing arm has a proximal end with a through hole for the steel rod 810 and a small slot cut at their opposite end which fits over the needle 200 along its length. Each steel rod 810 acts as an axis about which the arms 820 swing. Each arm's slot opposes the neighboring arm's slot. These opposite facing slots act to entrap the needle 200 and prevent it from buckling along 270° of the circumference of the needle at any one arm 820 . Because the slots oppose each other, it is highly unlikely that the needle 200 can buckle along a length greater than the length of any individual slot. Even along one slot, the needle 200 can only buckle in the direction that the slot is open, eliminating the risk of buckling along 270° of the needle circumference. These axes 810 are spaced from each other such that alternate swing arms meet at an angle. A particularly preferred angle of intersection of the swing arms is 90°, but a range between 45 and 135 is also acceptable. By alternating the swing arms 820 in this fashion the needle slot of each swing arm 820 has an opening that is offset by roughly 90 degrees from its neighboring swing arm 820 . This radically reduces the risk of needle 200 buckling as the ability to buckle in any single plane is eliminated. The needle 200 can only buckle along any one length supported by any one swing arm 820 in the direction that the needle slot is open. As the tendency to buckle is strongly dependent upon the free length available to buckle, the risk of buckling is exponentially lower than an unprotected needle. A particularly useful swing arm slot length has been found to be less than 0.5 inches for needles within the preferred gauge range of 17 to 20 with a particularly useful length being 0.25 inches. The slot width and depth preferably closely matches the diameter of the needle used.
In this embodiment, the needle 200 moves through the anti-buckling mechanism 800 as it is advanced into the bottle's cork. As the needle 200 moves, a small taper on the needle's hub 240 pushes the swing arms 820 outward allowing the needle 200 to pass. There is also an elastic band 830 which acts to return the swing arms 820 to the needle 200 after they have been moved aside by the needle hub 240 or the hub extenders 250 . This elastic band 830 essentially acts as a return spring. The extended needle hubs 250 , depicted here as white cones, guide the swing arms 820 around the needle hub 240 and its larger base at the upper piece 430 without catching any edge due to the force of the elastic band 830 . Alternative embodiments of the anti-buckling mechanism might include a series of telescoping cylinders, a single sliding cylinder, a collapsible bellows that makes contact with the needle at the narrowest diameter of the bellows, or a stiff coiled spring making contact with the needle diameter at the spring's inner surface.
The bottle clamping mechanism 500 consists of two simple clamping arms 510 and a locking mechanism comprised of a screw 520 and nut 530 to secure the arms 510 at a fixed position. Each clamp arm swings about an axis 540 . This clamping mechanism 500 also ensures that the cork is centered beneath the needle 200 and that the needle guide and cork retaining system rests atop the bottle cork or sealing means.
A combined needle guide and cork retaining system 480 is shown as a simple disk with a small hole equal to or greater in diameter than the needle diameter that passes through its center. When the clamping mechanism 500 is secured to the bottle 700 , this component 480 preferably rests against the upper surface of the cork as depicted in FIG. 4E . As this component 480 is fixed in position relative to the clamping arms 510 , it acts to secure the cork in position during pressurization of the bottle.
FIGS. 5A and 5B depict further detail of the anti-buckling mechanism 800 shown in FIG. 4 . FIG. 5A shows a front view of a swing arm 820 with a slot 840 running along one end. FIG. 5B shows how this slot 840 fits over a length of the needle 200 . In this figure, the swing arm 820 on the left constrains the needle 200 within slot 840 . The swing arm 820 on right has swung away from the needle 200 about axis 810 . When both swing aims 820 are engaging the needle 200 , the needle is constrained such that the risk of needle buckling is reduced. By using multiple, alternating swing arms, the needle can be protected against buckling during advancement into and through a cork.
Alternative embodiments of the device might be integral to a bottle stand. In this embodiment there may be no need for a bottle clamp. The bottle could simply be slid along the bottle stand into the needle and anti-buckling mechanism. In this fashion the bottle would be on its side during insertion of the needle better guaranteeing contact between the needle tip and the fluid within the bottle. After use, the stand could be pivoted upward to allow the gas to vent.
In still further embodiments there might be more than one needle. Two needles would allow insertion of gas and extraction of fluid at the same time. One needle would be dedicated to allowing ingress of gas and would be connected to the pressurized gas source, while the other needle would allow the extraction of wine or fluid from within the bottle. In such an embodiment there may be no need for the trumpet valve described above, but simply for an on-off switch for the pressurized gas source. This could also be achieved with a two lumen needle wherein gas would travel down one lumen and wine would travel up the other. Each lumen could have a separate entrance and exit. These exits could be spaced from each other within the bottle to prevent circulation of gas.
Still further embodiments may employ a dilator instead of a needle. Such a dilator could be passed between the cork and the bottle wall into the wine, leaving no damage to the cork itself. Such a dilator could be cannulated and arcuately shaped to best match the outer diameter of the cork.
The bottle clamping mechanism employed in the above described embodiments comprises two clamping handles pivoting around axes secured to the bottom piece. These handles are lockable to the wine bottle through the use of a clamp bolt/screw and nut. Many alternative embodiments of a bottle clamp are possible. Alternatives to the bolt and nut lock include, but are not limited to a ratcheting lock, or a simple strap that can be slid down or wrapped around the swing arms, locks located at the axes of the swing arms, etc. The clamp handles could be replaced by a cylinder that fits over the wine bottle neck. Such a cylinder could have a split wall with a conically tapered outer surface. An outer ring could be slid along the conical surface to cause the inner diameter of the cylinder to decrease, clamping the cylinder about the bottle neck. A locking feature between the ring and the cylinder could be used to lock the cylinder to the bottle. This cylinder could be incorporated into the bottom piece.
While this invention has been particularly shown and described with references to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the scope of the invention encompassed by the appended claims. | Devices and methods are disclosed for extracting fluids from within a container sealed by a cork or septum without removal of the cork or septum or the contamination of the fluid within the container by reactive gases or liquids. Embodiments of the device can include a needle connected to a valve which is in turn connected to a source of pressurized gas for displacing the fluid. Further embodiments of the device can comprise additional components that act to force the needle to be inserted through the cork or septum along a linear path, to aid in preventing buckling of the needle, to clamp the device to the container, to prevent expulsion of the cork or septum from the container, and to guide the needle through a specified region of the cork or septum. Various valves, pressure regulators, pressure ranges, needle geometries, gas selections are also presented. This device is particularly suited for the dispensing and preservation of wine. | 1 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of Applicant's United States application, Ser. No. 375,496, filed July 2, 1973, and now abandoned, entitled "Solvent-Distributed, Powdered Rubber In Beater Saturated Sheets".
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates generally to beater saturation processes wherein a particular powdered rubber is deposited on fibers along with certain synthetic binders.
2. Description of the Prior Art
U.S. Pat. No. 1,926,028-Boughton describes a process of mixing rubber particles and fibers in a water slurry and forming a sheet from the mixture. After drying, the fiber-rubber sheet is treated with a solvent for the rubber in order that the rubber will be softened by the solvent and distributed among the fibers in order to adhere better to those fibers.
U.S. Pat. No. 1,787,952-Richter et al teaches the formation of a leather substitute by impregnating bibulous webs of interfelted cellulose fibers, such as those composed of wood pulp, with an aqueous rubber dispersion and then passing the web through a bath of rubber solvent such as benzol, whereupon a swelling of the rubber takes place.
SUMMARY OF THE INVENTION
The invention comprises adding to a slurry of fibers in water, a powdered chlorinated natural rubber and agitating the mixture to maintain the powdered rubber in dispersed form. The powdered chlorinated natural rubber is easily swellable by a rubber solvent to be used in a subsequent step. A synthetic latex binder is next added and precipitated on said fibers. The binder in the latex is either insoluble or only difficulty swellable by the solvent to be used in the subsequent step. The powdered rubber is swept with the binder to the fibers. The binder holds the powdered rubber on the fibers. A sheet is formed from the rubber-coated fibers. After removal of the water, the sheet is treated with a solvent which strongly swells the chlorinated natural rubber but which does not so swell the binder. Only by use of such a non-swelling binder will the fibers be held together in sheet form while the solvent is strongly swelling and smearing the chlorinated natural rubber. This solvent treatment serves to smear the chlorinated natural rubber throughout the sheet. Solvent is then removed. The resulting sheet is sufficiently strong, water resistant, and stable that it may be formed into fill for cooling towers.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a flow diagram of the process of the present invention;
FIG. 2 is a simplified three-dimensional representation of a sheet made by the present invention; and
FIG. 3 represents an enlarged section of FIG. 2 showing in general form details of the fibrous structure of the product.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The fibers to be used in the process of the present invention may be any of those fibers customarily used in the beater saturation processes, except snythetic fibers. Examples of usable fibers are asbestos, kraft, sulphite, cotton linters, and animal fibers such as wool. These fibers will be handled in the usual manner. They will be slurried in water to the usual consistency of beater saturation processes, normally in the range of 0.5% -3% by weight fibers in the slurry. Cellulosic fibers, asbestos fibers, and certain other fibers will normally be subjected to beating or other mechanical refining treatment in accordance with normal processes in order that the Canadian 3-gram freeness of the slurry will be in the range of about 100-600 cc's. Although beating will normally be the way the fibers are pretreated, other refining apparatus may be used such as disc refiners, Jordan engines, and the like.
After forming the slurry in the desired consistency and after any mechanical refining, the slurry will be subjected to any of the normal processes customarily used in the beater saturation of such fibers. The so-called alum-ammonia process may be used as set forth in U.S. Pat. No. 2,375,244-Pretzel. For asbestos fibers, the citric acid process may be used as set forth in U.S. Pat. No. 2,759,813-Feigley.
The next step will be the addition to the refined and pretreated slurry the chlorinated natural rubber in a fine or powdered form. The powdered rubber will simply be added by mixing the dry powder with the fibrous slurry, with sufficient agitation to maintain the powdered rubber in suspension with the fibers in the slurry. At this point in the process, the powdered rubber is present simply as a mechanically dispersed powder in the slurry.
The chlorinated natural rubber is an item of commerce available in powdered form in a variety of viscosities as determined in a 20% concentration in toluene. The specific volume of the material will generally average around 70 cubic inches per pound. It is soluble in toluene, xylene, aromatic hydrocarbon, esters, ketones, and some other commercially used solvents. It is used in the present process in the form of the white granular powder just as it is made and sold. Particle size is as follows: at least 95% passing a No. 20 sieve, 40% to 90% passing a No. 180sieve, and 40% passing a No. 325 sieve, the percentage being by weight of the original mass of particles and the sieves being of the Standard Screen Series, U.S. Bureau of Standards, 1919.
The powdered rubber is made by chlorinating a natural rubber to incorporate into the rubber an amount of chlorine of about 50%-70% by weight. Such rubber has particular utility for the use intended by the product of the present invention since it is readily solvent-soluble in certain commercial solvents, is highly fire resistant and, when distributed throughout the final sheet, lends itself to the formation of shaped cooling tower fill materials in corrugated and saddle form. The amount of the chlorinated natural rubber in powdered form to be added to the slurry will be about 25% by weight of rubber based on the dry weight of the fibers.
The next step in the process will be the addition of a synthetic latex to the slurry containing the dispersed powdered rubber. The synthetic latices to be used in the present process may be any of the latices customarily used in beater saturation processes, with the proviso that they must be substantially insoluble in the solvent to be subsequently used to strongly swell and smear the chlorinated natural rubber. The synthetic rubber latices may comprise copolymers of butadiene and styrene usually containing 50%-70% by weight butadiene. The NBR rubbers, copolymers of butadiene and acrylonitrile may also be used. Polychloroprenes, which are polymers of 2-chlorobutadiene-1,3, may be used and are preferred because they maintain the needed fire resistance in the preferred product. Many of these basic copolymeric latices are modified by the addition of a third copolymerizable ingredient to impart special properties to the synthetic rubber binder. The chosen synthetic rubber latex is simply added with agitation to the pretreated fibrous slurry containing the dispersed chlorinated natural rubber. Since the fibers have been pretreated for beater saturation, agitation will usually suffice to precipitate the binder onto the fibers. As the synthetic rubber particles from the latex precipitate onto the fibers, the particles carry with them the particles of the chlorinated natural rubber. The sticky nature of the synthetic latex binder aids in holding the powdered chlorinated natural rubber onto the fibers. If necessary or desirable, additional precipitating agents may be added to the slurry after the addition of the synthetic rubber latex in order to complete the precipitation.
The amount of synthetic rubber latex binder to be added will generally be in the range of 3%-50% by weight rubber binder based on the dry weight of the fibers. For the primary purpose of the present invention of making fill for cooling towers, it is preferred to add 10%-20% by weight of the synthetic rubber latex binder.
Once the binder has deposited on the fibers carrying with it the chlorinated natural rubber particles, a suitable sheet may be formed from the resulting slurry. The sheet may be formed in any of the conventional methods in the papermaking art. A sheet mold may be used, as may a fourdrinier wire or a cylinder machine. In the making of cooling tower fill, the sheet will preferably have a thickness in the range of about 0.012-0.080 inch. The water will be drained from the web, and the web will be dried in the usual manner. Drying will be carried out normally; moisture will be present in the sheet in the amount of about 2%-5% by weight. If the sheet at this stage is stored, it will normally reach equilibrium as to moisture content depending on ambient conditions. In this condition, the sheet will normally be open, that is, liquids may readily penetrate into the interior of the sheet. To this end, calendering or other pressing of the wet web or the dry sheet is normally to be avoided.
The next step in the present process is to immerse or otherwise treat the dry sheet with a solvent for the chlorinated natural rubber, the solvent not being capable of severely swelling the synthetic rubber binder in order that the sheet be able to hold together under the action of the solvent on the sheet. Where neoprene and the NBR rubbers are used as binder, toluene will be the solvent of choice. However, other solvents such as benzene, chlorinated aromatic solvents, chlorinated aliphatic solvents, and other aliphatic and aromatic solvents may be used provided they leave the synthetic rubber binder substantially nondissolved or only slightly swollen in order to preserve sheet integrity during the solvent treatment step. The dried sheet is conveniently treated with a solvent by passing the dried sheet on rollers into or through a bath of the solvent, followed by removal of the solvent-soaked sheet from the bath. As the sheet emerges from the bath, it may pass between rollers to press excess solvent from the sheet. It is to withstand such handling that the solvent must be one in which the chlorinated natural rubber is easily swellable and the rubber binder is difficultly swellable. As a general guide, an easily swellable rubber is one whose volume increases at least about 40% under the action of the solvent, and often the volume increase will be 100% or more. A difficultly swellable rubber is one whose volume increases no more than a maximum of about 20%.
The sheet must be in the solvent bath sufficiently long for the solvent to smear the chlorinated natural rubber throughout the sheet and to fuse the individual chlorinated natural rubber particles in the sheet into a stiffer coherent mass. The sheet should not be immersed in the bath sufficiently long that the chlorinated natural rubber is dissolved away completely. There will always be a certain small amount of loss of the chlorinated natural rubber in the solvent pressed from the sheet, and to minimize such loss, it is preferred that the sheet be immersed in the bath for a period of time sufficient for the solvent to spread around and smear the chlorinated natural rubber but insufficient to carry a significant amount of the natural rubber away. Penetration of the solvent into the sheet is immediate due to the open nature of the sheet, and solvation starts immediately. The time of immersion of the sheet in the solvent will depend to some extent on the thickness of the sheet, on the exact solvent used, and on the amount of chlorinated natural rubber on the fibers. For sheets having the thickness described earlier, it has been found that a period of time of immersion of 2 to 60 seconds will suffice to smear out the chlorinated natural rubber without undue loss. The goal of the immersion step is simply to smear and fuse the chlorinated natural rubber throughout the fibers in the sheet without significantly disturbing the normal binding properties of the synthetic rubber binder. Room temperature conditions will normally be used in the immersion step, although slightly elevated temperatures may reduce the time of immersion if such is desired.
After passing through any squeeze rolls on emergence from the bath, the sheet is dried to remove the solvent. This may be carried out in any convenient manner, due care being given to any flammability and inhalation hazards of the volatile solvent. Elevated temperatures will normally be used in solvent removal. A convenient way to remove the solvent will be in a forced hot air oven maintained at about 195° F. for a period of time of about 2 minutes. The synthetic binder particles maintain their function as a binder for the fibers substantially unchanged throughout the entire process.
The resulting sheet will be stiff and boardlike, and in the preferred embodiments of the present invention, extremely fire resistant. The sheet lends itself to molding under a variety of conditions into various configurations, particularly into corrugated forms and other shapes used as fill for towers in order to greatly increase the area of contact between a liquid and a gas such as air. Such molding processes are known and are normally carried out at a temperature in the range of 400°-475° F. The products made by the process of the present invention are advantageous in their adaptability to be formed into various shapes, their fire resistance, their resistance to deterioration under the constant flow of water and the impingement of high velocity air, and their ability to retain their shape.
The following examples illustrate several embodiments of the invention. All parts are by weight unless otherwise stated.
EXAMPLE 1
The following two formulations were prepared:
______________________________________ PartsIngredients I II______________________________________Asbestos 27.2 27.2Antioxidant (condensation product of sym- 0.09 0.09metrical dibetanaphthol-para-phenylenediamine)Pigment (carbon black) 0.403 0.403Water 1,420 1,420Chlorinated natural rubber (Parlon S-10) 6.8 6.8Neoprene LD-450 (chloroprene plus 7.180 --acrylonitrile copolymer)Geon 660X4 (vinylidene chloride-acrylic -- 7.2copolymer)______________________________________
The asbestos was added to the water with agitation and the powdered chlorinated natural rubber was next added. No special pretreatment steps were required. The synthetic rubber latex binder (Neoprene LD-450) was next added; the amount is 11% by weight based on the weight of the fibers. The binder particles precipitated on the asbestos fibers over a period of 1 to 2 minutes, carrying with them all of the dispersed powdered chlorinated rubber in the slurry.
When the water cleared showing that precipitation was complete, the rubber-coated fibers in water were poured into a small sheet mold and drained. The web was then gently pressed to remove additional water and was dried in an oven.
The dried sheet was dipped in toluene for 10 seconds. On removal from the toluene bath, the sheet was placed in a forced air circulating oven for several minutes until dry.
The resulting sheet was stiff, boardlike, and could readily be formed into a corrugated cooling water tower fill having good fire resistance and performing satisfactorily under tower conditions.
EXAMPLE 2
A hand sheet was made and dried in the usual manner utilizing the following ingredients:
______________________________________Ingredients Parts______________________________________Asbestos 27.2Water 1420Chlorinated natural rubber 6.8(Parlon S-10)Acrylic latex (Hycar 2671) 5.65______________________________________
After drying, five strips measuring about 1 inch by 5 inches were cut from the dried sheet. Each strip was separately immersed in five different solvents. The solvents used were methyl ethyl ketone, acetone, benzene, toluol, and xylol. The five strips exhibited differing degrees of stiffness, the stiffer strips indicating more complete solvent action and smearing of the chlorinated natural rubber as it was distributed throughout the sheet. Based on simple handling of the sheets, in decreasing order of stiffness, the solvent action was best in toluene, then xylene, then methyl ethyl ketone, then acetone, then benzene. All strips were noticeably stiffened, however, thus demonstrating the smearing of the chlorinated natural rubber. | A beater saturation process wherein a fine powdered chlorinated natural rubber is added to papermaking fibers suspended in water. A synthetic binder in latex form is precipitated onto the fibers carrying with it the fine powdered rubber particles. This slurry is formed into a dry sheet and treated with a solvent which partially dissolves or substantially swells the chlorinated natural rubber but which does not so dissolve the synthetic latex binder. The chlorinated natural rubber is thus further distributed and smeared throughout the sheet by the solvent. The solvent is removed and a stiff strong sheet results. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This disclosure is generally related to electrical power systems, and more particularly to power module architectures suitable for rectifying, inverting and/or converting electrical power between power sources and loads.
2. Description of the Related Art
Power modules are typically self-contained units that transform and/or condition power from one or more power sources for supplying power to one or more loads. Power modules commonly referred to as “inverters” transform direct current (DC) to alternating current (AC), for use in supplying power to an AC load. Power modules commonly referred to as “rectifiers” transform AC to DC. Power modules commonly referred to as “DC/DC converters” step up or step down a DC voltage. An appropriately configured and operated power module may perform any one or more of these functions. The term “converter” is commonly applied generically to all power modules whether inverters, rectifiers and/or DC/DC converters.
Current flowing through various inductive paths within the module transiently stores energy which increases energy loss, reduces efficiency, and generates heat. When the flow of current changes, as in such a high frequency switching environment, large voltage overshoots often result, further decreasing efficiency. These large voltage overshoots typically reduce the power rating of the power module or require the use of circuitry devices with higher ratings than would otherwise be required, thus significantly increasing the cost of the power module.
To minimize the negative effects of current gradients, noise and voltage overshoots associated with the switching process of the module, large capacitors are generally placed in a parallel arrangement between the positive and negative DC connections or from each DC connection to a ground or chassis. These large capacitors are commonly referred to as “X” or “Y” capacitors. Relatively large external capacitors of about around 100 micro Farads are needed. By “external” it is meant that the element referred to is located outside of a power module. High frequency noise, and voltage overshoots that are initiated in the module by the switching process travel away from the source of the noise and voltage overshoots. A low impedance network may be used to provide a return path for the high frequency energy associated with noise and voltage overshoots. The further the energy travels, the more difficult it is to provide a low impedance network to return the energy. Therefore, capacitors attached between the positive and negative DC connections or from the DC connections to ground must be relatively large to minimize the impact of noise, and voltage overshoots. In addition, these external capacitors typically cause stray inductance, which renders the capacitor ineffective at frequencies higher than about 10 kHz.
These and other problems are avoided and numerous advantages are provided by the method and device described herein.
SUMMARY OF THE INVENTION
The disclosure is directed to an architecture for a power module that limits or dampens voltage overshoot, permitting the power module to handle larger loads, and/or allowing the use of circuitry with lower ratings than would otherwise be required and thus reducing cost.
In one aspect, a power module comprises: a lead frame forming at least a portion of a module housing; a first set of terminals accessible from an exterior of the lead frame; a second set of terminals accessible from the exterior of the lead frame; a positive DC bus received at least partially in the module housing; a negative DC bus received at least partially in the module housing; a number of high side switches received in the module housing and selectively electrically coupling a first one of the first set of terminals to respective ones of the second set of terminals; a number of low side switches received in the module housing and selectively electrically coupling a second one of the first set of terminals to respective ones of the second set of terminals; and at least one capacitor electrically coupled between the positive DC bus and the negative DC bus.
In another aspect, a power system comprises: a lead frame; a plurality of electrical terminals carried by the lead frame; a first bus bar coupled to the lead frame; a second bus bar coupled to the lead frame; a high side substrate coupled to the lead frame, the high side substrate comprising a number of electrically conductive high side collector areas and a number of electrically conductive high side emitter areas, the high side emitter areas electrically isolated from the high side collector areas; a low side substrate coupled to the lead frame, the low side substrate comprising a number of electrically conductive low side collector areas and a number of electrically conductive low side emitter areas, the low side emitter areas electrically isolated from the low side collector areas; a number of high side switches physically coupled to the high side substrate; a number of low side switches physically coupled to the low side substrate; and a number of capacitors, each of the capacitors electrically coupled between one of the high side collector areas and one of the low side emitter areas.
In a further aspect, method of forming a power module comprises: providing a lead frame; coupling a substrate comprising a high side and a low side to the lead frame, the high side comprising a number of high side collector areas and a number of high side emitter areas electrically isolated from the high side collector areas, the low side comprising a number of low side collector areas and a number of low side emitter areas electrically isolated from the high side collector areas; mounting a number of high side switches to the high side of the substrate; mounting a number of low side switches to the low side of the substrate; surface mounting at least one capacitor to a low side emitter area; and surface mounting the at least one capacitor to a high side collector area.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings, identical reference numbers identify similar elements or acts. The sizes and relative positions of elements in the drawings are not necessarily drawn to scale. For example, the shapes of various elements and angles are not drawn to scale, and some of these elements are arbitrarily enlarged and positioned to improve drawing legibility. Further, the particular shapes of the elements as drawn, are not intended to convey any information regarding the actual shape of the particular elements, and have been solely selected for ease of recognition in the drawings.
FIG. 1 is an isometric view of a power module comprising a housing, integrated cold plate, DC bus terminals, AC phase terminals, and power semiconductor devices.
FIG. 2A is an isometric view of the power module of FIG. 1 with a cover removed and some portions broken or removed to show the DC bus, the AC bus, and the power semiconductor devices carried by various regions on a substrate.
FIG. 2B is a top plan view of the power module of FIG. 2A showing a representative sampling of wire bonds electrically connecting various power semiconductor components, buses, and layers in the substrate as an inverter.
FIG. 3 is a schematic cross sectional view of one embodiment of the DC bus comprising a pair of L-shaped vertical DC bus bars spaced by an electrical insulation.
FIG. 4 is a schematic cross sectional view of one embodiment of the DC bus comprising a pair of generally planar DC bus bars spaced by an electrical insulation.
FIG. 5A is a partial isometric view of a portion of a low side of the power converter illustrating the surface mounting of snubber capacitors to a low side emitter area of the substrate.
FIG. 5B is an isometric view of a portion of a high side of the substrate illustrating the surface mounting of the snubber capacitors of FIG. 5B to high side collector area of the substrate.
FIG. 6 is an electrical schematic of the switches, freewheeling diodes, and snubber capacitors according to an illustrated embodiment.
DETAILED DESCRIPTION OF THE INVENTION
In the following description, certain specific details are set forth in order to provide a thorough understanding of various embodiments of the invention. However, one skilled in the art will understand that the invention may be practiced without these details. In other instances, well-known structures associated with power modules, power semiconductors and controllers have not been shown or described in detail to avoid unnecessarily obscuring descriptions of the embodiments of the invention.
Unless the context requires otherwise, throughout the specification and claims which follow, the word “comprise” and variations thereof, such as, “comprises” and “comprising” are to be construed in an open, inclusive sense, that is as “including, but not limited to.”
FIGS. 1 , 2 A, and 2 B show a base power module 10 , generally comprising: a lead frame or housing 12 , an integrated cold plate 14 attached to the housing 12 via bushings 15 , a DC bus 16 , an AC bus 18 ; circuitry 20 electrically coupled between the DC bus 16 and AC bus 18 , forming a high side 20 a and a low side 20 b of the power module 10 . The base power module 10 may further include one or more gate drivers 22 for driving some of the power semiconductors 20 .
Two sets of DC bus terminals 24 , 26 extend out of the housing 12 . In some applications one set of DC bus terminals 26 is electrically coupled to a positive voltage or high side of a power source or load and the other set of DC bus terminals is 24 is electrically coupled to a negative voltage or low side of the power source or load. In other applications, the DC bus terminals 24 , 26 are electrically coupled to respective DC bus terminals 24 , 26 on another power module. A set of AC phase terminals comprises three pairs of AC bus phase terminals 28 a , 28 b , 30 a , 30 b , 32 a , 32 b , extending out of the housing 12 . In some applications, one pair of AC phase terminals coupled to a respective phase (A, B, C) of a three phase power source or load. In other applications, some of the AC phase terminals are interconnected across or between the pairs, and coupled to power sources or loads.
FIG. 3 shows a schematic cross-sectional view of the power module 10 taken along section line 3 — 3 of FIG. 2 A. FIG. 3 is not an exact cross-sectional view, but has been modified to more accurately represent the electrical connections which would otherwise not be clearly represented in the FIG. 3 .
The integrated cold plate 14 comprises a metal base plate 39 , a direct copper bonded (DCB) substrate 40 which is attached to the metal base plate by a solder layer 41 . A cooling header 42 including a number of cooling structures such as fins 42 a , one or more fluid channels 42 b , a fluid inlet 42 c and a fluid outlet 42 d for providing fluid connection flow to and from the fluid channels 42 b , respectively.
The DCB substrate 40 typically comprise a first copper layer 40 a , a ceramic layer 40 b and a second copper layer 40 c which are fused together. The second copper layer 40 c may be etched or otherwise processed to form electrically isolated patterns or structures, as is commonly known in the art. For example, the second copper layer 40 c may be etched to form regions of emitter plating 43 a (i.e., emitter plating areas or emitter areas) and collector plating 44 a (i.e., collector plating areas or collector areas) on a low side of the power module 10 (i.e., side connected to DC bus bar 34 ). Also for example, the second copper layer 40 c may be etched to form regions of emitter plating 43 b and collector plating 44 b on the high side of the power module 10 (i.e., the side connected to DC bus bar 36 ).
A conductive strip 45 or wire bonds may extend between the collector plating 44 a of the low side and the emitter plating 43 b of the high side, passing through respective passages 46 formed under the DC bus bars 34 , 36 . As illustrated, the conductive strip 45 has be exaggerated in length on the low side of the power module 10 to better illustrate the electrical connection with the collector plating 44 a.
Power semiconductor devices 20 are attached to the various structures formed in the second copper layer 40 c via a solder 47 . The power semiconductor devices 20 may include one or more switches for example, transistors 48 such as integrated bipolar gate transistors (IGBTs) or metal oxide semiconductor field effect transistors (MOSFETS). The power semiconductor devices 20 may also include one or more diodes 50 . The power semiconductor devices 20 may have one or more terminals directly electrically coupled by the solder 47 to the structure on which the specific circuit element is attached. For example, the collectors of IGBTs 48 may be electrically coupled directly to the collector plating 44 a , 44 b by solder 47 . Similarly, the cathodes of diodes 50 may be electrically coupled directly to the collector plating 44 a , 44 b by solder 47 .
The DC bus 16 comprises a pair of L-shaped or vertical DC bus bars 34 a , 36 a . The upper legs of the L-shaped DC bus bars 34 a , 36 a are parallel and spaced from one another by the bus bar insulation 38 . The lower legs of the L-shaped DC bus bars 34 , 36 are parallel with respect to the substrate 40 to permit wire bonding to appropriate portions of the substrate. For example, the negative DC bus bar 34 a may be wire bonded to the emitter plating 43 a of the low side, while the positive DC bus bar 36 a may be wire bonded to the collector plating 44 b of the high side. The emitters of the IGBTs 48 and anodes of the diodes 50 may be wire bonded to the respective emitter plating 43 a , 43 b . Wire bonding in combination with the rigid structure of the DC bus 16 and housing 12 may also eliminate the need for a hard potting compound typically used to provide rigidity to protect solder interfaces. For low cost, the copper layers 40 a and 40 c may be nickel finished or aluminum clad, although gold or palladium may be employed at the risk of incurring higher manufacturing costs.
FIG. 4 shows another embodiment of the DC bus 16 for use in the power module 10 , the DC bus 16 comprising a pair of generally planar DC bus bars 34 b , 36 b parallel and spaced from one another by a bus bar insulation 38 . The DC bus bars 34 b , 36 b are horizontal with respect to a substrate 40 (FIGS. 1 and 2 ), with exposed portions to permit wire bonding to the various portions of the substrate 40 .
Because the DC bus bars 34 , 36 are parallel, counter flow of current is permitted, thereby canceling the magnetic fields and their associated inductances. In addition the parallel DC bus bars 34 , 36 and bus bar insulation 38 construct a distributed capacitance. As will be understood by one of ordinary skill in the art, capacitance dampens voltage overshoots that are caused by the switching process. Thus, the DC bus bars 34 , 36 of the embodiments of FIGS. 3 and 4 create a magnetic field cancellation as a result of the counter flow of current, and capacitance dampening as a result of also establishing a functional capacitance between them and the bus bar insulation 38 .
As best illustrated in FIGS. 5A , 5 B and 6 , the circuitry 20 includes a number of snubber capacitors 53 that are electrically coupled between the DC bus bars 34 , 36 to clamp voltage overshoot. For example, some of the snubber capacitors 53 are electrically coupled directly (i.e., surface mounted) to the emitter plating 43 a on the low side 20 b of the power module 10 and are electrically coupled directly (i.e., surface mounted) to the collector plating 44 b on the high side 20 a of the power module 10 . While the Figures show two snubber capacitors for each switching pair combination, the power module 10 may include fewer or a greater number of snubber capacitors as suits the particular application. Significant savings may be realized by effective clamping of voltage overshoot. For example, if switching is maintained below approximately 900V, a transformer may be eliminated. The snubber capacitors 53 can be soldered in the same operation as the soldering of the substrate 40 to the cold plate 14 , or the soldering of other elements of the circuitry 20 to the substrate 40 , simplifying manufacturing and reducing costs.
As best illustrated in FIGS. 2A and 2B , the circuitry 20 also includes a number of decoupling capacitors 55 which are electrically coupled between the DC bus bars 34 or 36 and ground to reduce EMI. In contrast to prior designs, the decoupling capacitors 55 are located on the substrate 40 inside the housing 12 . For example, some of the decoupling capacitors 55 are electrically coupled directly to the emitter plating 43 a on the low side 20 b of the power module 10 and some of the decoupling capacitors 55 are electrically coupled directly to the collector plating 44 b on the high side 20 a of the power module 10 . The decoupling capacitors 55 can be soldered in the same operation as the soldering of IGBTs 48 and 50 to the substrate 40 .
As best illustrated in FIGS. 1 and 2A , the DC bus bars 34 , 36 each include three terminals 24 , 26 , spaced along the longitudinal axis, to make electrical connections, for example, to a DC power source. Without being restricted to theory, Applicants believe that the spacing of the terminals 24 , 26 along the DC bus bars 34 , 36 provides lower inductance paths within the DC bus bars 34 , 36 and to the external DC voltage storage bank.
In contrast to typical power modules, the DC bus bars 34 , 36 are internal to the housing 12 . This approach results in better utilization of the bus voltage, reducing inductance and consequently permitting higher bus voltages while maintaining the same margin between the bus voltage and the voltage rating of the various devices. The lower inductance reduces voltage overshoot, and problems associated with voltage overshoot such as device breakdown. The increase in bus voltage permits lower currents, hence the use of less costly devices. The bus bar insulation 38 between the DC bus bars 34 , 36 may be integrally molded as part of the housing 12 , to reduce cost and increase structural rigidity. The DC bus bars 34 , 36 may be integrally molded in the housing 12 , or alternatively, the DC bus bars 34 , 36 and bus bar insulation 38 may be integrally formed as a single unit and attached to the housing 12 after molding, for example, via post assembly.
The power semiconductors 20 are directly mounted on the substrate 40 which is directly attached to the cold plate 14 via solder layer 41 , the resulting structure serving as a base plate. The use of a cold plate 14 as the base plate, and the direct mounting of the power semiconductors 20 thereto, enhances the cooling for the power semiconductors 20 over other designs, producing a number of benefits such as prolonging the life of capacitors 55 .
The power semiconductors 20 are operable to transform and/or condition electrical power. As discussed above, the power semiconductors 20 may include switches 48 and/or diodes 50 . The power semiconductors 20 may also include other electrical and electronic components, for example, capacitors 55 and inductors, either discrete or formed by the physical layout. The power module 10 and power semiconductors 20 may be configured and operated as an inverter (DC→AC), rectifier (AC→DC), and/or converter (DC→DC; AC→AC). For example, the power module 10 and/or power semiconductors 20 may be configured as full three phase bridges, half bridges, and/or H-bridges, as suits the particular application.
In at least one described embodiment, the power module 10 comprises three half bridges combined into a single three-phase switching module, or single half bridge modules that may be linked together to form a three phase inverter. As would be understood by one of ordinary skill in the art, the same DC to AC conversion may be accomplished with using any number of half bridges, which correspond to a phase, and each switching pair may contain any number of switching devices. For simplicity and clarity, many of the examples herein use a common three phase/three switching pair configuration, although this should not be considered limiting.
In at least one described embodiment, current flows from the power source through the positive DC bus bar 36 to the collector plating 44 b on the high side of the power module 10 . Current is then permitted to flow through one or more of the switching devices 48 and/or diodes 50 on the high side to the emitter layer 43 b . The current passes to the collector layer 44 a on the low side via the conductive strip 45 passing under the DC bus bars 34 , 36 . A phase terminal allows current to flow from the collector layer 44 a on the low side to a load such as a three phase AC motor. Similarly, the negative DC bus bar 34 couples the load to the switching devices 48 and/or diodes 50 on the low side via the emitter layer 43 a.
The overall design of the standard power module 10 , including the position and structure of the DC and AC buses 16 , 18 , topology and modularity of substrates 40 and the inclusion of six phase terminals 28 a , 28 b , 30 a , 30 b , 32 a , 32 b in the AC bus 16 provides great flexibility, allowing the standard power module 10 to be customized to a variety of applications with only minor changes and thus relatively small associated costs. A number of these applications are discussed below.
Although specific embodiments of and examples for the power module and method of the invention are described herein for illustrative purposes, various equivalent modifications can be made without departing from the spirit and scope of the invention, as will be recognized by those skilled in the relevant art. The teachings provided herein of the invention can be applied to power module and power converters, rectifiers and/or inverters not necessarily the exemplary power module and systems generally described above.
While elements may be describe herein and in the claims as “positive” or “negative” such denomination is relative and not absolute. Thus, an element described as “positive” is shaped, positioned and/or electrically coupled to be at a higher relative potential than elements described as “negative” when the power module 10 is coupled to a power source. “Positive” elements are typically intended to be coupled to a positive terminal of a power source, while “negative” elements are intended to be coupled to a negative terminal or ground of the power source. Generally, “positive” elements are located or coupled to the high side of the power module 10 and “negative” elements are located or coupled to the low side of the power module 10 .
The power modules described above may employ various methods and regimes for operating the power modules 10 and for operating the switches (e.g., IGBTs 48 ). The particular method or regime may be based on the particular application and/or configuration. Basic methods and regimes will be apparent to one skilled in the art, and do not form the basis of the inventions described herein so will not be discussed in detail for the sake of brevity and clarity.
The various embodiments described above can be combined to provide further embodiments. All of the above U.S. patents, patent applications and publications referred to in this specification, including but not limited to: Ser. Nos. 60/233,992; 60/233,993; 60/233,994; 60/233,995 and 60/233,996 each filed Sep. 20, 2000; Ser. No. 09/710,145 filed Nov. 10, 2000; Ser. Nos. 09/882,708 and 09/957,047 both filed Jun. 15, 2001; Ser. Nos. 09/957,568 and 09/957,001 both filed Sep. 20, 2001; Ser. No. 10/109,555 filed Mar. 27, 2002; and Ser. No. 60/471,387 filed May 16, 2003, are incorporated herein by reference, in their entirety, as are the sections which follow this description. Aspects of the invention can be modified, if necessary, to employ systems, circuits and concepts of the various patents, applications and publications to provide yet further embodiments of the invention.
These and other changes can be made to the invention in light of the above-detailed description. In general, in the following claims, the terms used should not be construed to limit the invention to the specific embodiments disclosed in the specification and the claims, but should be construed to include all power modules, rectifiers, inverters and/or converters that operate or embody the limitations of the claims. Accordingly, the invention is not limited by the disclosure, but instead its scope is to be determined entirely by the following claims. | A power module employs at least one capacitor electrically coupled across the input terminals to reduce voltage overshoot. The capacitor may be surface mounted to a high side collector plating area and a low side emitter plating area. The power module may employ a lead frame and terminals accessible from an exterior of a module housing, for making electrical couplings to externally located power sources and/or loads. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of co-pending patent application Ser. No. 14/154,401 entitled “Air Hose Hanger for a Rail Way Vehicle”, filed on Jan. 14, 2014, the entire disclosure of which is hereby incorporated by reference herein. This application is also related to co-pending patent application Ser. No. 29/479,247 entitled “Air Hose Hanger for a Rail Way Vehicle”, filed on Jan. 14, 2014, the entire disclosure of which is hereby incorporated by reference herein.
FIELD OF THE INVENTION
The present invention is directed generally towards hangers/couplers for supporting flexible air (i.e., brake) hoses between adjacent rail cars and, in particular, towards hangers/couplers for supporting flexible air (i.e., brake) hoses between adjacent rail cars known as “cushioned cars” which include cushioned couplers for shock absorption.
BACKGROUND OF THE INVENTION
A brake system for a rail car, and preferably a cushioned car, generally includes a pipe which is attached to the rail car, and which pipe terminates in a valve at the end of the rail car. The valve is connected to a flexible hose which connects to a flexible hose on an adjacent car via a glad hand to connect the brake line pipe of adjacent cars together for proper operation of the braking system. The flexible hose on each car is supported by a hanger bracket, which is designed to maintain the hose a specified distance from the ground. Typically, this distance is set by Association of American Railroads (“AAR”) standards. Such a connection permits the rail cars (in addition to the flexible hoses) to be readily connected to, and disconnected from, each other. Further, the flexible nature of the hose helps support the brake system through turns when the axes of the rail cars are angled with respect to one another.
However, a problem with cushioned couplers (used extensively on autorack train cars—i.e., cushioned cars) is the issue of needing brake hose supports that will move in tandem with the couplers to hold up hose slack while preventing air hose separations at the glad hand connections. It is estimated that air hose separation is one of the largest causes of train stoppage for cushioned cars. Additionally, the AAR standard distance from the trainline support casting to the end of the coupler, as well as the distance of the air hose above the ground, also needs to be maintained.
Since the geometries of the various rail cars differ, it is difficult to provide a hanger/coupler that will maintain the above-identified distances for the various rail cars, while offering ease of use and ensuring proper installation.
The present invention is directed toward overcoming one or more of the above-mentioned problems.
SUMMARY OF THE INVENTION
The air hose hanger of the present invention is designed for applications in the rail industry, specifically dealing with long-travel, cushioned couplers (which are used extensively on autorack train cars, also referred to as “cushioned cars”), and the issue of needing brake hose supports that will move in tandem with the couplers to hold up hose slack while preventing air hose separations at the glad hand connections. The inventive air hose hanger is designed to mount to the area of the coupler head that includes the lightener holes. The inventive air hose hanger includes an arm that will extend a certain distance downward and toward the centerline of the rail car in a plane generally perpendicular to the longitudinal center plane of the car. The arm then turns and extends down the centerline of the rail car away from the coupler head a predetermined distance. At the end of the arm, a hose connection is provided which suspends the air hose above the track/ground (e.g., at a distance within AAR standards). The hose connection can be allowed to rotate 360°, or can be limited via rotation stops or other mechanisms to rotate only about a predetermined angular range. Once the air hose is connected thereto, the hose connection will rotate, or swivel, to accommodate the taking up and letting out of slack in the semi-rigid (yet still flexible) rubber air hose as the coupler moves in and out, or as the cars move through curves, causing the couplers to angle with respect to each other. Rotation of the hose connection can also be limited by the air hose itself. This rotation, or swiveling, will also isolate the glad hand connections from any forces on the hose itself, as they will be transferred into the hose connection at the end of the arm extension, which is not susceptible to hose separation issues.
The inventive air hose hanger includes a bolt-on, or otherwise attached, head which will mount directly to the coupler, and an arm extension which will bolt, or otherwise attach, to the head. The arm extension and the head are in separate pieces to account for different coupler types (e.g., E, F, etc.), as well as to allow the arm extension to be interchangeable between bolt-on type mounting heads and/or a welded-on mounting head, depending on customer preference or specific/unique applications. Thus, the air hose hanger of the present invention has the advantage in that it can be used on a different variety of rail cars with different geometries by simply changing the head mounting design coupler. This allows the arm extension to be used with different head designs to be able to attach to the different types of couplers.
In one embodiment, the method by which the bolt-on head mounts to the coupler relies on exploiting a feature of all couplers, namely, the lightener holes (named as such because they reduce the total casting weight of the coupler by removing material therefrom in an area of the coupler where it is typically not needed). The lightener holes are thru-holes extending into the coupler, and span from the front to the rear of the coupler. The lightener holes have a larger opening at the front end of the coupler head than at the rear end of the coupler head. This change in the size of the lightener hole allows inserts to be used which can pass through the front lightener hole opening, but cannot pass through the rear lightener hole opening. Since two lightener holes are typically provided in the coupler, it is contemplated to utilize two inserts. The inserts can have a single threaded hole in the center of them that will allow them to receive a bolt from the bolt-on head and act as a solid connector therefore.
The bolt-on head of the inventive air hose hanger can also take advantage of a third mounting point to ensure correct orientation. This third mounting point is a small tab with a hole in it formed on the underside of the coupler, which tab/hole is normally used to attach a rubber, stretchy air hose hanger with S-hooks, much like a bungee cord. The bolt-on head of the inventive air hose hanger includes a small “thumb-like” extension that extends down from the head and outward to the tab on the coupler to allow a single bolt to secure the thumb-like extension to the tab on the coupler. All three of the connection points of the bolt-on head (e.g., at the two lightener holes and at the thumb-like extension) can be considered solid connections, meaning that with proper securement and using common unthreading prevention methods (e.g., cotter pins, bolt-locking tabs, etc.) the head will not come off or come loose due to vibration or shock forces, as well as normal operating forces.
In accordance with one aspect of the present invention, an air hose hanger for supporting flexible air hoses of a trainline braking system of a rail car is provided. The air hose hanger includes a head including a mounting plate for mounting the air hose hanger to a coupler of a rail car, the mounting plate including first and second apertures for receiving first and second bolts for attaching the mounting plate to the coupler, and an arm removably attached to the head. The arm includes a first arm removably attached to the head and extending in a substantially vertical direction away from the head, and a second arm integral with the first arm and extending in a horizontal direction substantially parallel to an axis of the coupler. The air hose hanger further includes first and second inserts received in first and second lightener holes which are preformed in the coupler, the first and second lightener holes extending from a front opening in the coupler to a rear opening in the coupler, wherein the front opening is larger than the rear opening, and wherein the first and second inserts are sized such that they are received in the front opening and are displaceable in the first and second lightener holes, but are larger than the rear openings such that they cannot pass there through, and wherein the first and second inserts are disposed in the lightener holes adjacent the rear openings and each include a threaded aperture for receiving the first and second bolts, respectively, for securing the head of the hanger to the coupler.
In one form, a hose connection is rotatably attached to an end of the second arm for rotatably supporting a flexible air hose attached to the hose connection.
In another form, the end of the second arm includes a hollow cylindrical member configured for receiving a cylindrical member of the hose connection, wherein the cylindrical member of the hose connection is attached to the hollow cylindrical member for rotatable movement of the hose connection with respect to the hollow cylindrical member.
In a further form, an extension extends from the head in a direction generally away from the second arm, the extension including an aperture configured for alignment with an aperture preformed in an underside of the coupler and attached to the coupler via a bolt passing through both apertures.
The arm can include a “+” or “x” shaped cross-section. Other geometric cross-sections are also contemplated. Further, the rail car can include a cushioned car and, accordingly, the coupler can include a cushioned coupler.
In yet a further form, the head and the arm include respective connector plates having a mating dove-tail connection for connecting the arm and head together, wherein the mating dove-tail connection ensure proper alignment of the head and arm prior to attachment. If the arm and head are properly aligned, apertures formed in the respective connector plates will align and allow bolts to pass there through, and wherein if the arm and head are not properly aligned, apertures formed in the respective connector plates will not align and prohibit bolts from passing there through.
In still a further form, the first arm comprises a tab having an aperture formed thereon, the aperture configured for receiving a hook of an elastic air support hanger attached to a flexible air hose.
While various materials can be used for the head and the arm, in a preferred form the head and arm can be made from, for example, ductile iron, heat treated ductile iron, or austempered ductile iron or steel for weldable designs.
In accordance with another aspect of the present invention, an air hose hanger for supporting flexible air hoses of a trainline braking system of a rail car is provided. The air hose hanger includes a head including a mounting plate for mounting the air hose hanger to a coupler of a rail car, the mounting plate including first and second apertures for receiving first and second bolts for attaching the mounting plate to the coupler, and an arm removably attached to the head. The arm includes a first arm removably attached to the head and extending in a substantially vertical direction away from the head, and a second arm integral with the first arm and extending in a horizontal direction substantially parallel to an axis of the coupler. The head is attached to the coupler at three preformed holes formed in the coupler, the three preformed holes comprised of first and second lightener holes preformed in the coupler, and a third aperture preformed in a tab on an underside of the coupler.
In one form, the air hose hanger further includes first and second inserts received in the first and second lightener holes which are preformed in the coupler, the first and second lightener holes extending from a front opening in the coupler to a rear opening in the coupler. The front opening is larger than the rear opening, and the first and second inserts are sized such that they are received in the front opening and are displaceable in the first and second lightener holes, but are larger than the rear openings such that they cannot pass there through. The first and second inserts are disposed in the lightener holes adjacent the rear openings and each include a threaded aperture for receiving the first and second bolts, respectively, for securing the head of the hanger to the coupler.
In another form, the air hose hanger further includes an extension extending from the head in a direction generally away from the second arm, the extension including an aperture configured for alignment with the third aperture preformed in the underside of the coupler and attached to the coupler via a bolt passing through both apertures.
In a further form, the air hose hanger further includes a hose connection rotatably attached to an end of the second arm for rotatably supporting a flexible air hose attached to the hose connection.
In yet a further form, the end of the second arm includes a hollow cylindrical member configured for receiving a cylindrical member of the hose connection, wherein the cylindrical member of the hose connection is attached to the hollow cylindrical member for rotatable movement of the hose connection with respect to the hollow cylindrical member.
In still a further form, the head and the arm include respective connector plates having a mating dove-tail connection for connecting the arm and head together, wherein the mating dove-tail connection ensure proper alignment of the head and arm prior to attachment. If the arm and head are properly aligned, apertures formed in the respective connector plates will align and allow bolts to pass there through, and wherein if the arm and head are not properly aligned, apertures formed in the respective connector plates will not align and prohibit bolts from passing there through.
In another form, the first arm comprises a tab having an aperture formed thereon, the aperture configured for receiving a hook of an elastic air support hanger attached to a flexible air hose.
The arm can include a “+” or “x” shaped cross-section. Further, the rail car can include a cushioned car and, accordingly, the coupler can include a cushioned coupler.
While various materials can be used for the head and the arm, in a preferred form the head and arm can be made from, for example, ductile iron, heat treated ductile iron, or austempered ductile iron or steel for weldable designs.
While the head and arm are described herein in the form of a two-piece design, it should be appreciated that a one-piece design is also contemplated where the head and arm are integral with each other.
It is an object of the present invention to provide an air hose hanger that solidly connects to a coupler using connections inherent to a typical coupler.
It is a further object of the present invention to provide a universal air hose hanger that may be utilized with rail cars of different geometries.
It is yet a further object of the present invention to provide a two-piece air hose hanger consisting of a head and arm extension, which allows for different arm extensions to be utilized with the same head to account for different geometries of rail cars.
It is still a further object of the present invention to provide an air hose hanger that exploits common features of couplers for each of installation.
It is another object of the present invention to provide an air hose hanger that offers ease of use and ensures proper installation.
Other objects, aspects and advantages of the present invention can be obtained from a study of the specification, the drawings, and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
Various features, details and advantages of the present invention arise from the following description in which different exemplary embodiments are illustrated in more detail by means of the attached drawings. In the figures:
FIG. 1 is a perspective view of an air hose hanger in accordance with the present invention;
FIG. 2 is a perspective view of an air hose hanger in accordance with the present invention connected to a rail car coupler and having a flexible air (i.e., brake) hose connected thereto;
FIG. 3 is a cross-sectional detailed view showing inserts provided in the lightener holes in the coupler for attachment of the air hose hanger head thereto taken along line 3 - 3 in FIG. 4 ;
FIG. 4 is a sectional detailed view illustrating the head of the inventive air hose hanger mounted to a rail car coupler;
FIG. 5 is a perspective detailed view showing the third connection point of the inventive air hose hanger to the rail car coupler;
FIG. 6 is a perspective detailed view showing inserts provided in the lightener holes in the coupler for attachment of the air hose hanger head thereto;
FIG. 7 is an exploded perspective view of the inventive air hose hanger;
FIG. 8 is a perspective view illustrating rotation of the hose connection;
FIG. 9 is a perspective view of an air hose hanger in accordance with an alternate embodiment of the present invention connected to a rail car coupler;
FIG. 10 is a perspective view of an air hose hanger in accordance with the alternate embodiment of the present invention connected to a rail car coupler and having a flexible air (i.e., brake) hose connected thereto;
FIG. 11 is a close up view illustrating the dove-tail connection between the head portion and the arm extension in accordance with the alternate embodiment of the present invention;
FIG. 12 is a cross-section view of the dove-tail connection between the head portion and the arm extension with the head portion and arm extension connected correctly; and
FIG. 13 is a cross-section view of the dove-tail connection between the head portion and the arm extension with the head portion and arm extension connected backward.
DETAILED DESCRIPTION OF THE INVENTION
As shown in FIGS. 1-2 and 7 , an air hose hanger in accordance with the present invention is shown at 10 . The air hose hanger is designed to be mounted to a rail car coupler 12 and rotatably support the flexible air/brake hose 14 connected between the rail cars as part of the train brake system, as will be described in more detail hereafter. As shown and described herein, the air hose hanger 10 is of a two-piece construction, and includes a head portion, or head, 16 having an arm extension, or arm, 18 extending therefrom. The arm 18 includes two portions, or arms, extending approximately 90° relative to each other such that the arm 18 is substantially “L” shaped. With the hanger 10 attached to the rail way coupler 12 (see e.g., FIG. 2 ), the arm 18 includes a first arm 20 that extends a certain distance downward and toward the centerline of the rail car (not shown) in a plane perpendicular to the longitudinal center plain of the rail car, and a second arm 22 that extends down the centerline of the rail car away from the coupler head a certain distance. As previously noted, the first 20 and second 22 arms are approximately 90° apart such that the arm 18 is substantially “L” shaped.
It is contemplated herein that the head 16 and arm 18 can be made of, for example, ductile iron, heat treated ductile iron, or austempered ductile iron or steel for weldable designs. However, one skilled in the art will appreciate that other materials may be used without departing from the spirit and scope of the present invention. One skilled in the art will further appreciate that while the head 16 and arm 18 are described herein in the form of a two-piece design, one-piece design is also contemplated where the head 16 and arm 18 are integral with each other, without departing from the spirit and scope of the present invention.
At the end of the arm 18 (specifically second arm 22 ), a hose connection 24 is provided for suspending the air (brake) hose 14 above the track and allowing the hose 14 to swivel, or rotate, (see arrow 26 in FIGS. 1 and 8 ) to accommodate the taking up and letting out of slack in the semi-rigid, yet still flexible, air hose 14 as the coupler 12 moves in and out. When the coupler 12 is installed in a rail car, it will generally move in front and back directions as well as left to right directions around turns. The hose connection 24 will rotate to accommodate for the slack in the coupling system.
Specifically, as shown in FIGS. 1-2 and 8 , the end of the second arm 22 includes a hollow cylindrical member 28 which receives a cooperating cylindrical member 30 of the hose connection 24 . A cotter pin (not shown) is extended through the top portion of the cylindrical member 30 to maintain the rotational relationship of cylindrical members 28 and 30 (see arrow 26 in FIGS. 1 and 8 ), as will be appreciated by one skilled in the art. Further, the angle of rotation of the hose connection 24 may be adjusted, via rotation stops or other mechanisms, to be limited to a predetermined angular range, or may rotate freely 360° and/or be limited by the air hose itself, as will be appreciated by one skilled in the art.
The hose connection 24 generally includes a first threaded aperture 32 which is connected to the air (brake) hose 14 (see FIGS. 1-2 and 8 ) and generally faces away from the rail car body when the hanger 10 is connected to the coupler 12 . A flanged aperture 34 is opposite, and in communication with, the threaded aperture 32 , and is also typically threaded. The flanged aperture 34 connects a flexible air (brake) hose between the hanger 10 and the angle cock valve (not shown) on the rail car body.
The head 16 is connected to the arm extension 18 via bolts 36 which extend through cooperating connector plates 38 , 40 formed on the end of the head 16 and the arm extension (specifically first arm 20 ), respectively, and are fastened, for example, using lock nuts or other fastening means. The head 16 is connected to the rail way coupler via two bolts 42 which are connected to inserts provided in the lightener holes of the rail way coupler 12 , as will be described hereafter. Providing the hanger 10 in a two-piece construction (head 16 and arm 18 ) allows the hanger to be used with different coupler types (e.g., E, F, etc.) by simply changing the head mounting design coupler. This allows the arm extension to be used with different head designs to be able to attach to the different types of couplers. Additionally, should the arm 18 or the hose connection 24 become damaged, they can be readily replaced without having to remove the entire hanger 10 from the coupler, resulting in cost savings in maintenance operations.
As shown in FIGS. 1-2 and 7 , the arm 18 has a generally “+” or “x” shaped cross-section. Such a cross-section adds strength to the arm 18 against lateral and/or longitudinal forces, and helps to facilitate connection of the arm 18 to the head 16 via the bolts 36 and connector plates 40 , 38 , respectively. For ease of connection, the head 16 also has a generally “+” or “x” shaped cross-section at an area directly adjacent the connector plate 38 . However, one skilled in the art will appreciate that the cross-section of the arm 18 (and also the head 16 in general and directly adjacent the connector plate 38 ) is/are not critical to the present invention, and the arm 18 (and head 16 ) may have any cross-sectional shape without departing from the spirit and scope of the present invention.
Referring to FIGS. 2-4 and 6 , the head 16 of the hanger 10 is connected to the coupler 12 utilizing the lightener holes provided in the coupler 12 . As previously noted, the lightener holes are provided in the coupler 12 to reduce the total casting weight of the coupler 12 by removing material from the coupler 12 where it is generally not needed. As shown in FIGS. 2-4 and 6 , the lightener holes generally include an upper lightener hole 44 and a lower lightener hole 46 . The upper and lower lightener holes 44 , 46 extend into the coupler 12 from a front opening 48 , 50 to a rear opening 52 , 54 , respectively. The front opening 48 , 50 is generally larger than the rear opening 52 , 54 .
Inserts 56 and 58 are inserted into the lightener holes 44 and 46 at the front openings 48 and 50 thereof, respectively. The inserts 56 , 58 are sized such that they are smaller than the front openings 48 , 50 , but larger than the rear openings 52 , 54 . The inserts 56 , 58 are inserted in the front openings 48 , 50 and moved through lightener holes 44 , 46 in the direction of dotted arrows (see FIGS. 4 and 6 ) until they sit adjacent the rear openings 52 , 54 . Since the inserts 56 , 58 are larger than the rear openings 52 , 54 , they will not pass through the rear openings 52 , 54 .
The inserts 56 , 58 include threaded apertures 60 formed therein. Preferably, the threaded apertures 60 are centered, but may be placed at any convenient point on the inserts 56 , 58 . The inserts 56 , 58 are aligned with the rear openings 52 , 54 and the bolts 42 pass through corresponding apertures formed in a mounting plate 62 of the head 16 and are threaded into the apertures 60 formed in the inserts 56 , 58 . The bolts 42 are tightened to pull the inserts 56 , 58 up against the edges of the coupler 12 that define the rear openings 52 , 54 to fasten the head 16 , and thus the hanger 10 , securely to the coupler 12 . By using the lightener holes 44 , 46 that are already formed in the coupler 12 , no additional holes or fastening means need formed in the coupler 12 . Additionally, FIGS. 4 and 7 show a lock washer 64 utilized in securing the bolts 42 to the inserts 56 , 58 . However, the lock washer 64 may be omitted.
Referring to FIGS. 1-2, 5 and 7 , to provide added stability and securement of the hanger 10 to the coupler 12 , a third connection point on the coupler 12 is used to fasten the hanger 10 thereto. In this regard, the head 16 includes an extension (e.g., a thumb-like extension) 66 which extends from the head 16 in a direction generally away from the rail car body. This third connection point attaches to a small tab 68 generally provided on the underside of the coupler 12 body, which tab 68 includes a hole for attaching an elastic air support hanger 72 with an S-hook 73 (see e.g., FIGS. 2 and 5 ), much like a bungee cord. The air support hanger 72 supports the air hose 14 . The end of the extension 66 includes an aperture 70 which is aligned with the aperture in the tab 68 and secured with a bolt 74 extending there through. A lock nut 76 and cotter pin 78 (see FIG. 5 ) are shown for securing the bolt 74 in place; however, one skilled in the art will appreciate that any means of securing the bolt 74 to effectuate this third connection point may be implemented without departing from the spirit and scope of the present invention. Since the extension 66 is secured using the aperture in the tab 68 typically used for attaching the elastic air support hanger 72 with the S-hook 73 (or other hook or attachment configuration), the extension 66 may include an additional aperture (not shown) to which the S-hook 73 may attach. Alternately, the S-hook 73 may hook over the extension 66 so that the air support hanger 72 may support the air hose 14 (see FIG. 2 ). The three connection points, namely the two lightener holes 44 and 46 and the tab 68 , provide secure and stable connection of the hanger 10 to the coupler 12 , such that the head 16 (and thus the hanger 10 ) will not come off or come loose due to vibration or shock forces, as well as normal operating forces.
While the present inventive hanger 10 , 10 ′ has particular utility for use with cushioned cars having cushioned couplers that move in a horizontal plane, it should be understood that the inventive hanger 10 , 10 ′ may be implemented and attached to any coupler to support the air hose. For example, the hanger 10 , 10 ′ may be attached to a rail way coupler that does not move in a generally horizontal plane.
Referring to FIGS. 9-13 , an alternate embodiment of the air hose hanger is illustrated with like elements of FIGS. 1-8 indicated with the same reference numbers and elements that have been modified indicated with a prime (“′”). As shown in FIGS. 9-10 , the air hose hanger 10 ′ is connected to the rail car coupler 12 utilizing the lightener holes 44 and 46 in the same manner as the air hose hanger 10 . The air hose hanger 10 ′ is of a two-piece construction, and includes a head portion, or head, 16 ′ having an arm extension, or arm, 18 ′ extending therefrom. The arm 18 ′ includes two portions, or arms, extending approximately 90° relative to each other such that the arm 18 ′ is substantially “L” shaped. With the hanger 10 ′ attached to the rail way coupler 12 , the arm 18 ′ includes a first arm 20 ′ that extends a certain distance downward and toward the centerline of the rail car (not shown) in a plane perpendicular to the longitudinal center plain of the rail car, and a second arm 22 ′ that extends down the centerline of the rail car away from the coupler head a certain distance. As previously noted, the first 20 ′ and second 22 ′ arms are approximately 90° apart such that the arm 18 ′ is substantially “L” shaped.
Similar to the prior embodiment, to provide added stability and securement of the hanger 10 ′ to the coupler 12 , a third connection point on the coupler 12 is used to fasten the hanger 10 ′ thereto. In this regard, the head 16 ′ includes an extension (e.g., a thumb-like extension) 66 ′ which extends from the head 16 ′ in a direction generally away from the rail car body. This third connection point attaches to a small tab 68 (see FIG. 5 ) provided on the underside of the coupler 12 body, which tab 68 includes a hole for generally attaching an elastic air support hanger 72 with an S-hook 73 (or other configured hook), much like a bungee cord. The extension 66 ′ is attached to the small tab 68 in a similar manner as previously described. Since the extension 66 ′ is secured using the aperture in the tab 68 typically used for attaching the elastic air support hanger 72 with a hook 73 , the first arm 20 ′ includes a small tab 80 having an aperture 82 extending there through. The tab 80 may be formed entirely on the first arm 20 ′ or, as shown in the Figures, formed on both the first arm 20 ′ and the connector plate 40 ′. As shown in FIG. 10 , the hook 73 extends through the aperture 82 in the tab 80 so that the air support hanger 72 may support the air hose 14 . While the tab 80 is shown provided on the first arm 20 ′, the tab 80 could also be provided on the head 16 ′ without departing from the spirit and scope of the present invention. The three connection points, namely the two lightener holes 44 and 46 and the tab 68 , provide secure and stable connection of the hanger 10 ′ to the coupler 12 , such that the head 16 ′ (and thus the hanger 10 ′) will not come off or come loose due to vibration or shock forces, as well as normal operating forces.
The head 16 ′ is connected to the arm extension 18 ′ via bolts 36 which extend through cooperating connector plates 38 ′, 40 ′ formed on the end of the head 16 ′ and the arm extension 18 ′ (specifically first arm 20 ′), respectively, and are fastened, for example, using lock nuts or other fastening means. To add stability to the hanger 10 ′ as well as to ensure proper installation, the head 16 ′ is attached to the arm extension 18 ′ via a dove-tail connection, shown at 84 , formed on the cooperating connector plates 38 ′, 40 ′, as shown more clearly in FIGS. 11-13 . While the connector plate 38 ′ is shown having a male dove-tail connector portion 86 and the connector plate 40 ′ is shown having a female dove-tail connector portion 88 , the male/female portions can be provided on either connector plate 38 ′, 40 ′, as will be appreciated by one skilled in the art.
During installation, the head 16 ′ may be attached to the coupler 12 first. The arm 18 ′ may be slid onto the head 16 ′ via the dove-tail connection 84 . To ensure proper installation, only if the head 16 ′ and arm 18 ′ are attached correctly will the apertures 90 in the connector plate 38 ′ align with the apertures 92 in the connector plate 40 ′, thus allowing bolts to pass there through to connect the two elements together. As shown in FIG. 12 , when the head 16 ′ and arm 18 ′ are aligned for proper installation, the apertures 90 and 92 will align with each other to receive bolts for connection of the elements. If, as shown in FIG. 13 , the head 16 ′ and arm 18 ′ are not properly aligned, the apertures 90 and 92 will be offset, thus prohibiting connection bolts from passing there through. Thus, in this manner, proper installation of the hanger 10 ′ in ensured.
While the present invention has described herein with particular reference to the drawings, it should be understood that various modifications could be made without departing from the spirit and scope of the present invention. Those skilled in the art will appreciate that various other modifications and alterations could be developed in light of the overall teachings of the disclosure. The presently preferred embodiments described herein are meant to be illustrative only and not limiting as to the scope of the invention which is to be given the full breadth of the appended claims and any and all equivalents thereof. Additionally, the disclosure of a range of values is a disclosure of every numerical value within that range. | An air hose hanger for supporting flexible air hoses of a trainline braking system of a rail car includes a head including a mounting plate for mounting the hanger to a coupler of a rail car, the mounting plate including first and second apertures for receiving bolts for attaching the mounting plate to the coupler, and an arm removably attached to the head. The arm includes a first arm removably attached to the head extending in a substantially vertical direction away from the head, and a second arm integral with the first arm and extending in a horizontal direction substantially parallel to an axis of the coupler. The head is attached to the coupler at three preformed holes formed in the coupler. The head is attached to the arm via respective connector plates having a mating dove-tail connection for connecting the arm and head together to ensure proper installation. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a neutralizer for cold waving. More specifically, it relates to a neutralizer for cold waving which is formulated by incorporating dibenzyl ketone, p-diacetyl benzene, 2-hydroxy-1,4-naphthoquinone, hinokitiol, shikonin, or a similar compound into a conventional neutralizer containing as a main ingredient an oxidizing agent. This neutralizer has the following two characteristics:
(a) An unpleasant odor (e.g., a mercaptan odor) is not substantially generated in the hair when the neutralizer is applied to the hair; and
(b) An elastic and shiny wave is formed in the hair.
2. Description of the Prior Art
As is well known in the art, permanent waving lotions are composed of (i) waving lotions containing, as a main component, reducing agents, that is, mercapto compounds such as thioglycolic acid and cysteine, and (ii) neutralizers containing oxidizing agents such as sodium bromate and hydrogen peroxide. However, the use of conventional permanent waving lotions involves a problem in that an extremely unpleasant mercaptan odor is generated in the hair when the permanent waving lotions are applied to the hair. This unpleasant odor specific to the permanent waving lotions cannot be removed from the hair even when the hair is shampooed several times. Thus, the use of conventional permanent waving lotions is not agreeable to consumers.
Various attempts have been made to eliminate the above-mentioned unpleasant mercaptan odor, among which are typical conventional methods for eliminating the unpleasant mercaptan odor employing so-called masking techniques in which perfumes having a strong odor are incorporated into permanent waving lotions, to thereby mask the unpleasant mercaptan odor in the hair.
However, the mercaptan odor still remains in the hair and has a bad or unpleasant odor. Moreover, since the density of gaseous mercaptan is heavier than that of air, the mercaptan odor drifts down from the hair toward the neighborhood of the nose, especially during shampooing or perspiration. Therefore, the mercaptan odor cannot be completely mashed by the perfume odor remaining in the hair. Furthermore, some people dislike the perfumes which are generally used in these masking methods, due to their strong and heavy odor.
For the above-mentioned reasons, it is considered that the mercaptan odor per se must be eliminated in order to fundamentally solve the above-mentioned problems of unpleasant odor.
SUMMARY OF THE INVENTION
Accordingly, the object of the present invention is to fundamentally eliminate the above-mentioned generation of an unpleasant odor from a neutralizer of a permanent waving lotion and to provide a neutralizer generating no substantial mercaptan odor when applied to the hair.
Other objects and advantages of the present invention will be apparent from the following description.
In accordance with the present invention, there is provided a neutralizer for cold waving comprising: (i) an oxidizing agent and (ii) at least one compound selected from the group consisting of the compounds having the general formula (I) to (XII), shown as follows. ##STR5## wherein --R 1 and --R 2 are independently --CH 3 , --CH 2 OH, --CH 2 Cl, --CH 2 Br, --CH 2 I, ##STR6## --CH 2 COOR 6 , --CH 2 CH 2 COOR 6 , --CH 2 COR 6 , --COR 6 , ##STR7## --R 3 , --R 4 , and --R 5 are independently --H, --COR 6 , --COOR 6 , --Cl, --Br, --I, --NO 2 , --OCH 3 , --OH, and --COOH;
--R 6 is a hydrogen atom, or an alkyl or alkenyl group having up to 3 carbon atoms;
--R 7 is --H, --OH, or --CH 3 ; and
--R 8 is --H, --COCH(CH 3 ) 2 , --COCH═C(CH 3 ) 2 , --COCH 3 ,
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be better understood from the following descriptions presented in connection with the accompanying drawings in which:
FIG. 1 is a graph illustrating a correlation between a neutralizer treatment time and a methylmercaptan generation amount obtained in Example 1; and
FIG. 2 is a graph illustrating a correlation between a neutralizer treatment time and a methylmercaptan generation amount obtained in Example 2.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The compounds (ii) usable in the formulation of the neutralizer according to the present invention are those having the above-mentioned general formulae (I) to (XII). These compounds may be used alone or in any mixture thereof. The preferable compounds are dibenzyl ketone, p-diacetyl benzene, 2-hydroxy-1,4-naphthoquinone, hinokitiol, shikonin, benzyl acetophenone, p-nitroacetophenone, p-hydroxyacetophenone, benzophenone, 2,5-dihydroxy-1,4-benzoquinone, 2-cyclohexenone, carvone, ethyllevulinate.
The compounds (ii) having the above-mentioned general formulae (I) to (XII) are preferably incorporated into the neutralizers according to the present invention in an amount of 0.0001% to 5.0% by weight, more preferably, 0.0005% to 5.0% by weight, based on the total weight of the neutralizers. When the amount of the compounds (ii) in the present neutralizers are less than 0.0001% by weight, the desired odor elimination effect cannot be obtained. Contrary to this, when the amount of the compounds (ii) in the present neutralizers is larger than 5.0% by weight, the compounds (ii) tend to be separated or precipitated so that the stable formulation is difficult, and the odor of the compounds (ii) per se is undesirably generated depending upon the kinds of the compounds (ii).
The neutralizers of the present invention contain, as a main component, any conventional oxidizing agent. Examples of such oxidizing agents are bromates such as sodium bromate and potassium bromate, hydrogen peroxide, sodium percarbonate, and sodium perborate.
These oxidizing agents may be used alone or in any mixture thereof. Although there is no specific limitation in the content of the oxidizing agents in the neutralizer, the oxidizing agents are preferably incorporated into the neutralizer in an amount of 0.5% to 20% by weight, more preferably 1% to 10% by weight, based on the total weight of the neutralizer.
The neutralizer of the present invention may optionally contain any conventional ingredients used in conventional neutralizers, as long as the desired effect of the present invention is not adversely affected. Examples of such conventional ingredients are pH adjusting agents such as potassium phosphate (monobasic, dibasic), sodium phosphate (monobasic, dibasic) oils such as liquid paraffines, squalene, fatty alcohols, triglyceride, esters, silicone oils, and lanolin, surfactants such as nonionic surfactants (e.g., polyoxyethylene alkyl ether), anionic surfactants (e.g., sodium lauryl sulfate, sodium laurate), and cationic surfactants (e.g., stearyl trimethyl ammonium chloride), sequestrants such as ethylene diamine tetra acetate (EDTA), colorants such as Guaiazulene, Quinoline yellow WS (D. & C. Yellow No. 10), Rhodamine B (D. & C. Red No. 19), perfumes, preservatives such as methyl parabene, sodium benzoate, and other agents such as water soluble polymers, cationic polymers, polypeptide, amino acids, and humectants.
The neutralizers of the present invention can be prepared in any conventional manner, with the proviso that the above-mentioned compounds (ii) are included therein. The above-mentioned compounds (ii) can be directly incorporated into the neutralizers. Alternatively, the compounds (ii) are previously solubilized by surfactants. Furthermore, the compounds (ii) are previously dissolved in oils and are then emulsified by surfactants, or are then incorporated into a higher alcohol-surfactant type liquid crystal gel.
The neutralizers according to the present invention may be applied to the hair in the same manner as conventional neutralizers. For example, waving lotions containing, as a main ingredient, reducing agents such as thioglycolic acid, thioglycolates such as sodium thioglycolate, potassium thioglycolate, ammonium thioglycolate, monoethanol amine thioglycolate, glycerol monothioglycolate, thiolactic acid and its salts, and L-Alginine thioglycolate, cysteine, cysteine derivatives such as N-acetyl-L-cysteine, and cysteine ethylester, and salts, such as hydrochloric acid, and sulfuric acid salts, of the cysteine derivatives, are first applied to the hair. After waving the hair, the neutralizers of the hair, the neutralizers of the present invention are applied to the hair. The hair thus treated with the neutralizers was rod out and, then, water rinsed.
EXAMPLE
The present invention now will be further illustrated by, but is by no means limited to, the following examples, in which all percentages and parts are expressed on a weight basis unless otherwise specified.
EXAMPLE 1
(1) A wave lotion and neutralizer were prepared according to the following standard formulations.
______________________________________Composition %______________________________________Waving lotion50% Aqueous ammonium thioglycolate 13.028% Special reagent grade aqueous 1.0ammoniaAmmonium bicarbonate 4.0Tetrasodium EDTA 0.1Sodium lauryl sulfate 0.1Purified water balanceNeutralizerSodium bromate 6.0Potassium phosphate, monobasic 0.4Disodium phosphate, dibasic 0.05Sodium lauryl sulfate 0.1Shikonin* 0.001Purified water balance______________________________________ ##STR9##
(2) 20% Index
Ten strands of non-damaged hair from the head of a 20 to 29 year old woman were bundled and were dipped in water. The hair was elongated by 20% in the completely wet state and the load (h 0 ) required was measured. After the measurement, the hair was at once dipped in water again and was allowed to stand in the water for a while. The hair was taken out from the water and was allowed to dry naturally for one day in a room temperature. The dried hair was treated with the above-prepared waving lotion at a temperature of 30° C. for 10 minutes and was then washed with water. Thereafter, the hair was treated with the above-mentioned neutralizer at a temperature of 30° C. for 10 minutes, followed by water washing. The hair thus obtained was again elongated by 20% in a completely wet state and the load (h) required was measured.
The 20% index was calculated from the following equation: ##EQU1##
The 20% index is a criterion of the recovery of hair strength with a neutralizer. A 20% index of 1.0 means that the hair is completely recovered to the original state. The smaller the 20% index, the weaker the recovery of the hair strength.
(3) Mercaptan generation amount and remaining odor of permanent waved hair after neutralizer is applied
A 0.5 g amount of non-damaged hair from the head of a 20 to 29 year old woman was placed in a 100 ml Erlenmeyer flask and 2 ml of the waving lotion was charged thereinto. Thus, the hair was uniformly dipped in the waving lotion. After the flask was stoppered, the hair was treated with the waving lotion at a temperature of 30° C. for 10 minutes, while shaking, in a constant temperature water bath. The hair was then rapidly washed with water and the excess water in the hair was removed by wiping with a towel. The hair was placed in another 100 ml Erlenmeyer flask and was then uniformly dipped in 1 ml of the neutralizer. The flask was plagged at the top thereof with paraffinefilm and the hair was treated with the neutralizer at a temperature of 30° C. for 20 minutes, while stirring, in a constant temperature water bath.
The gas generated in the upper space of the flask was sampled in a volume of 0.5 ml with a gas-tight cyringe every 5 minutes and was quantitatively determined by a gas chromatograph apparatus (GC-FPD). After 20 minutes' treatment, the treated hair was washed with water and the excess water in the washed hair was removed by wiping with a towel. The odor of the hair was organoleptically evaluated immediately after removal of the excess water. The hair was then allowed to stand for one day in a room temperature and the odor of the hair was again organoleptically evaluated while wetting with water.
The odor was evaluated according to the following criteria:
--: Strong mercaptan odor
-: Moderately strong mercaptan odor
±: Very weak mercaptan odor
+: No substantial mercaptan odor
++: No mercaptan odor
The results of the above-mentioned 20% index, mercaptan generation amount, and remaining mercaptan odor in the permanent wave treated hair are shown in Table 1 and FIG. 1. In FIG. 1, the mercaptan generation amounts in Table 1 are shown graphically, in which curve (1) represents the case where no shikonin was included in the neutralizer and curve (2) represents the case where 0.001% of shikonin was included.
TABLE 1__________________________________________________________________________Methylmercaptan generation amount, remaining odor,and 20% index when treated with neutralizer Remaining odorAmount of Immediatelycompound (ii) Treatment time (min.) after 1 dayin neutralizer 5 10 15 20 treatment after 20% Index**__________________________________________________________________________0% 3.14* 2.18 1.48 1.08 - - 0.712 ± 0.0130.001% 0.76 0.59 0.40 0.24 + ++ 0.762 ± 0.011__________________________________________________________________________ **Average of n = 5, *Average of n = 5 (ppm)
As is clear form the results shown in Table 1 and FIG. 1, the mercaptan generation amount of methylmercaptan having a rotten-onion like odor was very small, and no substantial remaining odor was detected. The effect of the use of shikonin was also observed in the recovery of hair strength in terms of the 20% index.
EXAMPLE 2
(1) Standard formulation
Waving lotion
Same as in Example 1.
______________________________________NeutralizerComposition %______________________________________Sodium bromate 10.0Potassium phosphate, monobasic 0.4Disodium phosphate.12 hydrate, 0.3dibasicCetanol 0.5Polyoxyethylene lauryl ether 0.1(15 mole EO)Sodium lauryl sulfate 0.05Compound (ii) of the present 0.05 or 0.1invention listed in Table 2Purified water balance______________________________________
(2) 20% Index
Determined in the same manner as in Example 1.
(3) Methylmercaptan generation amount and the remaining odor of the permanent waved treated hair when treated with neutralizer
Determined in the same manner as in Example 1.
The compounds used in this Example were those slightly soluble in water and, therefore, were formulated into a cetanol type liquid crystal gel base material.
The results are shown in Table 2 and FIG. 2. In FIG. 2, the mercaptan generation amounts of Table 2 are shown graphically, in which curve (1) represents the case where there was no addition of compound (ii), and curves (2), (3), and (4) represent the cases where the addition was made of 0.1% of benzyl acetophenone, 0.05% of dibenzyl ketone, and 0.1% of dibenzyl ketone, respectively. As is clearly shown in Table 2 and FIG. 2, an excellent effect was obtained according to the present invention.
TABLE 2__________________________________________________________________________Methylmercaptan generation amount, remaining odor, and20% index when treated with neutralizer RemainingCompound (ii) in Amount Treatment time (min) odor*** 20%**neutralizer (%) 5 10 15 20 (1 day after) Index__________________________________________________________________________No addition -- 2.30* 1.78 1.30 1.00 - 0.672Dibenzyl ketone 0.05 0.34 0.20 0.14 0.08 ++ 0.730 ##STR10## 0.1 0.27 0.16 0.12 0.07 ++ 0.735Benzyl acetophenone ##STR11## 0.1 0.45 0.30 0.19 0.11 ++ 0.731__________________________________________________________________________ *, **see Table 1. ***Evaluated in the same manner as in Example 1.
EXAMPLE 3
(1) Standard formulation Waving lotion
Same as in Example 1.
Neutralizer
Two types of th neutralizers prepared in Examples 1 and 2 were used. The neutralizers A and B are those prepared in Examples 1 and 2, respectively.
(2) Methylmercaptan generation amount and the remaining odor of permanent waved hair when treated with neutralizer
Determined in the same manner as in Examples 1 and 2, except that the quantitative determination of the methylmercaptan was carried out after the 15 minute treatment with the neutralizer.
Typical compounds (ii) according to the present invention listed in Table 3 were formulated into the above-mentioned standard formulation and the odor elimination effect thereof was determined.
The results are shown in Table 3. As is clear from the results shown in Table 1, the neutralizer Nos. 3 to 17 remarkably decrease the remaining mercaptan odor as compared with the comparative neutralizers Nos. 1 and 2.
TABLE 3__________________________________________________________________________Odor elimination effect of typical compounds according to the presentinvention Neutral- Methylmercaptan Remaining General A- izer amount odor 20%No. formula Compound (ii) mount type (ppm) (1 day Index)__________________________________________________________________________ 1 -- No addition -- A 1.48 - 0.712 2 No addition -- B 1.30 - 0.672 3 4 ##STR12## 0.05 0.1 B B 0.14 0.12 ++ ++ 0.730 0.735 5 R.sub.1COR.sub.2 ##STR13## 0.1 B 0.19 ++ 0.731 6 ##STR14## 0.1 B 0.35 + 0.705 7 ##STR15## 1.0 B 0.51 + 0.723 8 ##STR16## 0.1 B 0.21 ++ 0.727 9 ##STR17## ##STR18## 0.1 B 0.19 ++ 0.71110 ##STR19## 0.1 B 0.26 + 0.70511 12 13 ##STR20## ##STR21## 0.01 0.05 0.10 A 0.80 0.20 0.14 + ++ ++ 0.708 0.712 --14 ##STR22## ##STR23## 0.05 A 0.54 + --15 ##STR24## ##STR25## 0.05 A 0.65 + --16 ##STR26## 0.1 B 0.16 ++ --17 ##STR27## ##STR28## 0.05 A 0.38 + --__________________________________________________________________________ (Remarks) The determination and evaluation methods were the same as in Example 1.
EXAMPLE 4
A waving lotion having the following composition was prepared.
______________________________________Composition %______________________________________50% Aqueous ammonium thioglycolate 12.528% Aqueous ammonia (special reagent 1.0grade)Ammonium bicarbonate 4.0Tetrasodium EDTA 0.1Sodium laury sulfate 0.1Purified water balance______________________________________
The above components were mixed at room temperature to prepare the waving lotion.
A neutralizer having the following composition was prepared.
______________________________________Composition %______________________________________Sodium bromate 6.0Potassium phosphate, monobasic 0.4Disodium phosphate.12 hydrate, dibasic 0.3Sodium lauryl sulfate 0.1Polyvinylpyrrolidone-polyvinylstyrene 0.5emulsion polymer*Ethyl levulinate 0.1Shikonin 0.001Propylene glycol 5.0Purified water balance______________________________________ *clouding agent
(1) Preparatin of neutralizer
Sodium bromate, potassium phosphate, disodium phosphate (12 hydrates), sodium lauryl sulfate, and polyvinylpyrrolidone-polyvinylstyrene emulsion copolymer were added to purified water and these components were dissolved in the water at room temperature while stirring. On the other hand, the shikonin and ethyl levulinate were mixed with the propylene glycol. This mixture was dissolved upon slight heating. The resultant solution was added to the above-prepared mixture, while stirring, to obtain a reddish-purple colored emulsion type neutralizer.
(2) Hair waving test
Hair was wound around rods, while 80 ml of the above-prepared waving lotion was applied to the hair. The remaining amount of the waving lotion was spread over the entire head portion. The hair was allowed to stand for 10 minutes after covering the head portion with a cap.
The hair was washed with slightly warm water and the hair was lightly wipped with a towel to remove excess water. The hair was then treated with 100 ml of the neutralizer by spreading it over the entire head portion. The treated hair was allowed to stand for 15 minutes. Thereafter, the rods were removed and the hair was washed with slightly warm water. The hair was then wiped with a towel to remove excess water.
Good curling of the hair was formed, no unpleasant odor specific to a permanent waving treatment remained in the hair, but a slightly fruity smell was detected.
EXAMPLE 5
A waving lotion having the same composition as in Example 4 was prepared in the same manner as in Example 4.
A neutralizer having the following composition was prepared.
______________________________________Composition %______________________________________Sodium bromate 10.0Potassium phosphate, monobasic 0.4Disodium phosphate.12H.sub. 2 O, dibasic 0.2Cetanol 0.5Polyoxyethylene oleyl ether 0.1(20 mol EO)Sodium lauryl sulfate 0.05Sodium 1-hydroxyethane-1,1- 0.1diphosphonateDibenzyl ketone 0.1Purified water balance______________________________________
(1) Preparation of neutralizer
A 29.35% amount of purified water was heated to about 80° C. and the cetanol, polyoxyethylene oleyl ether, and sodium lauryl sulfate were added thereto. The mixture was stirred in a beaker to form a solution. The resultant solution was water cooled from the outside of the beaker, while gently stirring, to thereby obtain a viscous gel. The dibenzyl ketone was added to the resultant gel and the mixture was uniformly stirred again.
On the other hand, the potassium phosphate, disodium phosphate·12H 2 O, and sodium 1-hydroxyethane-1,1-diphosphonate were added to the remaining purified water. The mixture was stirred until a clear solution was obtained. The above-prepared part was added to the resultant clear solution and was mixed while stirring to obtain a white milky neutralizer.
(2) Hair waving test
The hair was treated with the above-prepared waving lotion and neutralizer is the same manner as in Example 4.
As a result, good curling of the hair was formed, and no unpleasant odor specific to the permanent waving treatment remained in the hair. Only a slightly flowral smell was detected in the hair.
EXAMPLE 6
A waving lotion having the same composition as in Example 4 was prepared in the same manner as in Example 4.
A neutralizer having the following composition was prepared. T1 -Composition? %? -Sodium bromate 6.0 - Potassium phosphate, monobasic 0.4 - Disodium phosphate 12H 2 O, dibasic 0.05 - Lauryl betain 0.1 - Polyvinylpyrrolidone-polyvinylstyrene 0.5 - emulsion polymer - 2-hydroxy-1,4-naphthoquinone 0.1 - Trisodium EDTA 0.1 - Purified water balance? -
(1) Preparation of neutralizer
An orange colored emulsion type neutralizer was prepared in the same manner as in Example 4.
(2) Hair waving test
The hair was treated with the above-prepared waving lotion and neutralizer in the same manner as in Example 4.
As a result, good curling of the hair was formed, and no substantial odor was detected in the hair.
EXAMPLE 7
A waving lotion having the following composition was prepared in the same manner as in Example 4.
______________________________________Composition %______________________________________L-Cystine 6.0Monoethanolamine 2.528% Special reagent grade aqueous 1.0ammoniaTetrasodium EDTA 0.5Cetanol 0.5Polyoxyethylene oleyl ether 0.1(15 mole EO)Sodium lauryl sulfate 0.0550% Aqueous ammonium thioglycolate 0.5Purified water balance______________________________________
A neutralizer having the following composition was prepared.
______________________________________Composition %______________________________________Sodium bromate 6.0Potassium phosphate, monobasic 0.4Disodium phosphate.12H.sub.2 O, dibasic 0.1Sodium lauryl sulfate 0.12-Cyclohexenone 0.1Hinokitiol 0.03Purified water balance______________________________________
(1) Preparation of neutralizer
A clear liquid type neutralizer was obtained in the same manner as described in Example 4.
(2) Hair waving test
The hair was treated with the above-prepared waving lotion and neutralizer in the same manner as in Example 4.
As a result, a soft and elastic curling of the hair was formed. Only a slightly fruity smell was detected in the hair, but no substantial mercaptan odor remained.
EXAMPLE 8
A waving lotion having the same composition as in Example 4 was prepared in the same manner as in Example 4.
A neutralizer having the following composition was prepared.
______________________________________Composition %______________________________________Sodium bromate 6.0Potassium phosphate, monobasic 0.3Disodium phosphate.12H.sub.2 O, dibasic 0.1Sodium lauryl sulfate 0.1p-Diacetyl benzene 0.1Shikonin 0.001Polyvinylpyrrolidone-polyvinylstyrene 0.5copolymer1,3-Butylene glycol 1.0Purified water balance______________________________________
(1) Preparation of neutralizer
The p-diacetyl benzene and shikonin were added to the 1,3-butylene glycol and the mixture was heated to abot 80° C. to form a solution. On the other hand, sodium bromate, potassium phosphate, disodium phosphate·12H 2 O, sodium lauryl sulfate, and polyvinylpyrrolidone-polyvinylstyrene copolymer were added to the purified water and the mixture was uniformly stirred to form a solution. To the resultant solution, the above-prepared solution was added. The resultant mixture was thoroughly stirred to obtain a reddish purple colored cloudy neutralizer.
(2) Hair waving test
The hair was treated with the above-prepared waving lotion and neutralizer in the same manner as in Example 4.
As a result, good curling of the hair was formed and no mercaptan odor remained in the hair. | A neutralizer for cold waving comprising: (i) an oxidizing agent and (ii) at least one compound selected from the group consisting of the compounds having the general formula (I) to (XII), as follows. ##STR1## wherein --R 1 and --R 2 are independently --CH 3 , --CH 2 OH, --CH 2 Cl, --CH 2 Br, --CH 2 I, ##STR2## --CH 2 COOR 6 , --CH 2 CH 2 COOR 6 , --CH 2 COR 6 , --COR 6 , ##STR3## --R 3 , --R 4 , and --R 5 are independently --H, --COR 6 , --COOR 6 , --Cl, --Br, --I, --NO 2 , --OCH 3 , --OH, and --COOH;
--R 6 is hydrogen atom, or an alkyl or alkenyl group having up to 3 carbon atoms;
--R 7 is --H, --OH, or --CH 3 ; and
--R 8 is --H, --COCH(CH 3 ) 2 , --COCH═C(CH 3 ) 2 , --COCH 3 , ##STR4## This neutralizer generates no substantial mercaptan or other unpleasant odor when applied to the hair and forms an elastic and shiny permanent wave. | 0 |
FIELD OF THE INVENTION
[0001] The present invention relates to magnetic recording, and more particularly, to a magnetic head having an assymmetrical shape used in perpendicular shingled recording.
BACKGROUND OF THE INVENTION
[0002] High-density recording technology for magnetic disk devices has made significant progress in recent years, including remarkable advances in the miniaturization of the magnetic poles included with the magnetic recording heads. However, since a correlation between the strength of the recording magnetic field generated by the magnetic recording head and the volume of the magnetic pole exists, a problem arises in that increased miniaturization of the magnetic pole makes it more difficult to maintain the strength of the recording magnetic field.
[0003] Thermally-assisted recording has been developed as one way of dealing with this problem. Thermally-assisted recording works by heating the magnetic recording medium as recording takes place to reduce the coercive field strength, and is a method of recording which reduces the magnetic field strength required for writing. Moreover, more recently a microwave-assisted recording system has been proposed as another form of assisted recording which uses spin torque to enable recording densities greater than 1 Tb/in 2 . With this system, a high-speed magnetized rotor which rotates at high speed is positioned adjacent to the main magnetic pole of a perpendicular magnetic recording head, with microwaves being radiated onto the magnetic recording medium, recording data on a magnetic recording medium, which has large magnetic anisotropy. Application to the medium of microwaves generated by an oscillator means that the magnetic field required for magnetic reversal in the medium is reduced. This indicates that the strength of the recording magnetic field generated by the main magnetic pole of the magnetic recording head can be less than that required in other conventional devices not using microwaves.
[0004] Moreover, as cited both in U.S. Pat. No. 7,443,625 and Tagawa Kanai et al., SRC 27 th Technical Report Materials, May 2009, the shingled recording system has been proposed as another high-density recording system. With the shingled system, the tracks recorded in the magnetic recording medium by the magnetic head are partially overlapped. This enables a magnetic recording device to have a track pitch smaller than the tracks recorded. It is also considered possible to use a perpendicular magnetic recording device in which the width of the magnetic pole of the recording head is wider than in conventional devices.
[0005] In light of the above situation, it would be beneficial to have a magnetic head that can produce a sufficient recording magnetic field strength while being operated in recently developed systems, such as microwave-assisted recording systems and shingled recording systems.
SUMMARY OF THE INVENTION
[0006] In one embodiment, a magnetic head includes a main magnetic pole having a protruding portion such that a distance from a first side of a trailing edge of the main magnetic pole to a leading edge of the main magnetic pole is different from a distance from a second side of the trailing edge of the main magnetic pole to the leading edge of the main magnetic pole, an auxiliary magnetic pole, and a coil wound around a magnetic circuit, the magnetic circuit including the main magnetic pole and the auxiliary magnetic pole.
[0007] In another embodiment, a magnetic head includes a main magnetic pole having a protruding portion such that a distance from a first side of a trailing edge of the main magnetic pole to a leading edge of the main magnetic pole is different from a distance from a second side of the trailing edge of the main magnetic pole to the leading edge of the main magnetic pole, an auxiliary magnetic pole, and a coil wound around a magnetic circuit, the magnetic circuit including the main magnetic pole and the auxiliary magnetic pole. The protruding portion of the main magnetic pole is comprised of a magnetic material having a higher degree of saturated flux density than the remainder of the main magnetic pole. Also, the protruding portion of the main magnetic pole is comprised of a magnetic material having a higher iso-magnetic permeability than the remainder of the main magnetic pole, and a magnetic body is positioned towards the trailing side of the main magnetic pole and towards a track width side of the main magnetic pole.
[0008] Any of these embodiments may be implemented in a magnetic data storage system such as a disk drive system, which may include a magnetic head, a drive mechanism for passing a magnetic medium (e.g., hard disk) over the magnetic head, and a controller electrically coupled to the magnetic head.
[0009] Other aspects and advantages of the present invention will become apparent from the following detailed description, which, when taken in conjunction with the drawings, illustrate by way of example the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is an oblique view of a magnetic disk device, according to one embodiment.
[0011] FIG. 2 is a diagram showing the front end of a head assembly, according to one embodiment.
[0012] FIGS. 3( a )-( b ) show several views of a portion of a magnetic head, according to one embodiment.
[0013] FIG. 4 is a cross-sectional view of a magnetic head at the track center, according to one embodiment.
[0014] FIG. 5 shows iso-magnetic field curves illustrating an effect of using the magnetic head, according to one embodiment.
[0015] FIG. 6 shows iso-magnetic field curves illustrating an effect of using a magnetic head, according to a comparative example.
[0016] FIG. 7 shows magnetic gradients illustrating an effect of using the magnetic head, according to one embodiment.
[0017] FIG. 8 is a plan view of the magnetic head seen from the floating surface, according to one embodiment.
[0018] FIG. 9 shows iso-magnetic field curves illustrating an effect of using the magnetic head, according to one embodiment.
[0019] FIG. 10 is an oblique view of the tip of a main magnetic pole in a magnetic head, according to one embodiment.
[0020] FIG. 11 is a plan view of a magnetic head seen from the floating surface, according to one embodiment.
[0021] FIG. 12 is a plan view of the magnetic head seen from the floating surface, according to one embodiment.
[0022] FIGS. 13( a )-( c ) show a diagram of a construction process of a magnetic head, according to one embodiment.
[0023] FIGS. 14( a )-( c ) show a schematic diagram illustrating the overlapping of tracks in a shingled magnetic recording system.
DETAILED DESCRIPTION
[0024] The following description is made for the purpose of illustrating the general principles of the present invention and is not meant to limit the inventive concepts claimed herein. Further, particular features described herein can be used in combination with other described features in each of the various possible combinations and permutations.
[0025] Unless otherwise specifically defined herein, all terms are to be given their broadest possible interpretation including meanings implied from the specification as well as meanings understood by those skilled in the art and/or as defined in dictionaries, treatises, etc.
[0026] It must also be noted that, as used in the specification and the appended claims, the singular forms “a,” “an” and “the” include plural referents unless otherwise specified.
[0027] In one general embodiment, a magnetic head includes a main magnetic pole having a protruding portion such that a distance from a first side of a trailing edge of the main magnetic pole to a leading edge of the main magnetic pole is different from a distance from a second side of the trailing edge of the main magnetic pole to the leading edge of the main magnetic pole, an auxiliary magnetic pole, and a coil wound around a magnetic circuit, the magnetic circuit including the main magnetic pole and the auxiliary magnetic pole.
[0028] In another general embodiment, a magnetic head includes a main magnetic pole having a protruding portion such that a distance from a first side of a trailing edge of the main magnetic pole to a leading edge of the main magnetic pole is different from a distance from a second side of the trailing edge of the main magnetic pole to the leading edge of the main magnetic pole, an auxiliary magnetic pole, and a coil wound around a magnetic circuit, the magnetic circuit including the main magnetic pole and the auxiliary magnetic pole. The protruding portion of the main magnetic pole is comprised of a magnetic material having a higher degree of saturated flux density than the remainder of the main magnetic pole. Also, the protruding portion of the main magnetic pole is comprised of a magnetic material having a higher iso-magnetic permeability than the remainder of the main magnetic pole, and a magnetic body is positioned towards the trailing side of the main magnetic pole and towards a track width side of the main magnetic pole.
[0029] A shingled recording system, according to one embodiment, is a device in which tracks are recorded onto a magnetic recording medium by a magnetic head with the tracks partially overlapping. A magnetic recording device can be created which has a track pitch smaller than the tracks being recorded. It is also possible to have a magnetic head with a magnetic pole wider than those used in conventional magnetic recording devices by designing the magnetic pole differently. However, as the tracks are recorded in an overlapped fashion, the quality of the recording magnetic field is more important at the edges of the tracks than in the middle.
[0030] With conventional perpendicular recording heads, the strength and gradient of the magnetic field is large at the center of the track. For this reason, if a perpendicular magnetic recording head having a conventional structure is used as a shingled recording head, a difficulty arises where the good characteristics of the recording head will not be utilized. To improve recording performance, it is desirable to concentrate the distribution of the magnetic field more to the edge portions of the main magnetic pole of the recording head. Japanese Patent Office Pub. No. 2006-323899 and Tagawa Kanai et al.; SRC 27 th Technical Report Materials , May 2009, cite devices where a side shield is fitted to one side only, but further improvements to the head are desirable.
[0031] Taking note of the above situation, it is desirable to have a magnetic pole design for a magnetic recording head suitable for a shingled magnetic recording system in which the quality of the magnetic field in the vicinity of the track edges is improved. A magnetic head, according to one embodiment, has a structure whereby the distances from the leading edge to the left and right ends of the trailing side of the main magnetic pole are different.
[0032] In another embodiment, the trailing side of the main magnetic pole is provided with a protrusion or a step on one side only. Furthermore, the saturated magnetic flux density of the protruding portion of the main magnetic pole is large. In another embodiment, the magnetic permeability of the protruding portion of the main magnetic pole is high.
[0033] According to one embodiment, it is possible to provide a magnetic recording head suitable for a shingled magnetic recording system in which the magnetic gradient in the vicinity of the track edges is improved.
[0034] An embodiment of the magnetic disk device, head assembly, and head slider on which the magnetic recording head is mounted is described with reference to the drawings.
[0035] FIG. 1 shows an oblique view of a magnetic disk device 1 . In FIG. 1 , the top cover is not shown. Magnetic recording medium 2 and head assembly 4 are accommodated within the chassis of the magnetic disk device 1 . Magnetic recording medium 2 is attached to a spindle motor 3 which is provided on the bottom of the chassis. Head assembly 4 is supported on bearings so as to be rotatable adjacent to the magnetic recording head 2 . The front end of this head assembly 4 is provided with a suspension arm 5 , the tip of which supports a head slider 10 . At the same time, a coil motor 7 is provided at the rear end of head assembly 4 , such as a voice coil motor. The coil motor 7 is the drive source which rotates the head assembly 4 , and moves the head slider 10 across the magnetic recording medium 2 in an approximately radial direction.
[0036] FIG. 2 is a schematic diagram illustrating the front end of a head assembly 4 . In the diagram, directions X, Y, and Z, respectively, show the longitudinal, lateral, and depth directions for the head slider 10 . Of these, direction Z corresponds to the direction of float for the head slider 10 . Moreover, directions X and Y essentially correspond, respectively, to the rotational and diametric directions (in other words, the longitudinal and lateral directions of the track) of the magnetic recording head 2 . Furthermore, arrow DR shows the direction of rotation of the magnetic recording medium 2 , arrow LD shows the leading direction of the head slider 10 , and arrow TR shows the trailing direction of the head slider 10 .
[0037] Head slider 10 is supported at the tip of the suspension arm 5 . With this head slider 10 , surface 10 a , which faces disk-shaped medium 2 , is known as an Air Bearing Surface (ABS) and floats above the rotating disk-shaped medium 2 due to the wedge effect of a gas, such as air. This head slider 10 is provided with a slide base 12 of a flattened orthogonal shape comprised of sintered aluminum, titanium carbide, etc., and thin film section 14 is formed using a thin-film forming method on the end surface of the trailing side of the slide base 12 .
[0038] FIG. 4 is a schematic cross-sectional view showing the main parts of the thin film ( 14 , FIG. 2 ) provided on the trailing section of the head slider 10 . A recording head ( 32 , FIG. 4 ) is provided with a pillar 323 comprising a magnetic body between a main magnetic pole 321 and an auxiliary magnetic pole 325 . The main magnetic pole 321 , auxiliary magnetic pole 325 and pillar 323 are comprised of a soft magnetic material, such as permalloy, CoFe alloy, etc. The main magnetic pole 321 is attached to a tip section 327 via a yoke 326 . Tip section 327 extends as far as the medium-facing surface 10 a of the head, its tip surface 327 a appearing on the medium-facing surface 10 a . The trailing side and side edge of the tip section 327 are provided with a side shield 38 and a trailing shield 39 to enhance the magnetic gradient. Playback head 34 contains a playback element 341 comprising a magnetic resistance effect element and a pair of magnetic shields 343 , 344 which surround the magnetic resistance effect element. Furthermore, shield 37 comprising a magnetic body is provided with the purpose of reducing influx of the recording magnetic field into the magnetic shield 344 .
[0039] The main magnetic pole 321 is magnetized by a coil 329 wound around the yoke 326 , with the recording magnetic field being generated from the tip surface 327 a of the tip section 327 . The recording magnetic field generated from the tip section 327 penetrates magnetic recording layer 21 and intermediate layer 22 of the magnetic disk 2 perpendicularly, and is returned at the soft magnetic reversing layer 23 , being absorbed by the auxiliary magnetic pole 325 . The recording is magnetized and written into magnetic recording layer 21 by the recording magnetic field generated from the tip section 327 .
[0040] FIGS. 3( a )-( b ) show several views of the magnetic recording head, in some embodiments. FIG. 3( a ) is an overall plan view of the main parts of the thin film 14 seen from the floating surface, and FIG. 3( b ) is an enlarged view showing the vicinity of the end section of the main magnetic pole. The end section of the main magnetic pole, according to one embodiment, has a structure whereby the distances from the leading edge to a first and second end of the trailing side of the main magnetic pole are different. In other words, the main magnetic pole has a structure such that L 1 shown in FIG. 3( b ) is larger than L 2 . For purposes of explanation, and not limiting in any way, the first and second ends will be described as the left and right ends of the trailing side of the main magnetic pole, as depicted in FIG. 3( b ), for use in shingled recording systems where the tracks are written from the right to left. However, the protruding portion of the main magnetic pole may be on either side of the main magnetic pole, and is not limited to a left or right side as described herein. Thus, if the tracks are written from the left to the right, the protruding portion 328 may be positioned on the left side of the main magnetic pole.
[0041] With continued reference to FIG. 3( b ), this type of structure is possible due to the projecting portion 328 . Moreover, the structure of the side shield is such that it is only provided on the L 1 side, according to one approach. Of course, a shield may be provided on other sides of the main magnetic pole as well. By arranging the magnetic head in this way, it is possible to provide a magnetic recording head suitable for shingled magnetic recording in which the magnetic field gradient is improved in the vicinity of the track edges.
[0042] FIG. 5 is a diagram showing results of three-dimensional magnetic field calculation of magnetic field strength applied to the magnetic recording medium device of the magnetic head, according to one embodiment.
[0043] The calculation is performed as follows, with reference to FIG. 4 . The magnetic field generated from the main magnetic pole 321 including the tip section 327 is calculated in a three-dimensional magnetic field calculation which uses the limited element method. The gap between the tip section 327 of main magnetic pole 321 and the trailing shield 39 is about 25 nm. The gap between the tip section 327 of the main magnetic field 321 and the side shield 38 is about 40 nm. The width of the end section of the trailing side of the end surface 327 a of the main magnetic pole 321 is about 80 nm. End surface 327 a of the main magnetic pole 321 is bevelled to an angle α of about 9°, giving it a reverse trapezoidal shape in which the width of the leading edge end is narrower than the width of the trailing side end. The material of tip section 327 of the main magnetic pole 321 is assumed to be CoNiFe (but is not so limited), with a saturated magnetic flux density of 2.4 T, and relative magnetic permeability of 100. Yoke section 326 of the main magnetic pole 321 is assumed to be 80 at % Ni-20 at % Fe (but not so limited) with a saturated magnetic flux density of 1.0 T. For the auxiliary magnetic pole 325 , the saturated magnetic flux density of the material is assumed to be 1.0 T, with the width in the Y direction being about 30 μm, the length in the Z direction about 16 μm, and the length in the X direction about 2 μm.
[0044] Moreover, magnetic shields 343 , 344 of the playback head, and shield 37 are assumed to be 80 at % Ni-20 at % Fe (but not so limited) with a saturated flux density of 1.0 T, the width in the Y direction being about 32 μm, the length in the Z direction about 16 μm, and the length in the X direction about 1.5 μm. The magnetic material for the magnetic body 38 is assumed to be 45 at % Ni-55 at % Fe (but not so limited), with a saturated flux density of 1.7 T and relative magnetic permeability of 1000. The thickness of the trailing shield 39 and the side shield 38 is about 200 nm. The number of windings on coil 329 is assumed to be 4 turns, with the recording current being about 35 mA. The soft magnetic under layer 23 of the magnetic disk 2 is made of a material with a saturated flux density of 1.1 T, and a thickness of about 40 nm is assumed. The thickness of the magnetic recording layer 21 is about 19 nm. The thickness of the intermediate layer 22 is about 22 nm. It is presumed that the head slider 10 will float by about 9 nm. Thus the distance between the surface of the under layer 23 and the slider 10 is about 50 nm. The recording magnetic field is calculated as the value at the position of the magnetic recording layer 21 at a depth of about 18.5 nm from the medium-facing surface 10 a.
[0045] The X-axis in FIG. 5 shows the width direction and the Y-axis in the scanning direction. The interval between iso-magnetic curves is 1000 (×1000/4π[A/M]). It is clear that the magnetic field distribution is concentrated on the right side of the diagram. It will be seen that the magnetic field is greatest in the vicinity shown by the letter A in the diagram.
[0046] FIG. 6 shows iso-magnetic curves for a structure without a protruding portion 328 . The magnetic field has not increased in the position corresponding to letter A in FIG. 5 .
[0047] FIG. 7 shows the profile for the magnetic gradient at the magnetic field position of 8×10 3 (×1000/4π[A/M]). The X-axis shows the position in the track width direction, the Y-axis the magnetic gradient standardized for the respective maximum magnetic gradients. Compared to the conventional structure without a projecting portion ( 328 , FIG. 4 ), it is clear that with the structure disclosed herein, the magnetic gradient is largest at the center on the right side of the graph, referring to FIG. 7 . In the case of shingled recording, the edge of one side of the magnetic distribution is used to record the track. For this reason, the structure with a large magnetic gradient on one side is suitable for shingled magnetic recording.
[0048] To have a large variation in the magnetic distribution, it is desirable that the width in the track width direction of the protruding portion ( 328 , FIG. 4 ) be smaller than other track width directions for protruding portion 328 . Moreover, if the length of protruding portion 328 in the scan direction is greater than the width in the track width direction, it is possible to vary the magnetic distribution more.
[0049] FIG. 8 is a diagram showing the structure of another embodiment. It has a structure such that the trailing shield has a shape which follows the main magnetic pole. FIG. 9 shows iso-magnetic curves for which the magnetic distribution was calculated with the three-dimensional magnetic method used for the structure in FIG. 8 . The portions with a higher magnetic field density in the diagram have shifted to the right, meaning that the device is suitable for shingled magnetic recording.
[0050] FIG. 10 shows an oblique view of an example of the tip of the main magnetic pole, according to one embodiment. To vary the magnetic distribution so that it is suitable for shingled magnetic recording, it is desirable that protruding portion 328 be provided in the direction of height of the head element toward the first position (squeeze position) from the floating surface in which the width in the track width direction varies greatly.
[0051] Moreover, as shown in FIG. 11 , the saturated magnetic flux density of the magnetic body used across the range of protruding portion 328 may be larger than the tip section 327 of the main magnetic pole. In this way, it is possible to concentrate the flux to make it suitable for shingled magnetic recording. Moreover, the saturated magnetic flux density of the magnetic body on one side of the leading edge of protruding portion 328 may be made greater than tip section 327 of the other main magnetic pole. In addition to the saturated magnetic flux density, the relative magnetic permeability may also be larger.
[0052] In the case where side shields are provided on both sides as shown in FIG. 12 , it is desirable that gap W 1 between the main magnetic pole on the side of protruding portion 328 and the side shield be less than W 2 . In this way, it is possible to concentrate the magnetic distribution on one side of the track so that it is suitable for shingled magnetic recording.
[0053] The manufacture of the main magnetic pole, according to one embodiment, involves the formation of a non-magnetic layer after a magnetic film has been formed on the main magnetic pole, with a subsequent process in which the magnetic film of the main magnetic pole is cut away using this non-magnetic layer as a mask.
[0054] FIGS. 13( a )-( c ) show an example of this portion of a manufacturing process for the main magnetic pole, according to one embodiment. The diagram shows the shape seen from the floating surface, with the trailing and leading directions shown at the top and bottom of the diagram, the track width being shown to left and right.
[0055] In FIG. 13( a ) a situation where an inorganic insulating layer 50 has been formed is shown, and after the formation of the tip section 327 , resist pattern 51 is formed above it. Methods of forming tip section 327 include a process which uses a magnetron sputter method using photo resist as a mask, and a process which employs plating using the resist pattern used to form the main magnetic pole. Resist pattern 51 is characterized in being formed asymmetrically. Next, as shown in FIG. 13( b ), this resist pattern 50 is used as a mask, and a tip section 327 and inorganic insulation film 50 are cut away using ion milling. Materials suitable for inorganic insulation film 50 include, but are not limited to, Al 2 O 3 , AlN, Ta 2 O 5 , TiC, TiC 2 , SiO 2 , SiO, etc. In FIG. 13( c ) the resist pattern 51 is shown removed after ion milling. The side shield and trailing shields are then formed. The side shield may be formed in advance of the process shown in FIGS. 13( a )-( c ). Moreover, after the process in FIG. 13 and after forming the non-magnetic film for the trailing gap, a process may be carried out including chemical polishing, mechanical polishing, etc., to flatten the surface. Using this method, it is possible to manufacture the magnetic head described herein according to several embodiments.
[0056] In FIGS. 14( a )-( c ), an illustrative shingled recording system is shown. In FIG. 14( a ), a first track having a track width Tw 1 is recorded. The relative movement between the disc and the trapezoidal shaped head is such that the head scan moves in a direction pointing down. In FIG. 14( b ), a second track having a track width Tw 2 is recorded adjacent to the first track. As can be seen, the first and second track overlap slightly. In FIG. 14( c ), a third track having a track width Tw 3 is recorded adjacent to the second track. Once again, the third track overlaps slightly with the second track. Therefore, as previously described, the magnetic flux properties of the head at the track width edges is important in shingled recording systems. As shown here, tracks are written left to right, but may be written right to left.
[0057] While various embodiments have been described above, it should be understood that they have been presented by way of example only, and not limitation. Thus, the breadth and scope of an embodiment of the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents. | A magnetic head, according to one embodiment, includes a main magnetic pole having a protruding portion such that a distance from a first side of a trailing edge of the main magnetic pole to a leading edge of the main magnetic pole is different from a distance from a second side of the trailing edge of the main magnetic pole to the leading edge of the main magnetic pole, an auxiliary magnetic pole, and a coil wound around a magnetic circuit, the magnetic circuit including the main magnetic pole and the auxiliary magnetic pole. In another embodiment, a disk drive system includes a magnetic storage medium, at least one magnetic head as described previously for writing to the magnetic medium, a slider for supporting the magnetic head, and a control unit coupled to the magnetic head for controlling operation of the magnetic head. Additional systems and heads are also presented. | 6 |
BACKGROUND OF INVENTION
[0001] 1. Field of the Invention
[0002] Embodiments disclosed herein relate generally to methods and control devices for production of consistent water quality from membrane-based water treatment for use in improved hydrocarbon recovery operations.
[0003] 2. Background Art
[0004] Hydrocarbons accumulated within a subterranean hydrocarbon-bearing formation are recovered or produced therefrom through production wells drilled into the subterranean formation. When production of hydrocarbons slows, improved recovery techniques may be used to force the hydrocarbons out of the formation. One of the simplest methods of forcing the hydrocarbons out of the formation is by direct injection of fluid into the formation. This enhances production by displacing or sweeping hydrocarbons through the formation so that they may be produced from production well(s).
[0005] As shown in FIG. 1 , a prior art system for recovering hydrocarbons from a formation consists of an offshore rig 12 connected to a well 10 , which is completed in a subterranean hydrocarbon-bearing formation 14 . Generally, fluid is injected directly into the subterranean hydrocarbon-bearing formation 14 (indicated by the down arrow) and forces the hydrocarbons through the formation and out of the well 10 (indicated by the up arrow) via a production well, which may be the same or a different well. One type of such recovery operation uses water (e.g., seawater, produced water) as the injection fluid, which is referred to as a waterflood. Water is injected, under pressure, into the formation via injection wells, driving the hydrocarbons through the formation toward production wells.
[0006] Injection water used in waterflooding for offshore wells is typically seawater and/or produced water because of the low-cost availability of seawater and/or produced water at offshore locations. Another motivation for using produced water as an injection water offshore is the difficulty in some locations in disposing the produced water offshore. In any case, seawater and produced water are generally characterized as saline, having a high ionic content relative to fresh water. For example, the fluids are rich in sodium, chloride, sulfate, magnesium, potassium, and calcium ions, to name a few. Some ions present in injection water can benefit hydrocarbon production. For example, certain combinations of cations and anions, including K + , Na + , Cl − , Br − , and OH − , can stabilize clay to varying degrees in a formation susceptible to clay damage from swelling or particle migration.
[0007] However, it has also been found that certain ions, including calcium and/or sulfate, present in the injection water may have harmful effects on the injection wells and production wells and can ultimately diminish the amount or quality of the hydrocarbon product produced from the production wells. Specifically, sulfate ions can form salts in situ when contacted with metal cations such as barium and/or strontium, which may be naturally occurring in the reservoir. Barium and strontium sulfate salts are relatively insoluble and readily precipitate out of solution under ambient reservoir conditions. Solubility of the salts further decreases as the injection water is produced to the surface with the hydrocarbons because of temperature decreases in the production well. The resulting precipitates accumulate as barium sulfate scale in the outlying reservoir, at the wellbore of the hydrocarbon production wells, and downstream thereof (e.g., in flow lines, gas/liquid separators, transportation pipelines, etc). The scale reduces the permeability of the reservoir and reduces the diameter of perforations in wellbores, thereby diminishing hydrocarbon recovery from the hydrocarbon production wells. Divalent cations are particularly effective at stablizing sensitive clays.
[0008] It has also been reported that a significant concentration of sulfate ions in injection water promotes reservoir souring. Reservoir souring is an undesirable phenomenon whereby reservoirs are initially sweet upon discovery, but turn sour during the course of waterflooding and attendant hydrocarbon production from the reservoir. Souring contaminates the reservoir with hydrogen sulfide gas or other sulfur-containing species and is evidenced by the production of quantities of hydrogen sulfide gas along with the desired hydrocarbon fluids from the reservoir via the hydrocarbon production wells. The hydrogen sulfide gas causes a number of undesired consequences at the hydrocarbon production wells and downstream of the wells, including excessive degradation and corrosion of the hydrocarbon production well metallurgy and associated production equipment, diminished economic value of the produced hydrocarbon fluids, an environmental hazard to the surroundings, and a health hazard to field personnel.
[0009] The hydrogen sulfide is believed to be produced by an anaerobic sulfate-reducing bacteria. The sulfate-reducing bacteria is often indigenous to the reservoir and is also commonly present in the injection water. Sulfate ions and organic carbon are the primary feed reactants used by the sulfate reducing bacteria to produce hydrogen sulfide in situ. The injection water is usually a plentiful source of sulfate ions, while formation water is a plentiful source of organic carbon in the form of naturally-occurring low molecular weight fatty acids. The sulfate reducing bacteria effects reservoir souring by metabolizing the low molecular weight fatty acids in the presence of the sulfate ions, thereby reducing the sulfate to hydrogen sulfide. Stated alternatively, reservoir souring is a reaction carried out by the sulfate reducing bacteria which converts sulfate and organic carbon to hydrogen sulfide and byproducts.
[0010] A number of strategies have been employed in the prior art for remediating reservoir souring with limited effectiveness. These prior art strategies have primarily been single pronged attacks against either the sulfate reducing bacteria itself or against a specific food nutrient of the sulfate reducing bacteria. For example, many prior art strategies have focused on killing the sulfate reducing bacteria in the injection water or within the reservoir. Conventional methods for killing the sulfate reducing bacteria or limiting their growth may include ultraviolet light, biocides, and chemicals such as acrolein and nitrates. Other prior art strategies for remediating reservoir souring have focused on limiting the availability of sulfates or organic carbon to the sulfate reducing bacteria.
[0011] More recently, strategies for remediating reservoir souring have included the use of membranes to reduce the concentration of sulfate ions in injection water. For example, U.S. Pat. No. 4,723,603 shows that specific membranes can effectively reduce the concentration of sulfate ions in injection water, thereby inhibiting sulfate scale formation. As taught by the prior art, nanofiltration (NF) membranes are often preferred to reverse osmosis (RO) membranes because nanofiltration membranes generally permit a higher passage of sodium chloride compared to reverse osmosis membranes. Consequently, nanofiltration membranes are advantageously operable at substantially lower pressures and operating costs than reverse osmosis membranes. Furthermore, nanofiltration membranes also maintain the ionic strength of the resulting injection water at a relatively high level, which desirably reduces the risk of clay instability and correspondingly reduces the risk of water permeability loss through the porous substrata of the subterranean formation.
[0012] However, in addition to the problems associated with sulfate ions being present in the injection water, it has also been found that the salinity of an injection water can have a major impact on the recovery of hydrocarbons during waterfloods, with increased recovery resulting from the use of injection water of lower salinity than natural seawater but sufficient ionic strength to prevent clay instability. Depending on the type of formation, injection fluids having higher salinity may cause the reservoir wettability to become more oilwet. This is because the multivalent cations in the brine, such as Ca +2 and Mg +2 , are believed to act like bridges between the negatively charged oil and the negatively charged clay minerals that typically line the pore walls of the formation. The oil reacts with the clay particles to form organo-metallic complexes, which results in the clay surface being extremely hydrophobic and oilwet. As the oilwetness of the reservoir rock increases, hydrocarbons will adsorb onto the surface of the rock and thereby flow less easily from the formation, relative to water, which results in less hydrocarbon product being produced.
[0013] Lowering the electrolyte content (i.e., lowering the ionic strength) by lowering the overall salinity and especially reducing the concentration of multivalent cations in the formation reduces the screening potential of the cations. This results in increased electrostatic repulsion between the clay particles and the oil. Once the repulsive forces exceed the binding forces via the multivalent cation bridges, the oil particles are desorbed from the clay surfaces and the clay surfaces become increasingly waterwet. If, however, the electrolyte content is reduced too much (i.e., the formation fluid salinity is too low), the clay particles may be stripped from the pore walls (clay deflocculation), which will damage the formation. Thus, although it is desirable to have lower salinity injection water, it is important that the salinity levels be kept within a specified range.
[0014] Lower salinity water, however, is not often available at a well site. Lower salinity water is typically prepared, for example, by reducing the total ion concentration of higher salinity water using membrane separation technology (e.g., reverse osmosis). In known seawater desalination plants operating according to the reverse osmosis process, the seawater to be desalinated is subjected to a separation process by means of a semi-permeable membrane. Such a membrane is understood to be a selective membrane, which is permeable to a high degree to the water molecules, but only to a very low extent to the salt ions dissolved therein.
[0015] Membrane separation techniques used in the preparation of low salinity injection water use reverse osmosis (RO) membrane elements. Membrane separation techniques used in the preparation of low sulfate injection water and softened water use specialized nanofiltration (NF) membrane elements. The RO and NF processes use hydraulic pressure to produce lower salinity water from feed water through a semipermeable membrane. Depending on the membrane type, pressure and water conditions, an amount of salt also passes across the membrane, but the overall salinity of the product water is less than that of the feed water. Current RO technology can be used for desalinating both seawater and brackish water. The membranes used in the RO process are generally either made from polyamides or from cellulose sources.
[0016] The water to be treated is typically pretreated using cartridge filters, media filtration, microfiltration, or ultrafiltration methods, which are known to separate solids/particulates from the water based on their size. The water is then fed to the reverse osmosis and/or nanofiltration vessel using a high-pressure pump. The required pressure from the high-pressure pump is a function of the osmotic pressure, the temperature, the flux (i.e., the rate at which the water passes through a unit area of the membrane), and the volume of the feed water to be produced with a specific membrane area. The product water (i.e., the permeate) is discharged from the membrane module by way of a permeate conduit. A concentrate conduit serves for discharging concentrated ionic water.
[0017] Typically, conventional systems are only concerned with producing water having certain characteristics in amounts higher or lower than a predetermined level. Such systems focus only on a maximum allowable limit of a contaminant and treatment occurs as long as, and only if, the amount of the particular characteristic is above the set limit. Otherwise, the water is deemed acceptable for use. Most often, such a treatment plant will include several treatment blocks connected in series and/or parallel. In such systems, water is passed through as many of the multiple blocks, or through a particular block as many times, as is necessary for the particular characteristic in the water to reach the amount deemed acceptable for use.
SUMMARY OF INVENTION
[0018] In one aspect, embodiments disclosed herein relate to a method for treating seawater or other water sources for injection, the method including intaking a first amount of water into a plurality of treatment blocks, treating the first amount of water, outputting aqueous treated water streams from each of the plurality of treatment blocks, separating the aqueous treated water streams from each of the plurality of treatment blocks into aqueous permeate streams and concentrate reject streams, monitoring each of the aqueous permeate streams, controlling the operation of at least one of the plurality of treatment blocks based on predefined water-characteristic tolerances that fall within a predetermined concentration range based on the different qualities of the aqueous permeate streams, combining the aqueous permeate streams of at least two of the plurality of treatment blocks based on the identified characteristics and the predefined water-characteristic tolerances, and outputting the product water stream and the at least one concentrate reject stream. Treating the first amount of water includes pumping at least a portion of the first amount of water through the plurality of treatment blocks. Monitoring each of the aqueous permeate streams includes identifying different characteristics of the aqueous permeate streams.
[0019] According to another aspect, there is provided a membrane-based water treatment system, the system including a water intake system that intakes a first amount of water and a plurality of treatment blocks. Each of the plurality of treatment blocks includes at least one pump, a membrane pressure vessel, a monitor, and a controller. The pump feeds the first amount of intake water through the membrane pressure vessel. The membrane pressure vessel comprises at least one membrane element and separates the first amount of intake water into at least an aqueous permeate stream and a concentrate reject stream. The monitor is used to identify different characteristics of each of the aqueous permeate streams, monitor blending of the aqueous permeate streams from two or more treatment blocks, and to monitor the blended aqueous permeate streams from the two or more treatment blocks based on the identified characteristics and predefined water-characteristic tolerances.
[0020] Other aspects and advantages of the invention will be apparent from the following description and the appended claims.
BRIEF DESCRIPTION OF DRAWINGS
[0021] FIG. 1 shows a prior art offshore production well.
[0022] FIG. 2 shows a seawater treatment process according to one or more embodiments of the present invention.
[0023] FIG. 3A is a diagram of a seawater treatment unit on a vessel according to one or more embodiments of the present invention.
[0024] FIG. 3B is a diagram of a seawater treatment unit on an off-shore rig according to one or more embodiments of the present invention.
[0025] FIG. 3C is a diagram of a rig, a vessel, and a seawater treatment unit on the seafloor according to one or more embodiments of the present invention.
[0026] FIG. 4A shows another seawater treatment process according to one or more embodiments of the present invention.
[0027] FIG. 4B shows a treatment block according to one or more embodiments of the present invention.
[0028] FIG. 4C shows a spiral wound membrane element according to one or more embodiments of the present invention.
[0029] FIG. 4D shows a schematic for a hollow fine fiber membrane element according to one or more embodiments of the present invention.
[0030] FIG. 4E shows another seawater treatment process according to one or more embodiments of the present invention.
[0031] FIG. 5 shows an improved oil recovery system according to one or more embodiments of the present invention.
[0032] FIG. 6A shows a configuration for a system or method according to one or more embodiments of the present invention.
[0033] FIG. 6B shows a configuration for a system or method according to one or more embodiments of the present invention.
[0034] FIG. 7 shows a configuration for a system or method according to one or more embodiments of the present invention.
DETAILED DESCRIPTION
[0035] One or more embodiments of the present invention will be described below with reference to the figures. In one aspect, embodiments disclosed herein relate to systems and methods for treating seawater or other water source using customizable membrane technology to prepare an aqueous fluid having specific water characteristic tolerances that fall within predefined threshold values. In another aspect, embodiments disclosed herein relate to a water treatment process having a customizable membrane system that may include a bypass blend line which may be used depending on the water outputted from the customizable membrane system to achieve predefined threshold values. In yet another aspect, embodiments disclosed herein relate to the treatment of seawater using a customizable treatment system to produce an aqueous fluid which has specifically tailored properties and which is capable of being used as an injection fluid to be used in improved oil recovery operations. In yet another aspect, embodiments disclosed herein relate to blending treated fluids which have specifically tailored properties. In yet another aspect, embodiments disclosed herein relate specifically to improved oil recovery operations in offshore wells.
[0036] Seawater Treatment
[0037] Typically, seawater treatment systems are based on several factors. Most importantly, seawater treatment systems depend on the quality of the seawater (e.g., the temperature, salinity, and/or specific chemical composition of the water). In particular, the input water temperature variance of the seawater is the most common factor that varies to which the treatment system must react in order to produce consistent water quality. Water temperature impacts the treatment performance as a function of the water and salt transport property variation of the membranes. Warmer water will result in treated water with higher salinity than the same treatment of cooler water. In addition, as the membrane used in the treatment system ages, its performance changes, thereby impacting the water and salt transport properties and the resulting treated water quality. According to embodiments of the present invention, depending on these factors, a treatment system may be customized to produce any quality of output water desired.
[0038] As used herein, the term “predefined water-characteristic tolerances” is used to refer to the desired output water quality that falls within predefined threshold values for any system which will be using the treated water. For example, in downhole applications, it may be desired to produce a water having a salinity of between about 1,000 mg/L and about 30,000 mg/L, a sulfate ion content of between about 5 mg/L and 2,000 mg/L and hardness content of between 5 mg/L and 300 mg/L.
[0039] According to one or more embodiments of the present invention, a seawater treatment system may be used to produce water having predefined water-characteristic tolerances, for example, by controlling pumps within the system to ensure that any water having characteristics outside the predefined threshold values is appropriately blended either with treated or untreated (or both) filtered water to produce a water that has characteristics falling inside the predefined threshold values.
[0040] In one embodiment, a treatment system comprising multiple membrane blocks may be modified so as to change the operation of each of the membrane blocks themselves so they produce different quality water streams based on the predefined water-characteristic tolerances. These different quality water streams may then be blended together to form a product water stream having predefined water-characteristic tolerances. Alternatively, the product water stream may be further blended with untreated filtered seawater from a blend/bypass line.
[0041] In particular, control devices may be used (e.g., a monitor and/or transmitter) to modify or vary the operational parameters of each block based on the outputted permeate water streams. Operational parameters to be modified may include input feed pressure, flux, temperature, flowrate, and water recovery.
[0042] Referring to FIGS. 2 and 3 A-C, a seawater treatment system according to one or more embodiments is shown. As shown in FIG. 2 , the present invention provides a seawater treatment system 200 that may include a water intake system 201 , a membrane system 210 , permeate transfer and treatment system 220 , a concentrate discharge system 230 , a control system 240 , and a power source 290 . Water intake system 201 may include water intake(s) 202 , water intake pump(s) 204 , pre-filter(s) 206 , and membrane/media-filter(s) 208 ; membrane system 210 may include variable speed high-pressure pump(s) 212 , blend/bypass line(s) 225 , either a reverse osmosis and/or nanofiltration membrane(s) 214 , and monitor/transmitter(s) 226 ; the concentrate discharge system 230 may include a plurality of discharge ports; and permeate transfer and treatment system 220 may include permeate transfer pump(s) 222 . While in the exemplary embodiments shown, certain components may be shown by a single block/symbol, those skilled in the art will appreciate that each system described may be comprised of a plurality of such elements.
[0043] As shown in FIGS. 3A-C , the seawater treatment system 200 may be provided on a vessel 300 , on a rig 312 , and/or on the seafloor 316 . Alternatively, in one or more embodiments, the seawater treatment system 200 may be used onshore.
[0044] Additionally, according to one or more embodiments, treatment block 260 may be used to describe the system that includes, for example, membrane system 210 , blend/bypass line 225 , concentrate discharge system 230 .
[0045] The treatment block 260 is in communication with the water intake system 201 and the permeate transfer and treatment system 220 . Both the control system 240 and the power source 290 are in communication with one another, as well as in communication with the water intake system 201 , the permeate transfer and treatment system 220 , and treatment block 260 (i.e., membrane system 210 and concentrate discharge system 230 ). As used herein, the terms “communicate” or “communication” mean to mechanically, electrically, or otherwise contact, couple, or connect by direct, indirect, or operational means.
[0046] Within the water intake system 201 , water intake pump 204 pumps the intake water through pre-filter 206 to remove any large contaminants (e.g., sand, rocks, plants, debris, etc.) and then through a low pressure membrane or media filter 208 to remove large molecules (e.g., suspended solids, colloids, macromolecules, bacteria, oils, particulate matter, proteins, high molecular weight solutes, etc.). One of ordinary skill in the art will appreciate that depending on the specifications of the equipment and the type and density of particulate matter to be removed, various types of filters, including for example, sand or media filters, cartridge filters, ultra filters, and/or micro filters may be used.
[0047] Furthermore, the water intake system 201 may include one or more variable-depth extension members capable of extending into the body of water so as to intake water from a desired depth. Additionally, the extension member may include one or more intake screens designed to help prevent fouling of the intakes by marine life or other particles. One of ordinary skill in the art will appreciate that depending on the intended body of water from which water is being taken, other equipment may also be employed.
[0048] After passing through water intake system 201 , the filtered seawater may be provided to blend/bypass line 225 and transferred directly to permeate treatment and transfer system 220 where it may then be combined with a permeate stream produced from membrane 214 . Additionally, the filtered seawater may be provided to treatment block 260 wherein a variable speed high-pressure pump 212 pushes the filtered seawater through to membrane 214 , whereby a concentrate is created on the high pressure side of the membrane 214 and a permeate stream is created on the low pressure side of the membrane 214 .
[0049] The permeate stream produced from membrane 214 may comprise predefined water-characteristic tolerances, i.e., water that has specific ions and/or molecules removed therefrom, for example, the permeate stream may have lower sulfate ion content and/or lower salinity compared to the filtered seawater produced from water intake system 201 . The permeate stream may then be transferred, for example, from vessel 300 to rig 312 , from seafloor 316 to rig 312 , and/or from rig 312 to well 310 , through permeate transfer and treatment system 220 .
[0050] Alternatively, the permeate stream produced from membrane 214 may not comprise the desired predefined water-characteristic tolerances and may need to be further treated in order to reach the predefined water-characteristic tolerances. For example, the permeate stream may be blended with other permeate streams and/or untreated filtered seawater from the blend/bypass line. However, based on the quality of the permeate stream produced from membrane 214 , it may be necessary to change the operation of the membrane block itself so it will produce a different quality water stream based on the outputted permeate stream produced from the membrane and based on predefined water-characteristic tolerances. Such a change may be made by using a monitor 226 to first determine the quality of the outputted permeate stream and second to vary or change the operation of the membrane block itself (e.g., by controlling the pump 212 that pumps water into the membrane block 214 and/or a concentrate line valve 223 ), thereby changing the quality of the outputted permeate stream for subsequent batches of water.
[0051] Additionally, permeate streams from various treatment blocks 260 may be blended together, and may be blended with untreated filtered seawater from the blend/bypass line 225 to produce water having predefined water-characteristic tolerances. Each treatment block can use the same or a different type of RO or NF membrane requiring its respective pressure from the high-pressure pump 212 . Blending the various permeate streams from each treatment block can then provide a very specific composition of mono- and divalent ions as a function of optimum reservoir performance. According to one or more embodiments, this very specific composition may then be mixed with water from the blend/bypass line 225 .
[0052] According to one or more embodiments of the present invention, a monitor 226 may be used to detect the characteristics of the output permeate streams. Based on these characteristics, one or more monitor 226 may be used to change the operation of the membrane block 214 , for example, by controlling the variable speed high-pressure pump 212 in real-time to change the amount of water being pumped through membrane 214 , so as to produce different quality water having predefined water-characteristic tolerances. Additionally, based on these characteristics, untreated filtered seawater from the blend/bypass line 225 may be blended in with the output permeate streams in order to achieve a water having even more specific water-characteristics tolerances.
[0053] In one or more embodiments, a permeate stream from a treatment block 260 can be further treated using forward osmosis (FO) or other treatment, which impacts the chemical composition of the water to further refine the ionic balance as a function of achieving optimum reservoir performance.
[0054] In one or more embodiments, instead of seawater as the source of water through intake system 201 , brackish water or produced water could be the feed water, thereby allowing the flexibility to switch between brackish water, produced water, and seawater treatment.
[0055] The permeate transfer and treatment system 220 may be capable of transferring the permeate produced to a permeate delivery system comprising a pipeline in communication with the permeate transfer and treatment system 220 . The pipeline may transfer the permeate, for example, from vessel 300 to rig 312 , from seafloor 316 to rig 312 , and/or from rig 312 to well 310 . The permeate transfer and treatment system 220 may also be capable of treating the permeate produced either prior to, during, or after the permeate is transferred. Treatment of the permeate may include “post-treatment,” for example, chemical addition (e.g., in line chemical injection) and/or deaeration (e.g., in a vacuum system).
[0056] The concentrate created on the high pressure side of the membrane 214 comprises the ions and/or molecules removed by membrane 214 . The concentrate is then disposed of, for example, through a plurality of concentrate discharge ports within the concentrate discharge system 230 . However, before the concentrate is disposed of, an energy recovery device (not shown) may be used to capture the energy possessed by the concentrate and return such energy to the variable speed high-pressure pump 212 .
[0057] Furthermore, the concentrate may be diluted or otherwise treated prior to disposal. For example, in one or more embodiments, the concentrate discharge system 230 may be configured to increase the mixing of the concentrate discharged into the surrounding body of water. The plurality of discharge ports of the concentrate discharge system 230 may be physically located above or below the water line 318 of the vessel 300 and/or the rig 312 . Also, the discharge ports may be disposed on a variable-depth extension member that can be positioned so as to promote dispersion of the concentrate into the body of water.
[0058] In one or more embodiments, the effluent from membrane 214 (either the permeate stream or the concentrate) may take one or more subsequent passes through membrane 214 and concentrate streams may be recycled to earlier positions in the treatment scheme.
[0059] According to one or more embodiments of the present invention, separate power source(s) may provide power to each of the water intake system 201 , permeate transfer and treatment system 220 , treatment block 260 (i.e., membrane system 210 concentrate discharge system 230 ), monitor 226 , and propulsion device 302 . For example, each of the water intake pump 204 , variable speed high-pressure pump 212 , monitor 226 , and permeate transfer pump 222 may be in communication with a separate power source.
[0060] According to one or more embodiments, the seawater treatment system 200 may be land-based or provided on a vessel. Where the seawater treatment system 200 is provided on a vessel 300 , vessel 300 may further comprise a propulsion device 302 in communication with the power source 290 . The vessel 300 may be a self-propelled ship, a moored, towed, pushed or integrated barge, or a flotilla or fleet of such vessels. The vessel 300 may be manned or unmanned. The vessel 300 may be either a single-hull or double-hull vessel.
[0061] Alternatively, in one or more embodiments, a single power source may provide power to a combination of two or more of the water intake system 201 , membrane system 210 , permeate transfer and treatment system 220 , concentrate discharge system 230 , monitor 226 , and/or propulsion device 302 where the seawater treatment system 200 is provided on a vessel 300 . For example, electric power for the variable speed high-pressure pump 212 may be provided by a generator driven by the power source for the vessel's propulsion device, such as a vessel's main engine. In such an embodiment, a step-up gear power take off or transmission would be installed between the main engine and the generator in order to obtain the required synchronous speed.
[0062] Further, an additional coupling between the propulsion device and the main engine allows the main engine to drive the generator while the vessel is not under way. Moreover, an independent power source (not shown), such as a diesel, steam, or gas turbine, renewable energy generator, or combinations thereof, may power the treatment block 260 , the propulsion device 302 , or both.
[0063] In other embodiments, the power source for seawater treatment system 200 may be dedicated solely to the seawater treatment system 200 .
[0064] In one or more embodiments, the plurality of concentrate discharge ports of the concentrate discharge system 230 may act as an auxiliary propulsion device for the vessel 300 or act as the sole propulsion device for the vessel 300 . Some or all of the concentrate may be passed to propulsion thrusters to provide idling or emergency propulsion.
[0065] In one or more embodiments, the power source 290 may comprise electricity producing windmills and/or water propellers that harness the flow of the air and/or water to generate power for the seawater treatment system 200 and/or the operation of the vessel 300 and/or rig 312 .
[0066] For embodiments where the seawater treatment system 200 is on a vessel 300 , the water intake system 201 may be capable of taking in seawater from the water surrounding the vessel 300 and providing it to the treatment block 260 . In such embodiments, the water intake 202 of the water intake system 201 may include one or more apertures in the hull of the vessel 300 below the water line 318 . An example of a water intake 202 is a sea chest (not shown). Water is taken into the vessel 300 through the one or more apertures (i.e., water intake 202 ), passed through the water intake pump 204 , pre-filter 206 , membrane/media filter 208 , and either supplied to the variable speed high-pressure pump 212 or supplied to the blend/bypass line 225 , or both.
[0067] For embodiments where the seawater treatment system 200 is on an offshore rig 312 , the water intake system 201 may be capable of taking in seawater from the water surrounding the rig 312 and providing the seawater to the treatment block 260 . In such embodiments, the water intake 202 of the water intake system 201 may include an intake riser(s), screen(s), and external or submerged pump(s).
[0068] For embodiments where the seawater treatment system 200 is on the seafloor 316 , the water intake system 201 may be capable of taking in seawater from the water surrounding the seawater treatment system 200 and providing it to the membrane system 210 . In such embodiments, the water intake 202 of the water intake system 201 may include an intake well or riser, screen(s) and pump(s).
[0069] The membrane system 210 may comprise a variable speed high-pressure pump 212 , a membrane 214 , a blend/bypass line 225 , and a monitor 226 .
[0070] In one or more embodiments, membrane 214 is an ion selective membrane, which may selectively prevent or at least reduce hardening or scale-forming ions (e.g., divalent ions including sulfate, calcium, and magnesium ions) from passing across it, while allowing water and other specific ions (e.g., monovalent ions including sodium, chloride, bicarbonate, and potassium ions) to pass across it. The selectivity of the membrane may be a function of the particular properties of the membrane, including pore size and charge characteristics of the polymeric structure comprising the membrane. For example, a polyamide membrane, a cellulose acetate membrane, a nano-embedded membrane, a piperazine-derivative membrane and/or other membrane innovation may be used to selectively prevent or at least reduce sulfate, calcium, and magnesium ions from passing across it. In one or more embodiments, membrane 214 may reduce up to about 99% of the sulfate ions.
[0071] In one or more embodiments, membrane 214 is a desalting membrane, which may lower the total salinity or ionic strength of the filtered seawater by preventing or at least reducing ions (e.g., sodium, chloride, calcium, potassium, sulfate, bicarbonate, and magnesium ions) from passing across it.
[0072] In one or more embodiments, membrane 214 is a nanofiltration membrane. Examples of commercially available nanofiltration membranes suitable for use in the treatment process of the present disclosure may include, for example, FILMTEC™ SR90 Series, NF 200 Series, NF90 Series which is available from The Dow Chemical Company (Minneapolis, Minn.), or membranes with similar rejection properties from other membrane manufacturers.
[0073] In one or more embodiments, membrane 214 is a reverse osmosis membrane. Examples of commercially available reverse osmosis membranes suitable for use in the treatment process of the present disclosure may include, for example, FILMTEC™ SW 30 Series, which is available from The Dow Chemical Company (Minneapolis, Minn.), or other membranes with similar rejection properties from other membrane manufacturers.
[0074] As shown in FIGS. 4A-B , the seawater treatment system 200 may include a membrane system 210 that includes a plurality of membrane pressure vessels (shown as 214 , 216 , and 218 ), which may be arranged in parallel. Although three membrane pressure vessels are shown, other embodiments may include more or less than three membranes. According to one or more embodiments, each membrane pressure vessel 214 , 216 , 218 , may include a plurality of membrane elements 250 installed therein. Although six elements 250 are shown in each membrane pressure vessel, other embodiments may include more or less than six elements 250 .
[0075] Further, in one or more embodiments, at least one of each of a conductivity sensor 224 , a flow sensor 226 , and a hardness sensor 227 may be disposed on the blend/bypass line 225 . In one or more embodiments, each of the conductivity sensor 224 , the flow sensor 226 , and the hardness sensor 227 may be disposed on the blend/bypass line 225 to measure conductivity, flow, and hardness of water, respectively, passing through the blend/bypass line 225 on each permeate of the membrane pressure vessel. For example, as shown in FIG. 4A , each of the conductivity sensor 224 , the flow sensor 226 , and the hardness sensor 227 may be disposed on the blend/bypass line 225 to measure conductivity, flow, and hardness of water, respectively, in the blend/bypass line 225 after the water passes through each membrane pressure vessel 214 , 216 , 218 . Those having ordinary skill in the art will appreciate that each of the conductivity sensor 224 , a flow sensor 226 , and a hardness sensor 227 may be any conductivity sensor, flow sensor, or hardness sensor known in the art.
[0076] Furthermore, in one or more embodiments, the seawater treatment system 200 may include a desalination water controller 265 . In one or more embodiments, the desalination water controller 265 may take signals from desalination plant sensors and output signals to the main plant 240 .
[0077] As shown in FIGS. 4B-C , according to one or more embodiments, each element 250 may comprise, for example, reverse osmosis membrane elements, nanofiltration membrane elements, or other membrane elements known in the art. Membrane elements 250 may comprise one of several configurations known in the art, for example, spiral wound (SW) and/or hollow fine fiber (HFF).
[0078] As shown in FIG. 4C , according to one or more embodiments, elements 250 may comprise spiral wound elements 250 . Spiral wound elements 250 may be constructed from flat sheet membranes 254 and 256 and may include a backing material 258 to provide mechanical strength. The membrane material may be cellulosic (i.e., cellulose acetate membrane) or non-cellulosic (i.e., composite membrane). For cellulose acetate membranes, the two layers may be different forms of the same polymer, referred to as “asymmetric.” For composite membranes, the two layers may be completely different polymers, with the porous substrate often being polysulfone.
[0079] In the spiral wound design, the membrane is formed in an envelope that is sealed on three sides. A supporting grid, called the product water carrier, is on the inside. The envelope is wrapped around a central collecting tube 261 , with the open side sealed to the tube. Several envelopes, or leaves, are attached with an open work spacer material 262 between the leaves. This is the feed/concentrate, or feed-side spacer. The leaves are wound around the product water tube 261 , forming spirals if viewed in cross section. Each end of the unit may be finished with a plastic molding, called an “anti-telescoping device,” and the entire assembly may be encased in a thin fiberglass shell (not shown). Feed water may flow through the spiral over the membrane surfaces, roughly parallel to the product water tube 261 . Product water flows in a spiral path within the envelope to the central product water tube 261 . A chevron ring (not shown) around the outside of the fiberglass shell may force the feed water to flow through the element 250 .
[0080] As shown in FIG. 4D , according to one or more embodiments, elements 250 may comprise hollow fine fiber elements 270 . The design of the hollow fine fiber elements 270 may include a plurality of hollow fiber membranes 272 being placed in a membrane pressure vessel 280 . The hollow fine fiber may be a polyaramid or a blend of cellulose acetates. The membranes 272 may have an outside diameter of about 100 to about 300 microns and in inside diameter between 50 and about 150 microns. The fibers may be looped in a U-shape, so both ends are imbedded in a plastic tubesheet 274 . The pressurized seawater may be introduced into the vessel (indicated by arrow 276 ) along the outside of the hollow fibers. Under pressure, desalted water passes through the walls of the hollow fiber membranes 272 and flows down the inside of the fiber membranes 272 to a permeate collection tube 278 for collection (as indicated by arrow 282 ), while the separated concentrate is removed from the membrane pressure vessel 280 (as indicated by arrow 284 ).
[0081] According to one or more embodiments, all of the membrane pressure vessels in membrane system 210 may comprise elements 250 having only reverse osmosis membrane elements installed therein. In another embodiment, all of the membrane pressure vessels in membrane system 210 may comprise elements 250 having only nanofiltration membrane elements installed therein. In other embodiments, one or more membrane pressure vessel (e.g., membrane pressure vessel 214 ) may comprise elements 250 having either nanofiltration or reverse osmosis membrane elements installed therein while the remaining membrane pressure vessels (e.g., membrane pressure vessels 216 and 218 ) comprise elements 250 having only reverse osmosis or nanofiltration membrane elements installed therein. While specific examples of combinations of membrane pressure vessels and membrane element types are listed here, these examples are not intended to be exhaustive and other combinations may be used. Those skilled in the art will appreciate other appropriate examples and combinations, which are intended to be encompassed by one or more embodiments.
[0082] As shown in FIGS. 3A-C , one or more treatment blocks 260 may be installed on the deck 304 of a vessel 300 , on the platform 305 of a rig 312 , and/or on the seafloor 316 , depending on the location of the seawater treatment system 200 . Additionally, the one or more treatment blocks may also be installed in other parts of the vessel 300 and/or the rig 312 , or even on multiple levels of the vessel 300 and/or the rig 312 . For example, each treatment block may be installed in a separate container. Several containers can be placed on top of each other to optimize the use of the deck 304 and/or platform 305 to decrease the time and expense associated with construction of the seawater treatment system on the vessel 300 and/or rig 312 . The one or more treatment blocks may be installed in series or in parallel.
[0083] Within the water intake system 201 , water intake pump 204 pumps the intake water through pre-filter 206 to remove any large contaminants (e.g., sand, rocks, plants, debris, etc.) and then through filter 208 to remove large molecules (e.g., suspended solids, colloids, macromolecules, bacteria, oils, particulate matter, proteins, high molecular weight solutes, etc.). After passing through water intake system 201 , the filtered seawater is provided to treatment block 260 by variable speed high-pressure pump 212 . Although only one treatment block 260 is shown, according to one or more embodiments, there may be more than one treatment block arranged in series and/or in parallel.
[0084] According to one or more embodiments, within treatment block 260 , there may be one or more membrane pressure vessels (e.g., 214 , 216 , and 218 ). In one embodiment, the pressurized seawater may be pushed through the first membrane pressure vessel (e.g., 214 ) having one or more elements 250 with membrane elements installed therein, thereby creating a first permeate stream and a first concentrate stream. The first permeate stream may comprise water that has specific ions removed therefrom, for example, the first permeate stream may have lower sulfate ion content and/or lower salinity compared to the filtered seawater produced from water intake system 201 . The first concentrate stream may comprise the ions and/or molecules removed by the membrane elements in the first membrane pressure vessel (e.g., 214 ). The first concentrate stream may then be disposed of, for example, through a plurality of concentrate discharge ports within the concentrate discharge system 230 . However, before the first concentrate is disposed of, an energy recovery device (not shown) may be used to capture the energy possessed by the first concentrate stream and return such energy to the variable speed high-pressure pump 212 .
[0085] According to one or more embodiments, one or more monitors 226 may be used to determine the characteristics of the output permeate streams created by the one or more membrane pressure vessels 214 , 216 , 218 . According to one or more embodiments, one or more monitors 226 may be used to determine the characteristics of the streams created by blending the output permeate streams with the blend/bypass lines. Based on these characteristics, monitors 226 may be used to change the performance of the membranes in pressure vessels 214 , 216 , 218 to produce different quality water by controlling the variable speed high-pressure pumps 212 to change, real-time, the amount of water being pumped through membrane pressure vessels 214 , 216 , 218 . Similarly, based on these characteristics, monitors 226 may be used to control the amount of untreated filtered seawater water provided to the blend/bypass line 225 , i.e., monitors 226 may be used to trigger an amount of untreated filtered seawater water being blended in with the output permeate streams in order to achieve a water having even more specific characteristics.
[0086] According to one or more embodiments, this process may continue for as many membrane pressure vessels as there are in the treatment block 260 . Additionally, this process may continue for as many treatment blocks 260 as there are in the treatment system 200 , until a final permeate stream, optionally having untreated filtered seawater water blended therein, is produced from a final membrane pressure vessel. The final permeate stream may then be transferred, for example, from vessel 300 to rig 312 , from seafloor 316 to rig 312 , and/or from rig 312 to well 310 , through the permeate transfer and treatment system 220 .
[0087] In one or more embodiments, the membrane elements installed within the membrane pressure vessels (e.g., 214 , 216 , and 218 ) are all ion selective membrane elements that lower the salinity or ionic strength of the seawater by selectively preventing or at least reducing certain ions (e.g., sodium, calcium, potassium, and magnesium ions) from passing through the membrane elements, while allowing water and other specific ions (e.g., sulfate, calcium, magnesium, and bicarbonate ions) to be produced for use and/or further treatment. In other embodiments, the membranes elements are all ion selective membranes that selectively prevent or at least reduce hardening or scale-forming ions (e.g., sulfate, calcium, magnesium, and bicarbonate ions) from passing through the membrane elements, while allowing water and other specific ions (e.g., sodium and potassium ions) to be produced for use and/or further treatment.
[0088] In one or more embodiments, the seawater treatment system 200 may include multiple treatment blocks 260 , wherein the multiple treatment blocks 260 each comprise different membrane pressure vessels. For example, in one embodiment, one or more treatment block 260 may include membrane pressure vessels (e.g., 214 , 216 , and 218 ) having membrane elements installed therein wherein the membrane elements comprise only nanofiltration membrane elements, while one or more separate treatment block 260 includes membrane pressure vessels (e.g., 214 , 216 , and 218 ) having membrane elements installed therein wherein the membrane elements comprise only reverse osmosis membrane elements. Additionally, one of ordinary skill in the art would recognize that the number of treatment blocks in a system may vary in one or more embodiments. Further, one of ordinary skill in the art in possession of the present disclosure will recognize that the membrane elements may vary and may be, for example, spirally wound, hollow fiber, tubular, plate and frame, or disc-type.
[0089] According to one or more embodiments, the variable speed high-pressure pump that operates to push the pretreated water through the treatment block 260 may be controlled by monitor 226 and may comprise any pump suitable to generate the hydraulic pressure necessary to push the water through the one or more membrane pressure vessels. However, the pump discharge pressure must be controlled in order to maintain the designated permeate flow and, more importantly, to not exceed the maximum allowed feed pressure for the membrane elements being used. This is of particular importance because if the maximum allowed feed pressure is exceeded, the membrane element may blow out and thereby fail prematurely. Because the maximum allowed feed pressure for nanofiltration elements is typically much less than the maximum allowed feed pressure for reverse osmosis element, conventional membrane systems having more than one type of membrane (e.g., nanofiltration and reverse osmosis) typically require more than one pump (i.e., a pump for each type of membrane). Conventional systems with nanofiltration membranes installed cannot change to reverse osmosis membranes due to this pressure differential.
[0090] However, according to one or more embodiments, the treatment block 260 may include a variable-speed high-pressure pump 212 that is controlled by monitor 226 and that provides the filtered seawater to more than one membrane pressure vessel. Because the membrane pressure vessels may vary in size and/or may include different types of membrane elements, and therefore require varying feed pressures, the high-pressure pump 212 must be able to provide an adjustable feed pressure based on the type of system being used and based on the water characteristics detected by the monitor 226 . In one or more embodiments, the variable speed high-pressure pump may comprise, for example, a positive displacement pump.
[0091] In one or more embodiments, a pump may be used to provide approximately 16,068 m 3 /d (or 670 m 3 /hr or 2950 gpm) at varying pressures. Specifically, for a seawater reverse osmosis (SWRO) treatment system with an energy recovery device (ERD), the lowest needed pressure is about 26.5 bar and the highest needed pressure may be about 30.2 bar. For an NF system with no ERD, the lower required pressure is about 27 bar while the highest required pressure may be about 39 bar. For a sulfate reducing nanofiltration (SRNF) system with no ERD, the lowest needed pressure may be about 14 bar and the highest required pressure may be about 19 bar.
[0092] One or more embodiments of the present invention may also include variable frequency drives (VFD) on the high-pressure pump. The VFD are systems that control the rotational speed of an alternating current (AC) electric motor by controlling the frequency of the electrical power supplied to the motor. By employing VFD, the pressures created by the variable speed high-pressure pump can also be varied according to the specific needs of the system at any time, for example, as a function of operation, membrane type, water quality objectives, and/or seawater temperature and salinity.
[0093] Referring to FIG. 4E , in one or more embodiments, a slip stream line 295 may be included in the system. Like elements of the system shown in FIG. 4E to the elements shown and described in other embodiments are given like reference numerals and detailed description thereof is omitted. In embodiments including a slip stream line 295 , the controller 260 may also control valves 296 connecting the slip stream line 295 to other lines in the system for addition of specially-treated water. The valves 296 may be located at various positions in the system, e.g., at the entrances of the system pumps, at water blending points in the system, etc. For instance, the slip stream line 295 may contain water having an additive acid or base to assist with balancing the quality of the water being processed. Additionally, the slip stream line may contain warmer or cooler water than the water in the system to assist with balancing the temperature of the water being processed. Controller 260 may blend water from slip stream 295 so as to improve overall system efficiency, reduce power consumption, etc.
[0094] Accordingly, one or more embodiments provide a seawater treatment system having the flexibility to switch between multiple membrane elements using high-pressure pumps that may be varied, real-time, by a controller that monitors the characteristics of the output permeate streams and then transmits a signal to the high-pressure pumps to either pump more or less water through the membrane elements and/or blend in untreated filtered seawater from the blend/bypass line to achieve a water having specifically tailored properties without having to pass through multiple treatment systems. For example, as shown in FIGS. 4A-4B , VFDs 212 A may be integrated into the seawater treatment system 200 and may allow the pressures created by the high-pressure pumps 212 to be varied according to the specific needs of the seawater treatment system 200 at any time.
[0095] As discussed above, seawater has a high ionic content relative to fresh water. For example, seawater is typically rich in ions such as sodium, chloride, sulfate, magnesium, potassium, and calcium ions. Seawater typically has a total dissolved solids (TDS) content of at least about 30,000 mg/L. According to one or more embodiments, it is preferred that the permeate stream have a total dissolved solids content of between about 1,000 mg/L and about 30,000 mg/L.
[0096] Improved Oil Recovery
[0097] As noted above, improved oil recovery processes commonly inject water into a subterranean hydrocarbon-bearing reservoir via one or more injection wells to facilitate the recovery of hydrocarbons from the reservoir via one or more hydrocarbon production wells. The water can be injected into the reservoir as a waterflood in a secondary oil recovery process. Alternatively, the water can be injected into the reservoir in combination with other components as a miscible or immiscible displacement fluid in a tertiary oil recovery process. Water is also frequently injected into subterranean oil and/or gas reservoirs to maintain reservoir pressure, which facilitates the recovery of hydrocarbons and/or gas from the reservoir.
[0098] According to one or more embodiments, injection fluids may include aqueous solutions (e.g., seawater) that have been treated according to methods disclosed above. In a particular embodiment, the seawater may first undergo filtration in a water intake system whereby the seawater is pumped through a first filter to remove any large contaminants (e.g., sand, rocks, plants, debris, etc.) and then through a second filter to remove large molecules (e.g., suspended solids, colloids, macromolecules, bacteria, oils, particulate matter, proteins, high molecular weight solutes, etc.). One of ordinary skill in the art will appreciate that depending on the specifications of the equipment and the type and density of particulate matter to be removed, various types of filters, including for example, sand or media filters, cartridge filters, ultra filters, and/or micro filters may be used.
[0099] After passing through the water intake system, the filtered seawater may be provided to a seawater treatment system such as the one depicted in the figures of the present disclosure. Specifically, as shown in FIGS. 4A-B , the filtered seawater may be provided to a treatment block 260 and either sent through blend/bypass line 225 or pumped by variable speed high-pressure pump 212 , which pushes the filtered seawater through to one or more membrane pressure vessels (e.g., 214 , 216 , and 218 ), thereby creating a permeate stream and a concentrate stream.
[0100] The permeate stream may comprise water that has specific ions and/or molecules removed therefrom, for example, the permeate stream may have lower sulfate ion content and/or lower salinity compared to the filtered seawater produced from the water intake system. A monitor may be used to detect the characteristics of the permeate stream and, based on these characteristics, control the high-pressure pumps and blend line and effectively produce a water that is customized for a very specific purpose. As shown in FIG. 5 , the permeate stream may then be transferred, for example, from vessel 300 to rig 512 , from seafloor 516 to rig 512 , and/or from rig 512 to well 510 , through permeate transfer system 520 and used as an injection fluid for improved recovery of hydrocarbons from a subterranean hydrocarbon-bearing formation 514 .
[0101] The concentrate stream may comprise the ions and/or molecules removed by the membrane elements within the one or more membrane pressure vessels. The concentrate stream may then be disposed of, for example, through a plurality of concentrate discharge ports within the concentrate discharge system. However, before the concentrate is disposed of, an energy recovery device may be used to capture the energy possessed by the concentrate stream and return such energy to variable speed high-pressure pump. Also, the concentrate may be diluted or otherwise treated prior to disposal.
[0102] In one or more embodiments, the effluent from the one or more membrane pressure vessels (either the permeate stream and/or the concentrate stream) may take one or more subsequent passes through treatment block 260 . Additionally, in some embodiments, more than one treatment block and/or more than one blend/bypass line may be used in the seawater treatment system.
[0103] In one or more embodiments, a method for recovering hydrocarbons from a subterranean hydrocarbon-bearing formation 514 may include injecting the permeate stream into a hydrocarbon-bearing formation 514 via an injection well 560 , displacing hydrocarbons with the permeate towards an associated hydrocarbon production well 580 , and recovering the hydrocarbons from the formation 514 via the hydrocarbon production well 580 .
[0104] Preferably, the methods of one or more embodiments may result in an increase in hydrocarbon recovery from a hydrocarbon bearing formation, for example in the range of about 2% to about 40%, when compared with a waterflood treatment using untreated high salinity injection water.
[0105] As shown in FIGS. 6A-B , the systems and methods of one or more embodiments of the present invention may be included in various configurations. Specifically, as shown in FIGS. 6A-B , a system and/or method of the present invention may be configured so that the variable speed high-pressure pump 212 pushes the filtered seawater 611 through one or more treatment blocks, thereby creating a concentrate stream 634 and a permeate stream (not shown), wherein the permeate stream may then be analyzed using a monitor (not shown) to determine the characteristics of the output permeate stream. Based on these characteristics, the monitor may be used to control the variable speed high-pressure pump 212 real-time by varying the amount of water being pumped through membrane 214 . Additionally, based on these characteristics, untreated filtered seawater from the blend/bypass line 225 may be blended in with the permeate stream in order to achieve a water having specific characteristics.
[0106] The concentrate stream 634 may then be disposed of, for example, through a plurality of concentrate discharge ports within the concentrate discharge system. However, before the concentrate stream 634 is disposed of, an energy recovery device 232 may be used to capture the energy possessed by the concentrate stream 634 and return such energy to variable speed high-pressure pump 212 . Also, the concentrate stream 634 may be diluted or otherwise treated prior to disposal. Alternatively, as shown in FIG. 6B , a system and/or method of the present invention may be configured so that the concentrate stream 634 bypasses the concentrate discharge system, for example, via elbow piping 613 .
[0107] Additionally, in other embodiments of the present invention, the systems and/or methods of the present invention may be capable of switching back and forth between systems shown in FIGS. 6A-B . For example, when blending of untreated filtered seawater with the permeate streams is desired, the monitor may be used to control the variable speed high-pressure pump so as to pump an appropriate amount of water through one or more treatment blocks and produce one or more permeate streams which may then be blended with untreated filtered seawater from the blend/bypass line; however, when blending of untreated filtered seawater is not required, the blend/bypass line may be bypassed.
[0108] Furthermore, as shown in FIG. 7 , a system and/or method according to one or more embodiments of the present invention may include both an energy recover device 232 and elbow piping 613 , wherein the energy recover device 232 and the elbow piping 613 are connected via valves 614 . In one embodiment, the valves 614 may be left open so as to allow the concentrate stream 634 to be piped directly in to the energy recover device 232 . In another embodiment, some valves 614 may be closed so as to bypass the energy recover device 232 . Also, the concentrate stream 634 may be diluted or otherwise treated prior to disposal.
EXAMPLES
[0109] The following examples are provided to further illustrate the application and use of the methods and systems disclosed herein for treating seawater.
Example 1
[0110] A system comprised of a treatment block of seawater reverse osmosis membranes and a treatment block of seawater nanofiltration membranes is configured such that the flowrates to each treatment block and the respective high-pressure pump to each block can be regulated. The treatment block is comprised such that it produces approximately 60% of the permeate flow using the nanofiltration block operating at 42% recovery and 40% of the permeate flow using the reverse osmosis block operating at 40% recovery. In this example, the specific (target) salinity (total dissolved solids) of the blended permeate is 2,900 mg/L (+/−100 mg/L) and the maximum allowable hardness is 60 mg/L (as defined by the combined calcium and hardness ion concentration, in mg/L). The operating range of the system is 25 to 30° C.
[0111] Exhibit 1 provides the natural deviation of the salinity and hardness of a conventional system, comprised of 60% nanofiltration and 40% reverse osmosis, over the temperature range.
[0000]
Exhibit 1
Permeate Flow
Conventional System
Distribution
Membrane Flux, Lmh
TDS, mg/L
Hardness
NF
RO
NF
RO
25
2918
51.1
60%
40%
14.57
14.50
30
3723
67.2
60%
40%
14.57
14.50
[0112] The results indicate that the permeate at 25° C. meets the permeate water quality specifications but the permeate produced at 30° C. does not.
[0113] If the feed flows are reapportioned between the two treatment blocks such that 49% of the permeate flow originates from the nanofiltration block and 51% originates from the reverse osmosis block, with corresponding changes in membrane flux and feed pressures, then the blended permeate quality will meet the water quality specifications at 30° C., as shown in Exhibit 2.
[0000]
Exhibit 2
Permeate Flow
Conventional System
Distribution
Membrane Flux, Lmh
TDS, mg/L
Hardness
NF
RO
NF
RO
25
2918
51.1
60%
40%
14.57
14.50
30
2905
51.7
49%
51%
15.76
18.50
[0114] In Exhibit 2, approximately 25% of the NF membranes were removed from service due to lack of need, through the use of automated valve.
[0115] Example 2
[0116] A system comprised of a treatment block of seawater reverse osmosis membranes and a by-pass stream treatment block of seawater nanofiltration membranes is configured such that the flowrates to each treatment block and the respective high-pressure pump to each block can be regulated. The treatment block is comprised such that it produces approximately 92.8% of the permeate flow using the seawater reverse osmosis membrane block operating at 45% recovery and the remaining permeate flow using a slipstream of permeate from a multi-pass nanofiltration membrane block operating at 75%, 80% and 80% recovery, respectively, for the three-pass system. In this example, the specific (target) salinity (total dissolved solids) of the blended permeate is 2,000 mg/L (+/−50 mg/L) and the maximum allowable calcium is 10 mg/L, the maximum allowable magnesium is 10 mg/L, and the maximum allowable sulfate is 10 mg/L. The operating range of the system is 22 to 31° C.
[0117] Exhibit 3 provides the natural deviation of the salinity, calcium, magnesium and sulfate over the temperature range.
[0000]
Exhibit 3
System with Conventional Operation
Ca 2+ ,
Mg 2+ ,
Permeate Flow Distribution
TDS, mg/L
mg/L
mg/L
SO 4 2−
SWRO
3-pass NF
22
1872
1.0
2.8
2.3
92.9%
7.1%
25
2016
1.4
3.3
2.7
31
2183
2.0
4.6
3.7
[0118] The results indicate that the permeate produced at 25° C. meets the permeate water quality specifications but the permeate produced outside this design point does not meet the salinity requirement.
[0119] If the high salinity, low hardness, low sulfate slipstream is used to adjust the salinity across the operating seawater temperature range, then the blended permeate salinity can be controlled within the setpoint of 2,000 mg/L, as shown in Exhibit 4.
[0000]
Exhibit 4
System with Conventional Operation
Ca 2+ ,
Mg 2+ ,
Permeate Flow Distribution
TDS, mg/L
mg/L
mg/L
SO 4 2−
SWRO
3-pass NF
22
2005
1.1
2.8
2.3
92.3%
7.7%
25
2016
1.4
3.3
2.7
92.9%
7.1%
31
2017
1.9
4.6
3.8
93.6%
6.4%
[0120] For a 100,000 bbl/day (15,898 m 3 /day) injection system, the flowrate of the RO system will vary between 92,300 and 93,600 bbl/day (14,674 and 14,481 m 3 /day) and the NF slipstream requirements will vary between 7,700 and 6,400 bbd/day (1,224 and 1,017 m 3 /day). The control system will adjust the required flows from the respective systems to meet the conductivity setpoint and any excess water can be disposed to sea (due to its high quality) or alternatively, the production of the two systems can be dialed up or turn as needed, noting the resulting change in flux.
[0121] Additionally, while the above embodiments were described as being application for offshore water treatment, one of ordinary skill in the art would appreciate that the treatment techniques may also be used in land-based operations, particularly when the feed water has a high salinity and/or high ionic content.
[0122] Furthermore, one skilled in the art in possession of this specification will appreciate that the system and method are also applicable to other water treatment environments. For example, by substituting one or more treatment blocks as appropriate, municipalities could use the system and method to produce potable or otherwise treated water.
[0123] Advantageously, one or more embodiments may provide one or more of the following. In offshore operations, the most common source of injection water is seawater, which has significant levels of contaminants that may be removed before the seawater can be used as an injection water. Depending on the type of formation being drilled, certain components of the seawater must be removed while others must remain in order to protect the formation from damage and to maximize the hydrocarbons produced from the formation. Using a combination of water treatment approaches may allow for water treatment processes which are able to effectively and cost efficiently prepare injection water that is specifically tailored for the formation being drilled and thereby allows for improved oil recovery. Further, water quality and specific water-characteristics can be closely controlled to ensure maximum effectiveness in varying downhole environments. Also, the water treatment processes may be used to reduce costs associated with the preparation of injection water because the most expensive component, i.e., the high-pressure pump, can be operated at variable pressures using information from the permeate streams and output streams.
[0124] 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 treating water including intaking a first amount of water into a plurality of treatment blocks, treating the first amount of water, outputting aqueous treated water streams from each of the plurality of treatment blocks, separating the aqueous treated water streams from each of the plurality of treatment blocks into aqueous permeate streams and concentrate reject streams, monitoring each of the aqueous permeate streams, controlling the operation of at least one of the plurality of treatment blocks based on predefined water-characteristic tolerances that fall within a predetermined concentration range based on the different qualities of the aqueous permeate streams, combining the aqueous permeate streams of at least two of the plurality of treatment blocks based on the identified characteristics and the predefined water-characteristic tolerances, and outputting the product water stream and the at least one concentrate reject stream. | 2 |
BACKGROUND OF THE INVENTION
In a principal aspect, the present invention relates to a latch mechanism for retaining a drawer mounted on telescopic slides in a cabinet. Mechanics' cabinets and tool cabinets typically are fabricated from sheet metal and include a cabinet enclosure with drawers mounted on telescoping slides. A typical example of such a construction is depicted in U.S. Pat. No. 4,681,381 and U.S. Pat. No. 5,435,640 which are incorporated herewith by reference.
Typically, in order to provide security for the contents within the cabinet drawers, a locking system is provided. The locking system will normally include a key actuated mechanism which enables locking the drawers in a closed position. Actuation or release of the key operated mechanism is necessary in order to release or unlock the drawers.
In addition to permanently locking the drawers in a closed position, it is also appropriate and desirable to provide a means by which the drawers will remain or be retained in a closed position unless positively opened by the mechanic or user of the cabinet. This is a desirable feature in a cabinet construction in order to preclude accidental opening of drawers thereby resulting in an unbalanced condition that would cause the cabinet to turn over due to the weight of tools and other items in the drawers acting as a cantilever weight causing the cabinet to tip. Additionally, it is desirable to provide a positive mechanism to maintain the drawers in a closed position so that the drawers will not accidentally open when the cabinet is, for example, being transported from one position to another. Also, it is desirable to keep the drawers in a closed, but not necessarily locked, position so that the drawers will not protrude unexpectedly or undesirably thereby posing a danger.
Thus, there has developed a need to provide a mechanism that is inexpensive, yet reliable, and which enables unlocked drawers to remain in the closed position unless positively opened. Certain mechanisms of this nature are depicted in the prior art. For example, U.S. Pat. No. 5,435,640 depicts a catch mechanism which maintains or holds a drawer in a closed position in a cabinet enclosure. The catch relies upon the elastomeric characteristics of the catch. In the event the elastomer material fails, however, the catch then fails. Thus, there has developed a need for an improved latch or safety catch mechanism for drawers which are not maintained in the locked position.
SUMMARY OF THE INVENTION
Briefly, the present invention comprises a latch mechanism for a sliding drawer mounted in a cabinet supported by telescoping slides. The latch mechanism is attached to the front side of the sliding drawer and includes a handle which extends over the front edge of the front side of the drawer as well as a section depending from the front edge and extending into the interior of the cabinet. Catch members are attached to the ends of the handle on the inside of the drawer and a biasing mechanism, such as a coil spring, biases the handle member so that the catch members are biased upwardly into position for engagement with strikes located on the inside of the cabinet enclosure adjacent the top front edge of the cabinet drawer when the drawer is in the closed position. The handle also includes tabs which interlock and engage the handle with the front panel or front side of the cabinet drawer.
By positioning the catch members at the opposite ends of the handle and between the front sides of the drawer, lateral movement of the handle is precluded thereby maintaining the handle in a stable yet pivotal position on the front edge of the cabinet drawer. Strikes are included on a section of each of the telescoping slides attached to the interior side wall of the cabinet.
Thus, it is an object of the invention to provide an improved latch mechanism which maintains sliding drawers in a cabinet in a closed position.
A further object of the invention is to provide a latch mechanism which is rugged, comprised of a very few number of parts, and which must be positively actuated in order to effect opening of a drawer.
Yet another object of the invention is to provide a latch mechanism which may be incorporated in the front handle of a drawer and which will automatically hold the drawer in a closed position when the drawer is moved to that closed position.
These and other objects, advantages and features of the invention is set forth in the detailed description which follows.
BRIEF DESCRIPTION OF THE DRAWING
In the detailed description which follows reference will be made to the drawing comprised of the following figures:
FIG. 1 is an isometric view of a typical cabinet having a construction which incorporates the latch mechanism of the present invention;
FIG. 2 is a side cross sectional view of the latch mechanism as incorporated in a drawer depicting the latch mechanism in the closed or locked, as well as the open, or released position;
FIG. 3 is an exploded enlarged isometric view of the latch mechanism depicted as detail 3 in FIG. 1;
FIG. 4 is an enlarged isometric view of the strike portion of the latch mechanism of the invention as depicted at detail 4 in FIG. 1; and
FIG. 5 is a cross sectional view of the assembly depicting the latch mechanism taken along the line 5 — 5 in FIG. 1 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, a cabinet 10 includes a first lateral sidewall 12 and a second lateral sidewall 14 parallel to and spaced from wall 12 . The walls 12 and 14 in combination with the other walls and braces forming the cabinet define an enclosure 16 . A first telescopic slide 20 is attached to the inside of lateral wall or side 12 . A second telescopic slide 22 is attached to the opposite lateral side or wall 14 . The telescopic slides 20 and 22 include multiple sections such as sections 24 , 26 and 28 of slide 20 . The slides, such as slide 20 , are affixed to the lateral sidewalls 12 , 14 by interengagement of appropriate tabs, tangs and slots in a manner known to those of ordinary skill in the art. The telescopic sections 24 , 26 and 28 slide with respect to one another again in a manner known to those of ordinary skill in the art. Section 24 is maintained fixed within the enclosure 16 defined by the cabinet 10 . The slide 22 comprises a mirror image of the slide 20 .
The slides 20 and 22 together support a single drawer 30 which includes a back wall or back side 32 , a first lateral side wall 34 , and a second, parallel spaced lateral side 36 , as well as a front side wall 38 . The drawer 30 is supported by the telescopic section, such as telescopic section 28 , which is affixed to drawer side wall 34 by means of interengagement of tabs or projections with slots, again in the manner known to those of ordinary skill in the art. Positioning of the slides 20 and 22 is effected so that the drawer 30 will efficiently and effectively slide into and out of the cabinet 10 . Slides 20 , 22 extend along the top edge of the drawer 30 .
The subject matter of the invention relates, in particular, to a front handle 40 which includes a latch mechanism for maintaining the drawer 30 in a closed position except when the handle 40 is appropriately actuated to release the drawer 30 from the closed position. The mechanism for effecting such retention is depicted in greater detail in FIGS. 2-5. Thus, the front side wall 38 of the drawer 30 includes a top edge 44 which, in the embodiment depicted, comprises a horizontal run 46 extending from a vertical front face or run 48 defining the front side wall 38 . The horizontal run 46 extends outwardly from the interior of the drawer 30 . The run 46 extends between the lateral sides 34 and 36 . A series of horizontal slots 50 are provided in face 48 adjacent the upper edge 44 in the front side wall 38 .
The handle or handle member 40 includes a horizontal run 52 which typically fits against the run 46 . Downwardly depending decorative and protective edge 54 connects with the run 52 on the outside of the drawer 30 . Depending vertically downward from the run 52 is a downward run 56 which extends on the inside of the drawer 30 spaced inwardly from the front side wall 38 . At strategic positions along the width of the downwardly depending front run 56 are a series of notched tabs 58 which are designed to fit through the horizontal openings 50 in face 48 .
Catch members 60 and 62 are positioned at the opposite ends on the lateral sides of the run 56 . The catch members 60 , 62 comprise vertical plates attached to the downwardly depending run 56 . Each catch member 60 , 62 includes an upwardly extending tab or tang 64 . The catch members 60 and 62 are positioned on the inside of the walls or lateral sides 34 and 36 , respectively. Thus, the catch members 60 and 62 preclude lateral or side to side movement of the handle 40 when the assembly comprising the handle 40 is in position. Spring members, such as coil springs 66 , are positioned intermediate the run 56 and the wall 38 to bias the handle 40 in the counterclockwise direction in FIG. 2 thereby positioning the catch members 60 and 62 in an extended counterclockwise position, or locking or closed position.
Strikes or strike members 70 , 72 are constructed for cooperation with the catch members 60 and 62 respectively and are attached as an integral part of the telescoping slides 20 and 22 . Thus, the strike member 70 is a component part of the section 24 of the telescopic slide 20 . The strikes 70 , 72 comprise a horizontal plate with a strike passage 76 defined in the plate for receipt of a catch tab 64 as depicted in FIG. 2 .
Thus, in operation, the drawer 30 is moved to the closed position by pushing the drawer 30 into the enclosure 16 of the cabinet 10 . This causes the telescopic slide members 20 and 22 to telescope to the closed position. The locking tab 64 as associated with each catch 60 , 62 will then ride into the opening 76 . It is to be noted that there is a ramp or cam surface 78 on each of the catch members 60 and 62 . The cam surface 78 engages against the front edge 80 of the strikes 70 and 72 forcing the handle 40 to pivot against the biasing force of the spring 66 about the top edge 46 of wall 38 until the catch 60 , 62 is biased in the counterclockwise direction to fit into the opening 76 . In the position depicted in FIG. 2, in solid lines, the drawer 30 is maintained in the closed and locked position. To release the drawer 30 one must manually engage the handle 40 and pivot the handle about the top edge 46 against the biasing force of the spring 66 to the position depicted in phantom in FIG. 2 . This enables the drawer 30 to be released and the telescopic members 20 and 22 then permit the drawer 30 to be withdrawn from the enclosure 16 .
The construction of the present invention has various advantages. Positive holding of the drawer in the closed position is effected. The drawer may be opened by easy manual operation. Because the handle 40 extends across the entire front face of the drawer, positioning and engaging the handle 40 is easily accomplished. Because of the manner in which the component parts are interengaged, the handle 40 remains locked or fixed in position pivotally on the top edge of the drawer 30 , yet cannot be removed from the drawer 30 . Additionally, because there are catch members 60 , 62 on each side of the drawer 30 , the drawer 30 cannot be easily skewed and there is positive locking.
The particular shape of the catch members 60 , 62 may be altered in order to adjust the force of the engagement of the catch member 60 , 62 and the strike 70 , 72 . Also, the part defining the strike 70 , 72 and the part defining the catch member 60 , 62 may have a reversed shape configuration. That is, the strike opening 76 may be positioned in place of the catch member 60 and vice versa. Thus, there may be a reversal of component parts in order to effect the locking operation. Various other modifications may be made without departing from the spirit and scope of the invention. The invention is, therefore, to be limited only by the following claims and equivalents thereof. | A lock mechanism for a sliding drawer of the type mounted on telescopic slides in a cabinet includes a pivotal handle bar on the top front edge of the cabinet drawer front wall. The handle includes catch mechanisms biased for engagement with a strike extending from the drawer slides mounted on the inside of the cabinet. Manual rotation of the handle moves the handle and thus the catch mechanisms out of engagement with the strike enabling the cabinet drawer to be opened. | 4 |
BACKGROUND OF THE INVENTION
Fungal diseases or mycoses may be superficial, affecting primarily skin, hair and mucous membrane, or may be deep or systemic, affecting lungs and other internal organs. The superficial mycotic infections which are caused by organisms referred to as dermatophytes are generally considered more annoying than serious. The deep or systemic mycotic infections which are caused generally by different organisms are quite serious, frequently resulting in death.
Antifungal agents considered with specific reference to deep or systemic fungal infections caused by organisms such as Candida species, Cryptococcus neoformans, Histoplasma capsulatum and the like are found for the most part to be fungistatic, i.e., merely inhibit the growth of the fungal organism without effecting a kill. A few fungicidal agents are known. Amphotericin B and other polyenes are known to damage membranes that contain ergosterol and therefore are effectively fungicidal. However, their use is normally precluded because of a number of severe side effects. Other possibly fungicidal drugs, e.g. 5-fluorocytosine, have side effects or may be limited by the scope of their spectrum. 5-Fluorocytosine is further limited by the ease with which an organism develops resistance to it. In the search for antifungal drugs for treating systemic infections, it is desirable to find a drug or a combination of drugs which is effective at low concentration levels thereby minimizing side effects. It is particularly desirable to find a drug or a combination of drugs in which the resultant drug is fungicidal.
STATEMENT OF THE INVENTION
The present invention concerns an improved method for the treatment of deep or system mycotic infections made possible by the discovery than when certain fungistatic agents namely, a 14 α-methyldemethylase inhibiting azole compound and a β-lactone compound, are employed in combination, a synergistic antifungal combination is obtained. It has been found further than certain combinations are able further to cause irreversible damage to the fungi resulting in a killing or cidal effect on the fungi. The β-lactone compound as a component is especially desirable because the high effectiveness of the β-lactone compound itself is such as to render the combination effective at very lose doses. The invention also concerns fungicidal compositions which are suitable for use in the treatment of system mycotic infections.
DESCRIPTION OF THE INVENTION
The fungicidal composition of the present invention comprises a β-lactone compound and a 14 α-methyldemethylase inhibiting compound.
The β-lactone component is a compound having the formula ##STR1## or a pharmaceutically acceptable salt thereof. The compound is named 11-(3-hydroxymethyl-4-oxo-2-oxetanyl)-7-methyl-2,4-undecadienoic acid and may be produced by fungi; it is also known as Antibiotic 1233A reported by Aldridge et al, Chem. Comm., 1970, p. 639 and in J. Chem. Soc (c), 1971, pp. 3888-3890 (1972). The antifungal properties of the compound against fungi such as Trichophyton sp., Cryptococcus sp., Hormodendrum sp., Geotrichum sp., and Candida sp. are disclosed in the U.S. Ser. No. 825,496 filed Feb. 3, 1986, now abandoned; published by EPO under 0234752, Sept. 2, 1987. The teachings of the foregoing are incorporated herein by reference.
The pharmaceutically acceptable salts of the β-lactone component of this invention include those formed from cations such as sodium, potassium, aluminum, calcium, lithium, magnesium, zinc, and from bases such as ammonia, ethylenediamine, N-methyl-glucamine, lysine, arginine, ornithine, choline, N,N'-dibenzylethylenediamine, chloroprocaine, diethanolamine, procaine, N-benzylphenethylamine, diethylamine, piperazine, tris(hydroxymethyl)aminomethane, and tetramethylammonium hydroxide.
The 14-α-methyldemethylase inhibiting azole compounds are generally well-known for treating human mycotic infections, and the more important compounds imidazoles and triazoles. Many of these compounds are in use clinically as fungistats or are being developed for such purpose. The generic drug names for those compounds already developed or being developed have the suffix "conazole." In subsequent discussions, the compounds will sometimes will be referred to as "conazole compounds," even though some may not have a generic name. The foremost compound is ketoconazole which is cis-1-acetyl- 4-[4-[[2-(2,4-dichlorophenyl)-2-(1H-imidazole-1-ylmethyl)-1,3-dioxolan-4-yl]methoxy]-phenyl]piperazine. Other fungistatic conazole compounds which are 14 α-methyldemethylase inhibitors and which are either in clinical use or in development include fluconazole, α-(2,4-difluorophenyl)-α-(1H-1,2,4-triazol-a-ylmethyl)-1H-1,2,4,-triazole-1-ethanol; miconazole, 1-[2,4-dichloro-β-(2,4-dichlorobenzyloxy) phenethyl]imidazole as nitrate; econazole, 1-[2-(2,4-dichlorophenyl)-2-(4-chlorobenzyloxy) ethyl]imidazole; isoconazole, 1-[2,4-dichloro-β(2,6- dichlorobenzyloxy)phenethyl]imidazole as nitrate; terconazole, cis-1,4,2-(2,4-dichlorophenyl)-2-(1-ylmethyl)-1,3-dioxolan-4-yl-methoxy-phenyl-4-(methyl-ethyl)piperazine; tioconazole, 1-[2-[(2-choloro-3-thienyl)methoxy]-2-(2-choloro-3-thienyl)methoxy]-2-(2,4-dichloro-phenyl) ethyl]-1H-imidazole;bifonazole, 1-[(4-biphenyl)phenyl-methyl]-1H-imidazole. Still other azoles include ICI-153066 (ICI Pharmaceutical Division), [(R,S)-1-(2,4-dichlorophenyl)-1-(4- fluorophenyl)-2-(1,2,4-triazol-1-yl)ethanol]; Bay-n-7133 (Bayer AG, West Germany), 1-(4-chlorophenoxy)-3,3'- dimethyl-2-(1,2,4-triazol-1-yl)-methylbutan-2-ol; (E)-1-(5-chlorothien-2-yl)-2-(1H-imidazole-1-yl)ethanone-2, 6-dichlorophenylhydrazone hydrochloride; SM-4770 (Sumitomo Chemical Co., Ltd.), (R)-3-(n-butylthio)-2-(2,4-dichloro-phenyl)-1-(imidazole-1-yl)-2-propanol hydrochloride; oriconazole or itraconazole, (+)-cis-4-[4-[4-[4-[[2-(2,4-dichlorophenyl)-2-(1H-1,2-4-triazol-1-ylmethyl)-1,3-dioxolan-4-yl]-methoxy] phenyl]- 1-piperazinyl]phenyl]-2,4-dihydro-2-(1-methylpropyl)-3H-1,2,4-triazol-3-one; fenticonazole, α-(2,4-dichlorophenyl)-β,N-imidazolylethyl-4-phenyl-thiobenzylether nitrate; oxiconazole,(Z)-[2,4-dichloro-2-imidazole-1-yl)acetophenone]-0-(2,4-di-chlorobenzyl)oxime; omoconazole(E)-1-[2,4-chloro-β-[2-(p-chloro-phenoxy)ethoxy]-α-methylstyryl]imidazole ;aliconazole. Still other imidazole antifungal compounds which may be employed include methyl-4-[3-2-methyl-5-nitro-1H-imidazole-1-yl)propyl]piperazine, 5-nitro-(1-methylimidazolyl-t-butyl)(2-hydroxy-5-methoxyphenyl)carbinol, Z-1-[2-(2,4-dichlorophenyl)-3-methyl-1-pentenyl]-1H-imidazole hydrochloride, cis-3-(2-chloro-3-thienylmethyloxy)-2,3-dihydro-5-fluoro-2-(1-imidazolymethyl)benzo[b]thiophene.
The azole compounds may have a basic nitrogen and therefore may be present as an acid addition salt. Pharmaceutically acceptable salts suitable as acid addition salts include those from acids such as hydrochloric, hydrobromic, hydroiodic, phosphoric, sulfuric, trifluoroacetic, trichloracetic, oxalic, maleic, pyruvic, malonic, succinic, citric, mandelic, benzoic, cinnamic, methanesulfonic, ethanesulfonic, trifluoromethanesulfonic and the like. Reference to conazole compounds is intended to embrace both forms.
Many of the conazole compounds are established antifungal compounds. Ketoconazole is one of the preferred antifungal compounds for its broad spectrum and substantial absence of side effects. The combination of ketoconazole and 11-(3-hydroxy-methyl-4-oxo-2-oxetanyl)-7-methyl-2,4-undecadienoic acid hereinafter ("β-lactone compound") represents a preferred embodiment of the present invention.
The synergistic antifungal and fungicidal combinations of the present invention are effective in the the treatment of mycotic infections caused by such fungal organisms as Candida species, for example, C. albicans, C. tropicalis, and C. stellatoidea.
The efficacy of the combination of the present invention in producing a synergistic antifungal as well as fungicidal effect may be seen in the in vitro interaction studies for the determination of activity and determination of viable cells. Synergistic antifungal properties have been demonstrated with ketoconazole and the β-lactone compound in tests against a representative fungal organism known to be the causative agent of mycotic infections, such as Candida albicans. Representative synergistic antifungal and fungicidal properties of combinations of the β-lactone compound and various conazole compounds are demonstrated against Candida albicans as seen in the following examples.
Minimum Inhibitory Concentration of β-Lactone Compound
11-(3-hydroxymethyl-4-oxo-2-oxetanyl)-7-methyl-2,4-undecadienoic acid (β-lactone compound), was solubilized in 100 percent dimethylsulfoxide (DMSO). Twofold dilutions were made with DMSO to obtain final drug concentrations in the broth dilution assay tubes ranging from 0.625 to 100 μg/ml.
The Candida albicans, MY 1055, yeast culture maintained in yeast nitrogen base/glucose (1/2 percent), YNB/G, was transferred to fresh medium and incubated 7 hours at 37° with shaking at 250 rpm. After incubation, each culture was diluted to A 600 =0.0004 U/ml which was previously determined to be equal to 3000 cfu/ml (colony forming units per milliliter).
1 milliliter of YNB/G inoculated with yeast culture was added to sterile test tubes. The tubes were incubated at 250 rpm, 37° C. for 17 hr. The minimum inhibitory concentrations (MIC) was recorded as the lowest concentration of drug showing visible growth.
The minimum inhibitory concentration, against Candida albicans MY 1055, was determined to be a 2.5 μg/ml.
Minimum Fungicidal Concentration of β-Lactone Compound
In the manner above described for the determination of minimum inhibitory concentration, broth dilution assay tubes were prepared ranging from 0.625 to 100 μg/ml and 1 milliliter of YNB/G inoculated with Candida albicans MY 1055 sterile test tubes. The tubes were incubated at 250 rpm at 37° C. for 17 hours.
The minimum fungicidal concentration (MFC) was determined by serially diluting samples of MIC tubes in 0.9% saline. Aliquots were plated on Sabouraud dextrose agar. The plates were incubated at 37° for 48 hr. and the colonies counted. From the counts obtained, the number of cfu/ml in the undiluted drug-culture tube was calculated. The MFC is defined as the minimum amount of drug required to reduce the number of viable cells initially present in the drug-culture tubes greater than or equal to 95%. The MFC was 10 μg/ml.
Synergistic & Fungicidal Effect β-Lactone and Ketoconazole
Synergistic and fungicidal effects were determined by treating exponential phase Candida albicans cultures with β-Lactone at MIC and MFC levels and ketoconazole at 0.1 μg/ml or a 1 μg/ml alone or in combination. Exponential phase cultures were prepared by diluting an overnight culture 1:50 or 1:1000 in YNB/G. After incubating the diluted cells 7 or 17 hrs. at 37° C., the exponential phase cells were diluted in YNB/G to A 600 =0.0004 u/ml to obtain 3000 cfu/ml.
10 microliters (μl) of β-lactone compound or ketoconazole prepared in DMSO was added to 1 ml of diluted exponential phase cells. The tubes were incubated at 37° C. at 250 rpm for 27 hours. Periodically, aliquots were diluted in 0.9% saline and plated on Sabouraud dextrose agar plates to determine the number of cfu/ml.
A. Synergistic Effect
The result for the β-lactone compound at minimum inhibitory concentration of 2.5 μg/ml with and without 1 μg/ml of ketoconazole are seen in Table 1 and FIG. 1.
TABLE 1______________________________________Fungal Growth (CFU/ML) β-Lactone Compound β-Lactone Keto- (2.5 μg/ml) +Time No Compound conazole Ketoconazole(Hours) Drug (2.5 μg/ml) (1 μg/ml) (1 μg/ml)______________________________________ 0 2.95 × 10.sup.3 2.95 × 10.sup.3 2 3.85 × 10.sup.3 3.85 × 10.sup.3 5.1 × 10.sup.3 9.20 × 10.sup.3 4.5 1.30 × 10.sup.4 8.80 × 10.sup.3 1.09 × 10.sup.4 8.50 × 10.sup.3 7 6.65z10.sup.4 1.12 × 10.sup.4 2.40 × 10.sup.4 6.75 × 10.sup.311 9.45 × 10.sup.5 1.28 × 10.sup.4 6.90 × 10.sup.4 7.00 × 10.sup.317 4.05 × 10.sup.7 9.35 × 10.sup.3 1.36 × 10.sup.5 5.90 × 10.sup.222 7.30 × 10.sup.7 1.23 × 10.sup.4 3.30 × 10.sup.5 9.00.10.sup.127 7.00 × 10.sup. 7 1.80 × 10.sup.4 7.20 × 10.sup.5 2.50 × 10.sup.2______________________________________
The results show that after 17 hours, there is a definite synergistic effect of the combination of the β-lactone compound and ketoconazole.
B. Fungicidal Effect
The results for the β-lactone compound at 4 times the minimum inhibitory concentration with and without 1 μg/ml of ketoconazole are seen in Table 2 and FIG. 2.
TABLE 2______________________________________Fungal Growth (CFU/ML) β-Lactone Compound β-Lactone Keto- (10 μg/ml) +Time No Compound conazole Ketoconazole(Hours) Drug (10 μg/ml) (1 μg/ml) (1 μg/ml)______________________________________ 0 2.95 × 10.sup.3 2.95 × 10.sup.3 2 3.85 × 10.sup.3 6.50 × 10.sup.3 5.1 × 10.sup.3 5.20 × 10.sup.3 4.5 1.30 × 10.sup.4 7.50 × 10.sup.3 1.09 × 10.sup.4 3.95 × 10.sup.3 7 6.65 × 10.sup.4 3.35 × 10.sup.3 2.40 × 10.sup.4 3.85 × 10.sup.311 9.45 × 10.sup.5 8.70 × 10.sup.2 6.90 × 10.sup.4 7.00 × 10.sup.117 4.05 × 10.sup.7 5.00 × 10.sup.1 1.36 × 10.sup.5 022 7.30 × 10.sup.7 6.50 × 10.sup.1 3.30 × 10.sup.5 527 7.00 × 10.sup.7 7.50 × 10.sup.1 7.20 × 10.sup.5 0______________________________________
The results show that after 17 hours, complete kill of the microorganism is effected by the combination of the β-lactone at MFC (10 μg/ml) and ketoconazole at 1 μg/ml.
Synergistic Effect of β-Lactone Compound and Different Conazoles
The effectiveness of the combination of the β-lactone compound with various conazole compounds may be illustrated with ketoconazole, fluconazole and itraconazole.
The β-lactone compound and the following conazole compounds: cis-1-acetyl-4-[4-[[2-(2,4-dichlorophenyl)-2-1H-imidazole-1-ylmethyl)-1,3-dioxolan-4-yl]-methoxyl]phenyl]piperazine (ketoconazole), α-(2,4-difluorophenyl)-α-(1H-1,4-triazol-1-ylmethyl)1H-1,2-4-triazole-1-ethanol (fluconazole and cis-4-[4-[4-[4-[[2-(2,4-dichlorophenyl)-2-(1H-1,2,4-triazole-1-ylmethyl)-1,3-dioxolan-4-yl]-methoxy] phenyl]-1-piperazinyl]phenyl-2,4-dihydro-2-(1-methylpropyl)-3H-1,2,4-triazol-3-one (itraconazole), were dissolved in DMSO and serially diluted in the manner previously described.
Assay tubes were prepared in a manner similar to that previously described and in operations carried out in a manner similar to that previously described, the effect of various conazole compounds on the MIC of the β-lactone compound were determined. The results are summarized in Table 3.
TABLE 3______________________________________Effect of Azole Antifungals on the MIC'S of theβ-Lactone Compound Against Candida albicans MY 1055POTENTIA- MIC'S OF β-LACTONE COMPOUNDTOR FLUCON- ITRACONAZOLE KETOCON-(μg/ml) AZOLE (μg/ml) AZOLE______________________________________0 2.5 2.5 2.5 0.3125 1.25 2.5 0.6251.25 0.625 1.25 0.6255.0 0.625 1.25 0.625______________________________________
Synergistic Effect of β-Lactone Compound and Ketoconazole Against Fungal Panel
In a manner similar to that above described for effect against Candida albicans the synergistic effect of the combination of the β-lactone compound and ketoconazole against a fungal panel was determined by plating on potato dextrose agar.
First the MIC for the β-lactone compound and the MIC for the ketoconazole were determined against an array of organisms. Thereafter, the effects on the MIC of adding 0.031, 0.125, 0.5 and 2 μg/ml of ketoconazole were determined. The results are seen in Table 4.
TABLE 4______________________________________Minimum Inhibitory Concentration (MIC) Keto- β-Lactone Compound in cona- Presence of Ketoconazole zole μg/ml of Ketoconazole AloneOrganism 0 0.031 0.123 0.5 2 μg/ml______________________________________A. niger >50 >50 >50 >50 >50 >2C. miyabeamis 0.78 0.39 0.78 0.195 N.G. 2F. oxysporium >50 >50 >50 >50 >50 >2U. zeae 3.125 3.125 0.78 0.19 0.19 >2C. neoformans 12.5 12.5 3.125 0.19 0.19 >2C. albicans 3.125 0.78 0.78 0.19 0.19 >2(Y1055)C. albicans 3.125 0.78 0.195 0.19 0.19 >2(Y1750)______________________________________
From the foregoing test results and from known dosage ranges of the "conazole compound" as applied to man, it is determined that generally from about 2.85 to about 4.75 mg/kg of body weight of the conazole compound and about 2.85 to about 4.75 mg/kg of body weight of the β-lactone compound is to be employed while considering patient's health, weight, age and other factors which influence response to a drug as well as the particular drug to be employed. These amounts when expressed as doses suitable for man are in the range of from about 200 to about 400 mg of each active ingredient given BID by oral or parenteral route.
According to the present invention, the synergistic antifungal or fungicidal composition may be formulated for injection and may be present in unit dosage form in ampoules or in multidose containers, if necessary, with an added preservative. The compositions may also take such forms as suspensions, solutions or emulsions in oily or aqueous vehicles, and may contain formulating agents such as suspending, stabilizing and/or dispersing agents. Alternatively, the active ingredients may be in powder form for reconstituting with a suitable vehicle prior to parenteral or oral administration.
The compounds also may be prepared in tablet or capsule form as well as in liquid form for oral administration. These also may be in unit dosage form.
For parenteral applications the drugs may be formulated in conventional parenteral solutions such as 0.85 percent sodium chloride or 5 percent dextrose in water, or other pharmaceutically acceptable compositions.
The outstanding properties are most effectively utilized when the conazole compound and the β-lactone compound are formulated into novel pharmaceutical composition with a pharmaceutically acceptable carrier according to conventional pharmaceutical compounding techniques.
In preparing the compositions in oral dosage form, the component drugs are intimately admixed with any of the usual pharmaceutical media, including for liquid preparations, liquid carriers such as water, glycols, oils, alcohols, and the like, and for solid preparations such as capsules and tablets, solid carriers such as starches, sugars, kaolin, ethyl cellulose, generally with a lubricant such as calcium stearate, together with binders, disintegrating agents and the like. Because of their ease in administration, tablets and capsules represent the most advantageous oral dosage form. It is especially advantageous to formulate the compositions in unit dosage form for ease of administration and uniformity of dosage. Compositions in unit dosage form constitutes an aspect of the present invention.
The term "unit dosage form" as used in the specification and claims refer to physically discrete units, each unit containing a predetermined quantity of active ingredient calculated to produce the desired therapeutic effect in association with the pharmaceutical carrier. Examples of such unit dosage forms are tablets, capsules, pills, powder packets, wafers, measured units in ampoules or in multidose containers and the like. A unit dosage of the present invention will generally contain from 200 to 400 milligrams of each of the component drugs.
The following examples illustrate novel compositions useful in the practice of the present invention, but are not to be construed as limiting:
EXAMPLE I
1000 compressed tablets each containing 200 milligrams of ketoconazole and 300 milligrams of β-lactone compound are prepared from the following formulation:
______________________________________ Grams______________________________________Ketoconazole 200β-Lactone compound 300Starch 750Dibasic calcium phosphate hydrous 5000Calcium stearate 2.5______________________________________
The finely powered ingredients are mixed well and granulated with 10 percent starch paste. The granulation is dried and compressed into tablets.
EXAMPLE II
1000 hard gelatin capsules, each containing 210 milligrams of ketoconazole and 290 milligrams of β-lactone compound are prepared from the following formulation:
______________________________________ Amount______________________________________Ketoconazole 210 gramsβ-Lactone compound 290 gramsStarch 250 gramsLactose 750 gramsTalc 250 gramsCalcium stearate 10 grams______________________________________
A uniform mixture of the ingredients is prepared by blending and used to fill two-piece hard gelatin capsules.
EXAMPLE III
250 milliliters of an injectable solution are prepared by conventional procedures having the following formulation:
______________________________________ Amount______________________________________Dextrose 12.5 gramsWater 250 millilitersKetoconazole 200 milligramsβ-Lactone compound 200 milligrams______________________________________
The ingredients are blended and thereafter sterilized for use. | Novel fungicidal compositions comprising a 14α-methyldemethylase inhibiting azole compound and a β-lactone compound and a method for controlling mycotic infections is disclosed. | 0 |
This is a division of application Ser. No. 714,866 filed Aug. 16, 1976 now U.S. Pat. No. 4,316,716.
BACKGROUND OF THE INVENTION
This invention generally relates to fiber production and more particularly to a method and apparatus for producing large diameter spun filaments.
In the manufacture of synthetic fiber filaments, it is generally recognized that filament size is a function of a "drawing" operation wherein a continuous spun strand is submitted to a battery of equipment especially designed to "finish" the filament according to a predetermined specification. The filaments may therefore be spun and spooled for future drawing or may be spun-drawn to effect particular characteristics to the filamentary material. The "drawing" operation is known and understood by persons knowledgeable in the art and is therefore considered beyond the scope of the instant invention.
Prior to drawing, the molten polymer is conventionally "pumped" through an orifice at a substantially constant pressure in a vertically oriented spinnerette and air-quenched in a vertical cooling unit or water-quenched in a horizontal water bath. For spun filaments of the larger sizes (5-30 mil) threadline stability is insufficient for vertical air-cooling inasmuch as "necking down" of the molten polymer occurs at the orifice exit. This natural drawing or necking down of the polymer is difficult to control and therefore it is not the practice to air-quench filaments of this larger size. In this circumstance, water-quenching becomes necessary but the throughput for this cooling process is low, thus increasing the expense of producing the larger sizes.
Filaments having drawn or "finished" diameters in excess of 3-mils have become attractive for various applications and it is desirable, therefore, to produce them economically. Inasmuch as liquid cooling decreases production throughput, it would seem ideal if larger size filaments could be air-cooled since high threadline speeds could be achieved. In conventional cross flow air-cooling processes, multi-filament spinning has a tendency to fuse filaments while mono-filament spinning lacks threadline stability. Thus, problems exist in the state of the art where larger sizes are being considered.
The present invention applies a technique of electrostatic cooling that is described in the publication "Electronic Design", volume 19, No. 20, of Sept. 20, 1971, entitled "High Voltage Ionic Discharges Provide Silent Efficient Cooling". According to this technique, a high voltage ionic discharge cools a hot surface by producing a turbulence that disturbs the thin boundary layer of air molecules on the surface. These air molecules act as an insulating barrier against further cooling of the surface and thus decrease cooling efficiency.
In this respect, therefore, the present invention comprises a method and apparatus for bombarding a molten polymer filament with accelerated electrons in the presence of forced air-cooling to substantially increase the rate of cooling and allow for the formation of larger filament diameters in the spinning process. More specifically, the invention comprises a collar configuration that is mounted proximate to a conventional extruder spinnerette orifice to effect electrostatic cooling of the molten filament as it exits from the spinnerette.
The features and advantages of the invention will become apparent from the following detailed description when considered in conjunction with the accompanying drawings in which like parts bear like reference numerals.
IN THE DRAWINGS
FIG. 1 diagrammatically illustrates the application of the invention to polymer filament spinning;
FIG. 2 is an enlarged plan view, in section, of the electrostatic collar forming an essential part of the invention; and
FIG. 3 is a sectional perspective view of the collar taken on line 3--3 of FIG. 2.
DESCRIPTION OF THE INVENTION
Referring to FIG. 1, the method of the invention is shown utilizing apparatus generally indicated by reference numeral 10 for cooling a molten polymer filament 12 as it exits an extruder spinnerette 14. The molten polymer passes through a cooling unit 16 which will be described in detail hereinafter with respect to FIGS. 2 and 3. A roller 18 picks up the filament whereupon it is fed to further processing equipment 20 which may/may not include finish drawing. An air supply 22 is connected into unit 16 to provide air quenching of the molten polymer as it passes down through the unit, and to increase the efficiency of the air-cooling, a high voltage, low amperage d.c. supply 24 is connected to electrode terminals in the unit.
With reference now to FIG. 2, the cooling unit 16 is shown in a sectional plan view looking down through the top with the polymer filament 12 assumed to be entering the page. As illustrated, unit 16 is essentially a cylinder or collar of a non-conductive plastic material. Mounted within the collar are at least three vertical rows of cathode electrodes 30, that are connected via line 32 to the negative terminal of the high voltage power supply 24. Opposite each vertical row of cathodes 30 is a vertical row of anode electrodes 34 connected via line 36 to the positive terminal of the power supply 24. FIG. 3 more clearly illustrates the row arrangement of the electrodes 30 and 34. To provide separation and prevent arcing between adjacent electrodes a plurality of T-section insulators 38 are mounted within the collar 16. The insulators support a screen 40 at the cross bar of the T-section, which screen is in coaxial alignment with the collar 16 and prevents any filament contact with the electrodes. Also mounted to opposite insulators are at least two non-conductive plastic tubes 42 that are closed at the top of the collar and connected at the bottom to the air supply 22. A plurality of vertically spaced orifice 44 are located in each air supply tube such that cooling air is directed to the axis of the collar for quenching filament 12.
In applying the electrostatic collar 16 to the production of polymer filaments, the following should be considered.
(1) The force, whether electrostatic or air, must be balanced or the resultant force kept to a minimum such that the filament or filament group will not be pushed to one side.
(2) Since the polymer is a poor conductor, static charges will build up surrounding the filament. This charge, if not evenly distributed, will eventually push the filament to the cathode or anode electrodes.
(3) When spinning multiple filament yarns, charge may accumulate on the individual filaments with the resultant tendency to repel each other and make spinning very difficult.
(4) The electron flux within the collar must be optimized to avoid ionization of the air and shortcircuiting of the electron flow.
In consideration of the above, an electrostatic collar configuration as illustrated in the drawing and having a 35 kv potential across it in the presence of air-cooling was successful in producing a filament having a 13.5 mil diameter. This filament was subsequently drawn to a "finished" filament exhibiting the following properties:
Diameter: 6 mil
Denier: 225
Tensile Strength: 3.54 lbs.
Tenacity: 7.17 g/d
Elongation to Break: 14.5%
While certain representative embodiments and details have been shown for the purpose of illustrating the invention, it will be apparent to those skilled in the art that various changes and modifications may be made therein without departing from the spirit or scope of the invention. | Large diameter filaments are produced by increasing the cooling efficiency of a molten polymer as it exits a spinnerette orifice. The cooling is accomplished in a collar configuration having means for directing cooling air and an ionic discharge in a direction transverse to the axis of the filament as it passes through the collar. | 3 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims benefit from U.S. Provisional Patent Application No. 61/914,187, entitled “Plugless Glazing System,” filed on Dec. 10, 2013, which is hereby incorporated in its entirety by reference.
FIELD OF INVENTION
The present invention relates generally to a glazing system for door, and more particularly, to a plugless glazing system for a door.
BACKGROUND
Entry doors for residences, business, and industrial facilities utilize entry doors of various designs. One popular design is a door designed with a window inset in the door. An entry door with a window often utilizes window trim in addition to the glass panel. In standard designs, two mating parts attach to oppose pieces of window trim. The first mating part attaches to the exterior window trim, holding the glass, trim, and the door slab together. The second mating part attaches to the interior window trim and locates and mates with the part attached to the exterior window trim.
Standard designs require external screws or other fasteners to secure the interior trim to the exterior trim. The use of external screws requires the use of trim plugs or other means to improve the aesthetic appearance of the interior trim. As trim plugs are painted and stained separately from the trim, this can lead to differences between the shade, hues, and glosses of the trim and trim plugs. Additionally, it is time consuming to prepare individual trim plugs for painting and staining.
It is also time consuming to install trim plugs during the door assembly process as one door may require up to 26 trim plugs. The trim plugs need to be installed carefully so that they properly cover the screw heads and that they attach to and blend in with the interior trim. Improperly fitted trim plugs can cause paint and/or stain chipping, marring or hazing, which leads to a potentially inferior finish to the door.
Therefore, there is a need for a more efficient connection system for entry door window trim. Specifically, there is a need for a plugless trim system that provides a better finish and is more aesthetically pleasing.
SUMMARY
Provided is a plugless locking system for attaching trim over a space between a glazing member and a framing member, the plugless locking system includes a first plugless lock that is configured to attach to an exterior trim. The first plugless lock may include a base having an exterior side and an opposite interior side, the exterior trim may be configured to attach to the exterior side of the base. A first member may extend from the interior side of said base and a second member may extend from the interior side of said base and be generally parallel to said first member. A cavity may be defined by the base, the first member and the second member. A first arm may extend from said first member, said first arm configured to operatively engage a surface of the glazing member and a second arm may extend from said second member, said second arm configured to operatively engage a surface of the framing member. At least one aperture may be provided within the first plugless lock.
A second plugless lock may be configured to attach to an interior trim, wherein the second plugless lock attaches with said first plugless lock, the second plugless lock includes a branch configured to be at least partially received within said cavity of the first plugless lock. At least one flange member may extend from said branch, the flange member may be configured to operatively engage said aperture to attach said second plugless lock with said first plugless lock. The interior trim and the exterior trim may be positioned over the space between the glazing member and the framing member.
The second plugless lock includes a first flange member and second flange member wherein each flange member includes a first end having a clip and a second end including a groove. The grooves of the first and second flange members may be positioned opposite from the clips along the branch. The groove may be configured to abut against a mating profile of said interior trim to support the second plugless lock relative to the interior trim.
A fastener may attaches the first plugless lock to the exterior trim and another fastener may attach the second plugless lock to the interior trim wherein the fasteners may be concealed by the plugless locking system once the plugless locking system is installed within the space between the glazing member and the framing member. The first plugless lock and the second plugless lock may not be viewable once the plugless locking system is installed within the space between the glazing member and the framing member.
The branch includes a first flange member spaced from a second flange member, the first flange member includes a first clip configured to operatively engage a first aperture of the first plugless lock and the second flange member includes a second clip configured to operatively engage a second aperture of the first plugless lock. The first flange member may include a first groove extending from the branch opposite from the first clip and the second flange member may include a second groove extending from the branch opposite from the second clip. The grooves may be configured to abut against a mating profile of said interior trim to support the second plugless lock relative to the interior trim.
The first clip and second clip may be configured to bias relative to one another to operatively attach to the first and second apertures, respectively. The mating profile may include a space defined by a first rib and a second rib or may include a ridge that extends along the underside of the interior trim.
Provided by this disclosure is an entry door that includes a window glass positioned within a door slab, wherein there is a space between the window glass and the door slab. A plugless locking system is configured to fit in the space between the window glass and the door slab. The plugless locking system having a first plugless lock configured to receive an exterior trim, the first plugless lock includes a base having at least one aperture. A first member may extend generally perpendicularly from said base and a second member may extend generally perpendicularly from said base and generally parallel to said first member. A cavity may be positioned generally between said first and second members. A first ledge and a second ledge may extend from said first and second members, respectively. Said first and second ledges may be configured to operatively engage said window glass and door slab. A second plugless lock may be configured to receive an interior trim, wherein the second plugless lock attaches with said first plugless lock, the second plugless lock includes a branch configured to be received within said cavity. At least one clip may extend from said branch, the clip may be configured to operatively engage said aperture to attach said second plugless lock with said first plugless lock. At least one groove may extend from said branch and be positioned opposite said clip. The groove may be configured to abut against said interior trim.
The grooves may be configured to abut against a mating profile of said interior trim to support the second plugless lock relative to the interior trim. The mating profile may include a space defined by a first rib and a second rib. The mating profile may include a ridge that extends along the underside of the interior trim.
A fastener may attach the first plugless lock to the exterior trim and another fastener may attach the second plugless lock to the interior trim wherein the fasteners are concealed by the interior trim and the exterior trim when the plugless locking system is installed within the space. The first plugless lock and the second plugless lock may not be viewable once the plugless locking system is installed within the space between the glass window and the door slab.
Also provided is a method for attaching an interior trim and an exterior trim to an entry door having a window glass, the method includes the steps attaching an exterior trim to a first plugless lock configured to receive the exterior trim through the use of at least one fastener. The combination of the exterior trim and the first plugless lock may be inserted into a space between a door slab and window glass on an exterior surface of the entry door, with the first plugless lock end being inserted first and upon complete insertion, the exterior trim resting on the exterior surface of the entry door and an exterior surface of the window glass. An interior trim may be attached to a second plugless lock configured to receive the interior trim through the use of at least one fastener. The combination of the interior trim and the second plugless lock may be inserted into a space between the door slab and window glass on an interior surface of the entry door, with the second plugless lock end being inserted first and, upon complete insertion, the interior trim resting on the interior surface of the entry door and an interior surface of the window glass. The first plugless lock may be mated with the second plugless lock in the space between the door slab and window glass of the entry door.
In one embodiment, a groove of the second plugless lock is inserted within a mating profile of the interior trim and the second plugless lock may be attached to the interior trim with a fastener.
In another embodiment, a ridge of a mating profile of the interior trim is mated with a groove of the second plugless lock and the second plugless lock may be attached to the interior trim with a fastener.
BRIEF DESCRIPTION OF THE DRAWINGS
Operation of the invention may be better understood by reference to the detailed description taken in connection with the following illustrations, wherein:
FIG. 1A is an exterior view of an entry door;
FIG. 1B is an interior view of the entry door;
FIG. 2 is a cross-sectional view of an entry door with a window glass with a plugless locking system;
FIGS. 3A, 3B, 3C, and 3D are perspective views of various first plugless locks;
FIG. 4 is a bottom view of a first plugless lock;
FIGS. 5A, 5B, and 5C are side views of various first plugless locks;
FIGS. 6A, 6B, and 6C are perspective views of various second plugless locks;
FIGS. 7A and 7B are bottom views of various second plugless locks;
FIGS. 8A and 8B are side views of various second plugless locks;
FIGS. 9A, 9B, and 9C are perspective views of a first plugless lock mating with an exterior trim;
FIGS. 10A and 10B are perspective views of a first plugless lock mated with an exterior trim;
FIGS. 11A, 11B, and 11C are perspective views a second plugless lock mating with an interior trim;
FIGS. 12A and 12B are perspective views of a second plugless lock mated with an interior trim;
FIG. 13 is a side view of a plugless locking system being installed in an entry door;
FIGS. 14A and 14B are perspective views of a plugless locking system mated without an entry door; and
FIGS. 15A, 15B, 15C and 15D are exploded views of embodiments of the plugless locking system.
DETAILED DESCRIPTION
Reference will now be made in detail to exemplary embodiments of the present invention, examples of which are illustrated in the accompanying drawings. It is to be understood that other embodiments may be utilized and structural and functional changes may be made without departing from the respective scope of the invention. Moreover, features of the various embodiments may be combined or altered without departing from the scope of the invention. As such, the following description is presented by way of illustration only and should not limit in any way the various alternatives and modifications that may be made to the illustrated embodiments and still be within the spirit and scope of the invention.
An entry door 10 capable of being attached to a building structure, the entry door 10 having a window glass 12 , is shown in FIG. 1A . The entry door 10 may be of any appropriate shape and size, the present teachings are not limited to the shape and size of the entry door 10 shown and described herein. The window glass 12 may be of any appropriate shape and size, the present teachings are not limited to the shape and size of the window glass 12 shown and described herein. Further, the window glass 12 is not limited to glass; it may also be plastic or any other suitable material. The window glass 12 may be clear, colored, opaque, or any combination of such. Further, the window glass 12 may be comprised of multiple pieces, e.g., a stained glass window design. These, however, are merely exemplary embodiments of the entry door 10 and window glass 12 —any appropriate door or window glass may be used with the present teachings. While the entry door 10 is shown and described as being a door to enter a structure, it may also be an internal door, closet door, or any other type of door; the present teachings are not limited to the use and type of door shown and described.
When terms such as “interior,” “exterior,” “inner,” “outer,” “lower,” “upper,” “horizontal,” and “vertical” are used herein, reference is made to the entry door 10 of the present teachings when oriented as shown, for example, in FIGS. 1A and 1B . It should be understood that such terms are used in their relative senses and are intended to be and are merely exemplary and not all-inclusive nor exclusive.
As shown in FIGS. 1A and 1B , the entry door 10 may have a door slab 14 , which may be formed from a variety of materials, including, but not limited to, wood, plastic, steel, fiberglass, aluminum or any other appropriate material—or it may be a combination of any such material. The entry door 10 may have an exterior surface 16 and an interior surface 18 . When the entry door 10 is used as an entry door to a building, for example, the exterior surface of the door 16 is the side of the door exposed to the outside of the building. In this situation, the interior surface of the door 18 is exposed to the interior of the building.
The window glass 12 may also have an exterior surface 20 and an interior surface 22 . The exterior surface of the window glass 20 may be exposed to the outside of the building in the example above. The interior surface of the window glass 22 may be exposed to the interior of the building.
The window glass 12 may have both an exterior trim 24 contacting the exterior surface of the door 16 and the exterior surface of the window glass 20 and an interior trim 26 contacting the interior surface of the door 18 and the interior surface of the window glass 22 . The exterior and interior trims 24 , 26 may be of any appropriate configuration. The exterior and interior trims 24 , 26 may provide an aesthetically pleasing finish to the entry door 10 . The exterior and interior trims, 24 , 26 may be formed of any appropriate material, including, without limitation, wood, plastic, fiberglass, steel, aluminum, or any other material—or a combination of such materials.
The window glass 12 may be secured to the door slab 14 by a plugless locking system 30 as shown in FIG. 2 . The plugless locking system 30 may include a first plugless lock 32 and a second plugless lock 34 .
As shown in FIGS. 3A-D , 4 , and 5 A-C, the first plugless lock 32 may be generally rectangular in shape with a base 36 having a width smaller than the distance between the door slab 14 and the window glass 12 in the entry door 10 . The base 36 may have a first base end 38 having at least one aperture 40 A and a second base end 42 opposite from the first base end 38 having at least one aperture 40 B. The base 36 may have additional apertures 85 that may mate with the exterior trim 24 allowing for repeatable installation of the plugless locking system 30 .
The first plugless lock 32 may also include a first side 44 of any appropriate configuration. The first side 44 may include a relief aperture 46 and a first side end 97 attached generally perpendicularly to the base 36 at a first base side 47 . The first side 44 may also include a second side end 99 attached generally perpendicularly to a first ledge or arm 48 . The first plugless lock 32 may further include a second side 50 having a relief aperture 52 and a first side end 95 , which may be attached perpendicularly to the base 36 at the second base side 53 . The second side 50 may also include a second side end 93 attached generally perpendicularly to a second ledge or arm 54 . The first side 44 and the second side 50 may be generally parallel to one other, but are not limited to this configuration.
A cavity 56 may be formed between the first side 44 and the second side 50 , the cavity 56 having a width generally equivalent to that of the base 36 . Further, the first side 44 may be shorter than the second side 50 and accordingly, the first arm 48 and the second arm 54 may be at different elevations. However, the first plugless lock 32 may be of any appropriate configuration and is not limited to that shown and described herein.
As shown in FIGS. 6A-C , 7 A-B, and 8 A-b, the second plugless lock 34 may include a branch 58 . The branch 58 may include a first flange member 60 positioned at one end of the branch 58 and a second flange member 62 position at an opposing end of the branch 58 . The first flange member 60 may be spaced from the second flange member 62 . A channel 64 may be defined by the space between the first flange member 60 and the second flange member 62 and bordered by the branch 58 . The first flange member 60 may include a first end 66 having a first clip 68 and a second end 70 having a first groove 72 . The first end 66 of the first flange member 60 and the first clip 68 may be configured to be received by the at least one aperture 40 A of the base 36 of the first plugless lock 32 .
The second flange member 62 of the second plugless lock 34 may include a first end 74 having a second clip 76 and a second end 78 having a second groove 80 . The first flange member 60 and the second flange member 62 may be generally parallel to one other, and both may extend at a substantially right angle from branch 58 . In one embodiment, the first clip 68 may be opposite from the second clip 76 such that each clip may be biased relative to the other to be received within apertures as illustrated by FIGS. 6A and 6B . Both the first plugless lock 32 and the second plugless lock 34 of the plugless locking system 30 may be formed from a variety of materials, including, but not limited to, plastic, steel, fiberglass, aluminum or any other appropriate material or any combination of such. By way of a non-limiting example, the plugless locking system 30 may be formed from a strong UV resistant injection molded plastic or composite, such as acrylonitrile butadiene styrene (ABS) or polycarbonate (PC).
The exterior trim 24 may be attached to the base 36 of the first plugless lock 32 through the use of a fastener 82 operatively inserted through a central hole 83 , as shown in FIGS. 4, 9A, 9B, 9C, 10A and 10B . The present teachings of the fastener 82 are not limited to the screw shown. Any appropriate fastener 82 may be used without departing from the present teachings. The exterior trim 24 may be formed from a variety of materials, including, but not limited to, plastic, metal, wood, or any other suitable material or combination of such. The fastener 82 may be any type of fastener, including, but not limited to, a screw, nail, nut, bolt, lag, or any other appropriate fastener. The fastener 82 may be inserted through aperture 83 as illustrated by FIGS. 2 and 15A . and is to be concealed from view once the interior trim 26 and the exterior trim 24 of the system are installed in place.
Similarly, as shown in FIGS. 11A, 11B, 11C, 12A, and 12B , the interior trim 26 may be attached to the second plugless lock 34 through the engagement with a mating profile 90 along an underside 92 of the interior trim 26 with the first groove 72 and the second groove 80 of the second plugless lock 34 . In this embodiment, the mating profile 90 includes a ridge 122 that extends along the underside 92 of the interior trim 26 and is shaped to fit within the first and second grooves 72 , 80 . This configuration may prevent unwanted rotation between the interior trim 26 and the second plugless lock 34 as they are being attached. A fastener 82 may be operatively inserted through a central hole 84 of the second plugless lock 34 . In one embodiment, the underside 92 of the interior trim 26 includes an extension portion 94 configured to receive the fastener 82 as it extends through the aperture 84 along the branch 58 of the second plugless lock 34 . The extension portion 94 may extend from the underside 92 of the interior trim 26 and abut against the branch 58 as the fastener 82 is installed. The extension portion 94 may extend radially passed the edges of the branch 58 to form an overlap portion 96 . The interior trim 26 may be formed from a variety of materials, including, but not limited to, plastic, metal, wood, or any other suitable material. The fastener 82 may be any type of fastener, including, but not limited to, a screw, nail, nut, bolt, lag, or any other appropriate fastener.
The first plugless lock 32 may be configured to be received in a space 100 between the door slab 14 and the window glass 12 as shown in FIGS. 2, 9A and 13 . The combination of the first plugless lock 32 and the attached exterior trim 24 may be inserted into the space 100 , with the base 36 of the first plugless lock 32 leading. When fully inserted, the first plugless lock 32 may fit snugly between the window glass 12 and the door slab 14 . The exterior trim 24 may rest on the exterior surface 16 of the door 14 and the exterior surface 20 of the glass 12 . In one embodiment, a sealer material may be positioned between the exterior trim 24 and the exterior surfaces 16 , 20 . The sealer material may be a foam material or tape material applied to the trim 24 before installation. Additionally, the sealer material may be a silicone or other type of water based sealing material. The exterior trim 24 may bridge the space 100 between the door slab 14 and the window glass 12 , creating a water tight seal on the entry door 10 .
After insertion into the space 100 , the first arm 48 of the first plugless lock 32 may abut the interior surface 22 of the window glass 12 and the second arm 54 of the first plugless lock 32 may abut the interior surface 16 of the door slab 18 .
The second plugless lock 34 may also be configured to be received by the space 100 between the door slab 14 and the window glass 12 . The second plugless lock 34 and the attached interior trim 26 may be inserted into the space 100 , with the first clip 68 of the first flange member 60 and the second clip 76 of the second flange member 62 of the second plugless lock 34 leading. When fully inserted, the second plugless lock 34 may fit snugly between the window glass 12 and the door slab 14 with the interior trim 26 resting against the interior surface 18 of the door 14 and the interior surface 22 of the window glass 12 . In one embodiment, a sealer material may be positioned between the interior trim 26 and the interior surfaces 18 , 22 . The sealer material may be a foam material or tape material applied to the trim 26 before installation. Additionally, the sealer material may be a silicone, polyurethane or other type of water based sealing material. This sealer material may be useful to reduce raddling of the trim.
The second plugless lock 34 may be inserted inside the cavity 56 of the first plugless lock 32 . The first end 66 of the first flange member 60 of the second plugless lock 34 may be inserted through the at least one aperture 40 A of the first plugless lock 32 . The first end 74 of the second flange member 62 of the second plugless lock 34 may be inserted through the at least one aperture 40 B of the first plugless lock 32 . First and second clips 68 , 76 along the first ends 66 , 74 respectively, may be flexible so that they may compress to pass through the at least one apertures 40 A, 40 B and expand upon exiting the at least one apertures 40 A, 40 B to generally resist opposing movement of the second plugless lock 34 . The resulting mating combination of the first and second plugless locks 32 , 34 may create a removable connection that allows for the replacement of the window glass 12 , exterior trim 24 , and/or interior trim 26 . FIGS. 14A and 14B show this connection without the entry door 10 , to show the mating of the first and second plugless locks 32 , 34 . Further, the second plugless lock 32 illustrated by FIGS. 6C, 8A, 8B , may be attached to interior trim 26 as illustrated by FIGS. 11A, 11B, 11C, 12A and 12B . This embodiment, is configured to be attached to the first plugless lock 32 that includes a relief apertures 46 , 52 for receiving the extension portion 94 of the interior trim 26 . In this embodiment, the overlap portion 96 of the extension portion 94 may extend within relief apertures 46 and 52 for a snug fit connection.
Additionally, in another embodiment, the first plugless lock 32 illustrated by FIGS. 3B, 3C, 15A, 15B and 15C include apertures 102 A, 102 B positioned along sidewalls 104 A, 104 B that extend from the base 36 and between the first side 44 and the second side 50 . These side apertures 102 A, 102 B are configured to receive the first and second clips of the second plugless lock 36 illustrated by FIGS. 6A and 6B .
Further, as illustrated by FIGS. 15A, 15B, 15C, and 15D , a locating feature is provided wherein the second ends 70 , 78 of the first flange 60 and second flange 62 , respectively, may be inserted into the mating profile 90 along an underside 92 of the interior trim 26 . In this embodiment, the matting profile 90 includes a first rib 110 and a second rib 112 . The first and second ribs 110 , 112 extend along the underside 92 and are spaced from one another along the underside 92 of the interior trim 26 . The ribs 110 , 112 may define a space that includes at least one slot 114 and a shoulder 116 therein. The first groove 72 may be configured to be received within the slot 114 while the remaining portion of the second ends 70 , 78 may abut against the shoulder 116 . This embodiment allows a user to quickly locate the proper position of the second plugless lock 34 relative to the interior trim 26 without risk of unwanted relative rotation.
Although the embodiments of the present invention have been illustrated in the accompanying drawings and described in the foregoing detailed description, it is to be understood that the present invention is not to be limited to just the embodiments disclosed, but that the invention described herein is capable of numerous rearrangements, modifications and substitutions without departing from the scope of the claims hereafter. The claims as follows are intended to include all modifications and alterations insofar as they come within the scope of the claims or the equivalent thereof. | The present invention involves an entry door having a window glass situated in a door slab and a space between the window glass and the door slab. A plugless locking system is configured to fit in the space between the window glass and the door slab. The plugless locking system has a first plugless lock is configured to receive an external trim and is configured to mate with a second plugless lock. The second plugless lock is configured to receive an interior trim. The combination of the mated first and second plugless lock fit within the space between the window glass and door slab and secure interior and exterior trim to the entry door. Also disclosed is a method for using the plugless locking system in an entry door. | 4 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates in general to the field of electronic execution of transactions and more specifically to the field of authorizing a transaction by a user. In the wording of the present document, a “transaction” should be understood in particular to refer to a legal or factual procedure, the authorization of which by an authorized user must be verifiable without any doubt. Such a transaction may be, for example, an electronic payment or some other financial transaction or an electronic declaration of intent.
[0003] 2. Description of Related Art
[0004] For an electronic authorization of a transaction, it is customary to use a personal feature of the authorizing user that is known only by the user and/or can be given only with the cooperation of the user. In the past, mainly secret numbers (PINs=personal identification numbers) have been used as these personal features, but the use of biometric features is becoming increasingly important. Such a biometric personal feature can be determined, for example, by scanning a fingerprint or by photographing the face or an eye of the user or by recording a sample of the user's handwriting.
[0005] To authorize a transaction, the user is usually instructed to enter the personal feature at a terminal and/or to make the feature accessible to the terminal. Here, however, there is the problem that the user does not in general have a reliable option for convincing himself/herself of the integrity of the terminal. If the user were to make his/her personal feature accessible to a terminal set up with fraudulent intent, then the user's personal feature, such as his/her fingerprint, could be recorded and later misappropriated by the falsified terminal.
[0006] German laid-open publication DE 41 42 964 A1 discloses a system in which a secret provided by the user—e.g., a password known only to the user—is stored in encrypted form in a chip card. Before the user is instructed to enter a PIN as a personal feature, a terminal reads out the encrypted password and displays it to the user in plain text. From the display of the correct password, the user can see that this is a terminal that can be trusted because a falsified terminal could not decrypt the encrypted code word.
[0007] The system described above, however, presupposes that the user is carrying a chip card or some other data carrier on which the encrypted password is stored with him/her. It would be more convenient for the user if this were not obligatorily necessary. In conjunction with biometric authorization procedures in particular, an additional requirement is often that no additional data carriers are to be used. For example, in biometric authorization of a payment transaction, this is an essential point in designing the procedure to be as simple as possible.
SUMMARY OF THE INVENTION
[0008] Therefore, an object of the present invention is to avoid the aforementioned problems at least in part and to provide a technique for authorizing a transaction by a user using a terminal which gives the user an opportunity to recognize a falsified terminal. In some embodiments, the invention should be adapted especially to the use of biometric authorization techniques.
[0009] According to the invention, this object is achieved entirely or in part by a method executed by a terminal according to Claim 1 , a method executed by a background system according to Claim 8 , a method according to Claim 13 , a device according to Claim 16 and a computer program product according to Claim 17 . The dependent claims define preferred embodiments of the present invention for authorizing a transaction by a user using a terminal which is capable of communicating with a background system, with steps performed by the terminal: determining identification information which identifies the user, sending data to the background system to authenticate the terminal at the background system and to transmit user identification data from which the identity of the user can be derived, to the background system, receiving secret data assigned to the user from the background system, playing back a secret given by the secret data to the user, determining a personal feature of the user, and sending data which is related to the personal feature of the user to the background system to signal or document the authorization of the transaction by the user.
[0010] Further according to the invention, this object is achieved entirely or in part by a method for authorizing a transaction by a user, the method using a background system capable of communicating with a terminal, with steps performed by the background system: receiving data from the terminal, the data authenticating the terminal at the background system, the identity of the user being derivable from the data, if the authentication of the terminal at the background system has been successful, then accessing secret data stored in a database and assigned to the user, and sending data from which the secret data can be determined, to the terminal, and receiving data from the terminal, the data pertaining at least to a personal feature of the user and documenting the authorization of the transaction by the user.
[0011] Yet further according to the invention, this object is achieved entirely or in part by a method for authorizing a transaction by a user using a terminal capable of communicating with a background system, with the steps: determining, by the terminal, identification information which identifies the user, communicating between the terminal and the background system to authenticate the terminal at the background system and to transmit user identification data from which the identity of the user can be derived to the background system, if the authentication of the terminal at the background system has been successful, then the background system accesses secret data stored in a database and assigned to the user, and data from which the secret data can be determined is sent to the terminal, playing back, by the terminal, a secret given by the secret data to the user, determining, by the terminal, a personal feature of the user, and performing the transaction using data pertaining at least to the personal feature of the user.
[0012] The invention also comprises a terminal, a background system, and a computer program product.
[0013] The dependent claims concern features of some embodiments of the invention.
[0014] The present invention is based on the basic idea of storing data about a secret that is known only to the user in a background system (host system) with which the terminal is capable of exchanging data. The background system transmits the secret data of the user to the terminal only when the terminal has been successfully authenticated by the background system—i.e., has proven to be an authorized terminal. The background system usually stores secret data of many users so identification of the user is necessary before the background system can access the secret data assigned to the user.
[0015] The secret that is sent by the background system to the terminal in the form of secret data after successful authentication of the terminal is replayed to the user. The user can then be ensured that the terminal is trustworthy. To authorize the transaction, the user can then enter his/her personal feature or can make it accessible to the terminal without the user having to fear any misuse. The transaction is then performed, with the personal feature of the user serving to verify the authorization.
[0016] The invention offers the considerable advantage of an authentication of the terminal that can be verified by the user without requiring the user to have a data carrier. Acceptance of biometric authorization procedures can thereby be increased considerably, in particular because many users have concerns regarding possible misuse of their biometric data.
[0017] The order of enumeration of the steps in the method claims should not be understood as a restriction of the scope of protection. Instead, embodiments of the invention are provided in which these method steps are carried out in a different order or entirely or partially in parallel or entirely or partially interleaved. This pertains in particular to a possible interleaving of the related steps of the terminal and the background system in which data is acquired, transmitted and processed. Furthermore, in particular the authentication of the terminal at the background system and the transmission of the user's identification data to the background system may take place in a single step or in multiple substeps—in any order.
[0018] For authentication of the terminal at the background system, any method that would rule out the use of counterfeit terminals or would at least greatly impede such use may be employed here. As a rule, such authentication methods are based on a secret key of the terminal, and either symmetrical or asymmetrical encryption may be used. The terminal may transmit information to the background system for authentication, this information allowing the background system to determine whether the terminal has the secret key. The secret key itself, however, should not be accessible to an unauthorized person even if the unauthorized person taps into and analyzes a large number of communication operations between the terminal and the background system.
[0019] In some embodiments, a message secured with a MAC (message authentication code) or a cryptographic signature is used for authentication of the terminal. This message may contain user identification data that has been input into the terminal by the user or derived by the terminal from identification information pertaining to the user.
[0020] The secret that is supplied back to the user may be any type of information that is easily identified by the user and would be difficult or impossible for a counterfeit terminal to guess. Depending on the output options of the terminal, the information may consist of, for example, a displayed text and/or a displayed image and/or an acoustic output and/or tactile information.
[0021] To prevent the possibility of manipulation by spying on successful transactions of a user, some embodiments use a secret that changes from one transaction to the next and may, for example, be selected from a plurality of given secret information. In some embodiments, information regarding previous transactions, e.g., a photograph of the user at the last transaction performed—may be included in the secret or may form the secret.
[0022] In some embodiments, the personal feature of the user is a biometric feature. Depending on the embodiment of the terminal, for example, a fingerprint of the user may be determined and/or a sample of the user's signature may be recorded and/or a photograph or scan of the user or individual body parts of the user may be prepared and/or a voice sample of the user may be analyzed. However, this is not to exclude embodiments of the invention in which the personal feature is a password or a secret number or in which the personal feature is stored on a data carrier. However, such embodiments are less preferred because they are not so convenient for the user.
[0023] The personal feature is preferably transmitted by the terminal to the background system and is checked there. In the case of a successful check on the personal feature, the transaction is considered as having been authorized and the terminal may output a corresponding acknowledgement, for example. Embodiments in which the personal feature is checked entirely or partially by the terminal are not ruled out. To do so, however, it is usually necessary for information required for the check to be transmitted from the background system to the terminal, but this should be desirable only in exceptional cases for safety reasons.
[0024] In some embodiments, the communication transactions between the terminal and the background system are protected by suitable measures from spying and/or attacks by devices connected between them, especially so-called replay attacks. For example, time stamps and/or sequence numbers may be used for this purpose. In advantageous embodiments, an encryption of all messages—preferably with a session key that is issued again for each session—is provided.
[0025] The computer program product according to the invention has program instructions for implementing the method according to the invention in a terminal and/or a background system. Such a computer program product may be a physical medium, e.g., a semiconductor memory or a diskette or a CD-ROM. The computer program product may also be, for example, a non-physical medium, e.g., a signal transmitted over a computer network.
[0026] The device according to the invention may be in particular a terminal or a background system or a combination of a terminal and a background system. In some embodiments, the device and the computer program product have features which correspond to the features mentioned in the present description and/or in the dependent method claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] Additional features, objects and advantages of the present invention are apparent from the following description of several exemplary embodiments and alternative embodiments. Reference is made to the schematic drawings in which:
[0028] FIG. 1 shows a system according to an exemplary embodiment of the invention in a schematic block diagram representation, and
[0029] FIG. 2A and FIG. 2B each show a section of an exemplary flow chart of a successfully authorized transaction in the system of FIG. 1 .
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0030] FIG. 1 shows a background system 10 having a server 12 and a database 14 . The server 12 is embodied in the form of a powerful computer which is controlled by a program according to the method described below. The background system 10 serves, over a network 16 , a plurality of terminals, one terminal 18 of which is shown as an example in FIG. 1 . The network 16 may have multiple subsections which may be embodied, for example, as a local network and/or as a data packet network such as the Internet and/or as an analog or digital telephone network.
[0031] In the present exemplary embodiment, the terminal 18 is designed as a compact independent device which has operating elements such as a keyboard or keypad 20 , display elements such as a graphic display 22 and elements for computing biometric features. In the present exemplary embodiment, a fingerprint sensor 24 and a camera 26 are provided for the latter purpose. In alternative embodiments, more or fewer or other biometric sensors may be provided. Furthermore, embodiments of the terminal 18 which do not have any biometric sensors but instead require input of a personal feature via the keyboard 20 are also conceivable.
[0032] In the exemplary embodiment illustrated in FIG. 1 , the terminal 18 is designed as an independent device which is controlled by a built-in microprocessor according to the method described below. In simple embodiments, transaction data—e.g., a purchase price to be paid—is entered via the keyboard 20 , but it is preferable for such data to be transmitted to the terminal 18 via an electronic interface (not shown in FIG. 1 ). A cash register, for example, may be connected to the interface. In other alternative embodiments, the terminal 18 is not an independent device but instead is incorporated, for example, into a cash register or an automatic apparatus or an access control device.
[0033] The sequence of a successfully authorized transaction illustrated in FIG. 2A and FIG. 2B begins in step 30 with an identification of the user, with identification information 32 being determined. At this point in time, the user cannot yet assume that the terminal 18 is trustworthy, so as a rule non-confidential identification information 32 is used. For example, in step 30 the user may enter as identification information 32 a customer number or a telephone number or his/her name—optionally together with his/her date of birth, if this is necessary for unambiguous identification—by using the keyboard 20 of the terminal 18 .
[0034] In particular in the case of extensive identification information 32 , the use of memory cards or memory modules may be provided in some embodiments. For example, the identification information 32 may be printed as plain text or as a bar code on a card and analyzed by a reader of the terminal 18 —e.g., the cameras 26 . In a similar way a magnetic card or a compact radio module (RF tag) may be used for convenient storage of the identification information 32 , but then of course the terminal 18 must also be equipped with a suitable reader. The methods mentioned above are not mutually exclusive. For example, if the data carrier is not at hand, the user may enter his/her name and date of birth via the keyboard 20 as a more time-consuming alternative.
[0035] In another alternative embodiment, biometric information is used as the identification information 32 . For example, a photograph of the user's face recorded by the camera 26 may be used for identification of the user. Furthermore, a fingerprint of the user recorded by the fingerprint sensor 24 may also be used, for example. If the transaction is authorized on the basis of a fingerprint, the user should use a different finger for identification purposes.
[0036] In step 34 the terminal 18 calculates data 36 that is transmitted to the background system 10 . This data 34 contains in encrypted form user identification data ID and a first time stamp TS 1 . The encryption is indicated by the designation “ENC( . . . )” in FIG. 1 ; the symbol “∥” stands for joining two respective components of a message.
[0037] The user identification data ID is identical in some embodiments to the identification information 32 determined by the terminal 18 in step 30 . This may be the case in particular if the identification information 32 is in compact form. However, if very extensive identification information 32 is obtained by the terminal 18 , e.g., in the case of biometric data acquisition, preprocessing in the terminal 18 may be advantageous to derive suitable feature values to be used as the user identification data ID from the identification information 32 .
[0038] The data transmitted to the background system 10 in step 34 is also protected by a data securing code, which is referred to below as MAC (message authentication code). Conceptually a MAC is a hash value or “fingerprint” into which is input first the message to be transmitted—in this case the encrypted user identification data ID and the first time stamp TS 1 —and also a secret key of the terminal 18 . Methods of calculating a MAC are known and are described for example in chapter 9.5 of the book “ Handbook of Applied Cryptography ” by A. Menezes et al., CRC Press, 1996, pages 352-359.
[0039] In step 38 the background system 10 performs an authentication of the terminal 18 . In the present exemplary embodiment, the background system 10 knows the secret key of the terminal 18 and can therefore check the MAC calculated by the terminal 18 . In alternative embodiments, instead of a MAC based on a symmetrical encryption method, a cryptographic signature based on an asymmetrical method may be used. To analyze such a cryptographic signature, only a public key of the terminal 18 need be known to the background system 10 . Furthermore, embodiments in which a session key is negotiated between the terminal 18 and the background system 10 and a secure encrypted communications channel is established are also conceivable.
[0040] If the authorization of the terminal 18 in step 38 fails, the method is terminated. Otherwise the background system 10 performs a search query in the database 14 in step 40 to access secret data SEC assigned to the user. There may be a search for an entry in the database 14 containing the user identification data ID in identical form or merely a similarity comparison may be performed. The latter is provided in particular when the user identification data ID is derived from biometric identification information 32 .
[0041] Each entry assigned to a user in the database 14 contains secret data SEC on at least one secret of a user. In the present exemplary embodiment, a single static secret is used. Alternative embodiments with several secrets and/or dynamic secrets are described below.
[0042] In step 42 , the secret data SEC determined from the database 14 is provided with a second time stamp TS 2 , encrypted and secured with another MAC. The data 44 thus obtained is transmitted to the terminal 18 .
[0043] In step 46 ( FIG. 2B ) the terminal 18 first performs an authentication of the background system 10 on the basis of the MAC contained in the data 44 . This authentication is less critical than the authentication in step 38 because a counterfeit background system 10 would not have any knowledge of the secret expected by the user. Furthermore, in step 46 the terminal 18 evaluates the second time stamp TS 2 and checks on whether the time indicated there is later than the time of the first time stamp TS 1 . Some embodiments may also provide a check on whether or not a maximum allowed time difference has been exceeded between the two time stamps TS 1 and TS 2 .
[0044] The check of the time stamp serves to protect against an attack in which a previous communication operation is recorded and played back (so-called replay attack). In alternative embodiments, instead of or in addition to the time stamps, random numbers may also be used to match requests and the corresponding responses and/or a send sequence counter may be used.
[0045] In step 48 , the secret data SEC contained in encrypted form in the data 44 is decrypted and played back to the user as a secret 50 . The secret 50 may be any type of information suitable for proving to the user that there has been successful authentication of the terminal 18 at the background system 10 in step 38 . For example, as the secret 50 , the user may be shown an image selected by the user or a password selected by the user and appearing on the display 22 of the terminal 18 . In addition to or instead of the visual playback of the secret 50 , an acoustic and/or tactile playback is also possible.
[0046] Before or after or simultaneously with the playback of the secret 50 in step 48 , the transaction data 54 mentioned above, which may indicate the purchase price to be paid, for example, is displayed to the user in step 52 . Display of the correct secret 50 signals to the user that the terminal 18 can be trusted because the background system 10 would transmit the secret 50 to the terminal 18 only after successful authentication of the terminal 18 . Therefore, the user need not have any concerns about making accessible to the terminal 18 a personal feature 56 that has been established in advance.
[0047] The personal feature 56 may be, for example, a fingerprint which is input by the terminal 18 in step 58 when the user places his/her finger on the fingerprint sensor 24 . In alternative embodiments, other biometric features, e.g., a password spoken by the user or the iris of the user recorded by the camera 26 , may be used as the personal feature 56 . Furthermore a biometric feature may be combined with a password input or code number input via the keyboard 20 , or in some embodiments only a keyboard/keypad input may be provided or a keyboard/keypad input may be provided as an optional alternative to the biometric test.
[0048] The process whereby the user inputs the personal feature 56 into the terminal 18 or makes this feature accessible to the terminal 18 represents a declaration of intent with which the user authorizes the transaction. The user thereby states his/her consent, e.g., with the payment of the purchase price indicated in step 52 .
[0049] The terminal 18 then converts the personal feature 56 determined in step 58 into feature data FEAT which is a compact representation of the personal feature 56 . Such a conversion is desirable in particular for volume reduction of biometric data. In some alternative embodiments, the feature data FEAT and the personal feature 56 may also be identical.
[0050] The feature data FEAT is encrypted together with the transaction data 54 (labeled as “TD” in FIG. 2B ) and a third time stamp TS 3 and transmitted along with another MAC as data 62 to the background system 10 . In step 64 , the background system 10 checks the MAC and decrypts the data 62 . Furthermore in step 64 the background system 10 performs a time stamp check to be sure that the third time stamp TS 3 indicates a later point in time than the second time stamp TS 2 . If the check in step 64 has been successful, then in step 66 the background system 10 will perform a check of the feature data FEAT. In doing so, the background system 10 will access data contained in the database 14 in the entry assigned to the user.
[0051] Since the personal feature 56 in the exemplary embodiment described here is a biometric feature, in step 66 a corresponding biometric test method that has in particular a high reliability against false positive results must be performed. Such methods are known in many embodiments and as such are not the object of the present invention.
[0052] In case of a successful check of the personal feature 56 and/or the feature data FEAT in step 66 , the transaction is executed in step 68 . Depending on the type of transaction, for example, the background system 10 may relay data regarding the desired payment to an affiliated financial institution or may store such data in the data record assigned to the user in the database 14 . If the check of the feature data FEAT in step 66 has yielded a negative result, the transaction is not performed and the method is terminated. The same thing of course also applies if one of the previous test steps 46 and 64 has failed.
[0053] Then in step 70 , the background system 10 creates acknowledgement data CD regarding the successful transaction. This acknowledgement data CD is provided with a fourth time stamp TS 4 , encrypted and again secured with a MAC. The resulting data 72 is transmitted to the terminal 18 where in step 74 additional test steps pertaining to the MAC and the fourth time stamp TS 4 are performed. If this check fails, a corresponding warning may be output to the user and/or the background system 10 .
[0054] In the case of a successful check in step 74 , the terminal 18 outputs the decrypted acknowledgement data CD as an acknowledgement 78 in step 76 . The acknowledgement 78 may be displayed on the display 22 , for example, or printed out by means of a printer (not shown in FIG. 1 ). The method is thus concluded.
[0055] With the exemplary embodiment described so far, a single static secret is provided for each user. However, alternative embodiments are possible in which several versions of secret data SEC corresponding to different codings of the secret 50 for differently equipped terminals 18 are stored in the database 14 . In these embodiments, the terminal 18 transmits in step 34 additional information about the available playback options to the background system 10 , and in step 42 the background system 10 makes available suitable secret data SEC.
[0056] As an alternative or in addition to different versions of a secret, the database 14 may also have secret data SEC for several different secrets for each user in some embodiments. The choice of one of these secrets in step 40 may then be made, e.g., randomly or according to a given sequence so that in step 48 a secret 50 that changes from one transaction to the next is displayed to the user. For such a dynamic secret, replay attacks based on replaying previous transactions are made considerably more difficult.
[0057] As an alternative or in addition to the aforementioned possibility of creating a dynamic secret, it is also possible to provide for the background system 10 to generate secret data SEC for a dynamic secret in step 40 depending on previous transactions. In particular, the dynamic secret may consist entirely or partially of information about the last transaction performed. Thus for example the date and/or amount of the last purchase and/or a photograph of the customer recorded by the camera 26 at the last transaction may serve as a dynamic secret. In these embodiments, the required data must of course also be stored in database 14 .
[0058] It is self-evident that the details contained in the above description of exemplary embodiments should not be interpreted as restrictions of the scope of the present invention. Many modifications and other alternative embodiments are possible and are self-evident for those skilled in the art. | In a method for authorizing a transaction by a user with the aid of a terminal which can communicate with a background system, a secret, which is known to the user and to the background system but not to an unauthorized attacker, is used. The background system transmits secret data, which indicate the secret, only to the terminal if the terminal has successfully authenticated itself at the background system. Because, as a rule, secret data of several users are stored in the background system, the terminal detects in advance identification information which identifies the user, and transmits corresponding user identification data to the background system. When the terminal displays the secret to the user, the user can be certain that the terminal is trustworthy. A device and a computer program product comprise corresponding features. The invention provides a technique for authorizing a transaction by a user with the aid of a terminal which enables the user to recognize a falsified terminal. | 6 |
TECHNICAL FIELD
This invention relates to a method for preparing thermo-crosslinkable and/or thermoplastic elastomer blends.
"Thermoplastic elastomers (TPE)" is the generally accepted designation for materials in which the elastomeric phases (as soft component) are embedded in plastic material (as hard component). Depending on the nature of this embedding one distingishes between block copolymers and polyblends.
Furthermore, the thermoplastic elastomers may be classified as follows:
1 Types having high hardness
1.1 Copolyesters
1.2 Polyether block amides
2 Types having low hardness
2.1 Thermoplastic polyurethanes (TPU)
2.1.1 Polyetherurethanes
2.1.2 Polyesterurethanes
2.2 Thermoplastic polyolefins (TPO)
2.2.1 Ethylene-propylene-diene elastomer/polypropylene (EPDM/PP)
2.2.2 Acrylonitrile-butadiene copolymer/polypropylene (NBR/PP)
2.3 Styrene block copolymers
2.3.1 Styrene-butadiene-styrene triblock copolymer (SBS)
2.3.2 Styrene-ethylene/butylene-styrene triblock copolymer (SEBS).
BACKGROUND OF THE INVENTION
The preparation of thermo-crosslinkable and/or thermoplastic elastomer blends, in particular of vulcanizable rubber blends, can be effected batchwise or continuously, for example on a calender or in an internal mixer. In both cases, the duration of the mixing process is important, so that only moderate throughputs can be obtained.
However, the use of an internal mixer has the disadvantage that, due to the applied speed of rotation, the crude rubber blend is so strongly heated that for many mixture formulations no crosslinking reagents can be added. Therefore, it is often necessary either
to arrange a calender downstream of said internal mixer and to add sulfur and accelerators to the crude blend removed from the internal mixer on said calender only;
or alternatively
to prepare a preblend without sulfur and accelerator in a first mixing passage through said internal mixer, and thereafter to prepare the final blend with addition of sulfur and accelerator in a second mixing passage through said internal mixer.
So far, the attempts for achieving a continuous mixing in mixing extruders has failed for the abovementioned compulsion of observing this order. Calculations show that a spindle length of the order of 40 times diameter would be necessary (D being the spindle diameter). This is technically difficult to realize and economically unattractive.
Furthermore, the use of plasticized elastomers or the addition of large quantities of plasticizers is critical since the shearing forces produceable in the mixture are no longer sufficient for a regular mixing.
OBJECTS OF THE INVENTION
It is a primary object of the present invention to provide a method for preparing thermo-crosslinkable and/or thermoplastic elastomer blends, which method avoids the abovementioned disadvantages of the prior art.
It is a further object of the invention to provide such a method which considerably shortens the duration of mixing.
It is a still further object of the invention to provide a method for continuously preparing thermo-crosslinkable and/or thermoplastic elastomer blends, in particular vulcanizable rubber blends, which method allows the use of simple mixers or mixing extruders.
SUMMARY OF THE INVENTION
To meet these and other objects, the present invention provides a method for preparing thermo-crosslinkable and/or thermoplastic elastomer blends by mixing the elastomer with plasticizer oil and other additives, said method comprising the steps of:
(a) continuously premixing the crushed elastomer in an annular zone mixer with at least part of said plasticizer oil, and optionally with at least part of said other additives, to form a preblend in which said elastomer is decomposed and said additives are embedded in the polymer matrix;
and thereafter
(b) completing the mixing of said premix, and optionally of the remainder of said additives, in a mixing unit working batchwise or continuously.
In the method according to the invention, said annular zone mixer of said first step (a) has the function of decomposing the elastomer to such an extent that a mixing with the adjuvants becomes possible. Thus a large part of the total mixing process is effected in said annular zone mixer, whereas the function of said mixing unit of said second step (b), for example an internal or Banbury type mixer or mixing extruder, is reduced to a simple aftermixing. This was most surprising to a person skilled in the art.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In applying the method according to the invention, all known groups of adjuvants can be used, that is to say:
1 Crosslinking systems, in particular vulcanization agents.
2 Fillers, namely:
2.1 Active fillers which result in a decisive improvement of the mechanical properties, particularly of the tensile strength and the abrasion resistance, such as: types of active black carbon, aluminium and calcium silicate, and zinc oxide; or
2.2 Inactive fillers which do not result in a quantitative improvement of the vulcanized goods, for example calcium and magnesium carbonate, kaolin, barite, kieselguhr, and various clays;
2.3 For elastomers which are not filled with carbon black: dyes, namely:
2.3.1 Inorganic pigments, for example lithopone, titanium dioxide, iron oxide, and chrome oxide green; or
2.3.2 Organic dyes, for example azo, alizarin and phthalocyanine dyes.
3 Plasticizers for improving the processing properties, the elasticity, and the cold-behavior, namely:
3.1 For non-polar or weakly polar crude rubber types (for example natural rubber (NR), styrene-butadiene copolymers (SBR), polybutadiene (BR), isobutylene-isoprene copolymers (IIR)): mineral oil products.
3.2 For more polar types (for example acrylonitrilebutadiene copolymer (NBR) and polychlorobutadiene (CR)): phthalates (for example dibutyl and dioctylphthalate), phosphoric esters (for example tricresyl phosphate), and aromatic mineral oils.
3.3 Further processing adjuvants, for example factices (i.e vegetable oils treated with sulfur or sulfur chloride), lanoline, soft paraffin, soft polyethylene, bitumen, and pitch.
4 Age protectors for improving the resistance of the finished vulcanized good against oxygen, the action of light, and dynamic strain, namely:
4.1 For protecting elastomers the macromolecules of which contain double bonds against oxygen and ozone: antioxidants, for example amines and phenols;
4.2 Screening agents, in particular paraffinic substances, for example ceresin and ozocerite;
4.3 For retarding the hydrolysis of elastomers having the tendency to hydrolyze (for example polyurethane elastomers (PU) and ethylene-vinylacetate copolymers (EVA): polycarbodiimine.
5 Other adjuvants, namely:
5.1 Agent for influencing the stickiness, namely:
5.1.1 Agents for reducing the undesired adherence of the crude rubber during its processing, for example paraffin, lanoline, stearic acid and its salts;
5.1.2 Agents for improving the stickiness of the crude rubber during its assembly, for example colophonium, coumarone resins, alkylphenol acetylene condensates, as well as low-molecular polyethylenes.
5.2 Adhesives which are necessary for manufacturing firm joints between elastomers and metals, as well as compound materials with fabrics, for example in the tire production and for conveyor belts, namely:
5.2.1 For manufacturing metallic compound materials: for example cobalt naphthenate, recorcin resin, as well as increased quantities of sulfur;
5.2.2 For manufacturing textile compound materials: for example styrene-butadiene-vinylpyridine terpolymers in combination with resorcinol formaldehyde resins and special isocyanates.
5.3 Foaming agents for the manufacturing of porous vulcanized goods, for example sulfohydrazides (such as benzenesulfohydrazide), nitroso compounds (such as dinitrosopentamethylenetetramine and ammonium carbonate.
As a general rule, the adjuvants can be used with the commercial grain sizes in the micron-range. Their use in paste form provides the possibility of refining them, in particular to pulverize, to disperse or to degas them. This makes it possible to use coarse-grinded and therefore less expensive adjuvants, for example black carbons.
In carrying out the method of the invention, preferably said annular zone mixer of said first stage (a) is fed with all the additives.
This may be done by preparing one single paste from all additives, said single paste being introduced into said annular zone mixer of said first stage (a).
Alternatively, said additives may be shared for preparing several pastes, preferably two pastes, which are then introduced into said annular zone mixer of said first step (a), either separately or after being mixed together.
If said adjuvants are to be converted into a paste or pastes, respectively, the quantity of liquid ingredients, in particular that of the plasticizer oil, should obviously be high enough for allowing the effective forming of a paste or of pastes, respectively.
Preferably, groups of adjuvants which remain unchanged for different applications are combined into one paste. For example, when working with two pastes, one of them may colour-neutral and the other paste may be coloured. In this way it is possible to use the colour-neutral paste for the manufacturing of differently coloured elastomer mixtures, so that only the coloured paste is to be adapted to the desired colouring.
Said single paste or said pastes, respectively, may be refined before being introduced into said annular zone mixer of said first step (a), in particular by pulverization, by dispersing, or by degasification.
Since homogenous mixing of the various ingredients is the easier the quantities of the various adjuvants are equal, it is advisable to prepare first a prepaste of those adjuvants which are needed in relatively small quantities only, and to mix said prepaste with the other paste or pastes, respectively, before mixing it with the elastomer.
Alternatively, part of the adjuvants, which are in powdered form, may be directly introduced into said annular zone mixer of said first step (a) and/or part of the adjuvants may be directly introduced into said mixing unit of said second step (b). The latter is particularly useful if highly filled mixtures are to be prepared in which the quantity of plasticizer is relatively small as compared with that of the the fillers.
As it is generally known, annular zone mixers, which are used here as premixers, have a shaft provided with teeth which rotates with high speed, for example at 2000 r.p.m. (revolutions per minute), inside a smooth tube. Thereby, a turbulent annular zone is produced near the wall of the tube. The decomposition of the elastomer and its mixing with the other ingredients is essentially effected exclusively in this zone, due to the high frictional forces produced by said turbulence.
The method according to the invention may be used for preparing crosslinkable and/or thermoplastic elastomer blends from all crosslinkable or thermoplastic elastomers, and in particular from:
natural rubber (NR),
synthetic cis-1,4-polyisoprene (IR),
cis-1,4-polybutadiene (BR),
styrene-butadiene copolymer (SBR),
acrylonitrile-butadiene copolymers (NBR),
poly-2-chlorobutadiene (CR),
isobutylene-isoprene copolymers (IIR),
ethylene-propylene-dien terpolymers (EPDM),
ethylene-propylene copolymers (EPM),
ethylene-vinylacetate copolymers (EVA),
polyurethane elastomers (PU),
polysulfide elastomer (PSR),
polyacrylate elastomers (AR),
polyepichlorohydrin elastomers (CHR),
sulfochlorinated polyethylene (CSM),
fluorocarbon elastomers (FE),
silicone elastomers (SIR),
1,5-trans-polypentenamers (TPR),
ethylene-proyplene-dien elastomer/polyproylene polyblend (EPDM/PP),
acrylonitrile-butadien-copolymer/polypropylene polyblend (NBR/PP) ,
styrene-butadiene-styrene triblock copolymer (SBS).
styrene-ethylene/butaylene-styrene triblock copolymer (SEBS).
The method according to the invention shows a number of outstanding advantages, as compared with the status of the art, namely:
The admixing of the adjuvants is extremely simple and energy-saving, and can be done in one single passage.
The total duration of mixing is essentially shortened, irrespective of whether the mixing unit used in said second step (b) is working continuously or batchwise. In the latter case, the premix may obviously be stored until the next batch can be introduced into the mixing unit.
If the adjuvants are used in paste form, a dust-free working is possible. This is an important progress in industrial hygiene.
For completing the mixing process, a kneader working batchwise, for example an internal mixer, can be used.
If the mixing process is to be continuously completed, the continuously working mixing unit can be a mixing extruder of simple and light construction, working at a low speed of rotation, for example at 100 r.p.m. (revolutions per minute).. A spindle length of 12.sup.. D to 18.sup.. D is quite sufficient. Such mixing extruders have a very high throughput, as compared with the vulcanization devices according to the status of the art.
At the same time, the completion of the mixing is extremely energy-saving, since the elastomer after its removal from the annular zone mixer is already present in the form of a powder or a granulate and is preheated. Thus it does not need to be rendered flowable or kneadable in the mixing unit by the application of heat. Accordingly, the mechanical overdimensioning of the mixing device, which was so far necessary, is dropped.
The elastomers used can - per se - be unplasticized. This not only facilitates their pulverization or granulation, respectively, but also avoids the situation where, due to insufficient shearing forces, an effective mixing is no longer possible.
PREPARATION OF THE BLENDS FOR EXAMPLES 1 TO 3
Three vulcanizable rubber blends were prepared from the following ingredients in the manner described hereafter. The "parts" referred to are parts by weight.
______________________________________No. Component Parts Parts______________________________________1 BUNA AP 47.sup.1) 100.02 Zinc oxide RS 5.0 3.1 Stearic acid 1.0 3.2 Stearic acid 1.03 Total stearic acid 2.04 Chalk 250.0 5.1 Paraffinic/naphthenic mineral oil 70.0 5.2 Paraffinic/naphthenic mineral oil 10.05 Total paraffinic/naphthenic mineral oil 80.06 Iron oxide red 6.07 Sulfur 7.08 VULCACIT CZ.sup.2) 1.09 VULCACIT LDA.sup.3) 1.010 VULCACIT Thiuram.sup.4) 0.4Total 452.4______________________________________ .sup.1) EPDM = ethylenepropylene-dien terpolymer grain size smaller than 10 mm .sup.2) CPS = benzodiacetyl2-cyclohexyl sulfenamide .sup.3) ZDEC = zinc Ndiethyl thiocarbamate .sup.4) TMTB = tetramethyl thiuramdisulfide
EXAMPLE 1
All adjuvants (Nos. 2, 3, 4, 5, 6, 7, 8, and 10) were mixed to from one single paste. This paste, if desired after homogenization, was premixed with the elastomer (No. 1) in an annular zone mixer, the elastomer thereby being decomposed. Thereafter, the resulting premix was introduced into a mixing unit which was working batchwise, or into the material feed sector of a mixing extruder.
EXAMPLE 2
The adjuvants Nos. 2, 3.1, 4, 5.1, 7, 8, 9 and 10 were mixed to form a colour-neutral paste, and the adjuvants Nos. 3.2, 5.2 and 6 were mixed to form a coloured paste. These pastes, if desired after homogenization, were premixed with the elastomer (No. 1) in an annular zone mixer, the elastomer thereby being decomposed. Thereafter, the resulting premix was introduced into a mixing unit which was working batchwise, or into the material feed sector of a mixing extruder.
EXAMPLE 3
The adjuvants Nos. 2, 3, 7, 8, 9 and 10 were premixed to form a prepaste, and the adjuvants Nos. 4, 5 and 6 were mixed to form a main paste. Then, the two pastes were combined. The combined single paste, if desired after homogenization, was premixed with the elastomer (No. 1) in an annular zone mixer, the elastomer thereby being decomposed. Thereafter, the resulting premix was introduced into a mixing unit which was working batchwise, or into the material feed sector of a mixing extruder.
EXAMPLE 4
A typical tire mixture was prepared from the following ingredients, the "parts" referred to being again parts by weight:
100 parts rubber
10 parts plasticizer oil
60 to 80 parts carbon black
8 to 10 parts other adjuvants (including sulfur).
The rubber, the plasticizer oil and the other adjuvants were continuously premixed in an annular zone mixer rotating at 2000 r.p.m. (revolutions per minute). The resulting blend and the carbon black were then introduced into a kneader which was working batchwise, for example an internal mixer, or into a mixing extruder which was working continuously. There, the elastomer blend was completed. | A method for preparing thermo-crosslinkable and/or thermoplastic elastomer blends by mixing the elastomer with plasticizer oil and other additives, said method comprising the steps of:
(a) continuously premixing the crushed elastomer in an annular zone mixer with at least part of said plasticizer oil, and optionally with at least part of said other additives, to form a preblend in which said elastomer is decomposed and said additives are embedded in the polymer matrix;
and thereafter
(b) completing the mixing of said premix, and optionally of the remainder of said additives, in a mixing unit working batchwise or continuously. | 2 |
FIELD OF THE INVENTION
The present invention relates to a filtering device for a spinning head and a spinning head for the manufacture of plastic threads. Plastic melt flows in a housing through a filter element with filtering material before being discharged under pressure through the spinnerets. The filter element has a filtering material subjected through a distribution device to an axial pressing force dependent upon the strength or intensity of the pressure of the melt. For closing of sealing gaps, the axial pressing force works on the sealing edges of the filter element.
BACKGROUND OF THE INVENTION
With melt-spinning, the polymer melt must be subjected to a super-fine filtration by a sand filter, a metal powder filter or filter cartridges immediately before passage through the spinneret plate. EP 0 658 638 B1 discloses conducting the polymer melt through a plurality of metal gauze filter cartridges arranged parallel to one another. Disadvantageously, uniform flow through all of the filter cartridges is practically impossible, with the result that certain individual filter cartridges become polluted before the others. Entire sets of filter cartridges must be cleaned or exchanged following short operation times.
With a spinning head of the type shown in DE 42 25 341 A1, one single annular filter element is used and surrounds or encloses a mixed operation device in the interior of the housing. This arrangement serves to bring together the filtered melt flow which has been homogeneously and thoroughly mixed coming out of the filter. However, the conventional filter element is not sufficiently pressure-stable and the elasticity of the stretched out filter element does not suffice to close over its sealing edges to form a complete sealing of those potential passage points present in the form of sealing gaps. In order to overcome this drawback, presently the annular filter element has been replaced by plate filter packs. However, disruptive energy flow behavior arises as a result of the reorientation of the melt flow within the filter element with its plate filter disks when such a reorientation is thus required. The reorientation hinders the relevant filtering process for the plastic melt. Also, such a solution is costly in realization.
DE 42 27 114 discloses a spinning head whereby the stability of the annular filter element is increased on the basis of radial support obtained by a distribution device. However, its filter element allows only a very uneven flowthrough.
U.S. Pat. Nos. 4,661,249 and 2,881,474 disclose filter elements each incorporating a support pipe which has built-in fluid outlets in the walls surrounded or enclosed by a filtering material. The filter element in this case is stretched tightly around the ends in the housing parts of the filter device. At the ends, the sealing attained exists only within the range of predeterminable sealing values. Because of the static stretching, settling within the seals and a loss of seal effectiveness results.
SUMMARY OF THE INVENTION
Objects of the present invention are to provide an improved filter device for a spinning head, which allows energy-saving filtering operation, which is pressure-stable, which guarantees a good duration of the seal and which is of low cost in its realization.
Other objects of the present invention are to provide a spinning head in which a particularly homogenous plastic melt for the production of a multi-strand synthetic thread appears at the point of discharge.
The foregoing objects are obtained where the filter element, formed as an exchangeable structural unit, includes a support pipe with built-in fluid outlets in the wall. The support pipe is surrounded or enclosed by the filtering material. The filter material projects out axially at one end and/or is displaced axially rearward at least at one end, with its sealing edge over the support pipe. A pressure-stable structural unit is thus formed, which is operationally secure even when working with high melt pressures. Since the plastic melt flows in the direction of and uniformly over the entire length of the filter element in one direction, the flowthrough is opposed or contrasted without waste of energy. No artificial resistance is built up counter to the melt flowthrough. Through the projecting end or the rearwardly aligned end of the filtering material, which forms the relevant sealing edge, with the given elasticity behavior of the filter element, secure sealing of the possible passage points in the form of potential fissures in the seal is guaranteed. Since such a filter element can be manufactured of standard structural parts, especially of traditional metal gauze filtering materials, the filter element is of low cost to manufacture.
Since at least at one end, a flat sealing edge can be present in the case of the filter element, the overall rigidity of the filter element is enhanced. The closing of the sealing gap occurs under the force of the pressure being exerted. Dependent upon the pressing force, a pro-actively working sealing arrangement is thus realized for the filtering device with the spinning head, which seals progressively more tightly with application of progressively increasing pressure.
The spinning head according to the present invention is characterized especially in that the plastic melt is guided uniformly in its movement from the inlet all the way to the discharge and without remaining for different lengths of time in different areas. The output chamber formed between the melt passage support pipe and the distribution head guarantees uniform flowthrough through the filter element and unhindered carrying and removal of the filtered plastic melt to the discharge point. A high degree of pressure stability of the filter element is attained because of the support pipe.
In order to obtain a favorable flow passage, it is especially advantageous to widen the open flowthrough diameter of the output chamber by conical tapering of the distribution head in the direction of the discharge.
In order to improve the inlet passage of the plastic melt from the side into the filter element, a bottom of the pressure plate can be phased in on the displacement device between the pressure plate and the distributing head. The pressure plate operates as a sealing surface with the sealing edge of the filter element. Flow accumulation angles which are disadvantageous to the operation are thus avoided.
For this purpose, the bottom of the pressure plate is preferably inclined at an angle of from 0° to 40° in the direction of discharge of the plastic melt in the spinning head.
For the melt at the ends of the filter element, and especially at the end of the filter element turned facing or adjacent the pressure plate, to flow smoothly and without remarkable hindrance into the filtering material, a cylindrical filter cover is connected to both the support pipe and the filtering material. The seal surfaces of the filter element are constructed at the end of the cover. Especially advantageously, the filtering material at the end of the filter element turned toward or adjacent the pressure plate project out axially with its sealing edge over the support pipe or else be angled rearward, so that accumulation angles no longer occur.
The elasticity of the filter cover surprisingly is not limited by the radial stability of the support pipe. Through the fluid passages in the support pipe, the filter cover has an axial elasticity which under the axial pressing force pro-actively supports or assists with the closing of the sealing gaps around the sealing edges of the filter element. The elasticity of the filter element can thus be enhanced and increased, while the filter element does not have at its disposal traditional end caps of correspondingly rigid material. Rather, the elasticity is attained solely by consolidation of the filtering material and corresponding fusing or welding of the ends.
Other objects, advantages and salient features of the present invention will become apparent from the following detailed description, which, taken in conjunction with the annexed drawings, discloses preferred embodiments of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring to the drawings which form a part of this disclosure:
FIG. 1 is a side elevational view in section of a spinning head with a filter device according to the present invention;
FIG. 2 is a side elevational view in section of the filter element with a support pipe and filtering material according to a first embodiment of the present invention;
FIG. 2 a is a side elevational view in section of a filter element with a support pipe and filtering material according to a second embodiment of the present invention;
FIGS. 2 b and 2 c are enlarged, partial, side elevational views in section of the areas X and Y, respectively of FIG. 2 a; and
FIG. 3 is a side elevational view in section of the support pipe of FIG. 2 .
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1, a spinning head 10 for the manufacture of plastic threads from a plastic melt, especially from a polymer melt, is shown. Spinning head 10 has a housing 12 in the form of a hollow cylinder with a top inlet opening 14 for the inflow of the plastic melt and with a bottom discharge opening 16 accommodating a spinneret. The spinneret can discharge the filament of a multi-strand synthetic thread, and includes numerous nozzle bores (not shown). For the manufacture of the plastic filament, the bottom discharge opening 16 is closed off in a conventional manner with a spinneret plate. Therefore, the spinneret plate is not described in greater detail herein. In the detailed view shown in FIG. 1 on the right half of the image, the spinning head is represented in a discharge setting. In the left half of the image the spinning head is represented in the operation setting, in which under the pressure and force of the plastic melt the movable parts of spinning head 10 are represented in their operational position.
For a filtering process of the plastic melt before its discharge from the spinnerets, over the spinneret plate under pressure, this melt is guided or conveyed through a filter element 18 having filtering material 20 . The flow through the filter element occurs radially from the exterior inward. Such filter element 18 is shown in an improved representation in FIG. 2 . Filtering material 20 is subjected to the effect of an axial pressing force coming from a distributor device 22 dependent upon the strength or intensity of the melt pressure. For closing of sealing gaps 24 as possible passage points for the plastic melt, the axial pressing force works on the sealing edges 26 and 28 of filter element 18 . Filter element 18 , with formation of an exchangeable structural unit, as is shown in FIG. 2, has a support pipe 30 with fluid passages 32 for the plastic melt. FIG. 3 shows support pipe 30 . Not all of the passage points 32 are indicated. However these passage points, associated with one another in groups of three, are distributed uniformly along the exterior periphery of cylindrical support pipe 30 .
Filtering material 20 surrounds or encloses, and thus, maintains contact with support pipe 30 itself. As is further shown in FIG. 2, filtering material 20 in the alignment shown in the drawing projects at the top end with its sealing edge 26 aligned axially forward over support pipe 30 and projects at the bottom end aligned axially rearward.
Filtering material 20 preferably comprises a pleated filter cover 34 of wire gauze or of a metallic non-woven fabric, especially in the form of high-quality steel. For the connection of the cover ends, these ends are connected with one another by a longitudinal weld seam (not shown) forming a cylindrical hollow body. Instead of being pleated, the filter cover can also be wound in one or more layers around support pipe 30 (not shown). With the illustrated embodiment, filter cover 34 comprises a multi-layered, high-quality steel gauze with a filter fineness of between 5 micrometers and 500 micrometers, especially between 50 and 150 micrometers. The filtering material is also commercially available under the trade name “Chemicron”. When filter cover 34 is pleated, for each fold in the filter, an independent sealing edge 26 , 28 is obtained on each opposite end side of filer cover 34 . In addition to a pleated construction of filter cover 34 , this embodiment can also include a cylindrical filter cover passing through with flat exterior periphery. Furthermore, the relevant filtering material 20 can form one piece of or one part of it can form filter cover 34 , whereby support pipe 30 is an integral component part of the entire filter element. It is also possible, with a not shown embodiment, that support pipe 30 can be entirely deleted and a support frame can be formed exclusively by the filter element cylinder.
Filter cover 34 has predeterminable elasticity. Under the axial pressing force during the filtering process, in other words during the operation of spinning head 10 , the elasticity can assist with the closing of the relevant sealing gaps 24 in sealing edges 26 and 28 of filter element 18 . Furthermore, as shown in FIG. 2, the sealing edges 26 and 28 of filter element 18 are inclined in relation to the end circular plane 36 of support pipe 30 . Particularly, they are inclined outward at a predeterminable angle, especially about 15°, in the direction of the flow of the plastic melt into spinning head 10 . Two radial sealing gaskets 38 , parallel to the cited circular planes 36 , as shown in FIG. 2 are correspondingly sealed with a filter cover 34 . The gaskets are configured to be disk-shaped and are present for this purpose. Such a sealing occurs even when the filter cover, as already described, is configured to be a hollow cylinder. The exterior peripheral sealing is accomplished by sealing edges 26 and 28 . An effective sealing effect and sealed packing is attained by support pipe 30 cooperating with filter cover 34 , so that overall the filter element 18 produces the sealing effect.
Therefore, for the purpose of manufacture, the sealing edges 26 and 28 of filter element 18 in turn are formed by a peripherally sealed seam 40 , as seen in FIG. 2 . Seams 40 completely cover the visible ends along the pleated folds of filter cover 34 . Peripheral weld seam 40 is then reworked by grinding, abrading or sharpening or the like in such a manner that sealing edges 26 and 28 run along a closed peripheral curve to guarantee that it continues to maintain a smooth surface for sealing.
Distributor device 22 has a distributor head 42 with a pressure plate 44 located above it. Distributor head 42 is guided longitudinally movably within housing 12 within a cylindrical support installation 46 . Filter element 18 thereby surrounds and encloses the exterior periphery of the distributor head 42 and is supported with one end on the bottom of pressure plate 44 and the other end on a projection 48 from support installation 46 . The bottom of pressure plate 44 and the top of projection 48 are therefore also provided with an angle of inclination which corresponds to the angle of inclination of sealing edges 26 and 28 , and preferably is 15° as compared with the horizontal line.
However, the bottom of pressure plate 44 can be configured with an angle of inclination of 0°. Thus, a not shown sealing ring can also be used for the sealing of the sealing gap 24 . The sealing ring would be arranged between sealing edge 26 of the filter element and the seal surface of distribution device 22 .
For such a configuration, however, it is especially advantageous to use a filter element as illustrated in FIG. 2 a without a separate sealing ring. For this second embodiment of the filter element, the same references are used as for the previously described, first embodiment of the filter element. In addition, this new embodiment is explained only insofar as it differs essentially from the first embodiment. As particularly shown by the enlarged separate drawing Y of FIG. 2 c, in the direction of viewing in the drawing, the bottom sealing edge 28 is arranged axially angled rearward in relation to support pipe 30 . At the other end of filter element 18 , as shown in the enlarged separate drawing X of FIG. 2 b, the sealing edge 26 is arranged running flat, in other words in a horizontal plane lying together with the associated free end of support pipe 30 . The total rigidity of filter element 18 of FIG. 2 a is measured in such a manner that, under the increasing and eventually constant pressing force of the spinning head and particularly of its pressure plate 44 , the closing of sealing gap 24 is executed until it reaches the maximum sealing effect. Consequently, a secure sealing is attained in the area of the round weld seams, which essentially form the sealing edges 26 and 28 .
The exterior periphery of filter element 18 , with the support installation 46 , limits an admission chamber 50 . Admission chamber 50 is measured volumetrically in such a manner that any possible dead space is so limited as to be quite small. Support pipe 30 , with distributor head 42 , in turn limits an output chamber 52 for the plastic melt. Output chamber 52 also comprises individual longitudinal channels arranged in its longitudinal alignment so that space 52 can extend over the entire height of support pipe 30 . While admission chamber 50 as seen in the direction of viewing in FIG. 1 is tapered conically from the top downward, output chamber 52 is widened conically from the top downward. This tapering leads to optimum flow behaviors with the flowthrough of filter element 18 , with simultaneous depletion of the dead space.
Distributor head 42 works in the traditional manner together with a control head 54 . The control head is guided longitudinally movably in housing 12 along its interior wall. With increasing setting movement in the direction of distributor head 42 , the control head undertakes a side edge sealing 56 in relation to housing 12 . For the feed of the plastic melt on pressure plate 44 , control head 54 has a midline recess 58 . The plastic melt is distributed from recess 58 outward uniformly over the top of pressure plate 44 . Passing through a peripheral longitudinal channel guide 60 , the plastic melt passes from the channel guide out into admission chamber 50 . Control head 54 , as compared with distributor head 42 , is supported over a springy elastic spacing holder 62 , as a sort of a partial segment of a plate spring. Such a space holder can be supported correspondingly with its bottom end in turn on a border flange of support installation 46 or on distributor head 42 in order to limit the path of control head 54 .
With the setting movement of control head 54 from its right, non-operational position into the left operational position, the control head moves for a predeterminable distance. If, following surmounting of the free spring passage of spacing holder 62 , the force in connection with the pressure force of the plastic melt on pressure plate 44 moves distributor head 42 downward, this movement provides an increased clamping force on sealing edges 26 and 28 of filter element 18 . Also, sealing gaps 24 , while possible passage points between distributor head 42 and filter element 18 or else between element 18 and support installation 46 , are securely closed and sealed. By means of the elasticity of such a stretched filter element 18 , the increased seal effect with a proactive deformation of the sealing itself is then attained.
While various embodiments have been chosen to illustrate the invention, it will be understood by those skilled in the art that various changes and modifications can be made therein without departing from the scope of the invention as defined in the appended claims. | A filtering device for a spinning head for producing plastic threads. The spinning head has a housing in which the plastic melt flows through a filter element under pressure before exiting the spinnerets. The filter element is provided with a filtering material that is subjected to an axial contact pressure through a distributor device, according to the degree of pressure of the melt. This contact pressure acts upon the sealing edges of the filter element to close the sealing gaps. The special geometrical configuration of the filter element and/or its elasticity guarantee advantageous filtering in terms of energy. The filtering system is resistant to pressure and provides good, permanent sealing. | 3 |
CROSS-REFERENCE TO RELATED APPLICATION
The present application:
is a divisional of U.S. patent application Ser. No. 14/036,630, filed on Sep. 25, 2013, now U.S. Pat. No. 8,872,046, issued on Oct. 28, 2014, which:
is a divisional of U.S. patent application Ser. No. 13/571,159, filed on Aug. 9, 2012, now U.S. Pat. No. 8,591,700, issued on Nov. 26, 2013,which:
is a divisional of U.S. patent application Ser. No. 12/728,471, filed on Mar. 22, 2010, now U.S. Pat. No. 8,269,121, issued on Sep. 18, 2012, which:
is a divisional of U.S. patent application Ser. No. 12/270,518, filed on Nov. 13, 2008, now U.S. Pat. No. 7,714,239, issued on May 11, 2010, which:
is a divisional of U.S. patent application Ser. No. 11/750,622, filed on May 18, 2007, now U.S. Pat. No. 7,479,608, issued on Jan. 20, 2009, which:
claims the priority, under 35 U.S.C. §119, of U.S. Provisional Patent Application No. 60/801,989, filed on May 19, 2006; claims the priority, under 35 U.S.C. §119, of U.S. Provisional Patent Application No. 60/810,272, filed on Jun. 2, 2006; claims the priority, under 35 U.S.C. §119, of U.S. Provisional Patent Application No. 60/858,112, filed on Nov. 9, 2006; and claims the priority, under 35 U.S.C. §119, of U.S. Provisional Patent Application No. 60/902,534, filed on Feb. 21, 2007.
the entire disclosures of which are all hereby incorporated herein by reference in their entireties.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
n/a
FIELD OF THE INVENTION
The present invention lies in the field of switches, in particular, a force switch. The device can be used along with any tool in which a particular longitudinal force needs to be overcome prior to reaching a given detected force.
BACKGROUND OF THE INVENTION
In various applications, a compressible material is compressed between two surfaces for modification of the material in some way after being compressed. The material can be compressed too little, too much, or in an acceptable range of compression. It would be beneficial to provide an electrical switch that can indicate when the acceptable minimum compression force has been exceeded. It would further benefit if the switch actuates over a small gap and is longitudinally in-line with the device in which the switch is incorporated. It would also be beneficial if the minimum force setting of the switch could be pre-set to given force values.
BRIEF SUMMARY OF THE INVENTION
The invention overcomes the above-noted and other deficiencies of the prior art by providing an electronic switch that actuates over a small gap (on the order of 25 to 200 micrometers), is longitudinally in-line with the device in which the switch is incorporated, and switches dependent upon a longitudinally expanding external force that can be pre-set over a given floor force value.
A characteristic of the force switch described herein is that the longitudinal forces that the force switch can withstand are significantly higher than that existed in the past. With a force switch having approximately a 6 mm diameter, for example, an approximately 5 to 8 pound longitudinally pulling force changes the switch state while, at the same time, being able to withstand almost 300 pounds of longitudinal pulling or compressive force. This is an almost twenty-fold difference.
There are many uses for the force switch in various different technology areas.
In a first exemplary area of technology, the force switch can be used to measure compressive forces imparted upon tissue by medical devices. In many medical procedures, tissue is compressed between two surfaces before a medical device is caused to make a change in the compressed tissue. If the tissue is compressed too little, then the change sought to be effected might not be sufficient. If the tissue is, on the other hand, compressed too much, the change sought to be effected might actually destroy the area of interest. When compressing such tissue, there are measurable force ranges that fall between these two extremes. Knowing the “safe” force range can allow the user to select a pre-tensioning of the force switch to change its state (i.e., indicate to the user the pre-tensioned force has been exceeded) within the “safe” range of that tissue.
The force switch described herein can be constructed in a customized way to have the state-changing pre-tension match the “safe” range of the tissue to be operated upon.
One type of medical device that is used to change a state of tissue is a medical stapling device. Ethicon Endo-Surgery, Inc. (a Johnson & Johnson company) manufactures and sells such stapling devices. Circular stapling devices manufactured by Ethicon are referred to under the trade names PROXIMATE® PPH, CDH, and ILS. Linear staplers manufactured by Ethicon under the trade names CONTOUR and PROXIMATE also can use the force switch. In each of these exemplary staplers, tissue is compressed between a staple cartridge and an anvil and, when the staples are ejected, the compressed tissue is also cut. In this specific example, the tissue can be compressed too little (where blood color is still present in the tissue, too much (where tissue is crushed), or just right (where the tissue is blanched). Staples delivered have a given length and the cartridge and anvil need to be at a given distance so that the staples close upon firing. Therefore, these staplers have devices indicating the relative distance between the two planes and whether or not this distance is within the staple length firing range. However, these staplers do not have any kind of active compression indicator that would also optimize the force acting upon the tissue that is to be stapled. The force switch described herein provides such a feature. Some exemplary procedures in which these staplers could use the force switch include colon dissection and gastric bypass surgeries.
With the foregoing and other objects in view, there is provided, in accordance with the invention, a switch of a device having a longitudinal device axis, the switch comprising a switching element, a hollow body defining an interior cavity in which the switching element is movably disposed along the longitudinal device axis to define a first position along the longitudinal device axis and a second position along the longitudinal axis, the second position being different from the first position, a biasing element imparting an adjustable biasing force to the switching element to place the switching element in one of the first position and the second position until an external force imparted to the switching element along the longitudinal device axis exceeds the biasing force thereby causing the switching element to move to the other one of the first position and the second position, and an electrically-conductive contact coupled to the switching element and defining a first switching state when the switching element is in the first position and a second switching state when the switching element is in the second position.
In accordance with another feature of the invention, the switching element has a longitudinal switching axis disposed parallel to the longitudinal device axis, the switching element is movably disposed within the interior cavity of the hollow body and along the switching axis, and the biasing element imparts a variable longitudinal biasing force to the switching element.
In accordance with a further feature of the invention, the first position is a switch-making position, the second position is a switch-breaking position, the first switching state is a switch-making state, and the second switching state is a switch-breaking state.
In accordance with an added feature of the invention, the switching element is a piston.
In accordance with an additional feature of the invention, the electrically-conductive contact is physically coupled to the switching element and is movable along the longitudinal device axis between the first position and the second position.
In accordance with yet another feature of the invention, the switch further comprises a stop element defining a second interior cavity in which the switching element is movably disposed, wherein the stop element is at least partly disposed in the interior cavity of the hollow body.
In accordance with yet a further feature of the invention, the switching element further comprises a bias contact and the biasing element is disposed about at least a portion of the switching element between the stop element and the bias contact.
In accordance with yet an added feature of the invention, a magnitude of the biasing force is dependent upon a longitudinal position of the stop element within the interior cavity of the hollow body.
In accordance with yet an additional feature of the invention, the switching axis is disposed coincident with the device axis.
In accordance with again another feature of the invention, the biasing element imparts the biasing force to place the switching element in the switch-breaking position to create a normally open switch configuration.
In accordance with again a further feature of the invention, the biasing element imparts the biasing force to place the switching element in the switch-making position to create a normally closed switch configuration.
In accordance with again an added feature of the invention, a distance between the switch-making position and the switch-breaking position is between approximately 25 μm and approximately 750 μm.
In accordance with again an additional feature of the invention, a distance between the switch-making position and the switch-breaking position is between approximately 75 μm and approximately 200 μm.
In accordance with still another feature of the invention, the electrically-conductive contact is electrically insulated from the hollow body and the switching element.
In accordance with still a further feature of the invention, the switch further comprises an electric indication circuit electrically connected to the switching element and the electrically-conductive contact and having an indicator operable to transmit state-change information to signal a user that a state change of the switching element has occurred.
In accordance with still an added feature of the invention, the biasing element is a compression spring compressed between the bias contact and the stop element around the switching element to bias the switching element in a direction away from the stop element.
With the foregoing and other objects in view, there is also provided, in accordance with the invention, a switch comprising a hollow body defining an interior cavity, a switching element having a switching axis and movably disposed within the interior cavity of the hollow body along the switching axis to define a first position along the switching axis and a second position along the switching axis, the second position being different from the first position, a biasing element imparting an adjustable biasing force to the switching element to place the switching element in one of the first position and the second position until an external force imparted to the switching element along the switching axis exceeds the biasing force thereby causing the switching element to move to the other one of the first position and the second position, and an electrically-conductive contact coupled to the switching element and defining a first switching state when the switching element is in the first position and a second switching state when the switching element is in the second position.
With the foregoing and other objects in view, there is also provided, in accordance with the invention, a switch of a device comprising a hollow body defining an interior cavity, a switching element having a longitudinal switching axis and movably disposed within the interior cavity of the hollow body along the switching axis to define a first position along the switching axis and a second position along the switching axis, the second position being different from the first position, a biasing element imparting a adjustable longitudinal biasing force to the switching element to place the switching element in one of the first position and the second position until an external force imparted to the switching element along the switching axis exceeds the biasing force thereby causing the switching element to move to the other one of the first position and the second position, and an electrically-conductive contact coupled to the switching element and defining a first switching state when the switching element is in the first position and a second switching state when the switching element is in the second position.
Other features that are considered as characteristic for the invention are set forth in the appended claims.
Although the invention is illustrated and described herein as embodied in a force switch, it is, nevertheless, not intended to be limited to the details shown because various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
The construction and method of operation of the invention, however, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
Advantages of embodiments the present invention will be apparent from the following detailed description of the preferred embodiments thereof, which description should be considered in conjunction with the accompanying drawings in which:
FIG. 1 is a perspective view from a side of an exemplary embodiment of a force switch according to the invention.
FIG. 2 is a longitudinally cross-sectional perspective view from a side of the force switch of FIG. 1 through a near half of the switch;
FIG. 3 is a longitudinally cross-sectional perspective view from a side of the force switch of FIG. 1 through a near half of the switch;
FIG. 4 is a longitudinally cross-sectional perspective view from a side of the force switch of FIG. 1 through a near half of the switch;
FIG. 5 is a longitudinally cross-sectional perspective view from a side of the force switch of FIG. 1 through a near half of the switch;
FIG. 6 is a longitudinally cross-sectional perspective view from a side of the force switch of FIG. 1 through approximately a longitudinal axis of the switch;
FIG. 7 is a longitudinally cross-sectional perspective view from a side of the force switch of FIG. 1 through a far half of the switch;
FIG. 8 is an enlarged, longitudinally cross-sectional perspective view from a side of the force switch of FIG. 6 with the switch in an un-actuated position;
FIG. 9 is an enlarged, longitudinally cross-sectional perspective view from a side of the force switch of FIG. 6 with the switch in an actuated position;
FIG. 10 is a perspective view from a side of another exemplary embodiment of a force switch according to the invention.
FIG. 11 is a longitudinally cross-sectional perspective view from a side of the force switch of FIG. 10 through a near half of the switch;
FIG. 12 is a longitudinally cross-sectional perspective view from a side of the force switch of FIG. 10 through a near half of the switch;
FIG. 13 is a longitudinally cross-sectional perspective view from a side of the force switch of FIG. 10 through approximately a longitudinal axis of the switch;
FIG. 14 is a longitudinally cross-sectional perspective view from a side of the force switch of FIG. 10 through a far half of the switch;
FIG. 15 is a longitudinally cross-sectional perspective view from a side of the force switch of FIG. 10 through a far half of the switch;
FIG. 16 is an enlarged, longitudinally cross-sectional perspective view from a side of the force switch of FIG. 13 with the switch in an un-actuated position; and
FIG. 17 is an enlarged, longitudinally cross-sectional perspective view from a side of the force switch of FIG. 13 with the switch in an actuated position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Aspects of the invention are disclosed in the following description and related drawings directed to specific embodiments of the invention. Alternate embodiments may be devised without departing from the spirit or the scope of the invention. Additionally, well-known elements of exemplary embodiments of the invention will not be described in detail or will be omitted so as not to obscure the relevant details of the invention.
Before the present invention is disclosed and described, it is to be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting. It must be noted that, as used in the specification and the appended claims, the singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise.
While the specification concludes with claims defining the features of the invention that are regarded as novel, it is believed that the invention will be better understood from a consideration of the following description in conjunction with the drawing figures, in which like reference numerals are carried forward. The figures of the drawings are not drawn to scale.
Referring now to the figures of the drawings in detail and first, particularly to FIGS. 1 to 9 thereof, there is shown a first exemplary embodiment of a force switch 1 . FIGS. 10 to 17 illustrate a second exemplary embodiment of the force switch 1 . As will be described in more detail below, the first exemplary embodiment represents a “normally open” switch configuration and the second exemplary embodiment represents a “normally closed” switch configuration. Where features of the switch 1 are similar in the two embodiments, for ease of understanding, similar reference numerals will be used.
The force switch 1 can be incorporated into a device where force along the longitudinal axis of the device needs to be measured and an action needs to be taken when that force exceeds a given predetermined value. This force switch 1 can be used, for example, in a medical device, but is not limited to the exemplary embodiment of a medical device. As will be described in further detail below, the force switch 1 can be used with a circular surgical stapling device such as is disclosed in U.S. Pat. No. 5,104,025 to Main
FIGS. 1 to 9 represent different portions of the force switch 1 . FIG. 6 provides an example view through the longitudinal axis 2 of the force switch 1 that allows one to see all parts of the switch 1 . A contact piston 10 provides a central part around which other parts of the switch 1 may be explained. A nose piece or tip 20 is fastened to the distal end 12 of the contact piston 10 . The distal end 12 and an internal bore 22 of the tip 20 are illustrated with straight lines in FIGS. 4 to 9 , however, in a first exemplary embodiment, the distal end 12 can be provided with external male threads and the bore 22 can be provided with internal female threads. Alternatively, the tip 20 can be press-fit, glued, welded, or otherwise connected to the distal end 12 of the contact piston 10 . In the configuration shown in FIGS. 4 to 9 , a proximal portion 24 of the internal bore 22 has a non-threaded flat portion for receiving therein the distal-most end of the piston 10 such that, when completely threaded into the bore 22 , the proximal portion 24 acts as a stop for further threading of the distal end 12 therein.
At the proximal end of the piston 10 , a widening 14 is provided on the outside surface of the piston 10 and an internal bore 16 is formed in the interior thereof.
A hollow body tube 30 is disposed around at least a portion of the contact piston 10 . One exemplary embodiment of the interior of the tube 30 includes a relatively narrower proximal bore 32 and a relatively wider distal bore 34 (although the opposite configuration is also possible). The bores 32 , 34 surround a proximal portion of the piston 10 that includes a central shaft 18 thereof and the widening 14 . The exterior shape of the widening 14 and the interior shape of the proximal bore 32 are substantially equal. Accordingly, in a circular configuration, the interior diameter of the proximal bore 32 is substantially equal to the outer diameter of the widening 14 . As used herein, substantially equal means that there is only a sufficient clearance between the two parts to allow one to slide within the other. Thus, if a given first material requires a particular first spacing between the outer surface of the piston 10 and the inner surface of the body tube 30 to permit the piston 10 to move therein, then that first spacing exists between the two parts 10 , 30 , whereas, if a given second material requires a smaller (or larger) spacing between the outer surface of the piston 10 and the inner surface of the body tube 30 to permit the piston 10 to move therein, then that that second spacing exists between the two parts 10 , 30 .
There are two parts between the piston 10 and the body tube 30 , an adjustable end cap 40 and a bias device 50 . The exterior shape of the end cap 40 and the interior shape of the distal bore 34 are substantially equal. Accordingly, in a circular configuration, the interior diameter of the distal bore 34 is substantially equal to the outer diameter of the end cap 40 . Thus, when the end cap 40 is inserted into the distal bore 34 , the cap 40 substantially closes an interior space defined by the interior surfaces of the distal and proximal bores 34 , 32 , the exterior surface of the central shaft 18 , the distal transverse surface of the widening 14 , and the proximal end surface of the cap 40 . The bias device 50 is disposed inside this interior space. The bias device 50 and the cap 40 act together with the widening 14 to bias the piston 10 in a given direction, in this case, in the proximal direction. Force of the bias device 50 can be dependent upon the position of the cap 40 . For example, if the cap 40 is closer to the widening 14 , the bias device 50 can exert a first biasing force and if the cap 40 is further from the widening 14 , the bias device 50 can exert a second biasing force. Depending upon the bias device 50 used, the first force can be greater than the second, or vice-versa. It is beneficial, but not required, if the cap 40 is adjustable between various locations along the body tube 30 . In such a configuration, the bias device 50 can be adjusted to a user-desired pre-bias.
One embodiment of the cap 40 and bias device 50 is shown in FIGS. 2 to 9 . The following description, however, will be directed to the view of FIG. 8 . In this embodiment, the distal bore 34 has a larger diameter than the proximal bore 32 . The end cap 40 has exterior threads 42 that mate with non-illustrated internal female threads of the distal bore 34 . In such a configuration, the cap 40 can be rotated into the distal bore 34 along any longitudinal point within the distal bore 34 . With the proximal bore 32 having a smaller diameter than the distal bore 34 , the distal endpoint 36 of proximal bore 32 forms a stop for insertion of the cap 40 . The cap 40 is formed with an interior bore 44 having a shape substantially equal to the outer shape of the central shaft 18 of the piston 10 . Thus, while the cap 40 can be screwed into the distal bore 34 such that longitudinal forces will not press the cap 40 out from the distal bore 34 , the central shaft 18 of the piston 10 can move longitudinally freely within the bore 44 and with respect to the cap 40 .
The bias device 50 is embodied, in this example, as a compression spring 50 . As such, when the spring 50 is placed around the central shaft 18 of the piston 10 up to the distal transverse surface of the widening 14 , and when the threaded cap 40 is also placed around the central shaft 18 and screwed at least partially within the distal bore 34 , the spring 50 can be compressed between two extremes defined by the longitudinal connection distance that the cap 40 can traverse between being securely but barely inside the distal bore 34 and fully inserted therein up to the stop 36 .
Because the piston 10 moves, it can form one contact of an electrical switch for signaling a state of the piston 10 . Another contact needs to be provided that is electrically insulated from the piston 10 . Thus, the piston 10 needs to be associated with a switch sub-assembly so that the electrical switch is in a first state when the piston 10 is in a first longitudinal position and in a second state when the piston 10 is in a second longitudinal position (the first and second states being off/on or on/off). This switch sub-assembly is formed at a proximal end of the piston 10 and the body tube 30 and, in the following text, is shown in two exemplary embodiments. The first embodiment, the “normally open” switch has been mentioned as being related to FIGS. 1 to 9 . The second embodiment relates to FIGS. 10 to 17 and is a “normally closed” switch.
The normally open switch sub-assembly is explained with regard to FIGS. 8 to 9 . A switch bushing 60 has a distally projecting stub 62 that is inserted into the proximal end of the body tube 30 . This stub 62 can be connected to the body tube 30 in any number of ways (e.g., by bonding, welding, adhesive, press-fit, screw threads). The proximal end of the switch bushing 60 is attached to a mounting body 70 . In one embodiment, each of the piston 10 , the tip 20 , the body tube 30 , the cap 40 , the switch bushing 60 , and the mounting body 70 are electrically conductive and provide a first electrical contact of the force switch 1 . However, the tip 20 and cap 40 need not be conductive. To form a second electrical contact that, when put into electrical connection with the first contact, completes an electrical circuit (or interrupts an electrical circuit as shown in FIGS. 10 to 17 ), an insulating body needs to be disposed between the second contact and the first contact needs to be operatively moved into (or out of) contact with the second contact.
Various switch embodiments disclosed herein include parts that are electrically conductive and actually form part of the electronic circuit. The switch according to the present invention, however, is not limited to embodiments where parts of the switch form the circuit. An alternative configuration can take advantage only of the mechanical switch-breaking aspects of the invention to have the movement of the piston actuate a separate electrical switch adjacent the switch, e.g., the piston. Such an external switch can be embodied as what is referred to in the art as a tact switch because such a switch is very small. Various microswitches can be used as well if there is sufficient room for such larger switches.
In the exemplary embodiment of FIGS. 1 to 9 , the second electrical contact is formed by a contact ring 80 and the insulating body is formed by an insulating stub 90 . The part that connects the ring 80 and the insulating stub 90 to the piston 10 is a T-shaped connecting bar 100 . Each of the ring 80 , the stub 90 , and the bar 100 are nested in their shape so that they can fit in an easy assembly into the switch bushing and the body tube 30 . The insulating stub separates the contact ring 80 from the connecting bar 100 , which is in electrically conductive contact with the piston 10 and the switch bushing 60 .
More specifically, the internal bore 16 is shaped to receive a distal boss 102 of the connecting bar 100 . The connection between the distal boss 102 and the internal bore 16 can be like any of the embodiments of the connection between the piston 10 and the tip 10 . If the boss 102 has an external male thread, for example, then the internal bore 16 has a corresponding female internal thread. Such an exemplary configuration makes attachment of the connecting bar 100 and the piston 10 easy with regard to manufacturing costs and time.
The contact ring 80 has an internal bore 82 having a shape dimensioned to correspond substantially to the outer shape of a distal contact portion 92 of the insulating stub 90 . This external outer shape of the distal contact portion 92 can take any polygonal shape, such as circular, ovular, rectangular, square, star, triangular, for example. Regardless of this outer shape, the shape of the internal bore of the contact ring 80 corresponds thereto so that the contact ring 80 can be inserted thereon and fixed (whether by press-fit, adhesive, bonding, welding, or any other connection process) thereto so that control of contact between the ring 80 and any other portion of the first contact can be made with high precision.
After the contact ring 80 is connected to the insulator stub 90 , the combined assembly can be connected to the connecting rod 100 . The external shape of an intermediate portion of the rod 100 is made to correspond to an internal shape of a bore 94 extending through the insulator stub 90 . Again, the outer shape of the intermediate portion of the rod 100 can take any polygonal shape, such as circular, ovular, rectangular, square, star, triangular, for example. Regardless of this outer shape, the shape of the internal bore of the insulator stub 90 corresponds thereto so that the insulator stub 90 can be inserted thereon and fixed (whether by press-fit, adhesive, bonding, welding, or any other connection process) thereto so that control of contact between the ring 80 , mounted to the stub 90 , and any other portion of the first contact can be made with high precision.
With such a connection, the connecting rod 100 electrically contacts the piston 10 (and, thereby, the tip 20 , the body tube 30 , the cap 40 , the switch bushing 60 , and the mounting body 70 ). The outer shape/diameter of the contact ring 80 is dimensioned to be smaller than the inner shape/diameter of the switch bushing 60 and insertion of the contact ring 80 inside the switch bushing 60 creates a transverse gap 110 therebetween. Thus, the contact ring 80 is electrically isolated from the switch bushing 60 on the outer side thereof by the transverse gap 110 and is electrically isolated (insulated) from the connecting rod 100 on the inner side thereof by being in direct contact with the outside surface of the insulator stub 90 .
To make an electric circuit including the contact ring 80 and any electrically conducting part of the first contact ( 10 , 20 , 30 , 40 , 60 , 70 ), an electrical connection must be made at the contact ring 80 . One exemplary embodiment for such a connection is illustrated in FIGS. 5 to 9 . Specifically, the connecting bar 100 is formed with the proximal longitudinal bore 103 extending from the proximal transverse exterior surface 104 up to and including at least a part of the intermediate portion the connecting rod 100 that is located at a longitudinal position where the contact ring 80 is disposed. A further transverse bore 106 is formed to connect the longitudinal bore 103 with an interior surface of the contact ring 80 . In such a configuration, an insulated wire 206 can be threaded through the longitudinal 103 and transverse 104 bores and fastened (e.g., by welding) to the interior surface of the contact ring 80 . For ease of such a connection, the contact ring 80 can be formed with a depression (or a series of depressions) on the inside surface for receiving the electrical portion of the wire while the insulating portion of the wire remains in contact with the entirety of the longitudinal 103 and transverse 104 bores of the connecting rod 100 .
Such an electrical connection is, for example diagrammatically shown in FIG. 7 , where circuitry 200 is disposed between the contact ring 80 and the mounting body 70 . This exemplary circuitry includes a power source 202 and a contact indicator 204 (i.e., an LED) that lights the LED when the electrical circuit is completed. If the mounting body 70 and the insulated wire 206 are each connected to the circuitry 200 (as shown in FIG. 7 ), then, when electrical contact occurs between the contact ring 80 and any part of the first contact ( 10 , 20 , 30 , 40 , 60 , 70 ), the LED 204 will illuminate.
With the above exemplary configuration set forth, the functioning of the switch 1 between the first and second states can be described with regard to a comparison between FIGS. 8 and 9 . The piston 10 is longitudinally fixed to the tip 20 and to the connecting rod 100 . Further, the insulator stub 90 and the contact ring 80 are longitudinally fixed to the exterior of the connecting rod 100 . The piston 10 is slidably disposed inside the bore 44 of the cap 40 at the distal end and is slidably disposed inside the proximal bore 32 of the tube body 30 . Thus, the entire piston sub-assembly ( 10 , 20 , 80 , 90 , 100 ) can move in a longitudinal direction because a longitudinal gap 112 exists between the distal transverse surface of the contact ring 80 and a proximal end surface 64 of the stub 62 of the switch bushing 60 . It is this gap 112 that forms the space over which the force switch 1 can function.
The bias device (e.g., compression spring) 50 disposed between the adjustable cap 40 and the distal transverse surface of the widening 14 imparts a proximally directed force against the piston 10 when the cap 40 is adjusted to compress the spring 50 . This force, referred to herein as a pre-tension, keeps the contact ring 80 at a distance from the electrically conductive stub 62 of the switch bushing 60 —which is defined as the longitudinal gap 112 . Without any external force imparted on the force switch 1 , the pre-tension will always keep the contact ring 80 at this position and electrical contact between the first contact and the contact ring 80 will not occur. A distally directed external force F imparted upon the tip 20 could alter this situation. See FIG. 9 . If the force F is not as great as the pre-tension force imparted by the spring 50 , then the spring will not compress any further than it has already been compressed by the adjustable cap 40 . However, if the force F is greater than the pre-tension force imparted by the spring 50 , then the spring will compress and the tip 20 along with the remainder of the piston sub-assembly—the piston 10 , the connecting rod 100 , the insulating stub 90 , and the contact ring 80 —will move in a distal longitudinal direction. The distal longitudinal direction is limited by the proximal end surface 64 of the stub 62 of the switch bushing 60 because contact between the end surface 64 and the distal side of the contact ring 80 completely prevents further movement of the tip 20 . This configuration, therefore, provides an electrical switch that has an adjustable longitudinal pre-tension force that must be overcome before the switch 1 can actuate and complete the electrical circuit that is “open” until the contact ring 80 touches the switch bushing 60 . FIG. 9 shows the piston sub-assembly ( 10 , 20 , 80 , 90 , 100 ) in the actuated distal position and FIG. 8 shows the piston sub-assembly in the un-actuated proximal position
One exemplary process for assembly of the force switch 1 of FIGS. 1 to 9 , has the spring 50 inserted over the central shaft 16 of the piston 10 . The cap 40 is also screwed into the proximal bore 34 of the body tube 30 . The piston-spring sub-assembly is, then inserted through the interior bore 44 of the cap 40 and the tip 20 is fastened (e.g., screwed) onto the distal end 12 of the piston 10 . This forms a piston sub-assembly.
The insulating stub 90 is attached to the intermediate portion of the connecting bar 100 by being placed, first, over the distal boss 102 and, second, over the intermediate portion. Similarly, the contact ring 80 is attached to the insulating stub 90 by being placed thereover. The ring 80 is longitudinally connected to the insulating stub 90 and the stub 90 is longitudinally connected to the intermediate portion of the connecting bar 100 . The insulated wire 206 is passed through the bore of the mounting body 70 and through both the longitudinal 103 and transverse 106 bores of the connecting rod 100 and electrically connected to the interior surface of the contact ring 80 without electrically connecting the wire 206 to any portion of the mounting body 70 or the connecting bar 100 . This connection forms a switch sub-assembly that is ready to be connected to the piston sub-assembly.
Either or both of the distal boss 102 of the connecting bar 100 or the stub 62 of the switch bushing 60 can have threads for connecting the boss 102 to the piston 10 and/or the stub 62 to the body tube 30 . As such, the entire switch sub-assembly can be connected (both physically and electrically) to the piston sub-assembly. With these two sub-assemblies connected together, only the mounting body 70 needs to be connected to the proximal end of the switch bushing 60 . Such a connection can take any form, for example, the connection can be a weld or a mated set of screw threads.
FIGS. 10 to 17 illustrate a second exemplary embodiment of the force switch 1 having a “normally closed” switch configuration.
FIGS. 10 to 17 illustrate different portions of the force switch 1 . FIG. 14 provides an example view approximately through the longitudinal axis 2 of the force switch 1 that allows visualization of all parts of the switch 1 . The contact piston 10 provides a central part around which other parts of the switch 1 may be explained. The tip 20 is fastened to the distal end 12 of the contact piston 10 . The distal end 12 and the internal bore 22 of the tip 20 are illustrated with straight lines in FIGS. 13 to 15 and 17 , however, in the exemplary embodiment, the distal end 12 can be provided with external male threads and the bore 22 can be provided with internal female threads. Alternatively, the tip 20 can be press-fit, glued, welded, or otherwise connected to the distal end 12 of the contact piston 10 . In the configuration shown in FIGS. 13 to 15 and 17 , the proximal portion 24 of the internal bore 22 has the non-threaded flat portion for receiving therein the distal-most end of the piston 10 such that, when completely threaded into the bore 22 , the proximal portion 24 acts as a stop for further threading of the distal end 12 therein.
The piston 10 has a proximal end at which the widening 14 is provided to extend radially the outside surface of the piston 10 . The internal bore 16 is formed in the interior of the piston 10 at the proximal end.
As shown in the enlarged view of FIG. 16 , a hollow body tube 120 is disposed around at least a portion of the contact piston 10 . As compared to the first embodiment of the body tube 30 , the interior of this tube 120 has a constant diameter bore 122 . The bore 122 has a shape substantially equal to an exterior shape of the widening 14 and surrounds the central shaft 18 of the piston 10 . Accordingly, in a circular configuration, the interior diameter of the bore 122 is substantially equal to the outer diameter of the widening 14 .
There are two parts of the force switch 1 disposed between the piston 10 and the body tube 120 : a spring stop puck 130 and a bias device 50 . The exterior shape of the spring stop puck 130 and the interior shape of the bore 122 are substantially equal. Accordingly, in a circular configuration, the interior diameter of the bore 122 is substantially equal to the outer diameter of the spring stop puck 130 so that the spring stop puck 130 slides within the bore 122 substantially without play but also without substantial friction. This spring stop puck 130 differs from the end cap 40 in that it floats entirely separate within the body tube 120 . More specifically, as the tip 20 is threaded onto the distal end 12 of the piston 10 , the proximal transverse surface pushes against but is not fixed to the distal transverse surface of the puck 130 . In such a configuration, it would, at first glance, seem to indicate that the compression spring 50 could only be set to one given compression value because the puck 130 has a fixed longitudinal length. This would be correct except a set of pucks 130 are provided, each having different longitudinal lengths. Therefore, the pre-tensioning of the spring 50 is adjusted by selecting one of the set of pucks 130 . Also, it is not necessary to thread the tip 20 entirely onto the distal end 12 of the piston 10 as shown in FIG. 13 , for example. Thus, if the tip 20 is not entirely threaded on the piston 10 , user-desired pre-tensioning of the bias device 50 occurs by providing a specifically sized puck 130 and threading the tip 20 onto the piston 10 at a predefined distance. Alternatively, the puck 130 can solely determine the pre-tension if the tip 20 is entirely threaded onto to the piston 10 . One embodiment of the stop puck 130 and bias device 50 is shown in FIGS. 10 to 17 . The following description, however, is directed to the view of FIG. 13 . The stop puck 130 is formed with an internal bore 132 having a shape substantially equal to the outer shape of the piston 10 so that the piston 10 can traverse through the puck 130 without hindrance.
When the spring stop puck 130 is within the bore 122 , the stop puck 130 substantially closes an interior space defined by the interior surfaces of the bore 122 , the exterior surface of the central shaft 18 , the distal transverse surface of the widening 14 , and the proximal transverse surface of the puck 130 . The bias device 50 is disposed inside this interior space. The bias device 50 and the stop puck 130 act together with the widening 14 to bias the piston 10 in a given direction, in this case, in the proximal direction. Force of the bias device 50 is dependent upon the longitudinal length of the stop puck 130 .
The bias device 50 is embodied, in this example, as a compression spring 50 . As such, when the spring 50 is placed around the central shaft 18 of the piston 10 up to the distal transverse surface of the widening 14 , and when the stop puck 130 is also around the central shaft 18 and the tip 20 is attached to the piston 10 , the spring 50 is compressed or pre-tensioned therebetween.
Because the piston 10 moves, it can form one contact of an electrical switch for signaling a state of the force switch 1 . Another contact needs to be provided that is electrically insulated from the piston 10 . Thus, the piston 10 needs to be associated with a switch sub-assembly so that the electrical force switch 1 is in a first state when the piston 10 is in a first longitudinal position and in a second state when the piston 10 is in a second longitudinal position (the first and second states being off/on or on/off). This switch sub-assembly is formed at a proximal end of the piston 10 and the body tube 120 and, in the following text, applies to the second exemplary “normally closed” embodiment.
The switch bushing 60 has a distally projecting stub 62 that is inserted into the proximal end of the body tube 120 . This stub 62 can be connected to the body tube 120 in any number of ways (e.g., by bonding, welding, adhesive, press-fit, screw threads). The proximal end of the switch bushing 60 is attached to a mounting body 70 . In one embodiment, each of the piston 10 , the tip 20 , the body tube 120 , the stop puck 130 , the switch bushing 60 , and the mounting body 70 are electrically conductive and provide a first electrical contact of the force switch 1 . However, the tip 20 and stop puck 130 need not be electrically conductive. To form a second electrical contact that, when put into electrical connection with the first contact, interrupts an electrical circuit as shown in FIGS. 10 to 17 , an insulating body needs to be disposed between the second contact and the first contact needs to be operatively moved out of contact with the second contact.
In the exemplary embodiment of FIGS. 10 to 17 , the second electrical contact is formed by a contact pin 140 and the insulating body is formed by an insulating bushing 150 . The part that connects the insulating bushing 150 and the contact pin 140 to the piston 10 is a T-shaped, electrically conductive, contact screw 160 . The insulating bushing 150 and the contact pin 140 are nested in their shape so that they can fit in an easy assembly into the switch bushing 60 and the mounting body 70 . The insulating bushing 150 physically and electrically separates the contact pin 140 from the mounting body 70 and the switch bushing 60 , which is in electrically conductive contact with at least the piston 10 and the switch bushing 60 .
More specifically, the internal bore 16 is shaped to receive a distal boss 162 of the contact screw 160 . The connection between the distal boss 162 and the internal bore 16 can be like any of the embodiments of the connection between the piston 10 and the tip 10 . If the boss 162 has an external male thread, for example, then the internal bore 16 has a corresponding female internal thread. Such an exemplary configuration makes attachment of the contact screw 160 and the piston 10 easy with regard to manufacturing costs and time. A transverse end surface 164 of the contact screw 160 also provides a stop for indicating complete insertion of the distal boss 162 inside the internal bore 16 of the piston 10 .
The insulating bushing 150 has an internal bore 152 having a shape dimensioned to correspond substantially to the outer shape of a proximal contact portion 142 of the contact pin 140 . This external outer shape of the proximal contact portion 142 can take any polygonal shape, such as circular, ovular, rectangular, square, star, triangular, for example. Regardless of this outer shape, the shape of the internal bore 152 of the insulating bushing 150 corresponds thereto so that the insulating bushing 150 can be inserted thereon and fixed thereto (whether by press-fit, adhesive, bonding, welding, or any other connection process) so that control of contact between the contact pin 140 and any other portion of the first contact can be made with high precision.
After the insulating bushing 150 is connected to the contact pin 140 , the combined insulating sub-assembly can be connected to the mounting body 70 . The external shape of a proximal portion of the insulating bushing 150 is made to correspond to an internal shape of an internal bore 72 extending through the mounting body 70 . Again, the outer shape of the proximal portion of the insulating bushing 150 can take any polygonal shape, such as circular, ovular, rectangular, square, star, triangular, for example. Regardless of this outer shape, the shape of the internal bore of the mounting body 70 corresponds thereto so that the insulating bushing 150 can be inserted thereon and fixed thereto (whether by press-fit, adhesive, bonding, welding, or any other connection process) so that control of contact between the contact pin 140 (mounted in the insulating bushing 150 and the mounting body 70 ) and any other portion of the first contact can be made with high precision.
With such a connection, the contact screw 160 electrically contacts the piston 10 (and, thereby, the body tube 120 , the switch bushing 60 , and the mounting body 70 , and possibly even the tip 20 and the stop puck 130 if desired). The outer shape/diameter of a distal transverse widening 144 of the contact pin 140 is dimensioned to be smaller than the inner shape/diameter of the switch bushing 60 and insertion of the contact pin 140 inside the switch bushing 60 creates a transverse gap 110 therebetween. Thus, the transverse gap 110 electrically isolates the distal widening 144 of the contact pin 140 from the inside of the switch bushing 60 , and the proximal contact portion 142 of the contact pin 140 is electrically isolated (insulated) from the mounting body 70 and the switch bushing 60 on the outer side thereof by being in direct contact with the interior bore 152 of the insulating bushing 150 .
To make an electric circuit between the contact pin 140 and any electrically conducting part of the first contact (e.g., 10 , 20 , 60 , 70 , 120 , 130 ), an electrical connection must be made at the contact pin 140 . One exemplary embodiment for such a connection is illustrated in FIGS. 11 to 17 . Specifically, the contact screw 160 is formed with a proximal transverse widening 166 extending radially from the intermediate portion thereof and defines a proximal transverse surface 168 . The bias device 50 biases the piston 10 and, thereby, the contact screw 160 in a proximal direction to electrically conductively contact the distal transverse surface 148 of the contact pin 140 to the proximal transverse surface 168 of the contact screw 160 . Because such contact needs to only be made between these two surfaces to complete an electrical circuit of the switch sub-assembly, the outer shape/diameter of the proximal widening 166 of the contact screw 160 can be any size or shape that slides within the interior bore 66 of the switch bearing 60 .
The other electrical contact of the contact pin 140 resides on the proximal side of the contact pin 140 . In one exemplary embodiment, a longitudinal bore 146 is formed from the proximal transverse surface of the contact pin 140 inward and receives therein an insulated wire 206 . The conductor of this wire 206 can be fastened (e.g., by welding) to the interior surface of the longitudinal bore 146 . Such an electrical connection is, for example diagrammatically shown in FIG. 7 . In such an exemplary configuration, the power source 202 supplies power to the contact indicator 204 (LED) and lights the LED when the electrical circuit is completed, which will always be the case in this normally closed configuration of the force switch 1 . Conversely, when electrical contact between the first contact and the contact pin 140 is removed, the LED 104 will turn off. Of course, the indicator need not be visual (e.g., the LED 104 ). It can also be audible (e.g., speaker with sound) or tactile (e.g., vibration), or any combination thereof.
It is also possible to provide circuitry 300 between the contact pin 140 and the mounting body 70 that lights the LED 204 only when the electrical circuit is opened (i.e., not completed). Any logic circuitry can be used to control the LED 204 based upon the two states of the force switch 1 shown in FIGS. 10 to 17 . For example, the logic 300 including a NOR gate and an AND gate can be connected to the force switch 1 circuit as shown in FIG. 13 . In such a configuration, when the switch 1 is in its normally closed state, the LED is off and when contact is broken, as shown in FIG. 17 , the LED will illuminate.
With the above exemplary configuration set forth, the functioning of the switch 1 between the first and second states can be described with regard to a comparison between FIGS. 16 and 17 .
As set forth above, the contact pin 140 is longitudinally secured within the insulating bushing 150 and the insulating bushing 150 is longitudinally secured within at least one of the switch bearing 60 and the mounting body 70 . The body tube 120 is longitudinally secured to the distal end of the switch bearing 60 . The stop puck 130 is disposed, freely longitudinally, between the spring 50 and the tip 20 . The piston 10 is longitudinally fixed to the tip 20 and to the contact screw 160 and this piston sub-assembly slides within the body 120 biased in the proximal direction by the spring 50 . Accordingly, the entire piston sub-assembly ( 10 , 20 , 130 , 160 ) can move in a distal longitudinal direction to compress the spring 50 inside the body tube 120 and this compression distance forms a space 134 (see FIG. 17 ) over which the force switch 1 functions as a switch.
The bias device (e.g., compression spring) 50 disposed between the puck 130 and the distal transverse surface of the widening 14 imparts a proximally directed force against the piston 10 when the puck 130 compresses the spring 50 . This force, referred to herein as a pre-tension, keeps the contact screw 160 against the electrically conductive distal transverse surface of the contact pin 140 . Without any external force imparted on the force switch 1 , the pre-tension will always keep the contact pin 140 at this position and electrical contact between the first contact and the contact pin 140 will remain. A distally directed external force F imparted upon the tip 20 could alter this situation. See FIG. 17 . If the force F is not as great as the pre-tension force imparted by the spring 50 , then the spring 50 will not compress any further than it has already been compressed by the puck 130 . However, if the force F is greater than the pre-tension force imparted to the piston 10 by the spring 50 , then the spring 50 will compress further and the tip 20 , along with the remainder of the piston sub-assembly ( 10 , 130 , 160 ) will move in a distal longitudinal direction. The distal longitudinal direction is limited by the greatest compression distance of the spring 50 , which, in most applications of the force switch 1 , will not occur. This configuration, therefore, provides an electrical switch that has an adjustable longitudinal pre-tension force that must be overcome before the switch 1 can actuate and complete the electrical circuit that is “closed” until the contact screw 160 no longer touches the contact pin 140 . The switching distance of the force switch 1 of FIGS. 10 to 17 is defined by the longitudinal gap 112 existing between the proximal transverse surface of the stub 62 and the distal transverse surface of the widening 166 . FIGS. 17 and 19 show the piston sub-assembly ( 10 , 130 , 160 ) in the actuated distal position and FIG. 16 shows the piston sub-assembly in the un-actuated proximal position.
One exemplary process for assembly of the force switch 1 of FIGS. 10 to 17 , the distal end of the switch bushing 60 having the projecting stub 62 is fastened longitudinally to the proximal end of the body tube 120 . The piston 10 inserted inside the body tube 120 and the spring 50 inserted over the central shaft 16 of the piston 10 inside the body tube 120 . The puck 130 is placed over the distal end 12 of the piston 10 and the tip 20 is fully or partially screwed onto the exterior threads of the distal end 12 of the piston 10 . At this point, if the tip is fully screwed onto the piston 10 , the piston 10 will impart the pre-tension force onto the stub 62 of the switch bushing. To avoid this force, the tip 20 can be only partially screwed onto the distal end 12 of the piston 10 . The contact screw 160 is, then, screwed into the internal bore 16 of the piston 10 at the proximal end thereof to capture the stub 62 between the widening 14 of the piston 10 and the widening 166 of the contact screw 160 . This forms a piston-spring sub-assembly.
The mounting body 70 is longitudinally fixedly connected to the contact pin 140 with the insulating bushing 150 therebetween. Because of the nested shapes of these parts, the order of the connection is limited only by the costs and time for manufacturing the connections. Alternatively, the insulating bushing 150 and the contact pin 140 can be placed inside the distal end of the mounting body 70 , but, in such a case, these two parts could move longitudinally if the distal end of the force switch 1 is tilted downward. This forms a contact pin sub-assembly.
The piston-spring and contact pin sub-assemblies are connected together by fastening, longitudinally, the mounting body 70 to the switch bushing 60 . If the tip 20 is fully screwed onto the piston 10 , then the fastening will have to overcome the pre-bias force of the spring 50 . If, however, the tip 20 is minimally screwed onto the piston 10 such that no pre-bias exists in the spring 50 , then, after all longitudinal fastening has occurred, the tip 20 can be fully screwed onto the distal end 12 of the piston 10 to place the spring 50 in the pre-tensioned state. The conductor of the insulated wire 206 is attached in the longitudinal bore 146 of the contact pin 140 to complete the circuit 300 .
In each case of the normally open and normally closed configurations, the longitudinal gap 112 has a length of between approximately 25 μm (0.001″) and approximately 750 μm (0.030″), or in a shorter range between approximately 75 μm (0.003″) and approximately 200 μm (0.008″).
The conductive parts of the force switch 1 can be of stainless steel, copper, nickel-plated copper, nickel-plated brass, for example. Where the conductor of the insulated wire 206 needs to be soldered, each of these materials will be sufficient.
The range of force that the force switch 1 applicable for switching between the two states can be between approximately 3 ounces to approximately 20 pounds, or a shorter range of approximately 5 pounds to approximately 8 pounds.
With regard to the mechanics of selecting the spring 50 , the desired pre-tension force is selected to be within or at the mid-range of the range of a given spring 50 . In other words, the change in state of the force switch will occur not close to a maximum of the spectrum of the spring 50 pre-tension but, instead, somewhere in the middle of the spectrum.
The circuitry described above only provides a binary output—whether or not the force on the external object that is transmitted through the force switch 1 is greater or less than the pre-tensioning. If the force switch is provided with a strain gauge, also referred to as a load cell, then a continuous force output can be displayed to the user in which, for example, a row of LEDs gradually light up dependent upon the amount of force or an LCD or LED numerical field increments numerical values corresponding to the amount of force imparted through the force switch 1 .
The force switch 1 above will now be described with respect to use in an intraluminal anastomotic circular stapler as depicted, for example, in U.S. Pat. No. 5,104,025 to Main et al. (“Main”), and assigned to Ethicon Endo-Surgery, Inc. This reference is hereby incorporated herein in its entirety. As can be seen most clearly in the exploded view of FIG. 7 in Main, a trocar shaft 22 has a distal indentation 21 , some recesses 28 for aligning the trocar shaft 22 to serrations 29 in the anvil and, thereby, align the staples with the anvils 34 . A trocar tip 26 is capable of puncturing through tissue when pressure is applied thereto. FIGS. 3 to 6 in Main show how the circular stapler 10 functions to join two pieces of tissue together. As the anvil 30 is moved closer to the head 20 , tissue is compressed therebetween, as particularly shown in FIGS. 5 and 6 . If this tissue is overcompressed, this surgical stapling procedure might not succeed. The interposed tissue can be subject to a range of acceptable compressing force during surgery. This range is known and is dependent upon the tissue being stapled. The stapler shown in Main cannot indicate to the user any level of compressive force being imparted upon the tissue prior to stapling. However, if the force switch 1 described herein is substituted for the trocar shaft 22 , then the stapler 10 will be capable of showing the user when the compressive force (acting along the longitudinal axis 2 of the force switch 1 ) has exceeded the pre-tension of the switch 1 . This pre-tension can be selected by the user to have a value within the range of acceptable tissue compressive force.
FIGS. 1 and 10 of the present application show a tip 20 having a pointed distal end that can function within at least the CDH surgical stapler manufactured and sold by Ethicon Endo-Surgery, Inc. The proximal end of the trocar shaft 22 in Main requires a male threaded screw for attachment to the head 20 . Other circular staplers require an opposing tang embodiment that is shown in FIGS. 1 and 10 of the present application. Thus, the mounting body 70 can be in the form illustrated in FIGS. 1 to 17 or in the form shown in FIG. 7 in Main. The tip 20 and mounting body 70 can be customized to fit into any kind of similar surgical device.
The foregoing description and accompanying drawings illustrate the principles, preferred embodiments and modes of operation of the invention. However, the invention should not be construed as being limited to the particular embodiments discussed above. Additional variations of the embodiments discussed above will be appreciated by those skilled in the art.
Therefore, the above-described embodiments should be regarded as illustrative rather than restrictive. Accordingly, it should be appreciated that variations to those embodiments can be made by those skilled in the art without departing from the scope of the invention as defined by the following claims. | A switch comprising a switching element, a hollow body defining an interior cavity in which the switching element is movably disposed along a longitudinal device axis to define a first and second positions along the longitudinal device axis, the second position being different from the first position, a biasing element imparting an adjustable biasing force to the switching element to place the switching element in one of the first position and the second position until an external force imparted to the switching element along the longitudinal device axis exceeds the biasing force thereby causing the switching element to move to the other one of the first position and the second position, and an electrically-conductive contact coupled to the switching element and defining a first switching state when the switching element is in the first position and a second switching state when the switching element is in the second position. | 7 |
CROSS REFERENCE TO RELATED APPLICATION
This application claims benefit of priority to Japanese Patent Application No. 11-192081 filed Jul. 6, 1999, the entire content of which is incorporated by reference herein.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an active guide system guiding a movable unit such as an elevator cage.
2. Description of the Background
In general, an elevator cage is hung by wire cables and is driven by a hoisting machine along guide rails vertically fixed in a hoistway. The elevator cage may shake due to load imbalance or passenger motion, since the cage is hung by wire cables. The shake is restrained by guiding the elevator cage along guide rails.
Guide systems that include wheels rolling on guide rails and suspensions, are usually used for guiding the elevator cage along the guide rails. However, unwanted noise and vibration caused by irregularities in the rail such as warps and joints, are transferred to passengers in the cage via the wheels, spoiling the comfortable ride.
In order to resolve the above problem, various alternative approaches have been proposed, which are disclosed in Japanese patent publication (Kokai) No. 51-116548, Japanese patent publication (Kokai) No. 6-336383, and Japanese patent publication (Kokai) No. 63-87482. These references disclose an elevator cage provided with electromagnets operating attractive forces on guide rails made of iron, whereby the cage may be guided without contact with the guide rails.
Japanese patent publication (Kokai) No. 63-87482 discloses a guide system capable of restraining the shake of the elevator cage caused by irregularities of the guide rails by controlling electromagnets so as to keep a constant distance from a vertical reference wire disposed to be adjacent to the guide rail, thereby providing a comfortable ride, and reducing a cost of the system by getting rid of an excessive requirement of accuracy for an installation of the guide rails.
However, in the present guide system for elevators as described above, there are some following problems.
The vertical reference wire may be easily set up in case of low-rise buildings having a relatively short length hoistway for an elevator, while it is difficult to fix the vertical reference wire in a hoistway so as to be adjacent to guide rails in case of high-rise buildings or super high-rise buildings recently built and appeared. Further, after fixing the vertical reference wire, the vertical reference wire itself often loses its linearity because of a deformation by an aged deterioration of buildings or an influence of thermal expansion. Therefore, it causes a problem that a lot of time and cost is needed for maintaining the fixed vertical reference wire. Furthermore, electromagnets may not be excited in advance against irregularities on the guide rails, since a vertical position of the cage cannot be detected by using the vertical reference wire. Accordingly, a vibration restraining control may not start to run until a position relationship with the vertical reference wire goes wrong due to the irregularities. As a result, a certain extent of shaking may not be restrained in view of the principle. Therefore, there is a limit to improving a comfortable ride in this system.
SUMMARY OF THE INVENTION
Accordingly, one object of this invention is to provide a guide system for an elevator, which improves a comfortable ride by effectively restraining the shake of an elevator cage.
Another object of the present invention is to provide a minimized and simplified guide system for an elevator.
The present invention provides a guide system for an elevator, including a movable unit configured to move along a guide rail, a beam projector configured to form an optical path of a light parallel to a moving direction of the movable unit, a position detector disposed on the optical path and configured to detect a position relationship between the optical path and the movable unit, and an actuator coupled to the movable unit and configured to change a position of the movable unit by a reaction force, caused by a force operating on the guide rail on the basis of the output of the position detector.
BRIEF DESCRIPTION OF THE DRAWINGS
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 detailed description when considered in connection with the accompanying drawings, wherein:
FIG. 1 is a perspective view of a guide system for an elevator cage of a first embodiment of the present invention;
FIG. 2 is a perspective view showing a relationship between a movable unit and guide rails;
FIG. 3 is a perspective view showing a structure of a guide unit of the guide system;
FIG. 4 is a plan view showing magnetic circuits of the guide unit;
FIG. 5 is a block diagram showing a circuit of a controller;
FIG. 6 is a block diagram showing a circuit of a controlling voltage calculator of the controller;
FIG. 7 is a block diagram showing a circuit of another controlling voltage calculator of the controller;
FIG. 8 is a perspective view showing a structure of a guide unit of a guide system of a second embodiment;
FIG. 9 is a plan view showing the guide unit of the second embodiment;
FIG. 10 is a block diagram showing a circuit of a controller of the second embodiment;
FIG. 11 is a block diagram showing a circuit of a speed calculator of the controller of the second embodiment;
FIG. 12 ( a ) is a side view showing a position detector of a third embodiment;
FIG. 12 ( b ) is a front view showing a position detector of a third embodiment;
FIG. 13 ( a ) is a side view showing a position detector of a fourth embodiment;
FIG. 13 ( b ) is a front view showing a position detector of a fourth embodiment; and
FIG. 14 is a side view showing a position detector of a fifth embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, wherein like reference numerals designate identical or corresponding parts throughout the several views, the embodiments of the present invention are described below.
The present invention is hereinafter described in detail by way of illustrative embodiments.
FIGS. 1 through 4 show a guide system for an elevator cage of a first embodiment of the present invention. As shown in FIG. 1, guide rails 2 and 2 ′ made of ferromagnetic substance are disposed on the inside of a hoistway 1 by a conventional installation method. A movable unit 4 ascends and descends along the guide rails 2 and 2 ′ by using a conventional hoisting method (not shown), for example, winding wire cables 3 . The movable unit 4 includes four guide units 5 a , 5 b , 5 c , 5 d attached to the upper and lower corners thereof for guiding the movable unit 4 without contact with the guide rails 2 and 2 ′.
Laser radiators 6 a , 6 b and 6 c , which are fixed on the ceiling of the hoistway 1 , radiate lasers parallel to the guide rails 2 and 2 ′ respectively, and form optical paths 7 a , 7 b and 7 c in the hoistway 1 . The laser radiators 6 a , 6 b and 6 c may be, for example, laser oscillating tubes or a laser emitting semiconductor devices.
Two two-dimensional photodiodes 8 a and 8 b are attached at different vertical positions on the side of the movable unit 4 as position detectors. Further, a one-dimensional photodiode 8 c is attached adjacent to the photodiode 8 b at the same vertical level as the photodiode 8 d . These photodiodes 8 a , 8 b and 8 c are disposed in the optical paths 7 a , 7 b and 7 c , respectively. The two-dimensional photodiodes 8 a and 8 b detect positions of the respective optical paths 7 a and 7 b in two-dimensions (x and y directions in FIG. 1 ). The one-dimensional photodiode 8 c detects a position of the optical path 7 c in one-dimension i(y direction in FIG. 1 ).
The optical paths 7 a and 7 b by the laser radiators 6 a and 6 b are formed in a verticals direction, and received on the two-dimensional photodiodes 8 a and 8 b fixed at different vertical positions relative to each other. Positions of the movable unit 4 with respect to the following five modes of motions of the movable unit 4 are detected on the basis of respective receiving positions of the optical paths 7 a and 7 b by a calculation described below.
I. y-mode(back and forth motion mode) representing a right and left motion along a y-coordinate on a center of the movable unit 4
II. x-mode(right and left motion mode) representing a right and left motion along a x-coordinate
III. θ-mode(roll mode) representing a rolling about the center of the movable unit 4
IV. ξ-mode(pitch mode) representing a pitching about the center of the movable unit 4
V. ψ-mode(yaw-mode) representing a yawing about the center of the movable unit 4
The laser radiator 6 c forms the optical path 7 c tilting slightly so that a receiving spot on a receiving plane of the photodiode 8 c shifts in the y direction shown in FIG. 1 as the movable unit 4 moves from the lowest position to the highest position in the hoistway 1 . Since the photodiode 8 b and the photodiode 8 c are disposed at the same level and close to each other, a vertical position of the movable unit 4 in the hoistway is accurately detected by subtracting a value of an optical axis position on the photodiode 8 b in the y-direction from a value of an Optical axis position on the photodiode 8 c in the y-direction, even if a position of the movable unit 4 is changed.
The movable unit 4 includes an elevator cage 10 having supports 9 a , 9 b and 9 c on the side surface thereof for the respective photodiodes 8 a , 8 b and 8 c , and guide units 5 a - 5 d . The guide units 5 a - 5 d include a frame 11 having sufficient strength to maintain respective positions of the guide units 5 a - 5 d.
The guide units 5 a - 5 d are respectively attached at the upper and lower corners of the frame 11 and face toward the guide rails 2 and 2 ′, respectively. As illustrated in detail in FIGS. 3 and 4, each of the guide units 5 a - 5 d includes a base 12 made of non-magnetic substance such as Aluminum, Stainless Steel or Plastic, an x-direction gap sensor 13 , a y-direction gap sensor 14 , and a magnet unit 15 b . In FIGS. 3 and 4, only one guide unit 5 b is illustrated, and other guide units 5 a , 5 c and 5 d are the same structure as guide unit 5 b . A suffix “b” represents components of the guide unit 5 b.
The magnet unit 15 b comprises a center core 16 , permanent magnets 17 and 17 ′, and electromagnets 18 and 18 ′. The same poles of the permanent magnets 17 and 17 ′ are facing each other putting the center core between the permanent magnets 17 and 17 ′, thereby forming an E-shape as a whole. The electromagnet 18 comprises an L-shaped core 19 , a coil 20 wound on the core 19 , and a core plate 21 attached to the top of the core 19 . Likewise, the electromagnet 18 ′ comprises an L-shaped core 19 ′, a coil 20 ′ wound on the core 19 ′, and a core plate 21 ′ attached to the top of the core 19 ′. As illustrated in detail in FIG. 3, solid lubricating materials 22 are disposed on the top portions of the center core 16 and the electromagnets 18 and 18 ′ so that the magnet unit 15 d does not adsorb to the guide rail 2 ′ due to an attractive force caused by the permanent magnets 17 and 17 ′, when the electromagnets 18 and 18 ′ are not excited. For example, a material containing Teflon, black lead or molybdenum disulfide may be used for the solid lubricating materials 22 .
Each attractive force of the above-described guide units 5 a - 5 d is controlled by a controller 30 shown in FIG. 5, whereby the cage 10 and the frame 11 are guided with no contact with the guide rails 2 and 2 ′.
The controller 30 is divided as shown in FIG. 1, but is functionally combined as a whole as shown in FIG. 5 . The following is an explanation of the controller 30 . In FIG. 5, arrows represent signal paths, and solid lines represent electric power lines around the coils 20 a , 20 ′ a - 20 d , 20 ′ d . In the following description, to simplify an explanation of the illustrated embodiment, suffixes “a”-“d” are respectively added to figures indicating the main components of the respective guide units 5 a - 5 d in order to distinguish them.
The controller 30 , which is attached on the elevator cage 4 , comprises a sensor 31 detecting variations in magnetomotive forces or magnetic reluctances of magnetic circuits formed with the magnet units 15 a - 15 d , or in a movement of the movable unit 4 , a calculator 32 calculating voltages operating on the coils 20 a , 20 ′ a - 20 d , 20 ′ d on the basis of signals from the sensor 31 in order for the movable unit 4 to be guided with no contact with the guide rails 2 and 2 ′, power amplifiers 33 a , 33 ′ a - 33 d , 33 ′ d supplying an electric power to the coils 20 a , 20 ′ a - 20 d , 20 ′ d on the basis of an output of the calculator 32 , whereby attractive forces in the x and y directions of the magnet units 15 a - 15 d are individually controlled.
A power supply 34 supplies an electric power to the power amplifiers 33 a , 33 ′ a - 33 d , 33 ′ d and also supplies an electric power to a constant voltage generator 35 supplying an electric power having a constant voltage to the calculator 32 , the x-direction gap sensors 13 a , 13 ′ a - 13 d , 13 ′ d and the y-direction gap sensors 14 a , 14 ′ a - 14 d , 14 ′ d . The power supply 34 transforms an alternating current power, which is supplied from the outside of the hoistway 1 with a power line(not shown) for lighting or opening and closing doors, into an appropriate direct current power in order to supply the direct current power to the power amplifiers 33 a , 33 ′ a - 33 d , 33 ′ d.
The constant voltage generator 35 supplies an electric power with a constant voltage to the calculator 32 and the gap sensors 13 and 14 , even if a voltage of the power supply 34 varies due to an excessive current supply, whereby the calculator 32 and the gap sensors 13 and 14 may normally operate.
The sensor 31 comprises the x-direction gap sensors 13 a , 13 ′ a - 13 d , 13 ′ d , the y-direction gap sensors 14 a , 14 ′ a - 14 d , 14 ′ d , the photodiodes 8 a , 8 b and 8 c , and current detectors 36 a , 36 ′ a - 36 d , 36 ′ d detecting current values of the coils 20 a , 20 ′ a - 20 d , 20 ′ d.
The calculator 32 controls, magnetic guide controls for the movable unit 4 in every motion coordinate system shown in FIG. 1 . The motion coordinate system includes a y-mode (back and forth motion mode) representing a right and left motion along a y-coordinate on a center of the movable unit 4 , an x-mode(right and left motion model) representing a right and left motion along a x-coordinate, a θ-mode(roll mode) representing a rolling about the center of the movable unit 4 , a ξ-mode(pitch mode) representing a pitching about the center of the movable unit 4 , a ψ-mode(yaw-mode) representing a yawing about the center of the movable unit 4 . In addition to the above modes, the calculator 32 also controls every attractive force of the magnet units 15 a - 15 d operating on the guide rails, a torsion torque around the y-coordinate caused by the magnet units 15 a - 15 d , operating on the frame 11 , and a torque straining the frame 11 symmetrically, caused by rolling torques that a pair of magnet units 15 a and 15 d , and a pair of magnet units 15 b and 15 c operate on the frame 11 . In brief, the calculator 32 additionally controls a ζmode (attractive mode), a δ-mode (torsion mode) and a γ-mode (strain mode). Accordingly, the, calculator 32 controls in a way that exciting currents of coils 20 converge zero in the above-described eight modes, which is a so-called zero power control, in order to keep the movable unit 4 steady by only attractive forces of the permanent magnets 17 and 17 ′ irrespective of a weight of a load.
This control method is disclosed in detail in Japanese Patent Publication(Kokai) No. 6-178409, the subject matter of which is incorporated herein by reference. A guide control of this embodiment is executed on the basis of the position data of the optical paths 7 a , 7 b and 7 c . The following describes the guide control executed in this embodiment.
To simplify the explanation, it is assumed that a center of the movable unit 4 is on a vertical line crossing a diagonal intersection point of the center points of the magnet units 15 a - 15 d disposed on four corners of the movable unit 4 . The center is regarded as the origin of respective x, y and z coordinate axes. If a motion equation in every mode of magnetic levitation control system with respect to a motion of the movable unit 4 , and voltage equations of exciting voltages applying to the electromagnets 18 and 18 ′ of the magnet units 15 a 15 d are linearized around a steady point, the following formulas 1 through 5 are obtained.
Formula 1 is as follows: { M Δ y ab ″ = 4 ∂ F ya ∂ y a Δ y + 4 ∂ F ya ∂ i a1 Δ i y + U y ( L x0 - M x0 ) Δ i y ′ = - N ∂ Φ b1 ∂ y a Δ y ′ - R Δ i y + e y Δ y = Δ y a + Δ y b + Δ y c + Δ y d 4 Δ i y = Δ i ya + Δ i yb + Δ i yc + Δ i y d 4 e y = Δ e ya + Δ e yb + Δ e yc + Δ e y d 4
Formula 2 is a follows: { M Δ x ab ″ = 4 ∂ F xb ∂ x b Δ x + 4 ∂ F xb ∂ i b1 Δ i x + U x ( L x0 + M x0 ) Δ i x ′ = - N ∂ Φ b1 ∂ x b Δ x ′ - R Δ i x + e x Δ x = - Δ x a + Δ x b + Δ x c - Δ x d 4 Δ i x = - Δ i xa + Δ i xb + Δ i xc - Δ i x d 4 e x = - Δ e xa + Δ e xb + Δ e xc - Δ e x d 4
Formula 3 is as follows: { I θ Δ θ ab ″ = l θ 2 ∂ F xb ∂ x b Δ θ + l θ 2 ∂ F xb ∂ i b1 Δ i θ + T θ ( L x0 + M x0 ) Δ i θ ′ = - N ∂ Φ b1 ∂ x b Δ θ ′ - R Δ i θ + e θ Δ θ = - Δ x a + Δ x b - Δ x c + Δ x d 2 l θ Δ i θ = - Δ i xa + Δ i xb - Δ i xc + Δ i x d 2 l θ e θ = - Δ e xa + Δ e xb - Δ e xc + Δ e x d 2 l θ
Formula 4 is as follows: { I ξ Δ ξ ab ″ = l θ 2 ∂ F yb ∂ y b Δ ξ + l θ 2 ∂ F yb ∂ i b1 Δ i ξ + T ξ ( L x0 + M x0 ) Δ i ξ ′ = - N ∂ Φ b1 ∂ y b Δ ξ ′ - R Δ i ξ + e ξ Δ ξ = - Δ y a - Δ y b + Δ y c + Δ y d 2 l θ Δ i ξ = - Δ i ya - Δ i yb + Δ i yc + Δ i y d 2 l θ e ξ = - Δ e ya - Δ e yb + Δ e yc + Δ e y d 2 l θ
Formula 5 is as follows: { I θ Δ ψ ab ″ = l ψ 2 ∂ F yb ∂ y b Δ ψ + l ψ 2 ∂ F yb ∂ i b1 Δ i ψ + T ψ ( L x0 + M x0 ) Δ i ψ ′ = - N ∂ Φ b1 ∂ y b Δ ψ ′ - R Δ i ψ + e ψ Δ ψ = Δ y a - Δ y b - Δ y c + Δ y d 2 l ψ Δ i ψ = Δ i ya - Δ i yb - Δ i yc + Δ i y d 2 l ψ e ψ = Δ e ya - Δ e yb - Δ e yc + Δ e y d 2 l ψ
With respect to the above formulas, Φ b is a flux, M is a weight of the movable unit 4 , I θ , I ξ and I ψ are moments of inertia around respective y, x and z coordinates, U y and U x are the sum of external forces in the respective y-mode and x-mode, T θ , T ξ and T ψ are the sum of disturbance torques in the respective θ-mode, ξ-mode and ψ-mode, a symbol “′” represents a first time differentiation d/dt, a symbol “″” represents a second time differentiation d 2 /dt 2 , Δ is a infinitesimal fluctuation around :a steady levitated state, L x0 is a self-inductance of each coils 20 and 20 ′ at a steady levitated state, M x0 is a mutual inductance of coils 20 and 20 ′ at a steady levitated state, R is a reluctance of each coils 20 and 20 ′, N is the number of turns of each coils 20 and 20 ′, i y , i x , i θ , i ξ and i ψ are exciting currents of the respective y, x, θ, ξ and ψ modes, e y , e x , e θ , e 86 and e ψ are exciting voltages of the respective y, x, θ, ξ and ψ modes, l θ is each of the spans of the magnet units 15 a and 15 d , and of the magnet units 15 b and 15 c , and l ψ represents each of the spans of the magnet units 15 a and 15 b , and of the magnet units 15 c and 15 d.
Moreover, voltage equations of the remaining ζ, δ and γ modes are given as follows.
Formula 6 is as follows: ( L x0 + M x0 ) Δ i ζ ′ = - N ∂ Φ b1 ∂ x b Δ ζ ′ - R Δ i ζ + e ζ Δ ζ = Δ x a + Δ x b + Δ x c + Δ x d 4 Δ i ζ = Δ i xa + Δ i xb + Δ i xc + Δ i x d 4 e ζ = Δ e xa + Δ e xb + Δ e xc + Δ e x d 4
Formula 7 is as follows: ( L x0 - M x0 ) Δ i δ ′ = - N ∂ Φ b1 ∂ y b Δ δ ″ - R Δ i δ + e δ Δ δ = Δ y a - Δ y b + Δ y c - Δ y d 2 l ψ Δ i δ = Δ i ya - Δ i yb + Δ i yc - Δ i y d 2 l ψ e δ = Δ e ya - Δ e yb + Δ e yc - Δ e y d 2 l ψ
Formula 8 is as follows: ( L x0 + M x0 ) Δ i γ ′ = - N ∂ Φ b1 ∂ x b Δ γ ′ - R Δ i γ + e γ Δ γ = Δ x a + Δ x b - Δ x c - Δ x d 2 l θ Δ i γ = Δ i xa + Δ i xb - Δ i xc - Δ i x d 2 l θ e γ = Δ e xa + Δ e xb - Δ e xc - Δ e x d 2 l θ
With respect to the above formulas, y is variation of the center of the movable unit 4 in the y-axis direction, x is variation of the center of the movable unit 4 in the x-axis direction, θ is a rolling angle about the y-axis, ξ is a pitching angle about the x-axis, ψ is a yawing angle about the z-axis, and the guide rails 2 and 2 ′ are the reference points. In case the optical path 7 a (or 7 b ) is the reference point, a suffix “ab” is added. y ab is a variation of the center of the movable unit 4 in the y-axis direction. x ab is a variation of the center of the movable unit 4 in the x-axis direction. θ ab is a rolling angle about the y-axis. ξ ab is a pitching angle about the x-axis. ψ ab is a yawing angle about the z-axis. Symbols y, x, θ, ξ and ψ of the respective modes are affixed to exciting currents i and exciting voltages e respectively. Further, symbols a-d representing which of the magnet units 15 a - 15 d are respectively affixed to exciting currents i and exciting voltages e of the magnet units 15 a - 15 d . Levitation gaps x a -x d and y a -y d to the magnet units 15 a - 15 d are made by a coordinate transformation into y, x, θ, ξ and ψ modes by the following formula 9.
Formula 9 is as follows: y = 1 4 ( y a + y b + y c + y d ) x = 1 4 ( - x a + x b + x c - x d ) θ = 1 2 l θ ( - x a + x b - x c + x d ) ξ = 1 2 l θ ( - y a - y b + y c + y d ) Ψ = 1 2 l ψ ( y a - y b - y c + y d )
Exciting currents i a1 ,i a2 -i d1 , i d2 to the magnet units 15 a 15 d are made a coordinate transformation into exciting currents i y , i x , i θ , i ξ , i ψ , i ζ , i δ and i γ the respective modes by the following formula 10.
Formula 10 is as follows: i y = 1 8 ( i a1 - i a2 + i b1 - i b2 + i c1 - i c2 + i d1 - i d2 ) i x = 1 8 ( - i a1 - i a2 + i b1 + i b2 + i c1 + i c2 - i d1 - i d2 ) i θ = 1 4 l θ ( - i a1 - i a2 + i b1 + i b2 - i c1 - i c2 + i d1 + i d2 ) i ξ = 1 4 l θ ( - i a1 + i a2 - i b1 + i b2 + i c1 - i c2 + i d1 - i d2 ) i ψ = 1 4 l ψ ( i a1 - i a2 - i b1 + i b2 - i c1 + i c2 + i d1 - i d2 ) i ζ = 1 8 ( i a1 + i a2 + i b1 + i b2 + i c1 + i c2 + i d1 + i d2 ) i δ = 1 4 l ψ ( i a1 - i a2 - i b1 + i b2 + i c1 - i c2 - i d1 + i d2 ) i γ = 1 4 l θ ( i a1 + i a2 + i b1 + i b2 - i c1 - i c2 - i d1 - i d2 )
Controlled input signals to levitation systems of the respective modes, for example, exciting voltages e y , e x , e θ , e ξ , e ψ , e ζ , e δ and e γ which are the outputs of the calculator 32 , are made by an inverse transformation to exciting voltages of the coils 20 and 20 ′ of the magnet units 15 a - 15 d by the following formula 11.
Formula 11 is as follows: e a1 = e y - e x - l θ 2 e θ - l θ 2 e ξ + l ψ 2 e ψ + e ζ + l ψ 2 e δ + l θ 2 e γ e a2 = - e y - e x - l θ 2 e θ - l θ 2 e ξ - l ψ 2 e ψ + e ζ - l ψ 2 e δ + l θ 2 e γ e b1 = e y + e x + l θ 2 e θ - l θ 2 e ξ - l ψ 2 e ψ + e ζ - l ψ 2 e δ + l θ 2 e γ e b2 = - e y + e x + l θ 2 e θ + l θ 2 e ξ + l ψ 2 e ψ + e ζ + l ψ 2 e δ + l θ 2 e γ e c1 = e y + e x - l θ 2 e θ + l θ 2 e ξ - l ψ 2 e ψ + e ζ + l ψ 2 e δ - l θ 2 e γ e c2 = - e y + e x - l θ 2 e θ - l θ 2 e ξ + l ψ 2 e ψ + e ζ - l ψ 2 e δ - l θ 2 e γ e d1 = e y - e x + l θ 2 e θ + l θ 2 e ξ + l ψ 2 e ψ + e ζ - l ψ 2 e δ - l θ 2 e γ e d2 = - e y - e x + l θ 2 e θ - l θ 2 e ξ - l ψ 2 e ψ + e ζ + l ψ 2 e δ - l θ 2 e γ
With respect to the y, x, θ, ξ and ψ modes , since motion equations of the movable unit 4 pairs with voltage equations thereof, the formulas 15 are arranged to an equation of state shown in the following formula 12.
Formula 12 is as follows:
x 5 ′=A 5 x 5 +b 5 e 5 +p 5 h 5 +d 5 u 5
In the formula 12, vectors x 5 , A 5 , b 5 , p 5 and d 5 , and u 5 are defined as follows by formula 13.
Formula 13 is as follows: x 5 = [ Δ y Δ y ab Δ y ′ Δ y ab ′ Δ i y ] , [ Δ x Δ x ab Δ x ′ Δ x ab ′ Δ i x ] , [ Δ θ Δ θ ab Δ θ ′ Δ θ ab Δ i θ ] , [ Δ ξ Δ ξ ab Δ ξ ′ Δ ξ ab ′ Δ i ξ ] or [ Δ ψ Δ ψ ab Δ ψ ′ Δ ψ ab ′ Δ i ψ ] A 5 = [ 0 0 1 0 0 0 0 0 1 0 a 21 0 0 0 a 23 a 21 0 0 0 a 23 0 0 a 32 0 a 33 ] b 5 = [ 0 0 0 0 b 31 ] , d 5 = [ 0 0 d 21 d 21 0 ] , p 5 = [ 0 0 - 1 0 0 ] u 5 = U y , U x , T θ , T ξ , or T ψ
wherein h 5 represents irregularities on the guide rail 2 ( 2 ′) to the optical path 7 a ( 7 b ).
Where the following formula 14 is provided, h 5 is defined by a formula 15.
Formula 14 is as follows:
h y =y ab −y,h x =x ab −x,h θ =θ ab −θ
h ξ =ξ ab −ξ,h ψ =ψ ab −ψ
Formula 15 is as follows:
h 5 =h y ″,h x ″,h θ ″,h ξ ″,h ψ ″
Further, e 5 is a controlling voltage for stabilizing the respective modes.
Formula 16 is as follows:
e 5 =e y ,e x ,e θ ,e ξ ″or″e ψ
The formulas 6-8 are arranged into an equation of state shown in the following formula 18, by defining a state variable as the following formula 17.
Formula 17 is as follows:
x 1 =Δi ζ ,Δi δ ,Δi γ
Formula 18 is as follows:
x 1 ′=A 1 x 1 +b 1 e 1+d 1 u 1
If offset voltages of the controller 32 in the respective modes are marked with v ζ , v δ and v γ , A 1 , b 1 , d 1 and u 1 in each mode are presented as follows.
Formula 19 is as follows: (ζ-mode) A l = - R L x0 + M x0 , b l = 1 L x0 + M x0 , d l = 1 L x0 + M x0 u l = - N ∂ Φ b1 ∂ x b Δ ζ ′ + v ζ (δ-mode) A l = - R L x0 - M x0 , b l = 1 L x0 - M x0 , d l = 1 L x0 - M x0 u l = - N ∂ Φ b1 ∂ y b Δ δ ′ + v δ (γ-mode) A l = - R L x0 + M x0 , b l = 1 L x0 + M x0 , d 1 = 1 L x0 + M x0 u l = - N ∂ Φ b1 ∂ x b Δ γ ′ + v γ
wherein e 1 is a controlling voltage of each mode.
Formula 20 is as follows:
e 1 =e ζ ,e δ ,ore γ
The formula 12 may achieve a zero power control by feedback of the following formula 21.
Formula 21 is as follows:
e 5 =F 5 x 5 +∫K 5 x 5 dt
In case of letting F a , F b , F c , F d and F e be proportional gains, and K e be integral gain, the following formula 22 is given.
Formula 22 is as follows:
F 3 =[F a F b F c F d F e ]
K 3 =[0000K e ]
Likewise, the formula 18 may achieve a zero power control by feedback of the following formula 23.
Formula 23 is as follows:
e 1 =F 1 x 1 +∫K 1 x 1 dt
F 1 is a proportional gain. K 1 is an integral gain.
As shown in FIG. 5, the calculator 32 , which provides the above zero power control, comprises subtractors 41 a - 41 h , 42 a - 42 h and 43 a - 43 h , average calculators 44 x and 44 y , a gap deviation coordinate transformation circuit 45 , a current deviation coordinate transformation circuit 46 , a controlling voltage calculator 47 , a controlling voltage coordinate inverse transformation circuit 48 , a vertical position calculator 49 , a position deviation coordinate transformation circuit 50 , and an irregularity memory circuit 51 . The calculator 32 providese not only the zero power control but also a guide control on the basis of a reference coordinate by detecting a position of the movable unit 4 by using the photodiodes 8 a , 8 b and 8 c , and the optical paths 7 a , 7 b and 7 c formed by the laser radiators 6 a , 6 b and 6 c.
The subtractors 41 a - 41 h calculate x-direction gap deviation signals Δg xa1 , Δg xa2 ,-Δg xd1 , Δg xd2 by subtracting the respective reference values x a01 , x a02 , -x d01 , x d02 from gap signals g xa1 , g xa2 ,-g xd1 , g xd2 from the x-direction gap sensors 13 a , 13 ′ a - 13 d , 13 ′ d . The subtractors 42 a - 42 h calculate y-direction gap deviation signals Δg ya1 , Δg ya2 ,-Δg yd1 , Δg yd2 by subtracting the respective reference values y a01 , y a02 ,-y d01 , y d02 from gap signals g ya1 , g ya2 , g yd1 , g yd2 from the y-direction gap sensors 14 a , 14 ′ a - 14 d , 14 ′ d . The subtractors 43 a - 43 h calculate current deviation signals Δi a1 , Δi a2 ,-Δi d1 , Δi d2 by subtracting the respective reference values i a01 , i a02 ,-i d01 , i d02 from exciting current signals i a1 , i a2 ,-i d1 , i d2 from current detectors 36 a , 36 ′ a - 36 d , 36 ′ d.
The average calculators 44 x and 44 y average the x-direction gap deviation signals Δg xa1 , Δg xa2 ,-Δg xd1 , Δg xd2 , and the y-direction gap deviation signals Δg ya1 , Δg ya2 ,-Δg yd1 , Δg yd2 respectively, and output the calculated x-direction gap deviation signals Δx a -Δx d , and the calculated y-direction gap deviation signals Δy a -Δy d . The gap deviation coordinate transformation circuit 45 calculates y-direction variation Δy of the center of the movable unit 4 on the basis of the y-direction gap deviation signals Δy a -Δy d , x-direction variation Δx of the center of the movable unit 4 on the basis of the x-direction gap deviation signals Δx a -Δx d , a rotation angle Δθ in the θ-direction(rolling direction) of the center of the movable unit 4 , a rotation angle Δξ in the ξ-direction(pitching direction) of the movable unit 4 , and a rotation angle Δψ in the ψ-direction(yawing direction) of the movable unit 4 , by the use of the formula 9.
The current deviation coordinate transformation circuit 46 calculates a current deviation Δi y regarding y-direction movement of the center of the movable unit 4 , a current deviation Δi x regarding x-direction movement of the center of the movable unit 4 , a current deviation Δi θ regarding a rolling around the center of the movable unit 4 , a current deviation Δi ξ regarding a pitching around the center of the movable unit 4 , a current deviation Δi ψ regarding a yawing around the center of the movable unit 4 , and current deviations Δi ζ , Δi δ and Δi γ , regarding ζ, δ and γ stressing the movable unit 4 , on the basis of the current deviation signals Δi a1 , Δi a 2 ,-Δi d1 , Δi d2 by using the formula 10.
The vertical position calculator 49 calculates a vertical position of the movable unit 4 in the hoistway 1 on the basis of the outputs of the photodiodes 8 b and 8 c disposed at the same level. The position deviation coordinate transformation circuit 50 calculates positions Δy ab , Δx ab , Δθ ab , Δξ ab and Δψ ab in each mode of the movable unit 4 on the reference coordinate on the basis of the outputs of the photodiodes 8 a and 8 b , and outputs the calculated results to the controlling voltage calculator 47 .
The irregularity memory circuit 51 subtracts an output of the gap deviation coordinate transformation circuit 45 from a position of the movable unit 4 measured by the vertical position calculator 49 and an output of the position deviation coordinate transformation circuit 50 , and then consecutively stores irregularity data h y , h x , h θ , h ξ and h ψ of the guide rail 2 ( 2 ′) to the optical path 7 a ( 7 b ), which are transformed into a position of the movable unit 4 . The irregularity memory circuit 51 timely reads vertical position data and the irregularity data corresponding to a vertical position of the movable unit 4 and outputs them to the controlling voltage calculator 47 .
The controlling voltage calculator 47 calculates controlling voltages e y , e x , e θ , e ξ , e ψ , e ζ , e δ and e γ for magnetically and securely levitating the movable unit 4 in each of the y, x, θ, ξ, ψ, ζ, δ, and γ modes on the basis of the outputs Δy, Δx, Δθ, Δξ, Δψ, Δi y , Δi x , Δi θ , Δi ξ , Δi ψ , Δi ζ , Δi δ and Δi γ of the gap deviation coordinate transformation circuit 45 and the current deviation coordinate transformation circuit 46 . The controlling voltage coordinate inverse transformation circuit 48 calculates respective exciting voltages e a1 ,e a2 -e d1 ,e d2 of the magnet units 15 a - 15 d on the basis of the outputs e y , e x , e θ , e ξ , e ψ , e ζ , e δ and e γ by the use of the formula 11, and feeds back the calculated result to the power amplifiers 33 a , 33 ′ a - 33 d , 33 ′ d.
The controlling voltage calculator 47 comprises a back and forth mode calculator 47 a , a right and left mode calculator 47 b , a roll mode calculator 47 c , a pitch mode calculator 47 d , a yaw mode calculator 47 e , an attractive mode calculator 47 f , a torsion mode calculator 47 g , and a strain mode calculator 47 h.
The back and forth mode calculator 47 a calculates an exciting voltage e γ in the y-mode on the basis of the formula 21 by using inputs Δy and Δi y . The right and left mode calculator 47 b calculates an exciting voltage e x in the x-mode on the basis of the formula 21 by using inputs Δx and Δi x . The roll mode calculator 47 c calculates an exciting voltage e θ in the θ-mode on the basis of the formula 21 by using inputs Δθ and Δi θ . The pitch mode calculator 47 d calculates an exciting voltage e ξ in the ξ-mode on the basis of the formula 21 by using inputs Δξ and Δi ξ . The yaw mode calculator 47 e calculates an exciting voltage e ψ in the ψ-mode on the basis of the formula 21 by using inputs Δψ and Δi ψ . The attractive mode calculator 47 f calculates an exciting voltage e ζ in the ζ-mode on the basis of the formula 23 by using input Δi ζ . The torsion mode calculator 47 g calculates an exciting voltage e δ in the δ-mode on the basis of the formula 23 by using input Δi δ . The strain mode calculator 47 h calculates an exciting voltage e γ in the γ-mode on the basis of the formula 23 by using input Δi γ .
FIG. 6 shows in detail each of the calculators 47 a - 47 e.
Each of the calculators 47 a - 47 e comprises a differentiator 60 calculating time change rate Δy′, Δx′, Δθ′, Δξ′ or Δψ′ on the basis of each of the variations Δy, Δx, Δθ, Δξ and Δξ, a differentiator 61 calculating time change rate Δy′ ab , Δx′ ab , Δθ ab , Δξ ab or Δψ′ ab on the basis of each of the variations Δy ab , Δx ab , Δθ ab , Δξ ab and Δψ ab from the reference position, and gain compensators 62 multiplying each of the variations Δy-Δψ and Δy ab -Δψ ab , each of the time change rates Δy′-Δψ′ and Δy′ ab -Δψ′ ab and each of the current deviations Δi y -Δi ψ , by an appropriate feedback gain respectively. Each of the calculators 47 a - 47 e also comprises a current deviation setter 63 , a subtractor 64 subtracting each of the current deviations Δi y -Δi ψ from a reference value output by the current deviation setter 63 , an integral compensator 65 integrating the output of the subtractor 64 and multiplying the integrated result by an appropriate feed back gain, an adder 66 calculating the sum of the outputs of the gain compensators 62 , and a subtractor 67 subtracting the output of the adder 66 from the output of the integral compensator 65 , and outputting the exciting voltage e y , e x , e θ , e ξ or e ψ , of the respective y, x, θ, ξ and ψ modes. The gain compensator 62 and the integral compensator 65 may change a set gain on the basis of vertical position data H and the irregularity data h y , h x , h θ , h ξ and h ψ corresponding to a vertical position of the movable unit 4 .
FIG. 7 shows internal components in common among the calculators 47 f - 47 h.
Each of the calculators 47 f - 47 h comprises a gain compensator 71 multiplying the current deviation Δi ζ , Δi δ or Δi γ by an appropriate feedback gain, a current deviation setter 72 , a subtractor 73 subtracting the current deviation Δi ζ , Δi δ or Δi γ from a reference value output by the current deviation setter 72 , an integral compensator 74 integrating the output of the subtractor 73 and multiplying the integrated result by an appropriate feedback gain, and a subtractor 75 subtracting the output of the gain compensator 71 from the output of the integral compensator 74 and outputting an exciting voltage e ζ , e δ or e γ of the respective ζ, δ and γ modes.
The following explains an operation of the above-described guide system of the first embodiment of the present invention.
Any of the ends of the center cores 16 of the magnet units 15 a - 15 d , or the ends of the electromagnets 18 and 18 ′ of the magnet units 15 a - 15 d adsorb to the facing surfaces of the guide rails 2 and 2 ′ through the solid lubricating materials 22 at a stopping state of the magnetic guide system. At this time, an upward and downward movement of the movable unit 4 is not interfered with because of the effect of the solid lubricating materials 22 .
Once the guide system is activated at the stopping state, fluxes of the electromagnets 18 and 18 ′, which possesses the same or opposite direction of fluxes generated by the permanent magnets 17 and 17 ′, are controlled by the controller 30 . The controller 30 controls exciting currents to the coils 20 and 20 ′ in order to keep a predetermined gap between the magnet units 15 a - 15 d and guide rails 2 and 2 ′. Consequently, as shown in FIG. 4, a magnetic circuit Mcb is formed with a path of the permanent magnet 17 , the L-shaped core 19 , the core plate 21 , the gap Gb, the guide rail 2 ′, the gap Gb″, the center core 16 , and the permanent magnet 17 ; and a magnetic circuit Mcb′ is formed with a path of the permanent magnet 17 ′, the L-shaped core 19 ′, the core plate 21 ′, the gap Gb′, the guide rail 2 ′, the gap Gb″, the center core 16 , and the permanent magnet 17 ′. The gaps Gb, Gb′ and Gb″ , or other gaps formed with the magnet units 15 a , 15 c and 15 d , are set to certain distances so that magnetic attractive forces of the magnet units 15 a - 15 d generated by the permanent magnets 17 and 17 ′ balance with a force in the y-direction (back and force direction) acting on the center of the movable unit 4 , a force in the x-direction (right and left direction), and torques acting around the x, y and x-axis passing on the center of the movable unit 4 . When some external forces operate on the movable unit 4 , the controller 30 controls exciting currents flowing into the electromagnets 18 and 18 ′ of the respective magnet units 15 a - 15 d in order to keep such balance, thereby achieving the so-called zero power control.
Now, the movable unit 4 is positioned at the lowest floor. The movable unit 4 , which is controlled to be guided with no contact by the zero power control, starts to move upwardly by a hoisting machine (not shown). In this first upward stage, the movable unit moves slowly enough so that the zero power control can control to follow irregularities on the guide rails. During the first initial running, positions H of the movable unit 4 and the irregularity data h y , h x , h θ , h ξ and h ψ are stored in the irregularity memory circuit 51 . Consequently, outputs of the irregularity memory circuit 51 are zero during the first initial running. After the first initial running and storing of the position data H and the irregularity data from the lowest floor to the highest floor, the collected data is used for the next running. The position data H and the irregularity data may be rewritten in the same way as the above-described method at any time, if necessary.
After the first initial running, a guide control is carried out as follows. When the movable unit 4 passes relatively gentle irregularities such as warps, a shake of the movable unit 4 caused by irregularities on the guide rails 2 and 2 ′ may be restrained effectively, since the controller 30 feeds back each of the variations Δy-Δψ and Δy ab -Δψ ab and each of the time change rates Δy′-Δψ′ and Δy′ ab -Δψ′ ab to each of the exciting voltages e y , e x , e θ , e ξ and e ψ via the gain compensator 62 .
Since the irregularity data h y , h x , h θ , h ξ and h ψ and the vertical position data H are read out by the irregularity memory circuit 51 and the gain compensator 62 and the integral compensator 65 input these data, the gain compensator 62 and the integral compensator 65 may change controlling parameters at intervals having irregularities during a later running, if vertical position data and the intervals having irregularities are set to the gain compensator 62 and the integral compensator 65 after the initial running.
Even if a difference in level or a gap caused by a repetition of thermal expansion and contraction or an earthquake occur at a joint of the guide rail 2 ( 2 ′), a shake of the movable unit 4 may be restrained by changing controlling parameters so that guiding forces of the magnet units 15 a - 15 d possess an extremely low spring constant on the condition that the movable unit 4 positions at the interval having irregularity, a velocity of the movable unit 4 is fast, and a change rate of the irregularity data h y , h x , h θ , h ξ and h ψ exceeds the predetermined value.
In case the magnetic guide system stops working, the current deviation setters 62 for the y-mode and the x-mode set reference values from zero to minus values gradually, whereby the movable unit 4 gradually moves in the y and x-directions. At last, any of the ends of the center cores 16 of the magnet units 15 a - 15 d , or the ends of the electromagnets 18 and 18 ′ of the magnet units 15 a - 15 d adsorb to the facing surfaces of the guide rails 2 and 2 ′ through the solid lubricating materials 22 . If the magnetic guide system is stopped at this state, a reference value of the current deviation setter 62 is reset to zero, and the movable unit 4 adsorbs to the guide rails 2 and 2 ′.
In the first embodiment, although the zero power control, which controls to settle an exciting current for an electromagnet to zero at a steady state, is adopted for no contact guide control, various other control methods for controlling attractive forces of the magnet units 15 a - 15 d may be used. For example, a control method, which controls to keep the gaps constant, may be adopted, if the magnet units areto follow the guide rails 2 and 2 ′ more precisely.
A guide system of a second embodiment of the present invention is described with reference to FIGS. 8 and 9.
In the first embodiment, although no contact guide control is achieved by adopting the magnet units 15 a - 15 d as guide units 5 a - 5 d , it is not limited to the above described system. As shown in FIGS. 8 and 9, guide units 100 a - 100 d in a wheel supporting type may be attached to the upper and lower corners of the movable unit 4 in the same way as the first embodiment. Although only guide unit 100 b is illustrated in FIGS. 8 and 9, the other guide units 100 a , 100 c and 100 d have the same structure as the guide unit 100 b.
The guide unit 100 b of the second embodiment comprises three guide wheels 111 , 112 and 113 disposed to surround the guide rail 2 ( 2 ′) on three sides, suspension units 114 , 115 and 116 , disposed between the respective guide wheels 111 - 113 and the movable unit 4 , operating guiding forces on the guide rail 2 ( 2 ′) by pressing the guide wheels 111 - 113 , and a base supporting the suspension units 114 - 116 .
Each of the guide units 100 a - 110 d is fixed to a corresponding corner of the frame 11 through the base 117 . The suspension units 114 - 116 each include a respective one of linear pulse motors 121 , 122 and 123 , suspensions 124 , 125 and 126 , and potentiometers 127 , 128 and 129 for gap sensors.
The linear pulse motors 121 - 123 comprise respectively stators 131 , 132 and 133 , and linear rotors 134 , 135 and 136 . The linear rotors 134 - 136 move along concave grooves of the stators 131 - 133 formed in the shape of a U as a whole. Moving speeds of the linear rotors 134 - 136 correspond to values of speed signals individually provided to pulse motor drivers 141 , 142 and 143 of the linear pulse motors 121 - 123 .
The suspensions 124 - 126 comprise L-shaped plates 144 , 145 and 146 (not shown) fixed on the linear rotors 134 - 136 , supports 151 (not shown), 152 and 153 (not shown) fixed on the L-shaped plates 144 - 146 and including axles 147 , 148 and 149 on the opposite sides thereof, pairs of plates 157 a and 157 b , 158 a and 158 b , and 159 a and 159 b pivotably connected to the supports 151 - 153 by putting the axles 147 - 149 between the pairs of plates 157 a , 157 b - 159 a , 159 b at the basal portion thereof, and supporting the guide wheels rotatably by the axles 154 , 155 and 156 at the tips thereof by putting the supports 151 - 153 and the guide wheels 111 - 113 between the pairs of plates 157 a , 157 b 159 a , 159 b . The suspensions 124 - 126 also comprise coil springs 161 , 162 and 163 , guiding rods 164 , 165 and 166 put through the coil springs 161 - 163 and fixed to the L-shaped plates 144 - 146 at the rear ends thereof, and guards 167 , 168 and 169 fixed at a position that the each coil spring 161 - 163 operates a predetermined pressing force on the pairs of plates 157 a , 157 b - 159 a , 159 b , and pierced through the guiding rods 164 - 166 .
The potentiometers 127 - 129 detect turning angles of the pairs of plates 157 a , 157 b - 159 a , 159 b around the axes 147 - 149 of the supports 151 - 153 , and function as gap sensors outputing a distance between the guide rail 2 ( 2 ′) and the center of each axles 154 , 155 and 156 .
A guiding force of each guide wheel 111 - 113 of the guide units 100 a - 100 d is controlled by a controller 230 shown in FIG. 10, thereby guiding the elevator cage 10 and the frame 11 against the guide rails 2 and 2 ′.
The controller 230 is divided and disposed at the same position as the controller 30 of the first embodiment shown in FIG. 1, but functionally combined as a whole as shown in FIG. 10 . The following is an explanation of the controller 230 . In FIG. 10, arrows represent signal paths, and solid lines represent electric power lines. In the following description, identical numerals are added to the same components as the controller 30 of the first embodiment. Further, suffixes “a”-“d” are respectively added to figures indicating the main components of the respective guide units 100 a - 100 d in order to indicate instaling positions on the frame 11 .
The controller 230 , fixed on the frame 11 , comprises a sensor 231 detecting a distance between the guide rail 2 ( 2 ′) and the center of each guide wheel 111 a , 112 a , 113 a - 111 d , 112 d , 113 d of the guide units 100 a - 100 d , a calculator 232 calculating a moving speed of each of the moving elements 134 - 136 of the linear pulse motors 121 a , 122 a , 123 a - 121 d , 122 d , 123 d for guiding the movable unit 4 in response to output signals from the sensor 231 , pulse motor drivers 211 a , 212 a , 213 a - 211 d , 212 d , 213 d driving each moving element 134 - 136 at a designated speed on the basis of outputs of the calculator 232 , thereby controlling a guiding force of each guide wheel 111 a , 112 a , 113 a - 111 d , 112 d , 113 d in both x and y directions individually.
A power supply 234 supplies an electric power to the linear pulse motors 121 a , 122 a , 123 a - 121 d , 122 d , 123 d through pulse motor drivers 211 a , 212 a , 213 a - 211 d , 212 d , 213 d and also supplies an electric power to a constant voltage generator 235 supplying an electric power having a constant voltage to the calculator 232 , and the potentiometers 127 a , 128 a , 129 a - 127 d , 128 d , 129 d constituting x-direction gap sensors and y-direction gap sensors. The constant voltage generator 235 supplies an electric power with a constant voltage to the calculator 232 and the potentiometers 127 a , 128 a , 129 a - 127 d , 128 d , 129 d , even if a voltage of the power supply 234 varies due to an excessive current supply, whereby the calculator 232 and the potentiometers 127 a , 128 a , 129 a - 127 d , 128 d , 129 d may normally operate.
The sensor 231 comprises the potentiometers 127 a , 128 a , 129 a - 127 d , 128 d , 129 d and the photodiodes 8 a - 8 c.
Likewise the first embodiment, the calculator 232 controls a guide control for the movable unit 4 in every motion coordinate system shown in FIG. 1 . The motion coordinate system includes a y-mode (back and forth motion mode) representing a right and left motion along a y-coordinate on a center of the movable unit 4 , an x-mode (right and left motion mode) representing a right and left motion along a x-coordinate, a θ-mode (roll mode) representing a rolling about the center of the movable unit 4 , a ξ-mode (pitch mode) representing a pitching about the center of the movable unit 4 , and a ψ-mode (yaw-mode) representing a yawing about the center of the movable unit 4 .
To simplify the explanation, it is assumed that a center of the movable unit 4 ist on a vertical line crossing a diagonal intersection point of the center points of the guide units 100 a - 100 d disposed on four corners of the movable unit 4 . Where the center is regarded as the origin of respective x, y and z coordinate axes, a motion equation in every mode is given by the following formulas 24 through 28.
Formula 24 is as follows: M Δ y ab ″ = - 8 K s Δ y - 8 η s Δ y ′ - 8 K s v y + U y Δ y = Δ y a1 - Δ y a2 + Δ y b1 - Δ y b2 + Δ y c1 - Δ y c2 + Δ y d1 - Δ y d2 8 v y = v a1 - v a2 + v b1 - v b2 + v c1 - v c2 + v d1 - v d2 8
Formula 25 is as follows: M Δ x ab ″ = - 4 K s Δ x - 4 η s Δ x ′ - 4 K s v x + U x Δ x = - Δ x a + Δ x b + Δ x c - Δ x d 4 v x = - v a3 + v b3 + v c3 - v d3 4
Formula 26 is as follows: I θ Δ θ ab ″ = - K s l θ 2 Δ θ - η s l θ 2 Δ θ ′ - K s l θ 2 v θ + T θ Δ θ = - Δ x a + Δ x b - Δ x c + Δ x d 2 l θ v θ = - v a3 + v b3 - v c3 + v d3 2 l θ
Formula 27 is as follows: I ξ Δ ξ ab ″ = - 2 K s l θ 2 Δ ξ - 2 η s l θ 2 Δ ξ ′ - 2 K s l θ 2 v ξ + T ξ Δ ξ = - Δ y a1 + Δ y a2 - Δ y b1 + Δ y b2 + Δ y c1 - Δ y c2 + Δ y d1 - Δ y d2 4 l θ v ξ = - v a1 + v a2 - v b1 + v b2 + v c1 - v c2 + v d1 - v d2 4 l θ
Formula 28 is as follows: I θ Δ ψ ab ″ = - 2 K s l ψ 2 Δ ψ - 2 η s l ψ 2 Δ ψ ′ - 2 K s l ψ 2 v ψ + T ψ Δ ψ = Δ y a1 - Δ y a2 + Δ y b1 - Δ y b2 - Δ y c1 + Δ y c2 - Δ y d1 + Δ y d2 4 l θ v ψ = v a1 - v a2 + v b1 - v b2 - v c1 + v c2 - v d1 + v d2 4 l ψ
Ks is a spring constant of each suspension 124 - 126 per a unit moving distance of each guide wheel 111 - 113 . The term η s is a damping constant of each suspension 124 - 126 per a unit moving distance of each guide wheel 111 - 113 . The terms v y , v x , v θ , v ξ and v 104 are moving speed command values of moving elements 134136 in the respective y, x, θ, ξ and ψ modes.
Gaps x a -x d and y a1 , y a2 -y d1 , y d2 corresponding to suspension units 114 - 116 are made by a coordinate transformation into y, x, θ, ξ and ψ coordinates by the following formula 29.
Formula 29 is as follows: y = 1 8 ( y a1 - y a2 + y b1 - y b2 + y c1 - y c2 - y d1 + y d2 ) x = 1 4 ( - x a + x b + x c - x d ) θ = 1 2 l θ ( - x a + x b - x c + x d ) ξ = 1 2 l θ ( - y a1 + y a2 - y b1 + y b2 + y c1 - y c2 + y d1 - y d2 ) ψ = 1 2 l ψ ( y a1 - y a2 - y b1 + y b2 - y c1 + y c2 + y d1 - y d2 )
Controlled input signals to suspension systems of the respective modes, for example, moving speed command values v y , v x , v θ , v ξ and v ψ which are the outputs of the calculator 232 are made by an inverse transformation to velocity inputs v a1 , v a2 , v a3 -v d1 , v d2 , v d3 of the pulse motor drivers 211 a , 212 a , 213 a - 211 d , 212 d , 213 d by the following formula 30.
Formula 30 is as follows: v a1 = v y - l θ 2 v ξ + l ψ 2 v ψ , v a2 = - v y + l θ 2 v ξ - l ψ 2 v ψ , v a3 = - v x - l θ 2 v θ v b1 = v y - l θ 2 v ξ - l ψ 2 v ψ , v b2 = - v y + l θ 2 v ξ + l ψ 2 v ψ , v b3 = v x - l θ 2 v θ v c1 = v y + l θ 2 v ξ - l ψ 2 v ψ , v c2 = - v y - l θ 2 v ξ + l ψ 2 v ψ , v c3 = v x - l θ 2 v θ v d1 = v y + l θ 2 v ξ + l ψ 2 v ψ , v d2 = - v y - l θ 2 v ξ - l ψ 2 v ψ , v d3 = - v x + l θ 2 v θ
Motion equations of the movable unit 4 with respect to the y, x, θ, ξ and ψ modes expressed by formulas 24-28 are arranged to an equation of state shown in the following formula 31.
Formula 31 is as follows:
x′ 5 =A 5 x 5 +b 5 v 5 +p 5 h 5 +d 5 u 5
In the formula 31, vectors x 5 , A 5 , b 5 , p 5 and d 5 , and u 5 are defined as follows.
Formula 32 is as follows: x 5 = [ Δ y Δ y ab Δ y ′ Δ y ab ′ v y ] , [ Δ x Δ x ab Δ x ′ Δ x ab ′ v x ] , [ Δ θ Δ θ ab Δ θ ′ Δ θ ab ′ v θ ] , [ Δ ξ Δ ξ ab Δ ξ ′ Δ ξ ab ′ v ξ ] or [ Δ ψ Δ ψ ab Δ ψ ′ Δ ψ ab ′ v ψ ] A 5 = [ 0 0 1 0 0 0 0 0 1 0 a 21 0 a 22 0 a 21 a 21 0 a 22 0 a 21 0 0 0 0 0 ] b 5 = [ 0 0 0 0 b 31 ] , d 5 = [ 0 0 d 21 d 21 0 ] , p 5 = [ 0 0 - 1 0 0 ] u 5 = U y , U x , T θ , T ξ or T ψ
The term h 5 representing irregularities on the guide rails 2 and 2 ′ against the reference optical paths 7 a and 7 b is defined by the following formula 34, where the following formula 33 is provided.
Formula 33 is as follows:
h y =y ab −y,h x =x ab −x,h θ =θ ab −θ
h ξ=ξ ab −ξ,h ψ =ψ ab −ψ
Formula 34 is as follows:
h 5 =h″ y ,h″ x ,h″ θ, h″ ξ orh″ ψ
Further, v 5 is a velocity input to the linear pulse motor for stabilizing the motion in each mode.
Formula 35 is as follows:
v 5 =v y ,v x ,v θ ,v ξ orv ψ
The formula 31 provides guide control by feeding back the following formula 36.
Formula 36 is as follows:
v 5 =F 5 x 5 +∫K 5 x 5 dt
Where proportional gains are represented by F a , F b , F c , F d and F e and an integral gain is represented by K e , F 5 and K 5 are expressed by the following formula 37.
Formula 37 is as follows:
F 5 =[F a F b F c F d F e ]
K 5 =[0K e 000]
As shown in FIG. 10, the calculator 232 comprises subtractors 241 a - 241 d and 242 a - 242 h , a gap deviation coordinate transformation circuit 245 , a speed calculator 247 , a speed coordinate inverse transformation circuit 248 , a vertical position calculator 49 , a position deviation coordinate transformation circuit 50 , and an irregularity memory circuit 51 .
The subtractors 241 a - 241 d calculate x-direction gap deviation signals Δg xa -Δg xd by subtracting the respective reference values x a0 -x d0 from gap signals g xa -g xd from the potentiometers 129 a - 129 d constituting x-direction gap sensors. The subtractors 242 a - 242 h calculate y-direction gap deviation signals Δg ya1 , Δg ya2 -Δg yd1 , Δg yd2 by subtracting the respective reference values y a01 , y a02 -y d01, y d02 from gap signals g ya1 , g ya2 ,-g yd1 , g yd2 from the potentiometer 127 a , 128 a - 127 d , 128 d constituting y-direction gap sensors.
The gap deviation coordinate transformation circuit 245 calculates y-direction variation Δy of the center of the movable unit 4 on the basis of the y-direction gap deviation signals Δg ya1 , Δg ya2 -Δg yd1 , Δg yd2 , x-direction variation Δx of the center of the movable unit 4 on the basis of the x-direction gap deviation signals Δg xa -Δg xd , a rotation angle Δθ in the θ-direction(rolling direction) of the center of the movable unit 4 , a rotation angle Δξ in the ξ-direction(pitching direction) of the movable unit 4 , and a rotation angle Δψ in the ψ-direction(yawing direction) of the movable unit 4 , by the use of the formula 29.
The vertical position calculator 49 calculates a vertical position of the movable unit 4 on the basis of the outputs of the two-dimensional photodiode 8 b and the one-dimensional photodiode 8 c disposed at the same level. The position deviation coordinate transformation circuit 50 calculates deviation positions Δy ab , Δx ab , Δθ ab , Δξ ab and Δψ ab of the movable unit 4 in every mode about the reference coordinates on the basis of the outputs of the two-dimensional photodiodes 8 a and 8 b , and outputs the calculated results to the speed controller 247 . The irregularity memory circuit 51 subtracts an output of the gap deviation coordinate transformation circuit 245 from a position of the movable unit 4 measured by the vertical position calculator 49 and an output of the position deviation coordinate transformation circuit 50 , and then consecutively stores irregularity data h y , h x , h θ , h ξ and h ψ of the guide rail 2 ( 2 ′) to the optical path 7 a ( 7 b ) which are transformed into a position of the movable unit 4 . The irregularity memory circuit 51 timely reads vertical position data and the irregularity data corresponding to a vertical position of the movable unit 4 and outputs them to the speed calculator 247 .
The speed calculator 247 calculates each speed command v y , v x , v θ, v ξ and v ψ of the moving elements 134 - 136 in the respective modes for guiding the movable unit 4 in each y, x, θ, ξ and ψ mode on the basis of outputs Δy, Δx, Δθ, Δξ and Δψ of the gap deviation coordinate transformation circuit 245 . The speed coordinate inverse transformation circuit 248 calculates each moving speed v a1 ,v a2 , v a3 -v a1 , v a2 ,v a3 of the moving elements 134 - 136 of the suspension units 114 a , 115 a , 116 a - 114 d , 115 d , 116 d on the basis of outputs v y , v x , v θ , v ξ and v 104 of the speed calculator 247 by using the formula 30, and feeds back the calculated results to the pulse motor drivers 211 a , 212 a , 213 a - 211 d , 212 d , 213 d.
The speed calculator 247 comprises a back and forth mode calculator 247 a , a right and left mode calculator 247 b , a roll mode calculator 247 c , a pitch mode calculator 247 d , and a yaw mode calculator 247 e.
The back and forth mode calculator 247 a calculates a moving speed v y in the y-mode on the basis of the formula 36 by using inputs Δy and Δy ab . The right and left mode calculator 247 b calculates a moving speed v x in the x-mode on the basis of the formula 36 by using inputs Δx and Δx ab . The roll mode calculator 247 c calculates a moving speed v θ in the θ-mode on the basis of the formula 36 by using inputs Δθ and Δθ ab . The pitch mode calculator 247 d calculates a moving speed v ξ in the ξ-mode on the basis of the formula 36 by using inputs Δξ and Δξ ab . The yaw mode calculator 247 e calculates a moving speed v ψ in the ψ-mode on the basis of the formula 36 by using inputs Δψ and Δψ ab .
FIG. 11 shows in detail each of the calculators 247 a - 247 e.
Each of the calculators 247 a - 247 e comprises a differentiator 260 calculating time change rate Δy′, Δx′, Δθ′, Δξ′ or Δψ′ on the basis of each of the gap variations Δy, Δx, Δθ, Δξ and Δψ, a differentiator 261 calculating time change rate Δy′ ab , Δx′ ab , Δθ′ ab , Δξ′ ab or Δψ′ ab on the basis of each of the variation Δy ab , Δx ab , Δθ ab , Δξ ab and Δψ ab from the reference position, and an integrator 268 integrating each moving speed v y , v x , v θ , v ξ and v ψ in the respective modes and outputting moving distances l y , l x , l θ , l ξ and l ψ , gain compensators 262 multiplying each of the variations Δy-Δψ and Δy ab -Δψ ab , each of the time change rates Δy′-Δψ′ and Δy′ ab -Δψ′ ab and each of the moving distances l y -l ψ , by an appropriate feedback gain respectively. Each of the calculators 247 a - 247 e also comprises a coordinate deviation setter 263 , a subtractor 264 subtracting each of the variation Δy ab -Δψ ab from a reference value output by the coordinate deviation setter 263 , an integral compensator 265 integrating the output of the subtractor 264 and multiplying the integrated result by an appropriate feed back gain, an adder 266 calculating the sum of the outputs of the gain compensators 262 , and a subtractor 267 subtracting the output of the adder 266 from the output of the integral compensator 265 , and outputting the moving speeds v y , v x , v θ , v ξ and v ψ , of the respective y, x, θ, ξ and ψ modes. The gain compensator 262 and the integral compensator 265 may change a set gain on the basis of vertical position data H and the irregularity data h y , h x , h θ , h ξ and h ψ corresponding to a vertical position of the movable unit 4 .
The following explains an operation of the above-described guide system of the second embodiment of the present invention.
In case the movable unit 4 , which is guided with the guide units 100 a - 100 d , starts to move upwardly by a hoisting machine(not shown) and passes relatively gentle irregularities such as warps, a shake of the movable unit 4 caused by irregularities on the guide rails 2 and 2 ′ may be restrained effectively, since the controller 230 feeds back each of the variations Δy ab -Δξ ab , and each of the time change rates Δy′ ab -Δψ′ ab to each of the moving speed v y , v x , v θ , v ξ and v ψ via the gain compensator 262 .
Likewise the first embodiment, since the irregularity data h y , h x , h θ , h ξ and h ψ and the vertical position data H are read out by the irregularity memory circuit 51 , and the gain compensator 262 and the integral compensator 265 input these data, the gain compensator 262 and the integral compensator 265 may change controlling parameters at intervals having irregularities.
Even if a difference in level or a gap caused by a repetition of thermal expansion and contraction or an earthquake occur at a joint of the guide rail 2 ( 2 ′), a shake of the movable unit 4 may be restrained to a minimum by changing controlling parameters so that guiding forces of the guide units 100 a - 100 d possess an extremely low spring constant.
The following is an explanation of a guide system of a third embodiment of the present invention. According to the first and second embodiments, the photodiodes 8 a - 8 c directly receive lasers radiated by the laser radiators 6 a - 6 c as shown FIG. 1 . However, the optical paths 7 a - 7 c are not limited to the above, and other constructions shown in FIG. 12 may be adopted. That is, the elevator cage 10 includes supports 302 fixing mirrors 301 facing the cage 10 at a 45 degree angle, and includes the photodiodes 8 a - 8 c on the side surface thereof, whereby the optical paths 7 a - 7 c made a right-angled turn reach to the photodiodes 8 a - 8 c.
According to the third embodiment, since the surfaces of the photodiodes 8 a - 8 c are disposed at a right angle, the surfaces are hardly covered with dust, thereby enabling a long term use without cleaning.
In the first, second and third embodiments, three laser radiators are used for forming three optical paths 7 a - 7 c . However, the number of the laser radiators are not limited to the above system, one optical path 7 b may be divided into two optical paths by attaching a half mirror 311 fixed with two supports 312 as shown in FIG. 13 .
In this case, the half mirror 311 on the optical path 7 b generates a transmitted light T 1 and a reflected light Tb perpendicular to the transmitted light T 1 . The transmitted light T 1 is incident on a mirror 314 slightly tilted and disposedt on the bottom of the hoistway 1 through a base 313 . The reflected light Tb is incident on the photodiode 8 b.
An optical axis of the transmitted light T 1 is reflected in a slightly inclining direction on the y and z coordinate plane and incident on the photodiode 8 c by being reflected by a mirror 301 ′ facing downward fixed on the side of the elevator cage 10 through a support 302 ′ at a position adjacent to the half mirror 311 .
According to the above optical system, the same guide control as the first and second embodiments may be achieved. Further, since relatively expensive laser radiators are reduced from three to two, an elevator system cost may be reduced.
Moreover, as shown in FIG. 14, an optical path created by only one laser radiator 6 d may be divided into two with a half mirror 321 and a mirror 322 . In this case, since the photodiode 8 c is eliminated and the only photodiodes 8 a and 8 b are used, a vertical position of the movable unit 4 is not detected. The number of optical paths may be voluntarily selected as desired.
Further, in the above embodiments, although laser oscillating tubes are respectively adopted as the laser radiators 6 a , 6 b and 6 c , laser emitting semiconductor devices may be substituted for the laser oscillating tubes. Furthermore, the controllers 30 and 230 may be constituted of either an analog circuit or a digital circuit.
According to the present invention, since a position correction against a shake of a movable unit is executed on the basis of a gap between an optical path forming a reference position and the movable unit, and when the movable unit passes a position corresponding to an irregularity on a guide rail which is stored in advance during the initial running, an antiphase force is operated on the guide rail against the irregularity or the shake of the movable unit, the shake may be restrained, thereby improving a comfortable ride.
Further, since a plurality of optical paths is formed, a position correction against a shake of a movable unit may be executed by detecting gaps around a plurality of axes, for example, a horizontal axis and a vertical axis.
Furthermore, since a hoistway is a dark place, even a relatively low power laser radiator may create a reference optical path, thereby dispensing with a cooler system and enabling to form a reference optical path at a low cost.
Moreover, since an optical path is slightly inclined against a vertical line and a one-dimensional photodiode is disposed on the optical path, a vertical position of the movable unit may be detected on the basis of the incident position of a coherent light on the photodiode, especially a position corresponding to an irregularity on a guide rail may be detected during an initial running.
Further, since a two-dimensional photodiode is disposed on a vertical optical path, a gap position of the movable unit may be detected on the basis of the incident position of a coherent light on the photodiode. Since two two-dimensional photodiodes are disposed at the different levels and disposed on a respective vertical optical paths, three-dimensional position of the movable unit may be detected and corrected on the basis of the incident positions of the coherent lights on the photodiodes.
Furthermore, a magnetic levitation force generated from electromagnets is used for a guide system, the movable unit may be guided with no contact with guide rails, thereby realizing a comfortable ride.
Moreover, a mirror or a half mirror is equipped for changing a direction of an optical path, the number of laser radiators may become fewer than the number of optical paths, thereby reducing cost.
Further, since a vertical position of the movable unit is detected by using two optical paths that are not parallel to one another, a vertical position of the movable unit may be detected accurately with no contact.
Various modifications and variations are possible in light of the above teachings. Therefore, it is to be understood that within the scope of the appended claims, the present invention may be practiced otherwise than as specifically described herein. | A guide system for an elevator, including a movable unit configured to move, such as,ascend and descend, along a guide rail, a beam projector configured to form an optical path of a light parallel to a moving direction of the movable unit, a position detector disposed on the optical path and configured to detect a position relationship between the optical path and the movable unit, and an actuator coupled to the movable unit and configured to change a position of the movable unit by a reaction force caused by a force operating on the guide rail on the basis of the output of the position detector. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to coding of a signal, and more specifically, to an adaptive coding method for estimating probability of entropy encoding.
2. Description of the Related Art
In entropy, arithmetic coding, and decoding, it is known in order to calculate entropy, such that probability estimate of a signal which should be encoded and thereafter should be decoded is required. In arithmetic coding (encoding) and decoding, large data can be compressed by the probability estimate with high precision. As a consequence, the probability estimate is preferably adapted to a change in symbol probability with a priority.
U.S. Pat. No. 5,025,258 discloses such a technique that the adaptive degrees of the symbols to be encoded and decoded to the estimated probability are optimized. This conventional technique will now be described more in detail with reference to FIG. 1 and FIG. 2.
FIG. 1 represents a block diagram for showing the prior art entropy encoder 101 in a simple manner. This entropy encoder 101 accepts the data symbols s(k), and encodes the data symbols S(K) thereof into the data stream a(i). Then, these data symbol S(K) are transferred via a transfer medium 102 to the remotely located entropy decoder 103. To acquire the receiver data stream, the entropy decoder 103 decodes these data symbols S(K) via the transfer medium as a replica of the transferred symbol s(k). The symbol s(k) contains elements (0, - - - , s-1), namely:
S(K)ε(0, - - - , s-1) (1)
As explained above, the symbol is given as either a desirable multi-value or a desirable binary value.
As a result, in this example, the encoder 101 includes the arithmetic encoder unit 104, the context extractor 105, the adaptive probability estimator 106, and the line interface 107. Both the symbol s(k) and the probability estimate p(k) are supplied to the arithmetic encoder unit 104 so as to produce the encoded data stream a(i) by executing therein the well known method. Such an arithmetic encoder unit is well known in this technical field. This arithmetic encoder unit is apparently known from, for instance, "Compression of Black-White Image with Arithmetic Coding", IEEE Transaction on Communications VOL. cos-29, pages 858 to 867 issued in June, 1981; "ARITHMETIC ENCODER/DECODER FOR ENCODING/DECODING SYMBOL WITH BINARY ELEMENT" entitled in U.S. Pat. No. 4,633,490 issued on Dec. 30, 1986; and furthermore "Arithmetic Coding for Data Compression", Communications of the ACM, VOL.30, No. 6, pages 520 to 540, issued in June, 1987, which is related to the arithmetic encoder/decoder for encoding/decoding the symbol having the multi-value element. The line interface 107 interfaces the encoded data stream a(i) to transfer this encoded data stream a(i) to the transfer medium 102. This transfer medium 102 sequentially supplies the data stream a(i) to the remotely located decoder 103. As a consequence, the line interface 107 includes such a proper apparatus capable of formatting the data stream into the signal format used in the transfer medium 102. As the well known example of this possible transfer medium 102, there are a T-transfer trunk, an ISDN based subscriber line, and a local area network (LAN). Such a line interface is also well known in this technical field.
The context extractor 105 extracts the context of the received symbol s(k), namely, in this case:
C(K)ε(0, - - - , c-1) (2)
In other words, the context extractor 105 produces the context (namely, condition) specific to such a symbol s(k) formed based upon the previously supplied symbol. For example, in an image compression system, the symbol s(k) indicates a color of a present pixel to be encoded, and a context c(k) is determined based on a color of the previous pixel, as explained before. For instance, both a color of a pixel (P) which is located adjacent to the present pixel on the same line and appears immediately before, and a color of a preceding pixel (A) appearing on a line located immediately before the line of the present pixel are employed so as to form a context c(k) for the symbol s(k) adapted to the binary value. In this manner, if both the pixel P and the pixel A are white, then the context c(k) is equal to 0. If both the pixel P and the pixel A are black, then the context c(k) is equal to 1. When the pixel P is black and also the pixel A is white, the context c(k) is equal to 2. When both the pixel P and the pixel A are black, the context c(k) is equal to 3. U.S. Pat. No. 4,633,490 discloses another context extractor (condition producer) with using the binary notation. As apparently from the foregoing descriptions, any ordinarily skilled engineers could extend such a binary-notation context extractor in order to obtain a context to which a multi-value has been applied. The context c(k) which is extracted and expressed is supplied to the adaptive probability estimator 106.
The adaptive probability estimator 106 is employed so as to produce a probability predicted value with respect to an input signal and a relevant context:
The input signal is given as follows:
S(K)ε(0, - - - , s-1) (3)
The relevant context is given as follows:
C(K)ε(0, - - - , c-1) (4)
The probability predicted value is given as follows:
P(K)= (5)
As a consequence, the adaptive probability estimator 106 holds, or saves an array (n s ,c) having dimensions "S" and "C" at a final stage. In this case, the respective elements "n s ,c " of this array are an accumulation of occurrences of the symbol "s", namely "count" in the context "c", and the symbols "s" and "c" are dummy indexes for discriminating a location of "n s ,c " in the array. The adaptive probability estimator 106 may be readily realized by properly programming either a computer or a digital signal processor. However, it is conceivable that this adaptive probability estimator 106 may be formed as a semiconductor chip VLSI circuit in view of the better packaging mode.
A flow chart shown in FIG. 2 represents operations of the adaptive probability estimator 106 in which the adaptive speed of the symbol to be encoded with respect to the estimated probability is optimized to thereby produce the probability predicted value in high precision. The operation of the adaptive probability estimator 106 is commenced from a starting step 201. Next, at an operation block 202, the counts of "n s ,c " are initialized with respect to k=0, and all of values as follows:
n.sub.s,c =N.sub.s,c (6)
Sε(0, - - - , s-1) (7)
Cε(0, - - - , c-1) (8)
It should be understood that symbol "N s ,c " is equal to a certain preselected value. At an operation block 203, a next context c(k) is obtained. It should be noted fact that the new context is identical to the previously obtained context. Next, at an operation block 204, a total value of the counts is obtained as 2 for the context c(k) acquired with respect to all of the following values:
Sε(0, - - - , s-1) (9)
In other words, it is obtained as follows:
Z= (10)
At an operation block 205, the adaptive probability estimator 106 (FIG. 1) outputs the probability predicted values which are sequentially supplied to the arithmetic encoder unit 104 (FIG. 1). Since this probability predicted value is obtained by the first execution, this probability predicted value is calculated based upon only the initial condition and the acquired context c(k). In the subsequent execution, the probability predicted value is calculated based on a total value of counting the occurrences of the symbol s(k) for the context c(k), namely an accumulated value. At a step 205, the probability predicted value is outputted in this manner. That is to say:
Po(k)= (11)
Ps-1(k)= (12)
At an operation block 206, a symbol s(k) to be encoded is obtained. At an operation block 207, the count value for the obtained symbol s(k) and the context c(k) is incremented by 1. In other words:
ns(k), c(k) (13)
which are incremented by 1.
At an operation block 208, at least a first characteristic of a set of defined parameters, and at least a second characteristic are obtained. Each element of the set of the defined parameters is an accumulation corresponding to a context of a reception signal to be encoded, namely a function of a count. In other words, a predetermined set of parameters is equal to an occurrence time in which the occurrence of the symbol s(k) with respect to the context c(k) is "accumulated", namely n0,c(k), - - - , ns-1,c(k). In this example, at least the first characteristic corresponds to a minimum value of the accumulated occurrence times with respect to the context c(k). Namely, this minimum value is given as follows:
MIN=MINIMUM{n,c(k), . . . ns-1, c(k)} (14)
In this example, at least the second characteristic corresponds to a maximum value of the accumulated occurrence times with regard to the context c(k), namely, this maximum value is given as follows:
MAX=MAXIMUM{n,c(k), . . . n-1, c(k)} (15)
At a condition branching point 209, a test is done as to whether at least the first characteristic is equal to, or greater than at least a first threshold value, namely
MIN≧T1 (16)
Otherwise, a test is made as to whether at least the second characteristic is equal to, or larger than at least a second threshold value, namely
MAX≧T2 (17)
When at least the first characteristic (MIN) is used, it is important such that the adaptive degree of the adaptive probability estimator 106 (FIG. 1) can be optimized. In this example, the adaptive degree may be optimized by using at least the first characteristic equal to the above-described minimum value MIN, and the smaller threshold value T1 equal to 8. In this manner, in the prior art, the possible signals for the context c(k), namely (0, - - - , s-1) must be produced at least 8 times in order to satisfy the following conditions:
MIN≧T1 (18)
As a result, the use of at least the first characteristic MIN and at least the first threshold value T1=8 produces such an adaptive speed ideally adapted to the actually evaluated probability value. In order not to interpret that the range in this example is limited, if the application of the binary notation and the probability evaluated as 1/2 are employed as an example, then the accumulated production is adjusted after referring to the context c(k) substantially below-mentioned times:
8+8=16 (19)
With respect to the probability evaluated as 1/4, the accumulated production is adjusted after referring to the context c(k) substantially below-mentioned times:
8+24=32 (20)
With respect to the probability evaluated as 1/8, the accumulated production is adjusted after referring to the context c(k) substantially below-mentioned times:
8+56=64 (21)
In this manner, the adaptive speed becomes fast with respect to the larger (not small) probability value than one as being evaluated whereas the adaptive speed necessarily becomes slow with respect to the smaller probability value than one as being evaluated. The adjustments of the adaptive speed are apparent from a step 209 and a step 210.
At least second characteristic corresponding to the maximum value MAX in this example is employed so as to avoid the overflow occurred in the accumulation of the occurrence of the symbol s(k) contained in the context c(k) in relation to at least the second threshold value T2. If the probability under evaluation is not equal to an excessively small value, then MAX does not constitute such a characteristic which requires the parameter adjustment. As a typical example, the value of the threshold value T2 is 2048. This example implies that another characteristic of a set of parameters is utilized. For instance, a total "Z" obtained at the step 204 is employed instead of MAX.
In this manner, when any one of the below-mentioned condition formula (22) and the following formula (23) can be satisfied, the process operation is returned to the step 209: the condition formula (22) is expressed by:
MIN≧T1 (22)
Also, the formula (23) is expressed by:
MAX≧T2 (23)
At an operation block 210, the symbol element accumulated in the context c(k) is adjusted. The adjustment of the adaptive speed is realized at a step 210 in relation to the step 209 which constitutes the cause of the adjustment. For example, the accumulation displayed, namely the count is determined by a so-called "half reduction" set by the following formula (25) about the accumulated occurrence for the context c(k) with respect to all of:
Sε(0, - - - , s-1) (24)
The formula (25) is expressed by:
n.sub.s,c (k)=(n.sub.s,c (k)+1)/2 (25)
Conventionally, when the condition of either the formula MIN T 1 or the formula MAX T 2 can be satisfied, the count is adjusted by the same method. As to a certain sort of application, it is convenient to separately adjust each of the above-described conditions. When the count is once adjusted, it should be noted that this adjusted count displays the accumulated occurrence. The adjustment of this accumulated occurrence makes the probability estimate more depend on the newer occurrence in the context c(k). As previously described, the accumulated occurrence produced in accordance with the formula MIN T 1 is adjusted, so that the adaptive degree can be ideally made coincident with the actual probability under evaluation. The adjustment of the accumulated occurrence of the symbol s(k) contained in the context c(k) produced in response to the formula MAX T 2 is to protect the possible arithmetic overflow condition under such a rare case that a very small probability value is estimated.
Thereafter, at a condition branching point 211, a test is made as to whether or not the symbol s(k) corresponds to a final symbol to be encoded/decoded. Normally, the number of symbols to be encoded is known. If this number is conversely not known, then the indication of the number of symbols is supplied to the adaptive probability estimator 106. When the test result is "YES" at the condition branching point 211, the operation of the element of the adaptive probability estimator 106 is accomplished via an END step 212. Conversely, when the test result is "NO" at the condition branching step 211, the control operation is returned to the step 203. Then, the proper operation is repeatedly performed from the step 203 to the step 211 until the test result at the step 211 becomes "YES".
Returning back to the step 209, if the test result becomes "NO", then the control operation is advanced to the step 211 at which the test is made as to whether or not the symbol s(k) corresponds to the final symbol to be encoded (or decoded). If the test result becomes "YES" at the step 211, then the operation of the element of the adaptive probability estimator 106 is accomplished via the END step 212. Conversely, when the test result becomes "NO" at the step 211, an index "k" is produced by being incremented by 1 at a step 213, and the control operation is returned to the step 203. The proper operation is repeatedly performed from the step 203 to the step 211 until the test result becomes "YES" at the step 211.
In the prior art, the decoder 103 includes the line interface 108, the arithmetic decoder unit 109, the context extractor 110, and the adaptive probability estimator 111. The line interface 108 executes the reverse function with respect to the function owned by the line interface 107, so that the input signal is deformatted by the known method so as to acquire the data stream s(i). The arithmetic decoder unit 109 executes the reverse function with regard to the function owned by the arithmetic decoder unit 104. As a consequence, both the received data stream a(i) and the probability estimate derived from the adaptive probability estimator 111 are supplied to the arithmetic decoder unit 109 so as to be used by executing the known method for acquiring the symbol s(k). Such an arithmetic decoder unit is well known in this technical field. This well known coding technique is described in the previous citations, i.e., "Compression of Black-White Image with Arithmetic Coding" IEEE, Transaction on Communications; "Arithmetic Encoder/Decoder for encoding/decoding symbol having binary value" (U.S. Pat. No. 4,633,490); and also "Arithmetic Coding for Data Compression applied to multi-value", Communications of the ACM. Since the structure/operation of the context extractor 110 are identical to those of the context extractor 105, explanations thereof are omitted. Similarly, since the structure/operation of the adaptive probability estimator 104 are identical to those of the adaptive probability estimator 111, explanations thereof are omitted.
In the conventional probability estimating method for the non-storage information source data, since the count value of the counter is reduced by 1/2 without any restriction in order to avoid the overflow of the counter when the count value becomes the maximum value, the estimated probability error is increased. Thus, there is a problem that the coding efficiency is deteriorated.
SUMMARY OF THE INVENTION
The present invention has been made to solve the above-described problem, and therefore, has an object to provide such a coding method capable of reducing an estimated probability error and of increasing a coding efficiency.
An adaptive coding method, according to a first invention, is featured by comprising:
a first step (502) for entering data to be coded so as to calculate occurrence probability of a symbol with respect to this entered data;
a second step (504) for judging as to whether the symbol with respect to the entered data is equal to a more probable symbol (MPS), or a less probable symbol (LPS);
a third step (505), (509) for calculating a region on a numerical line, which corresponds to the entered data, based upon the judgment result of the second step (504);
a fourth step (508), (510) for calculating an occurrence frequency of either the more probable symbol (MPS) or the less probable symbol (LPS) with respective to the entered input;
a fifth step (511) for comparing an occurrence time accumulated value calculated as the occurrence frequency at the fourth step with a preselected value (threshold value), and for reducing the occurrence time accumulated value by 1/2 in the case that the occurrence time accumulated value reaches the preselected value (threshold value); and
a sixth step (513) for defining the more probable symbol (MPS) and the less probable symbol (LPS) in correspondence with a predetermined region on a numerical line with respect to the data signal to thereby output coordinate values on the numerical line as a corded word.
In an adaptive coding method according to a second invention, at the fourth step, as an occurrence frequency (N LPS) of the less probable symbol (LPS) and an occurrence frequency (N MPS) of the more probable symbol (MPS), an occurrence time accumulated value is calculated, and as a total value (N TOTAL) of the occurrence frequencies of the less probable symbol (LPS) and of the more probable symbol (MPS), another occurrence time accumulated value is calculated; and
at the first step, occurrence probability of symbols is obtained by calculating the occurrence time accumulated value (N LPS, N TOTAL).
In an adaptive coding method according to a third invention, at the fourth step, as an occurrence frequency (N LPS) of the less probable symbol (LPS) and an occurrence frequency (N MPS) of the more probable symbol (MPS), an occurrence time accumulated value is calculated; and
at the first step, occurrence probability of symbols is obtained by calculating the occurrence time accumulated value (N LPS, N TOTAL).
In an adaptive coding method according to a fourth invention, the fourth step is provided between the first step and the second step.
In an adaptive coding method according to a fifth invention, in the case that the N MPS value of the more probable symbol (MPS) is smaller than T2 in the calculation of the occurrence frequency of the more probable symbol (MPS) at the fourth step, the calculation of the occurrence frequency of the more probable symbol (MPS) is carried out.
In an adaptive coding method according to a sixth invention, as to reducing the occurrence frequency of either the more probable symbol (MPS) or the less probable symbol (LPS) by 1/2 at the fifth step,
in such a case that the N MPS value of the more probable symbol (MPS) is larger than, or equal to T2 and also the N LPS value is larger than 1, the occurrence frequency of either the more probable symbol (MPS) or the less probable symbol (LPS) is reduced by 1/2.
In an adaptive coding method according to a seventh invention, in the case that the N MPS value of the more probable symbol (MPS) is smaller than T3, or the N MPS value of the more probable symbol (MPS) is smaller than T2 and also the N LPS value of the less probable symbol (LPS) is smaller than T4 in the calculation of the occurrence frequency of the more probable symbol (MPS) at the fourth step, the calculation of the occurrence frequency of the more probable symbol (MPS) is carried out.
In an adaptive coding method according to an eighth invention, in such a case that the N MPS value of the more probable symbol (MPS) is larger than, or equal to T3 and smaller than T2 as well as the N LPS of the less probable symbol (LPS) is larger than, or equal to T4, otherwise, the N MPS value of the more probable symbol (MPS) is larger than, or equal to T2 as well as the N LPS value of the less probable symbol (LPS) is larger than 1 in the 1/2 reduction of the occurrence frequency of either the more probable symbol (MPS) or the less probable symbol (LPS) at the fifth step, the 1/2 reduction process of the occurrence frequency of either the more probable symbol (MPS) or the less probable symbol (LPS) is carried out.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram for showing the arrangement of the prior art coding/decoding apparatus;
FIG. 2 is a flow chart for describing the process operation of the prior art adaptive probability estimator;
FIG. 3 is a graphic representation for showing a coding efficiency of a first embodiment of the present invention;
FIG. 4 is a flow chart for describing a coding process of the first embodiment;
FIG. 5 is a flow chart for indicating a process operation of RENORMALIZE of the first embodiment;
FIG. 6 is a flow chart for showing a process operation of UPDATEMPS of the first embodiment;
FIG. 7 is a flow chart for indicating a process operation of UPDATELPS of the first embodiment;
FIG. 8 is a flow chart for showing a process operation of COUNTCHECK of the first embodiment;
FIG. 9 is a flow chart for representing a coding process operation of a second embodiment of the present invention;
FIG. 10 is a flow chart for describing a process operation of UPDATEMPS of the second embodiment;
FIG. 11 is a flow chart for describing a process operation of UPDATELPS of the second embodiment;
FIG. 12 is a flow chart for describing a process operation of COUNTCHECK of the second embodiment;
FIG. 13 is a graphic representation for showing a coding efficiency of the second embodiment;
FIG. 14 is a flow chart for indicating a coding process of a third embodiment according to the present invention;
FIG. 15 is a graphic representation for showing a coding efficiency of the third embodiment;
FIG. 16 is a flow chart for showing a process operation of UPDATEMPS of a fourth embodiment of the present invention;
FIG. 17 is a flow chart for showing a process operation of COUNTCHECK of the fourth embodiment;
FIG. 18 is a diagram for explaining estimated probability of the fourth embodiment;
FIG. 19 is a diagram for explaining estimated probability of the fourth embodiment;
FIG. 20 is a graphic representation for indicating a coding efficiency of the fourth embodiment;
FIG. 21 is a graphic representation for indicating a coding efficiency of a fifth embodiment according to the present invention;
FIG. 22 is an illustration for representing state transition of coding operation;
FIG. 23 is an illustration for representing state transition of coding operation;
FIG. 24 is an illustration for representing state transition of coding operation;
FIG. 25 is an illustration for indicating state transition of a sixth embodiment according to the present invention;
FIG. 26 is a flow chart for showing a process operation of UPDATEMPS of the sixth embodiment;
FIG. 27 is a flow chart for showing a process operation of COUNTCHECK of the sixth embodiment;
FIG. 28 is a graphic representation for showing a coding efficiency of the sixth embodiment;
FIG. 29 is a flow chart for indicating a coding process of a seventh embodiment according to the present invention;
FIG. 30 is a graphic representation for showing a coding efficiency of the seventh embodiment;
FIG. 31 is a flow chart for showing a process operation of UPDATEMPS of an eight embodiment according to the present invention;
FIG. 32 is a flow chart for showing a process operation of COUNTCHECK of the eighth embodiment;
FIG. 33 is a graphic representation for showing a coding efficiency of the eighth embodiment;
FIG. 34 is a graphic representation for showing a coding efficiency of a ninth embodiment according to the present invention;
FIG. 35 is a flow chart for showing a process operation of UPDATEMPS of a tenth embodiment of the present invention;
FIG. 36 is a flow chart for showing a process operation of COUNTCHECK of the tenth embodiment;
FIG. 37 is a graphic representation for indicating a coding efficiency of the tenth embodiment;
FIG. 38 is a perspective view for showing an image processing apparatus of the embodiment; and
FIG. 39 is a perspective view for representing an application example of the image processing apparatus of the embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Now, a description will be given in more detail of preferred embodiments of the present invention with reference to the accompanying drawings.
EMBODIMENT 1
As an example of a coding method according to embodiment 1, a coding process operation when arithmetic coding is applied is represented as an entropy coding device with respect to binary data.
It should be noted that a region of a more probable symbol (MPS) is arranged downward, and a code is coded as a lower field value coordinate of an effective region. At this time, calculation precision is established by that the calculation is stopped at binary decimal 16 bits, and an integer portion is code-outputted.
Also, in embodiment 1, a description is made of the process operations about the adaptive probability estimator 106 and the arithmetic encoder unit 104 of the prior art shown in FIG. 1. Since it is well known that the circuit arrangements other than the encoder of FIG. 1 are also employed in this embodiment, descriptions thereof are omitted. It should also be noted that the circuit arrangements other than the encoder of FIG. 1 are similarly employed in other embodiments.
Variables employed in the below-mentioned descriptions are defined as follows:
That is, a variable "C" shows a code value; a variable "A" represents a region width value; a variable "AL" indicates an LPS region width value; a variable "MPS" denotes a more probable symbol (MPS) value; a variable "LPS" is a less probable symbol (LPS) value (1-MPS); and a variable "S" indicates a data value. A variable "NO" indicates an occurrence frequency of data 0 (counter); a variable "N1" represents an occurrence frequency of data 1 (counter); a variable "N LPS" shows min (N0, N1) (corresponding to MIN); a variable "N MPS" denotes max (N0, N1) (corresponding to MAX); a variable "P" indicates occurrence probability of a less probable symbol (LPS); and a variable "LEN" denotes a code length (binary bit number).
It should be understood that the variable N MPS corresponds to the variable MAX of the prior art and the variable N LPS corresponds to the variable MIN of the prior art in the following description of the coding process sequential operation. When the more probable symbol (MPS) value MPS is equal to 0, the variable N MPS corresponds to N0, whereas when the more probable symbol (MPS) value is equal to 1, the variable N MPS corresponds to N1. When the more probable symbol (MPS) value MPS is equal to 0, the variable N LPS corresponds to N1, whereas when the more probable symbol (MPS) value is equal to 1, the variable N LPS corresponds to N0.
Furthermore, constants employed in the process sequential operation are given as follows:
A constant "T1" indicates a maximum count value (first threshold value) of the variable N LPS.
A constant "T2" represents a maximum count value (second threshold value) of the variable N MPS.
The coding process sequential operations according to embodiment 1 are explained in the following FIG. 4, FIG. 5, FIG. 6, FIG. 7, and FIG. 8.
FIG. 4 is a flow chart for describing a process sequential operation of arithmetic coding of binary data based upon process operations by the adaptive probability estimator 106 and the arithmetic encoder unit 104 shown in FIG. 1. In this flow chart, at a step S500, a calculation is made of the more probable symbol (MPS) value MPS, the less probable symbol (LPS) value LPS, and the occurrence frequencies N0, N1 of the data 0, 1. At a step S501, the code value C, the region width A, and the code length LEN are initialized. At a step S502, the data value S is obtained, and thus the occurrence probability P of the less probable symbol (LPS) is calculated as N LPS/(N0+N1). At a step S503, the occurrence probability P of the less probable symbol (LPS) is multiplied by the entire region width value A to thereby calculate the region width value AL corresponding to the less probable symbol (LPS). At a step S504, a judgment is made as to whether or not the data value S is equal to the more probable symbol (MPS). When the judgment result is YES at the step S504, the region width value A is updated by another region width value (A-AL) corresponding to the more probable symbol (MPS), but the code value C is not updated, because the more probable symbol (MPS) is arranged in a lower portion at a step S505. At a step S506, if the updated region width value A is smaller than 0.5, then the normalizing process operation is carried out in such a manner that both the region width value A and the code value C are multiplied by an exponent of 2 until this region width value A becomes larger than, or equal to 0.5 by calling RENORMAL of a step S507.
At a step S508, the occurrence frequency of the more probable symbol (MPS) value is counted by calling UPDATEMPS. When the judgment result becomes N0 at the step S504, the normalizing process operation is carried out at a step 508 in such a manner that the region width value (A-AL) corresponding to the lower more probable symbol (MPS) is added to the code value C equal to the region lower limit value, the region width value A is updated by the region width value AL corresponding to the less probable symbol (LPS), and both the region width value A and the code value C are multiplied by an exponent of 2 until the region width value A becomes larger than, or equal to 0.5 by calling RENORMALIZE, because at this time, the region width value A necessarily becomes smaller than 0.5. At a step S510, the occurrence frequency of the less probable symbol (LPS) value is counted by calling UPDATELPS. At a step S511, in such a case that the count value of the occurrence frequency updated at the steps S508 and S510 by calling COUNTCHECK becomes larger than a constant, both the occurrence frequency (counter value) of the data 0 and the occurrence frequency (counter value) of the data 1 are reduced by 1/2 at the same time.
Now, in this case, as to the counter in, for example, an UPDATEL process (otherwise UPDATEM process), when the value of the constant T1 (or T2) equal to the maximum count value is the m-th power of 2, in order to realize by a binary counter with m digits, generally speaking, if the m-th power of 2 is expressed in the counter with m digits, then the overflow will occur and thus the count value becomes 0. There is no contradictory case that since the occurrence frequency 0 could not be realized, it is handled as the m-th power of 2 during the probability estimating calculation (step S502). Alternatively, the counter continuously may count the occurrence frequencies smaller than the actual occurrence frequencies by 1 (initial value being 0), and 1 may be added to the respective count values during the probability estimating calculation (step S502). In any cases, in the 1/2 reduction process, as to the counter with the overflowed digit, the count value must be updated as T1/2 (or T2/2). It should be noted that if there is no problem even when the counter overflows, the 1/2 reduction process operation may be carried out in the conventional manner.
At a step 512, a check is done as to whether or not the processed data S is the last data. If the processed data S is not the last data, then the process operation defined from the step S502 to the step 511 is repeatedly performed. At a step 513, a post process operation of the coding operation is performed. That is, 16 bits of a decimal portion (precision FLUSHBIT=16) of the code value C are multiplied by the 16-th power of 2, and then the multiplied 16 bits are outputted to the integer portion. This "16" is added to the code length LEN to produce a total code length. In summary, when the digital signal (data signal) is coded, both the more probable symbol (MPS) equal to such a symbol having high occurrence probability, and also the less probable symbol (LPS) equal to such a symbol having low occurrence probability are made in correspondence with a preselected range on a numerical straight line based upon a range (A 1-t ) of the previous symbol on the numerical straight line, and a predetermined range (AL) of the less probable symbol (LPS) on the numerical straight line. Thereafter, the coordinate values of these symbols on the numerical straight line are outputted as the code word. It should be noted that the general content of this coding operation is described more in detail in Japanese Patent Publication No.8-34434 published in 1996.
FIG. 5 is a flow chart for describing a process sequential operation of the normalizing process RENORMALIZE of the arithmetic coding variable, in which an arithmetic code length (LEN) is counted from the operation times thereof at the same time. At a step S520, the region width value A and the code value C are multiplied by 2, and 1 is added to the code length LEN. At a step 521, when the region width value A is smaller than 0.5, the process operation defined at the step S520 is repeatedly executed until this region width value A becomes larger than, or equal to 0.5. In this case, 1 bit of the code is outputted from the decimal portion to the integer portion every time the region width value A and the code value C are multiplied by 2.
FIG. 6 is a flow chart for showing a process sequential operation of UPDATEMPS for counting the occurrence frequency of the more probable symbol (MPS). At a step S540, 1 is added to an occurrence frequency counter N MPS of a more probable symbol (MPS) value MPS.
FIG. 7 is a flow chart for showing a process sequential operation of UPDATELPS for counting the occurrence frequency of the less probable symbol (LPS). At a step S560, 1 is added to an occurrence frequency counter N LPS of a less probable symbol (LPS) value LPS. At a step S561, if the occurrence frequency counter N LPS of the less probable symbol (LPS) is larger than the occurrence frequency N MPS of the more probable symbol (MPS), both the more probable symbol (MPS) value MPS and the less probable symbol (LPS) value LPS are inverted, namely replaced at a step S562.
FIG. 8 is a flow chart for describing a process sequential operation of COUNTCHECK in which the count value is reduced by 1/2 when the count value of the updated occurrence frequency becomes larger than a predetermined value. At a step S580, a judgment is made as to whether or not the occurrence frequency N LPS of the less probable symbol (LPS) is larger than, or equal to the set value T1, otherwise whether or not the occurrence frequency N MPS of the more probable symbol (MPS) is larger than, or equal to the set value T2. At a step 582, such a 1/2-reduction process operation is carried out ion such a way that, for instance, 1 is added to the respective occurrence frequencies N LPS and N MPS of the less probable symbol (LPS) and the more probable symbol (MPS), and then the added occurrence frequencies are multiplied by 1/2. The reason why after 1 is added to the respective symbol occurrence frequencies, the added occurrence frequencies are multiplied by 1/2 is such that these occurrence frequencies are not equal to 0.
It should also be noted that the above-described process sequential operations are directed to the single context. Alternatively, a multi-context may be processed. When the multi-context is handled, at the step 502, the below-mentioned variables may be processed while the context CX is acquired at the same time with the data value, and the acquired context is used as an array (table) in which the context CX is employed as an index.
For instance, a variable MPS(CX) is used as a more probable symbol (MPS) value; a variable LPS(CX) is employed as a less probable symbol (LPS) value (1-MPS(CX)); a variable N0(CX) is used as an occurrence frequency (counter) of data 0; a variable N1(CX) is employed as an occurrence frequency (counter) of data 1; a variables N LPS (CX) is used as min (N0(CX), N1(CX)) (corresponding to first characteristic MIN); and a variable N MPS(CX) is employed as max (N0(CX), N1(CX)) (corresponding to second characteristic MAX).
Then, assuming now that occurrence probability p0 of data is constant, a calculation was made of a coding efficiency E=H(p0)/LEN based on entropy H(p0) obtained from the set occurrence probability and also the code length LEN obtained from the simulation. Also, as the constant condition of the simulation, it is set by that T1=2 and T2=8. While the occurrence probability p0 of the data is changed and also the respective data lengths are selected to be 100000, the coding operation was carried out with the single context. The coding result is indicated in FIG. 3.
In the above description, the coding efficiency is calculated (see FIG. 3) by setting the variables (array in multi-context) to the more probable symbol (MPS) value MPS. Even when the occurrence frequencies are identical to each other, since the multiplication type arithmetic coding operation is executed, only the code length loss occurs, which is caused by the digit cancelling error due to such a fact that the fixed data value is allocated as the more probable symbol (MPS). It should be understood that although the more probable symbol (MPS) value is inverted at the step S562 of FIG. 7, it may be regarded that the more probable symbol (MPS) value is not used as the fixed data value, but is discriminated at the time when the occurrence frequencies are identical to each other. Also, even when the arithmetic coding unit is arranged in such a manner that the integer portion also owns the finite precision, the codes are outputted outside in the unit of N bits, for example, 8 bits (1 byte), and the bits sequentially overflowed can be neglected, this arrangement gives no adverse influence to the above-explained effects capable of improving the probability estimating precision and also the coding efficiency irrelevant to the control method for the carry propagate process operation required thereto. Also, in this arithmetic coding unit, the more probable symbol (MPS) is arranged at the lower portion with respect to the less probable symbol (LPS). Alternatively, this more probable symbol (MPS) may be arranged at the upper portion. With respect to the given binary data, the binary arithmetic coding operation is applied to the arithmetic coding unit. When the multi-value data is given, this binary arithmetic coding operation may be replaced by a multi-value arithmetic coding operation. With respect to the single context, each of the counters and the predicted value are employed as a pair. With respect to a multi-context, plural pairs of the counters and the predicted values may be employed which are identical to a total number of contexts. Furthermore, this gives no adverse influence to the effect capable of essentially improving the probability estimating precision and the coding efficiency irrelevant to the correction process from the final code value to the minimum effective digit, and the removing process of the code bit 0 subsequent to the terminal. It should be noted in the embodiment 1 that preselected values may be used as the constants T1 and T2.
EMBODIMENT 2
FIG. 9 is a flow chart for describing an arithmetic coding process sequential operation according to a second embodiment of the present invention. Since this coding process sequential operation is similar to that of the first embodiment shown in FIG. 4, only changed process operations will now be explained. At a step S590, a count value of an occurrence frequency counter as to the step 500 is set as the occurrence frequency N LPS of the less probable symbol (LPS), and a total N TOTAL of occurrence frequencies of the less probable symbol (LPS) and the more probable symbol (MPS), whereas initial values of N LPS and N TOTAL are 1, and 2, respectively. At a step S591, a denominator of such a calculation by which the probability P of the less probable symbol (LPS) is obtained from the occurrence frequency is set to N TOTAL from a summation between N MPS and N LPS.
Since a flow chart shown in FIG. 10 is similar to that of FIG. 6, a description will now be made of only changed process sequential operations. At a step S600, a count value of the occurrence frequency counter N MPS for the more probable symbol (MPS) at the step 504 is set as a count value of a total T TOTAL made of the occurrence frequencies of the more probable symbol (MPS) and of the less probable symbol (LPS).
Since a flow chart shown in FIG. 11 is similar to that of FIG. 7, a description will now be made of only changed process sequential operations. At a step S610 a counting process operation is newly added to count a count value of a total T TOTAL made of the occurrence frequencies of the more probable symbol (MPS) and of the less probable symbol (LPS) at the step S560. Also, at a step S611, a judgment is made as to whether or not two times of the occurrence frequency N LPS of the less probable symbol (LPS) are larger than a total N TOTAL of the occurrence frequencies for the less probable symbol (LPS) and the more probable symbol (MPS). In other words, a check is made as to whether or not the occurrence frequency N LPS exceeds a half value of the total N TOTAL. If N LPS exceeds N TOTAL, then the more probable symbol (MPS) value MPS and the less probable symbol (LPS) value LPS are inverted at a step S562.
Since a flow chart shown in FIG. 12 is similar to that of FIG. 8, a description will now be made of only changed process sequential operations. At a step S620 and a step S621, a judging operation (S620) and a counting operation (S621) are performed based on a count value of the occurrence frequency counter N MPS for the more probable symbol (MPS) at the steps 581 and 582 to a count value of a total N TOTAL made of the occurrence frequencies of the more probable symbol (MPS) and of the less probable symbol (LPS).
Similar to embodiment 1, in accordance with embodiment 2, assuming now that the occurrence frequency p0 of the data is constant, the coding efficiency E=H(p0)/LEN was calculated from the entropy H(p0) obtained from the set occurrence probability and also the code length (LEN) obtained from the simulation. As the constant condition of the simulation, it is set T1=2 and T2=8. While the occurrence frequency p0 of the data is varied, the respective data lengths are set to 100000. Then, the coding process operation was carried out by a single context. The coding results are indicated in FIG. 13.
As previously described, in accordance with the above-explained embodiment 1 and embodiment 2, the arithmetic coding process operation is applied to the entropy coding device, and the minimum process operation required to calculate the code length thereof is carried out. In the drawings, the process operation by the arithmetic coding unit is defined by the steps S501, S503, S505 to S507, and S509. Such a fact that the probability estimator can be separated from the arithmetic coding unit implies that the arithmetic coding unit as previously explained as one example can be replaced by another entropy coding unit. This fact may be similarly interpreted in all of the below-mentioned embodiments. Also, as the entire process flow, such an explanation will be made of such a case that the arithmetic coding is applied so as to calculate the code length for the performance evaluation since only the information is used which can be commonly referred to the decoding operation, the probability predicted value during the decoding operation can be completely reproduced.
EMBODIMENT 3
Similar to embodiment 1 and embodiment 2, there is shown a coding process sequential operation according to embodiment 3 of the present invention when the arithmetic coding operation is applied to the binary data. It should be understood that variables and constants employed in this coding process sequential operation are similar to those used in embodiment 1 and 2.
FIG. 14 indicates a flow chart for explaining the coding process sequential operation according to embodiment 3. A characteristic difference of embodiment 3 from embodiments 1 and 2 is such that the step S511 is interposed between the step S503 and the step 504, and the contents of other process steps are not changed.
At the COUNTCHECK step S511, a comparison is made between the occurrence frequency value N LPS of the less probable symbol (LPS) and a predetermined value T1. When N LPS is greater than T1, the value of the occurrence frequency N1 of the data 1 is reduced by 1/2. Also, at the COUNTCHECK step A511, the occurrence frequency value N MPS of the more probable symbol (MPS) is compared with a preselected value T2, and if N MPS is larger than T2, then the value of the occurrence frequency N2 of the data is reduced by 1/2.
In this case, in accordance with embodiment 3 in which the 1/2 reduction process is carried out after estimating the probability, since a total quantity of combinations (conditions) of the counter values becomes large, the coding efficiency can be improved, as compared with the above-explained embodiments 1 and 2, in which the 1/2 reduction process is carried out immediately after the occurrence frequency of the less probable symbol (LPS) becomes T1 and the occurrence frequency of the more probable symbol (MPS) becomes T2, namely before estimating the probability.
For example, in the conventional mode, since the counter value is updated by a half value thereof, even when, for instance, the total of the more probable symbol (MPS)s and the less probable symbol (LPS)s and also the respective count values of the less probable symbol (LPS)s are equal to any of (8, 1) and (8, 2), the probability estimated after being updated by (4, 1) becomes 1/4.
In accordance with embodiment 3, if the respective count values are updated by 1/2 after the probability has been estimated, then the respective counter values can be discriminated as 1/8 and 2/8 in the above example. As a result, since the conditions of the probability value can be further classified, the coding efficiency can be increased.
FIG. 15 represents the results capable of increasing the coding efficiency. In FIG. 15, assuming now that the occurrence frequency p0 of the data is constant, the coding efficiency E=H(p0)/LEN was calculated from the entropy H(p0) obtained from the set occurrence probability and also the code length (LEN) obtained from the simulation. As the constant condition of the simulation, similar to embodiment 1, it is set T1=2 and T2=8. While the occurrence frequency p0 of the data is varied, the respective data lengths are set to 100000. Then, the coding process operation was carried out by a single context.
It should also be understood that even when the arithmetic coding unit is arranged in such a manner that the integer portion also owns the finite precision, the codes are outputted outside in the unit of N bits, for example, 8 bits (1 byte), and the bits sequentially overflowed can be neglected, this arrangement gives no adverse influence to the above-explained effects capable of improving the probability estimating precision and also the coding efficiency irrelevant to the control method for the carry propagate process operation required thereto.
Also, in this arithmetic coding unit, the more probable symbol (MPS) is arranged at the lower portion with respect to the less probable symbol (LPS). Alternatively, this more probable symbol (MPS) may be arranged at the upper portion. With respect to the given binary data, the binary arithmetic coding operation is applied to the arithmetic coding unit. When the multi-value data is given, this binary arithmetic coding operation may be replaced by a multi-value arithmetic coding operation. With respect to the single context, each of the counters and the predicted value are employed as a pair. With respect to a multi-context, plural pairs of the counters and the predicted values may be employed which are identical to a total number of contexts.
Furthermore, this gives no adverse influence to the effect capable of essentially improving the probability estimating precision and the coding efficiency irrelevant to the correction process from the final code value to the minimum effective digit, and the removing process of the code bit 0 subsequent to the terminal.
It should be noted in embodiment 3 that preselected values may be used as the constants T1 and T2.
EMBODIMENT 4
Similar to embodiment 1 and embodiment 2, there is shown a coding process sequential operation according to embodiment 4 of the present invention when the arithmetic coding operation is applied to the binary data. It should be understood that variables and constants employed in this coding process sequential operation are similar to those used in embodiments 1 and 2.
This coding process sequential operation is indicated in FIG. 16.
A difference between the flow chart of embodiment 4 shown in FIG. 16 and the detailed flow chart of UPDATEMPS of embodiment 1 is such that at a step S541, a counting operation is carried out only when the occurrence frequency N MPS of the more probable symbol (MPS) is smaller than the constant value T2 equal to the maximum count value.
A difference between a flow chart of embodiment 4 shown in FIG. 17 and the detailed flow chart of COUNTCHECK of embodiment 1 is such that the step S581 is replaced by a step S583, and the 1/2 reduction process defined at the step S528 is carried out in the case that the occurrence frequency N MPS of the more probable symbol (MPS) is larger than the constant value T2, and furthermore, the occurrence frequency N LPS of the less probable symbol (LPS) is larger than 1 as an additional condition.
In this case, since the execution of the 1/2 reduction process is brought into the waiting condition only when the occurrence frequency N MPS of the more probable symbol (MPS) is equal to the constant value T2 corresponding to the maximum count value, and furthermore the occurrence frequency N LPS of the less probable symbol (LPS) is equal to 1 at the step S582, there is a possibility that the occurrence frequency of the more probable symbol (MPS) becomes T2 at the step S541. At this case, no counting operation is carried out.
In this case, the error of the estimated probability occurred when the counting process operation is not carried out with respect to the occurrence of the more probable symbol (MPS), under (N MPS=T2, N LPS=1), and also the execution of the 1/2 reduction process operation is waited (see FIG. 19) can be made smaller with respect to such an ideal case that the counting operation can be infinitely carried out without considering the maximum value of the counter, as compared with such an embodiment mode 1 that the 1/2 reduction process operation is carried out under no restriction (see FIG. 18) immediately after the occurrence frequency of either the less probable symbol (LPS) or the more probable symbol (MPS) becomes maximum.
For instance, in the prior art, after the count value is updated, in particular, when the count value of the less probable symbol (LPS) becomes 1, the probability estimating error is enlarged, so that the coding efficiency is lowered.
Therefore, in accordance with this embodiment, when the count value of the less probable symbol (LPS) becomes 1, this count value is not updated by 1/2, but the count value remains. As a consequence, the probability estimating error can be made smaller and the coding efficiency can be increased.
FIG. 20 indicates results representative of increasing of the coding efficiency achieved by embodiment 4. In FIG. 20, assuming now that the occurrence frequency p0 of the data is constant, the coding efficiency E=H(p0)/LEN was calculated from the entropy H(p0) obtained from the set occurrence probability and also the code length (LEN) obtained from the simulation. As the constant condition of the simulation, it is set T1=2 and T2=8 similar to the embodiment mode 1. While the occurrence frequency p0 of the data is varied, the respective data lengths are set to 100000. Then, the coding process operation was carried out by a single context.
Since the counting operation of the occurrence frequency is stopped, the coding efficiency is increased in such a case that the probability of the less probable symbol (LPS) is located near an inverse number (1/T2) of a maximum value of a total number of the more probable symbol (MPS) and the less probable symbol (LPS). When the probability is smaller than this inverse number (1/T2), the estimated error is increased, so that the coding efficiency is lowered. However, this coding efficiency is increased, as compared with such a case that the counting operation of the occurrence frequency is not stopped.
It should also be noted that even when the arithmetic coding unit is arranged in such a manner that the integer portion also owns the finite precision, the codes are outputted outside in the unit of N bits, for example, 8 bits (1 byte), and the bits sequentially overflowed can be neglected, this arrangement gives no adverse influence to the above-explained effects capable of improving the probability estimating precision and also the coding efficiency irrelevant to the control method for the carry propagate process operation required thereto.
Also, in this arithmetic coding unit, the more probable symbol (MPS) is arranged at the lower portion with respect to the less probable symbol (LPS). Alternatively, this more probable symbol (MPS) may be arranged at the upper portion. With respect to the given binary data, the binary arithmetic coding operation is applied to the arithmetic coding unit. When the multi-value data is given, this binary arithmetic coding operation may be replaced by a multi-value arithmetic coding operation. With respect to the single context, each of the counters and the predicted value are employed as a pair. With respect to a multi-context, plural pairs of the counters and the predicted values may be employed which are identical to a total number of contexts.
Furthermore, this gives no adverse influence to the effect capable of essentially improving the probability estimating precision and the coding efficiency irrelevant to the correction process from the final code value to the minimum effective digit, and the removing process of the code bit 0 subsequent to the terminal.
It should be noted in embodiment 4 that preselected values may be used as the constants T1 and T2.
EMBODIMENT 5
Similar to embodiment 1 and embodiment 2, there is shown a coding process sequential operation according to embodiment 5 of the present invention when the arithmetic coding operation is applied to the binary data. It should be understood that variables and constants employed in this coding process sequential operation are similar to those used in embodiments 1 and 2.
The coding process sequential operation according to embodiment 5 is so arranged by that the flow charts shown in FIG. 16 and FIG. 17 according to embodiment 4 are applied to the flow chart shown in FIG. 4.
In this arrangement, since the 1/2 reduction process operation is brought into the waiting condition only when the occurrence frequency of the more probable symbol (MPS) is equal to the constant value T2 corresponding to the maximum count value and also the occurrence frequency of the less probable symbol (LPS) is equal to 1, the probability value 1/T2 at this time is increased with respect to that of the embodiment mode 1.
FIG. 21 represents the results capable of increasing the coding efficiency. In FIG. 21, assuming now that the occurrence frequency p0 of the data is constant, the coding efficiency E=H(p0)/LEN was calculated from the entropy H(p0) obtained from the set occurrence probability and also the code length (LEN) obtained from the simulation. As the constant condition of the simulation, similar to embodiment 1, it is set T1=2 and T2=8. While the occurrence frequency p0 of the data is varied, the respective data lengths are set to 100000. Then, the coding process operation was carried out by a single context.
It should also be understood that even when the arithmetic coding unit is arranged in such a manner that the integer portion also owns the finite precision, the codes are outputted outside in the unit of N bits, for example, 8 bits (1 byte), and the bits sequentially overflowed can be neglected, this arrangement gives no adverse influence to the above-explained effects capable of improving the probability estimating precision and also the coding efficiency irrelevant to the control method for the carry propagate process operation required thereto.
Also, in this arithmetic coding unit, the more probable symbol (MPS) is arranged at the lower portion with respect to the less probable symbol (LPS). Alternatively, this more probable symbol (MPS) may be arranged at the upper portion. With respect to the given binary data, the binary arithmetic coding operation is applied to the arithmetic coding unit. When the multi-value data is given, this binary arithmetic coding operation may be replaced by a multi-value arithmetic coding operation. With respect to the single context, each of the counters and the predicted value are employed as a pair. With respect to a multi-context, plural pairs of the counters and the predicted values may be employed which are identical to a total number of contexts.
Furthermore, this gives no adverse influence to the effect capable of essentially improving the probability estimating precision and the coding efficiency irrelevant to the correction process from the final code value to the minimum effective digit, and the removing process of the code bit 0 subsequent to the terminal.
It should be noted in the embodiment mode 5 that preselected values may be used as the constants T1 and T2.
The effects/advantages of the above-described embodiment 1 to 5 will now be explained.
As to embodiment 3 (FIG. 15), embodiment 4 (FIG. 20), and embodiment 5 (FIG. 21), there are represented the coding efficiencies under condition of T1=2 and T2=8. The state transitions at this time will now be explained with reference to FIG. 22. In this drawing, a state surrounded by a broken line indicates such a state used to estimate the probability when the 1/2 reduction process operation is carried out just after the occurred symbols are counted in embodiment 3. A state surrounded by a solid line indicates such a state employed to estimate the probability when the 1/2 reduction process operation is carried out immediately before the occurred symbols are counted in embodiment 3 and embodiment 4. In embodiment 5, both (N0=8, N1=1) and (N0=1, N1=8) are added to the state of embodiment 1. Any of these states represent transitable states except for the states stayed only in the initial transition stage. For instance, (N0=1, N1=1) is achieved only under initial condition. Both (N0=8, N1=2) and (N0=2, N1=8) are used only when under (N0=8, N1=1) and (N0=1, N1=8), the occurrences of the more probable symbol (MPS)s are not counted in embodiment 4 and embodiment 5. A total number of states is either 13 (embodiment 1) or 15 (embodiment 5) in such a case that the 1/2 reduction process operation is performed just after the symbol occurrence is counted (a portion surrounded by a broken line). A total number of states is either 25 (embodiment 3) is or 15 (embodiment 4) in such a case that the 1/2 reduction process operation is performed just before the symbol occurrence is counted. As a consequence, there are the larger total number of states in the case that the 1/2 reduction process operation is carried out immediately before the symbol occurrence is counted.
Also, for example, when the constants T1 are different from each other, namely when T1=8 and T2=8 (FIG. 23), the total number of states are 40, 47, 47, 42 in this order of embodiments 1, 2, 4, and 5. When T1=4 and T2=8 (FIG. 24), the number of states are 28, 38, 38, 40 in this order of embodiments 1, 2, 4, and 5.
Furthermore, when the more probable symbol (MPS)s are discriminated, only such the number of states under which a total number of N0 becomes equal to a total number of N1 within the surrounded frame are increased. This discriminatively indicates that the occurrence frequency is transferred to the same number of states, depending upon the transition (longitudinal direction) by the appearance of the data value 0, and the transition (lateral direction) by the appearance of the data value 1 in this drawing. In these examples, since the arithmetic coding operation with employment of the multiplication is applied as the entropy coding device, the size of the effective region can be equally divided. However, in the case of the subtraction type arithmetic coding operation for reducing the calculation load, the fixed value and the remainder thereof are allocated to the size of the effective region. As a consequence, at this time, the coding efficiency is increased by allocating the larger region to the more probable symbol (MPS) having the high occurrence probability.
In the case that an occurrence frequency is counted by a binary counter with 3 digits, when 8 is set as the maximum count value T2, this binary counter is overflowed. However, since there is no possibility that the occurrence frequency becomes 0, if this occurrence frequency is interpreted as the substitution of 8, then this occurrence frequency counting operation can be realized without extending the digit number of the binary counter, while maintaining the 3 digits. Also, the occurrence frequencies with respect to the respective contexts are stored into a memory. After the counting process operation and the 1/2 reduction process operation have been carried out with respect to the read frequency values, the processed frequency values are again written into this memory, so that a total quantity of calculators can be reduced in packaging.
EMBODIMENT 6
Embodiment 4 and embodiment 5 have described that the coding efficiency could be increased in such a manner that even when the occurrence frequency of the more probable symbol (MPS) becomes T2, if the occurrence frequency of the less probable symbol (LPS) is equal to 1, then no 1/2 reduction process operation is carried out. Embodiment 6 is featured by that as one example, while the embodiment 4 is employed as a basic idea, two constants are further introduced, and a state is increased such that the occurrence frequency of the more probable symbol (MPS) becomes larger than, or equal to T3, and also the occurrence frequency of the less probable symbol (LPS) becomes smaller than, or equal to T4. FIG. 25 indicates a state transition diagram in the case that T1=4, T2=10, T3=8, and T4=2. Such a state that the occurrence frequency N MPS of the more probable symbol (MPS) is smaller than, or equal to T3 is similar to the state previously explained in the embodiment mode 4. Next, a calculation is made of performance in such a case that the 1/2 reduction process operation is brought into the waiting condition when (N TOTAL=T2, N LPS=1).
It should be noted that symbol "T3" indicates an intermediate value of N TOTAL (otherwise N MPS); symbol "IT4" shows an intermediate value of N LPS; symbol "T3" represents a third threshold; and symbol "T4" denotes a fourth threshold value.
In FIG. 26 and FIG. 27, there are shown a coding process sequential operation according to embodiment 6 in flow chart form.
A difference of this coding process sequential operation (see FIG. 26) according to embodiment 6 from that (see FIG. 16) of embodiment 4 is given as follows: That is, when the occurrence frequency N MPS of the more probable symbol (MPS) is smaller than the constant value T3 at a step S542, or when the occurrence frequency N MPS of the more probable symbol (MPS) is smaller than the constant value T2 corresponding to the maximum count value, and further the occurrence frequency N LPS of the less probable symbol (LPS) is smaller than the constant value T4 at a step S543, the occurrence frequency N MPS of the more probable symbol (MPS) is counted at a step S540.
A difference of this coding process sequential operation (see FIG. 27) according to embodiment 6 from that (see FIG. 17) of embodiment 4 is given as follows: That is, the step S583 is replaced by the steps S584 and S585. Also, in such a case that the occurrence frequency N MPS of the more probable symbol (MPS) is larger than, or equal to the constant value T3 and smaller than the constant value T2, as well as the occurrence frequency N LPS of the less probable symbol (LPS) is larger than the constant value T4 at a step 583, the 1/2 reduction process operation defined at the step S582 is carried out. Otherwise, in such a case that the occurrence frequency N MPS of the more probable symbol (MPS) is larger than the constant value T2 corresponding to the maximum count value, as well as the occurrence frequency N LPS of the less probable symbol (LPS) is larger than 1, the above-described 1/2 reduction process operation defined at the step S582 is carried out.
FIG. 28 represents the results capable of increasing the coding efficiency of this embodiment. In FIG. 28, assuming now that the occurrence frequency p0 of the data is constant, the coding efficiency E=H(p0)/LEN was calculated from the entropy H(p0) obtained from the set occurrence probability and also the code length (LEN) obtained from the simulation. As the constant condition of the simulation, it is set T1=8 (T1 having substantially no meaning), T2=10, T3=8, and T4=2, which are acquired by extending the embodiment mode 1. While the occurrence frequency p0 of the data is varied, the respective data lengths are set to 100000. Then, the coding process operation was carried out by a single context.
It should also be understood that even when the arithmetic coding unit is arranged in such a manner that the integer portion also owns the finite precision, the codes are outputted outside in the unit of N bits, for example, 8 bits (1 byte), and the bits sequentially overflowed can be neglected, this arrangement gives no adverse influence to the above-explained effects capable of improving the probability estimating precision and also the coding efficiency irrelevant to the control method for the carry propagate process operation required thereto.
Also, in this arithmetic coding unit, the more probable symbol (MPS) is arranged at the lower portion with respect to the less probable symbol (LPS). Alternatively, this more probable symbol (MPS) may be arranged at the upper portion. With respect to the given binary data, the binary arithmetic coding operation is applied to the arithmetic coding unit. When the multi-value data is given, this binary arithmetic coding operation may be replaced by a multi-value arithmetic coding operation. With respect to the single context, each of the counters and the predicted value are employed as a pair. With respect to a multi-context, plural pairs of the counters and the predicted values may be employed which are identical to a total number of contexts.
Also, this gives no adverse influence to the effect capable of essentially improving the probability estimating precision and the coding efficiency irrelevant to the correction process from the final code value to the minimum effective digit, and the removing process of the code bit 0 subsequent to the terminal.
It should be noted in embodiment 6 that preselected values may be used as the constants T1, T2, T3, and T4.
EMBODIMENT 7
In the previously explained embodiments, the variable related to either the constant T2 or the constant T3 has been explained as the occurrence frequency N MPS of the more probable symbol (MPS). It should be understood that a summation between an occurrence frequency of a more probable symbol (MPS) and an occurrence frequency of a less probable symbol (LPS) is employed as this variable in the below-mentioned embodiments.
In the coding process sequential operation according to embodiment 7, the coding process sequential operation of embodiment 3 is changed by that the occurrence frequency counter of the more probable symbol (MPS) is used as a counter for a total occurrence frequency of a more probable symbol (MPS) and a less probable symbol (LPS).
That is, the coding process sequential operation according to embodiment 7 is represented in FIG. 29.
Similar to the relationship with embodiment 3, the coding process sequential operation shown in FIG. 29 is featured by that a call COUNTCHECK step S511 is interposed between the step S503 and the step 504. Other process sequential operations of embodiment 7 are not changed.
FIG. 30 represents the results capable of increasing the coding efficiency. In FIG. 30, assuming now that the occurrence frequency p0 of the data is constant, the coding efficiency E=H(p0)/LEN was calculated from the entropy H(p0) obtained from the set occurrence probability and also the code length (LEN) obtained from the simulation. As the constant condition of the simulation, similar to embodiment 4, it is set T1=4 and T2=8. While the occurrence frequency p0 of the data is varied, the respective data lengths are set to 100000. Then, the coding process operation was carried out by a single context.
It should also be understood that even when the arithmetic coding unit is arranged in such a manner that the integer portion also owns the finite precision, the codes are outputted outside in the unit of N bits, for example, 8 bits (1 byte), and the bits sequentially overflowed can be neglected, this arrangement gives no adverse influence to the above-explained effects capable of improving the probability estimating precision and also the coding efficiency irrelevant to the control method for the carry propagate process operation required thereto.
Also, in this arithmetic coding unit, the more probable symbol (MPS) is arranged at the lower portion with respect to the less probable symbol (LPS). Alternatively, this more probable symbol (MPS) may be arranged at the upper portion. With respect to the given binary data, the binary arithmetic coding operation is applied to the arithmetic coding unit. When the multi-value data is given, this binary arithmetic coding operation may be replaced by a multi-value arithmetic coding operation. With respect to the single context, each of the counters and the predicted value are employed as a pair. With respect to a multi-context, plural pairs of the counters and the predicted values may be employed which are identical to a total number of contexts.
Also, this gives no adverse influence to the effect capable of essentially improving the probability estimating precision and the coding efficiency, according to the present invention, irrelevant to the correction process from the final code value to the minimum effective digit, and the removing process of the code bit 0 subsequent to the terminal.
It should be noted in embodiment 7 that preselected values may be used as the constants T1 and T2.
EMBODIMENT 8
In a coding process sequential operation according to embodiment 8, the coding process sequential operation of embodiment 4 is changed by that the occurrence frequency counter of the more probable symbol (MPS) is used as a counter for a total occurrence frequency of a more probable symbol (MPS) and a less probable symbol (LPS).
That is, the coding process sequential operation according to embodiment 8 is represented in FIG. 31 and FIG. 32.
Similar to the relationship with embodiment 1 and embodiment 3, the coding process sequential operation described in FIG. 31 is featured by that a judgment defined at a step S630 is newly added, and if a total N TOTAL of the occurrence frequencies of the more probable symbol (MPS) and the less probable symbol (LPS) become T2, then the counting operation of the occurrence frequency is not performed.
Similar to the relationship with the embodiment mode 1 and embodiment 3, the coding process sequential operation described in FIG. 32 is featured by that a judgment defined at a step S640 is changed. Also, in the case that the total N TOTAL of the occurrence frequencies of the more probable symbol (MPS) and the less probable symbol (LPS) is larger than, or equal to T2, as well as the occurrence frequency N LPS of the less probable symbol (LPS) is larger than, or equal to 1, the 1/2 reduction process operation of the occurrence frequency is carried out.
FIG. 33 represents the results capable of increasing the coding efficiency. In FIG. 33, assuming now that the occurrence frequency p0 of the data is constant, the coding efficiency E=H(p0)/LEN was calculated from the entropy H(p0) obtained from the set occurrence probability and also the code length (LEN) obtained from the simulation. As the constant condition of the simulation, similar to embodiment 2, it is set T1=4 and T2=8. While the occurrence frequency p0 of the data is varied, the respective data lengths are set to 100000. Then, the coding process operation was carried out by a single context.
It should also be understood that even when the arithmetic coding unit is arranged in such a manner that the integer portion also owns the finite precision, the codes are outputted outside in the unit of N bits, for example, 8 bits (1 byte), and the bits sequentially overflowed can be neglected, this arrangement gives no adverse influence to the above-explained effects capable of improving the probability estimating precision and also the coding efficiency irrelevant to the control method for the carry propagate process operation required thereto.
Also, in this arithmetic coding unit, the more probable symbol (MPS) is arranged at the lower portion with respect to the less probable symbol (LPS). Alternatively, this more probable symbol (MPS) may be arranged at the upper portion. With respect to the given binary data, the binary arithmetic coding operation is applied to the arithmetic coding unit. When the multi-value data is given, this binary arithmetic coding operation may be replaced by a multi-value arithmetic coding operation. With respect to the single context, each of the counters and the predicted value are employed as a pair. With respect to a multi-context, plural pairs of the counters and the predicted values may be employed which are identical to a total number of contexts.
Furthermore, this gives no adverse influence to the effect capable of essentially improving the probability estimating precision and the coding efficiency, according to the present invention (embodiment mode), irrelevant to the correction process from the final code value to the minimum effective digit, and the removing process of the code bit 0 subsequent to the terminal.
It should be noted in the embodiment mode 8 that preselected values may be used as the constants T1 and T2.
EMBODIMENT 9
In a coding process sequential operation according to embodiment 9, the coding process sequential operation of embodiment 5 is changed by that the occurrence frequency counter of the more probable symbol (MPS) is used as a counter for a total occurrence frequency of a more probable symbol (MPS) and a less probable symbol (LPS).
That is, the coding process sequential operation according to embodiment 9 is arranged in such a way that the flow operation of FIG. 29 in embodiment 8 is returned to the flow operation of FIG. 9 in embodiment 2 based on the flow operation of FIG. 5 in embodiment 1, the flow operations of FIG. 9 and FIG. 11 in embodiment 2, and the flow operations of FIG. 31 and FIG. 32 in embodiment 8.
FIG. 34 represents the results capable of increasing the coding efficiency. In FIG. 34, assuming now that the occurrence frequency p0 of the data is constant, the coding efficiency E=H(p0)/LEN was calculated from the entropy H(p0) obtained from the set occurrence probability and also the code length (LEN) obtained from the simulation. As the constant condition of the simulation, similar to embodiment 4, it is set T1=4 and T2=8. While the occurrence frequency p0 of the data is varied, the respective data lengths are set to 100000. Then, the coding process operation was carried out by a single context.
It should also be understood that even when the arithmetic coding unit is arranged in such a manner that the integer portion also owns the finite precision, the codes are outputted outside in the unit of N bits, for example, 8 bits (1 byte), and the bits sequentially overflowed can be neglected, this arrangement gives no adverse influence to the above-explained effects capable of improving the probability estimating precision and also the coding efficiency irrelevant to the control method for the carry propagate process operation required thereto.
Also, in this arithmetic coding unit, the more probable symbol (MPS) is arranged at the lower portion with respect to the less probable symbol (LPS). Alternatively, this more probable symbol (MPS) may be arranged at the upper portion. With respect to the given binary data, the binary arithmetic coding operation is applied to the arithmetic coding unit. When the multi-value data is given, this binary arithmetic coding operation may be replaced by a multi-value arithmetic coding operation. With respect to the single context, each of the counters and the predicted value are employed as a pair. With respect to a multi-context, plural pairs of the counters and the predicted values may be employed which are identical to a total number of contexts.
Furthermore, this gives no adverse influence to the effect capable of essentially improving the probability estimating precision and the coding efficiency, according to the present invention (embodiment mode), irrelevant to the correction process from the final code value to the minimum effective digit, and the removing process of the code bit 0 subsequent to the terminal.
It should be noted in embodiment 9 that preselected values may be used as the constants T1 and T2.
EMBODIMENT 10
In a coding process sequential operation according to embodiment 10, the coding process sequential operation of embodiment 6 is changed by that the occurrence frequency counter of the more probable symbol (MPS) is used as a counter for a total occurrence frequency of a more probable symbol (MPS) and a less probable symbol (LPS).
That is, the coding process sequential operation according to embodiment 10 is represented in FIG. 35 and FIG. 36.
A difference of the process sequential operation shown in FIG. 35 according to embodiment 10 from that of embodiment 6 is given as follows: When the total N TOTAL of the occurrence frequencies of the more probable symbol (MPS) and the less probable symbol (LPS) is smaller than the constant value T3 at a step S650, or when the total N TOTAL of the occurrence frequencies of the more probable symbol (MPS) and the less probable symbol (LPS) is smaller than the constant value T2 corresponding to the maximum count value, as well as the occurrence frequency N LPS of the less probable symbol (LPS) is smaller than the constant value T4 at a step S651, the total N TOTAL of the occurrence frequencies of the more probable symbol (MPS) and the less probable symbol (LPS) is counted at a step S652.
A difference of the process sequential operation shown in FIG. 36 according to embodiment 10 from that of embodiment 6 is given as follows: When the total N TOTAL of the occurrence frequencies of the more probable symbol (MPS) and the less probable symbol (LPS) is smaller than the constant value T2 and also larger than, or equal to the constant value T2, as well as the occurrence frequency N LPS of the less probable symbol (LPS) is larger than, or equal to the constant value T4 at a step S600, a 1/2 reduction process operation defined at a step S662 is carried out. Otherwise, when the total N TOTAL of the occurrence frequencies of the more probable symbol (MPS) and the less probable symbol (LPS) is larger than, or equal to the constant value T2 corresponding to the maximum count value, as well as the occurrence frequency N LPS of the less probable symbol (LPS) is larger than 1 at a step S661, the 1/2 reduction process operation defined at the step S662 is performed.
FIG. 37 represents the results capable of increasing the coding efficiency. In FIG. 37, assuming now that the occurrence frequency p0 of the data is constant, the coding efficiency E=H(p0)/LEN was calculated from the entropy H(p0) obtained from the set occurrence probability and also the code length (LEN) obtained from the simulation. As the constant condition of the simulation, similar to embodiment 8, it is set T1=4 (T1 having substantially no meaning), T2=10, T3=8, T4=2. While the occurrence frequency p0 of the data is varied, the respective data lengths are set to 100000. Then, the coding process operation was carried out by a single context.
It should also be understood that even when the arithmetic coding unit is arranged in such a manner that the integer portion also owns the finite precision, the codes are outputted outside in the unit of N bits, for example, 8 bits (1 byte), and the bits sequentially overflowed can be neglected, this arrangement gives no adverse influence to the above-explained effects capable of improving the probability estimating precision and also the coding efficiency irrelevant to the control method for the carry propagate process operation required thereto.
Also, in this arithmetic coding unit, the more probable symbol (MPS) is arranged at the lower portion with respect to the less probable symbol (LPS). Alternatively, this more probable symbol (MPS) may be arranged at the upper portion. With respect to the given binary data, the binary arithmetic coding operation is applied to the arithmetic coding unit. When the multi-value data is given, this binary arithmetic coding operation may be replaced by a multi-value arithmetic coding operation. With respect to the single context, each of the counters and the predicted value are employed as a pair. With respect to a multi-context, plural pairs of the counters and the predicted values may be employed which are identical to a total number of contexts.
Furthermore, this gives no adverse influence to the effect capable of essentially improving the probability estimating precision and the coding efficiency, according to the present invention (embodiment mode), irrelevant to the correction process from the final code value to the minimum effective digit, and the removing process of the code bit 0 subsequent to the terminal.
It should be noted in embodiment 10 that preselected values may be used as the constants T1, T2, T3, and T4.
In the above-described embodiment 7 to embodiment 10, in such a case that the total N TOTAL of the occurrence frequencies of the more probable symbol (MPS) and the less probable symbol (LPS) is counted, there is a possibility that it becomes (N TOTAL=T2+1, N LPS=2) when no counting process operation by the more probable symbol (MPS) is carried out under (N TOTAL=T2, N LPS=1), but the counting process operation is performed since the less probable symbol (LPS) occurs, so that the 1/2 reduction process operation is executed. In this case, as one example, when the sufficient precision/capacity are not secured in the counter, or the memory, only the less probable symbol (LPS) may be counted to be handled as (N TOTAL=T2, N LPS=2).
In such a case that if the total of the occurrence frequencies of the more probable symbol (MPS)s, or the occurrence frequencies of the more probable symbol (MPS) and also the less probable symbol (LPS) is equal to T2, as well as the occurrence frequency of the less probable symbol (LPS) is equal to 1, then the 1/2 reduction process operation is brought into the waiting condition, otherwise the counting operation of the more probable symbol (MPS) is not carried out, the 1/2 reduction process operation is not carried out when the occurrence frequency of the less probable symbol (LPS) becomes larger than, or equal to 2. As a consequence, for instance, even when the respective count values are directly reduced by 1/2, it can be guaranteed that the count value to be updated does not become 0. Also, all of the calculations of the 1/2 reduction values are not always equal to each other. For example, in the case of a specific value, e.g., an odd number, and an even number, otherwise in the case that the 1/2 reduction process operation is done based on the minimum value condition, or the maximum value condition, the individual calculations may be applied.
In summary, a coding method is featured by comprising a step for extracting a context of a supplied signal; an adaptive probability estimating step for estimating probability of the signals supplied from a signal source and the context; a step for encoding entropy so as to produce a replica of the encoded signal in response to the estimated probability upon receipt of the signal from the signal source; and a step for interfacing the encoded replica as an output to a transfer medium. At the adaptive probability estimating step, when the probability is estimated by an occurrence frequency of non-storage information data, preset values are added to the respective counter values, depending on such a fact as to whether such a count value of frequencies smaller than a frequency at which a count value for a certain context becomes a maximum value is equal to an odd number, or an even number, and thereafter the added counter values are reduced by 1/2.
Also, a coding method is featured by comprising a step for extracting a context of a supplied signal; an adaptive probability estimating step for estimating probability of the signals supplied from a signal source and the context; a step for encoding entropy so as to produce a replica of the encoded signal in response to the estimated probability upon receipt of the signal from the signal source; and a step for interfacing the encoded replica as an output to a transfer medium. At the adaptive probability estimating step, when the probability is estimated by an occurrence frequency of non-storage information data, if the count value is equal to 1 for a frequency smaller than a frequency at which the count value for a certain context becomes the maximum value, then the 1/2 reduction process operation of the count value is not carried out. Instead, while the count process operations of all of the frequencies for this context are stopped until the count value of the smaller frequency becomes 2, the probability estimated from this value is used as each of the estimated probability values.
Also, a coding method is featured by comprising a step for extracting a context of a supplied signal; an adaptive probability estimating step for estimating probability of the signals supplied from a signal source and the context; a step for encoding entropy so as to produce a replica of the encoded signal in response to the estimated probability upon receipt of the signal from the signal source; and a step for interfacing the encoded replica as an output to a transfer medium. At the adaptive probability estimating step, when the probability is estimated by an occurrence frequency of non-storage information data, in such a case that a count value for a certain context becomes a maximum value, the count value for this context is not directly reduced by 1/2. Instead, after a value preset by a count value of a smaller frequency has been added to this count value, the added count value is reduced by 1/2.
FIG. 38 is a perspective view for showing a structural example of an image processing apparatus 60 equipped with the adaptive coding method according to the above-explained embodiments 1 to 10.
In FIG. 38, the image processing apparatus 60 is equipped with a display unit 61, a keyboard 62, a mouse 63, a mouse pad 64, a system unit 65, and a compact disk apparatus 100.
As indicated in FIG. 38, the image processing apparatus according to this embodiment enters thereinto coded image information from the disk apparatus 100 (for instance, such a disk apparatus with using medium such as CD-ROM, FD, MO, PD or ZIP, and decodes this coded image information. Then, this image processing apparatus 60 transfers the decoded image information to the system unit 65 so as to be displayed on the display unit 61. The image processing apparatus 60 according to this embodiment may code image information displayed on the display unit 61 to thereby output this coded image information to the compact disk apparatus 100. Also, this image processing apparatus 60 may code image information and may transfer the coded image information via a line (not shown). However, the arrangement of the image processing apparatus according to this embodiment is not limited to the arrangement of the personal computer, or the workstation as shown in FIG. 38, but may be applied to any types of arrangements with using other components. For example, a video tape player may be employed as the input apparatus, instead of the compact disk apparatus 100. Alternatively, image data acquired from a network may be inputted instead of the above-described image information. Also, the input data may be made in an analog form, or a digital form.
Also, the image processing apparatus of this embodiment may be provided as an independent apparatus, as illustrated in FIG. 38. Alternatively, as shown in FIG. 39, this image processing apparatus may be realized by, as indicated in FIG. 39, peripheral apparatuses such as a printer 66, a scanner 68, a facsimile apparatus 69, a display apparatus (for example, display unit 61), and a storage apparatus (for instance, compact disk apparatus 100).
That is to say, the image processing apparatus of this embodiment implies any electronic appliance equipped with the adaptive coding methods, as previously described in the above-explained embodiments 1 to 10.
Also, the coding apparatus of this embodiment may be realized by employing an independent housing, or by being constituted as a portion of a system board, or a circuit board for a television camera, a measuring machine, and a computer. Alternatively, this coding apparatus may be realized by being constituted as a semiconductor chip. Although not shown in FIG. 39, the respective apparatuses indicated in FIG. 39 may be connected via a local area network (LAN), through which coded information may be transferred. Also, these apparatuses may be connected by employing a broadband network such as an ISDN (Integrated Services Digital Network), through which coded information may be transmitted/received.
Furthermore, the coding apparatus of this embodiment may be realized by using communication networks such as wired networks, radio communication networks, public/private communication lines, and electric/optical signal communication lines, through which coded information is transmitted/received.
As previously described, in accordance with embodiment 1 to embodiment 7, in such a coding method that only the occurrence frequency of data is stored as the variables or the array, in the case that the predicted value is judged from the largest occurrence frequency only by the counter for the respective data values, it is required to previously determine which value should be used as the predicted value when the occurrence frequencies are equal to each other. Also, in such a case that the values are roughly approximated in the calculation of the occurrence probability when the effective digit number is small, the predicted value calculated immediately before is made in correspondent with the larger occurrence probability. As a consequence, since this may be approximated to the occurrence trend of the preset data, the coding efficiency can be increased, as compared with the coding efficiency obtained when the predicted value is fixed.
Since the adaptive coding method according to the present invention has been arranged by employing the above-described process steps, the estimated probability error can be reduced and also the coding efficiency can be increased. | An adaptive coding method is comprised of: a fourth step (508), (510) for calculating an occurrence frequency of either the more probable symbol (MPS) or the less probable symbol (LPS) with respective to the entered input; a fifth step (511) for comparing an occurrence time accumulated value calculated as the occurrence frequency at the fourth step with a preselected value (threshold value), and for reducing the occurrence time accumulated value by 1/2 in the case that the occurrence time accumulated value reaches the preselected value (threshold value); and a sixth step (513) for defining the more probable symbol (MPS) and the less probable symbol (LPS) in correspondence with a predetermined region on a numerical line with respect to the data signal to thereby output coordinate values on the numerical line as a corded word. | 7 |
BACKGROUND
[0001] 1. Field
[0002] The present invention is related generally to wireless communication devices, and, more particularly, to a system and method for a distortion reduction calibration circuit in a wireless communication device.
[0003] 2. Description of the Related Art
[0004] Wireless communication systems are proliferating as more and more service providers add additional features and technical capabilities. A large number of service providers now occupy a relatively limited portion of the radio frequency spectrum. Due to this crowding, increased interference between wireless communication systems is commonplace. For example, wireless communication systems from two different service providers may occupy adjacent portions of the spectrum. In this situation, interference may be likely.
[0005] One example of such interference occurs in a code division multiple access (CDMA) wireless system. In one embodiment, a CDMA system occupies a portion of the frequency spectrum adjacent to a portion of the frequency spectrum allocated to a conventional cellular telephone system, sometimes referred to as an advanced mobile phone system (AMPS).
[0006] Conventional CDMA units attempt to eliminate undesirable signals by adding filters following the mixer stage. FIG. 1 illustrates one known implementation of a direct-to-baseband or low IF wireless system 10 in which a radio frequency (RF) stage 12 is coupled to an antenna 14 . The output of the RF stage 12 is coupled to an amplifier 16 , which amplifies the radio frequency signals. It should be noted that the RF stage 12 and the amplifier 16 may include conventional components such as amplifiers, filters, and the like. The operation of these stages is well known and need not be described in greater detail herein.
[0007] The output of the amplifier 16 is coupled to a splitter 18 that splits the processed signal into two identical signals for additional processing by a mixer 20 . The splitter 18 may be an electronic circuit or, in its simplest form, just a wire connection. The mixer 20 comprises first and second mixer cores 22 and 24 , respectively. The mixers 22 and 24 are identical in nature, but receive different local oscillator signals. The mixer core 22 receives a local oscillator signal, designated LOI, while the mixer core 24 receives a local oscillator signal, designated as LOQ. The local oscillator signals are 90° out of phase with respect to each other, thus forming a quadrature mixer core. The output of the mixer 20 is coupled to jammer rejection filter stage 26 . Specifically, the output of the mixer core 22 is coupled to a jammer rejection filter 28 while the output of the mixer core 24 is coupled to a jammer rejection filter 30 . The operation of the jammer rejection filters 28 and 30 is identical except for the quadrature phase relationship of signals from the mixer 20 . The output of the jammer rejection filters 28 and 30 are the quadrature output signals IOUT and QOUT respectively.
[0008] The jammer rejection filters 28 and 38 are designed to remove unwanted signals, such as signals from transmitters operating at frequencies near the frequency of operation of the system 10 . Thus, the jammer rejection filters 28 and 30 are designed to remove “out-of-band” signals. In operation, the jammer rejection filters 28 and 30 may be lowpass filters, bandpass filters, or complex filters (e.g., a single filter with two inputs and two outputs), depending on the implementation of the system 10 . The operation of the jammer rejection filters 28 and 30 are well known in the art and need not be described in greater detail herein. While the jammer rejection filters 28 and 30 may minimize the effects of out-of-band signals, there are other forms of interference for which the jammer rejection filters are ineffective.
[0009] For example, distortion products created by the mixer 20 may result in interference that may not be removed by the jammer rejection filters 28 and 30 . If one considers a single CDMA wireless unit, that unit is assigned a specific radio frequency or channel in the frequency spectrum. If an AMPS system is operating on multiple channels spaced apart from each other by a frequency Δω J , then the second-order distortion from the mixer 20 will create a component at a frequency Δω J in the output signal. It should be noted that the second order distortion from the mixer 20 will create signal components at the sum and difference of the two jammer frequencies. However, the signal resulting from the sum of the jammer frequencies is well beyond the operational frequency of the wireless device and thus does not cause interference. However, the difference signal, designated herein as Δω J , may well be inside the desired channel and thus cause significant interference with the desired signal.
[0010] In this circumstance, the AMPS signals are considered a jammer signals since they create interference and therefore jam the desirable CDMA signal. Although the present example refers to AMPS signals as jammer signals, those skilled in the art will appreciate that any other radio frequency sources spaced at a frequency of Δω J from each other may be considered a jammer.
[0011] If this second-order distortion signal is inside the channel bandwidth, the jammer rejection filters 28 and 30 will be ineffective and the resultant interference may cause an unacceptable loss of carrier-to-noise ratio. It should be noted that this interference may occur regardless of the absolute frequencies of the jammer signals. Only the frequency separation is important if the second-order distortion results in the introduction of an undesirable signal into the channel bandwidth of the CDMA unit.
[0012] Industry standards exist that specify the level of higher order distortion that is permitted in wireless communication systems. A common measurement technique used to measure linearity is referred to as an input-referenced intercept point (IIP). The second order distortion, referred to as IIP2, indicates the intercept point at which the output power in the second order signal intercepts the first order signal. As is known in the art, the first order or primary response may be plotted on a graph as the power out (P OUT ) versus power in (P IN ). In a linear system, the first order response is linear. That is, the first order power response has a 1:1 slope in a log-log plot. The power of a second order distortion product follows a 2:1 slope on a log-log plot. It follows that the extrapolation of the second order curve will intersect the extrapolation of the fundamental or linear plot. That point of intercept is referred to as the IIP2. It is desirable that the IIP2 number be as large as possible. Specifications and industry standards for IIP2 values may vary from one wireless communication system to another and may change over time. The specific value for IIP2 need not be discussed herein.
[0013] It should be noted that the second-order distortion discussed herein is a more serious problem using the direct down-conversion architecture illustrated in FIG. 1. In a conventional super-heterodyne receiver, the RF stage 12 is coupled to an intermediate frequency (IF) stage (not shown). The IF stage includes bandpass filters that readily remove the low frequency distortion products. Thus, second-order distortion is not a serious problem with a super-heterodyne receiver. Therefore, the IIP2 specification for a super-heterodyne receiver is generally not difficult to achieve. However, with the direct down-conversion receiver, such as illustrated in FIG. 1, any filtering must be done at the baseband frequency. Since the second-order distortion products at the frequency separation, Δω J , regardless of the absolute frequency of the jammers, the IIP2 requirements are typically very high for a direct-conversion receiver architecture. The IIP2 requirement is often the single most difficult parameter to achieve in a direct down-conversion receiver architecture.
[0014] As noted above, the second-order distortion is often a result of non-linearities in the mixer 20 . There are a number of factors that lead to imbalances in the mixer 20 , such as device mismatches (e.g., mismatches in the mixer cores 22 and 24 ), impedance of the local oscillators, and impedance mismatch. In addition, factors such as the duty cycle of the local oscillator also has a strong influence on the second-order distortion. Thus, the individual circuit components and unique combination of circuit components selected for a particular wireless communication device results in unpredictability in the IIP2 value for any given unit. Thus, calibration of individual units may be required to achieve the IIP2 specification.
[0015] Therefore, it can be appreciated that there is a significant need for a system and method for wireless communication that reduces the undesirable distortion products to an acceptable level. The present invention provides this and other advantages as will be apparent from the following detailed description and accompanying figures.
SUMMARY
[0016] Novel techniques are disclosed for distortion reduction calibration. In an exemplary embodiment, a distortion reduction circuit for use in a wireless communication device has a radio frequency (RF) receiver and comprises a gain stage having an input coupled to the receiver and an output with the gain stage controlling an amplitude of an output signal related to a second order nonlinear response within the receiver. An output coupling circuit couples the gains stage output to the receiver.
[0017] In one embodiment, the gain stage amplitude control is based on the amplitude of the second order nonlinear response within the receiver. The signal related to the second order nonlinear response within the receiver may be inherently generated by circuitry within the receiver or may be generated by a squaring circuit coupled to the receiver.
[0018] When implemented with an RF receiver generating a down-converted output signal, the output coupling circuit may comprise an adder having first and second inputs with the first input configured to receive the output signal from the receiver and the second input configured to receive the gain stage output signal. The gain stage may generate an output current related to the second order nonlinear response within the receiver. The output coupling circuit may be a direct connection to the down-converted output signal of the receiver.
[0019] In one embodiment, the circuit is for use in a factor calibration wherein the receiver generates a down-converted output signal and is configured to receive an external input signal to permit the adjustment of the gain stage to thereby minimize the second order nonlinear response of the receiver output signal.
[0020] In another embodiment, an automatic calibration circuit may be used with the wireless communication device wherein a signal source generates a test signal and a switch is selectively activated to couple the signal source to a receiver input terminal to couple the test signal to the receiver input terminal and thereby permit distortion reduction adjustments on the receiver.
[0021] The switch circuit maybe selectively activated in an auto-calibration mode or activated at predetermined times.
[0022] In one embodiment, the signal source comprises an internal signal generator. The internal signal generator may generate the test signal having multiple frequency components having a predetermined spectral spacing. In another embodiment, the wireless communication device includes an RF transmitter and the circuit may further comprise a transmitter control to control an input signal to the transmitter and selectively activated during the auto-calibration process to generate the test signal. In one embodiment, the circuit may further include an attenuator coupled to a transmitter output terminal to generate an attenuated output signal as the test signal.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] [0023]FIG. 1 is a functional block diagram of a conventional wireless communication receiver.
[0024] [0024]FIG. 2 is a functional block diagram of a generic implementation of the present invention.
[0025] [0025]FIG. 3 is a functional block diagram of a receiver mixer illustrating one implementation of the present invention.
[0026] [0026]FIG. 4 is a schematic diagram illustrating one possible implementation of the present invention.
[0027] [0027]FIG. 5 is a functional block diagram of an alternative implementation of the present invention.
[0028] [0028]FIG. 6 is a functional block diagram of another alternative implementation of the present invention.
DETAILED DESCRIPTION
[0029] The present invention is directed to a calibration circuit and method that simplifies the calibration process for individual wireless communication devices. The term “wireless communication device” includes, but is not limited to, cellular telephones, personal communication system (PCS) devices, radio telephones, mobile units, base stations, satellite receivers and the like. In one embodiment, the calibration circuit is used at assembly to compensate for variations in components. In an alternative embodiment, also described herein, an onboard calibration circuit can be used to compensate for component mismatch due to circuit aging or other changes in circuit operational parameters.
[0030] IIP2 performance presents a major challenge in direct conversion down-converters. The required values of IIP2 are usually very high and the actual performance tends to be difficult to predict because it is almost exclusively determined by statistical phenomena. That is, component mismatch tends to be a statistical phenomena. Even so-called “matched” components on an integrated circuit are subject to variations in operating characteristics due to processing variations of an integrated circuit. Similarly, external components are also subject to variation that is unpredictable and cannot be readily accounted for in designing a radio frequency (RF) circuit.
[0031] There are some known techniques for suppressing IIP2 distortion, but these processes tend to be complicated or introduce new spurs (i.e., undesirable frequency components) and require a change in frequency plan (i.e., reallocation of the frequency spectrum). In addition, these known techniques interfere with the RF path and will degrade other RF parameters such as noise figure and IIP3. As a result, these known circuits lead to more complicated circuitry, increased cost, and decreased performance.
[0032] In contrast, the present invention uses a feed-forward technique, which relies on a one-time calibration at the phone level. The circuitry of the present invention is designed such that it does not interfere with the RF path, and the RF path can therefore be optimized for other RF performance parameters (e.g., noise figure and IIP3), independently of IIP2. All of the calibration works at baseband frequencies, which facilitates the design and layout and enables lower power consumption.
[0033] As previously discussed, the second order nonlinear distortion is a significant problem in direct conversion receiver architectures (i.e., zero IF or low IF architectures). While heterodyne receiver architectures also generate second order distortion, other conventional techniques may be used to reduce the unwanted nonlinear distortion. For example, careful selection of the IF frequency followed by IF filtering may typically reduce the second order nonlinear distortion to an acceptable level in heterodyne receivers. While the discussion herein uses low IF or zero IF examples, the principles of the present invention may be applied to other receiver architectures, including heterodyne receivers.
[0034] Furthermore, the description presented herein may refer to a baseband signal, resulting from a low IF or zero IF mixing. However the principles of the present invention apply generally to a down-converted signal that is generated by a mixer. Therefore, the present invention is not limited by the receiver architecture, but can generally be applied to any down-converted signal having a second order nonlinear distortion.
[0035] The present invention is embodied in a system 100 , which is shown in an exemplary form in the functional block diagram of FIG. 2. The system 100 processes an RF in , signal, which is illustrated in FIG. 2 in the form of a voltage (V RF ). The RF in signal is processed by a conventional RF block 102 . The RF block may include amplifiers, filters, and the like. In addition, the RF block typically includes a mixer, such as the mixer 20 illustrated in FIG. 1 to convert the RF signal to a baseband signal. As illustrated in FIG. 2, the baseband signal comprises components that are identified as I BBdesired +i IM2 . This is intended to represent the desired baseband signal combined with the undesirable signal resulting from second order distortion within the RF block 102 .
[0036] The system 100 also includes a compensation branch 104 , which comprises a squaring circuit 106 , lowpass filter 108 , and variable gain amplifier (VGA) 110 . The squaring circuit 106 provides a squared version of the voltage V RF . As those skilled in the art will appreciate, the squaring circuit produces a number of undesirable harmonics at multiple frequencies. The low pass filter 108 is designed to eliminate the undesirable frequencies so that the compensation branch 104 does not produce undesirable interference. The VGA 110 is used to attenuate or amplify a compensation signal identified in FIG. 2 as i IM2cal . The compensation signal i IM2cal is combined with the output of the RF block by an adder 114 . The output of the adder 114 is the desired signal i outBB . If the compensation current i IM2cal equals the undesirable signal component i IM2 , the output signal i outBB equals the desired signal I BBdesired .
[0037] As illustrated in FIG. 2, the IM2 calibration scheme relies on canceling the IM2 output current generated by the RF block 102 with a programmable IM2 current derived from another source. In the present example, the programmable compensation current is derived directly from the RF signal, but does not interact with the RF pathway in the RF block 102 . Thus, the advantage of this technique is that it does not interfere with the RF path. Therefore, the introduction of IM2 calibration will not degrade other RF parameters such as gain, noise figure and IIP3.
[0038] For proper cancellation of the undesirable signal by the adder 114 , the two IM2 currents (i.e., i IM2 and i IM2cal ) must either be in-phase or 180 degrees out of phase. Due to the mechanism generating IM2, this is expected to be the case and will be derived below. As noted above, the RF block 102 contains conventional components, such as the mixer 20 (see FIG. 1). The IM2 current generated by the mixer 20 can be expressed in the form:
i IM2mix ( t )=α 2mix ·V RF ( t ) 2 (1)
[0039] Expressing V RF in polar form and taking into account that it may be attenuated by some factor α mix and phase-shifted by some phase φ mix through the mixer circuitry, we obtain:
i IM2mix ( t )=α 2mix ·(α mix ·A ( t )cos(ω RF ·t +Φ( t )+Φ mix )) 2 (2)
[0040] and expanding this yields
i IM2mix ( t ) = 1 2 · a 2 mix · α mix 2 · A ( t ) 2 ( 1 + cos ( 2 ω RF · t + 2 φ ( t ) + 2 φ mix ) ) ( 3 )
[0041] A portion of the signal represented by equation (3) is dependent on a value 2ω RF . This portion of equation (3) is of little concern in this analysis since it is very high frequency and will be filtered away using conventional techniques. However, the low-frequency part could land inside the desired baseband channel. So the IM2 product of interest from equation (3) is
i IM2mixLF ( t ) = 1 2 · a 2 mix · α mix 2 · A ( t ) 2 ( 4 )
[0042] Similarly, the IM2 compensation current generated at the output of the VGA 110 in FIG. 2 is given by
i IM2cal ( t ) = 1 2 · a cal · A ( t ) 2 ( 5 )
[0043] where α cal is a programmable scaling factor. Cancellation of IM2 by the adder 114 is achieved when
α cal =−α 2mix ·α mix 2 (6)
[0044] Thus, IM2 cancellation should be possible independently of the RF phase shift Φ mix through the mixer.
[0045] [0045] 039 In a typical implementation of the RF block 102 , the mixer cores are the main IM2 contributors. Therefore, to improve tracking between the IM2 source (i.e., the mixer core) and the IM2 calibration signal, it would be desirable to derive the IM2 calibration signal from the mixer cores themselves. This is fortunately straight-forward, because the emitter-nodes of the mixer core present a strong second-order non-linearity. Conceptually, the IM2 calibration circuit can be implemented as shown in the functional block diagram of FIG. 3. For the sake of clarity, FIG. 3 illustrates only a single mixer core (i.e., either the I mixer or the Q mixer core). Those skilled in the art will recognize that an additional mixer core and calibration circuit are implemented in accordance with the description provided herein. It should also be noted that the simplified functional block diagram of FIG. 2 represents a single ended system while the functional block diagram of FIG. 3 is a differential implementation with differential inputs and differential outputs. Those skilled in the art will recognize that the principles of the present invention may be applied to single ended or differential systems.
[0046] The RF block 102 comprises a transconductor 120 , which receives the input signal RF in the form of a differential voltage and generates differential output signals that are coupled to the inputs of a mixer core 122 through a series combination of a resistor R and a capacitor C. The output of the transconductor 120 illustrated in dashed lines are inputs to the other mixer core (not shown). The resistor R and capacitor C serve as current dividers to provide current to the mixer core 122 and the other mixer (not shown). The input currents to the mixer 122 are identified in FIG. 3 as I RF1 and I RF2 , respectively. It should be noted that the series RC circuit is not essential to the successful operation of the present invention. Rather, the RC circuit is merely one implementation of the splitter 18 (see FIG. 1). The present invention is not limited by the specific implementation of the splitter 18 . The mixer core 122 also receives a differential local oscillator (LO) as an input and generates a differential baseband output signal (BB OUT).
[0047] The mixer core 122 is shown in FIG. 3 using conventional symbols for schematic diagram. The mixer core may be implemented by a transistor circuit shown at the bottom of FIG. 3 using cross-coupled transistors in a known configuration for a differential mixer. The emitters of the various transistors in FIG. 3 are coupled together to form first and second input nodes that receive the RF signal. The input nodes are biased by bias current sources I B in a known manner. In an alternative embodiment, the transconductor 120 may supply sufficient bias current thus enabling the elimination of the bias current sources I B .
[0048] The transistor arrangement of the mixer core 122 illustrated in FIG. 3 comprises first and second pairs of transistors whose emitters are coupled together to form the input nodes of the mixer core 122 . The input nodes of the mixer core 122 are driven by the currents I RF1 and I RF2 , respectively. Also illustrated at the input nodes of the mixer core 122 in FIG. 3 are voltages V E1 and V E2 , respectively. As those skilled in the art can appreciate, the non-linear operation of the transistors result in a second order non-linearity of the input signal which is present at the input nodes of the mixer core 122 . This non-linear component is represented by the voltage V E1 and V E2 at the input nodes of the mixer core 122 . In the embodiment illustrated in FIG. 3, there is no need for an external squaring circuit, such as the squaring circuit 106 illustrated in FIG. 2. Rather, the system 100 relies on the second order nonlinear signal inherently generated within the mixer core 122 . The current I RF1 and I RF2 may be thought of as inputs to a squaring circuit (e.g., the squaring circuit 106 of FIG. 2) while the voltage V E1 and V E2 may be considered as outputs of the squaring circuit. The advantage of the implementation in FIG. 3 is that the squaring function is an inherent byproduct of the mixer core 122 and requires no additional circuitry (e.g., the squaring circuit 106 ) to generate the squared term used by the compensation branch 104 . A further advantage of the implementation illustrated in FIG. 3 is that the squared signal is generated by the mixer core 122 itself, which is also the source of the nonlinearity within the mixer core that results in the undesirable IM2 signal (represented in FIG. 2 as i IM2 ). Thus, the compensation current generated by the compensation branch 104 in FIG. 3 advantageously tracks the nonlinear signal generated within the mixer core 122 . Other components within the RF block 102 may be also serve as the source of the second order nonlinear signal. For example, the transconductor 120 may generate the second order nonlinear signal.
[0049] [0049]FIG. 3 also illustrates an implementation of the compensation branch 104 . Coupling resistors couple the RF currents I RF1 and I RF2 to a gain stage 126 . The output of the gain stage 126 is coupled to a variable attenuator 128 which generates calibration currents I IM2cal1 and I IM2cal2 .
[0050] The calibration current can be written as:
i IM2cal =I IM2cal1 −I IM2cal2 =α·g mcal ·ν E =α· g mcal ·α 2core ·I RF 2 (7)
[0051] which is of the desired form.
[0052] Using the emitter node of the mixer core 122 as the IM2 source for the calibration is desirable because, from a simplified point of view, the IM2 generated by the mixer cores can be explained as the strong IM2 signal present on the emitter node leaking unequally to the two outputs due to mismatches in the transistors used to implement the mixer core. If no mismatch were present, the mixer core would not generate any differential IM2 because the emitter IM2 would leak equally to both sides. Thus, it would be expected that the output IM2 tracks the emitter IM2 (i.e., the output IM2 would be given as a mismatch factor times the emitter IM2).
[0053] In the absence of temperature dependencies, the calibration current characterized in equation (7) above would provide a suitable correction current to eliminate IM2 generated by the mixer cores. Unfortunately, simulations show that this mismatch factor is temperature dependent, and the dependency depends on the type of mismatch (e.g., emitter resistance mismatch gives a different temperature profile than base-emitter capacitance mismatch, etc.). In practice, one type of mismatch will typically dominate so that the temperature dependence is repeatable. Therefore, it is desirable to let the α factor have a programmable temperature dependence. Thus, the term α in equation (7) may be altered to include the following characteristic:
α = α cal · ( 1 + β cal · T - T 0 T 0 ) ( 8 )
[0054] where α cal and β cal are programmable constants, T is temperature and T O is the temperature at which calibration is performed.
[0055] The abbreviated schematic of FIG. 4 illustrates a circuit that implements the desired calibration function. It uses a current steering DAC to set the calibration factor and currents I A and I B to set the temperature dependence. The circuit works as follows:
[0056] Firstly, we rewrite the various currents in terms of I A , I B , I ref , and I LF :
I DAC1 = 1 2 · ( 1 + α DAC ) · I ref I DAC2 = 1 2 · ( 1 - α DAC ) · I ref I o1A = 1 2 · ( 1 + α o ) · I LF1 I o2A = 1 2 · ( 1 - α o ) · I LF1 I o1B = 1 2 · ( 1 + α o ) · I LF2 I o2B = 1 2 · ( 1 - α o ) · I LF2 I 2 a = 1 2 · ( 1 + α 2 ) · I B I 2 b = 1 2 · ( 1 - α 2 ) · I B ( 9 )
[0057] Observing that I 4 =0.5·(I B −I A ), we additionally have:
I 3 a = I 2 a - I 4 = 1 2 · ( 1 + α 2 ) · I B - 1 2 · ( I B - I A ) = 1 2 · ( 1 + I B I A · α 2 ) · I A ( 10 )
[0058] and similarly
I 3 b = 1 2 · ( 1 - I B I A · α 2 ) · I A ( 11 )
[0059] Using the translinear principle, in which certain products of currents may be equated to other products of currents, we find that:
I o1A ·I 2b =I o2A ·I 2a I o1B ·I 2b =I o2B ·I 2a I DAC1 ·I 3b =I DAC2 ·I 3a (12)
[0060] and with the definitions provided by equations (9) and the translinear equations (12), equations (10) and (11) reduce to:
( 1 + α o ) · ( 1 - α 2 ) = ( 1 - α o ) · ( 1 + α 2 ) ( 1 + α DAC ) · ( 1 - I B I A · α 2 ) = ( 1 - α DAC ) · ( 1 + I B I A · α 2 ) ( 13 )
[0061] from which we see
α o = α 2 I B I A · α 2 = α DAC ( 14 )
[0062] and thus
α o = I A I B α DAC
[0063] Hence, the IM2 compensation current is given as
I 01 - I 02 = ( I o1A + I o2B ) - ( I o2A + I o1B ) = ( I o2B - I o1B ) - ( I o2A - I o1A ) = α 0 · ( I LF1 - I LF2 )
I o1 - I o2 = g m · v E · α DAC · I A I B ( 15 )
[0064] The desired temperature variation can be implemented by letting the current I B be a bandgap-referenced current, and the current I A be a combination of bandgap and proportional to absolute temperature (PTAT):
I A =I BG ·(1−β cal )+ I PTAT ·β cal
I B =α B ·I BG (16)
I PTAT ( T O )= I BG
[0065] This can be done very easily using programmable current mirrors, and we then obtain the desired function,
I o1 - I o2 = g m · α DAC α B · ( 1 + β cal · T - T 0 T 0 ) · v E ( 17 )
[0066] It should be noted that the form of equation (17) is similar to that of equation (8) above. Thus, FIG. 4 provides a circuit implementation of the compensation branch 104 . It should be noted that the gain stage 126 has differential inputs. One input is coupled, via two resistors, to the RF inputs of the mixer core 122 (see FIG. 3). Due to the switching currents of the transistors in the mixing core 122 , the signal provided to the input of the gain stage via the resistors contains both AC and DC components. The signal V ref is provided as a second input to the gain stage 126 . The voltage V ref has a value equivalent to the DC component of the signal provided from the mixer core 122 . This effectively cancels out the DC component and allows the gain stage 126 to amplify the AC signal only. The voltage V ref may be generated using another mixer with no RF input and using the same local oscillator (LO) input. The transistors of the mixer (not shown) are matched to the transistors of the mixer core 122 such that the DC signal produced by the mixer core (not shown) matches the DC component generated by the mixer core 122 .
[0067] Due to the circuit topology, we must ensure that I B >I A . The current I B current must be set large enough to ensure this. This is done through the α B current mirror ratio described above.
[0068] As previously discussed, component mismatch in the mixer core 122 (see FIG. 3) is a significant cause of IM2 distortion. Another cause of IM2 distortion that should be considered is RF-to-LO coupling within the mixer core 122 . Due to mismatch in device capacitances etc. an attenuated version of the RF signal may get coupled to the LO port. This signal will be proportional to the incoming RF current i RF (t) and may be phase shifted by an amount Φ leak .
[0069] On the LO port we may then have a signal component of the form,
V RFleakLO ( t )=γ leak I ( t )cos(ω RF t +φ( t )+φ leak ) (18)
[0070] where I(t) and φ(t) are a polar representation of i RF (t) (i.e., i RF (t)=I(t)cos(ω RF t+φ(t))).
[0071] The mixer core 122 will generate a mixing product between the RF signal on the LO port and the incoming RF current. Thus we obtain a signal component at the mixer output as follows:
i out — leak =k mix ν RFleakLO ( t ) i RF ( t ) (19)
[0072] where k mix is the conversion gain of the mixer core. Expanding the above expression yields:
i out_leak ( t ) = k mix γ leak I ( t ) cos ( ω RF t + φ ( t ) + φ leak ) I ( t ) cos ( ω RF t + φ ( t ) ) = 1 2 k mix γ leak I ( t ) 2 ( cos ( φ leak ) + cos ( 2 ω RF t + 2 φ ( t ) + 2 φ leak ) ) ( 20 )
[0073] As with the previous analysis, the high frequency component of equation (20) is easily removed with conventional filtering techniques and need not be considered further. However, it is necessary to consider the low-frequency part of equation (20), which may be represented as follows:
i out — leakLF ( t )=α leak I ( t ) (21)
[0074] where
[0075] [0075] a leak = 1 2 k mix γ leak cos ( φ leak ) .
[0076] As is apparent,α leak is a constant. Thus, the IM2 caused by RF-to-LO leakage can also be corrected by the described calibration method. It is still advisable, however, to avoid RF-to-LO leakage. This can most effectively be done by ensuring low source impedance on the LO port at RF frequencies, (e.g., by using emitter-followers to drive the mixer LO port).
[0077] Since the IM2 is statistical in nature because of the variation in components and manufacturing processes, each wireless communication device will require unique calibration current values. In one implementation, the compensation branch 104 is adjusted as part of a final assembly process in a factory test. The process described above provides sufficient correction for the IM2 current in the wireless communication device.
[0078] In an alternative embodiment, the wireless communication device may include additional circuitry to provide self-contained auto-calibration. The auto-calibration process can be automatically performed by the wireless device at regular intervals. An auto-calibration circuit is illustrated in the functional block diagram of FIG. 5. The functional block diagram of FIG. 5 comprises an antenna 140 and a duplexer 142 . Those skilled in the art will appreciate that the duplexer 142 allows a common antenna to be used for both transmission and reception of RF signals. The output of the duplexer 142 is coupled to a low-noise amplifier (LNA) 144 . The output of the LNA 144 is coupled to a receiver 146 . Those skilled in the art will appreciate that the receiver 146 generically describes all circuitry involved with the processing of received signals. This includes the RF block 102 and its associated components.
[0079] The output of the receiver 146 is coupled to a mobile station modem (MSM) 148 . The MSM 148 generically represents circuitry used for signal processing of the baseband signal. The MSM also processes baseband data for transmission. Accordingly, the MSM 148 is also coupled to a transmitter 150 . The transmitter 150 is intended to encompass all circuitry involved in the modulation of baseband signals to the appropriate RF signals. The output of the transmitter 150 is coupled to a power amplifier (PA) 152 . The PA 152 drives the antenna 140 via the duplexer 142 to transmit the RF signals. The operation of circuit components, such as the MSM 148 and transmitter 150 are well known in the art and need not be described in greater detail herein. The receiver 146 is also a conventional component with the exception of the added circuitry of the compensation branch 104 (see FIG. 2).
[0080] Because CDMA is a full-duplex system, the transmitter 150 can be on at the same time as the receiver 146 . The present invention takes advantage of this capability by using the transmitter 150 to generate a test signal on which to perform IM2 calibration. The simplified architecture illustrated in FIG. 5 takes advantage of the fact that IM2 distortion does not depend on the absolute frequencies of the signals, but only on their frequency separation. With the PA 152 and LNA 144 turned off, the transmitter 150 can generate a signal that is routed straight to the receiver 146 via semiconductor switches 156 and 158 . The output signal from the transmitter 150 is attenuated through a resistive attenuator 160 .
[0081] [0081] 063 The receiver 146 processes the received signal and the IM2 distortion caused by the receiver results in baseband distortion product. The MSM 148 can detect and minimize the distortion product by adjusting the IM2 calibration. Those skilled in the art will recognize that the calibration circuit of FIG. 5 may be used with any form of compensation circuit. Thus, the auto-calibration circuit is not limited to the compensation techniques described above. For example, the auto-calibration circuit of FIG. 5 could be used to compensate for the noise figure, circuit gain, linearity, IM3 signals as well as IM2 signals. In addition, the auto-calibration circuit of FIG. 5 may be used for different forms of IM2 compensation other than the circuit described above with respect to FIGS. 2-4. Thus, the present invention is not limited by the specific form of compensation circuit.
[0082] The main signal generated by the transmitter 150 falls far into the stop-band of the baseband filter (not shown) and does therefore not contribute any power at baseband. Consequently, the only power detected by the MSM 148 is the IM2 distortion product and circuit noise. Thus, the MSM 148 can perform the IM2 calibration based on a simple power measurement.
[0083] In an alternative embodiment, illustrated in FIG. 6, an internal signal source 162 within the receiver generates the desired test signal. In an exemplary embodiment, the signal source 162 generates a signal having at least two frequency components that are spaced apart by a predetermined frequency. As previously discussed, the wireless receiver may be sensitive to signals that are separated by a frequency of Δω J .
[0084] The signal source 162 is coupled to the input of the receiver 146 by a switch 164 . The switch 164 is activated only when the system 100 is placed in an auto-calibration mode. The auto-calibration can be performed at predetermined times, such as when the power is first applied to the wireless communication device. Alternatively, the auto-calibration can be performed periodically at predetermined time intervals.
[0085] It is to be understood that even though various embodiments and advantages of the present invention have been set forth in the foregoing description, the above disclosure is illustrative only, and changes may be made in detail, yet remain within the broad principles of the invention. Therefore, the present invention is to be limited only by the appended claims. | Techniques are disclosed for compensating for second-order distortion in a wireless communication device. In a zero-intermediate frequency (IF) or low-IF architecture, IM2 distortion generated by the mixer ( 20 ) results in undesirable distortion levels in the baseband output signal. A compensation circuit ( 104 ) provides a measure of the IM2 distortion current independent of the radio frequency (RF) pathway to generate an IM2 calibration current. The IM2 calibration current is combined with the baseband output signal to thereby eliminate the IM2 currents generated within the RF pathway. In one embodiment, the calibration is provided at the factory during final testing. In alternative embodiment, additional circuitry ( 156, 158 ) may be added to the wireless communication device to provide a pathway between the transmitter ( 150 ) and the receiver ( 146 ). The transmitter signal is provided to the receiver to permit automatic calibration of the unit. An internal signal source ( 162 ) may be used in place of the transmitter ( 150 ). The auto-calibration may be performed to eliminate IM2 distortion or permit optimization of the circuit to minimize other forms of distortion or interference. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a circuit and a method for generating a low-level current using semiconductor charge pumping.
More particularly this invention relates to a means of generating a range of current sources by varying the frequency of a repetitive voltage pulse input signal.
Also, this invention relates to utilizing one or many MOSFET devices in order to produce higher levels of current.
In addition, this invention relates to the ability to generate very stable current sources with high input impedances.
2. Description of Related Art
The prior art related to this invention includes various high input impedance low level current sources. Typically, these current sources are custom designed monolithic circuits. They are not modular or are they scalable from the lowest current level produced by a single device to high current levels produced by hundreds of device.
U.S. Pat. No. 6,285,243 B1 (Mercier et al.) “High Voltage Charge Pump Circuit” describes a circuit which transfers a voltage signal in an output stage without signal level degradation. By-pass techniques are used to avoid semiconductor damage or breakdown.
U.S. Pat. No. 6,326,839 B2 (Proebsting) “Apparatus for Translating a Voltage” discloses a low voltage current source is used for translating voltage levels using a charge pumping mechanism.
U.S. Pat. No. 6,323,721 B1 (Proebsting) “Substrate Voltage Detector” discloses low voltage current source circuit, which generates low voltage signals for powering a variable frequency oscillator.
U.S. Pat. No. 5,561,385 (Choi) “Internal Voltage Generator for Semiconductor Device” discloses an internal voltage generator for a semiconductor device, for generating an internal voltage within the device.
U.S. Pat. No. 6,278,315 (Kim) “High Voltage Generating Circuit and Method for Generating a Signal Maintaining High Voltage and Current Characteristics Therewith” discloses a high voltage generating circuit, which is used to generate a high voltage with a high current. This circuit is used for on-chip programming and erasing of electrically erasable programmable read only memory EEPROM or flash memory.
BRIEF SUMMARY OF THE INVENTION
It is the objective of this invention to provide a circuit and a method for generating a low-level current using semiconductor charge pumping.
It is further an object of this invention to provide a means of generating a range of current sources by varying the frequency of a repetitive voltage pulse input signal.
Also, it is further an object of this invention to utilizing one or many MOSFET devices in order to produce higher levels of current.
In addition, it is further an object of this invention to generate very stable current sources with high input impedances.
The objects of this invention are achieved by a frequency-controlled low-level current source based on charge pumping and using a single metal-oxide semiconductor field effect transistor, MOSFET, a voltage pulse generator attached to a gate of the MOSFET, a ground connected to a drain of the MOSFET, a ground connected to a source of the MOSFET, and an output current produced at a substrate terminal of the MOSFET. The frequency-controlled current source of this invention has a MOSFET device whose source region of the MOSFET is made of n+ semiconductor material. The drain of the MOSFET is made of n+ type semiconductor material. The circuit of this invention has a substrate of the MOSFET which is made of p type semiconductor material. The frequency-controlled current source MOSFET has claim 1 wherein a gate which is made of is made of poly-silicon. The current source has a voltage pulse applied to the MOSFET gate by the voltage pulse generator. The frequency-controlled current source's gate voltage pulse causes a charge inversion in to the p type substrate which results in negative charge accumulation in the p-type substrate located between said n+ MOSFET drain and said n+ MOSFET source. This negative charge accumulation is caused by the flow of electrons from the MOSFET source and MOSFET drain where some electrons are trapped in interface states. When the MOSFETgate pulse goes to its low state the mobile electrons, those that are not trapped in the interface states, will return to said MOSFET source and drain. The non-mobile trapped or electrons will recombine with the holes in the p-substrate. The trapped, recombined electrons results in a net flow of negative charge into the substrate. This net flow of negative charge is the resultant charge pump current which is generated by this low-level current source of this invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a cross-sectional view of the single MOSFET device embodiment of the current source of this invention.
FIG. 2 shows a plot of charge pump output current vs. the Vbase voltage of the input voltage pulse applied to the gate of the MOSFET device.
FIG. 3 contains a plot of charge pump output current vs. frequency of the gate input repetitive pulse voltage applied.
FIG. 4 shows the system level connection of the single MOSFET device current source of this invention.
FIG. 5 shows the multi-MOSFET device embodiment of this invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a cross-sectional view of the main embodiment of this invention. A metal oxide semiconductor field effect transistor MOSFET 111 is shown. The gate 160 is made of poly-silicon. The source 180 is connected to ground 145 . The drain 170 is also connected to ground 145 . Both the source 115 and drain 125 are made of n+ semiconductor material. The substrate 190 is made of p-type silicon material. The substrate is connected 135 to a DC current meter 150 , which is used to test the output current 120 produced by this change pump MOSFET.
The gate 160 is connected to the input line 110 . A repetitive voltage pulse signal 112 is applied to the input 110 . This pulse signal has a base voltage level Vbase 140 and a voltage amplitude delta equal to delta VA 130 .
Charge pumping in MOSFETs is a well-known phenomenon that is related to the recombination process at the SiO2/Si interface 190 involving the interface states as shown in FIG. 1 . For a MOSFET with the connections shown in FIG. 1 , when the transistor is pulsed into inversion, the p-type silicon surface 190 becomes deeply depleted and electrons will flow from the source 115 and drain 125 regions into the channel 190 where some of them will be captured by the interface states. When the gate pulse 112 is driving the surface back to accumulation, the mobile charges flow back to the source 115 and drain 125 but the charges trapped in the interface states will recombine with the majority carriers (i.e. holes for p-Si substrate) from the substrate 190 and give rise to a net flow of negative charge into the substrate 135 . The charge Qss which will recombine is given by
Qss= ( q* 2) S D P
Where (q*2) is the electron charge squared in coulombs squared, S is the channel area of the MOSFET (cm2), D it is the mean interface state density over the energy range swept through by the Fermi level and P is the total sweep of the surface potential. When applying repetitive pulses to the gate with frequency, f, this charge Qss will give rise to a steady-state current in the substrate 135 . This current 150 is the so-called charge pumping current, and it is given by
Icp=f Qss=f ( q* 2) S D P
where f is the frequency of the repetitive input gate voltage signal.
The charge pumping current can be observed with different pulse shapes (square, triangle or other pulse shapes). For square pulses, if the amplitude of the pulses is kept constant but the pulse base level Vbase is varied from inversion to accumulation, the charge pumping current 210 will vary with the Vbase 220 is shown in FIG. 2 . In the saturation region 230 with Vt−dVa<Vbase<Vfb 240 , 250 , where Vt, dVa and Vfb represent the threshold voltage, the pulse amplitude, and the flat band voltage, respectively, the charge pumping current is a constant 230 and is determined by the Icp equation (2) above.
The current source of this invention has its output current 310 proportional to the frequency 320 input pulses. The frequency 330 dependence of the charge pumping current at different V base within the saturation region is shown in FIG. 3 . A good linear frequency dependence was observed up to the frequency of 2.5 MHz (at higher frequencies 340 there was a slight departure because those “slower” interface states were not able to response quickly enough). The charge pumping current can serve as a low-level DC current source (for example a DC current 0.1 uA). As the charge pumping current is proportional to the frequency of the input pulses, the output current can be easily controlled through the frequency.
Another feature of the current source of this invention is that it is insensitive to the drift of pulse voltage. As can be seen in FIG. 2 , the charge pumping current was essentially independent of the Vbase in the saturation region 230 . If the pulse base level is within the saturation region, then the output current will be insensitive to a small drift of the pulse base level or top level. It is possible to have a desired saturation region through a proper selection of the values of the Vt, the Vfb and the dVa. The Vt and the Vfb depend on the substrate doping, gate materials, the fixed charges in the gate oxide, as well as the thickness of the gate oxide, and they can be controlled during the device manufacturing. To maintain a constant level of interface state, the pulse base level as well as the top level must be below the threshold voltage for the Fowler-Nordheim tunneling (7V for a 50 A thick gate oxide).
The current source circuit of this invention has an extremely high input resistance, as the gate oxide is an excellent isolator, the charge pumping current source will have an extremely high input resistance.
As can be seen in FIG. 4 , for low-level output current with current less than 0.1 uA, the frequency-controlled charge-pumping (FCCP) DC current source 410 can be fabricated using a single transistor, with the resistive load 430 connected in series with the substrate terminal 420 of the transistor. As is illustrated in FIG. 5 , if higher output current is desired, a two-dimensional array 530 , 540 of FCCP can be made up of hundreds of transistors. All of the gate terminals are tied together and connected to a single pulse generator 510 . The output current 520 is the linear sum of the charge-pumping currents contributed from all of the substrate terminals.
The advantage of this invention is the possibility of creating a range of low-level current sources. The range goes from a single MOSFET device to an array of MOSFET devices connected in parallel to create a higher level of current. In addition, the stability of the current source with respect to variations in the drift of the input pulse voltage is an important advantage. In addition, another advantage is the ability to control the output current by varying the frequency of the input pulse signal. The high input resistance of this current source is also an important feature of this invention.
While this invention has been particularly shown and described with Reference to the preferred embodiments thereof, it will be understood by those Skilled in the art that various changes in form and details may be made without Departing from the spirit and scope of this invention. | This invention provides a circuit and a method for generating a low-level current using semiconductor charge pumping. The invention provides a means of generating a range of current sources by varying the frequency of a repetitive voltage pulse input signal. Also, this invention utilizes one or many MOSFET devices in order to produce higher levels of current. The current source embodiments of this invention generate very stable current sources with high input impedances. | 7 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a divisional of commonly owned copending U.S. application Ser. No. 12/104,316 filed on Apr. 16, 2008, which is based on and claims domestic priority benefits under 35 USC §119(e) from U.S. Provisional Application Ser. No. 60/907,774 filed on Apr. 17, 2007, the entire content of which is expressly incorporated hereinto by reference.
FIELD OF THE INVENTION
[0002] The present invention relates generally to elastic composite yarns having an elastic core filament and a fibrous sheath covering the core filament. In especially preferred forms, the present invention is embodied in ring spun yarns having an elastic core which may be woven into fabrics exhibiting excellent recovery characteristics.
BACKGROUND AND SUMMARY OF THE INVENTION
A. Definitions
[0003] As used herein and in the accompanying claims, the terms below are intended to have the following definitions:
[0004] “Filament” means a fibrous strand of extreme or indefinite length.
[0005] “Fiber” means a fibrous strand of definite or short length, such as a staple fiber.
[0006] “Yarn” means a collection of numerous filaments or fibers which may or may not be textured, spun, twisted or laid together.
[0007] “Sliver” means a continuous fibrous strand of loosely assembled staple fibers without twist.
[0008] “Roving” means a strand of staple fibers in an intermediate state between sliver and yarn. According to the present invention, the purpose of a roving is to provide a package from which a continuous stream of staple fibers is fed into the twist zone for each ring spinning spindle.
[0009] “Spinning” means the formation of a yarn by a combination of drafting and twisting or prepared strands of staple fibers, such as rovings.
[0010] “Core spinning” means introducing a filamentary strand into a stream of staple fibers so that the staple fibers of the resulting core spun yarn more or less cover the filamentary strand.
[0011] “Woven fabric” means a fabric composed of two sets of yarns, warp and filling, and formed by interlacing (weaving) two or more warp yarns and filling yarns in a particular weave pattern (e.g., plain weave, twill weave and satin weave). Thus, during weaving the warp and fill yarns will be interlaced so as to cross each other at right angles to produce the woven fabric having the desired weave pattern.
[0012] “Draft ratio” is the ratio between the length of a stock filamentary strand from a package thereof which fed into a spinning machine to the length of the filamentary strand delivered from the spinning machine. A draft ratio of greater than 1.0 is thus a measure of the reduction in bulk and weight of the stock filamentary strand.
[0013] “Package length” is the length of a tensioned filament or yarn forming a package of the same.
[0014] “Elastic recovery” means that a filament or fabric is capable of recovery to its original length after deformation from elongation or tension stress.
[0015] “Percent elastic recovery” is a percentage ratio of the length of a filament or fabric following release of elongation or tension stress to the length of the filament or fabric prior to being subject to elongation or tension stress. A high percent elastic recovery therefore means that the filament or fabric is capable of returning substantially to its original pre-stressed length. Conversely, a low percent elastic recovery means that the filament or fabric is incapable of returning substantially to its original pre-stressed length. The percent elastic recovery of fabrics is tested according to ASTM D3107 (the entire content of which is expressly incorporated hereinto by reference).
[0016] An “elastic filament” means a filament that is capable of stretching at least about 2 times its package length and having at least about 90% elastic recovery up to 100% elastic recovery. Thus, the greater that a yarn of fabric which includes an elastic filament is stretched, the greater the retraction forces of such yarns and fabrics.
[0017] An “inelastic filament” means a filament that is not capable of being stretched beyond its maximum tensioned length without some permanent deformation. Inelastic filaments are therefore capable of being stretched only about 1.1 times their tensioned (package) length. However, due to texturing (crimping), an inelastic filament may exhibit substantial retraction force and thereby exhibit substantial percent elastic recovery.
BACKGROUND OF THE INVENTION
[0018] Composite elastic yarns are in and of themselves well known as evidenced, for example, by U.S. Pat. Nos. 4,470,250; 4,998,403; 5,560,192; 6,460,322 and 7,134,265. 1 In general, conventional composite elastic yarns comprise one or more elastic filaments as a core covered by a relatively inelastic fibrous or filamentary sheath. Such elastic composite yarns find a variety of useful applications, including as component filaments for making stretchable textile fabrics (see, e.g., U.S. Pat. No. 5,478,514). Composite yarns with relatively high strength inelastic filaments as a core surrounded by a sheath of other filamentary material are also known, for example, from U.S. Pat. No. 5,735,110. 1 The entire contents of each of these cited U.S. patents as well as each U.S. patent cited hereinafter are expressly incorporated into this document by reference as if each one was set forth in its entirety herein.
[0019] Woven fabrics made of such yarns, in particular ring spun yarns with an elastic core can be used to make woven stretch fabrics. Typically these fabrics have an elongation of 15 to 40% usually in the weft direction only, but sometimes also in the warp directions. A typical problem with these fabrics is that the recovery characteristics can be poor, usually on the order of as low as 90% (ASTM D3107).
[0020] Fabrics made with yarns having “inelastic filaments” with retraction power due to artificial crimp (textured or self textured as in elasterell-p, PTT/PET bi-component fibers) generally have low elongation in the range of 10 to 20%. In general, these fabrics have excellent recovery characteristics when tested using ASTM D3107.
SUMMARY OF THE INVENTION
[0021] It would therefore be highly desirable if the excellent recovery properties of inelastic filaments could be combined with the excellent elongation or stretch properties of elastic filaments in the same ring spun core yarn. If such a ring spun core yarn were possible, then several problems would be solved. For example, fabrics made from such ring spun core yarns would exhibit both good stretch and excellent recovery according to ASTM D3107, could be heat-set with better control of stretch properties, and could be made into garments and subsequently resin treated with much better recovery remaining after the treatment. It is towards fulfilling such a need that the present invention is directed.
[0022] Broadly, the present invention is embodied in ring-spun yarns which satisfy the need in this art noted above. In accordance with one preferred embodiment of the present invention, a composite yarn is provided which includes a filamentary core comprised of an elastic performance filament and an inelastic control filament, and a fibrous sheath surrounding the filamentary core, preferably substantially along the entire length thereof. The fibrous sheath is preferably ring-spun from a roving of staple fibers and thereby forms an incoherent mass of entangled spun stable fibers as a sheath surrounding the elastic and inelastic filaments.
[0023] According to some preferred embodiments of the invention, an elastic composite yarn is provided wherein at least one elastic performance filament comprises a spandex and/or a lastol filament, and wherein at least one inelastic control filament comprises a filament formed of a polymer of copolymer of a polyamide, a polyester, a polyolefin and mixtures thereof. Preferably, the fibrous sheath comprises synthetic and/or natural staple fibers. In especially preferred embodiments, the fibrous sheath comprises staple cotton fibers.
[0024] The elastic composite fibers of the present invention find particular utility as a component part of a textile fabric. Thus, according to some embodiments of the present invention, the composite elastic filaments will be woven into a textile fabric, preferably a denim fabric.
[0025] The composite elastic yarn may be made by providing a filamentary core comprised of at least one elastic performance filament and at least one inelastic control filament, wherein the at least one elastic performance filament has a draft ratio which is at least two times, preferably at least tree time, the draft ratio of the at least one inelastic control filament; and thereafter spinning a fibrous sheath around the filamentary core. The filamentary core may be supplied to the spinning section as a preformed unit, for example by joining the elastic and inelastic fibers in advance and providing such a filamentary core stock on a package to be supplied to the spinning section. Alternatively, the filamentary core may be formed immediately in advance of the spinning section by unwinding the elastic performance filament and the inelastic control filament from respective separate supply packages, and bringing filaments together prior to spinning of the fibrous sheath thereabout. The elastic performance filament and the inelastic control filament may thus be acted upon by respective draw ratio controllers so as to achieve the desired draw ration differential therebetween as briefly noted above.
[0026] These and other aspects and advantages will become more apparent after careful consideration is given to the following detailed description of the preferred exemplary embodiments thereof.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
[0027] Reference will hereinafter be made to the accompanying drawings, wherein like reference numerals throughout the various FIGURES denote like structural elements, and wherein;
[0028] FIG. 1 is a schematic representation of a yarn package of a composite yarn in accordance with the present invention;
[0029] FIG. 2 is a greatly enlarged schematic view of a section of the composite yarn shown in FIG. 1 in a relaxed (non-tensioned) state;
[0030] FIG. 3 is a greatly enlarged schematic view of a section of the composite yarn similar to FIG. 2 but shown in a tensioned state; and
[0031] FIG. 4 is a schematic representation of a process and apparatus for making the composite yarn in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0032] As depicted in FIGS. 1-3 , the present invention is most preferably embodied in a composite yarn 10 which may be wound around a bobbin BC so as to form a yarn package YP thereof. The yarn package YP may therefore be employed in downstream processing to form a textile fabric, preferably a woven fabric, according to techniques well known to those in this art.
[0033] The composite yarn 10 according to the present invention will necessarily include a filamentary core 10 - 1 comprised of at least an elastic performance filament 12 and an inelastic control filament 14 . The filamentary core 10 - 1 is surrounded, preferably along the entirety of its length by a fibrous sheath 10 - 2 comprised of a mass of spun staple fibers 16 .
[0034] Although not shown in FIGS. 2-3 , the filamentary core 10 - 1 may comprise additional filaments deemed desirable for the particular end use application contemplated for the composite filament 10 . Furthermore, filaments 12 and 14 are depicted in FIGS. 2-3 as monofilaments for ease of illustration only. Thus, the elastic performance filament 12 and/or the inelastic control filament 14 may be comprised of multiple filaments. In one especially preferred embodiment of the present invention, the elastic performance filament is a single filament while the inelastic control filament is a multifilament. More specifically, the preferred elastic performance filament may advantageously be formed of multiple elastic monofilaments which are coalesced with one another so as to in essence form a single filament. On the other hand, the inelastic control filament is formed of multiple monofilaments and/or multiple filaments of spun staple fibers.
[0035] As depicted schematically in accompanying FIG. 2 , when the composite yarn 10 is in a non-tensioned state, the inelastic control filament 14 is twisted relatively loosely around the elastic performance filament 12 . Such relative loose twisting of the inelastic control filament 14 about the elastic performance filament 12 thus allows the elastic filament 12 to be extensible under tension until a point is reached whereby the inelastic control filament 14 reaches its extension limit (i.e., a point whereby the relative looseness of the inelastic filament has been removed along with any extensibility permitted by filament texturing (crimping) that may be present such that any further tensioning would result in permanent deformation or breakage). Such a tensioned state is depicted schematically in accompanying FIG. 3 .
[0036] It will be understood that, since the fibrous sheath 10 - 2 is comprised of an incoherent mass of entangled, randomly oriented spun staple fibers, it will permit the extension of the elastic performance filament 12 to occur up to the limit of the inelastic control filament 14 without physical separation. Furthermore, the fibrous sheath itself serves to limit the extensibility of the elastic performance filament 12 , albeit to a much lesser extent as compared to the inelastic control filament 14 . Thus, throughout repeated tensioning and relaxation cycles, the fibrous sheath 10 - 2 will continue to visibly hide the filamentary core 10 - 1 .
[0037] Virtually any commercially available elastomeric filament may be employed satisfactorily as the elastic performance filament 12 in accordance with the present invention. Preferred are elastic filaments made from spandex or lastol polymers. As is well known, spandex is a synthetic filament formed of a long chain synthetic elastomer comprised of at least 85% by weight of a segmented polyurethane. The polyurethane segments of spandex are typically interspersed with relatively soft segments of polyethers, polyesters, polycarbonates or the like. Lastol is an elastic polyolefin having a cross-linked polymer network structure, as disclosed more fully in U.S. Pat. Nos. 6,500,540 and 6,709,742. Other suitable elastomeric polyolefins may also be employed in the practice of the present invention, including homogeneously branched linear or substantially linear ethylene/α-olefin interpolymers, e.g. as disclosed in U.S. Pat. Nos. 5,272,236, 5,278,272, 5,322,728, 5,380,810, 5,472,775, 5,645,542, 6,140,442, and 6,225,243.
[0038] A particularly preferred spandex filament is commercially available from Invista (formerly DuPont Textiles & Interiors) under the trade name LYCRA® having deniers of about 40 or about 70. A preferred lastol filament is commercially available from Dow Fiber Solutions under the tradename XLA™ having deniers of about 70, 105, or 140.
[0039] The inelastic control filament may be virtually any inelastic filament known to those in the art. Suitable inelastic control filaments include filaments formed of virtually any fiber-forming polymers such as polyamides (e.g., nylon 6, nylon 6,6, nylon 6,12 and the like), polyesters, polyolefins (e.g., polypropylene, polyethylene) and the like, as well as mixtures and copolymers of the same. Presently preferred for use as the inelastic control filament are polyester filaments, such as those commercially available from Unifi, Inc. in 1/70/34 stretch textured polyester or 1/70/34 in set textured polyester.
[0040] The relative denier of the elastic performance filament 12 and the inelastic control filament 14 may be substantially the same or substantially different. In this regard, the denier of the elastic performance filament 12 may vary widely from about 10 to about 140, preferably between about 40 to about 70. After the proper draft ratio is applied the denier of the elastic filament inside a tensioned yarn would be about 5 to 70, preferably between 10 and 25. The denier of the inelastic control filament 14 may vary widely from about 40 to about 150, preferably between about 70 to about 140. In one particularly preferred embodiment of the invention, the denier of the elastic performance filament 12 and the inelastic control filament 14 is each about 70.
[0041] As noted briefly above, the fibrous sheath 10 - 2 is formed from a relatively dense mass of randomly oriented entangled spun synthetic staple fibers (e.g., polyamides, polyesters and the like) or spun natural staple fibers (e.g., cotton). In especially preferred embodiments, the fibrous sheath 10 - 2 is formed of spun cotton fibers. The staple fiber length is not critical. Typical staple fiber lengths of substantially less than one inch to several inches may thus be used.
[0042] The composite yarn 10 may be made by virtually any staple fiber spinning process known to those in this art, including core spinning, ring spinning and the like. Most preferably, however, the composite yarn 10 is made by a ring spinning system 20 depicted schematically in accompanying FIG. 4 . As shown, the preferred ring spinning system 20 includes a ring-spinning section 22 . The elastic performance filament 12 and the inelastic control filament 14 forming the filamentary core 10 - 1 are removed from a creel-mounted supply package 12 a , 14 a , respectively, and brought together at a merger ring 24 prior to being fed to the ring-spinning section 22 . A roving 26 of the staple fibers to be spun into the fibrous sheath 10 - 2 is similarly removed from a creel mounted supply package 26 a and directed to the ring-spinning section 22 .
[0043] The size of the roving is not critical to the successful practice of the present invention. Thus, rovings having an equivalent cotton hank yarn count of between about 0.35 to about 1.00, preferably between about 0.50 to about 0.60 may be satisfactorily utilized. In one preferred embodiment of the invention, a roving of cotton staple fibers is employed having a cotton hank yarn count of 0.50 and is suitably spun with the elastic and inelastic core filaments to achieve a resulting equivalent cotton yarn count of 14/1. Filamentary cores totaling about 90 denier can be suitably spun with a fibrous sheath to equivalent cotton yarn counts ranging from 20/1 to 8/1, while filamentary cores totally 170 denier can be suitably spun with a fibrous sheath to yarn counts ranging from 12/1 to 6/1.
[0044] Individual independently controllable draft ratio controllers 28 , 30 and 32 are provided for each of the filaments 12 and 14 , and the roving 26 . According to the present invention, the draft ratio controllers 30 and 32 are set so as to feed the inelastic control filament 14 and the roving 26 of staple fibers to the ring-spinning section 22 at a draft ratio of about 1.0 (+/−about 0.10, and usually +/−about 0.05). The draft ratio controller 28 on the other hand is set so as to supply the elastic performance filament 12 to the ring-spinning section 22 at a draft ratio of at least about 2.0, and preferably at least about 3.0. Thus, when joined with the inelastic control filament 14 , the elastic performance filament 12 will be at a draft ratio which is at least two times, preferably at least three times, the draft ratio of the inelastic control filament 14 . The elastic performance filament 12 will thereby be under tension to an extent that it is extended (stretched) about 200%, and preferably about 300% as compared to its state on the package 12 a . On the other hand, as compared to its state on the package 14 a , the inelastic control filament 14 will be essentially unextended (unstretched).
[0045] The ring-spinning section 22 thus forms the fibrous sheath 10 - 2 around the filamentary core 10 - 1 using ring-spinning techniques which are per se known in the art. Such ring-spinning techniques also serve to relatively twist the inelastic control filament 14 about the elastic performance filament. Thus, the ring-spinning of the fibrous sheath 10 - 2 from the roving 26 of staple fibers and the draft ratio differential as between the elastic performance filament 12 on the one hand and the inelastic control filament on the other hand serve to achieve an elastic composite yarn 10 as has been described previously. The composite yarn may thus be directed to a traveler ring 34 and wound about the bobbin BC to form the yarn package YP.
[0046] The composite yarn 10 according to the present invention may be used as a warp and/or filling yarn to form woven fabrics having excellent elastic recovery characteristics. Specifically, according to the present invention, woven fabrics in which the composite yarn 10 is woven as a warp and/or filling yarn in a plain weave, twill weave and/or satin weave pattern, will exhibit a stretch of at least about 15% or greater, more at least about 18% or greater, most preferably at least about 20% or greater. Such fabrics in accordance with the present invention will also preferably exhibit a percent elastic recovery according to ASTM D3107 of at least about 95.0%, more preferably at least about 96.0% up to and including 100%.
[0047] The present invention will be further understood as careful consideration is given to the following non-limiting Examples thereof.
EXAMPLES
Example 1
[0048] A composite core yarn was made of 70 denier spandex filament commercially obtained from RadicciSpandex Corporation drafted at 3.1 and a 70 denier stretch textured polyester filament (Jan. 70, 1968) commercially obtained from Unifi, Inc. drafted at 1.0. The composite yarn was spun on a Marzoli ring spinning machine equipped with an extra hanger and tension controllers for the composite core yarn. A hank roving size of 0.50 was used and drafted sufficiently to yield a total yarn count of 14/1. The resulting composite yarn was woven on an X-3 weaving machine to create a vintage selvage denim with stretch. The reed density of 14.25 (57 ends in reed) was used instead of the normal 16.5. The resulting fabric was desized, mercerized, and heat set to a width of 30 inches on a Monforts tenter range. The resulting denim fabric stretch was 18% and the elastic recovery was 96.9% according to ASTM D3107.
[0049] A comparison fabric was made using a 14/1 regular core spun yarn containing only 40 denier spandex. The elastic recovery was only 95.5% when tested according to ASTM D3107.
Example 2
[0050] A denim fabric was woven using yarns of Example 1 as weft on a Sulzer rapier wide loom. This denim was made with one pick of the 14/1 multi-core yarn followed by one pick of 14/1 normal core spun with 40 denier spandex. This denim was made with 16.0 reed density (64 ends in reed). The fabric was desized and mercerized but not heat set. The resulting fabric had 29% stretch and a recovery of 96.0% based on ASTM D3107.
[0051] A comparison fabric was made using all picks of 14/1 normal core spun with 40 denier spandex. The comparison fabric had 25% stretch but only 95.3% recovery when tested according to ASTM 3107.
Example 3
[0052] A 3/1 twill bi-directional stretch denim made with warp and weft comprised of multi-core yarns made with the apparatus described in Example 1. The core consisted of a 1/70/34 textured polyester continuous filament strand drafted at 1.00 to 1.02, and a 40 denier spandex elastomeric (RadicciSpandex Corporation) drafted at 3.1. The wrapping or sheath of the core spun yarn consisted of cotton fibers sufficient to provide a total weight of 7.5/1 Ne in warp and 14/1 Ne in weft. The warp yarn was woven at low density and the fill yarn was woven at 48 weft yarns per inch. After mercerization, heat setting, and finishing the final yarn density was 64×52 giving a fabric weight of 11.25 oz. per square yard. The stretch after heat setting was 11% in warp direction with 97% average recovery. The stretch in the weft direction was 22% with a recovery of 96%.
Example 4
[0053] A 3/1 twill bi-directional stretch denim was made with warp and weft comprised of multi-core yarns made with the apparatus described in Example 1. The core consisted of a 1/70/34 textured polyester continuous filament strand drafted at 1.00 to 1.02, a 75 denier lastol elastomeric (Dow Chemical, XLA™) drafted at 3.8. The wrapping or sheath of the core spun yarn consisted of cotton fibers sufficient to provide a total weight of 7.5/1 Ne in warp and 11.25/1 Ne in weft. The warp yarn was woven at low density and the fill yarn was woven at 42 weft yarns per inch. After mercerization, heat setting, and finishing the final yarn density was 68×47 giving a fabric weight of 11.50 oz. per square yard. The stretch after finishing was 112.5% in warp direction with 97% average recovery. The stretch in the weft direction was 19% with a recovery of 96%.
Example 5
[0054] A 3/1 twill weft stretch denim was made with an all cotton warp having an average yarn number of 9.13 Ne at a density of 57 ends per inch in the loom reed. The weft was comprised of a multi-core yarn made with the apparatus described in Example 1. The core consisted of a 1/70/34 textured polyester continuous filament strand drafted at 1.00 to 1.02, and a 40 denier spandex elastomeric (RadicciSpandex Corporation) drafted at 3.1. The wrapping or sheath of the core spun yarn consisted of cotton fibers sufficient to make a total weight of 14/1 Ne. This yarn was woven at the rate of 45 weft yarns per inch. After mercerization, heat setting, and finishing the final yarn density was 75×48.5 giving a fabric weight of 9.75 oz. per square yard. The stretch after heat setting was 17% with 96.8 average recovery. The overall blend level for the fabric is 93% cotton/6% polyester/1% spandex.
Example 6
[0055] A 3/1 twill weft stretch denim was made with an all cotton warp having an average yarn number of 9.13 Ne at a density of 57 ends per inch in the loom reed. The weft was comprised of a multi-core yarn made with the apparatus described in Example 1. The core consisted of a 1/70/34 textured polyester continuous filament strand drafted at 1.00 to 1.02, and a 40 denier spandex elastomeric (RadicciSpandex Corporation) drafted at 3.1. The wrapping or sheath of the core spun yarn consisted of cotton fibers sufficient to make a total weight of 14/1 Ne. This yarn was woven at the rate of 50 weft yarns per inch. After mercerization and finishing the final yarn density was 77×55.5 giving a fabric weight of 10.5 oz. per square yard. The stretch was 26% with 96% average recovery. The overall blend level for the fabric was 92% cotton/7% polyester/1% spandex.
Example 7
[0056] A 3/1 twill weft stretch denim was made with an all cotton warp having an average yarn number of 9.13 Ne at a density of 57 ends per inch in the loom reed. The weft was comprised of a multi-core yarn made with the apparatus described in Example 1. The core consisted of a 1/70/34 textured polyester continuous filament strand drafted at 1.00 to 1.02, and a 75 denier lastol elastomeric (Dow Chemical, XLA™) drafted at 4.0. The wrapping or sheath of the core spun yarn consisted of cotton fibers sufficient to make a total weight of 11.25/1 Ne. This yarn was woven at the rate of 46 weft yarns per inch. After mercerization and finishing the final yarn density was approximately 75×51 giving a fabric weight of 11.5 oz. per square yard. The stretch was 17% with 96% average recovery. The overall blend level for the fabric is 93% cotton/6% polyester/1% lastol.
[0057] 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, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims. | Composite yarns have a filamentary core provided with at least one elastic performance filament and at least one inelastic control filament. A fibrous sheath, preferably formed from spun staple fibers, surrounds the filamentary core, preferably substantially along the entire length thereof. The at least one elastic performance filament most preferably includes a spandex and/or a lastol filament. The at least one inelastic control filament is most preferably formed of a textured polymer or copolymer of a polyamide, a polyester, a polyolefin and mixtures thereof. Preferably, the fibrous sheath is formed of synthetic and/or natural staple fibers, most preferably staple cotton fibers. The elastic composite fibers find particular utility as a component part of a woven textile fabric, especially as a stretch denim fabric, which exhibits advantageous elastic recovery of at least about 95.0% (ASTM D3107). | 3 |
RELATED APPLICATIONS
The present application claims the benefit of U.S. Provisional Applications Serial Nos. 60/061,305, filed Oct. 7, 1997, 60/062,555 filed Oct. 21, 1997 and 60/062,673, filed Oct. 22, 1997, which are hereby incorporated by reference in their entireties.
TECHNICAL FIELD OF THE INVENTION
The present invention relates generally to devices for burn-in and testing of integrated circuit chips (IC) and more specifically to techniques for cooling of the IC devices on the burn-in boards used to ensure that newly-manufactured chips are suitable for use. Still more particularly, the present invention comprises a socket adapted to provide improved cooling capacity and to a system for cooling the IC and socket effectively.
BACKGROUND OF THE INVENTION
It is well-known in the art of electronic device manufacturing to test, and/or “burn-in,” various electronic sub-components before assembling them into a larger device. For example, computer chips are frequently individually connected in a burn-in system for the purpose of ensuring that all of the desired electronic circuits in each chip are operational. The burn-in process accelerates aging of the chips and thus allows defective chips to be identified and discarded early in the manufacturing process. This is desirable because it allows the manufacturer to avoid the expense that would otherwise be wasted by constructing a larger, more expensive device containing the defective chip. In addition to burn-in, computer chips and other integrated circuits may be subjected to various other testing operations. The term “testing” as used herein is intended to encompass and include bum-in operations.
In a burn-in operation, each chip, integrated circuit (IC), or other electronic component, each of which is hereinafter referred to as a “device under test” or “DUT,” is connected to several electronic leads. These leads typically take the form of an array of small solder buttons that are positioned to correspond to electronic leads on the under-surface of the DUT. The DUT is placed on the arrayed leads so that an electrical connection is made at each desired point.
During the burn-in or test operation, heat is generated by the passage of current via the leads through the various circuits on the DUT. Heretofore, ICs were less powerful and, correspondingly, the amount of power consumed during burn-in of a computer chip was relatively small. For this reason, the amount of heat generated was such that burn-in devices could be air-cooled in most cases. With the advent of newer, more powerful chips, the amount of heat generated during burn-in has multiplied ten-fold, from about 3-10 watts, to 30-100 watts or more.
In addition, the increasing cost of chip packaging has motivated manufacturers to advance the burn-in step so that it is carried out before, rather than after, final packaging. This allows manufacturers to save the cost of packaging a defective chip, but means that the burn-in operation must be carried out on partially packaged ICs, where the silicon die itself may be exposed. Partially packaged ICs are less robust and more susceptible to damage than fully packaged chips. Thus, the burn-in operation cannot subject the DUTs to excessive or uneven forces.
Because the burn-in must be carried out at a controlled temperature, and because the chips cannot be exposed to temperature extremes, it is imperative that the significant heat generated during burn-in be removed. Air cooling does not provide sufficient cooling without a very large heat sink. Liquid cooling, using an electrically insulating fluid has been tried, but has proven nonviable for very high power DUTs. At the same time, burning-in or testing a partially packaged chip raises new considerations over burning-in or testing a fully packaged chip. For example, partially packaged chips are not typically adapted to readily dump heat at the required rate.
It is known that high-power transistors generate comparable amounts of heat during burn-in operations. However, the configuration of transistors and conventional transistor packages is such that cooling systems that are designed for transistor burn-in devices cannot readily be adapted to cool IC devices. In addition, transistors are typically sealed within durable metal or plastic packages, so that the handling concerns that arise in the context of burning in chips do not arise in transistor burn-in devices. Furthermore, as compared to the volume of high power transistors that require testing, the volume of ICs that must be tested is so many times greater that cost factors that are not as significant in the context of transistor testing become prohibitive when contemplated in the context of chip testing.
In addition to the problems associated with providing sufficient cooling capacity to a given burn-in device and providing a heat transfer surface does not limit that capacity, problems arise from the fact that the amount of heat generated during burn-in or testing varies significantly from DUT to DUT. It has been found that in some instances, the amount of heat generated varies by as much as two orders of magnitude. This variance make it difficult to simultaneously burn-in several devices, as a cooling system that adequately cools the DUTs that generate greater amounts of heat will over-cool the DUTs that generate less heat, causing their temperatures to fall below the desired burn-in temperature range. Conversely, a cooling system that properly cools the DUTs that generate lesser amounts of heat will under-cool the DUTs that generate more heat, causing their temperatures to rise above the desired burn-in temperature range.
Hence, it is desired to provide a DUT burn-in device that is capable of simultaneously removing at least 30-100 watts of heat from each of several chips, while maintaining the temperature of each DUT within a narrow desired range. Furthermore, the preferred device should be capable of maintaining the DUTs within the prescribed temperature even though the DUTs produce amounts of heat that may vary by more than an order of magnitude and even though some DUTs may generate as little as 3 watts of heat. The preferred device should also be readily incorporated into a system capable of simultaneously processing multiple DUTs. These objectives require that the device be capable of compensating for variance in heat generation between DUTs that are being burned in simultaneously. The preferred device should be able to handle unpackaged chips without damaging them either before, during or after the burn-in process. It is further desired to provide a burn-in device that is commercially viable in terms of cost, labor and reliability.
SUMMARY OF THE INVENTION
The present invention comprises a burn-in device that is capable of simultaneously removing at least 30-100 watts of heat from each of several DUTs, while compensating for variance in heat generation between DUTs and maintaining the temperature of each chip within a narrow desired range, including DUTs producing 3 watts or more of heat. The present invention is readily incorporated into a system capable of simultaneously burning-in multiple DUTs. The preferred device causes a minimum of damage to the DUTs and is commercially viable in terms of cost, labor and reliability.
The present invention comprises a novel socket for receiving and contacting an individual chip during burn-in, and to a system for supporting and cooling several of the sockets. The socket includes a cooling system that is capable of removing at least 3 to 10 times as much heat from a chip as previous systems. The cooling system includes at least one highly thermally conductive heat sink member held in good thermal contact with the chip or device-under-test (DUT).
The present invention includes an apparatus and technique for achieving good thermal contact between the heat sink member and the DUT. The preferred apparatus provides a conformal interface that conforms to any unevenness in the upper surface of the DUT. In a first embodiment, this thermal contact is obtained via an elastomeric heat pad and a heat spreader that together form the socket lid. The elastomeric heat pad is preferably covered by a thin metal film. In another embodiment, the conformal interface comprises a low melting point metal (LMPM) contained within a skin formed from a much higher melting point metal. In a less preferred embodiment, the interface comprises an ultra-smooth, highly polished metal surface.
According to the present invention, a separate burn-in socket receives each DUT. Each socket is preferably constructed such that the biasing force that allows good thermal contact between the heat sink and the DUT is controlled and distributed across the DUT, so as to avoid mechanical damage to the DUT. The preferred socket also provides means for applying sufficient contact force between the socket base and the DUT to allow for good electrical contact, while at the same time limiting the application of compressive force to the DUT so as to avoid damaging the DUT.
A preferred embodiment of the present invention further includes a temperature sensor for monitoring and providing data on the temperature of the cooling system in the vicinity of the DUT and a heat source for applying a controlled amount of heat to the DUT in response to the output of the temperature sensor. The temperature sensor is preferably embedded in the heat spreader near the interface with the DUT. The heat source is preferably also embedded in the heat spreader. The heat source is controlled by a controller in response to the signal generated by the temperature sensor.
A preferred embodiment of the present cooling system also includes a liquid-vapor cooling system in thermal contact with the heat sink and socket. The liquid-vapor cooling system preferably includes multiple liquid-vapor ducts controlled by a single controller, resulting in significant cost and operational savings over the prior art. In another embodiment, the liquid-vapor cooling system is replaced by a circulating liquid system, known as a liquid cooling unit (LCU). The LCU allows for burn-in temperatures of less than 60° C.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and advantages of the invention will become apparent upon reading the following detailed description and upon reference to the accompanying drawings, wherein:
FIG. 1 is a cross-sectional view through a burn-in or test socket constructed in accordance with a first embodiment of the present invention;
FIG. 2 is an enlarged view of an alternative embodiment of the thermal interface of the present invention;
FIG. 3A is a perspective exploded view of the heat-removal portion of the socket of FIG. 1;
FIG. 3B is a perspective exploded view of an alternative embodiment of the heat-removal portion of the socket of FIG. 1;
FIG. 4 is a side view taken along lines 4 — 4 of FIG. 3, showing internal components in phantom;
FIGS. 5A-B are top views of burn-in boards seated and unseated on corresponding heat sinks, respectively; and
FIG. 6 is a perspective front view of an entire test system, showing multiple groups of sockets and multiple heat sinks.
It will be understood that the device described in detail below can be operated in any orientation. Thus, relative terms such as “upper,” “lower,” “above,” and “below” refer to the various components of the invention as drawn and are used for illustration and discussion purposes only. Such terms are not intended to require these relationships in any embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1, one feature of the present invention comprises a burn-in or test socket 10 that meets the afore-mentioned objectives. Specifically, the present burn-in system comprises a socket 10 including a socket base 12 and a compression stop 16 , which is used in conjunction with a socket lid 20 , heat pad 22 , pressure plates 24 , springs 26 and heat spreader 30 . In FIG. 1, a DUT 40 is shown received in socket 10 . In some embodiments, pressure plates 24 and springs 26 may be omitted, if the socket and lid are constructed such that sufficient pressure is applied to the DUT by other means.
Socket
Socket base 12 is preferably constructed of a suitable non-conducting material such as are known in the art, and has a plurality of conducting electrical leads 14 embedded therein. Each lead 14 preferably terminates in an electrical contact 15 , which may comprise a surface feature such as a solder bump on the upper surface 13 (as drawn) of socket base 12 . Leads 14 are moveable into and out of engagement with the lower surface of DUT 40 .
It is preferred but not necessary that the upper surface 13 of socket base 12 include a beveled lip 17 that serves to guide the DUT into position on socket base 12 . Lip 17 preferably defines an area corresponding to the footprint of a DUT. This area is typically a square having an area that is slightly greater than the heat transfer area of the DUT. For example, each side of the area bounded by lip 17 may be 0.005 to 0.010 inches longer than the length of one side of the DUT. Compression stop 16 preferably extends farther above surface 13 than lip 17 . Compression stop 16 preferably comprises a rigid, non-compressible material configured so as to define or correspond to the perimeter of socket base 12 . In an alternative embodiment, compression stop 16 is integrally formed from the same piece as base 12 . Together, base 12 and stop 16 form one part of the two-part lidded socket 10 .
The other part of socket 10 is formed by socket lid 20 , heat spreader 30 , heat pad 22 , springs 26 and pressure plates 24 . These components are interconnected and move together into and out of engagement with the socket and the DUT. Socket lid 20 is preferably made of high temperature plastic or other similar material. Socket lid 20 is adapted to bear on compression stop 16 and includes a lower surface 27 for that purpose. Heat spreader 30 has a center portion 32 having a contact surface 33 to which is affixed heat pad 22 so as to define a highly thermally conductive interface. Heat spreader 30 further includes a flange 36 , which bears on compression stop 16 .
Additionally, heat spreader 30 includes an intermediate shoulder 34 that supports at least two downward-extending springs 26 . According to one preferred embodiment, eight springs 26 are affixed to shoulder 34 along two sides of center portion 32 . At least one pressure-distributing device, such as pressure plates 24 , is affixed to the opposite end of each spring 26 . Pressure plates 24 can be separate from one another as shown, or can be formed as a single piece (not shown) having any desired configuration. The system comprising springs 26 and pressure plates 24 is provided for the purpose of applying a compressive force to the DUT so as to ensure that good electrical contact is maintained between the electrical contacts on the DUT and leads 14 in the socket. A variety of mechanical systems other than the springs and plates described above can be used to apply a compressive force to the DUT. Some of these alternative systems are described in detail in commonly owned application Ser. No. 09/167,295, filed concurrently herewith and entitled Burn-In Board Having Adaptable Heat Sink Device, which is incorporated herein by reference.
Heat spreader 30 is preferably constructed of any suitable rigid, highly thermally conducting material. One preferred material is copper, and more preferably copper plated with another metal, such as nickel. Springs 26 are preferably conventional small coil springs, but can be any suitably compressible biasing means. Pressure plate 24 can be any rigid material that can be provided with a very smooth surface, and is preferably polished stainless steel. It is preferred that the surface 33 of heat spreader 30 be polished to at least approximately 8 microinches.
Thermal Interface
According to the present invention, the interface between the DUT 40 and heat spreader 30 is designed so as to provide maximum heat transfer from the DUT to the heat spreader. In order to accomplish maximum heat transfer, the interface must accommodate the uneven upper surface of the DUT. Overall, the thermal interface must be conformal, thermally conducting, durable and reusable. In addition, factors such as labor, material costs and manufacturing complexity must also be considered. It is to be understood that the systems described below are merely illustrative and not exhaustive of the various systems that meet these objectives.
According to a first preferred embodiment, a heat pad 22 is affixed to the lower surface (as drawn) of center portion 32 of heat spreader 30 . Heat pad 22 preferably comprises a material having a high thermal conductivity. More specifically, it is preferred that the material from which heat pad 22 is formed have a thermal conductivity of at least 0.2 BTU/ft, and more preferably at least 0.5 BTU/ft. Because the upper surface of the DUT is likely to have some irregularities, it is preferred that heat pad 22 also be somewhat conformal or resilient. A preferred category of materials can be described as thermally conductive polymeric composite materials. One preferred material that meets these criteria is a boron nitride loaded silicone elastomer sold under the trademark SIL-PAD 2000®, by the Bergquist Company of Minneapolis, Minn. SIL-PAD 2000® is preferably used in the form of a sheet having a thickness between about 4 and 20 thousands of an inch and preferably about 5/10 3 inch. Another preferred material is an alumina filled silicone elastomer sold under the trade name T-Flex 200 by Thermagon, Inc., 3256 West 25th Street, Cleveland, Ohio 44109. The resilient heat pad 22 is preferably provided in sheet form, with a preferred thickness for heat pad 22 being approximately 4 to 5 mils.
Because it is preferred that the surface that contacts the upper surface of the DUT leave no residue on the DUT, it is preferred to provide a thin foil coating 23 (FIG. 3A) over the resilient conductor that forms heat pad 22 . Another preferred embodiment uses a 2 mil thick copper foil that is electroplated with a 50 μlayer of gold. Still another preferred embodiment uses a 1 mil thick nickel foil that is electroplated with gold. Other less preferred foils include copper plated with platinum, copper plated with palladium and brass.
A second preferred embodiment for the thermal interface comprises a conformal cushion formed by a low melting point metal that melts at the operating temperature of the system, as illustrated in FIG. 2 . As shown, the thermal interface comprises a body 35 of low melting point metal, contained in a metal foil skin 37 . Skin 37 preferably comprises 1 mil nickel foil. If desired, the skin metal can comprise a different metal, such as gold-plated copper, or can be comprise or be plated with platinum, gold or palladium. It is preferred to plate the foil with a metal that does not leave a residue or contaminate the surface of the DUT. The metal skin is preferably clamped onto and sealed to the contact surface 33 of heat spreader 30 by a retainer 39 , or sealed with a solder bead (not shown). Together, the skin 37 and retainer 39 , contain the LMPM 35 when it melts. In an alternative embodiment shown in FIG. 3B, the LMPM 35 is contained by skin 37 and by a gasket 38 that is clamped between skin 37 and heat spreader 30 . Gasket 38 can be made of any suitable gasket material that is capable of maintaining a seal at the operating temperatures of the interface. In each case, at least one expansion port 30 a is included through heat spreader 30 for allowing thermal expansion of the LMPM 35 . If desired, ports 30 a can be plugged with plugs 30 b, as shown.
Together, the skin 37 and retainer 39 , or the skin 37 , gasket 38 and retainer 39 , contain the LMPM when it melts. The LMPM can be any suitable LMPM, such as are known in the art. LMPM's are sometimes referred to as fusible alloys. They include alloys of bismuth with lead, tin, cadmium, gallium, and/or indium. LMPM's can be designed to have melting points within desired temperature ranges by varying the proportions of these elements. According to the present invention, the LMPM that forms the thermal interface with heat spreader 30 melts between 29° C. and 65° C.
Because the melting point of the solder bead 39 that contains the LMPM must be higher than the melting point of the LMPM, it is preferable to attach skin 37 to bead 39 before the LMPM is emplaced if the solder approach is used. Once the perimeter of skin 37 is completely sealed to contact surface 33 , the desired volume of LMPM can be melted and poured or injected under the skin. This is preferably accomplished via access port 30 a . After the desired volume of LMPM is in place behind skin 37 , access passage is preferably sealed by any suitable means, such as solder, that is capable of remaining sealed at operating temperatures. This embodiment provides excellent heat conduction away from the DUT, as LMPMs typically have thermal conductivities of at least 100 BTU/ft, and often at least 200 BTU/ft.
Still another embodiment of the thermal interface can be constructed without using a conformal member at the interface. In this embodiment (not shown), the lower surface of heat spreader 30 is preferably covered directly with a metal foil as described above. This embodiment relies on the slight conformability of the heat sink material and foil and the relatively good heat transfer that is made possible by the elimination of a conformal member to ensure that sufficient heat is transferred from the DUT.
Thermal Compensation System
The present burn-in system is adapted to burn in DUTs having a variety of capacities. It is also known that, even within DUTs having the same specifications, a range of actual operational properties will be encountered. At the same time, the thermal tolerance of DUTs is relatively small and it is preferred that burn-in be carried out within a narrow temperature range. For example, chip manufacturers may specify that burn-in or testing be performed in the temperature range of from 60° C. to 125° C. As long as the cooling system provides a set cooling capacity for each socket, unequal heating among individual DUTs will result in uneven temperatures among the DUTs. Because the range of operational temperatures of a given set of DUTs is likely to exceed the specified burn-in temperature range, it is necessary to include a system for equalizing the temperatures across a set of DUTs.
In the present system, this is accomplished by providing excess cooling capacity and simultaneously supplying make-up heat to individual DUTs. More specifically, the cooling system, described below is designed and operated so as to remove approximately 10 percent more heat from each socket than is generated by the hottest DUT. Referring now to FIGS. 3A and 4, each heat spreader 30 preferably includes a thermocouple 42 or other suitable temperature sensor embedded in the body of the heat sink, near its contact surface 33 . Thermocouple 42 is preferably removable and replaceable and is connected to suitable signal processing equipment (not shown) by thermocouple leads 43 . Thermocouple 42 can be any suitable thermocouple, such as are well known in the art. Thermocouple 42 is preferably held in place by a set screw 42 a.
In addition, a small resistance heater or other type of heater 44 is also included in heat spreader 30 . Heater 44 may be any suitable heater, so long as it is capable of a fairly rapid response time. Heater 44 is preferably positioned behind thermocouple 42 with respect to contact surface 33 , so that thermocouple 42 senses the temperature at a point very near the surface of the DUT. Heater 44 is also preferably removable and replaceable and is connected to a power source by heater leads 45 . The power applied to heater 44 is preferably controlled by the signal processing equipment in response to the output of thermocouple 42 . At present, it is preferred that each heater 44 be capable of generating at least 30, more preferably at least 50 and most preferably at least 55 watts of heat. Heater 44 is preferably held in place by a set screw 44 a.
Liquid Vapor Cooling System
Referring now to FIGS. 5A-B, heat is conducted away from DUT by heat spreader 30 , which is in turn cooled by heat sink 50 . Each heat sink 50 cools a plurality of sockets. In a preferred embodiment, heat sink 50 includes a liquid-vapor (LV) duct 52 therethrough. LV duct 52 serves as a conduit for a cooling medium, such as but not limited to water (liquid and vapor). The water circulates through a closed loop (not shown) that includes duct 52 , a reservoir, a heater, a controller and a mechanical device that makes both electrical contact between electrical connectors 53 and 54 and mechanical thermal contact simultaneously.
Heretofore, liquid-vapor cooling systems have been used for cooling burn-in devices for high power transmitters, silicon controlled rectifiers and the like. The principles involved in operation of an LV cooling system are set out in U.S. Pat. No. 3,756,903 to Jones, which is incorporated herein in its entirety. However, as discussed above, the handling, cost, and other considerations associated with those devices make previously known cooling LV systems unsuitable for cooling integrated circuit chips as in the present application.
Heretofore, it has always been necessary to provide a separate controller for each duct 52 , so as to ensure that the cooling of one group of devices would not affect the cooling of another group of devices in the system. According the present invention, significant cost and space savings are realized by providing ducts 52 that are manifolded together in groups of at least two and preferably 4, thereby allowing an entire system of up to 72 sockets to operate with a single reservoir, heater and controller.
Referring now to FIG. 6, it will be understood that the socket and heat sink combination can be repeated several times within a single burn-in system 100 . According a preferred embodiment, LV ducts 52 are grouped and manifolded together so that they can be operated on a single system and controlled by a single controller. LV ducts 52 can be grouped so that all ducts from burn-in system 100 are controlled together, or can be grouped in subgroups containing less than all of the ducts.
Although the present system is described in terms of the preferred LV cooling system, it will be understood that any other cooling system can be used without departing from the scope of the present invention. For example, air, chilled water (such as in an LCU), or other cooling fluids can be placed in direct or indirect thermal contact with heat spreader 30 , so as to carry away the desired amount of heat.
Operation
When it is desired to perform a burn-in operation, a DUT 40 is placed on socket base 12 within the area bounded by lip 17 so that the electrical contacts on the DUT align with the appropriate contacts 15 on socket base 12 . The heat spreader 30 and the components affixed thereto are then lowered onto the base until lid 20 comes to rest on compression stop 16 . Referring now to FIGS. 1 and 5 A-B, a heat sink 50 is sandwiched between one or more pairs of opposed sockets 10 and the force F applied on the opposed sockets serves as the compression force on the components, including the DUT, within each socket. After each burn-in operation, the opposed sockets are withdrawn from contact with heat sink 50 , allowing each socket to be opened and the DUT to be removed.
Heat spreader 30 is sized and shaped such that when the force F is applied to it by heat sink 50 , heat pad 22 is pressed into good thermal contact with the upper surface of the DUT and springs 26 are slightly compressed. Heat pad 22 is compressed between the DUT and heat spreader 30 , but is not compressed to the limit of its compressibility. Likewise, springs 26 are not compressed to the limit of their compressibility and thus serve to transmit a limited compression force from heat spreader 30 to the DUT via pressure plates 24 . Hence, the application of force to the DUT is controlled within a desired range and any excess force is transmitted directly to the socket base via compression stop 16 . At the same time, the compressed heat pad 22 forms a good thermal contact between the DUT and heat spreader 30 , allowing heat spreader 30 and heat sink 50 to effectively remove all of the heat (30 watts or more) generated in the DUT during burn-in.
Like the applied force, the temperature of each DUT is precisely controlled within a predetermined, specified range during the burn-in operation. As stated above, this is accomplished by providing excess cooling capacity and then providing make-up heat as needed to individual DUTs. The LV system is set to remove from each socket more heat than the maximum amount of heat generated by any one of the DUTs. As each DUT is cooled, thermocouple 42 senses its temperature. If the temperature of a given DUT drops below the specified burn-in temperature range, the signal processor will cause heater 44 to provide a compensating amount of heat so as to maintain the temperature of the DUT within the desired range. It will be understood that this control loop can be accomplished by any suitable controller, including a microprocessor, and may include any suitable control algorithm, such as are known in the art.
EXAMPLE 1
Thermal Specs
Thermal specifications and operational details of one embodiment of a burn-in system 60 in accordance with the present invention are as follows:
Power handling: Each LVU can handle 2,500 watts of device dissipation. The standard test system with 8 LVU's can dissipate 20,000 watts. Each LCU can handle 5000 watts of device dissipation. The standard LCU test system with 8 LCU's can dissipate 40,000 watts.
In its highest power handling configuration with 4 DUTs per performance board, each DUT can dissipate up to 100 watts average power. Maximum device density per test system is 576 devices (12 devices per performance board, 6 performance boards per LVU, and 8 LVU's per test system, for a total of 48 boards containing 576 DUTs per test system). The system can be depopulated to allow for higher device power dissipation. The power supplies can deliver up to 75 watts of power to each device, and the LVU can handle 30 devices dissipating 75 watts each.
Preferred system density at 75 watts per device is 240 , for the LVU. Preferred system density at 75 watts per device is 480 devices for an LCU.
In an LVU, if the average DUT power is less than 27 watts, then device density can be increased to 15 DUTs on each performance board. At this load, 15 devices per board with the same number of board positions yields 720 DUTs per test system.
The present system DUT power supplies are capable of supplying 75 watts of DC power to each DUT in high power mode, or to each pair of devices in lower power mode.
Board density: As mentioned above, performance board density varies with expected average device power. For devices dissipating up to 34 watts average power, 12 parts per performance board are allowed. For devices dissipating between 35 and 52 watts, 8 parts per performance board are allowed. | A system and method for burning-in an integrated circuit chip including at least a socket capable of receiving and supporting the chip, electrical leads in the socket for connecting to corresponding leads on the chip, and a heat sink in thermal contact with a cooling medium. The heat sink includes a thermal interface in releasable thermal contact with the integrated circuit in the socket. The heat sink removes more heat from the integrated circuit than is generated during the burn-in process and the integrated circuit is maintained within a predetermined desired temperature range by monitoring the temperature of the integrated circuit and supplying make-up heat as needed. Multiple sockets can be grouped together and cooled by a manifolded cooling system, with the temperature of each integrated circuit being individually monitored and controlled. | 6 |
This patent is a continuation of U.S. patent application Ser. No. 08/564,508, filed Nov. 29, 1995, now U.S. Pat. No. 5,620,581.
FIELD OF INVENTION
The present invention relates to electroplating techniques and structures. Specifically, the present invention relates to techniques and structures for electrodepositing alloy metallic films having a uniform composition and thickness.
BACKGROUND OF THE INVENTION
Electroplating, the application of a metal to the surface of a material by electrolysis, is typically used in the fabrication of thin film devices to produce relatively thick layers of metal. The electroplating process involves applying an electrical energy source to vary the electropotential of a substrate workpiece in the presence of an electroplating solution.
One of the problems in the use of electroplating is the difficulty in maintaining a suitable uniformity in thickness and composition of deposited films. In the fabrication of thin film devices, such as magnetic core elements of thin film heads, advantages are achieved by fabricating the devices using a Permalloy material. The chemical description of a Permalloy material is NiFe. The iron content (Fe) of Permalloy is typically precisely controlled, in one example to 18 percent by weight. The process of electroplating a large alumina wafer, for example a 6 inch diameter circular wafer, typically dictates usage of an electroplating procedure resulting in a substantially uniform iron (e) concentration across the entire wafer. FIG. 1 is a pictorial diagram of a circular wafer 100, such as a six inch circular wafer, including a plurality of devices 110 which are fabricated using thin-film processes.
The nature of electrolytic plating of a substrate wafer is that the current density applied to the substrate is substantially greater at the periphery of the wafer than near the wafer center. FIG. 2 illustrates various regions of the circular wafer 100 having different current densities. A low current-density region 112 exists at the center of the wafer 100. A medium current-density region 114 surrounds the low current-density region 112. A high current-density region 116 encloses the medium current density region 114. These regions are for illustrative purposes since the current density varies continuously from the center of the wafer 100 to the periphery of the wafer 100. This higher current density results in an increased deposition rate of plated film at the periphery of the wafer. It follows that the film plating thickness is increased at the peripheral edges of the wafer as compared to the wafer interior. In the case of deposition of permalloy, an alloy of nickel and iron, the concentration of iron (Fe) is higher at the periphery of the wafer due to the higher current density in the peripheral region.
Problems of nonuniform deposition of thin films are accentuated for large wafers. For example, in large diameter circular wafers having a diameter of 6 inches or greater, deposition composition and thickness control is a very difficult problem.
The thin film thickness differences between the interior and periphery of a wafer cause practical difficulties in plating of specific structures. Illustratively, one type of selected electroplated structure, for example plating of a large bottom pole 310 having a length of 200 μm and a width of shown in FIG. 3, may have an iron content of 18% in the center region of the wafer, and 20% iron content in the periphery of the wafer. (Note that FIG. 3 is not drawn to scale.) Thus, the electroplating current distribution varies significantly in different regions of the wafer, resulting in a substantial variation in iron composition. Such a large variability in composition is not acceptable.
What is needed is a simple and cost-effective electroplating technique and system which maintains a substantially uniform metal composition and thickness while constructing thin film structures composed of a large number of thin film layers.
SUMMARY OF THE INVENTION
In accordance with the present invention, multiple-layer thin film devices are deposited by electroplating on an otherwise substantially clean substrate wafer. The composition of the electroplated layers is maintained substantially uniform using a cathode assembly on which the substrate wafer is mounted. The cathode assembly includes an inner cathode ring electrically connected to the wafer, a thief ring external to the cathode ring and an insulating ring connected between and electrically insulating the cathode and thief rings. The cathode ring and the thief ring are powered by separate power sources.
In accordance with a first embodiment of the present invention, an apparatus for electroplating metal films onto a workpiece includes a cathode ring having a flanged inner surface for holding the workpiece for electroplating and a notched outer surface. An insulator is connected to the outer surface of the cathode ring, having a flanged inner surface for nesting with the notched outer surface of the cathode ring and a notched outer surface. A thief ring is connected to the outer surface of the insulator ring, having a flanged inner surface for nesting with the notched outer surface of the insulator ring. The cathode ring is connected to a first negative terminal of a power supply, supplying a cathode current to the workpiece. The thief electrode is connected to a second negative terminal of a power supply, separate from the first negative terminal, for supplying a thief current.
In accordance with a second embodiment of the present invention, a method of electroplating a thin metal film onto a substrate wafer includes the steps of electroplating an otherwise substantially clean substrate wafer and maintaining a chemical composition of the electroplated layers substantially uniform using a cathode assembly for mounting the substrate wafer. The cathode assembly includes an inner cathode ring electrically connected to the wafer, a thief ring external to the cathode ring and an insulating ring connected between and electrically insulating the cathode and thief rings. The method also includes the step of powering the cathode ring and the thief ring using separate power sources.
BRIEF DESCRIPTION OF THE DRAWINGS
The features of the invention believed to be novel are specifically set forth in the appended claims. However, the invention itself, both as to its structure and method of operation, may best be understood by referring to the following description and accompanying drawings.
FIG. 1 is a top view of a thin film head wafer which serves as a substrate for fabrication of a plurality of thin film components using an electroplating process.
FIG. 2 is a top view of a thin film head wafer shown in FIG. 1 but also illustrating regions of the wafer having different current density characteristics.
FIG. 3 is a schematic diagram showing a structure which is fabricated using an electroplating system.
FIG. 4 is a pictorial schematic diagram of an electroplating system in accordance with an embodiment of the present invention.
FIG. 5 is a top view of a cathode assembly and workpiece utilized in the electroplating system shown in FIG. 4.
FIG. 6 is a cross-sectional view of the cathode assembly and workpiece shown in FIG. 3.
FIG. 7 is a cross-sectional view of the cathode assembly which illustrates locations in which insulation is typically weak.
FIG. 8 is a top view of a substrate wafer workpiece which illustrates current density of the wafer undergoing electroplating processing.
DETAILED DESCRIPTION
Referring to FIG. 4, an electroplating system 400 is shown which includes an electroplating cell 410 containing an electroplating solution. Electrodes within the electroplating cell 410 are furnished in an anode 412 and a cathode assembly 420 supported by respective plexiglass blocks 414 and 416. A workpiece, typically a substrate wafer 430, is mounted in a central aperture 422 of the cathode assembly 420. Thin film metal components 432 and 434 are fabricated on the substrate wafer 430. The substrate wafer 430 is, for example, a 6 inch radius wafer. The cathode assembly 420 includes an inner cathode ring 424, an intermediate insulator ring 426 and an outer thief ring 428. An adjustable dual-channel power supply 440 has two negative terminals 442 and 444 and a common positive terminal 446. The positive terminal 446 is connected to the anode 412. A first negative terminal 442 is connected to the cathode ring 424. A second negative terminal 444 is connected to the thief ring 428. Accordingly, the cathode ring 424 and thief ring 428 share one anode on the same adjustable dual channel power supply 440.
Referring to FIGS. 5 and 6, the cathode assembly 420 is shown in greater detail. The cathode ring 424 has a flanged inner surface 510, which holds the substrate wafer 430 in electrical contact, and a notched outer surface 512. The insulator ring 426 is connected to the outer surface 512 of the cathode ring 424 so that the notched outer surface 512 nests with a flanged inner surface 520 of the insulator ring 426. The insulator ring 426 also has a notched outer surface 522. The thief ring 428 is connected to the outer surface 522 of the insulator ring 426 so that the notched outer surface 522 nests within a flanged inner surface 530 of the thief ring 428.
The cathode ring 424 is a metallic ring. In one embodiment, the cathode ring 424 is constructed from stainless steel.
The thief ring 428 is connected to the second negative terminal 444, which is separated from the first negative terminal 442, connected to the cathode ring 424. The adjustable dual channel power supply 440 drives the cathode current during the electroplating operation by a connection via the first negative terminal 442. When electroplating is in progress and the adjustable dual channel power supply 440 is driving both first negative terminal 442 and second negative terminal 444, the thief ring 428 "steals away" iron (Fe) ions from the edge of the substrate wafer 430. When a NiFe permalloy is electroplated, a higher current density arises in a region at the periphery of the substrate, yielding a higher concentration of iron in this peripheral region. Utilization of the thief ring 428 and, more specifically, utilization of a thief ring 428 in which the thief current is adjustable, advantageously allow a substantial reduction in iron concentration around the periphery of the wafer. In other words, availability of iron ions near the peripheral edge area of the wafer 430 is reduced because electroplating is occurring on the thief ring 428. As a result, the thin film electroplated onto the substrate wafer 430 is deposited more uniformly, in terms of NiFe composition, because iron ions that migrate to form a high concentration at the peripheral edge area of the substrate wafer 430 are pulled off the wafer 430 onto the thief ring 428.
The insulator ring 426 furnishes insulation between the cathode ring 424 and the thief ring 428. FIG. 6 shows one embodiment of an insulator ring 426 where the outer edge has a lip extending upward and the inner edge has a lip extending downward so as to have a substantially "Z-shaped" cross-sectional form. The illustrative insulator ring 426 is a plastic insulator ring which is sized to fit tightly around the cathode ring 424. A plastic insulator ring advantageously furnishes a durable insulating layer. The plastic insulator ring may be either a machined ring or a molded ring. A machined is preferred.
Other insulating techniques, for example, coating the outer surface 512 of the cathode ring 424 with Teflon™ or Kyner™, forms an insulating layer between a cathode ring and a thief ring that inadequately coats the cathode ring. Using this insulating technique, sharp edges 710 and vertical surfaces 720 of the cathode ring, as shown in FIG. 7, do not receive an adequate insulating coating, unfortunately is associated with breakdown in the insulation between the cathode and thief ring, possibly resulting in short-circuiting.
In operation, a substrate wafer 430 is electroplated by placing the edges of the wafer onto the inner flange 510 of the cathode ring 424, which is electrically connected to the first negative terminal 442 of the adjustable dual channel power supply 440. The cathode ring 424 is connected to the seed layer on the substrate wafer 430, which acts as the cathode in the electrolytic plating process. Thus the ring is called the "cathode ring". One characteristic of the plating process is absent is that the current density is substantially greater at the edge of the substrate wafer 430 near the cathode ring 424, as is shown in FIG. 8. The thief ring 428 "steals" away some of the Fe ions at the edge of the substrate wafer 430 so that, although the current density remains high at the outer portion of the wafer 430, excess Fe ions are drawn off the outer portion of the wafer 430 by the thief ring 428 and plated onto the thief ring 428.
The second negative terminal 444 of the adjustable dual channel power supply 440 is controlled to vary the thief current density of the thief ring 428. By controlling the thief current density, the metal composition of the electroplated metal film is controlled. The thief current density is adjusted (increased or decreased) according to the particular iron (Fe) concentration desired at the periphery of the substrate. In one example, the large bottom pole structure 310 shown in FIG. 3 may be electroplated with the second negative terminal of the adjustable power supply regulated to achieve a thief current density of 3.0 Amperes per square foot, a lower current density than is used to electroplate the small side pole structure 320. The small side pole structure 320 may be plated at a thief current density of 4 to 5 amperes per square foot. Separate negative terminals 442 and 444 of adjustable dual channel power supply 440 are employed to generate separately-controlled current densities to the thief ring 428 and the cathode ring 424. The insulator ring 426 between the cathode ring 424 and the thief ring 428 is furnished to maintain these different current densities.
The description of certain embodiments of this invention is intended to be illustrative and not limiting. Numerous other embodiments will be apparent to those skilled in the art, all of which are included within the broad scope of this invention. For example, the anode, cathode and insulator elements of the cathode assembly are described as ring elements. The ring elements are most suitable for electroplating of structures on a circular wafer. However, the invention is just as applicable to other noncircular shapes and structures. Accordingly, the electroplating structure and method is applicable to noncircular structures that form a closed path and also noncircular structures that do not form a closed path. | Multiple-layer thin film devices are deposited by electroplating on an otherwise substantially clean substrate wafer. The composition of the electroplated alloy layers is maintained substantially uniform using a cathode assembly on which the substrate wafer is mounted. The cathode assembly includes an inner cathode ring electrically connected to the wafer, a thief ring external to the cathode ring and an insulating ring connected between and electrically insulating the cathode and thief rings. The cathode ring and the thief ring are powered by separate power sources. | 2 |
[0001] This nonprovisional application is a continuation of International Application No. PCT/EP2012/072902, which was filed on Nov. 16, 2012, and which claims priority to German Patent Application No. DE 10 2011 086 605.1, which was filed in Germany on Nov. 17, 2011, and which are both herein incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a method for closing a fillable collecting tank, particularly a fillable collecting tank of a heat exchanger for storing a fluid. Furthermore, the invention also relates to a heat exchanger.
[0004] 2. Description of the Background Art
[0005] Collecting tanks of heat exchangers are used for the intake, distribution, storage, and/or discharge of media. In this regard, collecting tanks are used in the conventional art, which are provided with a connecting piece and can be closed with a screw-on and thereby removable plastic cover.
[0006] Other heat exchangers are connected by means of the provided connecting pieces to tubes or pipes, so that sealing of the collecting tank is therefore unnecessary.
[0007] Other collecting tanks are provided with valves which are closed after filling. This is not suitable for large-scale use, however, because it is very involved and costly.
SUMMARY OF THE INVENTION
[0008] It is therefore an object of the present invention to provide a method by which the filling opening of a heat exchanger can be closed securely and easily.
[0009] In an embodiment of the present invention, a method for closing a fillable collecting tank is provided, particularly a fillable collecting tank of a heat exchanger for storing a fluid, with walls forming the collecting tank, whereby one of the wails is formed as a baseplate having openings for receiving tubes, whereby a filling opening for adding the fluid is provided in one of the walls, whereby the filling opening can be closed by the provision of a closing element that can be inserted into the filling opening or placed on the filling opening after the fluid has been added to the collecting tank. It is expedient in this regard, if the closing element is inserted or attached only after the filling, in order to facilitate the handling of the closing and without the indispensable use of costly components.
[0010] The closing element can be a deformable closing element. This confers the advantage that the deformable closing element is inserted in the non-deformed state in the filling opening or is placed on said opening, before a deformation process brings about the sealing of the filling opening.
[0011] The filling opening can be closed directly by the deformation of the deformable closing element. This is advantageous, because by using the deformable closing element directly in the filling opening a small and easily manageable and convenient closing element can be employed.
[0012] The deformable closing element can be inserted in the filling opening and is deformed in the filling opening or in the immediate vicinity of the filling opening to seal the filling opening.
[0013] The deformable closing element can be placed in, at, or on the filling opening and the closing element is deformed at a distance from the filling opening in order to close the collecting tank fluid-tight. This has the advantage that a sealing closing of the filling opening can occur away from the actual filling opening.
[0014] The closing element can be a tube-like element that at one of its ends can be connected to the filling opening and is closed in a region spaced apart from this end. In this regard, the tube-like element is closed by deformation. The end of the tube or a region adjacent to the end can be deformed by such a squeezing or coiling process so that it is sealed thereby.
[0015] The opening after the closing can be sealed or made tight in addition via a sealing component, also called a sealant. It is advantageous in this regard if the sealing component is an adhesive. The adhesive or sealing compent in general can be applied to the closing element, such as, for example, deposited or spread or sprayed on. Depending on the selected flowability of the adhesive or sealing component, it can run over the closing element and close possible gaps and provide additional sealing of the sealing site.
[0016] The closing element can be a substantially planar element placed on the filling opening. To this end, it is advantageous if the substantially planar element abuts the collecting tank at the edge of the filling opening around the filling opening and is connected sealingly there.
[0017] The planar element can be a metal sheet made of aluminum or an aluminum alloy.
[0018] The element can be attached to the collecting tank by means of welding,
[0019] The welding can be by ultrasonic torsional welding or ultrasonic longitudinal welding. A very locally limited welding is achieved thereby.
[0020] In an embodiment, a heat exchanger can be provided with at least one fillable collecting tank, particularly for storing a fluid, with walls forming the collecting tank, whereby one of the walls is formed as a baseplate having openings for receiving tubes, whereby a filling opening for adding the fluid is provided in one of the walls, whereby the filling opening is closed with a deformable closing element.
[0021] 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
[0022] 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 limitive of the present invention, and wherein:
[0023] FIG. 1 is a heat exchanger in a perspective view according to an embodiment;
[0024] FIG. 2 is a heat exchanger in a side view;
[0025] FIG. 3 is a side view of the collecting tank of the heat exchanger according to FIG. 1 and FIG. 2 ;
[0026] FIG. 4 is a block diagram for explaining a process for the production of a heat exchanger;
[0027] FIG. 5 is a block diagram for explaining a process for the production of a heat exchanger;
[0028] FIG. 6 a is a schematic illustration for the roughening and/or cleaning of a filling opening to be closed;
[0029] FIG. 6 b is a schematic illustration for filling an accumulator section of an evaporator;
[0030] FIG. 6 c is a schematic illustration for inserting a closing element;
[0031] FIG. 6 d is a schematic illustration for the roughening and/or cleaning of a filling opening to be closed;
[0032] FIG. 6 e is a schematic illustration for applying a sealing component, such as an adhesive;
[0033] FIG. 6 f is a schematic illustration for the curing of the sealing component;
[0034] FIG. 7 is a block diagram for explaining a process for the production of a heat exchanger according to an embodiment;
[0035] FIG. 8 is a block diagram for explaining a process for the production of a heat exchanger according to an embodiment;
[0036] FIG. 9 a is a schematic illustration of a filling opening;
[0037] FIG. 9 b is a schematic illustration of a filling opening with rivet;
[0038] FIG. 9 c is a schematic illustration of a filling opening with rivet;
[0039] FIG. 9 d is a schematic illustration of a filling opening with rivet;
[0040] FIG. 10 a is a schematic illustration of a filling opening;
[0041] FIG. 10 b is a schematic illustration of a filling opening with rivet;
[0042] FIG. 10 c is a schematic illustration of a filling opening with rivet;
[0043] FIG. 10 d is a schematic illustration of a filling opening with rivet;
[0044] FIG. 11 is a block diagram for explaining a process for the production of a heat exchanger according to an embodiment;
[0045] FIG. 12 is a block diagram for explaining a process for the production of a heat exchanger according to an embodiment;
[0046] FIG. 13 a is a schematic illustration of a filling opening;
[0047] FIG. 13 b is a schematic illustration of a filling opening with a filling tube;
[0048] FIG. 13 c is a schematic illustration of a filling opening with a closed filling tube;
[0049] FIG. 13 d is a schematic illustration of a filling opening with an angled filling tube;
[0050] FIG. 14 a is a schematic illustration of a heat exchanger from above with an angled filling tube;
[0051] FIG. 14 b is a schematic illustration of a heat exchanger from the side with an angled filling tube;
[0052] FIG. 14 c is a schematic illustration of a heat exchanger from the narrow side with an angled filling tube;
[0053] FIG. 15 a is a schematic illustration of a heat exchanger from above with an angled filling tube;
[0054] FIG. 15 b is a schematic illustration of a heat exchanger from the side with an angled filling tube;
[0055] FIG. 15 c is a schematic illustration of a heat exchanger from the narrow side with an angled filling tube;
[0056] FIG. 16 a is a schematic illustration of a heat exchanger from above with an angled filling tube;
[0057] FIG. 16 b is a schematic illustration of a heat exchanger from the side with an angled filling tube;
[0058] FIG. 16 c is a schematic illustration of a heat exchanger from the narrow side with an angled filling tube;
[0059] FIG. 16 d is a schematic illustration of a heat exchanger from the narrow side with an angled filling tube;
[0060] FIG. 17 a is a schematic illustration of a heat exchanger from above with an angled filling tube;
[0061] FIG. 17 b is a schematic illustration of a heat exchanger from the side with an angled filling tube;
[0062] FIG. 17 c is a schematic illustration of a heat exchanger from the narrow side with an angled filling tube;
[0063] FIG. 17 d is a schematic illustration of a heat exchanger from the narrow side with an angled filling tube;
[0064] FIG. 18 is a block diagram for explaining a process for the production of a heat exchanger according to an embodiment; and
[0065] FIG. 19 is a block diagram for explaining a process for the production of a heat exchanger according to an embodiment.
DETAILED DESCRIPTION
[0066] FIGS. 1 and 2 show a heat exchanger 1 in a perspective view or in a side view, respectively. In this case, heat exchanger I has a first collecting tank 2 and a second collecting tank 3 , which are each arranged on the two opposite ends of a tube-fin block 4 . Heat exchanger 1 with tube-fin block 4 is designed as dual-flow in a first region; this means that inlet tube 5 leads into collecting tank 3 ; next a medium flows from collecting tank 3 to collecting tank 2 through the tube-fin block in region 2 a, flows over from region 2 a to region 2 b, then flows from collecting tank 2 to collecting tank 3 in region 3 b through the tube-fin block, and flows out again through outlet tube 6 . An expansion valve 7 is connected to the end regions of the tubes at the two ends of tubes 5 and 6 , said ends being opposite to heat exchanger 1 .
[0067] Heat exchanger 1 further has a region 10 , which is arranged adjacent to the heat exchanger region with collecting tanks 2 and 3 and tube-fin block 4 . Region 10 of the heat exchanger comprises a collecting tank 11 and a collecting tank 12 and a tube-fin block 13 , whereby tube-fin block 13 is equipped with coaxially arranged heat exchanger tubes, so that a first fluid can flow in the interior of the inner tube and a second fluid can flow in the interspace between the inner tube and the outer tube. Collector 11 or collector 12 is designed such here that they have a first collecting space 14 and a second collecting space 15 , whereby first collecting space 14 preferably communicates with the interior of the inner tube and collecting space 15 communicates with the interspace between the inner tube and the outer tube. The two collecting spaces 14 and 15 are arranged in a collecting tank and separated from one another by a partition wall 16 . It is preferred now that collecting space 14 is connected via a fluid communication line to collecting tank 2 and the opposite collecting space 14 , located at the lower end, of collecting tank 12 is in fluid communication with collecting tank 3 . This has the effect that a fluid, which in the region of the inlet flows out of outlet tube 5 into collector 3 , on the one hand, can flow through tube-fin block 4 to collector 2 or, on the other, alternatively can flow from collector 3 into collector 12 . From there, the fluid would flow from collector 12 through the inner tube of the coaxial tube into collector 11 and from there would flow into collector 2 before the medium again flows back to collector 5 and leaves heat exchanger 1 from outlet tube 6 .
[0068] The design therefore creates more or less a triple-flow heat exchanger 1 , in which two flows are connected parallel and these are then connected in series to a third flow. Moreover, a further heat exchanger is located in region 10 , whereby a fluid, which can be collected and provided via collecting tanks 15 of upper collecting tank 11 and lower collecting tank 12 , can be provided in the tube regions between the inner tube and outer tube of region 10 .
[0069] In a preferred embodiment of the invention, heat exchanger 1 is a coolant evaporator, in which coolant flows in through the inlet tube, flows through the described fluid channels and collecting tanks through the heat exchanger, and then again leaves the heat exchanger at the outlet tube. The region of the additional heat exchanger in region 10 can be provided as a storage medium region, where a latent cold storage medium can be provided that is cooled during the operation of the evaporator based on the heat given off to the coolant, and in the case of an air flow with a turned-off evaporator function in a stationary coolant circuit the air can then be cooled by uptake of energy or enthalpy from the air.
[0070] The heat exchanger for the so-called accumulator region 10 is basically separated from the heat exchanger region of the evaporator for the flow of coolant fluid and is also not in fluid communication with the inlet or outlet tube 5 , 6 . There is a separation of media between the coolant and the cold storage medium.
[0071] Collecting space 15 of collecting tank 14 has an opening 17 for filling the heat exchanger, such as particularly the accumulator region of the heat exchanger; said opening can be easily seen in FIG. 3 and is arranged on a narrow side of collector 11 . In this regard, collector 11 is formed by walls 18 , 19 , 20 , 16 , and 21 , whereby collecting space 15 is formed by walls 18 , 19 , 20 , and 16 . Front wall 21 is part of the walls forming the collecting tank and incorporates opening 17 as a filling opening. The fluid to be added to heat exchanger 1 is added through said filling opening 17 and after the filling, filling opening 17 is closed by means of a closing element which is not shown.
[0072] The basic design and connection of such a so-called storage evaporator according to FIGS. 1 to 3 are disclosed in the publication DE 10 2006 051 865 A1 or in DE 10 2004 052 979 A1, which are both herein incorporated by reference.
[0073] The production of a heat exchanger occurs by the processes being described now, whereby a process is used for the production of the evaporator resulting in the evaporator as such. The building of the evaporator in this regard according to FIG. 4 begins with a provision of parts necessary for the assembly of the evaporator, such as the collector sheets for the tubes and fins and the connecting tubes, etc. Next, the relevant parts are fitted together to form the heat exchanger. In FIG. 4 , this occurs in block 30 in that the building of the evaporator is begun with the bundling of the tube-fin blocks and clamping of said tube-fin blocks. Next, the thus bundled tubes are pressed at their ends into the tube base of the collecting tank, see block 31 . This is also called the tube installation.
[0074] The now fully assembled heat exchanger where connecting tubes 5 , 6 can also be already connected, is then brazed in the brazing furnace, see block 32 . An optional surface coating occurs in block 33 after the brazing process. In block 34 , expansion valve 7 is then installed in inlet and outlet tubes 5 , 6 , according to FIG. 1 or 2 , see block 34 . After production of heat exchanger 1 and the valve installation, the main evaporator, also called the evaporator section of the heat exchanger, is tested according to block 35 , as well as the accumulator section 36 of the heat exchanger. Next, the region of filling opening 17 is cleaned, see block 37 . After this, the accumulator is evacuated, see block 38 , and then in block 39 the accumulator section is filled with a medium by means of a filling device.
[0075] Reference is made to the aforementioned publications DE 10 2006 051 865 A1 and DE 10 2004 052 979 A1 in regard to the filling process.
[0076] Next, after the filling the filling opening is closed by means of a closing element. According to block 40 , a deformable closing element such as, for example, a blind rivet is used advantageously here, which is inserted in filling opening 17 of FIGS. 1 to 3 and then deformed. Subsequently, in block 41 , the surface to be sealed, also called the adhesive surface in FIG. 4 , undergoes a cleaning process. The cleaning process can be a mechanical cleaning process or a chemical cleaning process. In block 42 the head of the rivet or closing element is then sealed with a sealing component such as, for example, an adhesive, whereby in block 43 the curing process of the sealing component or of the adhesive can be accelerated by applying UV radiation or some other radiation that accelerates curing.
[0077] A block diagram in FIG. 5 shows an alternative approach, whereby in block 50 the block is bundled and then clamped and thereby the evaporator construction is begun. Next, in block 51 the tube ends of the tubes are pressed into the openings of the tube bases of the collecting tanks, also called tube installation. Thereafter, in block 52 the heat exchanger is brazed. This occurs preferably during passage through a brazing furnace.
[0078] After the brazing of the heat exchanger, an optional surface coating can be undertaken, see block 53 . Next, the provided valve, in the case of the evaporator the expansion valve, is connected to the substantially finished heat exchanger, according to block 54 . In block 55 , leak testing of the main evaporator takes place and in block 56 the surface regions, to be sealed later, of the filling opening or the surface regions adjacent thereto are cleaned. Next, the accumulator section of the heat exchanger is also tested for leaks according to block 57 . Preferably, in this process step the evacuation of the accumulator section of the heat exchanger may also be carried out, since the filling process is facilitated by an evacuation. The filling of the accumulator section is provided in block 58 of FIG. 5 . Next, in block 59 the filling opening is closed by means of a deformable closing element such as, for example, a blind rivet. In block 60 , the surface to be sealed, also called the adhesive surface, is cleaned. In block 61 , the surface to be sealed, preferably also the surface around the rivet head, is sealed and in block 62 curing of the sealing component or of the adhesive occurs, preferably by means of irradiation with UV rays.
[0079] FIG. 6 , in six sub-figures 6 a to 6 f, shows the process of filling and closing the heat exchanger, particularly for the accumulator section of the storage evaporator.
[0080] FIG. 6 a shows that the filling area, such as particularly the filling opening, is cleaned or roughened by means of a cleaning element or a roughening element. Next, in FIG. 6 b a filling device is connected to the filling opening and the accumulator section of the evaporator is evacuated and then a latent storage medium is sucked in from a storage reservoir by the low pressure into the accumulator section of the evaporator. As a result, the accumulator section of the evaporator is filled with the latent storage medium. In FIG. 6 c , a closing element, preferably a blind rivet, is inserted in the filling opening. It can be seen in the top detail of FIG. 6 c how a sleeve-like blind rivet element is inserted as a closing element into the filling opening. FIG. 6 d shows that the region of the closing element head or the region arranged around it is roughened or cleaned. This occurs again as in FIG. 6 a by means of a roughening or cleaning device. It can be seen in FIG. 6 e that the head of the closing element is sealed by means of a sealing component such as, for example, by means of an adhesive. The final sealing of gaps still remaining after the deformation of the closing element is thereby accomplished. In FIG. 6 f , radiation is applied causing the accelerated curing of the sealing component, such as the adhesive.
[0081] It is especially preferred, if the closing of the filling opening occurs with a deformable closing element such as, for example, a blind rivet, with the diameter of the blind rivet being preferably between 5 and 15 mm. The use of a blind rivet provides sufficient mechanical strength of a rivet shaft length of about 3 to 10 mm. The rivet can be inserted in the closing opening preferably manually or also power-assisted such as, for example, pneumatically. A subsequent degreasing or roughening of the surface in the hole vicinity of the closing opening leads to better adhesion of the sealing component to be applied later, such as, for example, an adhesive. This also serves in particular as removal of flux residues by mechanical removal or by plasma treatment or by a chemical surface treatment.
[0082] The application of the sealing component, such as particularly the adhesive, in the area of the closing element, such as the rivet head, may prevent the escape of the latent storage medium. The transition from the closing element, such as, for example, the rivet head, to the surface region of the wall of the collector, preferably must be completely covered, with the sealing layer being preferably about 1 mm and extending beyond the edge. The optimal layer thickness of the adhesive or of the sealing component is 1 to 5 mm. An anaerobically curing adhesive is preferred in this case used such as, for example, Wellomer UV 4601. The adhesive can be applied manually or with a dosing pump.
[0083] The UV curing of the adhesive, for example, via a UV point source or a UV flood lamp, can preferably be used. The UV radiation dose is preferably set so that the adhesive on the surface is cured within about 10 seconds and in its entire depth within about 30 seconds. The optimal distance with such a point source of radiation is about 20 to 200 mm, whereby preferably 100 mm is set. The size of the point source of radiation can correspond approximately to the diameter of the applied surface region of the sealing component or of the adhesive drop, whereby an exhaust can also be provided to catch emerging solvent vapors of the adhesive or of the sealing component, so that these vapors are removed. It is preferred if the sealing component or the adhesive is post-cured anaerobically for about another 24 hours after the curing before installation in a climate control device.
[0084] The use of a deformable closing element, here, for example, a blind rivet, and the subsequent application of a sealing component, here, for example, as an adhesive, produce a sufficiently high mechanical strength and simultaneously reliable sealing against the escape of a relatively odor-intensive latent storage medium. This process is especially preferable because of a good integrability into a series process environment with short cycle times, whereby the possibility of leak testing and evacuation for filling can also be achieved in one process.
[0085] In case the closing element protrudes relative to the wall of the collecting tank and spreads the adhesive layer, only minor adjustments are necessary regarding the installation space within the climate control device. Usually this is easily accomplished, so that the above-described approach represents a preferred approach without causing major changes in the climate control device.
[0086] FIGS. 7 and 8 together with FIGS. 9 a to 9 d show a further alternative embodiment of the method of the invention for closing a filling opening of a heat exchanger.
[0087] A method is described in FIG. 7 , in which in block 70 the tube-fin blocks of the heat exchanger are bundled and clamped. It represents the first essential step for building the evaporator. The tube installation is carried out in block 71 , whereby in this region the ends of the tubes are pressed into the openings in the tube bases. Next, in block 72 a threaded pop rivet is inserted in the filling opening of the collecting tank. In block 73 , the thus assembled heat exchanger is brazed in a brazing furnace and in block 74 preferably a surface coating is provided on the heat exchanger. Next, in block 76 a leak test is performed on the main evaporator section through which the coolant can flow and then in block 77 the accumulator section of the heat exchanger can be leak-tested. Next or simultaneously, the accumulator section of the heat exchanger can be evacuated, see block 78 , and filled in block 79 . Next, closing of the filling opening occurs by insertion of a screw in the deformable closing part, such as the threaded pop rivet.
[0088] FIG. 8 shows an alternative approach, whereby in block 90 the the evaporator construction is carried out in that the blocks are bundled and clamped. The tube installation occurs in block 91 whereby the tube ends of the tubes are pushed and pressed into the provided openings or passages in the tube base; see block 91 in this regard. Next, a threaded pop rivet is inserted into the filling opening of the collecting tank and deformed, whereby in block 93 the heat exchanger is brazed. In block 94 , an optional surface coating is provided, whereby in block 95 a valve installation can be provided for installing the expansion valve. Next, leak testing of the main evaporator takes place according to block 96 , and leak testing and evacuation of the accumulator section of the evaporator according to block 97 . In block 98 , the accumulator section is filled and in block 99 the filling opening is closed. Preferably a screw is inserted into the pop rivet element.
[0089] FIG. 9 a shows in section the region of filling opening 100 in the region of the collecting tank wall 101 in the accumulator section of the heat exchanger. A bored hole in the wall of the collector is visible, which is not yet provided with a closure, however.
[0090] In FIG. 9 b it can be recognized how a deformable element 102 , as, for example, a pop rivet with an internal thread, is provided in the opening 100 in wall 101 . This pop rivet can be fitted to the opening preferably by deformation. In so doing, the deformation can be provided either in the pop rivet itself or in wall 101 in which the opening is provided. In FIG. 9 c , an alternative embodiment of pop rivet 103 is shown which is inserted in opening 100 of wall 101 , whereby shoulder 105 is provided on inner wall 104 ; said shoulder is used as a shoulder for countersinking an insertable screw head.
[0091] In FIG. 9 d , in contrast to FIG. 9 c , a sealing element 106 is furthermore provided, which, for example, can be a Teflon band, and is used for sealing the screw-in screw that can be inserted into the pop rivet.
[0092] The alternative solution according to FIGS. 7 to 9 d provides that according to a standardized evaporator construction, the filling opening is next made by means of a pop rivet with an internal thread that is inserted into the bored hole of the collector. In this case, for a slight projection over the evaporator width of about 0 to 3 mm, it can be provided that the screw in the pop rivet may be made as countersinkable, see FIG. 9 c . After insertion of the pop rivet, said pop rivet with its central bored hole can then be sealed by a screw. It can be advantageous in this case that the thread can be provided in addition with a sealing element 106 , for example, with a Teflon band or a Teflon coating, so that the screw is securely sealed relative to the thread and a latent medium escape from the collector can thereby be prevented long-term and permanently. The use of self-sealing screws or threaded elements is also conceivable.
[0093] FIGS. 10 a to 10 d show an alternative design of the rivet element in a filling opening 100 of a wall 101 . In this case, rivet elements 107 is formed such that it has a shoulder 108 on the outside of the wall and a deformable element 109 on the inside, providing a form-fitting connection of the element with wall 101 . Subsequently, in thread 110 , within the central opening of the rivet element a thread and a screw can be screwed in to seal the opening. In this case, according to FIG. 10 c a shoulder can also be provided in the rivet element to receive a screw head within the rivet element. Further, according to FIG. 10 d a sealing element 112 , such as preferably a Teflon band, can also be provided to better seal the insert of the screw.
[0094] FIGS. 11 and 12 describe a method in which a filling tube placed on the filling opening is closed after the filling by deformation.
[0095] In this case, a corresponding method is described in FIG. 11 , whereby in block 120 the building of the evaporator occurs by bundling of the tube-fin blocks and the clamping of these blocks. In block 121 , tube installation occurs by pushing or pressing of the tube ends into the openings of the tube bases. Next, the filling tube is installed, see block 122 . In so doing, the filling tube is pressed into an opening provided for this or alternatively pressed onto a bond provided for this. In block 123 , the thus assembled heat exchanger is brazed. In block 124 , an optional surface treatment or surface coating takes place, whereby as in block 125 a valve installation, for example, an expansion valve, takes place. In block 126 , the evaporator section of the heat exchanger, also called the main evaporator, is tested for leaks. In block 127 , the sealing testing of the accumulator section of the evaporator takes place. In block 128 , the accumulator section, which is filled in block 129 , is evacuated. In block 130 , the accumulator section is closed by pressing together or deformation of the filling tube. In block 131 , the filling tube is placed against the evaporator for adjustment of the outer contour, so that the filling tube does not unnecessarily produce a structural space due to a protruding tube.
[0096] An alternative method is described in FIG. 12 , whereby in block 140 the evaporator is constructed by bundling and clamping of the tube-fin blocks. In block 141 , tube installation occurs by pushing or pressing the tubes into the provided tube openings in the tube bases. In block 142 , installation of the filling tube takes place whereby the filling tube is pressed into a provided opening or onto a provided connecting piece. In block 143 , brazing in the furnace takes place and in block 144 an optional surface coating takes place, whereby in block 145 a valve, such as preferably an expansion valve, is mounted on the connecting tube. In block 146 , the leak testing of the evaporator section takes place and in block 147 the leak testing and evacuation of the accumulator section of the evaporator takes place, whereby in block 148 the accumulator is filled with the medium, such as particularly the latent storage medium, whereby the accumulator section in block 149 is closed by pressing together or deformation of the filling tube. Next, again in block 150 the outer contour of the evaporator is adjusted by placement of the filling tube against it.
[0097] FIGS. 13 a to 13 d show the connection of a filling tube with a collector of a heat exchanger, its closure, and its adaptation to the installation space conditions. In this case, in FIG. 13 a collector 160 is formed with a pipe connection 161 connected to the collecting space for the preferably accumulator section of the evaporator. In FIG. 13 b , filling tube 162 is pushed or pressed onto connecting piece 161 , this configuration allowing the filling to occur via the filling tube. In FIG. 13 c , filling tube 162 is deformed in region 163 , for example, squeezed together, thereby closing the filling tube. In FIG. 13 d , the filling tube is bent, so that it does not extend too far from the collecting tank of the evaporator and advantageously comes to abut a surface region of the evaporator. FIGS. 14 a to 14 c , FIGS. 15 a to 15 c , FIGS. 16 a to 16 d , and FIGS. 17 a to 17 d show arrangement variants for arranging a filling tube. FIG. 14 a , viewed from above, thereby shows the heat exchanger of the invention, such as the evaporator with collecting tank 170 , 171 of the evaporator section and tank 172 of the accumulator section of the evaporator. Filling tube 173 is arranged on an end side of collecting tank 172 of the evaporator section and, as can be seen in FIG. 14 b , arranged angled downward parallel to the tubes of the tube-fin block. FIG. 14 c shows this once again in a side view, whereby the filling tube communicates with the filling opening and is angled downward. FIG. 15 a shows the same collectors 171 , 170 , and 172 , whereby the filling tube is bent more or less U-shaped and is oriented parallel to the longitudinal extension of a collector. To this end, filling tube 174 is bent upwards and laterally more or less U-shaped between the collecting tanks and is arranged along the longitudinal axis of the collecting tanks. Different arrangement variants for filling tube 174 are shown in FIG. 15 c . Thus, the filling tube can be arranged in principle in a filter-shaped recess between collectors 171 and 172 ; a recess is arranged between collectors 170 and 171 or in a position adjacent to collector 172 , see arrow 175 , whereby the filling tube in this exemplary embodiment is placed in a spatial area where the collector forms an arc and therefore does not require so much installation space. In the examples of FIGS. 16 a to 16 d , collectors 170 , 171 , and 172 are provided accordingly and the filling tube is shown entering the collector from the side from the filling opening or from above, whereby the filling tube, angled in an I-shape, is oriented along the longitudinal direction of collector 172 . Alternatively, the filling tube can also be arranged parallel to the collecting tanks in the delta-shaped spatial areas according to reference character 177 or 178 .
[0098] FIGS. 17 a to 17 d show a variant in which the filling tube enters the collector from a bottom side of the tube base of the collecting tank, see FIG. 17 c , where filling tube 179 enters the collector through a lower edge area 180 . Accordingly, in a simplified design filling tube 179 can be oriented substantially perpendicular downward, so that it is oriented more or less parallel to side wall 181 of the collector and takes up as little space as possible. Viewed from above, according to FIG. 17 a , this arrangement is advantageous such that the header cannot be seen.
[0099] FIGS. 18 and 19 show further approaches to the method of the invention for closing a filling opening of a collecting tank of a heat exchanger. In this regard, FIG. 18 in block 190 shows the construction of the evaporator by bundling and clamping of the tube-fin blocks. In block 191 , tube installation takes place by pressing the tubes into the provided tube openings in the tube base. In block 192 , the heat exchanger is brazed in the furnace, whereby in block 193 an optional surface coating can occur, before in block 194 a valve installation, for example, for the expansion valve, takes place. In block 195 , the leak testing of the evaporator section of the heat exchanger takes place, whereby in block 196 the accumulator section of the heat exchanger is tested for leaks. Next, evacuation takes place in block 197 and filling of the accumulator in block 198 , whereby in block 199 the filling opening is closed by a deformable element, such as, for example, a rivet element or a blind rivet element, optionally with a washer.
[0100] FIG. 19 shows the approach in an exemplary embodiment of a further method of the invention, whereby in block 200 the evaporator construction is characterized by bundling and clamping of the blocks. In block 201 , tube installation takes place by pressing the tubes into the openings, provided for this, in the tube base. Brazing in the brazing furnace takes place in block 202 and an optional surface coating in block 203 . In block 204 , a valve installation can occur where, for example, an expansion valve is placed and connected at the provided connecting tube of the heat exchanger. Leak testing of the evaporator section of the heat exchanger takes place in block 205 , whereby leak testing of the accumulator of the heat exchanger takes place in block 206 , whereby an evacuation of the accumulator section takes place in block 207 , so that filling of the accumulator section can occur in block 208 . In block 209 a closing of the filling opening of the accumulator section occurs, for example, by a blind plug, which can then be sealed by post-brazing, see block 210 .
[0101] In an alternative method, the closing element is a substantially planar element placed on the filling opening. It is then attached to the collecting tank by means of welding. In this case, the welding is an ultrasonic torsional welding or an ultrasonic longitudinal welding. The element is thereby placed on the collecting tank also preferably made of aluminum or an aluminum alloy and acted upon by means of a punch moving in the torsional direction or in the longitudinal direction, also called a sonotrode, and welded.
[0102] In this regard, the substantially planar element are a metal sheet made of aluminum or an aluminum alloy. It may be advantageous here for the metal sheet to have an indentation that engages in the opening.
[0103] Advantageously, the metal sheet has a material thickness of about 0.5 to 3 mm, preferably 1 mm.
[0104] An energy input is advantageously from about 400 to 750 Ws at a clock rate of 1 second or less. Clock rates are advantageously in the range of 0.2 to about 0.5 seconds. A welding power of up to 10 kW at a force application of up to 10 kN is advantageous thereby.
[0105] 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 a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are to be included within the scope of the following claims. | A method for closing a fillable collecting tank, in particular a fillable collecting tank of a heat exchanger for storing a fluid, having walls forming the collecting tank, wherein one of the walls is formed as a baseplate having openings for receiving pipes, wherein a filling opening for adding the fluid is provided in one of the walls, wherein the filling opening can be closed by the provision of a closure element that can be inserted into the filling opening or can be placed onto the filling opening after the fluid has been added to the collecting tank. A heat exchanger is also provided. | 5 |
FIELD OF THE INVENTION
This invention relates to a low tire pressure warning (LTPW) system and particularly to such a system for occasionally reporting transmitter status and warning of adverse pressure changes.
BACKGROUND OF THE INVENTION
It has previously been proposed to monitor tire pressure by a transducer within each vehicle tire. Several schemes have been tried for advising the vehicle operator of tire pressure conditions, especially in the case of low tire pressure. It is known, for example, to generate a visible signal at the tire and to visually inspect the signal. It is also known to generate a magnetic field at the transducer in response to a low pressure condition, to detect the field by a detector mounted near each wheel, and to display a warning on the instrument panel.
It has also been proposed to mount a transducer and radio transmitter within each tire and a receiver on the vehicle dedicated to processing transmitted tire pressure data and displaying necessary information. Since the apparatus contained within the tire must be wholly self-contained and is not easily accessed for service, the device battery must be long-lasting, perhaps lasting for the life of the vehicle. In addition, it is not sufficient to transmit a signal only in the case of abnormal pressure, rather a signal must be issued occasionally to assure the receiver that the transmitting unit is operational. Such signaling consumes power and offers a challenge to long battery life.
To economize on power consumption, it has been proposed in the U.S. Pat. No. 5,285,189 entitled "Abnormal Tire Condition Warning System" to include in the pressure warning apparatus an inertia (or acceleration) switch sensitive to wheel rotation wherein the battery is connected to the transmitter only when rotation is sensed or a pressure switch closes. That system also includes a microprocessor having a sleep mode to conserve power. Another proposal also uses an inertia switch to initiate a state of health message when a certain speed is attained. An adverse aspect of these approaches is that the addition of the inertia switch to the system adds cost and diminishes reliability.
It is therefore a challenge to achieve long battery life and increased reliability while reducing cost through elimination of the inertia switch in the LTPW system. If this is accomplished by simply allowing signal transmission irrespective of wheel rotation, then a factory which inflates tires and tests the warning system will be subject to a very large number of signals that will interfere with testing of the LTPW units.
SUMMARY OF THE INVENTION
It is therefore an object of the invention to achieve a LTPW transmitter unit which attains long battery life without an inertia switch. Another object in such a unit is to avoid repetitious signaling before factory installation.
A LTPW system has a vehicle mounted receiver and a transmitter or sender mounted in each tire for sending pressure data to the receiver which displays a warning when appropriate. The transmitter includes a pressure switch or absolute pressure sensor coupled to a microprocessor which in turn controls a RF transmitter circuit. A battery is continuously connected to the microprocessor and the transmitter circuit. The microprocessor generally resides in a low power consumption sleep mode and wakes up every few seconds to execute software stored therein.
The software is able to define a factory test state and an in-use state. Initially an IN-USE flag is clear to allow tire assembly, battery installation and factory testing. The program senses when the tire is first pressurized to a threshold level and then issues only a single signal for the test of the unit. After the tire is pressurized for a time sufficient for the transmitter to be removed from the factory test state, the IN-USE flag is set; thereafter the unit will be in the in-use state and will issue signals intermittently.
When the microprocessor wakes up and finds that the IN-USE flag is set, it determines from a read pressure timer whether it is time to read pressure; if so the pressure is read and the timer is reset. The timer value is several wakeup cycles so that the pressure is checked perhaps every 10 to 30 seconds. If the pressure switch has changed to low pressure or if a pressure sensor detects a significant pressure drop, the transmitter will be energized to send a warning signal to the receiver. When the pressure is not read, a transmission timer is checked for transmission time. When it is transmission time, pressure data is read and then transmitted. Then the transmission time is set at between 3 and 5 minutes by random selection, and the microprocessor enters sleep mode. Each timer is decremented each wakeup cycle until it times out or is reset. This rate of usage is expected to yield battery life of about ten years.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other advantages of the invention will become more apparent from the following description taken in conjunction with the accompanying drawings wherein like references refer to like parts and wherein:
FIG. 1 is a schematic diagram of a low tire pressure warning system according to the invention;
FIG. 2 is a schematic diagram of the tire pressure sender portion of the system of FIG. 1;
FIGS. 3 and 4 are flow charts showing the operation of the transmitter portion of the system according to the invention.
DESCRIPTION OF THE INVENTION
Referring to FIG. 1, an automotive vehicle 10 has four tires 12, each equipped with a tire pressure sender (or transmitter) 14 residing within the tire and subject to tire pressure for transmitting radio signals carrying pressure related information. Each sender 14 has a unique identification code (ID) which is included in every transmission to verify the source of the signal. Transmitted signals are received by an antenna 16 coupled to a receiver 18. The receiver output data is fed to a processor 20 which is a microprocessor having a non-volatile memory such as an EEPROM for storage of tire ID and pressure data as well as a record of current transmitter activity. An algorithm within the microprocessor manages and evaluates the data and issues a low tire pressure signal to activate a telltale display 22 when a transmitted message indicates such a condition, and issues a damaged sender signal to activate a tell-tale display 24 when the pattern of received messages reveals less than four active senders.
The tire pressure sender 14, as shown in FIG. 2, has a controller 26 and an RF transmitter 28, each powered by a battery 30, and a transmitter antenna 32. The controller comprises a microprocessor configured to maintain a sleep state requiring very low power consumption until it is awakened by an internal or external timer. The controller 26 has a data output coupled to the transmitter 28 for defining the transmitted signal. A pressure transducer 36 comprises a pressure switch or sensor which is an input to the controller 26.
The pressure transducer 36, if it is a switch, is set to change state (open or closed) at a suitable warning pressure. As the pressure in a tire drops below the set pressure the switch changes state and the controller detects the change of state to cause transmission of a message containing a low pressure code. When pressure is restored to the tire, the pressure switch reverts to its original state and the controller transmits a message with a pressure OK code. The processor 20 responds to the messages by suitably activating or deactivating the low pressure tell-tale 22. If the pressure transducer 36 is an absolute pressure sensor having an actual pressure output, the controller will sample the pressure to report the pressure or a significant pressure change.
The controller 26 comprises a commercially available microprocessor which is programmed to operate in a factory test state and in an in-use state. The flow charts of FIGS. 3 and 4 represent the respective programs wherein the functional description of each block in the charts is accompanied by a number in angle brackets <nn> which corresponds to the reference number of the block. The factory test state is the initial condition of the controller when a battery is installed in the factory and an IN-USE flag has a default clear state. After tire assembly the units are tested when each tire is pressurize to verify pressure switch operation and signal transmission at the correct pressure. To prevent repetitive signaling from hundreds of tires in the factory, each transmitter is permitted only one signal during the factory test state. After a time delay, the IN-USE flag is set to terminate the factory test state and begin the in-use state.
The factory test program 38 is shown in FIG. 3. The program first checks the pressure to determine if it is above a set threshold <40>. If the pressure has not attained the threshold value an IN-USE counter is cleared <42> and the microprocessor returns to its sleep mode <44>. The microprocessor remains in the sleep mode for a set time, say, 3.5 seconds, and then wakes to again execute a wakeup cycle. If the pressure is above the threshold <40> and has just made the transition <46>, the IN-USE counter is initialized <48> to a value which defines the remaining life of the factory test state. The counter value should be large enough to assure time in the ordinary assembly process for the tire to leave the factory. When the counter is set, a single status message is transmitted <50> to complete the transmitter test. For cycles subsequent to issuing the status signal the IN-USE counter is decremented <52>. When the counter reaches 0 <54>, the IN-USE flag is set <56> to terminate the factory test state.
The general operating program is shown in FIG. 4. The microprocessor wakeup <60> occurs periodically. First the IN-USE flag is checked <62> to determine whether the transmitter is in service. If not the factory test routine is entered <38> but if the flag is set a pressure read timer is read to determine if it is time to read the pressure <64>. If not the pressure read timer is decremented <66> and a transmission timer is read <68> to see if it is time to transmit a pressure status report. If not, the transmission timer is decremented <70> and the microprocessor enters sleep mode <72>. If it is time to transmit a status report <68>, the pressure state (or value) of the transducer is read <74> and the appropriate data is transmitted <76>. In addition, a time within a range is randomly selected, the transmission timer is set to a count that corresponds to the selected time, and the pressure read timer is set to a predetermined count <78> before sleep mode is entered. If, in block 64, it is time to read the pressure, the pressure or pressure state is read <80>. If the pressure state has changed <82> that event is transmitted <76> and if not the program goes to block 78. Change of pressure state occurs if a pressure switch is operated or if a measure of absolute pressure has changed by a predetermined amount.
Keeping in mind that conservation of battery energy is important, the timer values are chosen to meet that goal as well as to supply current information on the tire pressure. The pressure read timer may be set to a count of about 5, for example, so that the pressure is checked every 20 seconds or so. Ordinarily a pressure check does not result in a signal transmission and thus uses minimal energy. The transmitter time may be selected from 3 to 5 minutes to provide frequent updates of the transmitter health.
The four pressure status transmissions on a vehicle are received by the receiver and processed independently. Each transmission will contain a status message which indicates the current state of the pressure switch (or reading of a pressure sensor) and will indicate to the receiver that all tire pressure monitors are working properly. If by chance two transmissions occur simultaneously, there is a danger that one signal would not be recorded. The clocks for operating the microprocessors are very close in frequency so that if two transmissions should coincide, they would remain in coincidence for a long time if they had the same transmitter time. The random selection of transmitter times prevents a continuation of coincident signals since the two transmitters will not likely be reset to the same time.
It will thus be seen that the LTPW system enables long battery life and frequent updates of tire pressure conditions without the use of an inertia switch or the like to limit the amount or frequency of data transmission. | A battery powered sensor in a tire has a microprocessor and a transmitter circuit permanently connected to a battery and a pressure switch or pressure sensor coupled to the microprocessor. The microprocessor has a sleep state and wakes up every few minutes to execute an algorithm which determines on a time basis whether to read the pressure state and transmit a report of significant changes, and determines on a randomly timed basis whether to transmit a status report. A factory test state permits only one signal transmission when the tire is inflated and inhibits other signals for a period to allow testing of many tires without interference from one another. | 1 |
BACKGROUND OF THE INVENTION
The present invention relates to a channel for the guidance or conveying of fibers, fiber slivers or yarns in a spinning machine, an open-end spinning device with such a channel, as well as a process for the manufacture of such a channel. A spinning machine with an open-end rotor spinning device is known from DE-A 37 34 544, in which the rotor housing is closed by means of a rotor lid, whereby the rotor lid and the channel located therein for the conveying of fibers into the spinning rotor are made in one piece by means of a molding or injection molding process. In order to obtain a bent form of the channel, the channel for fiber conveying is designed in such a manner in the open-end spinning device described in DE-A 37 34 544 that its two openings, the input opening for fibers and the output opening, are larger than the area of the channel between them, which is generally called the fiber feeding channel in open-end spinning machines. As a result, the cores which are necessary for the injection molding process which eventually produce the inside of the fiber feeding channel can be pulled out again from the form or from the completed rotor lid after the production of said rotor lid is completed. The molding method, in particular the injection molding method, makes it possible to produce the rotor lid in greater numbers, it being possible to produce the lid at the same time with lower tolerances and nevertheless economically. Such a channel has nevertheless the disadvantage that the design of its inner contour is very much restricted. In addition, the surface quality of the inside contour of the channel is not sufficiently high and must often be machined at high cost. A continuous transition between different cross-sections, e.g. also in the area of a diameter reduction of the channel or an enlargement of the diameter, is not possible or possible only with great difficulty.
OBJECTS AND SUMMARY OF THE INVENTION
It is therefore an object of the present invention to propose a channel with an inside contour that can be configured in various ways without any of the disadvantages of the state of the art, and in addition using the channel as a fiber feeding channel in an open-end rotor spinning, device as well as to propose a process for the manufacture of such a channel. Additional objects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.
Thanks to the design of the channel according to the invention for the guiding or conveying of fibers, fiber slivers or yarns, the channel can be made with practically any desired inside contour. The quality of the surface inside the channel is very high, i.e. it has none of the otherwise normal disfigurements which are caused by the manufacturing process. Pores and slivers, such as with cast channels for example, cannot occur. An embodiment of the channel according to the invention can be produced at low cost and equal quality, even in large quantities. Furthermore a channel designed according to the invention can be used in areas where channels with diameters measuring a few millimeters are needed, e.g. with twisting pipes or spinning nozzles, as well as where channels of 30 mm and more are used, e.g. as sliver channels, e.g. on draw frames. The channel is especially advantageous if made of brass, since brass maintains especially good surface quality even when extensive deformation takes place. In order to give it especially good resistance to wear, the channel can be made of steel according to another advantageous embodiment of the invention. If special steel is used, it is furthermore advantageously not oxidized. It is especially advantageous to use the channel as a conveying channel for fibers in an open-end friction spinning machine or rotor spinning machine. In another advantageous embodiment, the channel is a sliver channel on a draw frame.
By making the open-end rotor spinning device according to the invention, the lid as such, i.e. without the channel, as well as the channel can be produced in an optimized manner. The two can be made of different materials and be produced by different manufacturing methods, whichever is the most advantageous in either case. Thereby an optimum can be attained for each separate part. Thus the lid can be made of a low-cost material and the conveying channel of an especially resistant, wear-resistant material.
In designing the open-end rotor spinning device according to the present invention, the open-end spinning device can be made at especially low cost whereby at the same time diverse forms of the conveying channel are possible. It is in any case possible to make the inside of the conveying channel of an especially high quality. It is possible to produce nearly any inside contour of the conveying channel, whereby at the same time great surface quality is attained in the interior of the conveying channel and economic production is made possible. Designing the open-end rotor spinning device according to the invention, whereby the conveying channel is a tubular component which has been deformed by subjecting its interior to a medium under very high pressure (hydrostatic stretch deformation), the conveying channel of the open-end rotor spinning device is given favorable spinning characteristics thanks to the advantageous design of its inner contour and the evolution of its cross-sections. The surface on the inside of the conveying channel which comes into contact with the fibers is advantageously smooth, so that undisturbed conveying of the fibers takes place. The form of the inside contour of the conveying channel can be selected with practically no limitation, only in accordance with the technological requirements, and does not depend on manufacturing limitations. In the same manner, the material of the conveying channel can be selected free of any limitations existing for the production of the lid.
It is especially advantageous if the lid is produced by molding, e.g. injection molding, since by molding or injection-molding the lid can be made and the conveying channel can be inserted into the lid in one operational step. It is especially advantageous to make the lid of a metal material, since such material has proven itself especially in the manufacture of lids for open-end rotor spinning devices.
Aluminum or zinc alloys are especially advantageous for this. In another advantageous embodiment of the cover, the latter is made of a synthetic material, e.g. synthetic resin, a thermoplastic or of duroplast, since this material is especially economical and makes it possible to easily form the conveying channel. It is an especially advantageous embodiment for the insertion of the conveying channel if it or the conveying channel are provided with snap connections so that the two parts can be joined together easily. It is advantageous to design the connection in this case in such a manner that it can be detached again, so that either the conveying channel or the cover can be replaced. In another advantageous embodiment, the snap connection cannot be opened, so that a permanent connection exists between the conveying channel and the cover. It is especially advantageous and safe for the operation if this connection is positive and interlocking. In another advantageous embodiment of the open-end rotor spinning machine, its conveying channel is designed so that it has an essentially rectangular cross-section. In another advantageous embodiment, the conveying channel is provided with a receiving element which receives the fibers leaving the vicinity of the take-up rollers directly from the opener roller housing. For this, the receiving part is made in one piece with the conveying channel in an especially advantageous case. The opening of the opener roller housing need then not be made in the form of a channel, since the conveying channel takes over the fibers directly at the opener roller. In another advantageous embodiment of the open-end rotor spinning device, the cross-sectional configuration of the conveying channel is made so that it goes without transition from a substantially rectangular cross-section to an elliptical cross-section. If the configuration of the conveying channel is essentially rectangular, it should advantageously be designed so that the ratio of length to width at a distance of up to 40 millimeters from the opener rollers may have a value of more than 4:1. As a result the fibers detaching themselves from the opener roller are especially certain to be detached over the entire width of the opener roller. In another advantageous embodiment of the invention, the conveying channel being essentially rectangular. The length to width ratio at a distance of up to 20 millimeters from the outlet of the conveying channel is given a value of at least 2:1. This makes it possible to achieve undisturbed and advantageous feeding of the fibers into the open-end spinning rotor. Thanks to the advantageous design of the invention, whereby the conveying channel has an essentially rectangular cross-section, and the ratio of length to width at a distance of over 20 mm from the outlet of the conveying channel has a lower value than within the range between 0 and 20 millimeters, the result is that the outlet opening of the conveyor channel in the vicinity of the spinning rotor is given an especially advantageous form and that the remaining area of the conveying channel requires less space in the lid. Thanks to the advantageous embodiment of the invention, in which the conveying channel is provided with a sudden widening of its cross-section between outlet and intake portion, the reduction of speed of the conveying which takes place at this point results in a new orientation of the fibers. In another advantageous embodiment of the invention, the conveying channel has a cross-section in an area between 50 millimeter before its outlet and the outlet which is smaller than the cross-section at the outlet, so that as a result a strong acceleration of the conveying air in the conveying channel advantageously takes place, making it possible to achieve stretching of the fibers. Thanks to the embodiment of the invention in which the cross-section of the conveying channel becomes continuously wider towards the outlet of the fiber feeding channel, it is possible, e.g. in the vicinity of the outlet, to reduce the air speed to such an extent that the air is more easily separated from the fibers. Of special advantage is the embodiment in which the cross-sectional changes take place continuously, whereby especially favorable flow conditions can be ensured.
It is especially advantageous if the conveying channel is made of a brass alloy, as the latter has a good quality surface. In another advantageous embodiment, the conveying channel is made of a steel material since this is especially resistant and at the same time ensures good surface quality during manufacture. By using special steel according to the invention for the manufacture of the conveying channel, the wear of the latter is especially low. In an especially advantageous embodiment of the invention, a connection piece is formed on it. The connection piece is here made at the same time as the forming of the inside contour of the conveying channel, so that the transitions from conveyor channel to connection piece as well as to its inner surface are advantageously smooth and flowing. Thanks to the connection piece air and/or fibers can be taken from or fed to the conveying channel advantageously.
By manufacturing a conveying channel according to the process of the present invention, the result is that its surface inside the channel can be produced before changing the form with a high surface quality without damage to same when the conveying channel is given its final form. Furthermore, a conveying channel can be produced which may have nearly any desired inside contours. In addition, the process is suitable for the manufacture of large quantities of low-cost conveying channels with constant high quality. In an especially advantageous further development of the process, the outside contour is determined by a tool, so that forming to precise measurements and with repeatability of the conveying channel is possible.
In an especially advantageous embodiment of the process, a blank which has already been produced by forming is annealed several times if necessary so that its capacity of being formed is again increased, so that it can now be made in two or more steps. It is especially advantageous to use a brass alloy for the conveying channel, since it is especially easy to form while maintaining high surface quality. Steel is used to advantage as a material for the conveying channel as it is especially resistant to wear.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a lateral view of an open-end rotor spinning device, in a section;
FIG. 2 shows the lid of a rotor housing with a conveying channel molded into it;
FIG. 3 shows the lid of a rotor housing with a conveying channel molded into it;
FIG. 4 shows the lid of a rotor housing with snapped-in conveying channel;
FIG. 5 shows a lid with a conveying channel molded into it, in a section;
FIG. 6 shows a conveying channel made according to the invention which has several different cross-sectional configurations over its length;
FIG. 7 shows a diagram of an open forming tool; and
FIG. 8 shows a rotary plate of a draw frame with a sliver channel according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will now be made in detail to the presently preferred embodiments of the invention, one or more examples of which are shown in the drawings. Each example is provided by way of explanation of the invention, and not as a limitation of the invention. For example, features illustrated or described as part of one embodiment can be used on another embodiment to yield still a further embodiment.
An open-end rotor spinning device 1 as shown in FIG. 1 consists essentially of a spinning rotor 10, which is rotating in a rotor hosing 2, and of an opener unit 3 which opens a fiber sliver 31 delivered to it into individual fibers, so that these can be fed to the spinning rotor 10. The opener unit 3 is equipped with an opener roller 32 to open the fiber sliver 31 into individual fibers. The fiber sliver 31 is fed via the feed shaft 33. Opener roller 32 is driven via its pulley 321, around which a drive belt 322 is looped. The drive belt 322 is driven by a driven drive shaft 323, whereby it is held under tension by a tension roller 324. The fibers separated by the opener roller 32 leave the area of the opener roller through and opening 325 of the opener roller housing 326. This is caused by a negative pressure in the rotor housing 2 which continues via the conveying channel in the lid 21 of the rotor housing 2 until proximity of the opener roller. At variance with that which is shown in FIG. 1, the conveying channel 22 of the lid 21 can also extend to the opener roller 32, so that the conveying channel 22 is provided with a receiving element (222, FIG. 2) which then constitutes the opening 325 of the opener roller housing 326, as an alternative to FIG. 1. The conveying channel 22 extends with its outlet into the spinning rotor 10 which extends into the rotor housing 2. The spinning rotor 10 is mounted on its shaft 11 in a known manner by means of supporting disks 12 and is driven by tangential belts which are not shown. The shaft 11 extends through a seal 23 into the rotor housing 2. The rotor housing 2 has a suction opening 24 which is connected to a suction channel 241. The yarn 4 formed in the spinning rotor 10 is removed from the spinning rotor 10 by means of a pair of driven draw-off rollers 41 through a draw-off pipe 41 and is then wound up into a cross-wound bobbin. The open-end rotor spinning device 1 is supported on rods 49 which are part of the frame of the appertaining rotor spinning machine.
FIG. 2 shows a lid 21 of an open-end rotor spinning device designed according to the invention. The lid of FIG. 2 is shown in a top view of the side away from the spinning rotor. The lid 21 has a conveying channel 22 which is held by fastening ridges 221. The fastening ridges 221 are made of an aluminum alloy, as the rest of the lid 21, and are made by injection molding. The fastening ridges 221 are formed so that they surround the conveying channel 22 and thus connect it permanently to the lid 21. The conveying channel 22 itself is made of a brass alloy and was inserted into the mold when the cover 21 was formed, so that the conveying channel 22 has been connected to the lid 21 via the suitably formed fastening ridges. Due to the design of the lid according to the invention the latter, at variance with FIG. 1, can itself be very thin, since the conveying channel is an autonomous component and the lid only serves to cover the rotor housing and to support the conveying channel 22. The lid 21, since it is made to be replaceable, is provided with two bores 5 by means of which, and together with screws, it can be attached to a bearing plate (not shown) for example on the open-end rotor spinning device. In the center of the lid a hole 51 is provided for the passage of a draw-off pipe 42 (FIG. 1) to draw off the yarn from the rotor. The conveying channel is made in one piece with a receiving element 222 with which the conveying channel 22 presses in a sealing manner against the opener roller housing to receive fibers from same and to convey them to the spinning rotor. The conveying channel 22 has a cross-sectional diminution 223 between the receiving element 22 and its outlet which is away from the receiving element 222. In this area, the speed of flow of the mixture of fibers and air conveyed through the conveying channel increases so that a new orientation of the fibers in the flowing air is achieved. The conveying channel 22 is a part which is made separately from the lid 21 and has been made of a blank which is pipe-shaped according to the invention. For this, the blank was introduced into a divided form by which it was enclosed essentially completely. Between the blank and the inside contour of the form was, at first, an interval in many areas. On at least one of its ends, the blank was connected to a pressure source and was closed on its other side. By injecting a medium under high pressure (approx. 2,000 bar to 2,500 bar) the blank was formed through widening in such manner that its outer contour was pressed against the inside contour of the forming tool. This makes it possible to give the conveying channel through its outer contour nearly any desired inside contour. The inside contour practically matches the outside contour of the conveying channel, taking into consideration its wall thickness which was changed by forming. The conveying channel not only is provided with an inside contour which is independent of the constrictions of the molding process, but also an inside surface of very high quality. This means that the inside contour meets all requirements as to roughness and smoothness of the surface as required for the conveying of fibers. Machining is practically not required. The different dimensions of the conveying channel shown in FIG. 2 are represented in an exaggerated manner for the sake of clarity.
FIG. 3 shows a lid 21 of an open-end rotor spinning device made according to the invention in which the conveying channel 22 is also a component made separately from the remaining portion of the lid 21 and which was then molded into the lid during the molding of the lid 21, e.g. by injection molding. The conveying channel 22 is therefore shown by a broken line. The receiving part 222 to attach the conveying channel 22 to the opener roller is formed for the lid of FIG. 3 on the actual base part of the cover and not on the conveying channel 22. The evolution of the cross-section of the conveying channel 22 is similar to that of FIG. 2.
FIG. 4 shows a cover 21 for an open-end rotor spinning device in which the base body of the lid 21 and the conveying channel are also separately produced components, and where the lid 21 and the conveying channel 22 are connected to each other via snap-on connections 6. The snap-on connections surround the conveying channel 22 in part in the area of a groove 61, so that shifting of the conveying channel 22 within the snap-on connection is not possible. The result of this is a rigid connection between the conveying channel 22 and the lid 21 which does not become detached during the operation of the open-end rotor spinning device. To replace the lid or the conveying channel, the snap-on connection can be opened and the lid or conveying channel can be replaced.
FIG. 5 shows a lid 21 with a conveying channel 22 integrated into the mold. The cut-away drawing of the lid shows the conveying channel 22 laid open. Only the area of fiber entry into the conveying channel is in part surrounded by the lid. The conveying channel is made according to the invention; it is designed with a reduced cross-section in an area of 50 mm before its outlet 224. This reduced outlet has on the one hand a positive effect on the orientation of the fibers in the conveying channel and thereby also in the rotor and yarn, and on the other hand offers the advantage that the cross-sectional reduction 223 results in an interlocking connection between lid and conveying channel as the conveying channel 22 is formed into the lid 21. The conveying channel is furthermore equipped with a connection piece 225. Through the latter, air and/or fibers can be fed to the conveying channel or can be removed from same in a known manner when needed. In addition it is connected to a connection channel which is not shown, and which could be connected to the opener unit 3 or to the rotor housing, for example.
FIG. 6 shows a conveying channel produced in accordance with the process of the invention. The starting material for the blank is a hollow body, e.g. a pipe with a wall that is thicker than that of the completed, formed conveying channel. When already considerable forming is necessary to produce the blank, the blank is annealed to reduce tensions. For the conveying channel, metal materials, in particular steel, special steel, copper, brass and nickel, and to a limited extent also aluminum are used. A sufficient expandability of the material is important. Brass, steel, in particular special steel are especially advantageous in producing a conveying channel. In order to form the blank it is placed into a divided forming tool 7, see FIG. 7. The forming tool 7 is equipped with a recess, the pattern 73 in the mold joint 72 which matches the outer contour of the completed conveying channel. After closing the forming tool, the blank is filled from the inside with a medium under very high pressure, preferably water, so that the blank 71 widens and presses against the contour of the pattern 73 of the forming tool 71. Taking into account the wall thickness, the outer contour of the formed blank corresponds to the inside contour of the completed conveying channel. The two ends of the conveying channel may still have to be machined, e.g. by shortening them. By using the manufacturing method for a conveying channel according to the invention, inside contours can be produced which are not possible with the known processes, or are only possible at great cost. The surface quality attainable through the invention is especially advantageous. The different cross-sections of the conveying channel and their transitions as well as cross-sectional reductions 223 in segments, as shown in FIG. 6, for example, can easily be realized.
FIG. 7 shows a diagram of an open forming tool 7 with a blank 71. The mold joint 72 of the forming tool 7 is shown by hatch marks. The pattern 73 which is not hatch-marked, constitutes the outside contour of the complete conveying channel. Upon closing the forming tool 7, the open ends of the blank 71 are sealed off by connection pieces which are not shown, and the blank is filled from inside with water, the water is put under pressure and the blank is brought to press against the contour of pattern 73 of the forming tool. After removal, the ends of the formed blank are machined and the conveying channel has received its final form. It is easily possible to coat the conveying channel, e.g. in order to improve its resistance to wear or to improve its surface quality. A conveying channel made according to the present invention can be used advantageously also for fiber conveying on draw frames.
The present invention can be used not only as shown in detail with open-end rotor spinning machines but also with other open-end spinning machines, e.g. with friction spinning machines where the separated fibers are also conveyed through a fiber feeding channel of the spinning device. Furthermore it is advantageously possible to use a channel according to the invention in spinning machines where the yarn is treated or formed through a tubular false-twisting element, such as is indicated for example in DE 31 35 337 A1. Using a channel according to the invention as a sliver channel to convey fiber slivers on a draw frame is also very advantageously possible. Thus, for example, a sliver channel as shown in DE 41 39 910 A1, can be produced with finishing accuracy and at low cost according to the process of the invention. Especially a draw frame for doubling and drafting fiber slivers can be equipped to great advantage with a conveying channel according to the invention, so that the stretched fiber sliver can be deposited by the latter safely and delicately in a container, e.g. a can.
FIG. 8 shows part of a spinning machine, a draw frame, with a channel 22 which is integrated into the rotary plate 80 of the draw frame. Due to the fact that the rotary plate 80 rotates around its vertical axis, the fiber sliver is deposited via channel 88 in a known manner into the can 81 placed below the rotary plate 80. To ensure delicate deposit of the fiber sliver, it is necessary that the channel 22, here called the sliver channel, has a smooth, undisturbed surface on the inside. Channel 22 for a draw frame has an inside diameter of approx. 30 mm. By using the invention, the sliver channel can be produced more easily and at lower cost, whereby the sliver channel is given at the same time a surface and a form of high quality.
It should be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope and spirit of the invention. It is intended that the present application cover such modifications and variations as come within the scope of the appended claims and their equivalents. | With channels for the conveying of fibers, fiber slivers or yarns on spinning machines, problems are encountered in their manufacture. The channels must be made with a certain inside contour, where at the same time the quality of the surface inside the channel must be very good. The high surface quality is required in order to ensure trouble-free conveying. A channel is therefore proposed which is made as a tubular component, consisting of a metallic material and which has been produced by forming its interior by a medium under pressure. It is proposed for an open-end rotor spinning device to form the conveying channel separately from the other components of the lid of the rotor housing and to insert the channel into the lid. It is proposed in that case to use a channel according to the design shown above. | 3 |
This is a divisional application of application Ser. No. 832,760, filed on Feb. 25, 1986, which is a continuation-in-part of application Ser. No. 717,547, filed on Mar. 29, 1985.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to optically-active tartrate compounds, to methods of making such optically-active tartrate compounds and to the use of such optically-active tartrate compounds for the production of optically-active conversion products.
2. Prior Art
Due to the slight stability of the free group of acids, the racemic resolution of free carnitine causes difficulties; so the nitrile or the amides of carnitine are predominantly used for its racemic separation. For example, East German Pat. No. 23,217 teaches converting carnitine nitrile chloride, which has been converted by treatment with silver oxide into the hydroxide or by treatment with silver carbonate into the carbonate, with an optically-active acid into the diastereomers from which the suitable diastereomer is separated. The desired carnitine derivative is isolated from the suitable diastereomer. Another path, taught by Belgian Pat. No. 660,039, starts out from carnitine amide hydrochloride, which is converted with camphoric acid in the presence of AgNO 3 into the diastereomeric mixture. The suitable diastereomer is again separated and analyzed.
However, the above processes have considerable disadvantages. Among such disadvantages is the difficultly-separable salt impurities obtained in large quantities, which make the dissociation of the racemate difficult. Also the numerous steps of the processes which are required to provide the carnitine amides, respectively, carnitine nitriles, accessible for the racemate dissociation make a technical or commercial application too expensive with regard to costs. These difficulties are increased, since as a result of the use of silver salts, one must operate with the exclusion of light in order to avoid any blackening of the reaction material.
BROAD DESCRIPTION OF THE INVENTION
An object of the invention is to provide the new compound di-[3-chloro-2-hydroxy-propyltrimethylammonium]-tartrate. Another object of the invention is to provide the new compound di-[(-)-3-chloro-2-hydroxy-propyltrimethylammonium]-L-(+)-tartrate (sometimes herein termed COP-tartrate). A further object of the invention is to provide a process for the production of such new compounds. A still further object of the invention is to provide a method for the production of optically-active carnitine nitrile chloride from such new compounds. Another object of the invention is to provide a process which eliminates the above-described disadvantages of the prior art. Another object of the invention is to provide a process which produces, in a simple manner, optically-active carnitine nitrile chloride, especially (-)-carnitine nitrile chloride. Other objects and advantage of the invention are set out herein or are obvious herefrom to one skilled in the art.
The advantages and objects of the invention are achieved by the compounds and processes of the invention.
The invention includes optically-active di-[3-chloro-2-hydroxy-propyltrimethylammonium]-tartrate. For the production of (-)-carnitine nitrile chloride, one uses di-[(-)-3-chloro-2-hydroxy-propyltrimethylammonium]-L-(+)-tartrate (COP tartrate).
The new optically-active di-[3-chloro-2-hydroxy-proyltrimethylammonium]-tartrate has the formula: ##STR1##
The inventio also includes:
(a) di[(-)-3-chloro-2-hydroxy-propyltrimethylammonium]-L-(+)-tartrate; and
(b) di[(+)-3-chloro-2-hydroxy-propyltrimethylammonium]-D-(-)-tartrate.
The invention also involves producing the COP-tartrate. The COP-tartrate can be produced by several different methods. Preferably, the COP-tratrate is produced either by conversion of racemic 3-chloro-2-hyroxy-propyltrimethylammonium-chloride with L-(+)-tartaric acid, effectively in the presence of a trialkylamine, or by conversion of L-(+)-tartaric acid with trimethylamine and subsequent conversion with epichlorohydrin. When proceeding according to the first method, first the racemic 3-chloro-2-hydroxy-propyltrimethylammonium-chloride is produced from epichlorohydrin and trimethylamine and then the racemic 3-chloro-2-hydroxy-propyltrimethylammonium-chloride is converted with L-(+)-tartaric acid in the presence of a trialkylamines into the COP-tartrate.
The COP-tartrate can be dissociated from its diastereomer by crystallization.
The trialkylamine is preferably a trialkylamine wherein each of the alkyl groups has 2 to 12 carbon atoms. While the trialkylamine can have branched alkyl groups, preferably the trialkylamine only has straight-chain alkyl groups. Examples of the preferred trialkylamines are triethylamine, tributylamine, tripropylamine, tripentylamine and trioctylamine. Most preferably tributylamine is used.
A preferred embodiment for the production of the COP-tartrate according to the invention is described as follows: Starting out from 1 mole of dextrogyric tartaric acid, effectively 1.6 to 3 moles, preferably 1.8 to 2.5 moles, of tri-n-butylamine are converted with effectively 1.6 to 3 moles, preferably 1.8 to 2.2 moles, of racemic 3-chloro-2-hydroxy-propyltrimethylammonium-chloride for the production of the diastereomeric mixture. Preferably the conversion is operated in the presence of water and/or a solvent which is not miscible with water, such as, methylene chloride or chloroform, and at a temperature of 0° to 30° C., preferably 15° to 25° C. After separation of the tri-n-alkylamine hydrochloride by extraction with an inert solvent, such as, methylene chloride or chloroform, the desired isomer is isolated by fractional crystallization after evaporation of the aqueous phase under reduced pressure. Effectively, the diastereomeric mixture is dissolved in a solvent, for example, water or a lower alkanol, such as, ethanol or preferably methanol. The crystallization of the desired isomer of the COP-tartrate is effectively achieved by the addition of a diluent, preferably acetone.
According to another production method of the invention L-(+)-tartaric acid dissolved in water or suspended in an alcohol (lower alkanol), effectively methanol or ethanol, is placed in a vessel, subsequently neutralized with trimethylamine, and then the di-[trimethylammonium]-tartrate formed as an intermediate product is converted with epichlorohydrin at a temperature of 17° to 30° C. into the desired COP-tartrate and its diastereomers.
A preferred embodiment for the production of the COP-tartrate according to the invention is as follows: Starting out with 1 mole of L-(+)-tartaric acid, dissolved in 200 to 250 g of water or suspended in a lower (alkanol) alcohol, 1.6 to 2.5 moles, preferably 1.8 to 2.1 moles, of trimethylamine is added at a temperature of 0° to 30° C. The pH of the solution effectively is 6.5 to 7.5. Subsequently and effectively, 1.6 to 3 moles of epichlorohydrin is added and the temperature is held at 15° to 30° C., preferably 20° to 28° C.
Whenever the invention is operated with water, one aqueous phase develops. After evaporation of the water, effectively under vacuum, an oily residue results from which by treatment with organic solvent(s), effectively with methanol/acetone, the desired COP-tartrate is crystallized out. Whenever one operates with alcohols (e.g., lower alkanol, such as methanol or ethanol), then the desired COP-tartrate is precipitated and can be separated.
A further method for the production of COP-tartrate is where first the silver salt of the tartaric acid is produced from silver nitrate and alkali tartrate. Then the silver tartrate is suspended in water and is converted with racemic 3-chloro-2-hydroxy-propyltrimethylammonium-chloride. The desired COP-tartrate can be obtained by crystallization or can be separated from the diastereomeric salt.
The di-[(-)-3-chloro-2-hydroxy-propyltrimethylammonium]-L-(+)-tartrate of the invention has the following properties and characteristics:
Melting point of 159° C. (after recrystallization from methanol/acetone) [α] D 24 =-10.8° (c=1.04 in water) pH of the solution (1 percent) is 7
Analysis: C, calculated is 42.39%, found is 42.36% H, calculated is 7.56%, found is 7.99% N, calculated is 6.18%, found is 6.36%
IR (KBr) spectrum: 3.5, 6.30, 7.20, 9.15, 10.25 micron.
For the production of di[(+)-3-chloro-2-hydroxy-propyltrimethylammonium]-D-(-)-tartrate, the racemate dissociation is conducted using D-(-)-tartaric acid. Such product has the following properties and characteristics:
Melting point 159° C. (after recrystallization from methanol/acetone). [α] D 24 =+10.8° (c=1.04 in water).
As a result of the process of the invention, the racemate dissociation takes place very early in such production schemes. Thus one can work starting with the further steps up to the carnitine nitrile chloride and carnitine still with only one antipode, as a result of which the load of the further reactions by the other antipode is omitted. One ordinarily skilled in the art could not anticipate that no further racemization would occur in the case of a subsequent reaction which in the end leads to the carnitine.
The di-[(-)-3-chloro-2-hydroxy-propyltrimethylammonium-L-(+)-tartrate (COP tartrate) can be converted in a simple manner into the (-)-carnitine nitrile chloride and (-)-carnitine. At the same time, one can convert the COP-tartrate first of all with CaCl 2 , followed by separating the Ca-tartrate and isolating the (-)-3-chloro-2-hydroxy-propyltrimethylammonium-chloride. The CaCl 2 can be replaced with, for example, 2 equivalents of HCl (aqueous) and 1 equivalent of KDH (aqueous) or 1 equivalent of HCl (aqueous) and 1 equivalent KCl (aqueous). The latter can be converted using an alkali cyanide into the (-)-carnitine nitrile chloride. The alkali cyanide is, for example, LiCN or KCN, but preferably is NaCN. However, one can also carry out the decomposition, i.e., double salt conversion, of the COP-tartrate and the cyanide substitution reaction in one step. In that case, effectively an alkaline earth cyanide, preferably Ca(CN) 2 is used. At the same time the tartaric acid precipitates as the Ca-salt and the (-)-carnitine nitrile chloride can be isolated from the reaction solution. No matter which method is used, the setting free or reaction is carried out preferably in water as a solvent.
According to another method of the invention, the optically active 3-chloro-2-hydroxy-propyltrimethylammonium-chloride isolated from the dissociation of the COP-tartrate is converted by treatment with a strong base, such as, an alkali hydroxide, an alkali alcoholate or an alkali tert.-butylate, into the (-)-glycidyltrimethylammonium-chloride and the latter is converted by treatment with acetone cyanohydrin or prussic acid into the L-carnitine nitrile chloride. This method is carried out preferably in an alcohol (lower alkanol) as a solvent at a temperature around ambient temperature.
The purification of the product can be achieved effectively by simple crystallization from a solvent, such as, a lower (alkanol) alcohol. Thus, products with optical purities of 98 plus are obtained.
However, according to this process, the di-[(+)-3-chloro-2-hydroxy-propyltrimethylammonium]-D-(-)-tartrate can also be converted into the corresponding (+)-carnitine nitrile chloride.
DETAILED DESCRIPTION OF THE INVENTION
As used herein, all parts, percentages, ratios and proportions are on a weight basis unless otherwise stated herein or otherwise obvious herefrom to one skilled in the art.
EXAMPLE 1
Production Of Di-[3-chloro-2-hydroxy-propyltrimethylammonium]-tartrate
While stirring, 18.54 g (100 mmole) of tri-n-butylamine was added drop by drop to 7.50 g (50 mmole) of L-(+)-tartaric acid, which was dissolved in 50 ml of water, whereby the solution was heated to 30° C. Subsequently, 18.81 g (100 mmole) of 3-chloro-2-hydroxy-propyltrimethylammonium chloride, which was dissolved in 100 ml of water, was added to the solution. The resultant clear solution was extracted with 8 separate portions of 150 ml of methylene chloride. The extractions were evaporated under vacuum. 21.65 g (97.6 percent yield) of tributylamine hydrochloride was obtained. (Together, the two last extractions only still contained 0.14 g of material.) The aqueous layer was evaporated in a rotary evaporator until dry. 23.22 g of a very viscous oil (102.5 percent) resulted. This was dissolved hot in 30 ml of methanol. It was mixed slowly with 93 ml of acetone until it became cloudy. The latter was again made to disappear by the addition of a few drops of methanol. After 72 hours, the mother liquor was decanted. The crystal crust was washed with acetone/methanol (3:1) and was dried under vacuum. The yield was 7.20 g of crystals (31.8 percent or 63.6 percent of the theory). The crystals had a melting point of 147° to 170° C. The crude tartrate was dissolved in 10 g of hot methanol and gradually 45 ml of acetone were added, whereupon the crystallization immediately started. The crystallization vessel was kept overnight in the refrigerator. The mother liquor was decanted off; the crystal cake was washed with acetone and dried. 5.78 g of crystals, corresponding to 51 percent of the theory, were obtained. The crystals had a melting point of 150° to 152° C. and a [α] D 24 of -7.5° (c=1.04 in water). The tributylamine was recovered from the methylene chloride residue (raw tributylamine hydrochloride) with a yield of 96 percent by placing the residue in a solution of methylene chloride, shaking the solution with 1N of caustic soda solution and removing the solvent under vacuum.
EXAMPLE 2
Production Of Di-[(-)-3-chloro-2-hydroxy-propyltrimethylammonium]-L-(+)-tartrate
To 18.75 g (125 mmole) of L-(+)-tartaric acid, which was dissolved in 30 ml of water, 39 ml (259 mmole) of trimethylamine was added dropwise within 10 minutes while stirring. The temperature was kept at 30° C. The pH of the solution was 7. Subsequently, the solution was cooled to 15° C. and 23.15 g (250 mmole) of epichlorohydrin was added dropwise while stirring. The reaction temperature was kept at 25° C. and the stirring was continued until the mixture consisted only of a liquid phase. After completing the reaction, the water was evaporated under vacuum (Rotavap) at 40° C. 59.5 g of a viscous oil resulted. This residue was dissolved in 40 ml of hot methanol and gradually 135 ml of acetone were added until cloudiness occurred. After letting the solution stand for 72 hours, at ambient temperature, the mother liquor was decanted off and the crystals were washed with acetone/methanol (4:1) and dried under vacuum. 4.75 g of plate-shaped crystals resulted. The yield of crystals was 16.8 percent of the theory. The crystals had a melting point of 150° to 152° C. and a [α] D 24 of -8.1° (c=1 in water).
EXAMPLE 3
Production Of Di-[(-)-3-chloro-2-hydroxy-propyltrimethylammonium]-L-(+)-tartrate
150 g (1 mmole) of L-(+)-tartaric acid was suspended in 200 g of methanol and, at a temperature of 20° C., 106.2 g (1.8 mole) of trimethylamine and 250 g of ethanol were added within 1 hour. The temperature was kept at 20° C. The tartaric acid was dissolved while forming di-trimethylammonium-L-(+)-tartrate. Subsequently, 166.5 g (1.8 mole) of epichlorohydrin was added and the temperature was kept at 20° C. The stirring continued for 2 days while maintaining such temperature. The emerging crystals were filtered off, washed with acetone/methanol (4:1) and dried under vacuum. The product was obtained in a yield of 38.9 percent (77.8 percent of the theory). The product had a melting point of 157° to 158° C. and had a [α] D 24 of -9.1° (c=1 in water).
EXAMPLE 4
Production Of Di-[(-)-3-chloro-2-hydroxy-propyltrimethylammonium]-D-(-)-tartrate
46.25 g (127 mmole) of di-silver-L-(+)-tartrate was suspended in 350 ml of water and was mixed with a solution of 3-chloro-2-hydroxy-propyltrimethylammonium chloride, which was dissolved in water. The suspension was stirred for 4 hours. The silver chloride formed was filtered off and (for the purpose of quick drying) was washed with methanol and ether and then dried. 36.21 g of silver chloride (99.5 percent of the theory) resulted. The filtrate was completely evaporated in a rotary evaporator. The residue weighed 61.43 g (theory: 57.58 g) after drying in an oil vacuum (5 hours at room temperature). The crystal cake was dissolved in 80 ml of hot methanol and 260 ml of acetone was added gradually to the hot solution. The turbidity which developed was made to disappear by the addition of 2 ml of methanol. The vessel was closed and allowed to cool. After a few minutes, crystallization started at the wall of the vessel. After 48 hours, the vessel and its contents were still kept for 3 hours in a refrigerator (+4° C.). The mother liquor was decanted from the crystal crust. The crystals were washed with approximately 20 ml of acetone/methanol (1:5) and a little acetone, and were then dried under vacuum. 19.33 g of crystal clusters resulted which had a melting point o 159° C. (after crystallization from acetone/methanol) and a [α] D 24 of +10.8° (c=1.04 in water).
EXAMPLE 5
Production Of (-)-3-chloro-2-hydroxy-propyltrimethylammonium-chloride
4.50 g (40.5 mmole) of calcium chloride, which was dissolved in 15 ml of water, was added dropwise to 18.35 g of (40.5 mmole) of tartrate (according to Example 1), which was dissolved in 65 ml of water while rotating the vessel. The calcium tartrate immediately crystallically precipitated. After 5 minutes, the suspension was cooled in an ice bath (the solution had a pH of 7) and the calcium tartrate was filtered off. After washing with methanol and drying in air, the material weighed 10.08 g (theory for the tetrahydrate: 10.54 g, yield 95.6 percent). The filtrate (and wash-methanol) was evaporated at a 50° C. bath temperature in a rotary evaporator. The solid residue, which weighed 17.0 g (theory: 15.24 g), was digested at 70° C. with 25 ml of absolute ethanol. The suspension was cooled in an ice bath and the crystals were filtered. After washing with ethanol/acetone (1:1) and acetone, the material was dried in air. The yield was 10.24 g of colorless crystals (67.2 percent of the theory). The colorless crystals had a melting point of 214° C. and a [α] D 24 of -28.76° (c=0.97 in water).
EXAMPLE 6
Production of (-)-carnitine nitrile chloride
8.61 g (45.76 mmole) of the product produced according to Example 5 in 9 ml of methanol and 1 ml of water was mixed dropwise in a bath (50° to 55° C.) within 3 minutes with 3.43 g (47.0 mmole) of sodium cyanide in 8 ml of water. The reaction solution, which immediately became turbid, was left in the bath for 20 minutes (pH 8 to 9) and was then adjusted to pH 5 with 5.5N hydrochloric acid (3.0 ml of acid was needed). After cooling of the composition with a bath (-100° C.) for a few minutes, the melt obtained was filtered off, washed with ice-cold methanol and dried. 1.89 g of salt was obtained. The filtrate was concentrated under vacuum at a 40° C. bath temperature. The residue, a yellowish solid mass (10.6 g), was taken in 23 g of hot methanol. The warm solution (40° C.) was filtered (removal of 0.60 g of insoluble material). The filtrate was again filtered (separation of about 0.1 g of salt), heated until settling (weight of the solution, 24 g) and cooled to 0° C. The separated crystals were subjected to suction, washed with a little methanol (-10° C.) and ether, and dried. The yield was 4.62 g of almost colorless crystals (56.5 percent of the theory). The crystals had a melting point of 244° C. and a [α] D 24 of -28.30° (c=1.06 in water). The product contained starting material (tlc). After being twice recrystallized from ethanol (95 percent), long needles were obtained which had a melting point of 256° C. and a [α] D 24 of -25.9° (c=1.05 in water).
EXAMPLE 7
Production of (-)-glycidyltrimethylammoniumchloride ((-)-N,N,N-trimethyl-oxiranemethane amine)
At ambient temperature while stirring, a solution of 2.05 g NaOH (98 percent 50 mmole) in 45 ml of methanol was added dropwise to 9.5 g (50 mmole) of (-)-3-chloro-2-hydroxy-trimethylammonium-chloride [99.1 percent [α] D 24 =-29.5° (c=1, H 2 O), melting point 212° to 214° C.] dissolved in 35 ml of methanol. The mixture was stirred for 3 hours. The precipitated NaCl (2.6 g, 89 percent was filtered off and washed twice with portions of 5 ml of ethanol. The filtrate and the wash ethanol were evaporated. The raw product (8.95 g, 117 percent) was absorbed in 50 ml of chloroform, whereupon, after shaking, the product gradually dissolved except for some NaCl. This insoluble NaCl (0.60 g, 20 percent) was filtered off. After evaporating off the CHCl 3 , 7.6 g (99.3 percent) (-)-glycidyltrimethylammoniumchloride was obtained. The product did not contain any starting material (tlc). The product had a melting point of 121° to 123.5° C. and a [α] D 24 of -27.0° (c=1 in water). Analysis of the product showed:
IR (KBr): 3440s, 3030w, 2980w, 2940w, 1630m, 1485s, 1420w, 1270w, 1150w, 1100w, 980m, 935s, 900m, 870m 805w 770w
1 H-NMR (300 MHz, d 6 -DMSO): 2,69 (dd, 1H, J=5 and 3 Hz, H-C(3)); 2,93 (dd, 1H, J=5 and 5 Hz, H-C(3)); 3,22 (dd, 1H, J=13 and 8 Hz, H-C(1)); 3,23 (s, 9H, --N(CH 3 ) 3 ); 3,57 (dddd, 1H, J=8/5/3 and 3 Hz, H-C(2)); 4,04 (dd, 1H, J=13 and 3 Hz, H-C(1)).
EXAMPLE 8
Production Of (-)-glycidyltrimethylammonium-chloride ((n)-N,N,N-trimethyl-oxirane methane amine
At ambient temperature while stirring, a solution of 5.8 g KOtBu (97 percent, 50 mmole) in 20 ml of methanol was added dropwise to 9.5 g (50 mmole) of (-)-3-chloro-2-oxypropyltrimethylammonium-chloride [99.1 percent [α] D 24 =-29.5° (c=1, in water), melting point of 212° to 214° C.], which was dissolved in 35 ml of methanol. The mixture was stirred for 3 hours. The precipitated KCl (3.95 g, 105 percent was filtered off and washed twice with portions of 5 ml of ethanol. The filtrate and the wash-ethanol were evaporated. The raw product (9.15 g, 119 percent) was taken in 50 ml of chloroform, whereupon, after shaking, the product gradually dissolved except for some KCl. This insoluble KCl (0.05 g, traces) was filtered off. After evaporating off the CHCl 3 , 7.5 g (98 percent) (-)-glycidyltrimethylammonium-chloride was obtained. The product did not contain any starting material (tlc). The product had a melting point of 119° to 121° C. and a [α] D 24 of -27.1° (c=1 in water).
EXAMPLE 9
Production Of L-carnitine Nitrile Chloride
4.35 g of acetone cyanohydrin (98 percent, 50 mmole) and 7.9 g (50 mmole) of (-)-glycidyltrimethylammonium-chloride were added to 10 ml of MeOH (i.e., methanol). The mixture was stirred at 20° to 25° C. until all of its solid components were dissolved. After that the solution was heated within half hour to 45° C. and stirring at this temperature was continued for 4 hours (thin layer chromatogram). The product began to precipitate after one half hour at 50° C. The mixture was cooled to 20° C. The resultant white crystals were filtered, washed three times, each time with 6 ml of acetone, and dried. The yield was 7.5 g (81.6 percent of the theory) of such white crystals. The white crystals had a melting point of 246° C. (composition) and a [α] D 24 of -25.6° (c=1 in water). The product was 97.3 percent (HPLC) and contained 2.4 percent of (-)-glycidyltrimethylammonium-chloride. After recrystallization from ethanol (95 percent), long needles were obtained. The long needles had a melting point of 256° C. (decomposition) and a [α] D 24 of -25.8° (c=1 in water).
EXAMPLE 10
Production Of (-)-3-chloro-2-hydroxypropyltrimethylammonium chloride
228.3 g (0.5 mol) of di[(-)-3-chloro-2-hydroxy-propyltrimethylammonium]-L-(+)tartrate was dissolved in a mixture of 315 ml of H 2 O and 135 ml of ethanol at room temperature. Within a 2-minute period, 38.2 g (0.5 mol) of solid KCl was added to the stirred solution. The KCl dissolved within 2 to 3 minutes. 49.4 g of HCl (37 percent in H 2 O; 0.5 mol) was added dropwise to the solution within 10 minutes. During this addition, the K,H-tartrate precipitated and the pH dropped to 3.2. The reaction mixture was stirred for 1 hour at room temperature, cooled to 4° C. and the K,H-tartrate was filtered by means of suction, washed with alcohol/water and air dried. The yield was 94.2 g [100.1 percent, [α] D 20 =31.5° (c=1.1M NaOH)]. The filtrate (and wash solvent) was evaporated in a rotary evaporator at a bath temperature of 50° C. until the (-)-3-chloro-2-hydroxy-propyltrimethylammonium chloride began to precipitate. Then the mixture was cooled to room temperature. The crystals of (-)-3-chloro-2-hydroxy-propyltrimethylammonium chloride were filtered by suction, washed with ethanol/acetone and dried. The yield was 88.5 g [(47.0 percent, [α] D 24 =-29.7° (c=1, H 2 O)]. The mother liquor and the wash solvent were evaporated to dryness. The residue was digested with 160 ml of absolute ethanol at 70° C. The suspension was cooled in an ice bath. The crystals of (-)-3-chloro-2-hydroxy-propyltrimethylammonium chloride were filtered by means of suction, washed with ethanol/acetone and dried. The yield was 83.6 g [44.5 percent, [α] D 24 =29.3° (c=1, H 2 O)].
EXAMPLE 11
Production Of (-)-3-chloro-2-hydroxy-propyltrimethylammonium chloride
228.3 g (0.5 mol) of di-[(-)-3chloro-2-hydroxy-propyltrimethylammonium]-L-(+)tartrate was dissolved in a mixture of 315 ml of H 2 O and 135 ml of ethanol at room temperature. 88.9 g of HCl (37 percent in H 2 O; 0.9 mol) was added dropwise to the stirred mixture within 8 minutes and then a solution of 28.1 g of KOH (0.5 mol) was added dropwise in 30 ml of H 2 O within 10 minutes. the K,H-tartrate immediately precipitated crystalline. The pH was brought to 3.2 to 3.5 with 9.8 g HCl (37 percent in H 2 O; 0.1 mol). The reaction mixture was stirred for 1 hour at room temperature, cooled to 4° C., and the K,H-tartrate was filtered by means of suction, washed with ethanol/H 2 O and air dried. The yield was 94.6 g [100.8 percent, [α] D 20 =+31.3° (c=1.1M NaOH)]. The (-)-3-chloro-2-hydroxy-propyltrimethylammonium chloride was isolated as in Example 1.
EXAMPLE 12
Production Of (-)-3-chloro-2-hydroxy-propyltrimethylammonium chloride
The K,H-tartrate was prepared and filtered from 228.3 g (0.5 mol) of di-[(-)-3-chloro-2-hydroxy-propyltrimethylammonium]-L-(+)tartrate according to Example 10. Then the filtrate and the wash solvent were evaporated in a rotary evaporator to a weight of 350 g. 600 ml of toluene was added and the residual water was distilled off azeotropically. After distillation of about 150 g of water, the (-)-3-chloro-2-hydroxy-propyltrimethylammonium chloride crystallized out. The heterogeneous mixture was cooled to room temperature and filtered by means of suction. The crystals were washed twice, each time with 25 ml of ethanol/acetone 1:1 and dried. The yield was 17.65 g (93.6 percent) of (-)-3-chloro-2-hydroxy-propyltrimethylammonium chloride. Also, [α] D 24 =-29.8° (c=1.0 H 2 O). | Process for the production of optically-active di-[3-chloro-2-hydroxy-propyltrimethylammonium]-tartrate. Racemic 3-chloro-2-hydroxy-propyltrimethylammonium-chloride is converted by racemate resolution with optically-active tartaric acid into the optically-active di-[3-chloro-2-hydroxy-propyltrimethylammonium]-tartrate. Such optically-active tartrate compound is dissociated in tartaric acid and optically-active 3-chloro-2-hydroxy-propyltrimethylammonium-chloride and the latter is converted with inorganic cyanides. From the product, the production of optically-active carnitine nitrile chloride can be achieved. | 2 |
BACKGROUND OF THE INVENTIONS
1. Technical Field
The present inventions relate to the components and the procedure for installing a trim assembly at a wall and ceiling junction, and, more particularly, relates to a self-adjusting trim assembly designed to hide unsightly gaps at the junction between the top of a stationary wall finish and a ceiling expected to move.
2. Description of the Related Art
As construction techniques improved in recent years, free span concrete ceilings (poured or pre-cast spans devoid of columns and beams for intermediate support) have come into common usage. These free span structures are usually supported by interior walls or beams at the core of the building and by walls or beams at the exterior of the building.
Exterior support structures are frequently subject to temperature variances and forces not present on and around the interior (core) support structures. The dynamics involved with the exterior support structures cause them to expand, contract and move at different rates than the core structures, resulting in an anticipated flex or movement of the ceiling being supported. Therefore, non-supporting walls constructed between support structures have to be able to withstand the expected movement of the ceilings above them without sustaining damage. To prevent damage to non-supporting walls, deflection allowances are designed into those walls which include deflection framing components and a deflection gap between the top of the stationary wall finishes and the ceiling expected to move.
Initial usage of free span ceilings was primarily in commercial buildings where drop ceilings hid the necessary deflection gaps between stationary elements of a non-supporting wall and a flexing ceiling above. Often in commercial spaces, the area above the drop ceiling was used to house the required electrical feeds, plumbing, fire protection piping and the HVAC ducting. Those areas above dropped ceilings often exceeded a foot in height. When this construction method began to be used in residential building, providing a dropped ceiling below the structural ceiling proved to be impractical. Electrical systems, plumbing, fire protection and HVAC were relocated into the walls or soffits and the dropped ceilings were eliminated. Therefore, the structural ceiling became the finished ceiling. This resulted in eliminating the extra height on each floor required above dropped ceilings. In a multistory building, omitting these extra heights and the dropped ceilings added up to become a significant savings. However, when the structural ceiling became the finished ceiling, the unsightly deflection gap at the top of all the non-supporting walls became visible.
It is commonly desirable to provide aesthetically pleasing junctions or intersections between walls and ceilings. When an unsightly deflection gap is visible due to anticipated flexing of the ceiling, making an aesthetically pleasing junction at the deflection gap between the stationary wall finishes and the ceiling requires a necessary treatment or covering for the exposed deflection gap.
In construction where it is not necessary to have a deflection gap, there are numerous methods of treating the junction between a stationary wall and a stationary ceiling, such as taping the joint (applying a paper or mesh tape angle and finishing compounds to the wall and ceiling junction to make an unbroken finish between the ceiling and the wall) or by applying a standard molding like a crown molding, a cove molding, a square stock molding, a beam, etc. to enhance the appearance of the wall and ceiling junction. However, there are few options for treating the junction between a stationary wall finish and a ceiling that is expected to flex as the ceiling's support members expand, contract or move due normal conditions expected to effect the support structures.
The current, common options for treating a deflecting gap between a stationary wall finish and a slightly deflecting ceiling are flat taping the top of the stationary wall finish (applying paper or mesh tape and finishing compound on the wall surface only with the edge of the tape as close to the ceiling as possible without touching the ceiling) and/or caulking the gap between the top of the stationary wall finish and the ceiling.
The chief advantage to flat taping (as illustrated in prior art FIG. 1 ) is that imperfections on the top edge of the wall finish materials and the fire or sound caulking is partially hidden by the tape. However, the flat taping option is labor intensive, has a built in crack at the top and generally results in an even more unsightly junction once the ceiling deflects down on the top of the tape, which crushes and permanently deforms the tape. (Once the ceiling migrates back upward, an unsightly gap is more pronounced.)
The caulking option is also somewhat unsightly because slight defects (uneven cuts, jagged edges, etc.) at the top of the wall finish material are visible, dust and dirt tend to accumulate in the caulk space over time and the caulk tends to distort when the ceiling migrates in an upward or downward direction. To minimize the unsightly appearance at the edges of the wall finish materials, a finishing bead (as illustrated in prior art FIG. 2 ) was often installed at the top of the wall finish material and finished with finishing compound prior to the installation of the caulk. If a finish bead is used to define the top edge of the wall finish material and hide defects, the caulk method is more costly for materials and more labor intensive than flat taping. Being that caulk tends to loose it's elasticity and bonding propensity over time, it eventually tends to allow small cracks and gaps to develop. In many fire resistant and sound deadening wall designs, caulk is a necessary component. Therefore the cost of the materials and labor for the caulk itself was not a factor in determining the best finishing application for the wall and ceiling junction.
Many trims that could hide an unsightly wall/ceiling gap have been designed through the years past. However, known trims were not self-adjusting and do not accommodate flex in the ceilings. Most known existing trim systems attached to the surfaces of the stationary wall and the stationary ceiling. Many known improvements incorporated concealed brackets and fasteners. While the trims for treating the junction between a stationary wall and a stationary ceiling were functional in their designed environment, they all had one thing in common. They were designed to be applied to the surface of a finished wall and a ceiling and they did not accommodate flexing of the ceiling without distortion or system failure.
One example of a trim system used in stationary wall and ceiling applications was taught in U.S. Pat. No. 4,555,885 by Ronald P. Raymond and William C. Andric (1985). This demonstrated an extruded, trim system where the trim has a barbed protrusion that was designed to friction fit in the gap between the wall and ceiling materials with a nearly flat element of the trim extending onto the ceiling and another nearly flat element of the trim extending onto the wall (having a basic right angle shape visible) which covers the gap between the wall finish and the ceiling finish. Wide variations in the joint width, caused by the flex of the ceiling, challenges the reliability of this system. This system also does not leave sufficient room for fire or sound caulks which are required in many fire and sound rated wall assemblies.
Another example of a trim system used in stationary wall and ceiling applications was taught in U.S. Pat. No. 4,461,135 by Dallas A. Anderson and Harlan J. Grayden (1984). This system is a 2 piece system of a plurality of slip-on clips and a trim piece that pushes onto the clips. This system functions in a manner similar to a slip-on J bead (a common edge treatment for drywall and other panel materials). This system attaches to the top of the finish panel for the wall system. This combination of clips and a trim piece is then manually adjusted after installation by sliding the trim into position immediately adjacent to the ceiling. Because this system is not self-adjusting, once the ceiling flexes in it's expected up and down migrations, a pronounced gap is developed. Being that this system is not self-adjusting, the trim would require periodic adjustment after installation.
A different approach to maintaining a pleasing appearance at the wall/ceiling junction was demonstrated in U.S. Pat. No. 6,581,353 by Ronald J. Augustine (2001), whereby the flexing of the ceiling is compensated through suspending the entire wall construction from the ceiling. This option creates a static wall/ceiling junction which can be finished using any existing finish or stationary trim system. The necessary gap that allows for flexing of the ceiling is just above the floor, with the deflection gap hidden by the baseboard. Lateral support for this wall construction system is at the bottom of the wall and is provided by using the sliding component of this invention. Drawbacks to this type of construction are the extremely high material, labor and fastener costs, the relative instability of the partitions at the base and the inability of this design to meet most fire and sound resistance ratings.
Numerous crown molding designs such as those shown in U.S. Pat. Nos. 5,426,901 by Jaroslav Indracek (1995), 5,433,048 by Jean P. Strasser (1995), 4,642,957 by Troy C. Edwards (1987) and 7,451,574 by Micheal Timothey Spek (2008) include many improvements in reducing costs of installation and material costs for use at the junction of a stationary wall and a stationary ceiling. While many of these designs incorporate improvements such as brackets and preformed corners to help hide fasteners and facilitate faster installations, the chief drawback to all these systems is that they were not designed for use at a junction between a stationary wall finish and a flexible ceiling.
SUMMARY OF THE INVENTIONS
This invention is a self-adjusting trim system in all it's present and future embodiments that can be used in any building where the ceilings are expected to flex due to the inherent properties of the construction materials and support structures while the wall finishes abutting the ceilings are expected to remain stationary. To allow for the expected movement of the ceiling an unsightly gap must exist between the top of the stationary wall finishes and the flexing ceiling. Most often, the ceiling system expected to exhibit some amount of flex would be made of poured concrete or pre-cast concrete that spans from an inside (core) support wall to an outside (exterior) support wall. This invention is designed to have no adverse effect on the fire and/or sound ratings of the wall and ceiling systems. A key benefit of this system, in addition to solving the problem of providing an aesthetically pleasing finish to the stationary wall and flexing ceiling junction, is that this system of components and the installation procedure is very economical.
BRIEF DESCRIPTION OF THE DRAWINGS
The present inventions are illustrated by way of example and are not limited by the accompanying figures, in which like references indicate similar elements. Elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale.
The details of the embodiments will be more readily understood from the following detailed description when read in conjunction with the accompanying drawings wherein:
FIG. 1 illustrates a cutaway end view of the prior art of flat taping, a common way of hiding the necessary gap between the wall finish and the ceiling;
FIG. 2 shows a cutaway end view of the prior art of exposed caulking in the exposed gap, another common option where a finish bead and compound are installed on the top of the wall finish to establish a straight line defining the necessary gap between the wall finish and the ceiling which is then filled with caulk;
FIG. 3 illustrates a side view of the basic components upon which this invention is based;
FIG. 4 is an isometric view of the Retainer Clip component of the basic system which is essential to this invention;
FIG. 5 is an isometric view of a Joint Tab which is an optional component for aligning abutted trim components of the basic system;
FIG. 6 is an isometric view of a basic trim component, hereinafter referred to as the Trim Strip of the basic system which covers gaps between wall surfaces and ceiling surfaces;
FIG. 7 illustrates a cutaway end view of the components of the basic trim system installed in a typical wall construction;
FIG. 8 illustrates a cutaway end view of the components of the basic trim system with the Retainer Clip sized to accommodate the greater distance of the wall finish from the wall framing installed in another type of typical wall construction;
FIG. 9 is an end view of the Retainer Clip component in just one of many optional sizes;
FIG. 10 is a rear view of the Retainer Clip component;
FIG. 11 is a front view of the Retainer Clip component;
FIG. 12 is an end view of an embodiment of the Trim Strip component;
FIG. 13 is a front view of the Trim Strip component;
FIG. 14 is a rear view of the Trim Strip component;
FIG. 15 is an end view of the embodiments for a hook design for both the Retainer Clip and the Trim Strip component of the basic system;
FIG. 16 is an end view of an alternate hook design for both the Retainer Clip and the Trim Strip component of the basic system;
FIG. 17 is an end view of an alternate hook design for both the Retainer Clip and the Trim Strip component of the basic system;
FIG. 18 is an end view of an alternate hook design for both the Retainer Clip and the Trim Strip component of the basic system;
FIG. 19 illustrates a view of a corner in a room with the trim system installed and of the conditions behind properly installed trim after initial installation;
FIG. 20 illustrates a view of a corner in a room with the trim system installed and of the conditions behind the properly installed trim during cold weather exterior wall shrinkage when the designed gap between the static wall finish and the flex ceiling is reduced;
FIG. 21 illustrates a view of a corner in a room with the trim system installed and of the conditions behind the properly installed trim during hot weather exterior wall expansion when the designed gap between the static wall finish and the flex ceiling is expanded;
FIG. 22 illustrates a cutaway end view of the components of the basic trim system installed in a typical retrogressive wall construction using an alternate Retainer Clip designed to be installed after wall finishes have been previously installed;
FIG. 23 illustrates the basic components of a trim kit for a typical room; and
FIG. 24 illustrates the construction process of building a wall which incorporates the trim system during construction.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows the common, aesthetic treatment of the necessary gap between the top of the stationary wall finish and the ceiling that is expected to flex due to expansion, contraction and other anticipated movement of the support walls at each end of the ceilings. Note that the paper tape and finishing compound 15 is applied to the top edge of the wall finish 4 with a gap between the tape and compound 15 and the ceiling 3 above. Also shown are the framing components of this typical construction designed to allow for ceiling flex (vertical framing component 5 in a deflection or slip track 6 ), and caulk 7 in the gap between the top of the wall finish 4 and the ceiling 3 . The problem with this construction results during the anticipated upward and downward travel of the ceiling 3 , which crushes the top of the flat tape and compound 15 and then exaggerates the gap at the top of the tape when the ceiling 3 flexes in an upward direction. This treatment of the wall finish and ceiling gap is labor intensive and costly, but doesn't result in a permanent acceptable finish. A plurality of vertical framing components is usually contained within a wall assembly to provide the structure for the wall finishes to be used. In an assembly where the ceiling is expected to flex, the vertical framing components are expected to slide within the vertical legs of the deflection track without interfering with the up and down movement of the ceiling. For this reason, the vertical framing components and attached wall finishes are not attached to the deflection track. A deflection track is a framing component that is U-shaped with a vertical leg on each side that provides lateral stability to the wall framing assembly while concurrently allowing the ceiling to which the horizontal portion is attached to move without crushing the vertical wall framing components of the assembly.
FIG. 2 shows another common aesthetic treatment of the necessary gap between the top of the stationary wall finish and the ceiling that is expected to flex. This treatment shows a finishing bead with taping compound 16 at the top of the wall finish 4 . The necessary expansion gap between the top of the wall finish 4 and the ceiling 3 is then filled with caulk 7 . This caulk filled gap is always noticeable. As the ceiling 3 flexes, the caulk 7 deforms and eventually allows cracks to develop between the caulk and the ceiling 3 . Due to the uneven texture and shape of the caulk 7 , dust and dirt tends to accumulate in the caulk joint. This treatment is also labor intensive and costly without resulting in a permanent, aesthetically pleasing finish.
FIG. 3 is a side view of the primary components (Retainer Clip 1 and Trim Strip 2 ) of this invention (also shown during typical usage in FIGS. 7 and 8 and in special usage in FIG. 22 ). This invention is essentially; a 2-piece combination of components and the method of installation that enables the Trim Strip 2 of this combination to hide the essential gap that exists in a typical wall/ceiling junction where the wall finishes 4 are stationary and the ceiling construction 3 is designed to flex in response to changes in support structure heights. The following were considerations used in designing this invention:
1. Material Considerations.
In finish systems where it is necessary to maintain fire ratings, metal trim components could be preferable to other known materials such as plastic trim components because metal components tend not to contribute to combustion and do not omit the toxic fumes often generated by melting or combustion of other types of materials. Being the trim component of this system is a visible finish element of the wall construction, the trim component needs to be pre-primed or pre-finished, mold resistant, moisture resistant, resistant to distortion caused by building movement and rust and corrosion resistant. While the retainer clips are not visible after complete system installation, they still need to be resistant to distortion caused by building movement and rust and corrosion resistant. Materials and fabrication of system components need to be affordable. The Retainer Clip and the Trim Strip are preferably each formed from one piece of metal or other material to make the manufacture or installation more affordable.
2. Ease of Installation.
The Retainer Clips 1 for this system are small and light-weight, so that they are easily carried by the installer in a carpenter's pouch or nail apron. Installation of the Retainer Clip 1 is by screw attaching with framing screws 9 to deflection track 6 or a deflection angle 12 in a wall assembly while holding the Retainer Clip 1 up to the ceiling 3 . To make installation as fast as possible, spacing of clips need only be placed 2 ″ off the ends of each wall and placed approximately 2 to 4′ on center between the ends (insuring that the framing screws 9 do not engage the vertical framing component 5 portion of the framing so that movement of the deflection track 6 or deflection angle 12 is not inhibited). Exact spacing of Retainer Clips 1 is not required (except at joints of the Trim Strips 2 where the wall length exceeds the standard length of trim components 2 ). Therefore, installation time for installing Retainer Clips 1 is minimized. The system requires the Trim Strip 2 to be snapped into the Retainer Clips 1 after being measured and cut for length. Where Trim Strips 2 intersect each other or where they are required to abut each other in long wall instances, they have square cut ends during manufacture and are able to be abutted without requiring mitering, special connecting pieces or special cuts. In special instances where it is necessary to maintain alignment where slight deviations in the wall surfaces tend to misalign the butt joints of the Trim Strips 2 , a Joint Tab 10 (shown in FIG. 3 ) may be used. The cost to install these components is off-set by the elimination of flat-taping or the taping and finishing of a tape bead at the top of the wall finish as shown in FIGS. 1 and 2 , making this system extremely cost efficient.
3. Compatibility with Other Wall and Ceiling Components.
This system does not hinder in any way, the installation or performance of the framing or finishes in constructing the wall. In new construction, it does, however require the installation of the Retainer Clips 1 between the wall framing and the installation of the wall finishes. The Trim Strip 2 is installed after the wall finishes are installed. In instances where the walls were finished previously and where it is desired to provide this self-adjusting trim system at a later date, Retainer Clip 18 may be substituted for the basic system Retainer Clip 1 so that the existing wall finishes do not need to be disturbed in order to install this system. The Trim Strip 2 is then installed in the normal manner. Where fire caulk is a necessary component of a fire rated wall system, this molding system allows for the complete, economical installation of the caulk. This system allows for the complete, economical installation of wall framing, wall finishes and caulk, where specified, without slowing any operation or without hindering the operation of any system.
FIG. 4 is an isometric view of Retainer Clip 1 which shows the vertical back portion of the clip 1 a , the horizontal, projecting tongue 1 b and the location of the interlocking hook is portion 1 c . The horizontal tongue portion 1 b of the Retainer Clip 1 acts as a spring. The horizontal tongue portion 1 b of the Retainer Clip 1 is resilient enough to the degree that the interlocking hook 2 c of the horizontal top portion 2 a of the L-shaped Trim Strip can fit between the ceiling 3 and the horizontal projecting tongue 1 b of the Retainer Clip 1 during installation until the interlocking hook 2 c snaps into place and locks into interlocking hook 1 c of the Retainer Clip 1 . The resiliency of the Retainer Clip 1 causes a vertical force against the Trim Strip 2 towards the ceiling 3 thereafter. In certain embodiments made from some metals, Retainer Clips 1 may be made resilient to act like a spring when heat treated after bending. Some materials such as brass or plastics may not require heat treating to provide optimal resiliency due to inherent physical properties. (See FIGS. 15 through 18 for hook embodiments.) The vertical back portion of the retainer clip could range from ¼″ to 3″ wide and up to 4″ high. The horizontal projecting tongue portion of the Retainer Clip could range from ¼″ to 3″ wide and from ½″ to 3″ deep.
FIG. 5 is an isometric view of a Joint Tab 10 that is an optional connector used to align two abutting Trim Strip 2 pieces. This connecting tab is inserted into the end at the upturned portion of each Trim Strip 2 at the joint where each butts to align the components.
FIG. 6 is an isometric view of a primary Trim Strip 2 , showing the horizontal, top portion 2 a , the vertical face portion 2 b and the hook portion 2 c . The Trim Strip 2 is an elongated member formed of a resilient material with an L-shape in the cross section. The face portion 2 b is the only exposed portion of the trim system when properly installed. The top portion 2 a has the interlocking hook 2 c at the end which locks into the Retainer Clip 1 at the interlocking hook portion 1 c . The Trim Strip 2 is resilient enough to the degree that combined with the location of the interlocking hooks on the Retainer Clip 1 and the Trim Strip 2 , the resiliency of the Trim Strip 2 causes a horizontal force to press the lower end of the face portion 2 b of the Trim Strip 2 against the wall finish 4 . In certain embodiments made from some metals, Trim Strips 2 may be made resilient to act like a spring when heat treated after bending. Some materials may not require heat treating to provide optimal resiliency due to inherent physical properties. The face portion 2 b has a small portion that is turned toward the wall finish 4 and up to form a stand-off that rides on the wall finish 4 without damaging the finish of the wall after installation. The face portion 2 b could range from ½″ to 2″ high with the horizontal top portion just long enough to engage and interlock with the Retainer Clip 1 . The length of the Trim Strip 2 is expected to range from 10 to 12′ in standard lengths.
FIG. 7 shows a typical wall framing assembly of a deflection track 6 attached to the ceiling or deck construction 3 with a concrete pin or screw 8 and a vertical framing component 5 . The vertical framing component is usually a wood or metal stud and extends from the floor to within ½″ of the ceiling. Also shown are a wall finish 4 , caulk 7 and in the embodiments containing the Retainer Clip 1 and Trim Strip 2 . Also shown is the optional Joint Tab 10 . Wall finishes can be drywall, plaster, stone, brick, paneling, stucco, acoustical panels or any other synthetic material. While most assemblies use wood or metal framing studs, other materials could be used to serve as the vertical framing component such as concrete block, clay tile, poured concrete, etc.
An installation procedure is as follows: As shown, after the wall framing is installed, attach the Retainer Clip 1 is anchored to the deflection track. A preferred example of how to anchor the Retainer Clip 1 to the deflection track 6 is with a framing screw 9 . After the wall finish 4 is attached to the vertical framing component 5 of the framing assembly (but not to the deflection track 6 or Retainer Clip 1 ) and the caulk is installed, if required for sound or fire ratings, install the Trim Strip 2 component of the invention by forcing the horizontal portion of the Trim Strip 2 between the top of the Retainer Clip 1 and the ceiling construction 3 until it snaps into the Retainer Clip 1 hook. Once installed, the Trim Strip 2 is held tightly to the ceiling by the shape of and the tension exerted by the Retainer Clip 1 . The relative position of the hooks on the Retainer Clip 1 and the Trim Strip 2 is engineered to provide a slight amount of lateral force on the face of the Trim Strip 2 which in conjunction with the resilient properties of the Trim Strip 2 , holds it tight to the face of the wall finish 4 . This illustration shows a finish on one side of the wall framing only. However, finishes and the trim system would commonly be used on one or both sides of the framing in normal construction.
FIG. 8 shows another typical wall construction of a wall structure or framing system 11 (concrete block illustrated in this example, but it could be wood framing, metal framing, poured concrete or any other common construction system), a deflection angle 12 attached to the ceiling construction 3 by pin or screw 8 , wall furring 14 (resilient furring channel for this example) attached to the wall structure or wall framing, a wall finish 4 attached to the wall furring 14 with screw 13 , caulking backer rod 21 (used to minimize the amount of caulk required), caulk 7 and the embodiments with the Retainer Clip 1 and the Trim Strip 2 . This example of the usage of this invention shows that the Retainer Clip 1 needs to be available with various tongue sizes to accommodate the variety of expected wall finish systems. Being that Retainer Clips 1 are much more inexpensive to manufacture in a variety of sizes than a variety of Trim Strips 2 , the variety of Retainer Clips 1 option is currently preferred. This illustration shows a finish on one side of the wall framing only. However, finishes and the trim system would commonly be used on one or both sides of the framing in normal construction. A deflection angle serves the same function as a deflection track (previously described herein) but is usually used on one side only. Sometimes a deflection angle could be used on both sides of a wall structure where a deflection track is impractical. One or both of the deflection angle or the deflection track can be referred to by the generic term deflection component. Wall furring is used in some wall assemblies to improve the sound reduction coefficient of the entire assembly by adding an air space between the wall framing and the wall finishes. Wall furring is also used in some assemblies to provide backing for easier attachment of the wall finishes.
FIGS. 9 , 10 and 11 are end, rear and front views of the Retainer Clip 1 . While the vertical portion of the Retainer Clip 1 a is expected to remain approximately the same size through all embodiments, the tongue portion 1 b will be sized to accommodate various widths of wall finish treatments. Normal wall finish thicknesses in the United States are expected to range from ½″ to 1¾″. International finish thicknesses are expected to have a similar range. Special sized tongue portions 1 b should be made available on a special order basis.
FIGS. 12 , 13 and 14 are end, rear and front views of the primary Trim Strip 2 . The vertical and horizontal dimensions for the Trim Strip 2 are expected to be a standard size in the embodiments. The horizontal portion has a hook 2 c at the engagement side with the Retainer Clip 1 . The vertical side of the Trim Strip 2 is the portion that is faced into the room after installation and is the portion that covers the gap behind.
FIGS. 15 through 18 show possible options for the hook on both the Retainer Clip 1 and the Trim Strip 2 . As shown, FIG. 15 is the preferred hook option.
FIG. 19 illustrates a typical cross-section view of a portion of a multi-story concrete building having concrete walls and ceilings or decks. The blow-up shows an expanded corner of a wall when looking from the room side with the Stationary Wall and Flexible Ceiling Trim System installed. The blow-up shows a cut-away of the Trim Strip 2 (Retainer Clip 1 not shown) to show the top of the wall finish 4 and the resulting, engineered gap filled with caulk 7 . A typical deflection of a ceiling is expected to flex as much as about 0.375 inches or up to about 0.4% of the room height depending on temperature variations and support structure material properties. Further into the corner, another cut-away shows the framing (deflection track 6 and vertical framing component 5 ) behind the wall finish 4 and the caulk 7 . Also shown is the flexible ceiling 3 and the building exterior wall 20 support structure (which is subject to wide temperature variations causing the support structure to shrink and expand as the outside temperature varies).
FIG. 20 illustrates a typical cross-section view of a portion of a multi-story concrete building having concrete walls and ceilings or decks during cold weather. The blow-up shows a corner of a wall when looking from the room side with the Stationary Wall and Flexible Ceiling Trim System installed. The cut-away on this drawing shows the effect on the engineered gap between the top of the stationary wall finish 4 and the flexing ceiling 3 . Note that the caulk 7 in the gap is collapsed when the outside wall support structure 20 shrinks due to extremely cold temperatures. Also note that during this extreme temperature event, the Trim Strip 2 remains in tight contact with the ceiling and completely hides the gap distortion behind.
FIG. 21 illustrates a typical cross-section view of a portion of a multi-story concrete building having concrete walls and ceilings or decks during extremely hot weather. The blow-up shows a corner of a wall when looking from the room side with the Stationary Wall and Flexible Ceiling Trim System installed. The cut-away on this drawing shows the effect on the engineered gap between the top of the stationary wall finish 4 and the flexing ceiling 3 . Note that the caulk 7 in the gap is somewhat recovered (after being crushed during cold weather) when the outside wall support structure 20 expands due to extremely hot outside temperatures. However, an exaggeration 19 of the gap tends to develop between the top of the caulk 7 and the ceiling 3 as the total gap continues to grow due to the expanding of the exterior wall support structure 20 . Also note that during this extreme temperature event, the Trim Strip 2 remains in tight contact with the ceiling and completely hides the gap distortion behind.
FIG. 22 illustrates a cutaway end view of the components of the basic trim system installed in a typical retrogressive wall construction using an alternate Retainer Clip designed to be installed after wall finishes have been previously installed. This figure shows a typical wall construction of framing components containing a deflection track 6 attached to the ceiling or deck construction 3 with a concrete pin or screw 8 and vertical framing component 5 . Also shown are a wall finish 4 , caulk 7 and the embodiments substituting Retro-fit Retainer Clips 18 (for the standard Retainer Clip 1 ) and Trim Strip 2 . Installation procedure is as follows: In spaces where the Retro-fit Retainer Clips are to be installed, existing caulk needs to be removed. The Retro-fit Retainer Clip 18 can then be installed between the top of the deflection track 6 and the ceiling 3 using a conventional framing screw 9 to hold it in place. After the Retro-fit Retainer Clips 18 are installed, the caulk needs to be reinstalled where removed. Trim Strip 2 components of the invention are then installed by forcing the horizontal portion of the Trim Strip 2 between the top of the Retro-fit Retainer Clip 18 and the ceiling construction 3 until it snaps into the Retro-fit Retainer Clip 18 hook. Once installed, the Trim Strip 2 is held tightly to the ceiling by the shape of and the tension exerted by the Retro-fit Retainer Clip 18 . The relative position of the hooks on the Retro-fit Retainer Clips 18 and the Trim Strip 2 is engineered to provide a slight amount of lateral force on the face of the Trim Strip 2 which in conjunction with the resilient properties of the Trim Strip 2 , holds it tight to the surface of the wall finish 4 . The trim system would commonly be used on one or both sides of the framing in normal construction.
FIG. 23 illustrates the basic components of a self-adjusting trim kit for a typical room. This kit could have twenty five pieces of the Retainer Clips 1 , five pieces of the Trim Strip 2 and two pieces of Joint Tab 10 . Typically, several Retainer Clips would be supplied for each Trim Strip. When selecting the correct kit for the intended room, the end user would need to select the kit sized for the wall finish to be installed. For example: If the wall finish to be used is ⅝″ thick, the Retainer Clips 1 would need to be sized for the ⅝″ wall finish and the end user would need to select the kit containing the ⅝″ sized Retainer Clips. If the wall finish to be used is 1¼″ thick, the end user would have to select a kit containing the 1¼″ sized Retainer Clips. Every self-adjusting trim kit would contain the standard Trim Strip 2 and the standard Joint Tabs 10 .
FIG. 24 illustrates the steps during construction of a typical wall with the trim system installation incorporated into the final construction of the wall. In most cases, the same installation company would install the framing, wall finishes and the trim system. However, separate operations are usually performed by separate installation crews within the company.
In step 101 the wall partition framing is installed between the floor (not shown) and the ceiling 3 . The framing components include the vertical framing components 5 and the deflection track 6 . Note that the vertical framing components 5 are not attached to the deflection track 6 . Deflection track is attached to the flexing ceiling with fasteners 8 such as pins or screws. Installation of the trim system commences after step 101 .
In step 102 the first step in installing the trim system involves determining the thickness of the intended wall finish 4 . In step 103 following the determination of the wall finish thickness, the appropriate Retainer Clip 1 is selected to accommodate the intended wall finish thickness. A Retainer Clip 1 is chosen having a horizontal tongue sized according to the intended thickness of the wall finish. In step 104 , a plurality of Retainer Clips 1 are installed along the length of each side of a wall to receive a wall finish by attaching to the deflection track adjacent to the ceiling 3 with screws, nails, adhesive, rivets, etc. 9 . In step 105 the trim system installer must then wait until the wall finish system is installed and finished by others. If caulking 7 is needed, it is also installed by others prior to the installation of the Trim Strip 2 portion of the trim system. In step 106 the trim system installer measures the length of the Trim Strips to be installed and cuts the Trim Strips to the appropriate lengths. In step 107 the trim system installer then pushes the horizontal leg of the Trim Strips 2 between the top of the Retainer Clips 1 and the ceiling 3 until the trim strips lock into the Retainer Clips 1 .
During the life of the building, in step 108 , the Trim Strip will hide the gap between the top of the wall finishes and the ceiling during all the anticipated movement of the ceiling relative to the position of the wall finish through and including normal temperature and humidity variations and even including minor earthquakes or other unexpected minor building movements.
Any letter designations such as (a) or (b) etc. used to label steps of any of the method claims herein are step headers applied for reading convenience and are not to be used in interpreting an order or process sequence of claimed method steps. Any method claims that recite a particular order or process sequence will do so using the words of their text, not the letter designations.
Unless stated otherwise, terms such as “first” and “second” are used to arbitrarily distinguish between the elements such terms describe. Thus, these terms are not necessarily intended to indicate temporal or other prioritization of such elements.
Any trademarks listed herein are the property of their respective owners, and reference herein to such trademarks is generally intended to indicate the source of a particular product or service.
Although the inventions have been described and illustrated in the above description and drawings, it is understood that this description is by example only, and that numerous changes and modifications can be made by those skilled in the art without departing from the true spirit and scope of the inventions. Although the examples in the drawings depict only example constructions and embodiments, alternate embodiments are available given the teachings of the present patent disclosure. | A self-adjusting trim assembly used at the junction of a wall and ceiling where the wall finishes are to remain stationary while the ceiling is expected to flex due to loads on ceiling structure and normal variations in the height of the supporting structures due to temperature, moisture, creep or other factors effecting the height of the support structures. This trim assembly has two interlocking components comprised of a retainer clip having a vertical back portion ( 1 a ), a horizontal projecting tongue ( 1 b ) and the interlocking hook portion ( 1 c ) and also of a trim strip having a horizontal top portion ( 2 a ), a vertical face portion ( 2 b ) and an interlocking hook portion ( 2 c ) with the vertical face portion of the trim strip designed to cover the gap between stationary wall finishes and a flexing ceiling while trim strip remains flush with the ceiling structure, thus leaving no unsightly gap. | 4 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims under 35 U.S.C. §119(a) the benefit of Korean Patent Application No. 10-2011-0052630 filed Jun. 1, 2011, the entire contents of which are incorporated herein by reference.
BACKGROUND
[0002] (a) Technical Field
[0003] The present disclosure relates to a method for producing synthetic leather. More particularly, it relates to a method for producing synthetic leather, which is suitable for vehicle interior materials (such as seat covers, door trim sheets, etc.) and has improved air permeability, which is similar to that of genuine leather. Moreover, the synthetic leather produced by the present invention has increased hydrolysis resistance and chemical resistance, which genuine leather does not have, increased flame retardancy and, at the same time, has improved adhesion between a fabric and a film along with improved film texture.
[0004] (b) Background Art
[0005] Generally, synthetic leather is a fabric produced by forming a film with a synthetic resin such as polyvinyl alcohol (PVA) or polyurethane (PU) on a release paper (RP), on which a leather pattern or other predetermined pattern is embossed, and bonding the resulting film to a woven fabric, knitted fabric, or nonwoven fabric using an adhesive. The methods for producing synthetic leather generally include a dry method and a wet method.
[0006] According to the dry method, a film is formed on the surface of a release paper using a polyurethane solution or solvent-based polyurethane (PU) resin (prepared by dissolving polyurethane in toluene and methyl ethyl ketone (MEK). That is, a solvent-based polyurethane solution, for example, is coated on a release paper and dried to form a film on the release paper. Then, the resulting release paper is bonded to a fabric coated with an adhesive and dried, and the release paper is removed from the film, thereby forming the final film on the fabric.
[0007] The wet method, utilizes a resin, such as solvent-based PU resin, capable of forming a film is padded onto the surface of a fabric or onto the entire fabric. Alternatively, a PU resin may be coated on the surface of a fabric (such as a woven fabric, knitted fabric, or nonwoven fabric) embedded in a synthetic resin by gravure coating, for example, thus forming a film. Moreover, a wet/dry method, in which a release paper is attached to the thus formed film, may be used.
[0008] However, the synthetic leather produced by the above-described conventional methods, in which the thus formed film is bonded to the surface of the fabric by an adhesive, has no air permeability similar to that of genuine leather, since the surface of the fabric is completely covered by the film, as shown in the images of FIGS. 6A , 6 B, 7 A and 7 B.
[0009] Moreover, the use of adhesives causes contaminants such as volatile organic compounds (VOCs) and odors, not to mention that the use of solvents (such as toluene and MEK), which may be harmful to the human body, is not environmentally friendly.
[0010] The above information disclosed in this Background section is only for enhancement of understanding of the background of the invention and therefore it may contain information that does not form the prior art that is already known in this country to a person of ordinary skill in the art.
SUMMARY OF THE DISCLOSURE
[0011] The present invention has been made in an effort to solve the above-described problems associated with prior art. Accordingly, the present invention provides a method for producing synthetic leather, which is suitable for vehicle interior materials and has air permeability which is similar to that of genuine leather. The synthetic leather is produced by directly coating a water-soluble synthetic resin solution on the surface of a fabric to form a film thereon such that no volatile organic compounds (VOCs) and odors are generated and fine gaps formed on the fabric are partially left to have a certain degree of air permeability. Moreover, the synthetic leather produced by the present invention has increased hydrolysis resistance and chemical resistance, which genuine leather does not have, and improved durability and texture.
[0012] In one aspect, the present invention provides a method for producing synthetic leather having air permeability, the method comprising: a brushing process for brushing the surface of a fabric using a brushing machine to raise a nap; a back reinforcing process for coating a hydrolysis-resistant and flame-retardant resin solution on the back of the fabric, which is opposite to the surface on which the nap is raised, to reinforce the back of the fabric; and a film forming process for applying a water-soluble polyurethane resin solution to the nap raised on the surface of the fabric to form a film on the surface of the fabric.
[0013] In an exemplary embodiment, the method of the present invention further comprises: a pattern forming process for forming a pattern by performing an embossing process on the film disposed on the surface of the fabric after the film forming process has been completed; a painting process for imparting a color by spraying a water-soluble resin solution, which contains a pigment and a carbodiimide curing agent for improving water resistance and chemical resistance, on the surface of the film after the pattern forming process; and a surface reinforcing process for increasing the surface durability by spraying a top protective resin solution on the surface of the film after the painting process.
[0014] In another exemplary embodiment, the method of the present invention further comprises, performing before the brushing process, a softening process for imparting flexibility to the surface of the fabric by immersing the fabric in a softening solution containing a softener diluted in water and stored in a reservoir and drying the resulting fabric.
[0015] In still another exemplary embodiment, in the back reinforcing process, a hydrolysis-resistant and flame-retardant resin solution in an amount of about 52 to 60 g/m 2 is coated on the back of the fabric to reinforce the back texture of the fabric.
[0016] In yet another exemplary embodiment, in the film forming process, a water-soluble polyurethane resin solution in an amount of about 50 to 60 g/m 2 is applied to the nap of the fabric to form a film.
[0017] In still yet another exemplary embodiment, the film forming process comprises: a first coating process for coating a predetermined amount of hydrolysis-resistant, flame-retardant, and water soluble polyurethane resin solution on the surface of the fabric; a planarization process for planarizing and drying the surface of the film by heating and pressurizing the film after the first coating process; and a second coating process for coating the remaining amount of hydrolysis-resistant, flame-retardant, and water soluble polyurethane resin solution on the surface of the film after the planarization process.
[0018] In a further exemplary embodiment, in the first coating process, the water-soluble polyurethane resin solution in an amount of about 80 to 84% of the total weight is coated on the surface of the film and, in the second coating process, the water-soluble polyurethane resin solution in an amount of about 16 to 20% of the total weight is coated on the surface of the film.
[0019] In another further exemplary embodiment, in the planarization process, the film after the first coating process is dried by heating at a temperature of about 130 to 160° C.
[0020] In still another further exemplary embodiment, in the planarization process, the fabric after the first coating process is passed through a hot press roller such that the fabric is heated and pressurized at the same time.
[0021] Other aspects and exemplary embodiments of the invention are discussed infra.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] The above and other features of the present invention will now be described in detail with reference to certain exemplary embodiments thereof illustrated the accompanying drawings which are given hereinbelow by way of illustration only, and thus are not limitative of the present invention, and wherein:
[0023] FIG. 1 is a flowchart showing a method for producing synthetic leather according to an exemplary embodiment of the present invention.
[0024] FIG. 2 is a schematic process diagram showing the processes of the method for producing synthetic leather according to the present invention.
[0025] FIGS. 3A and 3B are images showing the surface of a fabric before and after a brushing process in the method for producing synthetic leather according to the present invention.
[0026] FIGS. 4A and 4B are images showing the surface and cross-section of synthetic leather produce by the method according to the present invention.
[0027] FIGS. 5A and 5B are images showing the surface and cross-section of genuine leather treated with color spray and top protective spray.
[0028] FIGS. 6A and 6B are images showing the surface and cross-section of synthetic leather produced by forming a polyurethane film according to a conventional method.
[0029] FIGS. 7A and 7B are images showing the surface and cross-section of synthetic leather produced by forming a PVC film according to a conventional method.
[0030] Reference numerals set forth in the Drawings includes reference to the following elements as further discussed below:
[0031] 11 : softening solution
[0032] 12 : reservoir
[0033] 20 : brushing fillets
[0034] 21 : fillets
[0035] 22 : drum
[0036] 31 : coating agent
[0037] 32 : coating machine
[0038] 41 : coating machine
[0039] 42 : hot press roller
[0040] 43 : coating machine
[0041] It should be understood that the appended drawings are not necessarily to scale, presenting a somewhat simplified representation of various exemplary features illustrative of the basic principles of the invention. The specific design features of the present invention as disclosed herein, including, for example, specific dimensions, orientations, locations, and shapes will be determined in part by the particular intended application and use environment.
[0042] In the figures, reference numbers refer to the same or equivalent parts of the present invention throughout the several figures of the drawing.
DETAILED DESCRIPTION
[0043] Hereinafter reference will now be made in detail to various embodiments of the present invention, examples of which are illustrated in the accompanying drawings and described below. While the invention will be described in conjunction with exemplary embodiments, it will be understood that present description is not intended to limit the invention to those exemplary embodiments. On the contrary, the invention is intended to cover not only the exemplary embodiments, but also various alternatives, modifications, equivalents and other embodiments, which may be included within the spirit and scope of the invention as defined by the appended claims.
[0044] It is understood that the term “vehicle” or “vehicular” or other similar term as used herein is inclusive of motor vehicles in general such as passenger automobiles including sports utility vehicles (SUV), buses, trucks, various commercial vehicles, watercraft including a variety of boats and ships, aircraft, and the like, and includes hybrid vehicles, electric vehicles, plug-in hybrid electric vehicles, hydrogen-powered vehicles and other alternative fuel vehicles (e.g., fuels derived from resources other than petroleum). As referred to herein, a hybrid vehicle is a vehicle that has two or more sources of power, for example both gasoline-powered and electric-powered vehicles.
[0045] Unless specifically stated or obvious from context, as used herein, the term “about” is understood as within a range of normal tolerance in the art, for example within 2 standard deviations of the mean. About can be understood as within 10%, 9%, 8%, 7%, 6%, 5%, 4%, 3%, 2%, 1%, 0.5%, 0.1%, 0.05%, or 0.01% of the stated value. Unless otherwise clear from context, all numerical values provided herein are modified by the term about.
[0046] The present invention provides a method for producing synthetic leather applicable to vehicle interior materials such as seat covers, door trim sheets, etc.
[0047] In particular, the synthetic leather produced by the present invention has air permeability, which is similar to that of genuine leather, increased hydrolysis resistance and chemical resistance, which genuine leather does not have, improved flame retardancy, and adhesion between a fabric and a film which has a more desirable film texture.
[0048] As shown in FIG. 1 , the method for producing synthetic leather having air permeability comprises a softening process (S 1 ), a brushing process (S 2 , or nap-raising process), a back reinforcing process (S 3 ), and a film forming process (S 4 ). Examples of fabrics used in the production of synthetic leather include knitted fabrics (such as Tricot brushed fabrics), woven fabrics, and nonwoven fabrics, which have good air permeability due to the large number of spaces between the threads and are easy to raise the nap on the surface.
[0049] First, where a film is to be formed, the softening process (S 1 ) is performed on the surface of a fabric before raising a nap to impart flexibility to the surface of the fabric, thus facilitating the brushing process (S 2 ). As shown in (a) of FIG. 2 , a softening solution 11 containing a softener such as a wax or silicone-based softener diluted in water may be stored in a reservoir 12 , and a fabric W may be immersed in the softening solution 11 to absorb the softener and is then dried.
[0050] Subsequently, the brushing process is performed after the softening process (S 1 ) by brushing the surface of the fabric using a brushing machine such as brushing fillets, thus raising a loop-type nap. As shown in (b) of FIG. 2 , brushing fillets 20 composed of fillets 21 bent in a predetermined direction on a drum 22 are brought into contact with the surface of the fabric W and rotated at high speed to raise a nap on the surface of the fabric W. As shown in the image of FIG. 3A before the brushing process and the image of FIG. 3B after the brushing process, a nap is raised on the surface of the fabric. Preferably, the brushing process (S 2 ) is repeatedly performed to maintain the uniformity of the nap over the entire surface of the fabric W.
[0051] Then, the back reinforcing process (S 3 ) is performed after the brushing process (S 2 ) has completed by applying a hydrolysis-resistant and flame-retardant coating agent 31 such as a phosphorus-based flame-retardant and water-resistant resin solution to the back side of the fabric W using a coating machine 32 , thus reinforcing the back of the fabric W. The back side of the fabric is defined as the side of the fabric which is opposite to the surface on which the nap is raised. As such, when the hydrolysis-resistant and flame-retardant resin solution is coated and cured on the back of the fabric W, the back texture of the fabric is hardened more than in conventional applications and the flexibility of the fabric W is reduced, thus maintaining the planarized surface of the fabric W.
[0052] Therefore, it is possible to prevent the decrease in the hydrolysis resistance due to combustible materials on the surface of the resin on the back of the fabric W carbonated by flame lamination, and thus this flame-retardant and water-resistant resin further improves the flame retardancy of the fabric.
[0053] Here, the amount of flame-retardant coating agent 31 is preferably set to a level that will not affect the back reinforcing function and the flame-retardant function and that will not cover the spaces between the threads of the fabric as shown in the images of FIGS. 4A and 4B , thus ensuring air permeability of the fabric W. For example, the amount of hydrolysis-resistant and flame-retardant resin solution coated is preferably about 52 to 60 g/m 2 . If the amount is less than 52 g/m 2 , the function of reinforcing the back texture of the fabric W is reduced, and thus the function cannot be sufficiently attained, whereas, if it exceeds 60 g/m 2 , the flame-retardant coating agent 31 penetrates the spaces between the threads of the fabric W, and thus the air permeability may be reduced. Subsequently, the film forming process (S 4 ) is performed after the back reinforcing process (S 3 ) by applying a thermosetting synthetic resin solution to the nap raised on the surface of the fabric W, thus forming a film on the surface of the fabric W.
[0054] A water-soluble polyurethane (PU) resin solution may be used as the thermosetting synthetic resin solution, and the amount of the water-soluble PU resin solution applied is preferably in the range of about 50 to 60 g/m 2 to improve the texture of the film and ensure the spaces between the naps, such that all the spaces between the naps, are at least partially not filled, thus allowing the film to have air permeability.
[0055] As a result, as shown in the images of FIGS. 6A and 6B , it is possible to produce synthetic leather having properties similar to the air permeability and surface texture of genuine leather. For example, if the amount of water-soluble PU resin solution applied is less than about 50 g/m 2 , most of the resin solution penetrates the spaces between the naps, which make it difficult to form a uniform film on the nap, thus degrading the texture of the film. Moreover, if the amount of PU resin solution applied exceeds about 60 g/m 2 , a uniform film can be formed on the nap to improve the texture of the film. However, the thus formed film covers the spaces between the naps, which make it difficult to ensure the space, thus reducing the air permeability. Thus, the most preferable range is in between 50 g/m 2 and 60 g/m 2 of PU resin.
[0056] These results were obtained by examining the differences in air permeability and texture through various examples (Example 1 to 3 and Comparative Examples 1 to 3), performed by varying the amount of thermosetting resin solution applied in the film forming process (S 4 ) of the method for producing synthetic resin, in which the softening process (51), the brushing process (S 2 ), the back reinforcing process (S 3 ), and the film forming process (S 4 ) are sequentially performed, and the results are shown in the following Table 1.
[0057] Here, the air permeability was evaluated by cutting the synthetic leathers produced in the Examples and the Comparative Examples into pieces having a size of 18×18 cm and taking three test pieces, respectively. Each sample was mounted at one end of a cylinder, a regulator is used such that an inclined manometer indicated a pressure of a water column of 12.7 mm H 2 O, and an air permeability tester (Frazier tester) was used. At this time, the amount of air passing through the sample was obtained by measuring the pressure indicated by a vertical manometer and the size of air orifice used.
[0058] Moreover, the texture of each sample was evaluated by a sensory test such as feeling tests conducted with 20 individuals. The results of the comparison with the texture of the synthetic leather produced by a conventional dry method were evaluated in three grades of “good”, “fair” and “poor” and determined by majority opinion.
[0000]
TABLE 1
Amount of PU resin
Air permeability
Classification
solution applied (g/m 2 )
(ml/cm 2 /sec)
Texture
Example 1
55
0.20
Good
Example 2
50
0.26
Fair
Example 3
60
0.12
Good
Comparative
45
0.31
Poor
Example 1
Comparative
65
0.07
Good
Example 2
Genuine leather
—
0.10
—
[0059] In the above Table 1, synthetic leathers of Examples 1 to 3 were produced by the same production method of the present invention, in which the softening process (S 1 ), the brushing process (S 2 ), the back reinforcing process (S 3 ), and the film forming process (S 4 ) were sequentially performed, except that the amount of water-soluble PU resin solution varied in the range of 50 to 60 g/m 2 in the film forming process (S 4 ).
[0060] Synthetic leathers of Comparative Examples 1 and 2 were produced by the same method as Examples 1 to 3, except that the amount of water-soluble PU resin solution was beyond the range of 50 to 60 g/m 2 in the film forming process (S 4 ).
[0061] As can be seen from the above Table 1, the synthetic leather produced with the PU resin solution in an amount of 55, 50, and 60 g/m 2 , respectively, in Examples 1 to 3 had air permeability higher than that of genuine leather, and the texture was more desirable than that of the conventional synthetic leather.
[0062] On the contrary, in the case of the synthetic leather produced with the PU resin solution in an amount of 45/m 2 in Comparative Example 1, the air permeability was higher than that of the genuine leather, however, the texture was less desirable than that of the conventional synthetic leather due to the decreased amount of the PU resin solution. Moreover, in the case of the synthetic leather produced with the PU resin solution in an amount of 65/m 2 in Comparative Example 2, the air permeability was higher than that of the genuine leather, however, the texture was more desirable.
[0063] It can be seen from the results of the Examples and the Comparative Examples that if the amount of water-soluble PU resin solution applied in the film forming process (S 4 ) was reduced, the air permeability was improved due to the increased number of spaces between the naps, but the texture of the film became poor and, on the contrary, if the amount of water-soluble PU resin solution applied was increased, the texture of the film was more desirable, but the air permeability became poor.
[0064] Thus, the above experimental results confirms that the synthetic leather produced with the PU resin solution in an amount within the range of 50 to 60 g/m 2 , respectively, in Examples 1 to 3 had increased air permeability and texture and thus it was suitable for the product, and the synthetic leather produced with the PU resin solution in an amount beyond the above range in Comparative Examples 1 and 2 had either insufficient air permeability or poor texture, and thus it could not achieve the objects of the present invention.
[0065] In a exemplary embodiment of the present invention, as shown in FIG. 1 and (d) of FIG. 2 , the film forming process (S 4 ) preferably comprises a first coating process (S 4 - 1 ) for coating a water-soluble PU resin solution in an amount of about 80 to 84% of the total weight on the surface of the film using a coating machine 41 , a planarization process (S 4 - 2 ) for planarizing and drying the surface of the film by uniformly heating and pressurizing the film after the first coating process (S 4 - 1 ) using a hot press roller 42 , and a second coating process (S 4 - 3 ) for coating the water-soluble PU resin solution in an amount of about 16 to 20% on the surface of the film after the planarization process (S 4 - 2 ) using a coating machine 43 .
[0066] Here, during the planarization process (S 4 - 2 ) after the first coating process (S 4 - 1 ), it is preferable that the film coated with the water-soluble PU resin solution is dried by heating at a temperature of about 130 to 160° C. Moreover, the film is preferably passed through the hot press roller 42 to heat and pressurize the film at the same time.
[0067] In the first coating process (S 4 - 1 ), the water-soluble PU resin solution is coated in the amount of about 40 to 50 g/m 2 , which corresponds to about 80 to 84% of the total weight of 50 to 60 g/m 2 . If the amount of water-soluble PU resin solution applied is less than the above range, the formation of the film on the surface is not sufficient, which results in poor durability (such as abrasion resistance, chemical resistance, and flame retardancy), whereas, if it is more than the above range, the air permeability is reduced. Therefore, the water-soluble PU resin solution is preferably applied in an amount of about 80 to 84% of the total weight.
[0068] Moreover, in the second coating process (S 4 - 3 ), the water-soluble PU resin solution is coated in the amount of about 10 to 12 g/m 2 , which corresponds to about 16 to 20% of the total weight. If the amount of water-soluble PU resin solution applied is more than the above range, the air permeability is reduced, whereas, if it is less than the above range, the surface texture is reduced. Therefore, the water-soluble PU resin solution is preferably applied in an amount of about 16 to 20% of the total weight.
[0069] Moreover, if the film is dried at a temperature below about 130° C. in the planarization process (S 4 - 2 ) after the first coating process (S 4 - 1 ), the coated resin is not sufficiently dried, which makes it difficult to emboss a leather pattern on the surface of the film, and the resin may end up being adhered to an embossing roll. Furthermore, if the film is dried at a temperature higher than about 160° C., the surface is hardened and roughened, thus creating an undesirable surface texture.
[0070] As such, if the amount of water-soluble PU resin solution applied in the first coating process (S 4 - 1 ) is greater than that in the second coating process (S 4 - 3 ), the resin solution quickly passes through the naps to improve the adhesion between the naps and the film. Then, the remaining amount of water-soluble PU resin solution is applied in the second coating process (S 4 - 3 ), which makes it possible to form a uniform film. Moreover, since the second coating process (S 4 - 3 ) is performed on the surface of the film planarized by the planarization process (S 4 - 2 ) after the first coating process (S 4 - 1 ), a more uniform film can be formed, and thus it is possible to impart a soft texture to the surface of the synthetic leather.
[0071] The present invention may further include a pattern forming process (S 5 ), a painting process (S 6 ), and a surface reinforcing process (S 7 ). The pattern forming process (S 5 ) is performed after the film forming process (S 4 ) by performing an embossing process on the film on the surface of the fabric W, thus forming a pattern. For example, a leather pattern is formed on a mold, and the mold is pressed on the fabric W at a temperature of 130 to 150° C. and a pressure of 100 to 200 bar, thus forming a leather pattern on the fabric W. Here, the surface quality is determined by the mold forming process, the temperature of the embossing process, and the process speed.
[0072] The painting process (S 6 ) is performed after the pattern forming process (S 5 ) by thinly spraying a water-soluble resin solution, which contains a carbodiimide curing agent and a diluted water-soluble polycarbonate resin for improving water resistance and chemical resistance, on the surface of the film to impart a color thereto.
[0073] The surface reinforcing process (S 7 ) is performed after the painting process (S 6 ) by thinly spraying a top protective resin, which contains an ester-based water-soluble PU resin, a diisocyanate curing agent, a silane, and a water-soluble polycarbonate resin, for ensuring the durability (such as heat resistance, cold resistance, chemical resistance, hydrolysis resistance, abrasion resistance, etc.) on the surface of the film to form a protective film for improving the durability of the pattern formed on the surface and ensuring good quality.
[0074] The following agents are effective to improve the durability (such as hydrolysis resistance, chemical resistance, abrasion resistance, etc.) of the surface of the film.
[0000]
TABLE 2
Classification
Agents used
Base coating process
Hydrolysis-resistant, flame-retardant and
water-soluble PU resin
Color spray process
Non-hydrophilic water-soluble PU resin
Pigment
Water-soluble polycarbonate resin
Carbodiimide curing agent
Top spray process
Durability improving resin
Diisocyanate curing agent
Water-soluble polycarbonate resin
Silane
Durability test results
Good hydrolysis resistance
(MS321-08)
Good chemical resistance
Alcohol-resistant, friction coloring
[0075] As shown in the above table, a water-resistant, water-soluble and flame-retardant PU resin was used to improve the water resistance, heat resistance, and chemical resistance during the base coating process, a polycarbonate resin, a carbodiimide curing agent, etc. were used during the color spray process, and a silane was additionally used to improve the adhesion between the resins during the top spray process. Therefore, when the pattern forming process (S 5 ), the painting process (S 6 ), and the surface reinforcing process (S 7 ) are further performed, the surface texture and quality of the synthetic leather can be further improved.
[0076] As described above, according to the present invention, after the nap-raising process performed on the surface of the fabric, a film is formed by applying a water-soluble PU resin solution to the nap of the surface of the fabric. At this time, the amount of resin solution applied is set within an appropriate range such that the spaces between the naps are not covered by the film, thereby allowing the fabric to have air permeability through the partially filled in spaces. Moreover, since the resin solution is directly applied to the surface of the fabric such that the resin solution penetrates the spaces between the naps, the adhesion between the fabric and the film is improved to prevent the fabric and the film from being separated or exfoliated. Furthermore, since the durability of the film is improved, the occurrence of cracks can be minimized, and the texture of the film can be maintained good. As a result, it is possible to produce synthetic leather having properties similar to those of genuine leather, and thus the quality of produced synthetic leather can be improved.
[0077] Moreover, according to the present invention, in the film forming process, the water-soluble PU resin solution is applied twice in the first and second coating processes. That is, the first coating process is performed such that the resin solution penetrates the spaces between the naps to improve the adhesion. Then, the planarization process for planarizing the surface of the film by uniformly heating and pressurizing the surface of the film is performed such that the resin solution effectively penetrates the spaces between the naps, and then the second coating process is performed. Therefore, the film formed on the naps has a uniform texture, thus further improving the surface quality of the synthetic resin.
[0078] Furthermore, according to the present invention, since a softener may be used to impart flexibility to the surface of the fabric before raising the nap on the surface of the fabric, the nap-raising, by the use of the brushing machine, is facilitated. After the film forming process, the process for forming a pattern on the film, the process for imparting a color by spraying a resin solution in which a pigment is diluted on the surface of the film, and the process of reinforcing the surface of the film by spraying a top protective resin on the painted surface of the film are sequentially performed to further improve the quality of the synthetic leather.
[0079] The invention has been described in detail with reference to exemplary embodiments thereof. However, it will be appreciated by those skilled in the art that changes may be made in these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents. | Disclosed is a synthetic leather produced by directly coating a water-soluble synthetic resin solution on the surface of a fabric to form a film thereon such that fine gaps formed on the fabric are partially left open to have a certain degree of air permeability. In particular, a brushing process is used for brushing the surface of a fabric using a brushing machine to raise a nap. Next, a hydrolysis-resistant and flame-retardant resin solution is coated on the back of the fabric, which is opposite to the surface on which the nap is raised, to reinforce the back of the fabric. A film forming process then applies a water-soluble polyurethane resin solution to the nap raised on the surface of the fabric to form a film on the surface of the fabric thereby producing a synthetic leather product that has air permeability properties that are superior to genuine leather. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is directed toward a cementing tool, a casing string equipped with a cementing tool, and methods of cementing such a casing string. Particularly, the cementing tool is provided with a rupture disc assembly that upon rupture permits cement to flow from the interior of the casing string through the tool sidewall and into the annulus defined by the casing string and downhole formation into which the casing string is run. The cementing tool permits obstructions or voids within the annulus to be bypassed during cementing operations, and allows for multiple-stage cementing operations to be conducted. Further, the cementing tool, if activated during cementing operations, restores the structural integrity of the casing string that might otherwise be lost through the use of other tools or processes.
2. Description of the Prior Art
Surface casing is typically the first casing string run and fully cemented in a well. Surface casing protects fresh water-bearing sands or formations from vertical migration of well fluids that might otherwise contaminate the fresh water carried by these formations. Often too, the well blow out preventer, which is the last line of defense against an uncontrolled well, is secured to the surface casing. Further, surface casing is used to hang off the next string of casing that is run into the well. Given the many functions of surface casing, it is important for the surface casing to be well supported in order to prevent buckling and damage when loaded in this manner.
The purpose of cementing the surface casing is to have a competent sheath of cement to both support and seal around the casing. During cementing operations, cement is introduced into the annulus created between the casing and the formation through which the casing is run. Cement can be introduced into the annulus in a number of ways. One method is “top job” approach wherein cement is directly injected into the annulus from the surface using one or more small diameter pipes pushed down into the annulus. This method may be useful in cementing shallow casing strings, but is not always reliable in that un-cemented pockets can be left in the annulus. Another method involves the circulation of cement down through the center of the casing string and back toward the surface through the annulus. When successfully completed, this method provides a higher degree of confidence that un-cemented pockets have been avoided or minimized. However, the annulus can become obstructed, such as with a collapsed portion of a loose formation which blocks the flow of cement through the annulus. In other instances, cement may be lost from the annulus into the well formation due to the high porosity of the rock or sand that the well bore is drilled through. This loss prevents the cement from reaching the surface and is known as lost circulation or lost returns. In these instances, the casing would need to be perforated above the obstruction or region of lost circulation so that a new flow path for cement into the annulus can be established. This is undesirable as it requires compromising the casing integrity.
Another solution has been proposed involving the use of differential valve (DV) tools. These tools have largely been used as a part of a multistage cementing operation. These tools are typically run where the cementing is planned to be placed in multiple lifts in a single string of pipe. The bottom section of casing is cemented normally. Then the tool is opened and drilling mud is circulated. After the bottom stage of cement has been set sufficiently, the top stage is cemented through the DV tool. These tools are disadvantageous in that the cementing must be performed in stages, rather than in a single pour, thus adding additional operating time to the cementing process. Further, these tools tend to be expensive and most require some kind of actuation operation, and then be drilled out once the cementing stage is completed.
SUMMARY OF THE INVENTION
The present invention overcomes a number of the difficulties associated with prior apparatus and methods for cementing a casing string by utilizing a cementing tool that couples adjacent casing sections and comprises an integral rupture disc assembly that can be selectively actuated so as to bypass obstructions in the annulus between the downhole formation and casing string or permit flow of cement into the annulus at a desired elevation.
According to one embodiment of the present invention, there is provided a cementing tool configured for attachment to a casing string. The cementing tool comprises a tubular body including a cylindrical sidewall having an interior surface and an exterior surface. The sidewall interior surface defines a central passage therethrough. At least one channel-forming member is provided that defines a channel located outboard from the central passage. The channel includes at least one open end. At least one port is formed in the sidewall that defines a path for fluid flow between the central passage and the channel. The cementing tool further comprises at least one rupture disc assembly comprising a rupture disc that, in its unruptured state, is disposed in fluid blocking relationship between the central passage and the at least one open end.
According to another embodiment of the present invention, there is provided a casing string that comprises at least one section of casing having a central bore and a cementing tool as described herein attached to one end of the section of casing.
According to yet another embodiment of the present invention, there is provided a method of cementing a casing string in a well. The method comprises positioning a casing string comprising a central bore and at least one cementing tool as described herein in a downhole formation. Next, cement is injected downhole through the casing string central bore and cement is caused to flow into an annulus located between the casing string and the formation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic representation of a casing string comprising a plurality of cementing tools disposed in a well bore;
FIG. 2 is a perspective view of a cementing tool according to one embodiment of the present invention;
FIG. 3 is a top view of the cementing tool of FIG. 2 ;
FIG. 4 a is a cross-sectional view of the cementing tool of FIG. 2 ;
FIG. 4 b is a cross-sectional view of an alternate embodiment of a cementing tool being equipped with male and female threaded connector structure;
FIG. 5 is a fragmented, cross-sectional view of the port and rupture disc assembly of cementing tool of FIG. 2 ;
FIG. 6 a is a cross-sectional view of a section of the well bore wherein the annulus between the downhole formation and casing has been obstructed;
FIG. 6 b is a cross-sectional view of a section of the well bore wherein a void region of lost circulation has been encountered;
FIG. 7 a is a cross-sectional view of a section of the well bore containing an obstruction wherein the rupture discs carried by the cementing tool have been ruptured and the flow of cement in the annulus is resumed above the obstruction;
FIG. 7 b is a cross-sectional view of a section of the well bore containing a void region wherein the rupture discs carried by the cementing tool have been ruptured and the flow of cement in the annulus is resumed above the void region;
FIG. 8 is a perspective view of a cementing tool according to another embodiment of the present invention;
FIG. 9 is a cross-sectional view of the cementing tool of FIG. 8 ;
FIG. 10 is a fragmented, cross-sectional view of the port and rupture disc assembly of cementing tool of FIG. 8 ;
FIG. 11 is a perspective view of a cementing tool according to yet another embodiment of the present invention;
FIG. 12 is a cross-sectional view of the cementing tool of the cementing tool of FIG. 11 ; and
FIG. 13 is a top view of the cementing tool of FIG. 11 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention provides apparatus and methods that are particularly suited for the running in and cementing of a casing string into a well bore. As illustrated in FIG. 1 , a casing string 10 has been run into a well bore 12 and cemented into place by filling the annulus 14 defined by casing string 10 and the downhole formation 16 with cement. In particular, casing string 10 comprises a plurality of casing sections 18 interconnected with a plurality of cementing tools 20 , which are described in greater detail below. As shown in the illustrated embodiment, cementing tools 20 are positioned within casing string 10 across a variety of elevations within downhole formation 16 . As explained below, the precise location of cementing tools 20 can be determined as a matter of general procedure or customized depending upon the downhole formations encountered when creating the well bore.
Turning next to FIGS. 2-4 , one embodiment of a cementing tool 20 in accordance with the present invention is illustrated. Generally, cementing tool 20 comprises a tubular body 22 having a cylindrical sidewall 24 . In certain embodiments, tool 20 comprises a collar or coupler that is easily inserted between adjacent casing sections. In other embodiments, tool 20 can be formed from other materials such as mechanical tubing, which may exhibit lengths much greater than that of a collar and have both male and female threaded ends. In the Figures, tool 20 is generally depicted as a collar for ease of illustration; however, this should not be taken as limiting the scope of the present invention. Sidewall 24 comprises an interior surface 26 , which defines a passageway 28 , and an exterior surface 30 , which cooperates with downhole formation 16 to define annulus 14 . When installed within casing string 10 , passageway 28 is in registry with the central bore 32 of the casing string. Thus, central bore 32 is substantially concentric with tubular body 22 . In certain embodiments, such as shown in FIG. 6 , passageway 28 and central bore 32 have essentially the same internal diameter.
Sidewall 24 also comprises at least one port 34 , and in the embodiments illustrated two ports, formed therein that extend between interior surface 26 and exterior surface 30 . Thus, port 34 defines a fluid flow path between the interior and exterior of tool 20 that is substantially perpendicular to the flow path through tool 20 defined by passageway 28 .
In each port 34 , a respective rupture disc assembly 36 is received and secured to sidewall 24 . In the embodiment illustrated in FIG. 5 , assembly 36 comprises a fitting 38 that is press fitted into port 34 and includes a first cylindrical portion 40 and a second cylindrical portion 42 . First cylindrical portion 40 generally has a larger diameter than second cylindrical portion 42 . Portions 40 is sized and configured to be received into an inboard portion 44 of port 34 , and portion 42 is sized and configured to be received in an outboard portion 46 of port 34 . First cylindrical portion 40 is connected to second cylindrical portion 42 by a tapered transition region 48 that is configured to abut a similarly configured tapered segment 50 of port 34 when assembly 36 is installed within port 34 . As noted above, fitting 38 is press fitted into port 34 . Thus, fitting 38 is affixed to and maintained within port 34 by frictional forces.
FIGS. 9 and 10 illustrate another embodiment of a rupture disc assembly 52 that comprises a two-part fitting 54 configured to be received in a port 56 formed in sidewall 24 . Fitting 54 comprises an internally threaded ferrule 58 that is secured to port 56 and an externally threaded nut 60 configured to be received within ferrule 58 . In certain embodiments, ferrule 58 is secured to port 56 by welding, although, it is within the scope of the present invention for ferrule 58 to be secured to port 56 in other ways, such as a threaded connection. In this embodiment, port 56 is of substantially uniform diameter across its entire length, as opposed to port 34 which contains differently sized inboard and outboard portions 44 , 46 , respectively. It is also noted that rupture disc assembly 52 , when installed in port 56 , lies substantially flush with interior surface 26 , whereas in the embodiment illustrated in FIG. 4 , rupture disc assembly 36 extends inwardly beyond interior surface 26 , although this does not necessarily need to be the case.
Both rupture disc assembly embodiments 36 , 52 comprise a rupture disc 62 . In the embodiment illustrated in FIG. 5 , rupture disc 62 is affixed to fitting 38 , and in the embodiment illustrated in FIG. 10 , rupture disc 62 is affixed to nut 60 . Rupture disc 62 may be affixed to its respective supporting structure by welding or any other means known to those of skill in the art. Alternatively, rupture disc 62 could be commonly machined from, and thus unitarily formed with, fitting 38 or nut 60 . In both illustrated embodiments, rupture disc 62 functions, in its unruptured state, to block the flow of fluid through ports 34 , 56 , respectively. Rupture disc 62 may also comprise structures that help define its opening characteristics, such as a line of weakness (not shown).
Cementing tool 20 also comprises at least one channel-forming member 64 secured to the sidewall exterior surface 30 . Member 64 cooperates with sidewall exterior surface 30 to define a channel 66 that, upon rupture of rupture disc 62 , is in fluid communication with the interior of tubular body 22 . As shown, channel 66 is longitudinal with respect to tool 20 , however, it is within the scope of the present invention for channel 66 to be oriented about different axes. As shown in FIGS. 2-5 , channel-forming member 64 comprises an elongated segment 68 having spaced apart, longitudinal end margins 70 , 72 , each of which are secured to sidewall exterior surface 30 . Elongated segment 68 comprises a generally V-shaped cross-sectional profile. In certain embodiments according to the present invention, channel-forming member 64 comprises a sealed end 74 and an open end 76 . As shown, channel 66 is substantially unobstructed thereby permitting, upon rupture of rupture disc 62 , free flow of a fluid or material from passageway 28 through port 34 , up channel 66 and out of open end 76 . However, it is within the scope of the present invention for channel-forming member 64 to include a check valve or other similar device, such as a screen or filter, which inhibits entry of debris or fluid into channel 66 from open end 76 . Furthermore, as illustrated in the Figures, channel-forming member 64 is disposed so that sealed end 74 is located closer to port 34 than open end 76 , but again, it is within the scope of the present invention for other configurations to be employed.
FIGS. 8-10 illustrate an alternate channel-forming member 78 in accordance with the present invention. Like channel-forming member 64 , channel-forming member 78 comprises an elongated segment 80 having spaced apart, longitudinal end margins 82 , 84 , each of which are secured to sidewall exterior surface 30 . Channel-forming member 78 also comprises a sealed end 86 and an open end 88 . However, channel-forming member 78 differs from channel-forming member 64 in that it comprises an arcuate cross-sectional profile. In most other respects, channel-forming member 78 and channel-forming member 64 are configured and function similarly.
As noted above, cementing tool 20 is configured to be attached to at least one casing section 18 . Tool 20 includes connecting structure 90 to facilitate this attachment. In the embodiment illustrated in FIG. 4 a , female connecting structure 90 is located at either end of tool 20 and comprises threaded connector sections 92 and 94 configured to mate with corresponding casing section connectors 96 and 98 , respectively. In the embodiment illustrated in FIG. 4 b , tool 20 ′ comprises female/male connecting structures 90 , 90 ′, with connector section 94 ′ being in the form of male pipe threads. Further, in particular embodiments according to the present invention, channel-forming member 64 , 78 lies entirely outboard of an outer longitudinal margin presented the casing section 18 . In other words, channel-forming member 64 , 78 lies within the annulus 14 defined by casing string 10 and downhole formation 16 .
The use of cementing tool 20 in the cementing of casing string 10 is illustrated in FIGS. 6 a , 6 b , 7 a and 7 b . In certain embodiments, casing string 10 comprises surface casing, which as noted above, performs a number of important functions. However, it is within the scope of the present invention for casing string 10 to comprise nearly any kind of pipe at any depth run into a well that will function as well casing, including drive pipe, conductor pipe, intermediate casing, drilling liner, production liner, and production casing. Surface casing, generally, can have a diameter of between 8⅝ inches up to 16 inches.
After casing string 10 has been run into downhole formation 16 , cement is placed in annulus 14 . In certain embodiments this is accomplished by injecting cement through casing central bore 32 toward its lowermost downhole margin 102 at which point the cement is directed into annulus 14 and flows upwardly toward the surface. In an ideal situation, cement continues to flow until the entirety of annulus 14 is filled with cement. However, it can arise that certain portions of downhole formation 16 do not possess sufficient integrity and can collapse around casing string 10 after it is run in, or alternatively a region of lost circulation may be encountered that can present a limitless void. When this occurs, an obstruction 104 , or void 105 , to the flow of cement 100 in annulus 14 is created. It is understood that the effect of either an obstruction 104 or void 105 is substantially the same in that the flow of cement upwardly through annulus 14 is impeded. Therefore, even though the following discussion is made in terms of encountering an obstruction 104 , a void 105 due to a region of lost circulation may be substituted therefor.
Should such an obstruction 104 (or void 105 ) be detected, the present invention advantageously permits the obstruction (or void) to be bypassed and the introduction of cement 100 into annulus 14 to continue without significant interruptions to the cementing operation, such as the need to pull or run tools downhole. If an obstruction 104 is encountered, the fluid pressure of the cement being pumped downhole may increase. In particular embodiments, the increase in cement pressure is detected by an operator, however, this does not always need to be so. At this point, a rupture disc 62 carried by rupture disc assembly 36 , 52 may be ruptured by increasing the pressure of the cement within casing string central bore 32 proximate rupture disc 62 so that the disc opens and cement may flow through port 34 , 56 and into the annulus thereby bypassing obstruction 104 . If cement returns to the surface are not achieved as expected, the operator may determine that a region of lost circulation has been encountered and the cement is being directed into a porous formation. The operator can then increase the pressure of the cement being flowed down through casing string central bore 32 to open rupture disc 62 . In certain embodiments, rupture disc 62 is configured to rupture at a pressure of up to 90% of the rated casing strength. This ensures that disc 62 does not rupture due to normal operating conditions experienced in the well, but rather only in response to encountering an annular obstruction or void during cementing operations. Further, if no obstruction is encountered during cementing operations, rupture disc 62 provides sufficient strength so as not to compromise the overall integrity of casing string 10 . As shown in FIG. 7 , once ruptured, cement 100 flows from passageway 28 through port 34 , into channel 66 and into annulus 14 at a location above the obstruction 104 . Thus, avoiding the creation of an annular “void” zone where casings string 10 is unsupported.
Generally, cementing tool 20 should be located within casing string 10 at a higher elevation than obstruction 104 . Knowledge of the formations through which the well is being drilled can assist the operator in positioning a cementing tool 20 within casing string 10 in a location that is likely to be at a higher elevation than where an obstruction 104 or void is likely to form. In certain operations, though, it may be difficult to forecast this information. In those situations, a plurality of cementing tools 20 can be periodically installed between casing sections 18 along the length of casing string 10 . The frequency of placement of cementing tools 20 can vary depending upon the conditions expected to be encountered in the well, however, in certain embodiments cementing tools can be located within casing string 10 at a spacing of approximately at least every 100 feet, at least every 250 feet, at least every 500 feet, or at least every 1000 ft. Use of a plurality of cementing tools 20 increases the likelihood that at least one cementing tool 20 will be located at a higher elevation than the obstruction, so that the obstruction can be bypassed.
In embodiments which comprise a plurality of cementing tools 20 located within casing string 10 , it may be possible for an operator to detect the presence of an obstruction 104 and determine its approximate elevation within annulus 14 . Thus, by controlling the pressure within the casing central bore 32 , the operator may be able to selectively actuate the rupture disc(s) 62 carried by a particular cementing tool 20 , while leaving the other rupture disc(s) of other cementing tools intact. In other embodiments, the pressure of the cement within casing central bore 32 can be adjusted to cause the rupture of all rupture discs 62 within casing string 10 , or only those located at elevations above the obstruction 104 . In certain embodiments, in order to facilitate this selective rupturing of rupture discs 62 , rupture discs of differing burst characteristics may be employed throughout casing string 10 .
In other embodiments of the present invention, the bursting pressure of rupture discs 62 may be selected to automatically rupture upon encountering elevated pressures within central bore 32 that attributable to the encountering of an obstruction 104 to prevent damage to the casing. In these embodiments, actual detection and identification of the location of an obstruction is obviated and cementing operations may continue without any meaningful interruption in the flow of cement into annulus 14 .
In still other embodiments, a plurality of cementing tools 20 may be employed so as to carry out multistage cementing operations. In certain instances it may be desirable to selectively cement only certain elevations of the casing string 10 . For example, wells with low formation pressures may not be able to sustain the hydrostatic forces of a full column of cement. In other applications, it may be desirable to isolate certain sections of the wellbore or use different blends of cement in the wellbore. Still, in cementing deep, hot holes, cement pump times can be limited so as to prevent full-bore cementing of the casing string during a single stage. In these examples and other situations, it may be desirable to cement casing string 10 in two or more stages.
Typically the stage cementing operation begins as described above in that cement 100 is run cement through casing central bore 32 toward its lowermost downhole margin 102 at which point the cement is directed into annulus 14 and flows upwardly toward the surface. Even though an obstruction or void may not be encountered, once the cement has reached a desired height in annulus 14 , the flow of cement is stopped. At this point, it may no longer be possible to resume the flow of cement in annulus 14 by flowing cement down to the lowermost margin 102 and back toward the surface. Instead, the operator can actuate rupture discs 62 at a desired elevation so that the flow of cement into annulus 14 can resume, thus beginning a second stage of cementing. This process can be repeated as necessary or desired.
Once cementing operations have been completed, drilling within the well can be continued by merely drilling out the cement within casing string central bore 32 . There are no tools that need to be drilled out along with the cement. Alternatively, once cementing or a cementing stage is completed, any cement remaining within central bore 32 can be pumped or circulated out prior to fully curing so that the step of drilling through cement can be avoided.
FIGS. 11-13 illustrate another cementing tool embodiment according to the present invention. A cementing tool 106 is illustrated having a pair of channel-forming members 108 that are integrated with tool sidewall 110 . Cementing tool 106 shares certain structural and functional characteristics with the embodiments of cementing tool 20 discussed above. However, the most notable differences concern the configuration of channel forming members 108 and the placement of the rupture disc assembly 118 . Channel-forming members 108 comprise thickened regions of sidewall 110 that have channels 112 formed therein. In certain embodiments, channels 112 comprise generally circular, longitudinal bores, primarily for ease of machining, but other configurations and orientations for channels 112 also may be used. A port 114 is formed in sidewall 110 which enables fluid communication between tool central passage 116 and channel 112 . Thus, a flow path between the interior of tool 106 and the downhole annulus is established.
A rupture disc assembly 118 is positioned within channel 112 in normally fluid blocking relationship between port 114 and a channel outlet 120 . Rupture disc assembly 118 includes a rupture disc 122 and may be configured similarly to rupture disc assemblies 36 , 52 discussed above. In one embodiment, rupture disc assembly 118 is threadably received and secured into a corresponding threaded portion 124 of channel 112 . When in its unruptured state, rupture disc 122 prevents fluid or cement being flowed through tool passage 116 from passing through channel out let 120 and into the downhole annulus. An optional check valve 126 may be installed toward outlet 120 to prevent fluid being circulated within the annulus or other material from entering channel 112 and interfering with the operation of rupture disc assembly 118 .
In one embodiment, port 114 is formed by machining a bore 128 through channel-forming member 108 and sidewall 110 until central passage 106 is reached. Likewise, channel 120 may be formed by machining a bore through channel-forming member 108 that is perpendicular to bore 128 . The orifice 130 in channel forming member 108 can later be plugged.
The installation and operation of cement tool 106 is similar to that described above with respect to cement tool 20 .
The following description sets for exemplary embodiments according to the present invention. It is to be understood, however, that these examples are provided by way of illustration and nothing therein should be taken as a limitation upon the overall scope of the invention. | A cementing tool ( 20 ) capable of being installed in a casing string ( 10 ) and configured to selectively permit the flow of cement through one or more ports ( 34 ) in the tool is provided. The ports ( 34 ) are normally sealed by rupture disc assemblies ( 36 ) comprising a rupture disc ( 62 ) that can be opened to permit flow of cement through the casing string central bore ( 32 ) and into the annulus ( 14 ) defined by the casing string ( 10 ) and the downhole formation ( 16 ). The cementing tool ( 20 ) is particularly useful during cementing operations in which the annulus ( 14 ) has become blocked by a collapsed portion of the formation by allowing the obstruction ( 104 ) to be bypassed and the flow of cement ( 100 ) into the annulus to be continued without substantial interruption. Tool ( 20 ) may also be used in multistage cementing operations. | 4 |
CROSS REFERENCE TO RELATED APPLICATION
Chesebro and Petersen U.S. patent application Ser. No. 626,412, filed Oct. 28, 1975 is a related application in that it also discloses a support member arrangement in which two strips are in interengaging relation.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention pertains to the art of electric heating units and in particular to support means for carrying insulating bushings which support open-coil electrical resistance heating elements.
2. Description of the Prior Art
Prior art patents which teach support members for carrying insulating bushings and supporting open-coil elements for electric heating units of the same type with which this invention is concerned are the following: U.S. Pat. Nos. 3,812,322; 1,751,797 and 1,628,876. In the arrangement of the first two listed patents, after the strips with cutouts are placed in their final assembled position, an additional step is required to secure the two strips in their assembled relation. In the first noted patent the two pieces are not common in their construction. In the second listed patent the fastening arrangement is of the type which does not permit ready disassembly of the two strips for the replacement of an insulating bushing.
The present invention has among its aims the provision of an improved construction in which common pieces may be used for the two strips and in which intentional disengagement of the two strips may be accomplished relatively easily.
SUMMARY OF THE INVENTION
In accordance with the invention, the two strips of basically common shape and having spaced-apart cutouts include barbs formed by retroverting the end margins of at least some of the intervening webs between the cutouts and with the end edges of the barbs being in facing relation in the final assembly in which the strips are in lapped, opposed relation, the sides of the circumferential grooves of the insulating bushings holding the strips sufficiently close together that the barbs are prevented from becoming disengaged from each other.
DRAWING DESCRIPTION
FIG. 1 is a plan view of a part of an electric heating unit according to the invention;
FIG. 2 is an exploded isometric view, greatly enlarged relative to FIG. 1, of a pair of strips and an insulating bushing prior to assembly; and
FIG. 3 is a sectional view, greatly enlarged, corresponding to one taken along the line III--III of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, the electric heating unit has the general form of an open-face perimetric frame formed of a base wall 12, side walls 14 and end wall 16. A plurality of support members generally designated 18 extend between the opposite side walls and carry ceramic insulating bushings 20 through which the open-coil electrical resistance heating element 22 is threaded.
The support members 18 for the bushings are of two-piece construction and may be best understood by reference to FIG. 2. The two metal strips 24 and 26 are of identical construction in the preferred form and include a series of spaced-apart, open-sided cutouts 28 and 30 for the respective strips, the cutouts being separated by the intervening webs 32 and 34 which have their end margins 36 and 38 bent back against the web to the retroverted positions shown in FIG. 2. The webs are made long enough so that after the retroversion, the end edges 40 and 42 will lie in a plane which, when the strips are assembled in lapping relation, will intersect the center of the openings formed by the cutouts of the two strips. That is, in the assembly the two strips are placed in opposed, lapping, registering relation so that a round opening is formed by the two opposing cutouts. In that assembled relation, the end edges of the end margins will be opposing or facing each other along a line passing through the centers of all the openings.
Each of the strips 24 and 26 may be provided with end flanges 44 and 46, respectively, if the parts are to be totally common, with the end flanges on one of the strips being used for fastening to the side walls of the heating unit by spot welding or the like. One suitable material for making the strips is 20 gauge sheet metal.
The ceramic insulating bushings 20 are each provided with a circumferential groove 48 which seats in the cutouts of one of the strips when the assembly is to be made. Then the other stip is moved into the noted lapping relation with the end margins passing each other until the end edges of the end margins have cleared each other.
Referring to FIG. 3, the relationship of the strips 24 and 26 and their elements to each other and the insulating bushing is made apparent by the enlarged view. The groove 48 has a width approximating the sum of four single thicknesses of the strip material so that strips can be assembled in the lapping relation with the end margins 36 and 38 passing each other during the assembly process. To the end that after the strips have been assembled with the bushing the strips do not disengage from each other, the retroversion of the end margins to form barb-like elements is slightly less than a complete 180° retroversion. In other words, a small acute angle is left between the end margins and web as at 50 so that after the end margins have passed each other in the assembly and the end edges clear, the end margins will flex back slightly to the positions shown in FIG. 3. Thus even though the strips can shift laterally with respect to each other and the bushing, the abutment of the end edges to each other is not totally lost, and accidental disengagement of the two strips from each other is prevented. However, if it should be desired to disengage the strips from each other, for the purpose of replacing a broken insulating bushing for example, the barb members may be flexed back toward the web so that the end edges will clear to permit the disengagement of the strips from each other.
The arrangement permits the assembly of the parts to make up the electric heating unit as follows. The strips 24 which have upwardly open cutouts are fastened at their ends to the side walls 14. The coil 22 having the required number of bushings 20 strung thereon is then placed in position with one bushing 20 seated in each cutout. The strips 26 are then pushed down in place in the grooves of the insulators until the barb ends clear each other and assume the FIG. 3 position. Thus the assembly is accomplished without the use of any tools or any requirement of fastening the one set of strips 26. | A pair of strips having spaced cutouts therein are placed in lapping relation so the cutouts form openings to receive insulating bushings having circumferential grooves therearound at least some of the end margins of the intervening webs between the cutouts being retroverted to take the form of barbs which in the assembled relation face corresponding barbs of the other strip. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority benefit under 35 U.S.C. §119(e) of U.S. Provisional Patent Application Ser. No. 60/973,739 filed 19 Sep. 2007. The disclosure of this application is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This invention relates generally to deuterium-enriched ciclesonide, pharmaceutical compositions containing the same, and methods of using the same.
BACKGROUND OF THE INVENTION
[0003] Ciclesonide, shown below, is a well known glucocorticoid.
[0000]
[0000] Since ciclesonide is a known and useful pharmaceutical, it is desirable to discover novel derivatives thereof. Ciclesonide is described in U.S. Pat. No. 5,482,934; the contents of which are incorporated herein by reference.
SUMMARY OF THE INVENTION
[0004] Accordingly, one object of the present invention is to provide deuterium-enriched ciclesonide or a pharmaceutically acceptable salt thereof.
[0005] It is another object of the present invention to provide pharmaceutical compositions comprising a pharmaceutically acceptable carrier and a therapeutically effective amount of at least one of the deuterium-enriched compounds of the present invention or a pharmaceutically acceptable salt thereof.
[0006] It is another object of the present invention to provide a method for treating persistent asthma, comprising administering to a host in need of such treatment a therapeutically effective amount of at least one of the deuterium-enriched compounds of the present invention or a pharmaceutically acceptable salt thereof.
[0007] It is another object of the present invention to provide a novel deuterium-enriched ciclesonide or a pharmaceutically acceptable salt thereof for use in therapy.
[0008] It is another object of the present invention to provide the use of a novel deuterium-enriched ciclesonide or a pharmaceutically acceptable salt thereof for the manufacture of a medicament (e.g., for the treatment of persistent asthma).
[0009] These and other objects, which will become apparent during the following detailed description, have been achieved by the inventor's discovery of the presently claimed deuterium-enriched ciclesonide.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0010] Deuterium (D or 2 H) is a stable, non-radioactive isotope of hydrogen and has an atomic weight of 2.0144. Hydrogen naturally occurs as a mixture of the isotopes 1 H (hydrogen or protium), D ( 2 H or deuterium), and T ( 3 H or tritium). The natural abundance of deuterium is 0.015%. One of ordinary skill in the art recognizes that in all chemical compounds with a H atom, the H atom actually represents a mixture of H and D, with about 0.015% being D. Thus, compounds with a level of deuterium that has been enriched to be greater than its natural abundance of 0.015%, should be considered unnatural and, as a result, novel over their non-enriched counterparts.
[0011] All percentages given for the amount of deuterium present are mole percentages.
[0012] It can be quite difficult in the laboratory to achieve 100% deuteration at any one site of a lab scale amount of compound (e.g., milligram or greater). When 100% deuteration is recited or a deuterium atom is specifically shown in a structure, it is assumed that a small percentage of hydrogen may still be present. Deuterium-enriched can be achieved by either exchanging protons with deuterium or by synthesizing the molecule with enriched starting materials.
[0013] The present invention provides deuterium-enriched ciclesonide or a pharmaceutically acceptable salt thereof. There are forty-four hydrogen atoms in the ciclesonide portion of ciclesonide as show by variables R 1 -R 44 in formula I below.
[0000]
[0014] The hydrogens present on ciclesonide have different capacities for exchange with deuterium. Hydrogen atom R 1 is easily exchangeable under physiological conditions and, if replaced by a deuterium atom, it is expected that it will readily exchange for a proton after administration to a patient. Hydrogen atoms R 15 -R 17 and R 43 -R 44 are weakly acidic and may be replaced by deuterium atoms by the action of a base system such as t-BuOK/t-BuOD. Deuterium atoms R 24 -R 35 and R 18 -R 23 are not easily incorporated by exchange reactions, but may be incorporated during the synthesis of ciclesonide from a steroid starting material. The remaining hydrogen atoms are not easily exchangeable for deuterium atoms. However, deuterium atoms at the remaining positions may be incorporated by the use of deuterated starting materials or intermediates during the construction of ciclesonide.
[0015] The present invention is based on increasing the amount of deuterium present in ciclesonide above its natural abundance. This increasing is called enrichment or deuterium-enrichment. If not specifically noted, the percentage of enrichment refers to the percentage of deuterium present in the compound, mixture of compounds, or composition. Examples of the amount of enrichment include from about 0.5, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 12, 16, 21, 25, 29, 33, 37, 42, 46, 50, 54, 58, 63, 67, 71, 75, 79, 84, 88, 92, 96, to about 100 mol %. Since there are 44 hydrogens in ciclesonide, replacement of a single hydrogen atom with deuterium would result in a molecule with about 2% deuterium enrichment. In order to achieve enrichment less than about 2%, but above the natural abundance, only partial deuteration of one site is required. Thus, less than about 2% enrichment would still refer to deuterium-enriched ciclesonide.
[0016] With the natural abundance of deuterium being 0.015%, one would expect that for approximately every 6,667 molecules of ciclesonide (1/0.00015=6,667), there is one naturally occurring molecule with one deuterium present. Since ciclesonide has 44 positions, one would roughly expect that for approximately every 293,348 molecules of ciclesonide (44×6,667), all 44 different, naturally occurring, mono-deuterated ciclesonides would be present. This approximation is a rough estimate as it doesn't take into account the different exchange rates of the hydrogen atoms on ciclesonide. For naturally occurring molecules with more than one deuterium, the numbers become vastly larger. In view of this natural abundance, the present invention, in an embodiment, relates to an amount of an deuterium enriched compound, whereby the enrichment recited will be more than naturally occurring deuterated molecules.
[0017] In view of the natural abundance of deuterium-enriched ciclesonide, the present invention also relates to isolated or purified deuterium-enriched ciclesonide. The isolated or purified deuterium-enriched ciclesonide is a group of molecules whose deuterium levels are above the naturally occurring levels (e.g., 2%). The isolated or purified deuterium-enriched ciclesonide can be obtained by techniques known to those of skill in the art (e.g., see the syntheses described below).
[0018] The present invention also relates to compositions comprising deuterium-enriched ciclesonide. The compositions require the presence of deuterium-enriched ciclesonide which is greater than its natural abundance. For example, the compositions of the present invention can comprise (a) a μg of a deuterium-enriched ciclesonide; (b) a mg of a deuterium-enriched ciclesonide; and, (c) a gram of a deuterium-enriched ciclesonide.
[0019] In an embodiment, the present invention provides an amount of a novel deuterium-enriched ciclesonide.
[0020] Examples of amounts include, but are not limited to (a) at least 0.01, 0.02, 0.03, 0.04, 0.05, 0.1, 0.2, 0.3, 0.4, 0.5, to 1 mole, (b) at least 0.1 moles, and (c) at least 1 mole of the compound. The present amounts also cover lab-scale (e.g., gram scale), kilo-lab scale (e.g., kilogram scale), and industrial or commercial scale (e.g., multi-kilogram or above scale) quantities as these will be more useful in the actual manufacture of a pharmaceutical. Industrial/commercial scale refers to the amount of product that would be produced in a batch that was designed for clinical testing, formulation, sale/distribution to the public, etc.
[0021] In another embodiment, the present invention provides a novel, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof.
[0000]
[0022] wherein R 1 -R 44 are independently selected from H and D; and the abundance of deuterium in R 1 -R 44 is at least 2%. The abundance can also be (a) at least 5%, (b) at least 9%, (c) at least 14%, (d) at least 18%, (e) at least 23%, (f) at least 27%, (g) at least 32%, (h) at least 36%, (i) at least 41%, (j) at least 45%, (k) at least 50%, (l) at least 55%, (m) at least 59%, (n) at least 64%, (o) at least 68%, (p) at least 73%, (q) at least 77%, (r) at least 80%, (s) at least 84%, (t) at least 89%, (u) at least 93%, (v) at least 97%, and (w) 100%.
[0023] In another embodiment, the present invention provides a novel, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 1 is 100%.
[0024] In another embodiment, the present invention provides a novel, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 15 -R 17 and R 43 -R 44 is at least 20%. The abundance can also be (a) at least 40%, (b) at least 60%, (c) at least 80%, and (d) 100%.
[0025] In another embodiment, the present invention provides a novel, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 18 -R 35 is at least 6%. The abundance can also be (a) at least 11%, (b) at least 17%, (c) at least 22%, (d) at least 28%, (e) at least 33%, (f) at least 39%, (g) at least 44%, (h) at least 50%, (i) at least 56%, (j) at least 61%, (k) at least 67%, (l) at least 72%, (m) at least 78%, (n) at least 83%, (o) at least 89%, (p) at least 94%, and (q) 100%.
[0026] In another embodiment, the present invention provides a novel, deuterium enriched compound of formula I, wherein the abundance of deuterium in R 17 -R 23 is at least 14%. The abundance can also be (a) at least 29%, (b) at least 43%, (c) at least 57%, (d) at least 71%, (e) at least 86%, and (f) 100%.
[0027] In another embodiment, the present invention provides a novel, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 25 -R 35 is at least 9%. The abundance can also be (a) at least 18%, (b) at least 27%, (c) at least 36%, (d) at least 45%, (e) at least 56%, (f) at least 64%, (g) at least 73%, (h) at least 82%, (i) at least 91%, and (j) 100%.
[0028] In another embodiment, the present invention provides an isolated novel, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof.
[0000]
[0029] wherein R 1 -R 44 are independently selected from H and D; and the abundance of deuterium in R 1 -R 44 is at least 2%. The abundance can also be (a) at least 5%, (b) at least 9%, (c) at least 14%, (d) at least 18%, (e) at least 23%, (f) at least 27%, (g) at least 32%, (h) at least 36%, (i) at least 41%, (j) at least 45%, (k) at least 50%, (l) at least 55%, (m) at least 59%, (n) at least 64%, (o) at least 68%, (p) at least 73%, (q) at least 77%, (r) at least 80%, (s) at least 84%, (t) at least 89%, (u) at least 93%, (v) at least 97%, and (w) 100%.
[0030] In another embodiment, the present invention provides an isolated novel, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 1 is 100%.
[0031] In another embodiment, the present invention provides an isolated novel, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 15 -R 17 and R 43 -R 44 is at least 20%. The abundance can also be (a) at least 40%, (b) at least 60%, (c) at least 80%, and (d) 100%.
[0032] In another embodiment, the present invention provides an isolated novel, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 18 -R 35 is at least 6%. The abundance can also be (a) at least 11%, (b) at least 17%, (c) at least 22%, (d) at least 28%, (e) at least 33%, (f) at least 39%, (g) at least 44%, (h) at least 50%, (i) at least 56%, (j) at least 61%, (k) at least 67%, (l) at least 72%, (m) at least 78%, (n) at least 83%, (o) at least 89%, (p) at least 94%, and (q) 100%.
[0033] In another embodiment, the present invention provides an isolated novel, deuterium enriched compound of formula I, wherein the abundance of deuterium in R 17 -R 23 is at least 14%. The abundance can also be (a) at least 29%, (b) at least 43%, (c) at least 57%, (d) at least 71%, (e) at least 86%, and (f) 100%.
[0034] In another embodiment, the present invention provides an isolated novel, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 25 -R 35 is at least 9%. The abundance can also be (a) at least 18%, (b) at least 27%, (c) at least 36%, (d) at least 45%, (e) at least 56%, (f) at least 64%, (g) at least 73%, (h) at least 82%, (i) at least 91%, and (j) 100%.
[0035] In another embodiment, the present invention provides novel mixture of deuterium enriched compounds of formula I or a pharmaceutically acceptable salt thereof.
[0000]
[0036] wherein R 1 -R 44 are independently selected from H and D; and the abundance of deuterium in R 1 -R 44 is at least 2%. The abundance can also be (a) at least 5%, (b) at least 9%, (c) at least 14%, (d) at least 18%, (e) at least 23%, (f) at least 27%, (g) at least 32%, (h) at least 36%, (i) at least 41%, (j) at least 45%, (k) at least 50%, (l) at least 55%, (m) at least 59%, (n) at least 64%, (o) at least 68%, (p) at least 73%, (q) at least 77%, (r) at least 80%, (s) at least 84%, (t) at least 89%, (u) at least 93%, (v) at least 97%, and (w) 100%.
[0037] In another embodiment, the present invention provides a novel mixture of, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 1 is 100%.
[0038] In another embodiment, the present invention provides a novel mixture of, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 15 -R 17 and R 43 -R 44 is at least 20%. The abundance can also be (a) at least 40%, (b) at least 60%, (c) at least 80%, and (d) 100%.
[0039] In another embodiment, the present invention provides a novel mixture of, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 18 -R 35 is at least 6%. The abundance can also be (a) at least 11%, (b) at least 17%, (c) at least 22%, (d) at least 28%, (e) at least 33%, (f) at least 39%, (g) at least 44%, (h) at least 50%, (i) at least 56%, (j) at least 61%, (k) at least 67%, (l) at least 72%, (m) at least 78%, (n) at least 83%, (o) at least 89%, (p) at least 94%, and (q) 100%.
[0040] In another embodiment, the present invention provides a novel mixture of, deuterium enriched compound of formula I, wherein the abundance of deuterium in R 17 -R 23 is at least 14%. The abundance can also be (a) at least 29%, (b) at least 43%, (c) at least 57%, (d) at least 71%, (e) at least 86%, and (f) 100%.
[0041] In another embodiment, the present invention provides a novel mixture of, deuterium enriched compound of formula I or a pharmaceutically acceptable salt thereof, wherein the abundance of deuterium in R 25 -R 35 is at least 9%. The abundance can also be (a) at least 18%, (b) at least 27%, (c) at least 36%, (d) at least 45%, (e) at least 56%, (f) at least 64%, (g) at least 73%, (h) at least 82%, (i) at least 91%, and (j) 100%.
[0042] In another embodiment, the present invention provides novel pharmaceutical compositions, comprising: a pharmaceutically acceptable carrier and a therapeutically effective amount of a deuterium-enriched compound of the present invention.
[0043] In another embodiment, the present invention provides a novel method for treating persistent asthma comprising: administering to a patient in need thereof a therapeutically effective amount of a deuterium-enriched compound of the present invention.
[0044] In another embodiment, the present invention provides an amount of a deuterium-enriched compound of the present invention as described above for use in therapy.
[0045] In another embodiment, the present invention provides the use of an amount of a deuterium-enriched compound of the present invention for the manufacture of a medicament (e.g., for the treatment of persistent asthma).
[0046] The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof. This invention encompasses all combinations of preferred aspects of the invention noted herein. It is understood that any and all embodiments of the present invention may be taken in conjunction with any other embodiment or embodiments to describe additional more preferred embodiments. It is also to be understood that each individual element of the preferred embodiments is intended to be taken individually as its own independent preferred embodiment. Furthermore, any element of an embodiment is meant to be combined with any and all other elements from any embodiment to describe an additional embodiment.
DEFINITIONS
[0047] The examples provided in the definitions present in this application are non-inclusive unless otherwise stated. They include but are not limited to the recited examples.
[0048] The compounds of the present invention may have asymmetric centers. Compounds of the present invention containing an asymmetrically substituted atom may be isolated in optically active or racemic forms. It is well known in the art how to prepare optically active forms, such as by resolution of racemic forms or by synthesis from optically active starting materials. All processes used to prepare compounds of the present invention and intermediates made therein are considered to be part of the present invention. All tautomers of shown or described compounds are also considered to be part of the present invention.
[0049] “Host” preferably refers to a human. It also includes other mammals including the equine, porcine, bovine, feline, and canine families.
[0050] “Treating” or “treatment” covers the treatment of a disease-state in a mammal, and includes: (a) preventing the disease-state from occurring in a mammal, in particular, when such mammal is predisposed to the disease-state but has not yet been diagnosed as having it; (b) inhibiting the disease-state, e.g., arresting it development; and/or (c) relieving the disease-state, e.g., causing regression of the disease state until a desired endpoint is reached. Treating also includes the amelioration of a symptom of a disease (e.g., lessen the pain or discomfort), wherein such amelioration may or may not be directly affecting the disease (e.g., cause, transmission, expression, etc.).
[0051] “Therapeutically effective amount” includes an amount of a compound of the present invention that is effective when administered alone or in combination to treat the desired condition or disorder. “Therapeutically effective amount” includes an amount of the combination of compounds claimed that is effective to treat the desired condition or disorder. The combination of compounds is preferably a synergistic combination. Synergy, as described, for example, by Chou and Talalay, Adv. Enzyme Regul. 1984, 22:27-55, occurs when the effect of the compounds when administered in combination is greater than the additive effect of the compounds when administered alone as a single agent. In general, a synergistic effect is most clearly demonstrated at sub-optimal concentrations of the compounds. Synergy can be in terms of lower cytotoxicity, increased antiviral effect, or some other beneficial effect of the combination compared with the individual components.
[0052] “Pharmaceutically acceptable salts” refer to derivatives of the disclosed compounds wherein the parent compound is modified by making acid or base salts thereof. Examples of pharmaceutically acceptable salts include, but are not limited to, mineral or organic acid salts of the basic residues. The pharmaceutically acceptable salts include the conventional quaternary ammonium salts of the parent compound formed, for example, from non-toxic inorganic or organic acids. For example, such conventional non-toxic salts include, but are not limited to, those derived from inorganic and organic acids selected from 1,2-ethanedisulfonic, 2-acetoxybenzoic, 2-hydroxyethanesulfonic, acetic, ascorbic, benzenesulfonic, benzoic, bicarbonic, carbonic, citric, edetic, ethane disulfonic, ethane sulfonic, fumaric, glucoheptonic, gluconic, glutamic, glycolic, glycollyarsanilic, hexylresorcinic, hydrabamic, hydrobromic, hydrochloric, hydroiodide, hydroxymaleic, hydroxynaphthoic, isethionic, lactic, lactobionic, lauryl sulfonic, maleic, malic, mandelic, methanesulfonic, napsylic, nitric, oxalic, pamoic, pantothenic, phenylacetic, phosphoric, polygalacturonic, propionic, salicyclic, stearic, subacetic, succinic, sulfamic, sulfanilic, sulfuric, tannic, tartaric, and toluenesulfonic.
EXAMPLES
[0053] Table 1 provides compounds that are representative examples of the present invention. When one of R 1 -R 44 is present, it is selected from H or D.
[0000]
1
2
3
4
5
6
[0054] Table 2 provides compounds that are representative examples of the present invention. Where H is shown, it represents naturally abundant hydrogen.
[0000]
7
8
9
10
11
12
[0055] Numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise that as specifically described herein. | The present application describes deuterium-enriched ciclesonide, pharmaceutically acceptable salt forms thereof, and methods of treating using the same. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention is in the field of jumping devices for the purposes of amusement and exercise. More specifically, this invention relates to a jumping device of the type including interaction with a user's hands and feet and having a high rebound platform and a flexible tether that can be grasped by a user. By such a device, a user can bounce indefinitely on the high rebound platform while maintaining the platform against the user's feet by way of the flexible tether.
2. Description of the Related Art
Jumping devices for amusement and exercise are well known. Perhaps the most common jumping device is the pogo stick. Conventional pogo sticks typically have a telescoping design that includes a tubular frame from which a spring-actuated plunger member extends downward and terminates in a tip that contacts the ground during use of the pogo stick. Transverse footrests are formed near the lower end of the frame to allow a user of the pogo stick to mount the pogo stick and compress a spring of the plunger by applying a downward force. A typical pogo stick is disclosed in U.S. Pat. No. 2,712,443, issued to H. H. Hohberger.
Conventional pogo sticks have several limitations. Conventional pogo sticks require several moving parts that increase manufacturing costs and reduce durability. Also, the use of a spring that is compressed by the telescoping action of the frame and the plunger member requires that the frame and the plunger member be rigid enough to transmit compressive force to the spring. The use of typical rigid materials (e.g., a rigid metal such as steel) increases the risk of injury to the user of the pogo stick if the user should fall and be struck with the pogo stick. In addition, the rigid materials cause conventional pogo sticks to generate significant noise during operation which makes conventional pogo sticks less amenable to quiet indoor use.
Moreover, conventional pogo sticks are typically designed with plunger member tips and footrests that have small surface areas relative to the surface area of the user's feet. This makes conventional pogo sticks unstable during mounting and operation of the pogo stick and requires that users have a fairly high degree of balancing skills in order to operate the pogo stick. Furthermore, the unstable nature of conventional pogo sticks limits the range of maneuvers that can be performed on conventional pogo sticks and makes conventional pogo sticks difficult to abandon during a fall.
Other less complicated devices have been developed having other spring means instead of such noisy mechanical springs. For example, in U.S. Pat. No. 3,627,314, issued to Brown, a pogo stick is described utilizing an inflatable ball having a platform surface and mounted to a stick handle. Although such a device eliminates some disadvantages, it is still relatively unstable, requires a fairly high degree of balance to operate and has limited maneuverability.
SUMMARY OF THE INVENTION
The present invention provides an improved jumping device that has minimal moving and rigid parts and a wide, stable jumping platform that provides more balancing time before jumping and allows a user to safely and quietly perform a range of jumping maneuvers. Also, folding the flexible tether facilitates convenient storage of the jumping device.
In one aspect, the present invention relates to a jumping device having a high rebound platform, a flexible tether attached to the platform, and a handle located on the tether.
In another aspect, the present invention relates to a method of jumping, including the step of providing a jumping device having a high rebound platform, a flexible tether attached at a first end to the platform, and a handle on the tether, the step of mounting the jumping device by placing a user's foot (or both feet) on the platform, grabbing the handle, then pulling the handle away from the platform, and jumping so that the platform alternates between compressed and uncompressed states.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a jumping device according to the present invention.
FIG. 2 is a front view of a platform and a lower portion of a tether of the jumping device shown in FIG. 1.
FIG. 3 is a rear view of the platform and a lower portion of the tether of the jumping device shown in FIG. 1
FIG. 4 is a fragmentary view of the platform and a lower port on of the tether of the jumping device shown in FIG. 1 with a portion of the platform removed so as to show a rod for fastening the tether to the platform.
FIG. 5 is a perspective view of a handle and an upper portion of the tether of the jumping device shown in FIG. 1.
FIG. 6 is a side view of an alternative high rebound platform formed as a bladder structure.
FIG. 7 is a perspective view of a jumping device according to a second embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1-5 show a jumping device 10 in accordance with a first embodiment of the present invention. Device 10 includes a high rebound platform 12, a tether 14 attached to the platform 12, and a handle 16 provided at an end of the tether 14.
High rebound platform 12 is formed so that platform 12 can be made to alternate between a compressed state and an uncompressed state. Generally, when a body elastically compresses due to the application of compressive forces, potential energy is stored in the deformed body. The transition of the body from a compressed state to an uncompressed state results in the conversion of potential energy to kinetic energy. A high rebound platform 12 in accordance with the present invention is a structure that can be made to elastically compress between a user's feet (which contact a foot support surface 18 located on the top of platform 12) and the ground or other rigid surface (which contacts an impact surface 20 located on the bottom of platform 12) by having at least a portion of the foot support surface 18 and at least a portion of impact surface 20 move closer to one another so that kinetic energy provided during the transition of the structure from a compressed state to an uncompressed state is sufficient to create a rebound force that assists the user in jumping. A high rebound platform 12 can be characterized by the basic ability to support a user to permit jumping without bottoming out and to provide some amount of energy to assist the user in jumping. It is envisioned that jumping device 10 can be designed to operate for a particular range of user weights. Therefore, high rebound platform 12 may be adapted to elastically compress and provide rebound force for the particular range of user weights for which the device 10 is designed. It is also envisioned that a product feature, shape of a component, color code, or other labeling scheme could be used to convey easily the range of user weights appropriate for a particular jumping device 10.
High rebound platform 12 is preferably formed from any one of a number of conventional solid, closed cell, or open cell materials that are commonly used to absorb impact or provide rebound. More specifically, platform 12 can be formed from rubbers including but not limited to natural foam rubber, natural butyl rubber (NBR), natural rubber (NR), thermoplastic rubber (TPR), and plastics including but not limited to polyethylene (PE), polyurethane (PU), and ethyl vinyl acetate (EVA). Generally, for a given high rebound material having a given contact surface area, the thicker (measured from foot support surface 18 to impact surface 20 of platform 12) platform 12 is, the greater the range of user weights over which the platform 12 will elasticly compress and provide a rebound force. It is also understood that with different high rebound materials and different contact surface areas various weight ranges can be accommodated.
FIGS. 1-4 show platform 12 formed from a plurality of layers 30, wherein the layers are attached to one another using conventional adhesives. Other conventional lamination techniques can be used instead. Preferred high rebound materials includes but are not limited to Zoatfoam EV-50 EVA foam from Zoatfoam Inc. of Hacketstown. N.J.; foam model MC3800S with EVA from Sentinal Co.; foam model 5A with EVA from Voltek, and foam product commercially available under the tradename Metalocene from E.I. Dupont de Nemours and Co., Wilmington, Del. As shown, each layer is preferably shaped so that when stacked, the layers 30 form a complete, shaped platform 12. The layers 30 can be shaped by use of conventional die-cut techniques, for example. The layers 30 may be shaped for functional or aesthetic reasons, and each layer may be the same or different as the others. The top and bottom layers, in particular, may also be shaped in the thickness direction so as to provide any desired surface features. For example, the foot support surface 18 or the impact surface 20 may be rounded, or may be patterned to enhance gripping of the surface(s) with a user's foot (or feet) or the floor. Such a pattern may be for anti-slip properties, or to permit use on wet surfaces or other materials (e.g., grass lawns, concrete, etc.) that may otherwise affect the material (e.g., by abrasion or puncture). Moreover, each of the layers 30 may be made of the same or different material. For example, the bottom layer may be of a tougher material to enhance its durability for particular surfaces like concrete. For use in homes, a softer (non-scratch) material may be desirable. Along these same lines, coatings or other surface treatments are also contemplated. Surface treatments include the provision of sheet material to cover all or a portion of the impact surface 20, for example. A non-slip material may be desirable for rendering the device more suitable for use on certain surface such as finished wood.
Alternatively, platform 12 can be formed as a single piece of rebound material. Like the laminated platform described above, a single block platform 12 can be shaped, coated or treated to have certain properties or for aesthetic reasons depending on an intended usage of the device 10. Moreover, even with a single layer construction, more than one distinct material portions thereof can be made by conventional techniques used in the making of the material, e.g., using coextrusion techniques. It is believed that for conventional rubbers and plastics, high rebound platform 12, whether formed from single or multiple layers, should have a thickness in the range of about 1 inch to about 12 inches and preferably has a thickness of about 4.5 inches for an average user.
Alternatively, as shown in FIG. 6, a high rebound platform 12' may be constructed from materials without relying on a rebound characteristic of the material itself, as is the case with a foam layer or foam layers. A resilient material may be shaped to form a bladder 30' (that may be similar to or different from the layered platform 12 of FIG. 1) and filled with a fluid 31'. Then, bladder 30' can be compressed between a user's feet (which contact a foot support surface 18' located on the top of platform 12') and the ground or other rigid surface (which contacts an impact surface 20' located on the bottom of platform 12') so that the fluid 31' (such as air) is compressed or bladder 30' is caused to expand, or both, to store potential energy and so that kinetic energy provided during the transition of the structure from a compressed state to an uncompressed state is sufficient to create a rebound force that assists the user in jumping.
Again referring to FIGS. 1-5, foot support surface 18 and impact surface 20 of platform 12 are advantageously shaped to allow a user of the device 10 more easily to maintain balance while operating the device 10. It is believed that platform 12 should have a depth (measured from a front face 22 to a back face 24 of platform 12) of at least about 2 inches and preferably has a depth in the range of about 4 inches to about 8 inches for an average user. It is also believed that platform 12 should have a width (measured from a first lateral side 26 to a second lateral side 28) of at least about 6 inches and preferably has a width of about 12 inches for an average user. In FIGS. 1-4, foot support surface 18 and impact surface 20 have the same shape, though, as above, foot support surface 18 and impact surface 20 could have shapes that differ from one another.
FIGS. 1-5 show a tether 14 formed preferably as a loop of flexible (i.e., non-rigid) cord having two straightenable portions 32 and 34 that are attached to the platform 12. As shown in FIG. 4, ends 36 and 38 of portions 32 and 34, respectively, can be connected to a rigid rod 40 (preferably formed from bamboo because it is rigid and lightweight) that is located within the layers 30 of platform 12. The ends 36 and 38 may be formed as loops that surround and connect to rod 40. An opening 42 can be formed in one or more of the layers of platform 12 so as to allow portions 32 and 34 of tether 14 to pass through foot support surface 18 of platform 12 and attach to rod 40. Other ways of connecting the tether portions 32 and 34 to the platform 12 are also contemplated. For example, the portions 32 and 34 can be passed through opening(s) of platform 12 all the way though and be tied to together at the impact surface 20 in which recesses can be formed to accommodate the tied portions 32 and 34 so as to provide a substantially flat, stable impact surface 20. Likewise, the rod 40 may be provided at any location within the thickness of the platform 12 (e.g., between any two layers 30) and may be of any effective shape (e.g., a plate-like element to which ends 36 and 38 are attached). Also, recesses may be formed in the layers 30 so as to accommodate the rod 40 and provide substantially flat foot support and impact surfaces 18 and 20.
Tether 14 is preferably significantly extendible and formed from an elastic material such as a textile-covered elastic cord or an extruded elastic tubing without a cover. Suitable tubing includes natural latex rubber tubing, commonly known as surgical tubing, because it is highly extendible. Alternatively, tether 14 can be formed from conventional non-elastic ropes, although an elastic tether 14 is preferred because an elastic tether 14 accommodates a wider range of user heights (by stretching to fit each user) and more securely holds the platform 12 against the user's feet during use due to the additional tension created by stretching the elastic tether 14. An extendible tether 14 may alternatively comprise one or portions of non-extendible materials combined with an extendible portion which may comprise stretchable cord as above or an extension spring.
Handle 16 is formed on the tether 14 so as to provide the user of device 10 with a convenient place to grab and pull tether 14 away from platform 12. In the embodiment shown in FIGS. 1-5, handle 16 is a T-shaped assembly attached to a loop end 44 of tether 14. Handle 16, perhaps shown best in FIG. 5, has a transverse rod 46 around which tether 14 is looped generally in a center portion 48 of rod 46 so as to define two gripping portions 50 and 52 of rod 46 on either side of center portion 48. A foam sheath 54 surrounds a portion of tether 14 near the loop end 44. Sheath 54 has opposing lateral openings 56 and 58 to allow rod 46 to pass through sheath 54. Sheath 54 also has opposing longitudinal openings 60 and 62 that allow the ends 36 and 38 of the tether 14 to be threaded around rod 46 during assembly so that the loop end 44 of tether 14 can be looped around rod 46. Gripping portions 50 and 52 are preferably covered with shaped foam tubing so as to form foam grips 64 and 66, respectively, which provide the user of device 10 with padded gripping surfaces and prevent the loop end 44 of tether 14 and sheath 54 from sliding along the rod 46 during use of the device 10. Preferably, lateral ends 68 and 70 of rod 46 have cross sectional areas that are greater than the cross sectional area of the interior portions of the rod 46 so as to prevent grips 64 and 66 from sliding off the rod 46. As shown in FIG. 5, lateral ends 68 and 70 are formed integrally with rod 46, although lateral ends 68 and 70 can be formed as separate pieces (e.g., as rimmed end caps) that are attached to rod 46. Alternatively, the tether portions 32 and 34 may be directly tied on to the rod 46, or otherwise connected by way of a mechanical faster or adhesive, or the like.
In operation, a user mounts the device 10 by placing the user's feet on the foot support surface 18 of platform 12 on either side of opening 42, grabs the handle 16 with both of the user's hands, pulls the handle 16 away from platform 12 so as to tension tether 14, and jumps upward. As the user's legs extend during jumping, tether 14 keeps the device 10 under the user's feet, which preferably is further facilitated by the use of an elastic tether 14 which is stretched to provide additional tension. Upon impact, the user's knees bend to help absorb impact and prepare for another extension. Also, upon impact a generally downward, compressive force is applied to foot support surface 18 of platform 12 causing platform 12 to be compressed between the user's feet and the ground (or other rigid surface) as foot support surface 18 moves closer to impact surface 20 so that potential energy is stored in platform 12. The user extends the user's legs so as to propel the user and the device 10 upward which causes platform 12 to transition from a compressed state to an uncompressed state so as to release the stored potential energy as kinetic energy that creates a rebound force to assist the user in jumping. This motion can be done repeatedly for an indefinite length of time, as each subsequent jump utilizes the same compression of platform 12 to provide a rebound-assisted jump. The user can execute a wide range of maneuvers on device 10, for example, by maneuvering the user's body as is done to perform maneuvers on conventional skateboards, snow boards, or downhill skis.
FIG. 7 shows a second embodiment of a jumping device 100 according to the present invention having a handle 116 formed integrally with a tether 114. Device 100 has a high rebound platform 112 that is preferably similar to platform 12 and is fabricated from similar materials in a similar manner. Tether 114 is similar to tether 14, is fabricated from similar materials in a similar manner, and is attached to platform 112 in the same way that tether 14 is attached to platform 12 except that tether 114 has only one end 136 that is tied to a rod 140 (similar to rod 40) located within the plurality of layers 130 of platform 112. A handle 116 is formed as a loop 172 by tying or otherwise attaching an end 174 of tether 114 to an intermediate portion 176 of tether 114. Preferably, end 174 is slidably attached to portion 176 so that the user of device 100 can alter the size of loop 172 by sliding end 174 along portion 176. This can be done by a sliding knot (as shown) or by way of a conventional sliding/clamping device to which an end of tether 114 can be tied. Device 100 can be used in the same manner as device 10.
As with any of the above specifically disclosed or suggested embodiments, the tether 14 (or 114) may comprise a single cord or may include any number cf cords, so long as there is a connection to a high rebound platform 12 (or 112), and some means is provided to facilitate grasping by a user. A jumping device that interacts with a user's feet and hands is thus provided. Other handle constructions are also contemplated and may be secured in any matter to the tether 14 (or 114).
As yet another specifically contemplated embodiment plural high rebound platforms can be used in combination with independent tethers. That is, two separate platforms may be provided, each having its own tether or tethers. Then, each tether may be combined together to form a handle or be connected to a separately provided handle. Each platform would preferably be connected to a tether or tethers in a way to permit independent leg movement. This may be facilitated by other fastening structures attached between the tether and the tether's platform, or by running plural tethers (or a loop from one tether) through the platform to extend on both sides of a user's foot to keep the platform oriented properly during use.
As still yet another specifically contemplated embodiment of a jumping device according to the present invention, a high rebound platform can comprise a foot support surface that is suspended from a rigid, trampoline-like frame. The foot support surface can be suspended from the frame by coil springs, stretchable cords, or other conventional tension springs devices. In this case, an impact surface is created by a portion of the frame that comes into contact with the ground or other rigid surface during use of the device. A flexible tether is attached to the high rebound platform, preferably in a position to be in between a user's feet, and a handle is formed on the tether to facilitate gripping by a user so as to provide the interaction between at least a hand and a foot of the user. The high rebound platform of this embodiment achieves a compressed state when the platform is compressed by the user's feet such that the foot support surface and/or the springs that attach the foot support surface to the frame, if any, are stretched and store potential energy in the deformed foot support surface and/or springs. When the high rebound platform transitions to the uncompressed state, the foot support surface and/or springs, if any, convert the potential energy to kinetic energy to provide a rebound force to assist the user in jumping. This embodiment is less advantageous for many uses, however, in that it requires more rigid parts and the platform is substantially compressible from only one surface (i.e., from the foot support surface).
Although the present invention has been described with reference to preferred embodiments, those skilled in the art will recognize that changes made be made in form and detail without departing from the spirit and scope of the invention. | A jumping device having a high rebound platform, a flexible tether operatively connected at a first end thereof to the high rebound platform, and a handle located on the tether. A method of jumping, including providing a jumping device having a high rebound platform, a flexible tether operatively connected at a first end thereof to the high rebound platform, and a handle on the tether, mounting the jumping device by placing a user's foot on the high rebound platform, grabbing the handle, pulling the handle away from the high rebound platform, and jumping so that the high rebound platform alternates between compressed and uncompressed states. | 0 |
[0001] This application claims priority to and the benefit of U.S. Provisional Application Nos. 61/446,147 and 61/446,149, filed Feb. 24, 2011, the full disclosures of which are incorporated herein by reference.
[0002] This application is a continuation-in-part of pending U. S. application Ser. No. 13/052,362, filed Mar. 21, 2011.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] This invention relates to an automatic transmission for a motor vehicle that includes planetary gearsets and clutches and brakes whose state of engagement and disengagement determines speed ratios produced by the transmission.
[0005] 2. Description of the Prior Art
[0006] In a front wheel drive vehicle, the axial space available for the transmission is limited by the width of the engine compartment and the length of the engine. In addition, the trend to increase the number of ratios available generally increases the number of components required. For these reasons, it is desirable to position components concentrically in order to minimize axial length. The ability to position components concentrically is limited, however, by the need to connect particular components mutually and to the transmission case.
[0007] Furthermore, it is desirable for the output element to be located near the center of the vehicle, which corresponds to the input end of the gear box. An output element located toward the outside of the vehicle may require additional support structure and add length on the transfer axis. With some kinematic arrangements, however, the need to connect certain elements to the transmission case requires that the output element be so located.
[0008] One of the transmission control devices, such as the D brake, may be used only as a latching device rather than as a dynamic device. To minimize parasitic viscous drag loss produced in the control device, it would be better if the brake were a latching mechanism rather than a hydraulically-actuated friction brake having interleaved discs and spacer plates.
SUMMARY OF THE INVENTION
[0009] A transmission latching mechanism includes a component of a transmission gearset, a member secured to and able to rotate with the component, and a piston fixed against rotation and moveable alternately to latch the mechanism, thereby holding the member against rotation and to unlatch the mechanism, thereby releasing the member to rotate.
[0010] The latching mechanism simplifies the brake, reduces the number of components as compared to the number required for a hydraulically-actuated friction brake, reduces the drag loss by eliminating the friction discs and plates, and requires a smaller space than the space required for a hydraulically-actuated friction brake.
[0011] The latching mechanism is a more robust component and requires lower cost to assemble and install than does a hydraulically-actuated friction brake.
[0012] The scope of applicability of the preferred embodiment will become apparent from the following detailed description, claims and drawings. It should be understood, that the description and specific examples, although indicating preferred embodiments of the invention, are given by way of illustration only. Various changes and modifications to the described embodiments and examples will become apparent to those skilled in the art.
DESCRIPTION OF THE DRAWINGS
[0013] The invention will be more readily understood by reference to the following description, taken with the accompanying drawings, in which:
[0014] FIG. 1 is a cross sectional side view of a multiple speed automatic transaxle;
[0015] FIG. 2 is cross sectional side view of the transaxle showing the front and middle cylinder assemblies;
[0016] FIG. 3 is a side perspective view showing sleeves that are fitted on the front support and middle cylinder assembly, respectively;
[0017] FIG. 4 is a view cross sectional side view of the transfer gears and shaft near the output of the transaxle of FIG. 1 ; and
[0018] FIG. 5 is a cross section side view taken through the latching mechanism and components of the transmission in the vicinity of the latching mechanism.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0019] Referring now to the drawings, FIG. 1 illustrates gearing, clutches, brakes, shafts, fluid passages, and other components of a multiple-speed automatic transaxle 10 arranged substantially concentrically about an axis 11 .
[0020] A torque converter includes an impeller driven by an engine, a turbine hydrokinetically coupled to the impeller, and a stator between the impeller and turbine. A transmission input shaft 20 is secured by a spline connection 21 to the turbine. The stator is secured by a spline connection 22 to a front support 24 , which is secured against rotation to a transmission case 26 .
[0021] A double pinion, speed reduction planetary gearset 28 includes a sun gear 30 , secured by a spline connection 31 to input shaft 20 ; a carrier 32 , secured by a spline connection 33 to the front support 24 ; a ring gear 34 , secured by a spline connection 35 to a front cylinder assembly 36 ; a first set of planet pinions 38 supported on carrier 32 and meshing with sun gear 30 ; and a second set of planet pinions 40 , supported on carrier 32 and meshing with ring gear 34 and the first pinions 38 . Ring gear 34 rotates in the same direction as input shaft 20 but at a reduced speed.
[0022] Rear gearset 46 and middle gearset 48 are simple planetary gearsets. Gearset 46 includes a set of planet pinion 50 supported for rotation on carrier 52 and meshing with both sun gear 54 and ring gear 56 . Gearset 48 includes a set of planet pinions 58 supported for rotation on carrier 60 and meshing with both sun gear 62 and ring gear 64 . Sun gear 54 is splined to a shaft that is splined to a shell 66 , on which shaft sun gear 62 is formed, thereby securing the sun gears 54 , 62 mutually and to the shell 66 . Carrier 52 is fixed to a shell 68 . Carrier 60 and ring gear 56 are fixed to each other and to output pinion 70 through a shell 72 . Ring gear 64 is fixed to shell 74 .
[0023] Front cylinder assembly 36 , which is fixed to ring gear 34 , actuates clutches 76 , 80 . Plates for clutch 76 includes plates splined to front cylinder assembly 36 alternating with plates splined to shell 74 . When hydraulic pressure is applied to piston 78 , the plates are forced together and torque is transmitted between ring gears 34 and 64 . When the hydraulic pressure is released, ring gears 34 and 64 may rotate at different speeds with low parasitic drag. Similarly, plates for clutch 80 include plates splined to front cylinder assembly 36 alternating with plates splined to shell 66 . When hydraulic pressure is applied to piston 82 , torque is transmitted between ring gear 34 and sun gears 54 , 62 . Pressurized fluid is routed from a control body 84 , through front support 24 , into front cylinder assembly 36 between rotating seals.
[0024] Middle cylinder assembly 86 , which includes carrier 32 , actuates brake 88 . Plates for brake 88 include plates splined to carrier 32 alternating with plates splined to shell 66 . When hydraulic pressure is applied to piston 90 , the brake holds sun gears 54 , 62 against rotation. Pressurized fluid is routed from the control body 84 , through front support 24 , between planet pinions 38 , 40 , into middle cylinder assembly 86 . Due to the location of clutch pack 88 , output element 70 is located in the more favorable position near the front of the gear box.
[0025] Rear cylinder assembly 92 is secured by a spline connection 93 fixed to input shaft 20 . When hydraulic pressure is applied to piston 94 , the plates of clutch 96 transmit torque between input shaft 20 and carrier 52 . Similarly, when hydraulic pressure is applied to piston 98 , the plates of clutch 100 transmit torque between input shaft 20 and sun gears 54 , 62 . Pressurized fluid is routed from the control body 84 , into rear cylinder assembly 92 .
[0026] When hydraulic pressure is applied to piston 102 , brake 104 holds carrier 52 and shell 68 against rotation. A one-way brake 106 passively prevents carrier 52 and shell 68 from rotating in the negative direction, but allows them to rotate in the forward direction. One-way brake 106 may optionally be omitted and its function performed by actively controlling brake 104 .
[0027] The D brake 104 is used only as a latching device not as a dynamic brake. To minimize parasitic viscous drag loss produced in brake 104 it is desired that excess oil not be present in the brake. Therefore, an oil dam formed by an oil seal 103 between the piston 94 of E clutch 96 and the inner race 107 of one-way brake 106 is provided to limit or prevent oil from entering the D brake 104 . The inner radial end of return spring 108 continually contacts the piston 102 that actuates brake 104 . The outer radial end of return spring 108 continually contacts a fixed structure, so that the spring flexes as the piston 102 moves in the cylinder of the D brake 104 . In this way, return spring 108 also participates in the oil dam by limiting or preventing radial flow of oil into the D brake 104 caused by centrifugal force.
[0028] This arrangement permits brake 88 and clutches 76 , 80 to be mutually concentric, located at an axial plane, and located radially outward from the planetary gearsets 28 , 46 , 48 such that they do not add to the axial length of the gearbox. Similarly, clutches 96 , 100 and brake 104 are mutually concentric and located radially outward from the planetary gearing 28 , 46 , 48 . Clutches 76 , 80 , 96 , 100 and brakes 88 , 104 , 106 comprise the control elements.
[0029] As FIGS. 2A , 2 B illustrate, the front cylinder assembly 36 is supported for rotation on the fixed front support 24 and carrier 34 . The front cylinder assembly 36 is formed with clutch actuation fluid passages, each passage communicating with one of the cylinders 114 , 116 formed in the front cylinder assembly 36 . Cylinder 114 contains piston 78 ; cylinder 116 contains piston 82 . One of the fluid passages in front cylinder assembly 36 is represented in FIG. 2 by interconnected passage lengths 109 , 110 , 111 , 112 , through which cylinder 116 communicates with a source of clutch control hydraulic pressure. Another of the fluid passages in front cylinder assembly 36 , which is similar to passage lengths 109 , 110 , 111 , 112 but spaced angularly about axis 11 from passage lengths 109 , 110 , 111 , 112 , communicates a source of clutch control hydraulic pressure to cylinder 114 . Passage lengths 109 are machined in the surface at the inside diameter of the front cylinder assembly 36 .
[0030] The front cylinder assembly 36 is also formed with a balance volume supply passage, similar to, but spaced angularly about axis 11 from passage lengths 109 , 110 , 111 , 112 . The balance volume supply passage communicates with balance volumes 120 , 122 . As shown in FIG. 2A , the balance volume supply passage includes an axial passage length 124 , which communicates with a source of balance volume supply fluid and pressure, and a radial passage length 126 , through which fluid flows into the balance volumes 120 , 122 from passage 124 . Passage 124 may be a single drilled hole extending along a longitudinal axis and located between the two clutch balance areas of the A clutch and B clutch. Passage 124 carries fluid to cross drilled holes 126 , which communicate with the balance volumes 120 , 122 .
[0031] Coiled compression springs 128 , 130 , each located in a respective balance dam 120 , 122 , urge the respective piston 78 , 82 to the position shown in FIG. 2 . Ring gear 34 is secured to front cylinder assembly 36 by a spline connection 132 .
[0032] Middle cylinder assembly 86 includes carrier 32 , which is grounded on the front support 24 . Carrier 32 includes first and second plates 134 , 135 and pinion shafts secured to the plates, one pinion shaft supporting pinions 38 , and the other pinion shaft supporting pinions 40 . Plate 135 is formed with a cylinder 140 containing a brake piston 90 .
[0033] A source of brake actuating hydraulic pressure communicates with cylinder 140 through a series on interconnected passage lengths 142 , 143 and a horizontal passage length that extends axially from passage 143 , through a web of carrier 32 , between the sets of planet pinions 38 , 40 , to cylinder 140 . These brake feed passages are formed in carrier 32 . When actuating pressure is applied to cylinder 140 , piston 90 forces the plates of brake 88 into mutual frictional contact, thereby holding sun gears 54 , 62 and shell 66 against rotation. A Belleville spring 146 returns piston 90 to the position shown in FIG. 2 , when actuating pressure is vented from cylinder 140 .
[0034] The front support 24 is formed with passages, preferably spaced mutually about axis 11 . These passages in front support 24 are represented in the FIGS. 1 and 2 by passage lengths 150 , 151 , 152 , through which hydraulic fluid is supplied to clutch servo cylinders 114 , 116 , brake servo cylinder 140 , and balance dams 120 , 122 . A passage of each of the front support passages communicates hydraulic fluid and pressure to cylinders 114 , 116 and balance dams 120 , 122 of the front cylinder assembly 36 through the fluid passages 109 , 110 , 111 , 112 , 113 , 124 formed in the front cylinder assembly 36 . Another passage of each of the front support passages communicates hydraulic fluid and pressure to cylinder 140 of the middle cylinder assembly 86 through the fluid passages 142 , 143 in carrier 32 .
[0035] The front support 24 includes a bearing support shoulder 154 , which extends axially and over an axial extension 156 of the front cylinder assembly 36 . A bushing 158 and bearing 160 provide for rotation of the front cylinder assembly 36 relative to the front support 24 . This arrangement of the front support 24 , its bearing support shoulder 154 , and front cylinder assembly 36 , however, prevents radial access required to machine a passage or passages that would connect first passage 152 in front support 24 to the second passage 109 in the front cylinder assembly 36 .
[0036] To overcome this problem and provide hydraulic continuity between passage lengths 109 , 152 , first passage 152 is formed with an opening that extends along a length of first passage 152 , parallel to axis 11 , and through an outer wall of the front support 24 . The opening faces radially outward toward second passage 109 . Similarly, second passage 109 is formed with a second opening that extends along a length of second passage 109 , parallel to axis 11 , and through an inner wall of the front cylinder assembly 36 . The second opening faces radially inward toward first passage 152 .
[0037] A first sleeve 162 is inserted axially with a press fit over a surface at an outer diameter of the front support 24 , thereby covering the opening at the outer surface of passage length 152 . Sleeve 162 is formed with radial passages 164 , 165 , which extend through the thickness of the sleeve 162 . Seals 176 , located at each side of the passages 164 , 165 prevent leakage of fluid from the passages.
[0038] A second sleeve 170 is inserted axially with a press fit over the second opening at the inside diameter of the front cylinder assembly 36 , thereby covering and enclosing the length of the second opening in the second passage 109 . Sleeve 170 is formed with radial openings, two of which are represented in FIG. 2 by openings 172 , 174 , aligned with the radial passages 164 , 165 formed in the first sleeve 162 .
[0039] Sleeves 164 and 170 provides hydraulic continuity from the source of fluid pressure carried in the passages of the front support 24 to the balance dams 120 , 122 and the servo cylinders 114 , 116 , 140 , through which clutches 76 , 80 and brake 88 are actuated.
[0040] Sleeves 162 , 170 also provide access that enables machining of the first and second passages 152 , 109 in the surface at the outside diameter of front support 24 and in the surface at the inside diameter of the front cylinder assembly 36 . FIG. 3 shows sleeves 162 , 170 and three seals 176 , which are fitted in recesses on sleeve 162 between each of its radial passages 164 , 165 .
[0041] As FIG. 4 shows output pinion 70 meshes with a transfer gear 180 , which is formed integrally with transfer pinion 182 on a transfer wheel 184 . A transfer shaft 186 , is secured at one end by a pinned connection 188 to a non-rotating housing component 190 , and at the opposite end is seated in a recess 192 formed in a non-rotating torque converter housing component 194 . Ball bearing 198 supports transfer wheel 184 on the torque converter housing 194 . Housing components 190 , 194 comprise a reaction component and may be formed integrally or preferably as separate components.
[0042] Ball bearing 198 is supported radially by being seated on a surface 196 of the torque converter housing 194 . A shoulder 199 on torque converter housing 194 contacts the right-hand axial surface of the inner race of bearing 198 , the second surface of bearing 198 . A snap ring 200 contacts the right-hand axial third surface 201 of the outer race of bearing 198 . Shoulder 199 and snap ring 200 limit rightward axial movement of bearing 198 .
[0043] A shoulder 202 formed on gear wheel 184 contacts the left-hand axial first surface of the outer race of bearing 198 . A thrust washer 204 contacts a left-hand axial fourth surface 205 of the inner race of bearing 198 . The thrust washer 204 contacts a shoulder 206 formed on transfer shaft 186 . Shoulders 202 and 206 limit leftward axial movement of bearing 198
[0044] The ring gear 210 of a differential mechanism 212 meshes with transfer pinion 182 and is supported for rotation by bearings 214 , 216 on housing 190 , 194 . Rotating power transmitted to output pinion 70 is transmitted through transfer gears 180 , 182 and ring gear 210 to the input of differential, which drives a set of vehicle wheels aligned with axis 220 .
[0045] A roller bearing 222 supports transfer wheel 184 on transfer shaft 186 . The thickness of a washer 224 , fitted in a recess 226 of housing 190 , is selected to ensure contact between thrust washer 204 and the inner race of bearing 198 .
[0046] The output pinion 70 and transfer gears 180 , 182 have helical gear teeth, which produce thrust force components in the axial direction parallel to axis 220 and in the radial direction, normal to the plane of FIG. 5 , which transmitting torque. A thrust force in the right-hand direction transmitted to the transfer gear wheel 184 is reacted by the torque converter housing 194 due to its contact at shoulder 199 with bearing 198 . A thrust force in the left-hand direction transmitted to the transfer gear wheel 184 is reacted by the housing 190 due to contact between snap ring 200 and bearing 198 , contact between bearing 198 and thrust washer 204 , contact between the thrust washer and transfer shaft 186 , and contact between shaft 186 , washer 224 and housing 190 .
[0047] As shown in FIG. 1A , the D brake 104 includes a first set of thin discs 230 secured to the outer race 232 of one-way brake 106 by a spline connection, which permits the discs 230 to move axially and prevents them from rotating relative to the race 232 , which is fixed to the transmission case or end cover against rotation.
[0048] Similarly, the D brake 104 includes a second set of thin discs 234 secured to the inner race 107 of one-way brake 106 by a spline connection, which permits the discs 234 to move axially and prevents them from rotating relative to the inner race 107 . The first and second discs are interleaved, such that each of the first discs 230 has a second disc 234 located on each axial side of the first disc.
[0049] Inner race 107 is fixed to the carrier 68 of gearset 46 , such that discs 234 , inner race 107 and carrier 68 rotate together as a unit at the same speed. The discs 230 , 234 become frictional engaged mutually when hydraulic pressure is applied to the cylinder 252 and piston 102 forced the discs into mutual contact, thereby fixing the inner race 107 and carrier 68 against rotation. The discs 234 rotate freely relative to discs 230 when hydraulic pressure is vented from cylinder 252 .
[0050] Preferably the outer and inner races 232 , 107 of one-way brake 106 are formed of a ferrous alloy of sintered powdered metal, and discs 230 , 234 are of steel. The reaction splines for the D brake 104 is preferably not formed in the aluminum case or aluminum end cover because of high local bearing stresses that would be induced in the case or end cover by the thin discs 230 , 234 . The discs 230 , 234 are thin to reduce parasitic loss in the D brake 104 . The D brake 104 reaction splines are formed as an integral part of the raceways 232 , 107 of the one-way brake 106 . The brake 106 is then splined to the transmission case.
[0051] Although the one-way transmission control member is described with reference to its being a brake 106 , it may be a clutch, which connects one member of a gearset to another member of the same gearset or a different gearset. Similarly, the hydraulically-actuated transmission control member is described with reference to its being a brake, but it may be a clutch instead.
[0052] Preferably the one-way brake 106 is a rocker one-way brake of the type having a pivoting rockers, each rocker retained is a pocket and actuated by centrifugal force and a compression spring, as described in U. S. Pat. Nos. 7,448,481 and 7,451,862.
[0053] FIG. 5 illustrates the D brake 104 as a latching mechanism 260 , which alternately connects carrier 52 and shell 68 to the transmission case, thereby holding the carrier against rotation, and disconnects carrier 52 and shell 68 from the transmission case so that they can rotate freely.
[0054] Shell 68 is secured by a spline connection 261 to member 262 . The inner race 263 of a one-way brake 264 is secured by a spline connection 265 to member 262 . The outer race 266 of brake 264 is fixed against rotation by being secured to axially directed spline teeth 270 formed on the end cover 272 of the transmission case.
[0055] Latching mechanism 260 includes a piston 274 , which moves substantially parallel to axis 11 and is fixed against rotation by being secured to the axial spline teeth 270 formed on the end cover 272 . Piston is actuated by actuating pressure in the cylinder 252 formed in the end cover 272 to slide rightward on spline teeth 270 , thereby latching mechanism 260 . When actuating pressure in cylinder 252 is vented and release pressure is supplied through passage 271 , 273 to a volume 282 of cylinder 252 , piston 274 is actuated by release pressure and the force of a return spring 276 to slide leftward on spline teeth 270 , thereby unlatching mechanism 260 .
[0056] A dam 278 , secured to the end cover 272 by a snap ring 280 , supports a dynamic seal 284 , which, together with seal 286 , hydraulically seals the volume 282 located between the piston 274 and the dam 278 .
[0057] Piston 274 is formed with a series of dog teeth 288 , which are spaced mutually about axis 11 and located at the inner surface of the piston. Member 262 is similarly formed with a series of dog teeth 290 , which are spaced mutually about axis 11 and located for engagement by teeth 288 as piston 274 moves rightward in cylinder 252 .
[0058] When cylinder 252 is pressurized and volume 282 is vented, piston 274 moves rightward against the force of spring 276 causing teeth 288 to engage teeth 290 , thereby connecting carrier 52 and shell 68 to the end cover 272 and holding the carrier and shell against rotation. When cylinder 252 is vented and volume 282 is pressurized, piston 274 moves leftward causing teeth 288 to disengage teeth 290 , thereby disconnecting carrier 52 and shell 68 from the end cover 272 and allowing the carrier and shell to rotate freely.
[0059] The one-way brake 264 produces a torque reaction for carrier 52 and shell 68 in one rotary direction and allows the carrier and shell to rotate freely in the opposite direction. Preferably the races 263 , 266 of one-way brake 264 are formed from a ferrous alloy of sintered powdered metal.
[0060] In accordance with the provisions of the patent statutes, the preferred embodiment has been described. However, it should be noted that the alternate embodiments can be practiced otherwise than as specifically illustrated and described. | A transmission latching mechanism includes a component of a transmission gearset, a member secured to and able to rotate with the component, and a piston fixed against rotation and moveable alternately to latch the mechanism, thereby holding the member against rotation and to unlatch the mechanism, thereby releasing the member to rotate. | 5 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to a power supply device with a redundant structure and containing plural sets of power supply circuit units and adapter cards.
[0003] 2. Description of the Related Art
[0004] A power supply as shown in FIG. 2 has been proposed for disk enclosure devices, although no publication of such system is known. The disk enclosure device (DES) 10 ′ includes two power supply units (PS 0 , PS 1 ) 7 , 17 , two adapter cards (ADP 0 , ADP 1 ) 41 ′, 42 ′ and a backboard (BB) 8 ′. The backboard (BB) 8 ′ is interposed between the power supply units (PS 0 , PS 1 ) 7 , 17 and adapter cards (ADP 0 , ADP 1 ) 41 ′, 42 ′ and respectively connected to each of them by the connectors 9 , 19 , 20 ′, 30 ′. This structure allows the operation to continue even if one unit among the power supply units (PS 0 , PS 1 ) 7 , 17 and adapter cards (ADP 0 , ADP 1 ) 41 ′, 42 ′ breaks down. In other words, the disk enclosure device possesses a redundant structure to ensure a stable supply of power.
[0005] More specifically, a power supply unit (PS 0 ) 7 and a backboard (BB) 8 ′ are connected by a connector 9 ; a power supply unit (PS 1 ) 17 and a backboard (BB) 8 ′ are connected by a connector 19 ; an adapter card (ADP 0 ) 41 ′ and a backboard (BB) 8 ′ are connected by a connector 20 ′; and an adapter card (ADP 1 ) 42 ′ and a backboard (BB) 8 ′ are connected by a connector 30 ′. The backboard (BB) 8 ′ has the power supply line pattern so that power is supplied from the power supply unit (PS 0 ) 7 to both the adapter cards (ADP 0 , ADP 1 ) 41 ′, 42 ′; and power is supplied from the power supply unit (PS 1 ) 17 to both the adapter cards (ADP 0 , ADP 1 ) 41 ′, 42 ′ in the same way. In other words, the power supply line pattern on the backboard (BB) 8 ′ includes a first linear pattern from the power supply unit (PS 0 ) 7 to adapter card (ADP 0 ) 41 ′; and a second linear pattern from the power supply unit (PS 1 ) 17 to the adapter card (ADP 1 ) 42 ′; and a third linear pattern intersecting these two linear patterns. The connectors 9 , 19 , 20 ′, and 30 ′ are here each utilized to make up one power supply line pattern from either a first or a second linear pattern.
[0006] The adapter card (ADP 0 ) 41 ′ is structured so that a hot swap circuit (Hot Swap 0 ) 5 , a diode 3 , and a DC/DC converter (DD Con) 2 are each directly connected from the input side and the DC/DC converter (DD Con) 2 outputs the power supplied from the power supply line pattern on the backboard (BB) 8 ′ via each component. The adapter card (ADP 1 ) 42 ′ is structured in the same way, with a hot swap circuit (Hot Swap 0 ) 15 , a diode 13 , and a DC/DC converter (DD Con) 12 each directly connected from the input side and the DC/DC converter (DD Con) 12 outputs the power supplied from the power supply line pattern on the backboard (BB) 8 ′ via each component.
[0007] In the disk enclosure device (DES) 10 ′ with this type of structure, if an electrical short for example occurs between the power supply and GND (ground) due to a problem or breakdown for example in the adapter card (ADP 0 ) 41 ′, then the hot swap circuit (HOT SWAP 0 ) 5 detects the excessive current and stops the output so that the adapter card (ADP 0 ) 41 ′ operation stops. It gives no effect, however, on the adapter card (ADP 1 ) 42 ′ and the power supply continues. Consequently, normal operation can continue. This continuation of normal operation is achieved since the entire device has a redundant structure.
[0008] In the case that an electrical short between the power supply and GND (ground) occurred in the same way due to a problem or breakdown for example in the adapter card (ADP 1 ) 42 ′, then the hot swap circuit (HOT SWAP 0 ) 15 detects the excessive current and stops the output so that the adapter card (ADP 1 ) 42 ′ operation stops. This gives no effect however on the adapter card (ADP 0 ) 41 ′ and the supply of power continues. Consequently, normal operation can continue. This continuation of normal operation is achieved since the entire device has a redundant structure.
[0009] When an electrical short occurs between the power supply and GND due to a problem within the power supply unit (PS 0 ) 7 stopping the output of the unit (PS 0 ) 7 , then the flow of current from the power supply unit (PS 1 ) 17 can be prevented due to a diode mounted on the output of the power supply unit (PS 0 ) 7 and the power supply unit (PS 1 ) 17 continues to supply power. Consequently, normal operation can continue since the entire device has a redundant structure.
[0010] Even in the case that an electrical short occurs between the power supply and GND due to a problem within the power supply unit (PS 1 ) 17 stopping the output of the unit (PS 1 ) 17 , the diode mounted on the output of the power supply unit (PS 1 ) 17 prevents the inflow of current from the power supply unit (PS 0 ) 7 . And the power supply unit (PS 0 ) 7 continues to supply power. Consequently, normal operation can continue since the entire device has a redundant structure.
[0011] The hot swap function for the hot swap circuits (HOT SWAP 0 ) 5 , 15 on the adapter cards (ADP 0 , ADP 1 ) 41 ′, 42 ′ here is disclosed in the known art such as in JP-A No. 519837/2003 (see abstract), etc.
[0012] As shown in FIG. 2 , the disk enclosure device (DES) 10 ′ can continue to supply normal power when one of the two power supply units (PS 0 , PS 1 ) 7 , 17 and the adapter cards (ADP 0 , ADP 1 ) 41 ′, 42 ′ becomes defective. However, when a pin in the connector 9 of the power supply unit (PS 0 ) 7 or the connector 19 of the power supply unit (PS 1 ) 17 for example becomes bent and an electrical short occurs between the power supply and GND, then power cannot be supplied and the entire disk enclosure device operation stops. The operation stops because both of the two power supply units (PS 0 , PS 1 ) 7 , 17 detect the excessive current and stop outputting power. So the supply of power to the adapter cards (ADP 0 , ADP 1 ) 41 ′, 42 ′ ends. When in the same way, a pin become bent on the connector 20 ′ of the adapter card (ADP 0 ) 41 ′ or on the connector 30 ′ of the adapter card (ADP 1 ) 42 ′ causing an electrical short between the power supply and GND, then, again, the two power supply units (PS 0 , PS 1 ) 7 , 17 detect excessive current and the supply of power to the two adapter cards (ADP 0 , ADP 1 ) 41 ′, 42 ′ stops. So the entire disk enclosure device operation stops.
[0013] In other words, the disk enclosure device (DES) 10 ′ of the related art has the problem that when any of the connectors 9 , 19 , 20 ′, 30 ′ becomes defective between the two power supply units (PS 0 , PS 1 ) 7 , 17 and the adapter cards (ADP 0 , ADP 1 ) 41 ′, 42 ′, and the backboard (BB) 8 ′, and causes an electrical short between the power supply and GND, then the operation of the entire device stops. So the safe operation cannot be guaranteed.
SUMMARY OF THE INVENTION
[0014] This invention provides a power supply device capable of continuing operation of the entire device even when one of the connectors between the plural power supply units and the plural adapter cards, and the backboard become defective, causing an electrical short between the power supply and GND.
[0015] The power supply device of this invention is capable of supplying power from a separate power supply unit, to a different one of the redundant hot swap circuits in each of the plural adapter cards. This invention is therefore capable of continuing operation of the entire device or in other words, continuing to supply power, even when an electrical short has occurred between the power supply and GND caused for example by a bent pin in one of the connectors of the adapter cards or the connectors for the power supply circuit units using insertable/removable live wires.
[0016] According to the present invention, there is supplied a power supply device which comprises at least two power supply units and the same number of adapter cards, each of the adaptor cards comprising a number of hot swap circuits at least equal to a number of the power supply units, wherein power from each of the at least two power supply units is supplied to a respective one of the hot swap circuits within each of the adapter cards.
[0017] According to the present invention, there is supplied a disk enclosure device which comprises the power supply device descried above.
[0018] According to the present invention, there is supplied a power supply method which comprises, supplying power from each of at least two power supply units to a respective one of a number of hot swap circuits within each of a number of adapter cards, wherein the number of hot swap circuits within an adaptor card is greater than or equal to the number of power supply units and the number of adaptor cards is equal to the number of power supply units.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is a circuit block diagram showing the basic structure of the power supply of an embodiment of this invention for use in disk enclosure devices; and
[0020] FIG. 2 is a circuit block diagram showing the basic structure of the power supply of the related art for use in disk enclosure devices.
DETAILED DESCRIPTION OF THE INVENTION
[0021] The power supply device of the preferred embodiment of this invention utilizes a redundant structure including two power supply circuit units, two adapter cards, and one backboard connected to them, and connectors connecting between the backboard and each of those power supply circuit units and adapter cards. Moreover, the redundancy is increased by adding a pair of hot swap circuits on each of the two adapter cards. The backboard includes a power supply line pattern for a first power supply system for supplying power from one of the power supply circuit units to one of the pair of hot swap circuits on the two adapter cards; and a second power supply system for supplying power from the other power supply circuit unit to the other one of the pair of hot swap circuits on the two adapter cards. The power supply line pattern installed on the backboard therefore preferably starts from each power supply circuit and respectively branches to each of the two adapters.
[0022] Each of the connectors connecting between the power supply circuit and the backboard are used in one power supply system. However, each of the connectors that connect between the adapter cards and the backboard is utilized in the two power supply systems.
[0023] Diodes are also installed on the outputs of each of the pair of hot swap circuits for each of the adapter cards. Each of the diode outputs on the same adapter card is preferably mutually connected to the other output. The input side of the DC/DC converter, which carries out DC to DC conversion, for supplying the specified power is preferably connected to the output side of the diodes.
[0024] This embodiment of the power supply of this invention is described next in detail while referring to the drawings.
[0025] FIG. 1 is an overall circuit block diagram showing the basic structure when the power supply of this embodiment of this invention is utilized in a disk enclosure unit (DES) 10 . As shown in the same structure in FIG. 2 , this disk enclosure unit (DES) 10 includes, a backboard (BB) 8 , and the connectors 9 , 19 , 20 , 30 . The connectors 9 , 19 , 20 , 30 are respectively connecting two power supply units (PS 0 , PS 1 ) 7 , 17 and two adapter cards (ADP 0 , ADP 1 ) 41 , 42 (PS 0 , PS 1 , ADP 0 , ADP 1 ) to the backboard (BB) 8 . This structure allows power to be continually supplied even if one unit among the power supply units (PS 0 , PS 1 ) 7 , 17 and adapter cards (ADP 0 , ADP 1 ) 41 , 42 becomes defective.
[0026] In this disk enclosure unit (DES) 10 , the structure of the two adapter cards (ADP 0 , ADP 1 ) 41 , 42 is different from the adapter cards (ADP 0 , ADP 1 ) 41 ′, 42 ′ of the dual system for the disk enclosure unit (DES) 10 ′ described using FIG. 2 .
[0027] In other words, the adapter card (ADP 0 ) 41 has a pair of hot swap circuits (HOT SWAP 0 , HOT SWAP 1 ) 5 , 6 . And the adapter card (ADP 0 ) 42 has a pair of hot swap circuits (HOT SWAP 0 , HOT SWAP 1 ) 15 , 16 . Consequently, there are dual (or redundant) hot swap circuits on each of the adapter cards. Besides the diodes 3 , 4 being connected to the respective hot swap circuits (HOT SWAP 0 , HOT SWAP 1 ) 5 , 6 , the output sides of these diodes 3 , 4 are mutually connected to each other and to the input side of the DC/DC converter (DD CON) 2 that carries out DC to DC conversion for supplying the specified power to the rear stages. Power is then supplied from the output side of the DC/DC converter (DD CON) 2 . Besides the diodes 13 , 14 being connected to the respective hot swap circuits (HOT SWAP 0 , HOT SWAP 1 ) 15 , 16 , the output sides of these diodes 13 , 14 are mutually connected to each other and to the input side of the DC/DC converter (DD CON) 12 that carries out DC to DC conversion for supplying the specified power to the rear stages. Power is then supplied from the output side of the DC/DC converter (DD CON) 12 .
[0028] The backboard (BB) 8 contains a power supply line pattern for supplying power from a power supply unit (PS 0 ) 7 to a hot swap circuit (HOT SWAP 0 ) 5 , 15 of each of the adapter cards (ADP 0 , ADP 1 ) 41 , 42 , and power from the other power supply unit (PS 1 ) 17 to the other hot swap circuit (HOT SWAP 0 ) 6 , 16 of each of the adapter cards (ADP 0 , ADP 1 ) 41 , 42 .
[0029] The first power supply system uses the connector 9 which connects the backboard (BB) 8 and one power supply unit (PS 0 ) 7 . The second power supply system uses the connector 19 which connects the backboard (BB) 8 and another power supply unit (PS 1 ) 17 . And two power supply systems use the connector 20 which connects one adapter card (ADP 0 ) 41 and the backboard (BB) 8 , and connector 30 which connects another adapter card (ADP 1 ) 42 and the backboard (BB) 8 . So the power supply line patterns formed on the backboard (BB) 8 described above include a pattern that branches from each of the connectors 9 , 19 to the both of connectors 20 , 30 .
[0030] In a disk enclosure unit (DES) 10 with this type of structure, the power from the power supply circuit unit (PS 0 ) 7 supplied via the connector 9 is branched at the power supply line pattern on the backboard (BB) 8 , and is sent via the connectors 20 , 30 to the hot swap circuit (HOT SWAP 0 ) 5 of the adapter card (ADP 0 ) 41 the hot swap circuit (HOT SWAP 0 ) 15 of the adapter card (ADP 1 ) 42 . Power from the power supply circuit unit (PS 1 ) 17 supplied via the connector 19 branches in the same way at the power supply line pattern on the backboard (BB) 8 , and is sent via the connectors 20 , 30 to the hot swap circuit (HOT SWAP 1 ) 6 of the adapter card (ADP 0 ) 41 and the hot swap circuit (HOT SWAP 1 ) 16 of the adapter card (ADP 1 ) 42 .
[0031] The operation in this disk enclosure unit (DES) 10 when a breakdown occurs in one of the connectors 9 , 19 , 20 , and 30 will now be described.
[0032] When a pin in the connector 9 possessing insertable/detachable pins in the power supply circuit unit (PS 0 ) for example becomes bent, and causes an electrical short between the power supply and GND, the power supply circuit unit (PS 0 ) 7 detects the excessive current and stops the power output so that the supply of power to the hot swap circuit (HOT SWAP 0 ) 5 of adapter card (ADP 0 ) 41 and the hot swap circuit (HOT SWAP 0 ) 15 of adapter card (ADP 1 ) 42 stops. However, since the power supply circuit unit (PS 1 ) 17 possesses a redundant structure, power continues to be supplied to the hot swap circuit (HOT SWAP 1 ) 6 of adapter card (ADP 0 ) 41 and the hot swap circuit (HOT SWAP 1 ) 16 of adapter card (ADP 1 ) 42 . Operation of the disk device therefore continues. Consequently, operation of the entire device can continue due to the redundant structure.
[0033] In the same way, even if a pin in the connector 19 possessing insertable/detachable pins in the power supply circuit unit (PS 1 ) 17 for example becomes bent, and causes an electrical short between the power supply and GND, the power supply circuit unit (PS 1 ) 17 detects the excessive current and stops the power output so that the supply of power to the hot swap circuit (HOT SWAP 0 ) 6 of adapter card (ADP 0 ) 41 and the hot swap circuit (HOT SWAP 1 ) 16 of adapter card (ADP 1 ) 42 stops. However, since the power supply circuit unit (PS 0 ) 7 possesses a redundant structure, power continues to be supplied to the hot swap circuit (HOT SWAP 0 ) 5 of adapter card (ADP 0 ) 41 and the hot swap circuit (HOT SWAP 0 ) 15 of adapter card (ADP 1 ) 42 . Operation of the disk device therefore continues. Consequently, operation of the entire device can continue due to the redundant structure.
[0034] On the other hand, when a pin in the connector 20 that supplies power to the hot swap circuit (HOT SWAP 0 ) 5 of the adapter card (ADP 0 ) 41 becomes bent, and causes an electrical short between the power supply and GND, then the power supply circuit unit (PS 0 ) 7 detects the excessive current and stops the power output so that the supply of power to the hot swap circuit (HOT SWAP 0 ) 5 of adapter card (ADP 0 ) 41 and the hot swap circuit (HOT SWAP 0 ) 15 of adapter card (ADP 1 ) 42 stops. However since the power supply circuit unit (PS 1 ) 17 possesses a redundant structure, power continues to be supplied to the hot swap circuit (HOT SWAP 1 ) 6 of adapter card (ADP 0 ) 41 and the hot swap circuit (HOT SWAP 1 ) 16 of adapter card (ADP 1 ) 42 . Operation of the disk device therefore continues. Consequently, operation of the entire device can continue due to the redundant structure.
[0035] Likewise, even if a pin in the connector 20 that supplies power to the hot swap circuit (HOT SWAP 1 ) 6 of the adapter card (ADP 0 ) 41 becomes bent, and causes an electrical short between the power supply and GND, the power supply circuit unit (PS 1 ) 17 detects the excessive current and stops the power output so that the supply of power to the hot swap circuit (HOT SWAP 1 ) 6 of adapter card (ADP 0 ) 41 and the hot swap circuit (HOT SWAP 1 ) 16 of adapter card (ADP 1 ) 42 stops. However since the power supply circuit unit (PS 0 ) 7 possesses a redundant structure, power continues to be supplied to the hot swap circuit (HOT SWAP 0 ) 5 of adapter card (ADP 0 ) 41 and the hot swap circuit (HOT SWAP 0 ) 15 of adapter card (ADP 1 ) 42 . Operation of the disk device therefore continues. Consequently, operation of the entire device can continue due to the redundant structure.
[0036] If on the other hand, a pin in the connector 30 that supplies power to the hot swap circuit (HOT SWAP 0 ) 15 , of the adapter card (ADP 1 ) 42 becomes bent, and causes an electrical short between the power supply and GND, then the power supply circuit unit (PS 0 ) 7 detects the excessive current and stops the power output so that the supply of power to the hot swap circuit (HOT SWAP 0 ) 5 of adapter card (ADP 0 ) 41 and the hot swap circuit (HOT SWAP 0 ) 15 of adapter card (ADP 1 ) 42 stops. However since the power supply circuit unit (PS 1 ) 17 possesses a redundant structure, power continues to be supplied to the hot swap circuit (HOT SWAP 1 ) 6 of adapter card (ADP 0 ) 41 and the hot swap circuit (HOT SWAP 1 ) 16 of adapter card (ADP 1 ) 42 . Operation of the disk device can therefore continue. Consequently, operation of the entire device can continue due to the redundant structure.
[0037] If however a pin in the connector 30 that supplies power to the hot swap circuit (HOT SWAP 1 ) 16 of the adapter card (ADP 1 ) 42 becomes bent, and causes an electrical short between the power supply and GND, then the power supply circuit unit (PS 1 ) 17 detects the excessive current and stops the power output so that the supply of power to the hot swap circuit (HOT SWAP 1 ) 6 of adapter card (ADP 0 ) 41 and the hot swap circuit (HOT SWAP 1 ) 16 of adapter card (ADP 1 ) 42 stops. However since the power supply circuit unit (PS 0 ) 7 possesses a redundant structure, power continues to be supplied to the hot swap circuit (HOT SWAP 1 ) 5 of adapter card (ADP 0 ) 41 and the hot swap circuit (HOT SWAP 1 ) 15 of adapter card (ADP 1 ) 42 . Operation of the disk device can therefore continue. Consequently, operation of the entire device can continue due to the redundant structure.
[0038] The power supply device of this invention is not limited to disk enclosure devices and may be applied to all types of devices requiring a stable supply of power such as computers, control devices, and measuring devices.
[0039] The present invention is not limited to the embodiment described above. For example, to give more redundancy, thus more stable supply, the power supply device with any plural number, exemplary 3 or 4 , of power supply units, adapter cards and hot swap circuits on an adapter card can be embodied by this invention. | A power supply device which comprises at least two power supply units and the same number of adapter cards, each of the adaptor cards comprising a number of hot swap circuits at least equal to a number of the power supply units is disclosed. In the power supply device power from each of the at least two power supply units is supplied to a respective one of the hot swap circuits within each of the adapter cards. | 8 |
FIELD
[0001] The present disclosure relates to systems and method for analyzing noise emitted from one or more noise sources, and more particularly to a system and method for processing time series data obtained from a plurality of acoustic arrays to analyze one complex noise source, or a plurality of complex, spatially separated and/or distributed noise sources.
BACKGROUND
[0002] The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.
[0003] In noise detection and analysis systems, acoustic transducers such as microphones are employed to collect noise signals emanating from one or more noise sources. However, single, omni-directional microphone measurements are incapable of discriminating between different noise signals emanating from multiple, and typically spatially separated and/or distributed, noise sources. The presence of multiple noise sources severely complicates the analysis of correlation data from the microphones.
[0004] An example of a difficult noise correlation problem is the noise radiated simultaneously from the inlet and exhaust nozzles of a jet aircraft engine, that is, two spatially separated noise sources. The inlet/exhaust noise sources separately radiate outwards to the external measurement field. If the inlet noise and the exhaust noise contain a noise signal emanating from a common source, for example a particular component or surface within the jet engine, then they can have a measurable degree of correlation in the external measurement field. The first challenge is thus determining whether or not the inlet and exhaust noise sources are correlated. This is complicated by noise from other various components of the engine that emanate from the engine or the downstream exhaust flow and are picked up by the microphones, as well as extraneous noise sources (e.g., vehicles operating in the area; aircraft flying overhead; construction work) existing in the measurement environment that is picked up by the microphones. These forms of extraneous noise, both coming from within and external to the engine and from sources remote from the engine, are picked up by the microphones and operate to “mask” the existence of any noise signal having a correlation that is picked up by the microphones.
[0005] In the above described example, even if a correlation between two noise signals, picked up by two spatially separated microphones, is determined to exist, then the next challenge is to determine the locations in the external measurement field at which the correlation values are a maximum (or of meaningful high level). Still another challenge is the determination of the spatial extent (in the measurement field) of the correlation which arises from spatially distributed noise sources. An example of such spatially distributed noise sources might be correlated noise sources along a wing flap trailing edge; correlated noise sources within the jet mixing region downstream of the jet engine exhaust nozzle; etc.
[0006] From the foregoing, it will be appreciated that determining when a correlation exists between two spatially separated noise sources presents significant challenges. Determining the locations within the measurement field where the correlations are a maximum, as well as the spatial extent within the measurement field where the maximum correlation exists, represent even further significant challenges with presently available noise monitoring/measuring systems and methods.
SUMMARY
[0007] In one aspect the present disclosure relates to a method for detecting the presence of a noise signal within a noise measurement field, where the noise measurement field includes a noise signal emanating from a noise source, and where the noise signal is mixed with extraneous noise existing within the noise measurement field. The method may comprise: using a plurality of acoustic transducers arranged in a plurality of arrays to monitor the noise measurement field at a plurality of spatially separated locations; sampling outputs from said acoustic transducers to generate time series data; and processing said time series data to identify whether said noise signal is present.
[0008] In another aspect a method is disclosed for determining a relationship between acoustic noise signals originating from acoustic waves radiating from multiple sources, where the multiple noise sources are located within a noise measurement field. The method may comprise: using a plurality of acoustic transducers arranged in first and second arrays to monitor the noise measurement field at a plurality of spatially separate locations within the noise measurement field; sampling electrical signals output from said acoustic transducers and generating time varying signals therefrom; processing said time varying signals by aligning the signals originating at the same time from a given spatial location into a delayed-time representation data set and generating an averaged time varying signal from each respective delayed-time representation data set from each of said first and second arrays; and analyzing said averaged time varying signals to determine a correlation between noise signals originating from said first and second arrays.
[0009] In another aspect the present disclosure provides a system for determining a relationship between acoustic noise signals originating from acoustic waves radiating from multiple sources, where the multiple noise sources are located within a noise measurement field. The system may comprise: a plurality of acoustic transducers arranged as acoustic phased array antennas in first and second arrays to monitor the noise measurement field at a plurality of spatially separate locations within the noise measurement field, the acoustic transducers adapted to generate electrical signals in response to reception of acoustic signals present within the noise measurement field; an array processing subsystem including beamforming algorithms to generate time series data therefrom; and a signal processing subsystem adapted to process said time series data and to generate a first averaged time varying signal associated with an output said first array, and a second time varying signal associated with an output from said second array, and further adapted to analyze said first and second averaged time varying signals to determine a correlation between noise radiating from said multiple sources.
[0010] Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.
[0012] FIG. 1 is a perspective view of a system in accordance with one embodiment of the present disclosure set up to monitor noise emanating from two spatially separated locations of a jet engine;
[0013] FIG. 1A is a diagram illustrating how the transducers that make up the two arrays may be selected;
[0014] FIG. 2 is a flowchart setting forth basic operations performed by the system shown in FIG. 1 in analyzing noise emanating from two spatially separated locations; and
[0015] FIG. 3 is a perspective view of another implementation of a system in accordance with the present disclosure in which a plurality of beam steered phased arrays, each having randomly distributed acoustic spiral arm transducers, are used to monitor noise signals emanating from a moving mobile platform, in this example a jet aircraft.
DETAILED DESCRIPTION
[0016] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses.
[0017] Referring to FIG. 1 , a system 10 for analyzing one noise source, or a plurality of spatially separated noise sources, is illustrated. In this example two spatially separated noise sources 12 and 14 are shown being at the primary exhaust nozzle 16 and fan exhaust nozzle 18 , respectively, of a jet engine 20 while the engine is operating. The noise sources 12 and 14 can be thought of as being positioned within a noise field shown in dashed lines 22 . The noise field 22 forms a complex noise field that includes not only the noise emanating from the first and second noise sources 12 and 14 but also from extraneous noise sources such as the engine generated noise in the downstream exhaust region, wind, other vehicles operating in a vicinity of the noise field 22 , aircraft and/or rotorcraft flying over the noise field, just to name a few. Thus, it will be appreciated that while two primary noise sources 12 and 14 are present in the noise field 22 , typically noise will exist from one or more additional sources as well.
[0018] It will also be appreciated that the present system 10 is not limited to use in analyzing only two distinct, spatially separated noise sources, but rather is equally well suited to analyzing one, three, four or more distinct and/or spatially distributed noise sources. Furthermore, the noise sources do not need to be stationary, as illustrated in FIG. 1 , but rather could involve moving mobile platforms, as will be discussed in connection with FIG. 3 . The system 10 and method of the present disclosure is expected to find particular utility in analyzing noise emitted and/or emanating from various areas or components of a jet aircraft. However, the system 10 and method of the present disclosure is equally well suited to analyzing noise associated with the operation of any form of fixed structure, or any form of mobile platform such as a land vehicle (car, truck, or bus) or a train. Still other potential applications may include analyzing noise associated with the operation of other forms of airborne mobile platforms such as rotorcraft, spacecraft and various forms of unmanned airborne vehicles. Still other potential applications may include analyzing noise associated with the operation of surface and underwater marine vessels.
[0019] In FIG. 1 the system 10 includes a plurality of acoustic transducers 24 that can be selected by the system 10 to form one, two or more acoustic phased array antennas. For convenience, the transducers 24 in FIG. 1 are shown forming two arrays, i.e., a first acoustic phased array antenna 26 (hereinafter simply the “first array” 26 ) and a second acoustic phased array antenna 30 (hereinafter “second array” 30 ). The first and second arrays 26 and 30 are further arranged in a desired orientation, for example along a longitudinal line or path 32 . However, the arrays 26 and 30 do not necessarily need to be arranged along a longitudinal path, as will be discussed further in the following paragraphs. Instead, the first and second arrays 26 and 30 could be located at any position within the noise field 22 , or possibly to form a dome or sphere around the noise source(s). The distance from each acoustic transducer 24 to the noise source is further known or assumed.
[0020] In the general case, beamforming measurements can first be made over a volume in space in order to determine the spatial extent and locations of noise sources. The beamforming spatial region may be restricted to, for example, a plane (e.g., a plane which cuts through the engine axis) or to a single line of interest (e.g., the engine axis centerline/rotation axis).
[0021] The acoustic transducers 24 are also preferably spatially separated from one another to provide non-redundant acoustic transducer-to-acoustic transducer spacing between any two of the acoustic transducers 24 . This non-redundant spacing technique inhibits spatial aliasing (i.e., false images) as is well known in the art.
[0022] It will be appreciated that while the arrays 26 and 30 are shown adjacent to one another, that they could also be arranged to overlap one another by a desired amount. This would allow for the determination of the relationship between the beamformed time series outputs of each of the arrays 26 and 30 when the relative spatial location of each array is changed. For example, with reference to FIG. 1A , the locations of transducers 24 of array 26 could be fixed, while the transducers 24 that are selected to form array 30 are varied. As an illustration of this, in FIG. 1A the initial selection of transducers 24 for array 30 is selected to be the exact same transducers as those that are designated to form array 26 , as indicated by dashed line A. Thus, the 9 transducers 24 (represented by squares) within dashed line A will be considered as all belonging to both array 26 and array 30 . In this case the outputs of both arrays 26 , 30 will be identical and there will be a perfect relationship between the beamformed time series output of each array.
[0023] The next selection of transducers 24 for array 30 could then include that group of transducers shown in FIG. 1A as being circled by dashed line B. This new selection of transducers 24 for array 26 is similar to the initial selection but now only overlaps a portion of array 26 (now designated by dashed line A), and thus shares only a portion of the transducers used for array 26 . In general, the relationship (i.e., magnitude of correlation) between the beamformed time series output of array 30 (represented by dashed lines B) and the output of the transducers 24 forming array 26 will typically now be less than in the preceding case. The spatial distance D 1 represents the spatial distance between the phase centers of the two arrays 26 and 30 . It will be appreciated, however, that any subset of microphones can be used to define an array. Both the number of microphones and length of the array subsets can be varied.
[0024] Subsequently, a new group of transducers 24 may be selected to form array 30 , as indicated by dashed line C, and will have spatial distance from array 26 represented by line D 2 . The output from array 30 (represented by dashed lines C) will have a correlation with the output from array 26 that may be even smaller yet than the previously selected transducers 24 (i.e., those indicated by dashed lines B). Finally, another group of transducers 24 within dashed lines D may be selected to form the array 30 . This group will have a spatial distance D 3 separating the phase centers of array 30 and array 26 . The magnitude of the correlation between the outputs of array 30 and array 26 may be even less than the previous selection of transducers 24 for the array 30 (i.e., those represented by dashed line C). This process thus yields the variation in space of the relationship between the array 30 output beamformed time series and the stationary (fixed location) array 26 beamform output time series. It will be appreciated that while in this example the transducers 24 selected for the array 26 have not changed, that the locations and selection of the transducers used for array 26 could also be varied.
[0025] In FIG. 1 the system 10 also includes a first array processing subsystem 34 and a second array processing subsystem 36 . The first array processing subsystem 34 includes suitable array processing algorithms that incorporate beamforming algorithms to generate beamformed time series data from the electrical output signals provided by each of the transducers 24 that form the first array 26 . Similarly, the second array processing subsystem 36 also includes suitable array processing algorithms that incorporate beamforming algorithms to generate beamformed time series data from the electrical output signals generated by the transducers 24 that are forming the second acoustic array 30 .
[0026] The electrical output signals from all transducers 24 are sampled simultaneously and recorded to computer hard disk. The first array processing subsystem 34 selects the electrical output signals from all of the transducers 24 of the first array 26 to generate the acoustic transducers 24 time series data (i.e., time varying electrical signals) from the first array 26 , while the second array processing subsystem 36 samples the electrical output signals (i.e., time varying electrical signals) from the second array 30 . In effect, the time varying signals from the acoustic transducers 24 of each array 26 , 30 are delayed in time in such a manner that an acoustic wave (i.e., noise wave) propagating from a given assumed noise source location will be registered at the same relative instant in the delayed-time representation of the data from the transducers 24 of array 26 , and at the same instant in the delayed-time representation of the data from the transducers 24 forming array 30 .
[0027] Thus, it will be understood that typically, the data is acquired simultaneously from all of the transducers 24 and then the data is saved to a computer disk. After the data has been written to disk, then one can then select whatever subsets of transducers one would like to employ for the first and second array correlation analyses. As noted later herein, though, one could imagine a “real-time system” for which the first and second arrays are mobile arrays and where the location of one of the arrays is continually changed in order to probe the noise field in order to determine the two array locations at which a desired correlation exists between the beamformed time series data output by the two arrays.
[0028] The delayed-time representation signals from all transducers 24 of array 26 are then summed together, and the signals from the transducers 24 of array 30 are separately also summed together. Since the signal of interest (the propagating noise wave) occurs at the same time instant in the delayed-time representation, the summation will produce a summed (reinforced) representation of the signal of interest, whereas all other signal components which are not in phase with the signal of interest will be suppressed. The values of the summed signals are then divided by the number of transducers used in the process (i.e., for each array 26 or 30 ) in order to provide the average (beamformed) time series representation of the signal arriving from the assumed source location.
[0029] By averaging the time series data from the first array processing subsystem 34 , the first averaged time varying signal effectively provides a spatially filtered representation of the noise signal emanating from first noise source location 12 with noise from other sources being suppressed. Also, this serves to reinforce the acoustic waves radiating from the first noise source location 12 that are picked up by the acoustic transducers 24 and used to provide the data that forms the first averaged time varying signal (i.e., beamformed time series) from array 26 . Similarly, the second averaged time varying signal from array 30 provides a spatially filtered representation of the noise signal emanating from the second noise source location 14 and suppresses noise from other sources besides the second noise source 14 .
[0030] This operation effectively serves to “beam-steer” the time series data being generated by each array processing subsystem 34 and 36 in the time domain, which results in beamformed time series data (having amplitude and a phase) in which noise sources other than the noise source of interest (i.e., noise sources 12 and 14 ) have been removed. This is a well-known method familiar to those skilled in the art and is referred to as “delay-and-sum” beamforming. However, the system and method of the present disclosure is not limited to the time-domain delay-and-sum beamforming methodology, but may just as well include frequency-domain beamforming methods and techniques. These methods allow for measurements of the noise originating at a location of interest to be reinforced while simultaneously suppressing the contributions from noise sources originating at locations other than the location of interest. It will be appreciated also that this beam-steering operation may instead be performed in the frequency domain through the vector product of the complex conjugate of the frequency domain steering vector with the vector of microphone spectral levels (both amplitude and phase) at a given frequency.
[0031] It will also be appreciated that the transducers 24 used to form the arrays 26 and 30 preferably all remain physically fixed in location (relative to the ground surface) during the entire test. This enables beamforming to be accomplished by the transducers 24 . Beamforming is a significant advantage because the transducers 24 do not need to be physically moved around (i.e., physically “steered”) during tests (although such could be done).
[0032] It will also be appreciated that in the industry, hand held/portable phased array systems are being developed and used for quick and easy localization of noise sources for a wide variety of applications (automobile engine/tire/sideview mirror noise, office room noise, etc.). The present system and method could easily be used with such devices. For example, one could place one of the portable arrays at one location and then use a hand held second array to move about the noise field until a desired correlation is achieved between the beamformed time series being output by the two arrays.
[0033] The system 10 further includes a signal processing subsystem 38 that may comprise a digital signal processing (DSP) subsystem. For convenience, this subsystem will be referred to simply as the “DSP subsystem” 38 . The DSP subsystem 38 receives the beamformed time series data from outputs 34 a and 36 a of the array processing subsystems 34 and 36 , respectively, and uses standard digital signal processing methods to analyze the correlation between the two averaged, time varying signals (i.e., between the beamformed time series signals). The signal processing methods include standard methods familiar to practitioners of the art, such as cross-correlation, cross-spectra, coherence and phase properties between the time varying signals. Also, it will be appreciated that the signal processing methods employed with the system 10 and method of the present disclosure are not limited to analysis of only two time varying signals (auto- and cross-power spectral analyses). Rather, the signal processing methods chosen for use may, employ polyspectral analyses wherein a mutual relationship among three or more array beamformed time series data are analyzed to determine the higher-order relationships amongst them (which, for three signals, includes calculations of the auto-bispectra, cross-bispectra, bicorrelations, auto-bicoherence spectrum, and so on). This may involve initially identifying if a correlation exists between the two time varying beam-steered signals.
[0034] The identification of the existence of a correlation between the two signals signifies that a common noise component is being received by both of the first and second arrays 26 and 30 . Put differently, this would mean that a noise signal emanating from the first noise source 12 is similar in content to the signal emanating from the second noise source 14 . This is because if the noise emanating from the two noise sources 12 and 14 is originating from a common source, in this example from the same common cause within the engine 20 , then they will have a measureable degree of correlation within the noise measurement field 22 .
[0035] The DSP subsystem 38 may also use suitable signal processing techniques to determine an approximate location within the external noise measurement field 22 at which the correlation between the two beamformed time series signals is at a maximum, as well as the spatial extent within the noise measurement field 22 of the correlation. This can be done (as described above with regard to FIG. 1A ) by fixing the location and distribution of transducers in one array and then varying the location (and possibly the distribution of transducers) in a second array. It may be that, as the separation distance metric between the two arrays is increased, the correlation between the beam-steered time varying signals from both arrays continuously decreases.
[0036] When the level of correlation decreases below some defined value, the array separation distance at which this occurs can be used to define a maximum correlation length (or correlation distance) between the fixed and the separated arrays over which a relationship is defined to exist. For some combination of transducer distributions and array location (other than the case where the two arrays are identically co-located and the correlation is a maximum), there may be a result for which the correlation between arrays initially decreases as the second array's separation distance from the first array increases, but then the correlation increases with further increases (to a local maximum in correlation value) at larger array separation distances. For example, the spatial extent in this example might be the determination that the correlation exists along a wing flap trailing edge, or that the correlation exists within the jet mixing region downstream of the exhaust nozzle 16 of the jet engine 20 . In the jet engine example, since it is known that jet noise radiates outwardly with a particular radiation pattern, for example containing two distinct lobes, then the first and second arrays 26 and 30 could be positioned along the known lobe radiation directions to determine the correlation, if any, between noise signals emanating along these paths, as well as to determine the extent of the regions over space for which the correlation exists.
[0037] Referring further to FIG. 1 , the display system 40 may be used to graphically display correlation information to a user for analysis. The display system may comprise a liquid crystal display (LCD), a cathode ray tube (CRT) display or any form of display that is suitable for displaying a graphic representation of the correlation information.
[0038] Referring to FIG. 2 , a flowchart 100 is shown that summarizes operation of the system 10 . The transducers 24 are selected that will form each of the first array 26 and the second array 30 , such that the arrays 26 and 30 are initially arranged within the noise field 22 at desired locations relative to the spatially separated noise sources 12 and 14 , as indicated at operation 102 . At operation 103 , with the noise source being active, the outputs of all acoustic transducers 24 are simultaneously sampled and recorded to computer hard disk. However, as noted earlier, “real-time” systems could be used (that is, data would not have to be recorded to disk since the beamforming could be accomplished using a specially built “beamforming chassis”. At operation 104 the first and second array processing subsystems 34 and 36 select the outputs from acoustic transducers 24 of the two spatially separated arrays 26 and 30 which have been recorded to computer disk at operation 103 . At operation 106 the array processing subsystems 34 and 36 each take the signals from the arrays 26 and 30 and align their respectively received signals to produce time series data (i.e., a delayed-time representation data set) representative of the electrical signals being received form their associated arrays 26 and 30 .
[0039] At operation 108 the DSP subsystem 38 generates a pair of averaged time varying (beamformed time series) signals from the time series data provided at the outputs 34 a and 36 a of the two array processing subsystems 34 and 36 . At operation 110 the DSP subsystem 38 analyzes the two, time varying signals (i.e., the beamformed time series) to determine a correlation, if any, between the two averaged, time varying signals. At operation 112 the DSP subsystem 38 may determine the spatial extent within the noise measurement field 22 where the correlation exists as well as where, within the noise field, that the correlation is at a maximum. At operation 114 the correlation information may be displayed on the display system 40 . Various commercially available software systems, for example MATLAB® offered by Mathworks of Natick, Mass., may be used for this purpose. This process may then be repeated one or more times by selecting different groups of transducers to form either of the first or second arrays 26 and 30 .
[0040] The system 10 can be further enhanced if a pressure transducer is positioned at or near the source region of interest (e.g., at a wing flap edge, near the lip of a jet engine inlet or near the inner edge of the fan/primary exhaust nozzle exits of a jet engine). This would allow for additional levels of correlation analyses in both static and flight test measurements.
[0041] Referring to FIG. 3 , a system 200 is shown for determining noise correlation but for a traveling mobile platform, in this example a flying jet aircraft 202 . It will be appreciated that the system 200 makes use of the array processing subsystems 34 and 36 , the DSP subsystem 38 and the display system 40 , although these subsystems are not illustrated in FIG. 3 . In the system 200 three arrays 204 , 206 and 208 are arranged contiguously on the ground 210 along a known flight path of aircraft 202 . Each array 204 - 208 may be formed by strategically positioned acoustic transducers 204 a, 206 a and 208 a, respectively, such that each array forms a multi-arm log spiral phased array antenna or any such distribution of transducers appropriate for the article being tested. The arrays 204 - 208 provide the beamformed time series data necessary for determining the correlation, if any, between the noise signals radiating from and associated with the aircraft and measured by the arrays 206 - 208 .
[0042] The configuration of the arrays 204 - 208 would provide the added benefit of obtaining multiple measurements of flight test aircraft noise for statistical analysis as opposed to a single measurement from arrays having co-located phase centers, since multiple, spatially separated (i.e., statistically independent) measurements would be acquired. In this embodiment the system 200 can also be used to determine array aperture size effects on the outputs of the arrays 204 - 208 . Each of the arrays 204 - 208 may be further decomposed into smaller sets of subarrays. Correlations of the output between these additional subarrays of, for example, array 206 a, can be used to study the effects of acoustic wave decorrelation across the arrays as the aperture size is varied.
[0043] It will also be appreciated that it is possible to create a “dome” or “sphere” surrounding the noise source, with transducers (i.e., microphones) “peppering” the inner surface so that correlations can be measured between any two array locations on the sphere.
[0044] The system 10 and method of the present disclosure thus enables noise correlation information to be obtained from a single or from spatially separated and/or distributed noise sources. A significant advantage of the present system 10 and method is that extraneous noise is filtered from the beamformed output time series from the array processing subsystems 34 and 36 . This enables a correlation between noise signals from spatially separated sensors to be much more easily detected and analyzed by the DSP subsystem 38 .
[0045] The present disclosure is inclusive of frequency domain beamforming/beam-steering and array signal processing methods for providing the averaged time varying signals from the first and second arrays. Mutual correlations among three (or more) arrays can be determined using polyspectral methods.
[0046] While various embodiments have been described, those skilled in the art will recognize modifications or variations which might be made without departing from the present disclosure. The examples illustrate the various embodiments and are not intended to limit the present disclosure. Therefore, the description and claims should be interpreted liberally with only such limitation as is necessary in view of the pertinent prior art. | A method for detecting the presence of a noise signal within a noise measurement field, where the noise measurement field includes a noise signal emanating from a noise source, and where the noise signal is mixed with extraneous noise existing within the noise measurement field. The method involves using a plurality of acoustic transducers arranged in a plurality of arrays to monitor the noise measurement field at a plurality of spatially separated locations. Outputs of the transducers are sampled to generate time series data. The time series data is processed to identify whether the noise signal is present. | 7 |
BACKGROUND OF THE INVENTION
Field of the Invention
The invention relates to what is known as a “safety trocar” which, in accordance with the present invention, has enhanced safety features and also has a lancet function.
As is well known in the industry, trocars are elongated sharp objects which are particularly used for making an incision in the course of surgical procedures, especially laparascopic and endoscopic procedures.
Such devices are used to penetrate the body wall, and thereby position a canula or tube through the body wall through which surgical instruments can be introduced for performing the desired surgical or medical procedures.
A long standing problem in the industry has been to provide suitable protection to underlying tissues and organs which might be damaged by an unshielded tip of a trocar. This problem is made more serious by virtue of the fact that the body wall gives substantial resistance to being pierced by the trocar, which then has the tendency to spring forward once the incision has been completed.
Many attempts have been made to provide suitable solutions to this problem. These various different attempts are too numerous to mention here. Nevertheless, despite these various efforts, the problem remains in the industry.
Based upon the foregoing, it is the primary object of the present invention to provide a trocar which has reliable and effective shielding and protection from injury to underlying organs and tissues.
It is a further object of the present invention to provide such a trocar which has additional functionality, specifically, in the form of a lancet.
SUMMARY OF THE INVENTION
In accordance with the present invention, the foregoing objects and advantages have been readily attained.
According to the invention, a trocar is provided which has a longitudinally moveable blade and also a longitudinally moveable trigger/shield member. As will be set forth in detail in the description below, a button and triggering assembly are provided which allow for a series of different operational positions of the trocar. These include a relaxed position wherein the sharp blade member of the trocar is proximally positioned, with the sharp tip of the trocar positioned proximally of both a distal housing portion of the trocar and also the shield member. In this position, the blade cannot be exposed regardless of position of the shield, and the blade is therefore completely shielded. The blade is also positionable to an armed position, wherein the blade is positioned distally so as to position the tip of the blade beyond the blunt housing tip, but not beyond the tip of the shield member. When armed, the blade is held in this position by a releasable lock member.
The trigger/shield member is freely moveable between an extended position wherein it extends beyond the tip of the trocar blade, even in the armed position, and a rearward position wherein the blade in the armed position can be exposed. The trigger/shield member is associated with the lock mechanism so that rearward movement of the trigger/shield member engages a ratchet or other surface with the blade lock, and forward movement of the shield member disengages the blade lock and thereby provides for the blade to withdraw proximally into the housing of the trocar.
Thus, in accordance with present invention, rearward movement of the trigger member caused by contact with body tissue to be pierced, followed by forward movement of the trigger member as the trigger member forces through the opening, disengages the blade and causes the blade to be withdrawn proximally into the housing of the trocar as desired. In this way, the blade is positioned into a safe location as soon as the incision is completed.
In accordance with a further embodiment of the invention, the trigger member is never locked in a forward position, but is rather only biased toward that position. Thus, trauma and injury to underlying tissues and organs from the trigger is also prevented.
In further accordance with the invention, the blade can be manually positioned to a distal location which extends beyond the distal-most position of the shield, and in this configuration the device can be used as a lancet as desired.
The structures and positions as described above will be more thoroughly described in connection with the detailed description presented below.
BRIEF DESCRIPTION OF THE DRAWINGS
A detailed description of preferred embodiments of the present inventions follows, with reference to the attached drawings, wherein:
FIG. 1 shows a trocar in accordance with the present invention in a relaxed position;
FIG. 2 shows a trocar in accordance with the present invention in an armed position;
FIG. 3 shows a trocar in accordance with the present invention with the blade and shield in a cutting position;
FIGS. 4 and 5 show a trocar in accordance with the present invention wherein the triggering assembly is being actuated;
FIG. 6 shows a trocar in accordance with the present invention with the blade positioned in a lancet position;
FIG. 7 illustrates an enlarged portion of the trocar of the present invention with the housing removed to illustrate functioning of the triggering assembly.
DETAILED DESCRIPTION
The invention relates to a shielded trocar with a lancet function. The trocar advantageously allows for enhanced shielding and security of the blade, and also allows for use of the blade as a lancet which broadens the usability of the surgical instrument as will be discussed below. Referring to the drawings, a preferred embodiment is illustrated. The drawings show sectional and to some extent perspective views to illustrate the details of the invention.
FIG. 1 shows a trocar 10 having a handle 12 positioned at a generally proximal end and a tip 14 positioned at a generally distal end.
According the invention, trocar 10 includes a substantially flat blade 16 which is slidably positioned relative to a tube or housing 18 . Blade 16 is mounted in a blade holder 20 which is also slidably positioned within tube 18 . A blade lock member 22 is pivotably mounted to blade holder 20 , and engagable in certain positions with tube 18 as will be discussed below. The entire assembly of blade 16 , blade holder 20 and blade lock member 22 are advantageously slidable within tube 18 and biased toward a proximal end of the device.
In further accordance with the invention, and still referring FIG. 1 , trocar 10 also advantageously includes a a substantially flat shield/trigger member 24 which is also slidably mounted within tube 18 , and shield 24 is longitudinally connected to a lock release member 26 . Shield 24 and lock release member 26 are advantageously biased by a spring in a distal direction relative to tube 18 .
The assembly of blade 16 , blade holder 20 and blade lock 22 are moveable along the axis of tube 18 between a withdrawn position wherein the sharpened tip of blade 16 is positioned within the housing, an extended locked position wherein sharp tip of blade 16 extends beyond the housing but not beyond extended shield 24 , and a lancet position wherein the sharp tip of blade 16 is extended beyond the extended distal tip of shield 24 .
This slidable movement is, as set forth above, dictated by influence of a spring and also by a handle button 28 which receives a connecting post 30 as well as a connecting sleeve 32 which are in contact with blade holder 20 as shown in FIG. 1 .
The assembly of shield member 24 and lock release member 26 are also advantageously axially moveable within tube 18 , and are biased toward a distal end of trocar 10 as discussed above. As will be discussed below, during use of trocar 10 to perform an incision, pressure is exerted upon shield 24 which causes shield 24 and lock release 26 to move proximally and allow the sharp tip of the blade in an armed position to be used for cutting.
Handle button 28 can advantageously be mounted within a proximally opening recess within a handle housing 34 for the device. Handle housing 34 can advantageously be shaped to fit comfortably within the hand of a user, and also preferably to mate with the housing of a canula (not shown) into which trocar 10 will be positioned.
FIG. 1 shows a spring 36 which advantageously can be positioned so as to exert force on blade holder 20 in a proximal direction and on shield 24 in a distal direction. This advantageously serves to bias both assemblies within tube 18 as desired.
Still further, a spring can advantageously be mounted to blade holder 20 for exerting a pivotable force on lock member 22 . This can advantageously be a coiled spring 38 which can be mounted to blade holder 20 with one arm 40 positioned between a spring block 42 and the back surface of a post holder 44 of blade holder 20 , and with a second arm 46 exerting a force on lock member 22 .
Trocar 10 still further advantageously includes two additional distal housing members 48 , 50 , which support shield 24 and blade 16 respectively.
Distal housing members 48 , 50 advantageously terminate in a blunt and rounded tip which is specifically designed and adapted to provide little or no risk of trauma or injury to any tissue which might contact same. Distal housing members 48 , 50 advantageously mount with or are otherwise connected to tube 18 and distal housing members 48 , 50 and tube 18 define the housing component of trocar 10 in accordance with the present invention.
FIGS. 2-5 illustrate the trocar of FIG. 1 with the components in various different positions.
Specifically, FIG. 2 shows trocar 10 with blade 16 , blade holder 20 and blade lock 22 locked in a distal armed position. In this position, lock 22 has a catch member 52 which is advantageously engaged against proximal movement, in this instance by extending into an opening or hole 54 in tube 18 . In this position, the sharp tip 56 of blade 16 extends beyond distal housing 48 , 50 , but is still overlapped by shield member 24 as shown. Trocar 10 is positioned in this configuration by depressing button 28 sufficiently that lock 52 engages with the opening 54 in tube 18 , and this engagement is advantageously visible from exterior of tube 18 so that a user can readily know whether trocar 10 is armed.
FIG. 3 shows the trocar in a position which would be accomplished during a cutting procedure. During such a procedure, shield 24 is pushed proximally against the bias of spring 36 so as to expose sharp tip 56 which pierces and penetrates the tissue as desired. The proximal movement of shield 24 also proximally moves lock release member 26 so as to engage a tooth 58 of lock release member 26 behind a portion of blade lock 22 as shown in FIG. 3 .
FIG. 4 shows the trocar of the present invention in a triggering position wherein the blade and shield have both now penetrated the body wall, and thus shield 24 is pushed distally by spring 36 . This distal movement of shield 24 positions shield 24 to again extend beyond the tip of blade 16 and causes lock release 26 to pivot lock 22 out of engagement with tube 18 . This is done by the distal movement of tooth 58 which causes trigger 22 to pivot relative to blade holder 20 in a clockwise motion and thereby disengage catch member or ridge 52 from the hole in tube 18 .
Turning to FIG. 5 , this action of lock release member 26 and subsequent disengagement of lock member 22 from tube 18 results in a proximal movement of blade 16 , blade holder 20 and blade lock member 22 driven by spring 36 so as to withdraw the sharp tip of blade 16 to within distal housing members 48 , 50 . It should be noted that when reference is made to the sharpened tip being “within” distal housing members 48 , 50 , what is meant is that the entire cutting edge of blade 16 is positioned at least coincident and preferably proximally of the extending blunt tip defined by distal housing members 48 , 50 .
From this position, it should be readily appreciated that absent depressing of button 28 , blade 16 is secured within the structure and cannot inflict any unintended damage to tissues and the like.
As set forth above, trocar 10 in accordance with present invention further has a lancet function which advantageously allows for blade 16 to be used to make cutting incisions as may be desired, regardless of the shield member.
FIG. 6 shows trocar 10 in this configuration, wherein a complete distal movement or depression of button 28 moves blade 16 , blade holder 20 and blade lock member 22 distally past the armed position to a position where the sharp tip 56 of blade 16 extends beyond shield 24 , even with shield 24 in the extended position. After the lancet function is completed, the trocar returns to the armed position as shown in FIG. 2 , and can be used for subsequent procedures as desired.
In accordance with the present invention, the blade lock 22 and lock release member 26 are shown in further detail in FIG. 7 .
FIG. 7 shows these components of trocar 10 in an enlarged manner and with tube 18 removed. Thus, FIG. 7 shows blade holder 20 with blade lock member 22 pivotably mounted within a recess 60 . This mounting defines a pivot point or axis of rotation of blade lock member 22 relative to blade holder 20 around the pivot point defined by recess 60 .
Further as shown, lock release member 26 has tooth member 58 which is adapted to proximally slide past and catch a downwardly projecting ledge or surface 62 of blade lock member 22 . To this end, tooth 58 can advantageously have a gradually sloping surface, which increases in height in a generally distal direction, and which thereby allows easy proximal movement of tooth 58 past surface 62 as desired.
FIG. 7 also shows the other end connection of lock release member 26 with shield 24 , in this instance with a distal end 64 of lock release member 26 having an opening 66 into which a protruding post 68 of shield member 24 extends. In this way, shield 24 and lock release member 26 are axially mounted one relative to the other. Of course, shield 24 and lock release member 26 can be connected in other ways.
It should be appreciated that blade lock member 22 is shown in the drawings to be pivotably mounted relative to the blade assembly and pivotably mounted relative to the blade assembly and pivotable into engagement with housing 18 . The reverse could also be true, with pivotable mounting of lock member 22 to housing 18 and pivot to engage the blade assembly.
It should also be noted that trigger/shield member 24 serves primarily as a trigger to cause retraction of the blade following an incision. In addition, the tip of trigger/shield 24 is relatively blunt and dull so as to serve a shielding function as well.
It should be readily appreciated that the trocar in accordance with the present invention advantageously provides for secure and safe positioning of the trocar through the body wall of a surgical patient while providing extraordinary protection to underlying tissues and organs from accidental or unintended injury during the procedure. Still further, the trocar in accordance with the present invention has an advantageous lancet function which provides additional useful employment of the trocar in accordance with the present invention.
The present description has been given as an exemplary embodiment of the present invention. It should readily be appreciated that these various components of the device can and would be provided from materials known to a person of skill in the art to be suitable for the intended purpose and to a suitable scale also for the intended purpose.
It should also be appreciated that various modifications of the parts and assembly of the present invention can be made and would still fall well within the scope of the present invention. Thus, the scope of the invention is defined by the amended claims, and the description given herein is in all respects to be treated as one example of the broad scope of the invention. | A trocar assembly includes a trocar housing having a blunt distal end and a proximal end; a blade assembly having a sharp tip and being slideable within the trocar housing between and armed position wherein the sharp tip extends distally beyond the blunt distal end and a relaxed position wherein the sharp tip is withdrawn proximally relative to the armed position; and a trigger member positioned relative to the housing to contact tissue when tissue is cut with the blade assembly in the armed position, and slideable by contact with the tissue to a proximal position which exposes the sharp tip and actuates a lock release member, the trigger member having member having a spring member biasing the trigger member distally so that removal of contact with the tissue allows the spring to move the trigger member distally, and further wherein distal movement of the trigger member with the lock release member activated releases the blade assembly from the armed position and allows the blade assembly to move to the relaxed position. | 0 |
BACKGROUND OF THE INVENTION
The invention relates to a safety device for all winches used in various hoisting and load-moving equipment. Such winches are driven by a motor via gears and the control lever is acted upon by the safety device.
A device of the invention is arranged to prevent excessive tension on the cable to be wound on the winch when a load drawn by the winch encounters resistance, this generally occurs at the end of the hoisting movement, and to prevent exaggerated unwinding of the cable when the load is interrupted in its descent by an obstacle, which generally occurs at the end of a downwards movement. A device of the invention may act at any point of the movement of the load if this movement is being impeded in some way, but it has no effect on the functioning of the winch when the load is moving freely.
The prior art in this field is illustrated by the disclosure in French Pat. No. 2,398,689. In this Patent, a safety device for the end of travel is added to the structure of a hoisting apparatus in the path of the metal cable between the winch and a first return pulley for the cable.
It is an object of this invention to provide a safety device which is designed to be combined with a gear and a winch so as to form a complete, compact unit which is independent of the structure of any hoisting apparatus.
Furthermore, in hoisting apparatus of the type comprising a truck moving on a ladder, the ladder often consists of a plurality of sections which slide telescopically into one another. When the ladder is extended by sliding the sections apart, cable has to be supplied progressively, which extends from the winch to the top of the last section of the ladder.
It is a further object of the invention to provide a compact device of the type mentioned hereinbefore which is improved so as to supply successive lengths of metal cable which unroll automatically from the winch as the ladder is extended.
SUMMARY OF THE INVENTION
According to the present invention there is provided a safety device for a winch having a rotatable drum on which cable means are arranged to be wound and unwound, the safety device comprising two spaced longitudinal elements between which said drum is arranged, each said longitudinal element extending away from the drum in the same direction, a first transverse element connecting the longitudinal elements, at least one telescopic sleeve pivotably mounted on said first transverse element, a calibrated spring being received within said telescopic sleeve, a second transverse element connecting the longitudinal elements, a yoke pivotably mounted on said second transverse element, a guide pulley for the cable means carried by said yoke, and an articulated linking member coupling said yoke to said telescopic sleeve and arranged to transmit to said sleeve the force exerted on the yoke by the tension of said cable means such that, when the tension of said cable means exceeds a predetermined value the spring causes the yoke to pivot.
According to a further aspect of the invention there is provided a safety device for a winch, the winch having a rotatable drum on which cable means are arranged to be wound and unwound, drive means for rotating the drum, gear means for connecting the drive means to rotate the drum, and the gear lever for selectively controlling the gear means, the safety device comprising two spaced longitudinal elements between which said drum is arranged, each said longitudinal element extending away from the drum in the same direction, a first transverse element connecting said longitudinal elements, a set of telescopic sleeves pivotably carried by said first transverse element, calibrated springs being received in said telescopic sleeves, a second transverse element connecting said longitudinal elements, a yoke pivotably mounted on said second transverse element, a guide pulley for the cable means carried by said yoke, and an articulated linking member coupling said yoke to said telescopic sleeves and arranged to transmit to said sleeves the force exerted on the yoke by the tension of said cable means such that, when the tension of said cable means exceeds a first predetermined value or falls below a second predetermined value the springs cause the yoke to pivot.
When the winch is of considerable width the longitudinal elements also extend in the opposite direction and are connected to two crosspieces serving to support and guide an orientatable winding pulley for the metal cable which, on being wound up, first of all passes over the guide pulley of the oscillating yoke.
A control lever is arranged to move with the gear lever, and the control lever is connected to the yoke by means of first and second articulated levers. The first lever is provided with two spaced bearing surfaces adapted to meet and manoeuver the control lever of the gears so as to return it to its neutral disengaged position after a specific course of travel in one direction or in the opposite direction. One of these bearing surfaces corresponds to the engagement of the gears for winding up the cable and the other corresponds to the engagement thereof for unwinding the cable.
In an embodiment a retractable member is provided which enables the first lever to be fixed to the control lever at will when the control lever is in the neutral disengaged position and the linking member is connected to the sleeves containing the calibrated springs by means of a coupling means which can be neutralized at will.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the present invention will hereinafter be described, by way of example, with reference to the accompanying drawings, in which:
FIG. 1 shows a plan view of a compact combined assembly comprising a winch and a safety device for the winch,
FIG. 2 is an elevation and section taken along ling II--II of FIG. 1 of the assembly in the neutral position,
FIGS. 3 and 4 are views similar to FIG. 2 indicating, respectively, the functioning of the safety device at the end of the downward travel and at the end of the upward travel of the load, and
FIG. 5 shows an elevation, analogous to FIG. 2, showing an embodiment of the safety device in use during the extension of a metal cable.
DESCRIPTION OF PREFERRED EMBODIMENTS
As is shown in FIGS. 1 to 4, a winch 1 is supported above a base 2 and is arranged to be rotationally driven by a motor (not shown) via gears 3 (omitted from FIG. 1 to make the drawing clearer). The gears 3 have a control lever 4 which is capable of occupying a neutral disengaged position N, an engaged position M for rolling metal cable 5 from the winch and lifting a load, and an engaged position D for unwinding the cable 5 and lowering a load under the restraint of the winch.
A safety device for the end of travel, generally designated 6, is designed to be combined with the gears 3 and the winch 1 and form with them a complete, compact assembly. This device 6 comprises two longitudinal elements 7, 8 spaced so as to contain the winch 1 between them. these elements 7, 8 are advantageously rigidly fixed to end plates 9, 10 between which the drum 11 of the winch 1 is located, and they extend beyond the drum 11 on the same side as the metal cable 5. The longitudinal element 8 is not shown in FIGS. 2 to 4.
A first transverse element 12 extends between the longitudinal elements 7, 8 and carries a set of two superimposed telescopic sleeves 13, 14 closed at their ends and each containing a calibrated spring 15, 16, respectively, the degree of compression of which can be regulated by adjusting means which are known per se. These springs 15, 16 are arranged on an extension of each other so as to act as will be explained hereinafter. In the embodiment illustrated, the sleeves 13, 14 form an assembly capable of pivoting as the transverse element 12 is pivotably mounted in the longitudinal elements 7, 8. Alternatively, the sleeves 13, 14 could be pivotably mounted relative to the transverse element 12, which could then be fixed relative to the longitudinal elements 7, 8.
More precisely, the lower part of the sleeve 13 is attached to the transverse element 12. The sleeve 13 has a slidable upper cap which carries the lower part of the sleeve 14, and the sleeve 14 has a slidable upper cap 22.
A second transverse element 17, which is more remote from the winch 1 than the first transverse element 12, extends between the longitudinal elements 7,8. The second transverse element 17 is supported by the longitudinal elements to be freely rotatable about a transverse axis 17A. This second transverse element 17 carries a yoke 18 in which there is mounted, in a freely rotatable manner, a guide pulley 19 for the metal cable 5. The pulley 19 can thus perform oscillating movements with the yoke 18 relative to the transverse axis 17A.
A linking member 20 functionally connects the assembly made up of the telescopic sleeves 13, 14 and the yoke 18, so as to transmit to the yoke the forces created by the springs 15, 16. In this embodiment, the linking member 20 has a U-shaped profile in the web of which there is an opening 21.
The sliding upper cap 22 of the sleeve 14 extends through the opening 21 until bearing surfaces 23 fixed to its free lower end abut the ends of the legs of the U-shaped member 20. Further, one side of the member 20 is articulated at 24 to the yoke 18 and the opposite side of the member 20 is articulated at 25 to a plate 26. The plate 26 is carried by the second transverse element 17 and oscillates with the yoke 18.
Preferably, and as illustrated, the yoke 18 and the pulley 19 are transversely offset relative to the sleeves 13, 14 in the space between the longitudinal elements 7, 8, so that the cable 5 has an unimpeded passage from the winch 1.
The control lever 4 of the gears 3 is generally a vertical lever.
The gear lever 4 is arranged to move a horizontal control lever 27 (omitted from FIG. 1) without play. Two further levers 28 and 29 articulated to each other at 30 functionally connected the yoke 18 and the horizontal lever 27. The first lever 28 is provided with two spaced bearing surfaces 31, 32 which are arranged to abut the control lever 27 and return it to its neutral disengaged position from either of the two engaged positions, by travelling along a predetermined path in one direction or in the opposite direction. The second lever 29 is arranged to move with the yoke 18. It may, therefore, be fixed either directly to the yoke 18 or as in this example, to the plate 26 depending on the relative arrangement of the different parts.
The device as described above operates as follows:
The normal position of the components during operation of the winch is shown in FIG. 2. The spring 15 is not under tension as long as the tension of the metal cable 5 does not exceed a predetermined value. The spring 16 is compressed as long as the tension of the cable does not fall below a predetermined value.
When the control lever 4 and hence the lever 27 has been put into its position D for unwinding the metal cable 5, for the controlled lowering of a load, the cable 5 exerts on the pulley 19 a force which keeps the spring 16 compressed. When this tension disappears as a result of the lowering of the load coming to an end, generally at the bottom of its downward movement, the spring 16 pushes the cap 22, and hence the linking member 20, thus causing the yoke 18 and the lever 29 to pivot relative to the axis 17A.
At the same time, the lever 28 is pushed back, so that the bearing surface 31 comes into contact with the control lever 27 in position D and pushes it back into position N. The disengagement thus produced puts an end to the unwinding of the cable 5. To hoist a load, the control levers 4 and 27 are put into position M. When the movement of the load ceases, generally at the top of its upward travel, the tension of the cable 5 increases until the force exerted on the pulley 19 causes pivoting of the yoke 18 and lever 29. As a result, the linking member 20 abuts on the bearing surfaces 23 and, via the cap 22 and the sleeve 14, the spring 15 is compressed inside the sleeve 13. During this movement, the lever 28 is pulled so that the upper bearing surface 32 makes contact with the control lever 27 in position M and pushes it back into its disengaged position N. The winch is thus stopped.
When the winch 1 is wide, the longitudinal elements 7 and 8 are extended on the other side of the winch 1 and are connected by two crosspieces 33 and 34. An orientable pulley 36 is pivotably mounted at 35 to the crosspiece 33. The pulley 36 is held in a yoke 37 provided with a support bearing 38 which rolls on the crosspiece 34. Thus, the cable 5 is guided while being wound on the drum of the winch.
A winch fitted with a safety device of the invention may be installed in a hoisting apparatus with a telescopic ladder which is used for guiding a truck. When this ladder is extended, the cable 5 has to be unwound progressively. The device described hereinbefore may be improved so that the unwinding of the cable takes place as required.
This improvement consists in making it possible to neutralize at will the coupling between the linking member 20 and the sleeves containing the calibrated springs.
In the embodiment shown in FIG. 5 a neutralized coupling means comprises the cap 22 provided with the bearing surfaces 23 which abut on the end face of the legs of the U-shaped linking member 20. The bearing surfaces 23 have a limited length in the direction of the perimeter of the cap 22, so that, by rotating the cap inside the opening 21, the bearing surfaces 23 can be placed inside the legs of the member 20. The spring 16 is totally unstressed when the bearing surfaces 23 approach the web of the U-shaped member 20, as shown in FIG. 5. Moreover, a retractable member 39 makes it possible to fixedly connect the first lever 28 to the control lever 27 at will. For example, a plate 39 having a shoulder portion 41 is articulated at one end about a pivot 40 located at the end of the control lever 27. When this plate 39 is positioned parallel to the lever 28 its shoulder portion 41 can be engaged just below the bearing surface 32 of the latter when the control lever 27 is in its neutral disengaged position N and the bearing surface 31 is located just below this lever.
When the safety device is in this state, with the springs 15 and 16 not in operation, any tension, however slight, exerted on the pulley 19 by the cable 5 during the extension of the telescopic ladder causes the yoke 18 of this pulley to pivot about the axis 17A in a direction which causes the lever 28 to move downwards. Immediately, the bearing surface 32 makes contact with the shoulder portion 41 and pushes the control lever 27 out of position N into position D, as shown in FIG. 5. The winch 1 is driven in the direction of unwinding of the cable 5. As soon as the tension in the latter disappears, the weight of the pulley 19 and the cap 18 causes an inverse return movement during which the bearing surface 31 returns the control lever 27 to the position N.
Returning to FIG. 2, it will be seen that the relative arrangement of the geometric pivot axes or axes of oscillation of the movable parts (yoke 18, sleeves 13, 14 of the calibrated springs) is chosen so that the moments of the forces brought into play remain substantially constant, despite the movements of the yoke 18 under the effect of the cable or the springs. Naturally, the metal cable 5 may be replaced by a cable of some other kind or a chain, without going beyond the scope of the invention.
As has already been stated, the device described above is a double action device. When its task is to stop the winch at the end of the upward travel of the load, it prevents excessive tension of the cable. Of course, any movement which causes excessive tension on the cable also causes the yoke 18 to pivot and hence disengages the winch. In particular, an excessive load fixed to the cable produces this result. The device of the invention thus also acts as a safety mechanism preventing overloading of the cable and winch and of the apparatus to which the winch and the device of the invention are fitted. In view of the fact that this protection, which prevents excessive tension on the cable and overloading to the apparatus as a whole, is greater than the protection which consists in preventing the cable from unwinding excessively, it would be possible, as a variant, to use the device of the invention solely for this purpose by dispensing with the sleeve 14 and the spring 16. In this case, the linking member 20 should be arranged so as to abut directly on the sliding cap of the sleeve 13. Only the bearing surface 32 of the lever 28 would be used to return the control lever 27 from position M to position N, as shown in FIG. 4. In this simpler form, the device of the invention affords safe protection against the greater danger, i.e. the danger of overloading, while retaining its quality of compactness and being easily combined with a winch. | The invention relates to a safety device for winch-type apparatus for moving loads.
Two longitudinal elements containing a winch between them are connected by a first transverse element on which two telescopic sleeves are pivotably mounted. A calibrated spring is received in each pivotable sleeve. A second transverse element also connects the two longitudinal elements. The second transverse element supports the sleeves and a yoke of a guide pulley for a cable to be wound and unwound from the winch. The tension in the cable causes the springs to pivot the yoke thereby preventing excessive tension on the cable when a load drawn by the winch encounters resistance and preventing excessive unwinding of the cable when the load is interrupted in its descent.
The safety device can be used in all winch-type apparatus, and in particular in hoisting apparatus with telescopic ladders for building sites. | 1 |
TECHNICAL FIELD OF THE INVENTION
Novel aqueous composition comprising novolac resins and polyols and their method of preparation and method of use.
BACKGROUND OF THE INVENTION
Phenolic resins made from phenol (P) and formaldehyde (F) include resoles and novolacs. Resoles have a F/P ratio of greater than 1. As such, resoles have the disadvantage that they contain free formaldehyde. This is in distinction to novolacs which have a F/P ratio of less than 1. As such, novolacs have a deficit of formaldehyde and, therefore, can also serve as formaldehyde scavengers. Novolacs can be used in their cured (or thermoset) state, but they can also be applied in an uncured, thermoplastic state (see WO2007/071387A2 (Dynea Erkner GmbH)).
At ambient conditions, the latter state is typically solid, and they can be described as glassy/congealed or amorphous solid materials. Upon temperature increase, the material consistency becomes softer and beyond the melting range becomes a liquid.
The manufacturing of novolacs is well known to a person skilled in the art, as may be found in A. Knop & L. A. Pilato, Phenolic Resins, Springer Verlag, 1985, Chapters 3 & 5.
Sometimes, it might be preferred to apply a novolac in a liquid form at around room temperature. A first approach (GB 899,776) dissolves novolacs in hydroxides of alkalines or earth alkalines. After drying or curing, the hydroxides remain on the surface, thereby increasing the pH to values, which are often undesirable.
In a second approach, novolacs can be dissolved in liquid resoles. However, as resoles exhibit a kinetically controlled self-curing process, they only have a limited storage stability, which then also limits the storage stability of the novolac-resole solutions.
In yet a further approach, novolacs can be dissolved in an organic solvent, such as described in U.S. Pat. No. 4,124,554, U.S. Pat. No. 5,200,455 or U.S. Pat. No. 4,167,500, disclosing the use of organic solvents to produce aqueous dispersions of novolacs. The use of such solvents is often unwanted, because they are often flammable and/or hazardous for the environment.
Whilst water would not have these disadvantages, novolacs do not dissolve therein and are not miscible therewith.
U.S. Pat. No. 5,670,571 (Georgia Pacific Resins) describes a method to produce an aqueous dispersion of a novolac resin and its use as a binder system for thermal insulation. Hereby, the water is added to the molten novolac and, therefore, this method is limited to novolacs having a melting point below 100° C. The process further employs surfactants (e.g. lecithin) and protective colloids (e.g. casein or polysaccharides sugar, or guar gum). Furthermore, the method of U.S. Pat. No. 5,670,571 produces only novolac particle sizes of 0.1-20 μm.
U.S. Pat. No. 6,130,289 (Lord Corporation) describes an aqueous dispersion of phenolic resins of the resole or novolac type. Dispersed within the aqueous phase is the reaction product of a phenolic resin precursor and a modifying agent wherein the modifying agent includes at least one ionic group and at least one functional moiety that enables the modifying agent to undergo condensation with the phenolic resin precursor. The modifying agent contains at least two distinct functional groups wherein one of the at least two functional groups is an ionic pendant group and another of the at least two functional groups is capable of reacting with a phenolic resin precursor.
Whilst the disclosures of the above documents relate to in-situ formed resins, U.S. Pat. No. 4,124,554 (Union Carbide Corporation) describes post-formed aqueous phenolic resin dispersions, i.e. to the dispersing of resins after these have been produced into particles. This invention uses polyvinyl alcohol (PVOH) to disperse reacted resins. To this end, a water miscible organic coupling solvent is needed in an amount from about 15 to about 30 percent. In contrast, the present invention does not need an organic solvent.
EP 0084681 (Union Carbide Corporation) describes a process for producing particulate novolacs by acid condensation with sulphur-containing catalysts or mixtures of them with following addition of water and neutralization. In order to achieve particulate novolac resin formation, up to 5% of particular protective colloids are added. The particles can be isolated by conventional means, and may result in mean particle sizes of up to 1 mm. Alternatively, the protective colloid can be used to form an aqueous dispersion of small resin particles (max. 50 μm). Suitable protective colloids are polysaccharides, whilst hydrolyzed PVOH or carboxymethyl cellulose (CMC) was reported to be unsuitable. The resins according to EP 0084681 may be cured by curing agents.
The use of starches in the process of encapsulating materials such as foods are described in, e.g., U.S. Pat. No. 4,812,445 (Nat Starch Chem Corporation) and WO99/25207 (Danisco), however, neither of these references suggest encapsulating novolac resins.
Despite the foregoing, there remains a need for a relatively inexpensive stable aqueous composition (such as a dispersion) of particulate novolac resins which can be applied as a film or coating to a substrate (such as fiberglass, agricultural/horticultural products, and lignocellulosic materials which include composite board, plywood, parquet, laminated veneer lumber (LVL), laminated flooring, door, wood for door frame and paper). An objective of the present invention is to fill this need.
SUMMARY OF THE INVENTION
The present invention, in part, is drawn to an aqueous composition comprising a particulate novolac resin and a polyol, wherein >50% of the number of total particles of novolac resin have a particle size of >15 μm and >5% of the number of total particles of novolac resin have a particle size of >50 μm, wherein the particulate novolac resin has a dropping point temperature of >127° C., and wherein the aqueous composition is essentially free of organic solvent. Ideally, the aqueous composition is in the form of a stable dispersion. The present invention includes a method for preparing the aqueous composition by combining a polyol, novolac resin particles and water, in any order.
The present invention, in part, is drawn to a film, coating or binder formed by applying the aqueous composition to a substrate and removing the aqueous solvent. The inventive composition has the added advantage that it can be used to scavenge formaldehyde.
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
FIG. 1 is a dispersion of novolac resin which is freshly made as described in Inventive Example 2 below; and
FIG. 2 is essentially the same dispersion as in FIG. 1 except that the dispersion has been aged 6 days.
DESCRIPTION OF THE INVENTION
An aspect of the invention is an aqueous composition comprising a particulate novolac resin comprising particles of more than about 50 μm and exhibiting a high dropping point temperature (as measured by DIN ISO 2176) and a polyol. The aqueous composition can be in the form of a stable dispersion of particulate novolac resins which can then be applied as a film or coating to a substrate.
The stability of the dispersion is a factor to be considered when tailoring the dispersion to be ideal for particular end use(s). The stability can be controlled by choosing the properties of the solid particulate phase as well as the continuous phase. Thus, present invention includes controlling of the properties of the novolac resin and the properties of the polyol along and the methods in which the ingredients of the dispersion are combined. The properties of the novolac resin which were found to be most clearly connected to the stability/instability of the dispersion are measured in a single measurement known as the dropping point temperature.
The dropping point is the temperature, at which a first drop of molten sample (novolac resin) falls out of the nipple (2.8 mm diameter) of a small cup that contains the examined sample and which is slowly heated up. To determine this parameter, the FP 900 thermo system equipped with the FP 83HT dropping point cell, both of Mettler Toledo, were used.
It was found that the dropping point temperature measurement is most helpful in identifying suitable novolac resins, since this measurement accounts for a variety of characteristics of the novolac resins, including melting point, molecular weight, intra- and intermolecular interactions, etc. Preferably, the dropping point temperature is greater than 127° C., more preferably is greater than 130° C., most preferably is more than 133° C.
The stability of the dispersion is determined by measuring the time after formation of the dispersion in a clear container until at least one layer containing a single phase is formed and can be seen (visually). The container containing the dispersion is kept under ambient conditions during the test. As mentioned above, the stability of the dispersion can be tailored depending upon the intended use. The dispersion can be tailored to exhibit at least a mid term stability of at least 5 hours and as such can be prepared soon before application to the substrate. In addition, the dispersion can be tailored to have a long term stability of at least 3 weeks, and as such is suitable for preparation long before application to the substrate. Moreover, it was found that if the inventive composition destabilizes and a single phase layer separates out, the dispersion can in most cases be rejuvenated upon shaking which effectively “restarts the clock” and the dispersion will show essentially the same stability as when freshly made.
It was found that novolac particles exhibit varying densities. Such varying densities may be the result of the manufacturing process, but may also be due to changes that a particle may undergo, e.g. by moisture pick up during aging. Thus, the hygroscopicity of the novolacs can be used to advantage by varying the density of the novolac particles and thus, can be used in existing but also novel applications.
It is preferred that the novolac particles remain in the solid state in the aqueous dispersion. The novolac resins are not soluble in water but are soluble/slightly soluble in certain organic solvents. As such, the aqueous dispersion is essentially free of organic solvent (i.e., contains less than an amount of organic solvent which would adversely affect the properties of the stable dispersion so that the stable dispersion could not be commercially used to prepare a film or coating). Preferably, there is less than 0.01 wt % organic solvent based on the weight of the dispersion.
Without wishing to be bound by the theory, it is believed, that the modifications of the properties of the continuous phase (especially density and viscosity) with the properties of the polyol is particularly effective in overcoming the difficulties of maintaining the particles in the dispersion without settling (forming a layer having a single phase).
Novolacs
Generally, the present invention aims at dispersing solid novolac particles, i.e., novolacs exhibiting a glass transition temperature of well above room temperature. Preferably, the novolac particles exhibit a high melt temperature range of more than 100° C., preferably of more than 110° C. Preferably, the novolac particles exhibit a low flow distance (when measured according to the Flow Distance Method as described herein below). More preferably, the flow distance is less than 45 mm, even more preferably, less than 30 mm, and even more preferably, less than 24 mm, and most preferably, less than 20 mm. Suitable novolac particles contain resins having a weight average molecular weight (Mw) of greater than 3,800 daltons, more preferably, greater than 4,000 daltons and most preferably 4,500-10,000 daltons.
Examples of such suitable resins, which are all commercially available from Dynea Oy, are shown in Table 1 below. Table 1 gives measurements of properties of individual batches of novolac resins (and these properties will vary somewhat from batch to batch).
TABLE 1
Molecular weight
Dropping
Novolac
M w
Flow dist. [mm]
point [° C.]
Prefere 888766R
6393
20
136.0
Prefere 824118D
9215
17.5
142.3
EXP 5E 8851
5432
24
134.2
Prefere 824440X
4651
30
133.1
Prefere 824439X
3737
46
126.2*
Prefere 824441X
—
49
123.8*
Prefere 824439X
3379
55
123.7*
Prefere 824441X
—
73
117.8*
Prefere 824442X
1982
110
105.8*
*comparative batches of novolacs having a dropping point temperature outside the inventive range
The novolac content of the dispersion may vary over a wide range, and a preset value may be determined by the future use of the dispersion. Typically, the dispersion will comprise greater than 1 wt % and may comprise as much novolac as possible for maintaining a dispersion, still having an aqueous liquid continuous phase. Typically up to 50 wt % (of the total weight of the dispersion) may be suitable.
The novolac resin can include comonomers along with P and F, so long as the surface properties of the particle do not change to an extent that the particles will give an unwanted reduction in stability to the dispersions (i.e., make them unsuitable for their intended purpose). It is preferred that the novolac resins are made solely with P and F and no other comonomers. These resins made solely with P and F show an increase in dropping point temperature with increased molecular weights. Nonpreferred examples of comonomers which may be excluded from the present invention are nonylphenol, paraffin oil, sunflower oil, castor oil, silicone oil, wood oil, wax and stearate.
Ideally, the novolac resins contain only low amounts of free phenol. Preferably, the novolac resins contain less than about 5 wt %, more preferably less than 1 wt %, and most preferably of less than 0.5 wt % phenol based on the weight of the resin.
Preferably, the novolac resins are moderately hydrophilic, i.e., they exhibit a contact angle (advancing) with water of between about 50° and 60° when measured according to the contact angle measurement method as described herein below.
The novolac resins can be used in a fully cured or partially cured state. In a preferred embodiment, the novolac resins are not fully cured and as such, can act as formaldehyde scavengers.
A particular advantage of the present invention is the ability to maintain stable dispersions of rather typical industrially available novolacs such as ground novolacs and is thus not limited to very small novolac particles, or to very narrow particle size distributions. Typically, the novolac particles exhibit relatively large particle sizes. Preferably, >50% of the number of total particles have a particle size of >15 μm, more preferably, >50% of the number of total particles have a particle size of >20 μm. Preferably, >5% of the number of total particles have a particle size of >50 μm, more preferably, >9% of the number of total particles have a particle size of >50 μm. Particle sizes up to about 1.0 mm can be used.
It should be noted, that these particle sizes are a measure of essentially dry particles, before these have been in extended contact with water or moisture. Upon such contact, novolacs typically embed water molecules within their polymer network, thereby showing a certain degree of swelling, which may be described even by forming a gelly state, coinciding with a change of characteristic properties, including density and hydrophilicity.
It is not unusual for novolac resins, that their moisture content increases upon contact with water or humid air from well below 2 wt % for “fresh” novolac to 6% or more after contact. Also, they tend to form agglomerates, which might make it difficult to perform the particle size determination of the primary, unagglomerated particles. However, if necessary, the particle size of the particles in an aqueous solution can be suitably determined by using conventional optical methods when the novolac resins have been freshly mixed in the aqueous solution.
Polyols
The present invention is directed to maintain such suitable novolac particles in a stable aqueous dispersion. This is achieved by adding a polyol to the aqueous continuous phase preferably before the novolac particles are added. Polyols have been found to be particularly effective in stabilizing the dispersion. The term “polyol” in the present invention is used to describe a molecule or polymer having more than one hydroxyl group.
An important requirement for the polyol is the absence of interactions such as chemical reactions with and/or dissolution of the novolac resin. Thus, for example, glycerol, which dissolves the novolac resin, is not preferred.
The polyol has the advantage that it can be made from renewable carbohydrate raw materials. These include oligosaccharides and polysaccharides such as native starch derived from various plants (legumes, potatoes, corn, wheat etc), low molecular weight carbohydrates (such as monosaccharides and disaccharides); alginic acid, agar agar, carrageen, tragacanth, gum arabic, guar gum, xanthan, karaya, maltodextrin, cationic corn (maize) dextrin, tara gum, pectin, locust bean gum, and the like. When the polyol is derived from various plants such as wheat, corn and potato, the polyol does not have to be isolated prior to use in the aqueous composition, i.e., crude starch-containing products can be used containing residues of proteins, polypeptides, lipids, etc. Crude starch-containing products can be, for example, glutenin or commercially available wheat flour (German type 405, definition according to DIN 10355) which is mostly carbohydrates but also contains about 10 wt % protein.
Natural starches have approximately 20-30% of the starch in the amylose form (having coiled chains of glucose residues) with the balance of starch being amylopectin (having branched chains of glucose residues). Some starches can reach as high as 70% amylose (such as HYLON VII®, National Starch Food Innovation) while others are essentially 100% amylopectin, such as waxy cornstarch, waxy potato starch, etc., It is preferred to use a starch having greater than 80% amylopectin which is assumed to have an increased ability of the branched chains of glucose residues to wrap around (physically entangle) the novolac particles. Most preferred is to use a waxy starch having essentially almost 100% amylopectin (i.e., >95 wt % or even >98 wt % amylopectin based on the total starch weight). These polyols which act to physically entangle the novolac particles act as a protective colloid. Also, amylose chains might retrogradate, i.e., crystallization due to the formation of hydrogen bonds, which might destabilize the dispersion.
The low molecular weight (i.e., less than 1,000 daltons) carbohydrates, such as mono- and disaccharides such as galactose, sucrose, lactose, dextrin, glucose and fructose can be used to advantage. This type of polyols has a significant effect on the stability of the dispersion by modifying the density of the continuous aqueous phase as discussed in further detail below.
Microbiologically produced oligosaccharides and polysaccharides can also be used, such as LEVAN® (a high molecular weight water soluble polymer of fructose, from Montana Polysaccharides Corp.)
Several insoluble renewable raw materials can also be used, such as cellulose, glycogen, pullulan (derived from e.g. Aerobasidium pullulans ), laminarin (from seaweed species), lichenin (lichens and mosses), chitin, chitosane, guar gum, inulin and the like. The polymeric carbohydrates range in their relative solubility in aqueous solutions.
In the event that the carbohydrate is so insoluble as to make it impractical to prepare dispersion solutions, the solubility can be increased by solubilizing the carbohydrate in a hydrolysis reaction using acidic, oxidative, thermal, or enzymatic means. The type of enzyme to hydrolyyze the carbohydrate can be any known in the art, and is preferably pullanase (α-dextrin endo-1,6-α-glucosidase) and/or α-amylase (1,4-α-D-glucan-4-glucanohydrolase). It is preferred to solubilize the insoluble carbohydrate with a hydrolysis promoting acid. For this procedure, an organic or inorganic acid can be used. It is envisioned that the hydrolysis promoting acid is any strong acid, but is preferably HCl, H 2 SO 4 , HBr, H 3 PO 4 , HF, HNO 3 and HClO 4 . It is most preferred to use HCl. The concentration of the hydrolysis promoting acid is 0.4 to 6.0 N. Preferably, the concentration is 0.5 to 4.5 N. Most preferably, the concentration is 0.5 to 3.0 N.
Without wishing to be bound by the theory, the present invention relies on two basic dispersion mechanisms.
Thus, in one aspect of the present invention, the properties of the continuous phase (especially density and viscosity) are modified, such as by reducing the density differences between the particles and the continuous phase. However, even if the densities of the continuous phase and the particles are exactly matched, this might not result in a stable dispersion, not only because of the particle-to-particle variation of density, but also, among possible further effects, because of possible moisture pick up of the particle (either from the ambient air before being added, or once it has been immersed in the continuous aqueous phase), thereby changing its density and thusly disturbing the equilibrium. An increase in viscosity of the continuous phase can, theoretically, slow down the settling (or raising) velocity. However, these velocities may be reduced to a rate, which can be considered as being stable for the application of the dispersions according to the present invention. Within the present context, there is no particular requirement for the flow regime of the particle, i.e., the settling of the particles can show Newtonian, or non-Newtonian behavior, such as shear thinning, or shear-thickening (dilatant), or thixotropic or rheopectic, or visco-elastic behavior.
Further, in a second aspect of the present invention, it has been found that certain polyols are effective as dispersion stabilizers by modifying more than the density and/or viscosity. Such polyols are also known as protective colloids, as these are thought to be attached (with covalent bond, ionic bond or by Van der Waals bond) with one end of their molecule to the particle, whilst another end of the molecule extends into the continuous phase.
The amount of the polyol may vary significantly for various systems. Generally, the amount is not critical as long as the desired effect of stabilizing the dispersion is achieved and a sufficient amount of novolac is dispersed. Thus, polyols which have high molecular weights, such as protective colloids have a concentration of at least 0.1 wt % (based on the weight of the solids). However, it is preferred that the amount of low molecular weight polyols, such as carbohydrates and mono- and disaccharides have a concentration of at least 5 wt % (based on the weight of the solids). On the other end, high amounts of stabilizer may create even more stable dispersions, which might, however, not be required for a certain application, and which might reduce the effective amount of novolacs in the dispersion, thusly increase the overall costs. Thus, the level of 55 weight % of the polyol (based on total base of the continuous phase—i.e. excluding the novolac) is considered a typical practical upper limit level. Optionally, and for certain applications preferably, the polyol can be a mixture of two or more components, which also may exhibit different stabilizing mechanisms.
As mentioned above, the relative density of the continuous phase to the density of the novolac resin is a factor which affects the stability of die dispersion. The continuous phase (prior to addition of novolac particles or after separation from these particles) preferably exhibits densities of more than 1 g/cm 3 , more preferably more than 1.05 g/cm 3 . Below in Table 3, is a list of densities of aqueous solutions containing varying amounts or glucose, sugar solution and maltodextrin.
TABLE 3
Density
Concentration
Glucose
Density
Density Maltodextrin
[Wt %]
syrup solution
sugar solution
solution
4
1.013
1.016
1.015
10
1.032
1.038
1.036
15
1.052
1.059
1.055
20
1.070
1.081
1.071
25
1.088
1.104
1.092
30
1.107
1.127
1.111
35
1.126
1.151
1.148
40
1.149
1.177
1.173
45
1.167
1.203
1.177
50
1.188
1.230
55
1.209
1.258
60
1.231
1.287
63
1.251
65
1.259
70
1.279
As mentioned above, the viscosity of the continuous phase is a factor which affects the stability of the dispersion and at a minimum can serve to slow the settling of the dispersed discontinuous solid phase with increased viscosity. Preferably, the continuous phase (prior to addition of novolac particles or after separation from these particles) exhibits a viscosity determined according to DIN 53211 (DIN Cup method, using 4 mm diameter hole, as described herein below) of at least 10 see, more preferably at least 20 sec.
Another way of measuring viscosity is by the Rolling Ball Method (also known as “Hoppler viscosimetry,” as described herein below). As shown in the following Table 4, the viscosity will typically increase with increased polyol, however, the overall viscosity of a solution containing more than one type of polyol can display synergism.
TABLE 4 Viscosity of water with added sugar and/or waxy corn starch @ 25° C. Polyol Content (wt %) Viscosity (mPas) None (pure water) 1.07 sugar 15 1.49 30 2.82 55 22 waxy corn starch 2 19.2 4 505 6 2907 Sugar and waxy corn starch 27.5 and 2 51.8
Further Additives
In an embodiment, the inventive dispersion consists of polyol(s), water, novolac resin particles and impurities. However, in an embodiment, the inventive dispersion comprises other additives which do not reduce the stability of the dispersion to a point which makes the dispersion impractical for its intended use. These additives include formaldehyde scavengers (such as free phenol at preferably less than 5 wt % based on the weight of the novolac resin), acids (such as oxalic acid, p-toluenesulfonic acid monohydrate, and salicylic acid), pigments, fillers, novolac hardeners (such as hexamethylene tetramine) and the like, in amounts well known to those skilled in the art.
Process of Preparing Dispersions
An aspect of the present invention is a process for preparing the aqueous composition comprising novolac resin particles having individual particles with a size greater than about 50 μm (which is explained in detail above) and exhibiting a dropping point temperature of more than 127° C., said process comprising the steps of: mixing at least one polyol with water and novolac particles in any order. In the event that the at least one polyol is of the type that acts like a protective colloid (such as starches with high amylopectin content), it is preferred to first mix the at least one polyol with water, optionally heating the mixture, and then adding said novolac particles to the mixture. In contrast, if the at least one polyol is of the type that acts as a density modifier (such as monosaccharides), the at least one polyol can be added to water or to a mixture of water and the novolac resin particles. Further, it is preferred that when the novolac resin particles are first combined with water, the at least one polyol is added shortly thereafter (i.e., the mixture is “freshly made”) to avoid significant swelling/gelling of the novolac resin particles.
The process can be entirely performed at temperatures of less than 30° C., however, if heating is used to facilitate mixing/solubilization, the mixture can be heated up to 100° C., preferably 90-100° C. Also, it is preferred to keep the temperature well enough below the melting point of the novolac resin, so that a stable dispersion can be obtained without die novolac combining.
Commercially available novolac resins can be used or the novolac resins can be made according to known methods. The method of forming the particles is not particularly limited, and includes grinding of the resins.
Application Of Stable Dispersions Of Novolacs To Substrates
Novolacs can be applied as an aqeous dispersion with low viscosity in various coatings and adhesive applications. For example, as binders for fiberglass, insulation products, agricultural/horticultural materials, lignocellulosic materials (paper and wood), etc.
For application as a thermoplastic binder in low density fiber boards, a dispersion was formed by mixing 20.62% sucrose, 1.5% waxy corn starch, 52.88% water and 25% ground novolac particles having a dropping point of 135° C. and an average particle size of about 30 μm with a particle size distribution of from about 0.9 μm to about 100 μm. The solid content of the dispersion (determined as described herein below) was 47.12% and the viscosity was determined to 75 mPas (Cone/Plate-Viscosity). The dispersion is stable for at least 30 days at ambient conditions. It exhibits a pH of between 5 and 7, and is essentially free of phenol and formaldehyde (<0.1%). As the novolac was an essentially uncured resin, it could function as a scavenger for formaldehyde after low density boards have been formed using such a dispersion.
For coating applications, the stable dispersion may be applied to a surface, such as metal, glass, and paper, and the water of the dispersion may be dried off with or without vacuum and suitable temperatures. Afterwards or at the same time the coating has to be treated with temperatures which are preferably at least the melting point of the novolac resin, more preferably more than the melting point of the resin, thusly forming a novolac film.
Similarly, a stable dispersion may be applied to fibrous structures such as nonwovens or fiberglass or mineral wool materials at a nonvolatile concentration of at least 5% and the water may be dried off under conditions described in the previous paragraph, such that the novolac binder concentrates thusly forming binder points.
EXAMPLES
The novolac resins used in the Examples have properties shown in the following Table 5:
TABLE 5
Novolac
Prefere
EXP 5E8851
Prefere
Prefere
Prefere
888766R
824118D
824440X
824441X
Dropping
136° C.
134.2° C.
142.3° C.
133.1° C.
117.8° C.
point
Free phenol
0.32%
0.15%
0.30%
0.29%
0.3%
grinding
Production
Production
Pilot line
Lab
Pilot line
line
line
Condux-mill
Ball mill
Condux-
Condux-mill
Condux-mill
mill
Particle size
0.9-122 μm
0.9-102 μm
0.9-146 μm
0.9-294 μm
0.9-122 μm
distribution
Average of
20 μm
21 μm
23 μm
52 μm
20 μm
particle size
Wt-% of
11.67%
9.2%
13.22%
52.02%
5.77%
particles
>50 μm
Wt-% of
69.89%
70.46%
67.17%
38.25%
77.32%
particles
<32 μm
Wt-% of
94.35%
96.34%
92.94%
53.31%
97.73%
particles
<63 μm
Wt-% of
99.05%
99.68%
98.41%
62.47%
99.74%
particles
<90 μm
Used in
Inv. Examples
Inv.
Inv.
Inv.
Comp.
example
1, 2, 12, 15 and
Examples
Examples 4-8
Example 13
Example 3
16 and Comp.
3, 9, 10, 11
and 14 and
Example 2
and 17
Comp.
Example 1
Inventive Example 1
60 g of waxy corn starch (Meritena 300, Tate&Lyle) is added to 1440 g water under stirring. The mixture is heated to 80-90° C. under stirring and kept for 30 minutes at this temperature. The mixture is cooled below 20° C. and then 500 g of finely ground novolac (Prefere 88 8766R of Dynea Erkner GmbH, see Table 5) is added under stirring. The dispersion is homogenized and stirred for additional 10 minutes. The viscosity (Hoppler, 20° C., DIN 53015) was 521 mPas. The characteristics (nonvolatile percentage and stability data) are given below in Table 6.
Inventive Example 2
10 g of waxy corn starch (C*Gel 04201, Cargill) is added to 480 g water under stirring. The mixture is heated to 80-90° C. under stirring and kept for 30 minutes at this temperature. The mixture is cooled to 15-20° C. and then 480 g of finely ground novolac (Prefere 88 8766R, Dynea Erkner GmbH, see Table 5) is added under stirring. The dispersion is homogenized. The viscosity was (Rheostress 25° C.) 261 mPas. The nonvolatile percentage and the stability data are given below in Table 6.
It was also found that if Example 2 is essentially repeated except that 1% of hexamethylenc tetraamine (novolac hardener) is added, the stability of the dispersion is not dramatically influenced.
FIG. 1 is a dispersion of Example 2 which is freshly made and FIG. 2 is essentially the same dispersion as in FIG. 1 except that the dispersion has been aged 6 days.
Inventive Example 3
420 kg water were mixed with 5 kg waxy corn starch (C*Gel 04201, Cargill) and heated to 85° C. At this temperature the mixture was kept for 15 minutes. Afterwards 325 kg sugar was added and when the sugar was dissolved completely the batch was cooled down to 15-23° C. 250 kg of ground novolac (EXP 5E8851, Dynea Erkner GmbH) which is characterized according to Table 5 was stepwise added and homogenized by stirring for 1 hour at 22° C. The nonvolatile percentage and the stability data are given below in Table 6.
Inventive Example 4
A mixture consisting of 1.5 wt-% waxy corn starch (C*Gel 04201, Cargill) and 52.88 wt-% water is heated to 98° C. for 10 minutes. Afterwards 20.62 wt-% sugar is added to the hot mixture. Under stirring the sugar is allowed to dissolve. When the mixture is cooled down to 21-23° C., 25 wt-% ground novolac (Prefere 82 4118D, Dynea Oy, see Table 5) is stirred under the liquid phase until the whole mixture is homogeneous. The nonvolatile percentage and the stability data are given below in Table 6.
Inventive Example 5
Into 1669 g water, 7.02 g waxy corn starch (C*Gel 04201, Cargill) is added and heated to 82-85° C. for 15 minutes. 1833.98 g sugar are dissolved in the mixture while cooling down to 20-25° C. Afterwards 1170 g, ground novolac (Prefere 82 4118D, Dynea Oy, see Table 5) is added. The dispersion is stirred until it is homogeneous. The nonvolatile percentage and the stability data are given below in Table 6.
Inventive Example 6
0.105 kg waxy corn starch starch (C*Gel 04201, Cargill) was mixed with 2.439 kg water and boiled for 5 minutes. 0.965 kg sugar is added and the mixture is cooled down to 21-24° C. 1.170 kg ground novolac (Prefere 82 4118D, Dynea Oy, see Table 5) is stirred into the liquid phase until a homogeneous dispersion is formed. The nonvolatile percentage and the stability data are given below in Table 6.
Inventive Example 7
A starch solution in water is prepared by dissolving 140.4 g waxy corn starch (C*Gel 04201, Cargill) in 1614.6 g water and heating to 85-95° C. The solution is held at this temperature for 20 minutes and cooled before use to 18-23° C.
Separately, a sugar solution is prepared by dissolving 965.25 g sugar in 789.75 g of water at a temperature of 50-55° C. The solution is cooled down to 18-23° C. before use.
1.755 kg of the starch solution in water (8 wt-%) is mixed with 1.755 kg of the sugar solution (55 wt-%) at 25° C. To that mixture 1.170 kg of ground novolac (Prefere 82 4118D, Dynea Oy, see Table 5 is added and stirred until the dispersion is homogeneous. The nonvolatile percentage and the stability data are given below in Table 6.
Inventive Example 8
41.25 wt-% sugars are dissolved in 33.75 wt-% water at 60-63° C. After cooling down to 18-22° C. 25 wt-% novolac (Prefere 82 4118D, Dynea Oy, see Table 5) is stirred in until receiving a homogeneous dispersion. The nonvolatile percentage and the stability data are given below in Table 6.
Inventive Example 9
Into a solution of low molecular wheat protein containing natural compounds in water containing a solids content of 40%, novolac (EXP 5E8851, Dynea Erkner GmbH, see Table 5) was added, in an amount to give a concentration of 25 wt % of the novolac based on the weight of the solution, at 23° C. and stirred until complete homogenization. The nonvolatile percentage and the stability data are given below in Table 6.
Inventive Example 10
Into 140 g of a solution of low molecular wheat protein containing natural compounds in water containing a solids content of 49.5%, 60 g of ground novolac (EXP 5E8851, see Example 3 and Table 5) was added to give a concentration of 30 wt % of the novolac based on the weight of the solution, at 23° C. and stirred until complete homogenization. The nonvolatile percentage and the stability data are given below in Table 6.
Inventive Example 11
53.34 g ground novolac (EXP 5E8851, Dynea Erkner GmbH, see Example 3 and Table 5) is stirred into a mixture consisting of 80 g of a 55 wt % sugar solution and 80 g of a 4 wt % mixture of wheat flour (type 405) in water at 23-25° C. until the dispersion is homogeneous. The nonvolatile percentage and the stability data are given below in Table 6.
Inventive Example 12
94.5 g of C*Sweet 01407 (Cargill) are well mixed with 55.5 g water. At 24-25° C., 49.95 g novolac (Prefere 888766R, Dynea Erkner GmbH, see Example 1 and Table 5) is stirred into the liquid phase until the dispersion becomes homogeneous. The nonvolatile percentage and the stability data are given below in Table 6.
Inventive Example 13
60 g novolac (Prefere 82 4440X, Dynea Oy, see Table 5), ground in the ball mill, are stirred into a solution of 73.5 g sugar in 66.5 g water, which was cooled to 20-23° C. before use. The nonvolatile percentage and the stability data are given below in Table 6.
Inventive Example 14
Waxy corn starch (Meritena 300, Tate&Lyle) is added to water to give 4 wt % waxy corn starch-solution. The mixture is heated to 95° C. and kept at this temperature for 10 minutes and then is cooled to 18-22° C. Separately a 55 wt % sugar solution is prepared by combining sugar and water. 35.11 g of the 4 wt % waxy corn starch-solution is combined with 35.11 g of the 55 wt % sugar solution. Under stirring 46.80 g ground novolac (Prefere 82 4118D, Dynea Oy, see Table 5) is added at 18-20° C. The dispersion is stirred until it is homogeneous. The nonvolatile percentage and the stability data are given below in Table 6.
Inventive Example 15
0.3 g waxy corn starch (C*Gel 04201, Cargill) and 0.3 g maltodextrine (C*Dry MD 01958, Cerestar) are mixed into 14.4 g water and are heated to 95° C. for 15 minutes. The mixture is cooled down to 20° C., and then 5 g ground novolac (Prefere 888766R, Dynea Erkner GmbH, see Table 5) is added and the dispersion is stirred until it is homogeneous. The nonvolatile percentage and the stability data are given below in Table 6.
Inventive Example 16
0.45 g cationic maize dextrine (C*Film MS 05978, Cerestar) is mixed with 14.4 g water and 0.15 g waxy corn starch (C*Gel 04201, Cargill). After heating to 85-92° C. for 20 minutes, the mixture is cooled down to 17-23° C. Afterwards 5 g of a ground novolac (Prefere 888766R, Dynea Erkner GmbH, see Table 5) is stirred into the fluid phase until the dispersion is homogeneous. The nonvolatile percentage and the stability data are given below in Table 6.
Inventive Example 17
60 g of solution containing 1% waxy corn starch (Meritena 300, Tate&Lyle) was prepared by heating to 100° C. and keeping so for 5 minutes. After cooling to 16-20° C., 40 g ground novolac (EXP 5E8851, Dynea Erkner GmbH, see example 1 and Table 5) is stirred into the starch solution until the dispersion becomes homogeneous. The dispersion keeps stable for at most 14 hours.
The following Comparative Examples 1 and 2 are nonpreferred embodiments of the invention.
Comparative Example 1
A solution of low molecular wheat protein containing natural compounds in water with solid content of 25% is neutralised using NaOH (1N). At 22-25° C. to 50 g of this solution 12.5 g ground novolac (Prefere 82 4118D, Dynea Oy, see Example 4 and Table 5) is added. This dispersion keeps stable only for several hours. Sedimentation can be observed after 6 hours of storage at ambient conditions.
Comparative Example 2
3.33 g ground novolac (Prefere 888766R, Dynea Erkner GmbH, see Example 1 and Table 5) is stirred into 10 g of a 35 wt % maltodextrine (C*Dry MD 01958, Cerestar) solution (which has been pretreated at 90° C. for 10 min) at temperature of 20-24° C. until the dispersion becomes homogeneous. The nonvolatile percentage and the stability data are given below in Table 6.
The following Comparative Example 3 is outside the invention.
Comparative Example 3
Essentially the same procedure as described above for Inventive Example 4 is repeated except that the novolac resin Prefere 82 4118D is replaced with a novolac resin Prefere 82 4441X (Dynea Oy) having a low dropping point.
Specifically, waxy corn starch (Meritena 300, Tate&Lyle) is added to water to give 4 wt % waxy corn starch-solution. The mixture is heated to 95° C. and kept at this temperature for 10 minutes and then is cooled to 18-22° C. Separately a 55 wt % sugar solution is prepared by combining sugar and water. 35.11 g of the 4 wt % waxy corn starch-solution is combined with 35.11 g of the 55 wt % sugar solution. Under stirring 23.41 g ground novolac (Prefere 82 444.1X, Dynea Oy, dropping point 117.8° C., see Table 1) is added at 18-20° C. The mixture is stirred. The novolac coagulates and no dispersion could be obtained.
TABLE 6
Composition Details of Examples
waxy
corn
Sugar
starch
Water
Novolac
Nonvolatiles
Example
[%]
[%]
[%]
[%]
Other [%]
[%]
Stability
Inventive 1
—
3.0
72.0
25
27.6%
at least 3
weeks
Inventive 2
—
1
49
49
50%
at most 3
weeks
Inventive 3
34.3
0.5
40.2
25
58.5%
at least 6
months
Inventive 4
20.62
1.50
52.88
25
47.6%
at least 6
months
Inventive 5
39.18
0.15
35.67
25
64.6%
at least 3
months
Inventive 6
20.62
2.25
52.13
25
49.0%
at least 6
months
Inventive 7
20.62
3.0
51.38
25
47.7%
at least 6
months
Inventive 8
41.25
—
33.75
25
68.4%
at least 3
months
Inventive 9
45
25
Wheat
54.9%
after 1 day
compounds
water layer
[30]
on the top
Inventive 10
35.35
30
Wheat
64.7%
at most
compounds
3weeks
[34.65]
Inventive 11
20.62
52.88
25
Wheat
47.2%
after 2 day
compounds
water layer
[1.50]
on the top
Inventive 12
—
27.76
24.98
Glucose
64.2%
after 3 day
syrup
water layer
[47.26]
on the
bottom
Inventive 13
36.75
—
33.25
30
67.7%
after 2 day
water layer
on the
bottom
Inventive 14
16.5
1.2
42.3
40
57.8%
at most 2
weeks
Inventive 15
—
1.5
72
25
Maltodextrine
—
at most 1
[1.5]
day
Inventive 16
—
2.25
72
25
Cationic
—
at most 5
maize
days
dextrin
[0.75]
Inventive 17
—
0.6
59.4
40
40.1%
at most 14
hours
Comparative 1
60
20
Wheat
39.8%
at most 1
compounds
hour
[20]
Comparative 2
—
48.76
24.98
Maltodextrine
—
at most 6
[26.25]
hours
Comparative 3
20.62
1.5
52.88
25
—
no
dispersion
obtained
The fragments of the ground novolac are irregular solid particles. Surprisingly, after being dispersed in the starch solution, it seems as if they are encapsulated by the waxy starch to form spherical shapes and thus, a neat dispersion is obtained. (See pictures 1 and 2)
This dispersion is stable for a long time and combines the advantages of a novolac with the application advantages of using water as a solvent.
The description of the methods of forming the novolac resins and the description of the novolac resins and the novolac resin compositions as described in the references cited above are herein incorporated by reference.
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 a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.
Test Methods
All test methods are—unless otherwise specified operated under ambient conditions.
Particle Size Distribution
The particle size of non-dispersed essentially dry novolac particles can suitably be performed by a laser diffraction analysis, such as by using an equipment of Sympatec (sensor: Helos; dispergator for dry substances: Rodos). The measurement range is determined using R4 ((0.5 (0.9)-350 μm). The measurement was carried out with pre pressure of 1.5 bar and trigger conditions of 1.5% optical density. The measurement results are discussed in Table 5.
Within the present context, the particle size reefers to the primary particles. It should be noted, that in both in the case of dry as well as wet analysis, and several or many particles may form particle cluster or aggregates. These should be disregarded in the measurements.
TABLE 7
Unless stated otherwise, the following tests were used:
Comments/specific test
Method
Standard reference
parameter
Flow distance method
DIN EN ISO 8619
3 g novolac + 0.3 g
hexamethylenetetramine,
125° C., 3 min 0°, 30 min 60°
Dropping point
DIN ISO 2176
according to user's manual
FP 83 Mettler Toledo
of Mettler Toledo FP900
Content of free Phenol
DIN EN IS0 8974
Gas chromatography
Water content of powdered
DIN 53715
method according to Karl
novolacs
Fischer
Determination of M w
GPC equipment Polymer
Labratories, Software PL
GPC; conditions: coloumn set
3 × PLgel 300 × 7.5 mm; 5 μm;
50, 100, 1000 A; solvent:
THF, 35° C., Flow rate 0, 6,
detector: HP MWD 1050,
280 nm, Standard:
Polystyrene
Contact angle
Equipment “Krüss”G40,
water contact angle
Liquid density
DIN EN ISO 3675
Hydrometer, 20° C.
measurement
Viscosity for stationary
DIN EN ISO 12058-1
Rolling ball viscometer
phase (Höppler)
20° C.
Viscosity of dispersion
DIN 53211
Flow time by the DIN cup,
20° C.
Viscosity (Cone/Plate)
DIN EN ISO 3219
Equipment “Thermo Fisher
Scientific, RS1”, Software
RheoWin, conditions:
cone/plate; 105 μm gap;
sensor: C35/2° T; rotation,
shear rate: 2000/sec, 25° C.
Solid content
DIN EN ISO 3251
3 g; 1 hr; 135° C.
Particle Size
Laser diffraction analysis
using a Sympatec (Helos, Rodos) | An aqueous composition including a particulate novolac resin and a polyol, wherein >50% of the number of total particles of novolac resin have a particle size of >15 μm and >5% of the number of total particles of novolac resin have a particle size of >50 μm, wherein the particulate novolac resin has a dropping point temperature of >127° C., and wherein the aqueous composition is essentially free of organic solvent. The aqueous composition will form a stable dispersion which is ideal for the preparation of a film or coating of substrates such as fiberglass, nonwoven fibers, or lignocellulosic materials which include composite boards, plywoods, parquets, laminated veneer lumber (LVL), laminated flooring, doors, wood for door frames and paper. | 3 |
This is a Divisional application of U.S. Ser. No. 08/234,759 filed Apr. 28, 1994, now U.S. Pat. No. 5,489,686 which is a Divisional application of U.S. Ser. No. 08/075,973 filed Jun. 11, 1993, now U.S. Pat. No. 5,350,757, which is a Divisional application of U.S. Ser. No. 07/885,263, filed May 19, 1992, now issued U.S. Pat. No. 5,246,943, granted Sep. 21, 1993.
BACKGROUND OF THE INVENTION
U.S. Pat. No. 4,812,462 describes 4,5,6,7-tetrahydro-1H-imidazo[4,5-c]pyridine derivatives as antagonists of angiotensin II (AII) binding at a particular subtype of its cellular receptors, namely the AT 2 receptor. By virtue of their AT 2 receptor antagonist property, these compounds are disclosed to have utility in the treatment of vascular restenosis, atherosclerosis and disorders related to excessive vasopressin (AVP) secretion, various disorders of the central nervous system (CNS), and also have utility in the regulation of female reproductive functions.
Atherosclerotic arterial occlusive disease is a major cause of morbidity and mortality in the United States (W. P. Castelli, Am. J. Med. 76:4-12 (1984)). One important strategy in the treatment of this disorder is the use of various revascularization techniques such as saphenous vein bypass grafting, endarterectomy, and transluminal coronary angioplasty. Unfortunately, the overall success of these revascularization procedures is limited by restenosis due to neointimal hyperplasia. The magnitude of this problem in clinical medicine is increasing with the rising rate of cardiovascular surgery and interventional therapy.
Several factors have been implicated in the pathogenesis of restenosis, including the hormone angiotensin II (Ang II), which is an integral part of the renin-angiotensin system and is a regulator of vascular tone and structure. Ang II is a potent vasoconstrictor which plays a central role in hypertension, congestive heart failure, and vascular diseases. In vivo, Ang II is implicated in the vascular hypertrophy of hypertension since angiotensin converting enzyme (ACE) inhibitors can prevent or attenuate medial hypertrophy in many models of hypertension (G. K. Owens, Hypertension 9:178-187 (1987)). Recently it has been found that inhibitors of ACE and angiotensin II antagonists (AT 1 subtype) will reduce or attenuate the development of intimal hyperplasia in the rat in response to injury (J. S. Powell, et al, Science 245:186-188 (1989); A. W. Clowes, et al, Hypertension 18[Suppl II]): II65-II69 (1991), W. Osterrieder, et al, Hypertension 18 [Suppl II]: II60-II64 (1991)). These growth inhibitory effects are independent of the hemodynamic effects of ACE inhibitors since treatment with other blood pressure lowering drugs does not inhibit this growth (J. S. Powell, et al, J. Card. Pharmacol. 16(Suppl. 4):S42-S 49 (1990)). Similar studies have shown that ACE inhibitors prevent vascular growth in response to injury in guinea pigs (J. P. Clozel, et al, Hypertension 18 [Suppl II]: II55-II59 (1991) and arterial and venous allograft-induced vascular injury in rats (D. Plissonnier, et al, Hypertension 18 [Suppl II]: II47-II54 (1991) and S. P. Roux, et al, Hypertension 18 [Suppl II]:-II43-II46 (1991)). Moreover ACE inhibitors can prevent or attenuate atherosclerosis in Watanabe rabbits (A. V. Chobanian, et al, Clinical Cardiol. 13:43-48 (1990)) and cholesterol fed primates (G. Abers, et al, J. Cardiovascular Pharmacol. 15 (Suppl 5):S56-S72 (1990)).
Angiotensin II has also been shown to play a role in the regulation of vascular smooth muscle cell growth in vitro. In cultured vascular smooth muscle cells, Ang II increases the rates of RNA and protein synthesis and under certain conditions is mitogenic. Moreover, Ang II increases the expression of the proto-oncogenes c-myc, c-jun, and c-fos, as well as growth factors which are involved in Ang II-induced growth, namely, platelet derived growth factor (PDGF), basic fibroblast growth factor, and transforming growth factor-β (TGF-β) (A. J. Naftilan, et al, J. Clin. Invest. 83:1419-1424 (1989)).
The results from multiple laboratories suggest the existence of receptor isoforms which possess different binding properties and different intracellular signals. Recently, two classes of receptor antagonists have been used to classify these receptors (A. T. Chiu, et al, Biochem. Biophys. Res. Comm. 165:196-203 (1989)). The AT-1 receptors, present on multiple cell types, appear to be coupled via G proteins to phospholipase C. AT-1 receptors are known to be selectively antagonized by Dup753 (A. T. Chiu, et al, Biochem. Biophys. Res. Comm. 172:1195-1202 (1990); D. T. Dudley, et al, Mol. Pharmacol. 38:370-377 (1990)). Stimulation of this receptor leads to inositol metabolism, increases in intracellular calcium, and activation of protein kinase C. Thus, The AT-1 receptor is the classical membrane Ang II receptor. Blockade of these receptors has been shown to inhibit induced vascular growth. It has been shown that AT-1 receptor antagonists also reduce or attenuate the development of intimal hyperplasia in the rat in response to injury (M. F. Prescott, et al, American Journal of Pathology 139:1291-1296 (1991); R. F. Kauffman, et al, Life Sciences 49:PL-223-PL-228 (1991), and H. Azuma, et al, Br. J. Pharmacol. (1991)).
A second Ang II receptor subtype, AT-2, has been recently discovered and this receptor has a more limited distribution and may not be coupled to G proteins. This receptor has been found to selectively bind compounds utilized in the present invention. The physiologic role of the AT 2 receptor has been speculated as mediator of the growth potentiation effects of Ang II. This is based on the observation that this receptor subtype is expressed during fetal development (E. F. Grady, et al, J. Clin. Invest. 88:921-933 (1991)). Viswanathan, et al (Biochem. Biophys. Res. Comm. 179:1361-1367 (1991)) reported that AT-2 receptors are the predominant isoform in the neonatal vasculature but are only a minor component in that of the adult. The mechanism of action of the compounds utilized in the present invention pertains to their binding to the AT-2 receptors found in proliferating vascular smooth muscle.
The present invention is also related to the discovery that the AT 2 receptor is found in the central nervous system (CNS) of mammals, and that compounds of general Formula I described herein are effective in blocking angiotensin II binding at AT 2 receptors in various brain regions. Angiotensin II is known to modulate CNS nerve sensitivity to neurotransmitters such as catecholamines, serotonin, and enkephalins, and additionally, angiotensin II is a neurotransmitter that regulates the release of hormones from the brain (Phillips, Ann. Rev. Physiol. 49:413-35 (1987)). Agents that block the activity of angiotensin II at AT 2 receptors in the CNS will ameliorate disorders associated with abnormal nerve activity and abnormal hormone secretion related to exaggerated AT 2 mediated responses to angiotensin II. The compounds of general Formula I, being AT 2 antagonists, have possible utility in the treatment and diagnosis of numerous neurological, psychiatric, neuroendocrine, neurodegenerative, and neuroimmunological disorders including, but not limited to, those associated with addiction, anxiety, depression, epilepsy, hyperactivity, memory, pain, Parkinsonism, psychosis, regulation of autonomic functions, sleep, and tardive dyskinesia.
Barnes, et al, in Brain Research 507: 341-343 (1990), describe the effects of angiotensin II as an inhibitor of potassium-stimulated release of ACh from human temporal cortex, giving rise to elevated levels of ACh in cortical tissue. Rats treated with an angiotensin converting enzyme (ACE) inhibitor, a drug that blocks the formation of angiotensin II, show reductions in striatal ACh. ACE inhibitors have been shown to enhance cognitive performance in rodent tests of cognition by Costall, et al, in Pharmacol. Biochem. & Behavior 33:573-579 (1989).
Since both ACE inhibitors and angiotensin receptor antagonists block the actions of angiotensin II in the brain, it is reasonable that both will enhance cognitive performance.
Another known CNS effect of angiotensin II is stimulation of the release of pituitary and hypothalamic hormones including vasopressin (AVP), oxytocin, adrenocorticotrophic hormone (ACTH), prolactin, and luteinizing hormone (LH). Thus, compounds of general Formula I have utility in treatment of various neuroendocrine disorders that are dependent upon the release of hormones resulting from angiotensin II stimulation of AT 2 receptors.
Vasopressin (AVP), also known as antidiuretic hormone, is a peptide hormone which causes decreased urinary output, increased urine density, and reduced thirst. In normal physiology, it is important for conservation of body fluid. Schiavone, et al, in Hypertension 17:425 (1991), describe the effects of AT 2 antagonists, in antagonizing the angiotensin II-induced secretion of AVP from isolated rat hypothalamo-neurohypophysial explants. Excessive secretion of AVP has been linked to a number of disorders including excessive water retention associated with the female reproductive disorder known as premenstrual syndrome (PMS) (Janowski, et al, Psychosomatic Medicine 35:143-154 (1973)) and impaired water excretion with adrenal insufficiency. It has also been linked to Schwartz-Bartter syndrome (an AVP secreting brain tumor), congestive heart failure, liver cirrhosis, nephrotic syndromes, central nervous injuries, acute psychotic states, lung disease, dysmenorrheic uterine hyperactivity, and premature labor (Laszlo, et al, ibid.). Compounds of general Formula I, by virtue of their ability to block angiotensin II-induced AVP secretion, have utility in treatment of the above disorders.
The present invention is also related to the discovery that AT 2 receptors are found in female reproductive organs of mammals including uterus (Data in Table 1, hereof and in Dudley, et al, ibid.) and ovaries. The role of angiotensin II in processes leading to ovulation has been reviewed by Andrade-Gordon, et al, in Biochemical Pharmacology 42:715-719 (1991). Compounds of general Formula I inhibit the binding of angiotensin II to AT 2 receptors in reproductive tissues, including uterus and ovarian follicles and hence antagonize the effects of angiotensin II therein.
AT 2 receptor antagonists thus have potential utilities in the regulation of fertility and the menstrual cycle.
SUMMARY OF THE INVENTION
The present invention relates to novel substituted 1,2,3,4-tetrahydroisoquinoline derivatives of Formula I ##STR1## or a pharmaceutically acceptable salt thereof wherein R 1 , R 2 , n, X, R 3 , R 4 , and R 5 are as defined below.
These compounds have potent and selective AT 2 antagonist activity (with no AT 1 antagonist properties). By virtue of this activity, compounds of Formula I have utilities including treatment of vascular smooth muscle proliferative diseases such as postsurgical vascular restenosis and atherosclerosis; treatment of various disorders of the CNS including disorders of memory and disorders related to excessive AVP secretion such as Schwartz-Bartter syndrome and PMS; and regulation of female reproductive functions.
The invention also includes a pharmaceutical composition comprising an antiatherosclerotic effective amount of a compound of Formula I above in admixture with a pharmaceutically acceptable carrier or excipient and a method for treatment in a mammal suffering therefrom which comprises administering to said mammal the above pharmaceutical composition in unit dosage form.
Further, the invention includes a pharmaceutical composition comprising an amount of a compound of Formula I above effective for treating female reproductive disorders in admixture with a pharmaceutically acceptable carrier or excipient, and a method for treating the same in a mammal suffering therefrom comprising administering to said patient the above pharmaceutical composition in unit dosage form.
The invention also includes a pharmaceutical composition comprising an amount effective for treating restenosis of a compound of Formula I above in admixture with a pharmaceutically acceptable carrier or excipient and a method of treating restenosis in a mammal suffering therefrom comprising administering to said mammal the above pharmaceutical composition in unit dosage form.
Also, the invention includes a pharmaceutical composition comprising an amount of a compound of Formula I above effective for treating cognitive decline in admixture with a pharmaceutically acceptable carrier or excipient; and a method of treating cognitive decline in a mammal suffering therefrom comprising administering to said mammal the above pharmaceutical composition in unit dosage form.
The invention includes a pharmaceutical composition comprising an amount of a compound of Formula I above, effective to treat disorders related to excessive AVP secretion in admixture with a pharmaceutically acceptable carrier or excipient, and a method for treating such disorders in a patient suffering therefrom comprising administering to said patient the above pharmaceutical composition in unit dosage form.
The invention includes a pharmaceutical composition comprising an amount of a compound of Formula I above, effective to treat vascular cardiac hypertrophy in admixture with a pharmaceutically acceptable carrier or excipient, and a method for treating such disorders in a patient suffering therefrom comprising administering to said patient the above pharmaceutical composition in unit dosage form.
The instant invention further includes methods for making compounds of Formula I and novel intermediates useful in the preparation.
DETAILED DESCRIPTION
The instant invention is for compounds of formula ##STR2## or a pharmaceutically acceptable salt thereof wherein: R 1 and R 2 are each independently hydrogen, lower alkyl, halogen, hydroxy, alkoxy, amino, alkylamino, dialkylamino, acylamino, CF 3 , carboxy, carboalkoxy, hydroxyalkyl, aminoalkyl, and nitro;
n is an integer from zero to 4;
X is absent, O, S, NH, N-alkyl, and is attached to the tetrahydroisoquinoline at the 5 or 6 position;
R 3 is hydrogen, alkoxy, aryloxy, alkylthio, or halogen attached either at the 6, 7, or 8 position;
R 4 is hydrogen, alkyl, hydroxyalkyl, CO 2 R 6 , CON(R 6 ) 2 wherein R 6 is hydrogen or lower alkyl; and
R 5 is alkyl, aryl, aralkyl which can be unsubstituted or substituted on the alkyl and/or on the aryl portion, diaralkyl (the aryl portion can be unsubstituted or substituted), COR 7 , SO 2 R 7 wherein R 7 is aralkyl, alkyl, diaralkyl, OR 8 , NR 8 R 9 wherein R 8 and R 9 are each independently hydrogen, alkyl, cycloalkyl, aryl, or aralkyl. More preferred compounds of the invention are
those of Formula I wherein
R 1 and R 2 are each independently hydrogen, lower alkyl, alkoxy, amino, carboxy, and nitro;
n is an integer of from 0 to 3;
X is O, S, or NH substituted at the 5 position;
R 3 is hydrogen, alkoxy, or halogen substituted at the 6 position;
R 4 is hydrogen, alkyl, hydroxyalkyl, CO 2 R 6 , CON(R 6 ) 2 ; and
R 5 is alkyl, aryl, or COR 7 .
Still more preferred compounds of the invention are those of Formula I wherein
R 1 and R 2 are each independently hydrogen, lower alkyl, alkoxy, carboxy, and nitro;
n is an integer of from 0 to 2;
X is O substituted at the 5 position;
R 3 is alkoxy substituted at the 6 position;
R 4 is CO 2 R 6 , or CON(R 6 ) 2 ; and
R 5 is COR 7 wherein R 7 is diaralkyl or NR 8 R 9 wherein R 8 and R 9 are each independently hydrogen, alkyl, or aryl and the aryl group may be substituted.
Yet still more preferred compounds of the invention are those of Formula I wherein
R 1 and R 2 are each independently hydrogen, methoxy, carboxy, methyl, nitro, or amino;
n is 0, 1, or 2;
X is O, NH;
R 3 is H, or --OCH 3 ;
R 4 is --COOH, COOCH 3 , COOC 2 H 5 , --CONH 2 , and ##STR3## and R 5 is hydrogen, ##STR4##
Certain compounds of the present invention possess one or more chiral centers and each center may exist in the R or S configuration. The present invention includes all enantiomeric and diastereomeric forms as well as the appropriate mixtures thereof.
Still more preferred compounds are:
2-(Diphenylacetyl)-6-ethoxy-1,2,3,4-tetrahydro-5-(phenylmethoxy)-3-isoquinolinecarboxylic acid,
2-(Diphenylacetyl)-1,2,3,4-tetrahydro-6-methoxy-5-(phenylmethoxy)-3-isoquinolinecarboxylic acid,
2-(2,2-Diphenylethyl)-1,2,3,4-tetrahydro-6-methoxy-5-(phenylmethoxy)-3-isoquinolinecarboxylic acid,
2-Butyl-1,2,3,4-tetrahydro-6-methoxy-5-(phenylmethoxy)-3-isoquinolinecarboxylic acid,
2-(Diphenylacetyl)-1,2,3,4-tetrahydro-6-methoxy-5-(phenylmethoxy)-3-isoquinolinecarboxylic acid,
2-[(Diphenylmethyl)sulfonyl]-1,2,3,4-tetrahydro-6-methoxy-5-(phenylmethoxy)-3-isoquinolinecarboxylic acid, and
1,2,3,4-Tetrahydro-6-methoxy-2-phenyl-5-(phenylmethoxy)-3-isoquinolinecarboxylic acid.
Yet still more preferred compounds are:
5-[(4-Aminophenyl)methoxy]-2-(diphenylacetyl)-1,2,3,4-tetrahydro-6-methoxy-3-isoquinolinecarboxylic acid,
5-[(4-Amino-3-methylphenyl)methoxy]-2-(diphenylacetyl)-1,2,3,4-tetrahydro-6-methoxy-3-isoquinolinecarboxylic acid,
5-[[4-(Dimethylamino)-3-methylphenyl]methoxy]-2-(diphenylacetyl)-1,2,3,4-tetrahydro-6-methoxy-3-isoquinolinecarboxylic acid,
(S)-2-(Diphenylacetyl)-1,2,3,4-tetrahydro-6-methoxy-5-(phenylmethoxy)-3-isoquinolinecarboxylic acid,
(R)-2-(Diphenylacetyl)-1,2,3,4-tetrahydro-6-methoxy-5-(phenylmethoxy)-3-isoquinolinecarboxylic acid,
2-(Diphenylacetyl)-1,2,3,4-tetrahydro-6-methoxy-5-[(phenylmethyl)thio]-3-isoquinolinecarboxylic acid,
2-(Diphenylacetyl)-1,2,3,4-tetrahydro-6-(methylthio)-5-(phenylmethoxy)-3-isoquinolinecarboxylic acid,
2-(Diphenylacetyl)-1,2,3,4-tetrahydro-6-methoxy-5-[(phenylmethyl)amino]-3-isoquinolinecarboxylic acid,
2-(Diphenylacetyl)-1,2,3,4-tetrahydro-6-methoxy-5-[methyl (phenylmethyl)amino]-3-isoquinolinecarboxylic acid,
2-(Diphenylacetyl)-1,2,3,4-tetrahydro-6-methoxy-5-(phenylthio)-3-isoquinolinecarboxylic acid,
2-(Diphenylacetyl)-1,2,3,4-tetrahydro-6-methoxy-5-(phenylthio)-3-isoquinolinecarboxylic acid,
2-(Diphenylacetyl)-1,2,3,4-tetrahydro-6-methoxy-5-[methyl(phenylamino)]-3-isoquinolinecarboxylic acid,
2-(Diphenylacetyl)-1,2,3,4-tetrahydro-6-methoxy-5-(phenylmethyl)-3-isoquinolinecarboxylic acid,
2-(Diphenylacetyl)-1,2,3,4-tetrahydro-6-methoxy-5-(2-phenylethyl)-3-isoquinolinecarboxylic acid,
2-(Diphenylacetyl)-1,2,3,4-tetrahydro-6-methoxy-5-phenyl-3-isoquinolinecarboxylic acid,
2-(Diphenylacetyl)-1,2,3,4-tetrahydro-5-(phenylmethoxy)-3-isoquinolinecarboxylic acid,
2-(Diphenylacetyl)-1,2,3,4-tetrahydro-6-methoxy-5-(phenylmethoxy)-3-isoquinolinecarboxamide, and
2-(Diphenylacetyl)-1,2,3,4-tetrahydro-N,N-dimethyl-6-methoxy-5-(phenylmethoxy)-3-isoquinolinecarboxamide.
The most preferred compounds of the invention are:
2-(Diphenylacetyl)-1,2,3,4-tetrahydro-6-methoxy-5-(phenylmethoxy)-3-isoquinolinecarboxylic acid,
2-(Diphenylacetyl)-1,2,3,4-tetrahydro-7-methoxy-6-(phenylmethoxy)-3-isoquinolinecarboxylic acid,
2-(Diphenylacetyl)-1,2,3,4-tetrahydro-6-methoxy-5-(2-phenylethoxy)-3-isoquinolinecarboxylic acid,
2-[Bis(4-chlorophenyl)acetyl]-1,2,3,4-tetrahydro-6-methoxy-5-(phenylmethoxy)-3-isoquinolinecarboxylic acid,
2-(Cyclopentylphenylacetyl)-1,2,3,4-tetrahydro-6-methoxy-5-(phenylmethoxy)-3-isoquinolinecarboxylic acid,
2-[(2,6-Dichlorophenyl)acetyl]-1,2,3,4-tetrahydro-6-methoxy-5-(phenylmethoxy)-3-isoquinolinecarboxylic acid,
1,2,3,4-Tetrahydro-6-methoxy-2-[(methylphenylamino)carbonyl]-5-(phenylmethoxy)-3-isoquinolinecarboxylic acid,
1,2,3,4-Tetrahydro-6-methoxy-2-[[(4-methoxyphenyl)amino]carbonyl]-5-(phenylmethoxy)-3-isoquinolinecarboxylic acid,
2-[[(4-Fluorophenyl)amino]carbonyl]-1,2,3,4-tetrahydro-6-methoxy-5-(phenylmethoxy)-3-isoquinolinecarboxylic acid,
2-(Diphenylacetyl)-1,2,3,4-tetrahydro-6-methoxy-5-phenylmethoxy-3-isoquinolinecarboxylic acid, ethyl ester,
5-[(4-Carbomethoxyphenyl)methoxy]-2-(diphenylacetyl)-1,2,3,4-tetrahydro-6-methoxy-3-isoquinolinecarboxylic acid, ethyl ester,
5-(4-Carboxyphenylmethoxy)-2-(diphenylacetyl)-1,2,3,4-tetrahydro-6-methoxy-3-isoquinolinecarboxylic acid,
2-(Diphenylacetyl)-1,2,3,4-tetrahydro-6-methoxy-5-[(4-methoxy-3-methylphenyl)methoxy]-3-isoquinolinecarboxylic acid, ethyl ester,
2-(Diphenylacetyl)-1,2,3,4-tetrahydro-6-methoxy-5-[(4-methoxy-3-methylphenyl)methoxy]-3-isoquinolinecarboxylic acid,
2-(Diphenylacetyl)-1,2,3,4-tetrahydro-6-methoxy-5-(4-nitrophenoxy)-3-isoquinolinecarboxylic acid, methyl ester,
5-(4-Aminophenoxy)-2-(diphenylacetyl)-1,2,3,4-tetrahydro-6-methoxy-3-isoquinolinecarboxylic acid, methyl ester,
5-(4-Aminophenoxy)-2-(diphenylacetyl)-1,2,3,4-tetrahydro-6-methoxy-3-isoquinolinecarboxylic acid, and,
(+)-2-(Diphenylacetyl)-1,2,3,4-tetrahydro-6-methoxy-5-(phenylmethoxy)-3-isoquinolinecarboxylic acid.
Novel intermediates of the invention include:
3-Methoxy-2-(phenylmethoxy)phenylalanine,
4-Methoxy-3-(phenylmethoxy)phenylalanine,
3-Methoxy-2-(2-phenylethoxy)phenylalanine,
3-Methoxy-2-(4-nitrophenoxy)phenylalanine,
1,2,3,4-Tetrahydro-6-methoxy-5-(phenylmethoxy-3-isoquinolinecarboxylic acid,
1,2,3,4-Tetrahydro-7-methoxy-6-(phenylmethoxy)-3-isoquinolinecarboxylic acid,
1,2,3,4-Tetrahydro-6-methoxy-5-(2-phenylethoxy)-3-isoquinolinecarboxylic acid,
1,2,3,4-Tetrahydro-6-methoxy-5-(4-nitrophenoxy)-3-isoquinolinecarboxylic acid,
1,2,3,4-Tetrahydro-5-hydroxy-6-methoxy-3-isoquinolinecarboxylic acid,
1,2,3,4-Tetrahydro-6-methoxy-5-(phenylmethoxy)-3-isoquinolinecarboxylic acid, ethyl ester,
1,2,3,4-Tetrahydro-5-hydroxy-6-methoxy-3-isoquinolinecarboxylic acid, ethyl ester,
1,2,3,4-Tetrahydro-6-methoxy-5-(4-nitrophenoxy)-3-isoquinolinecarboxylic acid, methyl ester,
N-Acetyl -3-methoxy-2-(phenylmethoxy)phenylalanine,
1,2,3,4-Tetrahydro-5-hydroxy-6-methoxy-2-[methyl(phenylamino)carbonyl]-3-isoquinolinecarboxylic acid, and
2-(Diphenylacetyl)-1,2,3,4-tetrahydro-5-hydroxy-6-methoxy-3-isoquinolinecarboxylic acid, ethyl ester.
Certain compounds of the present invention can exist in unsolvated forms as well as solvated forms, including hydrated forms. In general, the solvated forms, including hydrated forms, are equivalent to unsolvated forms and are intended to be encompassed within the scope of the present invention.
The compounds of Formula I are capable of further forming both pharmaceutically acceptable acid addition and/or base salts. All of these forms are within the scope of the present invention.
Pharmaceutically acceptable acid addition salts of the compound of Formula I include salts derived from nontoxic inorganic acids such as hydrochloric, nitric, phosphoric, sulfuric, hydrobromic, hydriodic, phosphorous, and the like, as well as the salts derived from nontoxic organic acids, such as aliphatic mono- and dicarboxylic acids, phenyl-substituted alkanoic acids, hydroxy alkanoic acids, alkanedioic acids, aromatic acids, aliphatic and aromatic sulfonic acids, etc. Such salts thus include sulfate, pyrosulfate, bisulfate, sulfite, bisulfite, nitrate, phosphate, monohydrogenphosphate, dihydrogenphosphate, metaphosphate, pyrophosphate, chloride, bromide, iodide, acetate, propionate, caprylate, isobutyrate, oxalate, malonate, succinate, suberate, sebacate, fumarate, maleate, mandelate, benzoate, chlorobenzoate, methylbenzoate, dinitrobenzoate, phthalate, benzenesulfonate, toluenesulfonate, phenylacetate, citrate, lactate, maleate, tartrate, methanesulfonate, and the like. Also contemplated are salts of amino acids such as arginate and the like and gluconate, galacturonate(see, for example, Berge, S. M., et al, "Pharmaceutical Salts," Journal of Pharmaceutical Science 66:1-19 (1977)).
The acid addition salts of said basic compounds are prepared by contacting the free base form with a sufficient amount of the desired acid to produce the salt in the conventional manner. The free base form may be regenerated by contacting the salt form with a base and isolating the free base in the conventional manner. The free base forms differ from their respective salt forms somewhat in certain physical properties such as solubility in polar solvents, but otherwise the salts are equivalent to their respective free base for purposes of the present invention.
Pharmaceutically acceptable base addition salts are formed with metals or amines, such as alkali or alkaline earth metals or organic amines. Examples of metals used as cations are sodium, potassium, magnesium, calcium, and the like. Examples of suitable amines are N,N'-dibenzylethylenediamine, chloroprocaine, choline, diethanolamine, ethylenediamine, N-methylglucamine, and procaine (see, for example, Berge, S. M., et al, "Pharmaceutical Salts," ibid.
The base addition salts of said acidic compounds are prepared by contacting the free acid form with a sufficient amount of the desired base to produce the salt in the conventional manner. The free acid form may be regenerated by contacting the salt form with an acid and isolating the free acid in the conventional manner. The free acid forms differ from their respective salt forms somewhat in certain physical properties such as solubility in polar solvents, but otherwise the salts are equivalent to their respective free acid for purposes of the present invention.
In the compounds of Formula I, the term "alkyl" means a straight or branched hydrocarbon radical having from one to eight carbon atoms and includes, for example, methyl, ethyl, n-propyl, isopropyl, n-butyl, sec-butyl, isobutyl, tert-butyl, n-pentyl, n-hexyl, and the like except where specifically stated otherwise.
The term halogen includes fluorine, chlorine, bromine, and iodine; the more preferred halogens are fluorine and chlorine.
The term alkoxy refers to an alkyl radical attached to the remainder of the molecule by oxygen; this includes but is not limited to methoxy, ethoxy, and propoxy groups.
The terms alkylamino and dialkylamino refer to one or two alkyl radicals attached to a nitrogen atom; N-methylamino and N,N-dimethylamino are examples.
Acylamino includes such groups as CH 3 CONH, CH 3 CH 2 CONH, PhCONH.
Carboalkoxy refers to groups such as alkyl esters of carboxylic acids.
Hydroxyalkyl refers to alkyl groups of from one to six carbon atoms which may be straight or branched, such as CH 2 OH.
Aryl is an aromatic hydrocarbon such as phenyl, naphthyl, and the like. The aryl may be unsubstituted or substituted by one or more selected from alkyl such as methyl or ethyl, alkoxy such as methoxy or ethoxy, hydroxy, halogen such as fluorine, chlorine, and bromine, NO 2 , NH 2 , NHalkyl, N(alkyl) 2 , SCH 3 , and SH.
Aralkyl and diaralkyl are as defined above for alkyl and for aryl. Such groups include but are not limited to PhCH 2 -- and Ph 2 CH--. The groups can be unsubstituted or substituted on the alkyl and/or on the aryl portion such as the group ##STR5##
Substituents on the alkyl portion are, for example, alkyl, dialkyl, or cycloalkyl.
Cycloalkyl is a cyclic group of from three to six carbon atoms, preferred cycloalkyls are cyclopentyl and cyclohexyl.
The strategy for preparation of compounds of Formula I is exempified in Scheme I. It involves benzylations of a phenolic aldehyde such as 1 with a benzyl halide ##STR6## in the presence of a weak inorganic base such as Na 2 CO 3 , K 2 CO 3 , or CsCO 3 and the like in a polar solvent such as ethanol, methanol, DMF, or DMA and the like. Preferred conditions for the alkylation employ one to five equivalents of powdered potassium carbonate in ethanol at 25° to 80° C. for 1 to 12 hours. The benzyloxybenzaldehyde derivative 2 is condensed with hydantoin. The condensation is performed under weakly acidic conditions in a solvent such as acetic acid or propanoic acid and the like using an appropriate catalyst such as β-alanine or sodium acetate at temperatures of 25° to 135° C. Preferred conditions for the condensation with aldehyde 2 employ 1 to 1.2 equivalents of hydantoin and 0.1 to 0.3 equivalents of β-alanine in glacial acetic acid at reflux for 1 to 12 hours. Reduction conditions for the benzylidene hydantoin 3 are designed to prevent debenzylation of the benzyl ether; thus either a zinc-hydrochloric acid method or hydrogenation with Raney nickel catalyst is preferred.
In the zinc-acid method 2 to 4 equivalents of zinc powder is added to a stirred suspension of the benzylidene hydantoin in a polar solvent such as methanol containing 10 to 100 equivalents of concentrated hydrochloric acid at 50° to 100° C. for 0.5 to 2 hours. The Raney nickel catalytic hydrogenation of the benzylidene hydantoin is effected by dissolution of the hydantoin in a polar solvent such as methanol containing a strong base, such as, but not limited to, 1.1 equivalents of KOH or (Me) 4 NOH. The preferred base for solubility purposes is (Me) 4 NOH. Other catalysts such as 20% palladium/carbon are effective with this basic solvent system when debenzylation is not a problem (see reduction of the phenylethoxy benzylidene hydantoin in Example 8).
The intermediate substituted phenylalanine derivatives (4) are generated from the above prepared benzyl hydantoins by a strong base hydrolysis utilizing 5% to 50% NaOH, KOH, or LiOH in aqueous medium at temperatures of 50° to 120° C. for 1 to 48 hours.
The cyclization of the phenylalanine 4 to a tetrahydroisoquinoline 5 proceeds under acidic conditions. Suitable conditions include 1 to 10 equivalents of 1 to 3N hydrochloric or sulfuric acid in the presence of 1 to 10 equivalents of formaldehyde, either as an aqueous solution or in the form of its dimethyl acetal, methylal, at 25° to 100° C. The preferred acid is 1N hydrochloric acid with methylal as the formaldehyde source.
The target acylated tetrahydroisoquinoline 6 may be obtained by a Schotten-Baumann type of acylation of the amino acid 5 with an acid chloride. The preferred conditions involve adding an acid chloride acylating agent (0.12 mole, 20% excess) either neat or as a solution in methylene chloride, ethyl acetate, THF, or dioxane, to a cooled (0° to 5° C.) vigorously stirred mixture of the amino acid, 0.20 to 0.22 mole of a strong base such as NaOH, KOH, or (Me) 4 NOH, and water with any of the above solvents. Adjustment of the pH to 3 yields the acylated amino acid 6. The preferred base is (Me) 4 NOH and the solvent is methylene chloride.
Alternatively, compound 5 may be esterified first with anhydrous alcohols and hydrogen chloride to 7 which are then acylated with YCOR 7 where Y is OH or an activating moiety such as halogen or an active ester group. Subsequent base hydrolysis of the esters 8 with alcoholic solvents such as methanol or ethanol and 1 to 2N sodium hydroxide at 50° to 80° C. for 0.25 to 6 hours gives the carboxylic acid derivatives such as 9.
An alternate method of preparing various phenol ethers is described in Scheme II. ##STR7##
A phenol intermediate 15 is generated by debenzylation of 5 either by catalytic hydrogenolysis with 20% palladium/carbon or by warming 5 to 50° to 100° C. with concentrated hydrochloric acid. The preferred method is concentrated hydrochloric acid at reflux for 10 minutes. The esterification to 16 is accomplished by the standard Fisher method with absolute ethanol-hydrogen chloride.
Acylation of 16 with an acid chloride under anhydrous conditions in an aprotic solvent such as methylene chloride, THF, or ether with an organic amine, such as triethylamine as a proton acceptor yields compounds like 17 which can now be alkylated to compounds like 18 by a variety of alkylating agents. Conditions for the alkylation are similar to those described for compound 1 in Scheme I. The conditions in this case are DMF as a solvent, NA 2 CO 3 as a base, and temperature at reflux for a 5-minute reaction time. Base hydrolysis of 18 with 2N sodium hydroxide in methanol at reflux yields the product 19.
Scheme III describes an alternate method of preparing intermediate substituted phenylalanine derivatives (4, 14). ##STR8##
The example in Scheme III describes a sequence starting from a p-nitrophenoxy benzaldehyde 10. Compound 10 is prepared by acylation of I with p-fluoronitrobenzene in DMF at reflux for 10 minutes with powdered K 2 CO 3 as a proton acceptor. The remainder of the sequence involves standard methods of preparing phenylalanine derivatives (4, 14) through the acetamidomalonate method. A typical compound active in a rabbit uterus binding assay for detecting angiotensin type 2 (AT 2 ) antagonists is compound 6 below. AT 2 Binding Assay is a modification of the procedure by D. T. Dudley, et al, Mol. Pharmacol. 38:370 (1990). The binding affinity of Compound 6 is IC 50 2.8 nM. ##STR9##
Other compounds of this invention and binding activities are listed in the Table I below.
TABLE I______________________________________ AT.sub.2 BindingExample IC.sub.50 (nM)______________________________________26 8.420 (Compound 6) 2.823 24.225 117.024 1.622 8.921 58.527 1,110.035 1.930 151.033 752.0______________________________________
As can be seen in Table I above, Example 20 (Compound 6) has a high binding affinity for the AT 2 receptor site. Since it was inactive in the AT 1 binding assay at 10 -5 M concentration, it is highly selective for the AT 2 site.
Based on the above data, the compounds of the instant invention are expected to have utility in treating restenosis, atherosclerosis and disorders involving excessive AVP secretion, CNS disorders, certain female reproductive disorders, and certain cognitive disorders.
For preparing pharmaceutical compositions from the compounds described by this invention, inert, pharmaceutically acceptable carriers can be either solid or liquid. Solid form preparations include powders, tablets, dispersible granules, capsules, cachets, and suppositories. A solid carrier can be one or more substances which may also act as diluents, flavoring agents, solubilizers, lubricants, suspending agents, binders, or tablet disintegrating agents. It can also be encapsulating material. In powders, the carrier is a finely divided solid which is in admixture with the finely divided active compound. In the tablet the active compound is mixed with a carrier having the necessary binding properties in suitable proportions and compacted in the shape and size desired. The powders and tablets preferably contain from 5 to 10 to about 70 percent of the active ingredient. Suitable solid carriers are magnesium carbonate, magnesium stearate, talc, sugar, lactose, pectin, dextrin, starch, gelatin, tragacanth, methylcellulose, a low melting wax, cocoa butter, and the like. The term "preparation" is intended to include the formulation of the active compound with encapsulating material as carrier providing a capsule in which the active component (with or without other carriers) is surrounded by carrier, which is thus in association with it. Similarly, cachets are included. Tablets, powders, cachets, and capsules can be used as solid dosage forms suitable for oral administration.
The confounds of the present invention may be administered orally, buccally, parenterally, by inhalation spray, rectally, or topically in dosage unit formulations containing conventional nontoxic pharmaceutically acceptable carriers, adjuvants, and vehicles as desired. The term parenteral as used herein includes subcutaneous injections, intravenous, intramuscular, intrasternal injection, or infusion techniques such as infusion pump.
For preparing suppositories, a low melting wax such as a mixture of fatty acid glycerides or cocoa butter is first melted, and the active ingredient is dispersed homogeneously therein by stirring. The molten homogeneous mixture is then poured into convenient sized molds, allowed to cool, and thereby solidify.
Liquified form preparations include solutions, suspensions, and emulsions. As an example may be mentioned water or water/propylene glycol solutions for parenteral injection. Liquid preparations can also be formulated in solution in aqueous polyethyleneglycol solution. Aqueous suspensions suitable for oral use can be made by dispersing the finely divided active component in water with viscous material, i.e., natural or synthetic gum, resins, methylcellulose, sodium carboxymethyl-cellulose, and other well-known suspending agents.
Also included are solid form preparations which are intended to be converted, shortly before use, to liquid form preparations for either oral or parenteral administration. Such liquid forms include solutions, suspensions, and emulsions. These particular solid form preparations are most conveniently provided in unit dose form and as such are used to provide a single liquid dosage unit. Alternately, sufficient solid may be provided so that after conversion to liquid form, multiple individual liquid doses may be obtained by measuring predetermined volumes of the liquid form preparation as with a syringe, teaspoon, or other volumetric container. When multiple liquid doses are so prepared, it is preferred to maintain the unused portion of said liquid doses at low temperature (i.e., under refrigeration) in order to retard possible decomposition. The solid form preparations intended to be converted to liquid form may contain, in addition to the active material, flavorants, colorants, stabilizers, buffers, artificial and natural sweeteners, dispersants, thickeners, solubilizing agents, and the like. The liquid utilized for preparing the liquid form preparation may be water, isotonic water, ethanol, glycerin, propylene glycol, and the like, as well as mixtures thereof. Naturally, the liquid utilized will be chosen with regard to the route of administration, for example, liquid preparations containing large amounts of ethanol are not suitable for parenteral use.
Preferably, the pharmaceutical preparation is in unit dosage form. In such form, the preparation is subdivided into unit doses containing appropriate quantities of the active component. The unit dosage form can be a packaged preparation, the package containing discrete quantities of preparation, for example, packeted tablets, capsules, and powders in vials or ampules. The unit dosage form can also be a capsule, cachet, or tablet itself, or it can be the appropriate number of any of these in packaged form.
The quantity of active compound in a unit dose of preparation may be varied or adjusted from 1 mg to 1000 mg, preferably 5 to 200 mg according to the particular application and the potency of the active ingredient. The compositions can, if desired, also contain other compatible therapeutic agents.
In therapeutic use the mammalian dosage range for a 70 kg subject is from 0.1 to 1500 mg/kg of body weight per day or preferably 1 to 500 mg/kg of body weight per day optionally in divided portions. The dosages, however, may be varied depending upon the requirements of the patient, the severity of the condition being treated, and the compound being employed. Determination of the proper dosage for a particular situation is within the skill of the art. Generally, treatment is initiated with smaller dosages which are less than the optimum dose of the compound. Thereafter the dosage is increased by small increments until the optimum effect under the circumstances is reached. For convenience, the total daily dosage may be divided and administered in portions during the day if desired.
The following examples are illustrative of the instant invention; they are not intended to limit its scope in any way.
EXAMPLE 1 ##STR10##
3-Methoxy -2-(phenylmethoxy)benzaldehyde
A mixture of 196.0 g (1.30 mole) of o-vanillin (Aldrich), 200 g of benzyl bromide (Aldrich), 500 g of anhydrous potassium carbonate and 1,500 mL of absolute ethanol is heated, with stirring, at reflux for 6 hours. After cooling, the supernatant is decanted and the remainder is filtered. The combined filtrate and supernatant is concentrated at reduced pressure to remove solvent. The remaining oil is extracted into 1 L of ether. The ether solution is washed with 500 mL of water, 600 mL of 1% potassium hydroxide solution, and 500 mL of water and then dried (potassium carbonate) and concentrated to give 263.4 g (84% yield) of product; mp 41°-43° C. Reported mp, 43° C. (Chem. Abstr. 62:16110a).
EXAMPLE 2 ##STR11##
3-Methoxy-2-(4-nitrophenoxy)benzaldehyde
A mixture of 14.10 g (0.10 mole) of 4-fluoronitrobenzene, 16.40 g (0.10 mole) of o-vanillin, 30 g of powdered potassium carbonate, and 40 mL of DMF is heated with stirring to the boiling point. After 10 minutes the mixture is cooled to 100° C. and 300 mL of ice water is added. Petroleum ether (200 mL) is added and the entire mixture is filtered and the cake is washed with 200 mL of water and then 200 mL of petroleum ether. The damp cake is slurried in 100 mL of methanol and filtered; wt 19.50 g (71% yield); mp 130°-131° C.; mass spectrum (DEI), 273 (M + ).
EXAMPLE 3 ##STR12##
5-[[3-Methoxy-2-(phenylmethoxy)phenyl]methylene]-2,4-imidazolidinedione
A solution of 96.90 g (0.40 mole) of 2-benzyloxy-3-methoxybenzaldehyde, 48.04 g (0.48 mole) of hydantoin, 8.02 g (0.09 mole) of β-alanine, and 200 mL of glacial acetic acid is stirred at reflux for 6 hours. Water (500 mL) is added and the separated solid is filtered, washed well with water, methanol, and then ether; wt 109.00 g (84% yield); mp 210°-212° C.
Anal. Calc. for C 18 H 16 N 2 O 4 : C, 66.65; H, 4.97; N, 8.64. Found: C, 66.77; H, 4.84; N, 8.74.
EXAMPLE 4 ##STR13##
5-[[4-Methoxy-3-(phenylmethoxy)phenyl]methylene]-2,4-imidazolidinedione
This compound is prepared from 3-benzyloxy-4-methoxybenzaldehyde (Aldrich) and hydantoin by the procedure described in Example 3; mp 242°-244° C.
Anal. Calc. for C 18 H 16 N 2 O 4 : C, 66.65; H, 4.97; N, 8.64. Found: C, 67.01; H, 5.07; N, 8.64.
EXAMPLE 5 ##STR14##
5-[[3-Methoxy-2-(2-phenylethoxy)phenyl]methylene]-2,4-imidazolidinedione
This compound is prepared from 2-(2-phenylethoxy)-3-methoxybenzaldehyde of Example 46 by the procedure of Example 3; mp 199°-201° C.
Anal. Calc. for C 19 H 18 N 2 O 4 : C, 67.44; H, 5.36; N, 8.28. Found: C, 67.48; H, 5.53; N, 8.36.
EXAMPLE 6 ##STR15##
(RS)-5-[[3-Methoxy-2-(phenylmethoxy)phenyl]methyl]-2,4-imidazolidinedione
Zinc powder (40.00 g; 0.61 mole) is added to a stirred suspension of 48.00 g (0.16 mole) of the benzylidine hydantoin from Example 3 in 1,200 mL of methanol under nitrogen. Concentrated hydrochloric acid (30 mL) is added and the mixture is heated on the steam bath for 20 minutes (after 10 minutes the starting benzylidene hydantoin dissolves). Another 30 mL of concentrated hydrochloric acid is added and the mixture is heated at reflux for another 20 minutes. The cooled (50° C.) mixture is cautiously filtered and the cake washed with 100 mL of methanol. Water (500 mL) is added to the filtrate to yield 24.60 g of crystalline product; mp 202°-204° C.
Recrystallization from methanol gives pure product; mp 205°-207 ° C. Anal. Calc. for C 18 H 18 N 2 O 4 : C, 66.24; H, 5.56; N, 8.59. Found: C, 66.10; H, 5.68; N, 8.60.
EXAMPLE 7 ##STR16##
(RS)-5-[[4-Methoxy-3-(phenylmethoxy)phenyl]methyl]-2,4-imidazolidinedione
A solution of 16.20 g (0.05 mole) of the benzylidene hydantoin from Example 4 in 100 mL of methanol and 25.0 g (0,055 mole) of 20% tetramethylammonium hydroxide-in-methanol is reduced with hydrogen and Raney nickel catalyst. After the theoretical uptake of hydrogen the mixture is filtered and acetic acid (ca 5 mL) and then water is added until just turbid. The first crop of solid is filtered. This is starting material. An additional 2 L of water is added to precipitate the product as crop 2; wt 7.60 g (47% yield). Recrystallization from methanol gives pure product; mp 155°-157° C.
Anal. Calc. for C 18 H 18 N 2 O 4 : C, 66.24; H, 5.56; N, 8.59. Found: C, 66.19; H, 5.60; N, 8.68.
EXAMPLE 8 ##STR17##
(RS)-5-[[3-Methoxy-2-phenylethoxy)phenyl]methyl]-2,4-imidazolidinedione
A solution of 16.92 g (0.05 mole) of the benzylidene hydantoin from Example 5 in 100 mL of methanol and 25.0 g (0,055 mole) of 20% tetramethylammonium hydroxide-in-methanol is reduced with hydrogen and 20% palladium on carbon catalyst. After the theoretical amount of hydrogen is absorbed, the catalyst is filtered. Acetic acid (ca 5 mL) and then 200 mL of water is added to precipitate the crystalline product; wt 15.00 g; mp 163°-165° C. Recrystallization from methanol gives pure product with the same melting point.
Anal. Calc. for C 19 H 20 N 2 O 4 : C, 67.04; N, 5.92; N, 8.23. Found: C, 66.97; H, 5.84; N, 8.24.
EXAMPLE 9 ##STR18##
(RS)-3-Methoxy-2-(phenylmethoxy)phenylalanine
A solution (8.50 g, 0.026 mole) of the corresponding hydantoin derivative from Example 6 in 500 mL of 5% sodium hydroxide is heated at reflux for 16 hours. To complete the hydrolysis, the solution is concentrated on the hot plate to ca 150 mL volume over a period of 6 hours. The mixture is cooled and the tacky sodium salt is filtered. The cake is dissolved in 200 mL of water and glacial acetic acid is added to pH 7.2 to precipitate crystals. The crude product is filtered and washed efficiently with cold water; wt 5.90 g. Recrystallization from methanol-ether gives pure racemic amino acid; wt 3.70 g; mp 190°-194° C.
Anal. Calc. for C 17 H 19 NO 4 •0.1H 2 O: C, 67.35; H, 6.38; N, 4.62; H 2 O (KF), 0.59. Found: C, 67.18; H, 6.32; N, 4.53; H 2 O, 0.80.
EXAMPLE 10 ##STR19##
(RS)-4-Methoxy-3-(phenylmethoxy)phenylalanine
This compound is prepared from the corresponding hydantoin derivative (Example 7) by a procedure similar to that in Example 9; tlc (1:5:20 acetic acid-methanol-chloroform system); Rf 0.4 (ninhydrin).
EXAMPLE 11 ##STR20##
(RS)-3-Methoxy-2-(2-phenylethoxy)phenylalanine
This compound was prepared from the corresponding hydantoin derivative from Example 8 by a procedure similar to that in Example 9; mp 180°-182° C.
Anal. Calc. for C 18 H 21 NO 4 : C, 68.55; H, 6.71; N, 4.44. Found: C, 68.61; H, 6.69; N, 4.46.
EXAMPLE 12 ##STR21##
(RS)-3-Methoxy-2-(4-nitrophenoxy)phenylalanine
A mixture of 5.47 g (0.0115 mole) of the malonic ester from Example 41, 150 mL of ethanol, and 100 mL of concentrated hydrochloric acid is heated, with stirring, at reflux overnight. After 20 hours reflux another 50 mL of concentrated hydrochloric acid is added and reflux is continued for 4 hours. The solution is concentrated at reduced pressure and the residue is dissolved in ca 200 mL of water. The turbid solution is clarified (Celite) and concentrated to dryness. The last amounts of water are removed by addition and removal of 3×100 mL of absolute ethanol to give 3.50 g of dry foam. Recrystallization is effected from ethanol-ether to give 2.95 g of pure product as a hydrochloride salt; mp 168°-171° C.
Anal. Calc. for C 16 H 16 N 2 O 6 •HCl•1.25H 2 O: C, 49.11; H, 5.03; N, 7.16; Cl, 9.06. Found: C, 49.26; H, 5.14; N, 7.15; Cl, 8.91.
EXAMPLE 13 ##STR22##
(RS)-1,2,3,4-Tetrahydro-6-methoxy-5-(phenylmethoxy-3-isoquinolinecarboxylic acid
A solution of 0.58 g (0.0019 mole) of the phenylalanine derivative from Example 9 in 15 mL of 1N hydrochloric acid is treated with 1.0 mL of methylal and allowed to stand at room temperature overnight. Saturated sodium acetate solution (5 mL) is added to precipitate the free amino acid as a white solid; wt 0.50 g. Recrystallization from methanol gives pure product; mp 236°-238° C. dec.
Anal. Calc. for C 18 H 19 NO 4 : C, 68.99; H, 6.11; N, 4.47. Found: C, 68.64; H, 6.23; N, 4.35.
EXAMPLE 14 ##STR23##
(RS)-1,2,3,4-Tetrahydro-7-methoxy-6-(phenylmethoxy)-3-isoquinolinecarboxylic acid
This compound is prepared from the phenylalanine derivative of Example 10 by a procedure similar to that in Example 13; mp 230°-240° C.
Anal. Calc. for C 18 H 19 NO 4 : C, 68.64; H, 6.23; N, 4.47. Found: C, 68.55; H, 6.03; N, 4.41.
EXAMPLE 15 ##STR24##
(RS)-1,2,3,4-Tetrahydro-6-methoxy-5-(2-phenylethoxy)-3-isoquinolinecarboxylic acid
This compound is prepared from the corresponding phenylalanine derivative of Example 11 by a procedure similar to that in Example 13; mp 232°-235° C.
Anal. Calc. for C 19 H 21 NO 4 : C, 69.70; H, 6.47; N, 4.28. Found: C, 69.33; H, 6.64; N, 4.33.
EXAMPLE 16 ##STR25##
(RS)-1,2,3,4-Tetrahydro-6-methoxy-5-(4-nitrophenoxy)-3-isoquinolinecarboxylic acid
This compound is prepared from the corresponding phenylalanine derivative of Example 12 by a procedure similar to that in Example 13. The product is isolated as a hydrochloride salt from the reaction medium; mp 260°-265° C.
Anal. Calc. for C 17 H 16 N 2 O 6 •HCl: C, 53.76; H, 4.25; N, 7.38. Found: C, 53.29; H, 4.69; N, 7.25.
EXAMPLE 17 ##STR26##
(RS)-1,2,3,4-Tetrahydro-5-hydroxy-6-methoxy-3-isoquinolinecarboxylic acid
A mixture of 5.01 g (0.016 mole) of the amino acid from Example 13 and 25 mL of concentrated hydrochloric acid is heated at reflux with stirring for 10 minutes. The mixture is cooled and the tacky solid containing benzyl chloride is filtered and washed with 2-propanol and ether; wt 3.80 g (86% yield). Recrystallization from methanol-ether gives pure product, hydrochloride salt; mp 254°-257° C. dec.
Anal. Calc. for C 11 H 13 NO 4 •HCl: C, 50.87; H, 5.43; N, 5.40. Found: C, 50.69; H, 5.52; N, 5.43.
EXAMPLE 18 ##STR27##
(RS)-1,2,3,4-Tetrahydro-6-methoxy-5-(phenylmethoxy)-3-isoquinolinecarboxylic acid, ethyl ester
A quantity of 7.85 g (0.025 mole) of the amino acid from Example 13 is dissolved in 1300 mL of warm absolute ethanol (35° C.). Hydrogen chloride gas is passed in until the temperature is 55° C. The solution is allowed to stand at room temperature for 2 days and concentrated to ca 100 mL volume. Ether (200 mL) is added to precipitate the ester as a hydrochloride salt; wt 8.30 g; mp 193°-195° C. Recrystallization from ethanol-ether gives pure hydrochloride salt; mp 193°-195° C.
Anal. Calc. for C 20 H 23 NO 4 •HCl: C, 63.57; H, 6.40; N, 3.71. Found: C, 63.62; H, 6.49; N, 3.65.
EXAMPLE 19 ##STR28##
(RS)-1,2,3,4-Tetrahydro-5-hydroxy-6-methoxy-3-isoquinolinecarboxylic acid, ethyl ester
This compound is prepared from the amino acid hydrochloride of Example 17 by a procedure similar to that in Example 18. The product is a hydrochloride salt; mp 213°-214° C. dec.
Anal. Calc. for C 13 H 17 NO 4 •HCl: C, 54.26; H, 6.30; N, 4.87. Found: C, 54.11; H, 6.27; N, 4.76.
EXAMPLE 20 ##STR29##
(RS)-2-(Diphenylacetyl)-1,2,3,4-tetrahydro-6-methoxy-5-(phenylmethoxy)-3-isoquinolinecarboxylic acid
A quantity of 4.55 g (0.01 mole) of 20% tetramethylammonium hydroxide-in-methanol is added to a suspension of 1.56 g (0.005 mole) of the amino acid from Example 13 in 50 mL of methylene chloride. The resulting solution is cooled to 0° C. and, with stirring, a solution of 1.09 g (0.005 mole) of diphenylacetyl chloride in 5 mL of methylene chloride is added. After 5 minutes at 0° C. and one-half hour of warming to room temperature, the methylene chloride is stripped off and water (80 mL) is added. 1N Sodium hydroxide (10 mL) is added to help solution. The supernatant is decanted and the pH is adjusted to pH 2 with 6N HCl to precipitate gum. Ether (10 mL) is added. Crystals develop. The entire mixture is filtered and washed with ether and water; wt 1.40 g. Recrystallization from ethyl acetate-petroleum ether gives 1.20 g (48% yield) of pure product; mp 163°-165° C.
Anal. Calc. for C 32 H 29 NO 5 : C, 75.72; H, 5.76; N, 2.76. Found: C, 75.84; H, 5.72; N, 2.75.
EXAMPLE 21 ##STR30##
(RS)-2-(Diphenylacetyl)-1,2,3,4-tetrahydro-7-methoxy-6-(phenylmethoxy)-3-isoquinolinecarboxylic acid
This compound is prepared from the amino acid of Example 14 by a procedure similar to that in Example 20 to give an amorphous solid; mass spectrum (DEI) 507 (M + ).
Anal. Calc. for C 32 H 29 NO 5 •0.7H 2 O: C, 73.88; H, 5.89; N, 2.69. Found: C, 73.89; H, 5.81; N, 2.68.
EXAMPLE 22 ##STR31##
(RS)-2-(Diphenylacetyl)-1,2,3,4-tetrahydro-6-methoxy-5-(2-phenylethoxy)-3-isoquinolinecarboxylic acid
This compound is prepared from the amino acid of Example 15 by a procedure similar to that in Example 20; mp 136°-138° C.
Anal. Calc. for C 33 H 31 NO 5 : C, 75.99; H, 5.99; N, 2.69. Found: C, 75.69; H, 6.03; N, 2.61.
EXAMPLE 23 ##STR32##
(RS)-2-[Bis(4-chlorophenyl)acetyl]-1,2,3,4-tetrahydro-6-methoxy-5-(phenylmethoxy)-3-isoquinolinecarboxylic acid
This compound is prepared from the amino acid of Example 13 and bis(4-chlorophenyl)acetyl chloride by a procedure similar to that in Example 20; mp 186°-188° C.
Anal. Calc. for C 32 H 27 Cl 2 NO 5 : C, 66.67; H, 4.72; N, 2.42. Found: C, 66.67; H, 4.81; N, 2.42.
EXAMPLE 24 ##STR33##
(RS)-2-(Cyclopentylphenylacetyl)-1,2,3,4-tetrahydro-6-methoxy-5-(phenylmethoxy)-3-isoquinolinecarboxylic acid
This compound is prepared from the amino acid of Example 13 and α-phenylcyclopentaneacetyl chloride by a procedure similar to that in Example 20.
Anal. Calc. for C 31 H 33 NO 5 : C, 74.52; H, 6.61; N, 2.80. Found: C, 73.47; H, 6.82; N, 2.65.
EXAMPLE 25 ##STR34##
(RS)-2-[(2,6-Dichlorophenyl)acetyl]-1,2,3,4-tetrahydro-6-methoxy-5-(phenylmethoxy)-3-isoquinolinecarboxylic acid
This compound is prepared from the amino acid of Example 13 and 2,6-dichlorophenylacetyl chloride by a procedure similar to that in Example 20; mp 205°-207 ° C.
Anal. Calc. for C 26 H 23 Cl 2 NO 5 : C, 62.41; H, 4.63; N, 2.80. Found: C, 62.34; H, 4.53; N, 2.81.
EXAMPLE 26 ##STR35##
(RS)-1,2,3,4-Tetrahydro-6-methoxy-2-[(methylphenylamino)carbonyl]-5-(phenylmethoxy)-3-isoquinolinecarboxylic acid
This compound is prepared from the amino acid of Example 13 and N-methyl-N-phenylcarbamoyl chloride by a procedure similar to that in Example 20; mp 134°-136° C.
Anal. Calc. for C 26 H 26 N 2 O 5 : C, 69.94; H, 5.87; N, 6.28. Found: C, 69.91; H, 6.00; N, 6.05.
EXAMPLE 27 ##STR36##
(RS)-1,2,3,4-Tetrahydro-6-methoxy-2-[[(4-methoxyphenyl)amino]carbonyl]-5-(phenylmethoxy)-3-isoquinolinecarboxylic acid
A solution of 1.49 g (0.01 mole) of p-methoxyphenyl isocyanate in 10 mL of tetrahydrofuran is added dropwise to a stirred mixture of 2.95 g (0.0094 mole) of the amino acid of Example 13, 10.0 mL of 1N sodium hydroxide, and 15 mL of tetrahydrofuran at 10° C. After addition, the reaction mixture is allowed to warm to room temperature over a period of 1 hour. The tetrahydrofuran is stripped off and 150 mL of water and then 3 mL of glacial acetic acid are added to precipitate crude product; wt. 4.00 g. Recrystallization from methanol gives pure product; mp 176°-180° C. dec.
Anal. Calc. for C 26 H 26 N 2 O 6 : C, 67.52; H, 5.67; N, 6.06. Found: C, 67.53; H, 5.60; N, 5.86.
EXAMPLE 28 ##STR37##
(RS)-2-[[(4-Fluorophenyl)amino]carbonyl]-1,2,3,4-tetrahydro-6-methoxy-5-(phenylmethoxy)-3-isoquinolinecarboxylic acid
This compound is prepared from the amino acid of Example 13 and 4-fluorophenyl isocyanate by a procedure similar to that in Example 27; mp 186°-187° C. dec.
Anal. Calc. for C 25 H 23 FN 2 O 5 : C, 66.66; H, 5.15; N, 6.22. Found: C, 66.43; H, 5.08; N, 6.08.
EXAMPLE 29 ##STR38##
(RS)-1,2,3,4-Tetrahydro-5-hydroxy-6-methoxy-2-[methyl(phenylamino)carbonyl]-3-isoquinolinecarboxylic acid
At room temperature, a solution of 1.23 g (0.108 mole) of N-methyl-N-phenylcarbamoyl chloride in 5 mL of dioxane is added to a stirred mixture of 2.07 g (0.008 mole) of the compound from Example 17 (hydrochloride salt), 24 mL (0.024 mole) of 1N sodium hydroxide, and 15 mL of dioxane. After 15 minutes at room temperature, the reaction mixture is heated at 75° C. for 5 minutes. The dioxane is removed at reduced pressure. Water (10 mL) and then 16 mL (0.016 mole) of 1N hydrochloric acid is added to precipitate the product; wt 2.00 g (64% yield). Recrystallization from methanol-methylene chloride gives pure crystals; wt 1.50 g; mp 235°-255° C.
Anal. Calc. for C 19 H 20 N 2 O 5 •0.33CH 3 OH: C, 63.27; H, 5.86; N, 7.64. Found: C, 63.27; H, 5.64; N, 7.79.
EXAMPLE 30 ##STR39##
(RS)-2-(Diphenylacetyl)-1,2,3,4-tetrahydro-6-methoxy-5-phenylmethoxy-3-isoquinolinecarboxylic acid, ethyl ester
A solution of 0.76 g (0.0033 mole) of diphenylacetyl chloride in 5 mL of methylene chloride is added dropwise to a stirred solution of 1.25 g (0.0033 mole) of the compound from Example 18 (hydrochloride), 20 mL of methylene chloride, and 0.74 g (0.0073 mole) of triethylamine. After 15 minutes the solvent is stripped off and 30 mL of ice water and 50 mL of ether are added. The separated ether phase is washed with 25 mL of water, 25 mL of 0.1N hydrochloric acid, and then dried (magnesium sulfate) and concentrated to give 1.20 g of product; mp 111°-113° C. Recrystallization from ethyl acetate-isopropyl ether gives 0.90 g of pure product; mp 114°-115° C.
Anal. Calc. for C 34 H 33 NO 5 : C, 76.24; H, 6.21; N, 2.62. Found: C, 76.23; H, 6.26; N, 2.55.
EXAMPLE 31 ##STR40##
(RS)-2-(Diphenylacetyl)-1,2,3,4-tetrahydro-5-hydroxy-6-methoxy-3-isoquinolinecarboxylic acid, ethyl ester
This compound is prepared from the amino ester of Example 19 and diphenylacetyl chloride by a procedure similar to that in Example 30; mass spectrum (CI): 446 (M+1).
EXAMPLE 32 ##STR41##
(RS)-5-[(4-Carbomethoxyphenyl)methoxy]-2-(diphenyacetyl)-1,2,3,4-tetrahydro-6-methoxy-3-isoquinolinecarboxylic acid, ethyl ester
A mixture of 0.89 g (0.002 mole) of the compound from Example 31, 0.69 g (0.003 mole) of 4-carbomethoxybenzyl bromide (Aldrich), 5.0 g of powdered anhydrous sodium carbonate, and 5 mL of DMF is heated at reflux, with stirring, for 5 minutes. The cooled mixture is treated with 50 mL of ice water. The precipitated product is extracted into 150 mL of ether. The solution is dried (magnesium sulfate) and concentrated; wt. of amorphous solid 1.20 g; mass spectrum (CI) 594 (M + ).
EXAMPLE 33 ##STR42##
(RS)-5-(4-Carboxyphenylmethoxy)-2-(diphenylacetyl)-1,2,3,4-tetrahydro-6-methoxy-3-isoquinolinecarboxylic acid
A solution of 1.10 g (0.0019 mole) of the diester from Example 32 in 100 mL of methanol and 15 mL of 2N sodium hydroxide is heated to the boiling point, allowing the methanol to distill off. After 1 hour (pot temperature=90° C.), 1N hydrochloric acid (35 mL) is added to precipitate a gum. On addition of 10 mL of ether, crystals develop; wt. 0.84 g. Recrystallization from ethyl acetate-petroleum ether gives pure product; mp 190°-192° C.
Anal. Calc. for C 33 H 29 NO 7 : C, 71.86; H, 5.30; N, 2.54. Found: C, 71.46; H, 5.15; N, 2.38.
EXAMPLE 34 ##STR43##
(RS)-2-(Diphenylacetyl)-1,2,3,4-tetrahydro-6-methoxy-5-[(4-methoxy-3-methylphenyl)methoxy]-3-isoquinolinecarboxylic acid, ethyl ester
This compound is prepared from the phenol derivative of Example 31 and 4-methoxy-3-methyl benzyl chloride by a procedure similar to that in Example 32. The product is purified by silica gel chromatography; tlc (1:1 ethyl-acetate/hexane), one spot, Rf 0.7.
EXAMPLE 35 ##STR44##
(RS)-2-(Diphenylacetyl)-1,2,3,4-tetrahydro-6-methoxy-5-[(4-methoxy-3-methylphenyl)methoxy]-3-isoquinolinecarboxylic acid
This compound is prepared by a hydrolysis of the ester from Example 34 as follows: a solution of 0.50 g (0.86 mmole) of the ester, 50 mL of methanol, and 2.0 mL of 1N sodium hydroxide is maintained at reflux for 15 minutes. The methanol is removed, water (30 mL) is added, and 1.0 mL of glacial acetic acid is added to precipitate the gummy product. Purification by silica gel chromatography eluting with 5% methanol-chloroform gives pure product; mp 140°-142° C.
Anal. Calc. for C 34 H 33 NO 6 : C, 74.03; H, 6.03; N, 2.54. Found: C, 73.64; H, 6.04; N, 2.42.
EXAMPLE 36 ##STR45##
2-Benzyloxy-3-methoxybenzylalcohol
A solution of 43.00 g (0.18 mole) of 2-benzyloxy-3-methoxy-benzaldehyde of Example 1 in 300 mL of absolute ethanol is treated, with stirring, with 7.56 g (0.20 mole) of sodium borohydride. The temperature rises to 50° C. After one-half hour 10 mL of acetone is added, keeping the temperature at less than 60° C. with cooling. After 15 minutes the volatiles are stripped off at reduced pressure. Ice water (500 mL) is added and the product is extracted into 600 mL of ethyl acetate. The dried (NA 2 SO 4 ) solution is concentrated. The remaining oil is dissolved in 100 mL of warm ether. Petroleum ether is added to turbidity to give 37.70 g (86% yield) of pure product; mp 58°-60° C.
Anal. Calc. for C 15 H 16 O 3 : C, 73.75; H, 6.60. Found: C, 73.74; H, 6.62.
EXAMPLE 37 ##STR46##
3-Methoxy-2-(4-nitrophenoxy)benzylalcohol
This compound is prepared from the corresponding aldehyde of Example 2 by a procedure similar to that described in Example 36; mp 121°-122° C.; mass spectrum (EI) 275 (M + ).
Anal. Calc. for C 14 H 13 NO 5 : C, 61.08; H, 4.76; N, 5.04. Found: C, 60.95; H, 4.73; N, 5.25.
EXAMPLE 38 ##STR47##
3-(Chloromethyl)-2-phenylmethoxyanisole
A suspension of 92.00 g (0.377 mole) of the alcohol, prepared as in Example 36, in 300 mL of toluene is cooled to 10° C. With stirring, a solution of 75.0 g (0.63 mole) of thionylchloride in 100 mL of toluene is added gradually. Five minutes after addition the reaction is stirred at room temperature for one-half hour. The volatiles are removed at reduced pressure to give 99.0 g (100%) of the product as an oil; tlc (1:1 ethyl acetate-hexane) one spot, Rf 0.8.
EXAMPLE 39 ##STR48##
3-(Chloromethyl)-2-(4-nitrophenoxy)anisole
This compound is prepared from the alcohol of Example 37 by a procedure similar to that of Example 38; mp 120°-123° C.; mass spectrum (EI) 293 (M + ).
EXAMPLE 40 ##STR49##
2-(Acetylamino)-2-[[3-methoxy-2-(phenylmethoxy)phenyl]methyl]-propanedioic acid, diethyl ester
A quantity of 136.20 g (0.42 mole) of 21 wt. % sodium ethoxide-in-ethanol is added to a stirred solution of 90.14 g (0.415 mole) of diethyl acetamidomalonate (Aldrich) in 800 mL of absolute ethanol. A solution of the benzyl chloride derivative of Example 38 in 500 mL of absolute ethanol is added and the mixture is heated at reflux for 2 hours. The cooled mixture is poured into 4 L of ice and water containing 20.0 g of glacial acetic acid. The supernatant is decanted from the separated gum. The gum is dissolved in 2 L of ether, the solution dried (magnesium sulfate), and concentrated to ca 300 mL volume. Petroleum ether (100 mL) is added to precipitate 107.1 g (66.4% yield) of pure crystalline product; mp 94°-96° C.
Anal. Calc. for C 24 H 29 NO 7 : C, 65.00; H, 6.59; N, 3.16. Found: C, 65.12; H, 6.75; N, 3.13.
EXAMPLE 41 ##STR50##
(Acetylamino)[[3-methoxy-2-(4-nitrophenoxy)phenyl]methyl]-propanedioic acid, diethyl ester
A quantity of 0.50 g (12.5 mole) of 60% sodium hydride oil is rinsed with dry tetrahydrofuran (5 mL). The THF is decanted and 20 mL of DMSO is added to the NaH under nitrogen. With stirring 2.50 g (11.5 mole) of diethyl acetamidomalonate is added to give vigorous evolution of hydrogen. After 2 hours at room temperature, 3.00 g (10.2 mole) of the benzyl chloride of Example 39 and 0.30 g (2.0 mole) of sodium iodide (pulverized) are added. The mixture is stirred for 3 days and poured into ca 300 mL of ice water containing 2 mL of glacial acetic acid. The resulting precipitate is extracted into ethyl acetate. The extract is washed with water and 5% sodium thiosulfate solution, dried (magnesium sulfate), and concentrated to give 4.64 g (96%) of crude product. Recrystallization from ethyl acetate gives pure product; mp 189°-190° C.; mass spectrum (DEI) 474 (M + ).
Anal. Calc. for C 23 H 26 N 2 O 9 : C, 58.22; H, 5.52; N, 5.90. Found: C, 58,39; H, 5,54; N, 5.99.
EXAMPLE 42 ##STR51##
(RS)-1,2,3,4-Tetrahydro-6-methoxy-5-(4-nitrophenoxy)-3-isoquinolinecarboxylic acid, methyl ester
A solution of 1.00 g (0.0026 mole) of the amino acid (hydrochloride salt) of Example 16 in 75 mL of methanol is saturated with hydrogen chloride gas, allowing the temperature to rise to near the boiling point. The solution is allowed to stand at room temperature overnight. The separated white crystals are filtered and washed with 50% methanol-ether to give 0.86 g of pure amino ester product as a hydrochloride salt; mp 237°-239° C. dec.
Anal. Calc. for C 18 H 18 N 2 O 6 •HCl: C, 54.76; H, 4.85; N, 7.10. Found: C, 54. 51; H, 4.81; N, 7.00.
EXAMPLE 43 ##STR52##
(RS)-2-(Diphenylacetyl)-1,2,3,4-tetrahydro-6-methoxy-5-(4-nitrophenoxy)-3-isoquinolinecarboxylic acid, methyl ester
A solution of 0.35 g (1.30 mole) of diphenylacetyl chloride in 2 mL of acetonitrile is added to a stirred mixture of 0.60 g (1.50 mole) of the amino ester hydrochloride of Example 42, 8 mL of acetonitrile, and 0.33 g (3.30 mole) of triethylamine. After 1 hour the mixture is poured into 50 mL cold 2% potassium bisulfate solution. The supernatant is decanted from the gum. The gum is extracted into 50 mL methylene chloride. The solution is dried (magnesium sulfate), charcoaled, filtered, and concentrated to give 0.81 g of pure product as a solid foam.
Anal. Calc. for C 32 H 28 N 2 O 7 : C, 69.56; H, 5.11; N, 5.07. Found: C, 69.29; H, 5.19; N, 4.78.
EXAMPLE 44 ##STR53##
(RS)-5-(4-Aminophenoxy)-2-(diphenylacetyl)-1,2,3,4-tetrahydro-6-methoxy-3-isoquinolinecarboxylic acid, methyl ester
A solution of 0.80 g (1.45 mole) of the nitrobenzene derivative of Example 43 in 50% methanol-THF is reduced with 5% palladium-on-carbon catalyst. The filtered solution is concentrated at reduced pressure to give 0.75 g of pure product as a solid foam; mass spectrum (EI) 522 (M + ).
Anal. Calc. for C 32 H 30 N 2 O 5 : C, 73.55; H, 5.79; N, 5.36. Found: C, 72.37; H, 5.76; N, 5.06.
EXAMPLE 45 ##STR54##
(RS)-5-(4-Aminophenoxy)-2-(diphenylacetyl)-1,2,3,4-tetrahydro-6-methoxy-3-isoquinolinecarboxylic acid
This compound is prepared by hydrolysis of the corresponding ester of Example 44 by a procedure similar to that of Example 35; mass spectrum (FAB) 509.2 (M+1).
EXAMPLE 46 ##STR55##
3-Methoxy-2-(2-phenylethoxy)benzaldehyde
A mixture of 111.0 g (0.73 mole) of o-vanillin, 130 g (0.70 mole) of β-phenethyl bromide, 1 L of DMF, and 300 g of anhydrous powdered potassium carbonate is heated with stirring at reflux for 3 hours. The cooled mixture is added to 2 L of ice water. The separated product is extracted with 1 L of ether. The ether solution is washed with 500 mL of 1N sodium hydroxide, dried (potassium carbonate), and concentrated to ca 300 mL volume. Hexane is added to turbidity and this solution is passed through a column of silica gel, eluting first with hexane to remove fast spot (Rf 0.9, 1:1 hexane-ethyl acetate, tlc system) and then with ethyl acetate to obtain 87.1 g (49%) of product; tlc (1:1 hexane-ethyl acetate) Rf 0.8.
EXAMPLE 47 ##STR56##
(+)-2-(Diphenylacetyl)-1,2,3,4-tetrahydro-6-methoxy-5-(phenylmethoxy)-3-isoquinolinecarboxylic acid
A quantity of 0.342 g (0.67 mole) of the compound from Example 20 is dissolved in 10 mL of ethyl acetate. The solution is treated with 0.083 g (0.67 mole) of 98% l (-)-α-methylbenzylamine. Petroleum ether is added until slightly turbid. Crystals separate on inducement; wt 0.185 g; mp 147°-149° C. Recrystallization from ethyl acetatepetroleum ether give the purified, least soluble diastereomeric salt; mp 157°-159° C. Regeneration of the free acid is accomplished by dissolution of the salt in a minimum amount of methanol and precipitation of the amorphous product (mp 80°-91° C.) with excess 1% potassium bisulfate solution; [α] D 23 +17.44° (0.9% MeOH).
Anal. Calc. for C 32 H 29 NO 5 •0.3H 2 O: C, 74.92; H, 5.82; N, 2.73. Found: C, 74.54; H, 5.42; N, 2.49.
EXAMPLE 48 ##STR57##
(RS)-N-Acetyl-3-methoxy-2-(phenylmethoxy)phenylalanine
A quantity of 300 mL of 1N sodium hydroxide is added to a hot solution of 44.40 g (0.10 mole) of the compound of Example 40 in 500 mL of methanol. The resulting mixture is heated on the steam bath, allowing the methanol to distill over (1 hour). Water (500 mL) is added and the supernatant is decanted from some gum. 6N Hydrochloric acid is added to the decantate to pH 3. CO 2 is vigorously liberated as crude solid separates.
Recrystallization from methanol-water gives 21.3 g (62% yield) of product; mp 169°-170° C.
Anal. Calc. for C 19 H 21 NO 5 : C, 66.46; H, 6.17; N, 4.08. Found: C, 66.37; H, 6.39; N, 4.02. | This invention relates to novel substituted 1,2,3,4-tetrahydroisoquinolines which are useful in the treatment of vascular restenosis, various disorders of the central nervous system, in the regulation of female reproductive functions, in cognitive enhancement, in atherosclerosis and in treating excessive AVP secretory disorders. Novel intermediates useful in the preparation of the compounds are also disclosed. Methods of using the compounds and pharmaceutical compositions containing them are disclosed. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of U.S. patent application Ser. No. 206,744, filed Nov. 14, 1980, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to angular orientation indicators and has particular reference to optical devices therefor.
In providing inertial navigation instruments for shipborne navigation systems, a need arises to isolate the inertial measurement unit (IMU) of a system from the ship structure in order to avoid the effects of structure-transmitted shock on the operation of the system. In a recently adopted design, a shockmount provides isolation of the IMU from the ship structure by a six-degree-of-freedom, low-frequency, elastomeric suspension which allows the IMU compliance in both rotation and translation. This suspension concept enables an elegantly simple mechanical suspension design to be used which is much lower in cost and which provides better isolation of the IMU from angular acceleration than does the use of conventional, irrotational ("hard") shockmounts.
In order to use this shockmount concept, it is necessary to maintain precise and continuous measurement of the attitude or angular orientation of the IMU relative to a ship-fixed reference frame so that the ship's roll, pitch and heading can be determined. These are typically required system outputs. Thus, a need arises for apparatus to provide an accurate, direct and continuous measurement of the IMU attitude relative to the ship.
A tracking autocollimator could be used for this purpose. Such a device uses a mirror mounted for rotation on a two-axis gimbal. However, such an approach has the disadvantage of requiring the use of mechanical moving parts in the gimbal structure. As is well known, the use of such mechanical moving parts is to be avoided, where possible, since they decrease the reliability of a device while increasing its complexity and cost.
SUMMARY OF THE INVENTION
An object of the present invention is the provision of precise, direct and continuous measurements of the attitude or angular orientation of a body relative to some reference frame such as, for example, an IMU relative to a ship-fixed reference frame as discussed above.
Another object of the invention is the provision measurements of the angular displacement of a body using a device which has no mechanical moving parts.
According to the present invention, the foregoing and other objects are attained by an electro-optical readout system having a sensor array of photodetectors disposed along a straight line on a planar surface. The planar surface is maintained substantially parallel to a selected axis about which it is desired to measure angular displacement due to rotation. The line of the sensor array is substantially perpendicular to the selected axis. A source of light is disposed on the planar surface close to the array but spaced apart therefrom. Optical means are provided to receive light from the source and to collimate it for transmission to a reflecting reference flat. The planar surface and the sensor array of photodetectors are in the focal plane of the optical means. The optical means, the light source and the planar surface having the sensor array thereon are assembled and mounted in fixed relationship to each other. The light striking the reference flat is reflected back through the optics into an image of the light source on the photodetector array. The position of the image on the array relative to a reference point, is a measure of the angular displacement between the reference flat and the planar surface about the selected axis.
In the preferred embodiment of the invention, the optics is designed to spread the image of the light source into a line extending substantially perpendicular to the line of the sensor array. In this case, the optics is formed to collimate the light transmitted to the reference flat in a first direction parallel to the line of the sensor array and to cause the light to diverge in a second direction orthogonal to the first direction and thus orthogonal to the sensor array of photodetectors.
The deployment of the major parts of an electro-optical sensor in accord with the invention is flexible in that the assembly of optics, photodetector array and light source may be mounted either on a first body or base which may be regarded as having a reference orientation or on another body rotatable relative to the first body. Whichever of the two bodies carries the assembly, the other body will carry the reference flat.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view in perspective of an electro-optic orientation sensor in accord with the invention.
FIG. 2 shows the effect of rotation on the sensor of FIG. 1.
FIG. 3 is a view in perspective of an alternative embodiment of the sensor.
FIG. 4 shows a view in perspective of yet another alternative embodiment of a sensor in accord with the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1, there is shown an electro-optic sensor 10 in accord with the invention. On a planar surface 12, a light source 14 is disposed adjacent to a linear array of photodetectors 16.
The light source 14 may be a light-emitting diode (LED) wherein the light is in the infra-red range. Plessey Telecommunications of Liverpool, England, makes a gallium arsenide infra-red emitter for fiber optic transmission links which is also useful as the light source 14 for this sensor.
The linear array of photodetectors 16 may be, for example, a photodiode array such as the Reticon RL-1024G solid state line scanner built by EG&G Reticon of Sunnyvale, Calif., for various commercial applications such as optical character recognition, pattern recognition and facsimile.
The planar surface 12 is at the focal plane of a collimating lens 18. Collimating lens 18 receives light from the LED 14 and transmits it to a reflecting reference flat 20.
Given that the electro-optic sensor 10 is to measure the orientation or attitude of a certain body rotatable with respect to a base, the planar surface 12 may be mounted on the rotatable body. In this case, the reference flat 20 will be mounted on the base. Conversely, if the planar surface 12 is fixed to the base, the reference flat 20 will be mounted on the rotatable body. Whichever of these two alternatives is chosen, the planar surface 12 and the reference flat 20 are so mounted that they are substantially parallel to each other when the rotatable body is at a reference attitude relative to the base.
The electro-optic sensor 10 is a single-axis sensor in that it is well adapted to measure angular displacement about only one selected axis. The selected axis is parallel to the planar surface 12, parallel to the reference flat 20 and perpendicular to the line of the photodiode array 16. Note the set of coordinate axes drawn near reference flat 20 in FIG. 1. The selected axis for the sensor 10 is the Y axis of these coordinates.
The light source 14 is disposed adjacent to the photodiode array 16. That photodiode in the array 16 which is closest to the light source 14 will typically be selected to be reference sensor element which, when energized by light reflected from the reference flat 20, indicates alignment of the rotatable body to its reference attitude.
In the situation where the reference flat 20 is precisely parallel to the planar surface 12, and where collimating optics only is interposed between the light source 14 and the reference flat 20, light reflected from the reference flat 20 would be focused into an image of the light source 14 at the light source 14 rather than on the photodiode array 16. This is undesirable since there would be no useful output of the sensor 10 in this case. However, it will be apparent to those skilled in the art that the spot image of the light source 14 can be focussed on the photodiode array 16 by introducing a bias rotation of the reference flat 20 relative to the planar surface 12, or vice versa, about the Z axis. In fact, in a single axis system, a bias could be maintained on the Z axis to insure that the spot image of the light source 14 falls on the photodiode array 16 for any angular displacement of the reference flat 20 relative to the planar surface 12 about the Y axis. However, such an arrangement is unlikely to be desirable since the operation of the sensor 10 would then be unduly dependent on a fixed orientation about the Z axis. It is for this reason that a diverging lens 22 is interposed between the collimating lens 18 and the reference flat 20 in the sensor 10 of FIG. 1. Diverging lens 22 causes light transmitted through it from the light source 14 to diverge in a direction perpendicular to the line of the photodiode array 14. The image 24 of the light source 14 which is reflected back onto the planarsurface 12 and photodiode array 16 is thus spread into a line extending substantially perpendicular to the line of the photodiode array 16. This compensates for the displacement of the light source 14 from the array line and also makes the sensor 10 insensitive to rotation about the Z axis.
In an experimental assembly of a sensor 10 in accord with the invention built to test its performance, the distance from the diverging lens 22 to the reference flat 20 was about seven inches. The diverging lens 22 was a 60 mm by 50 mm negative cylinder lens having a minus 145 mm focal length. The collimating lens 18 was a 40 mm diameter rotationally symmetric lens having a 160 mm focal length. The reflecting reference flat 20 was a 3-inch diameter mirror coated with gold to obtain high reflectance in the infra-red band of light wavelengths. Internal reflections in the spherical collimating lens 18 were reduced by forming anti-reflection coatings on the lens' surface and by adjusting its position.
Referring now to FIG. 2, the sensor 10 of FIG. 1 is seen as having experienced an angular displacement of the reference flat 20 about the Y axis. The reflected line image 24 is thus raised a distance above the reference diode element on the photodiode array 16. Scanning of the photodiode array 16 by suitable electronic circuitry detects the particular photodiode illuminated by this displacement of the line image 24.
The light source 14 is preferably pulsed to obtain high intensity light and therefore high sensitivity of the sensor 10, while keeping the average power dissipated in the source 14 low. The pulsing may be synchronized by the same circuitry used to scan the photodiode array 16.
It is seen that rotation of the reference flat 20 relative to the planar surface 12, or vice versa, about an axis parallel to the line image 24 causes the line image 24 to move along the linear photodiode array 16. Thus an individual illuminated photodiode provides a measure of the angular displacement about this axis (in this case, the Y axis). This input axis is normal to the line of sight of the sensor 10 and also normal to the axis of the negative cylinder lens 22. The long axis or array line of the photo-detector 16 is parallel to the axis of the cylinder lens 22. If rotation about the line of sight occurs, nothing changes. Hence the electro-optic sensor 10 is insensitive to such rotation. Also, if rotation occurs about an axis parallel to the negative cylinder lens axis (in this case, the Z axis), the line image 24 moves along itself and the same photodiode on the photodiode array 16 remains illuminated. Thus the sensor 10 is insensitive to rotations about these latter two axes. The sensor 10 is also insensitive to linear motions, which only affect the intensity of the returned line image 24.
In cases where the location of the reference flat 20 relative to the lenses is well established, greater sensitivity may be obtained if the negative cylinder diverging lens 22 of FIGS. 1 and 2 is replaced by a positive cylinder diverging lens 32 as shown in the electro-optic sensor 30 of FIG. 3. The axis of the lens 32 is parallel to the line of the array 16. The greater sensitivity is achieved with the positive cylinder diverging lens 32 because relatively more of the light energy is collected from the reference flat 20 and returned to the light image 24. Thus, the intensity of light at the photodiode array 16 is increased. For proper operation, the reference flat 20 must be displaced from the focal point of the lens 32 by at least about twenty percent of the focal length thereof. This is because the positive cylinder lens 32 produces no divergence at its focal point.
In applications of this invention such as the one discussed above, angular displacements are limited to fairly small angles. In such applications, the diverging lens 22 or 32 need not have a particularly large power or diverging effect. The diverging effect may be limited to be no more than is necessary to maintain the line image 24 in registration with the photodiode array 16 for the limited angular displacement about the Z axis.
Limiting the diverging effect of the cylinder lens 22 or 32 and thus limiting the length of the line image 24 has several advantages. First, the resulting intensity of the light at the photodetector is greater than it would be for a longer line image 24. In addition, it is relatively easier and less costly to provide cylinder lenses with low distortion when the lens is required to have only relatively low power.
It should be noted that neither of diverging lenses 22 and 32 is required to focus. All of the focussing necessary is provided by the rotationally symmetric collimating lens 18 in the embodiments of FIG.'s. 1, 2 and 3. Inasmuch as rotationally symmetric lenses are relatively much easier and less costly to fabricate with high power and low distortion, a collimiating lens 18 capable of providing very high resolution can be readily procured for use in this invention. Thus, due to the high resolution available in the collimating lens 18, it is appropriate to use a photodetector array 16 having a similarly high resolution in the embodiments of FIG.'s. 1, 2 and 3.
If the power of the cylinder lens 22 in FIGS. 1 and 2 is chosen to be equal to minus the power of the collimating optics 18, the first-order properties of these two lenses may be merged into a single positive cylinder lens 42 as shown in the electro-optic sensor 40 of FIG. 4. In this embodiment, cylinder lens 42 has its axis perpendicular to the line of the array of photodetectors 16. With this arrangement, the number of optical elements required is reduced. Planar surface 12 is at the focal plane of the lens 42.
By attempting to measure rotation about a single axis only, the electro-optic sensors 10, 30 and 40 of FIGS. 1-4 can use a linear photodiode array 16 rather than a two-dimensional array. Linear photodetector arrays have much better resolution than two-dimensional arrays. Furthermore, since a line image only is required, the sensors 10, 30 and 40 are not degraded by optical astigmatism. Thus, quite simple optics are typically adequate to practice the invention.
Where, as in the case of the IMU suspended for shipboard navigation discussed above, it is desired to measure the overall angular displacement of a body about a set of three orthogonal coordinate axes, three individual electro-optic sensors 10, 30 or 40, each as shown in FIGS. 1 and 2 or 3 or 4, are mounted so as to form an orthogonal triad.
The lenses shown in FIGS. 1-4 appear as single-element lenses. As will be apparent to those skilled in the art, however, compound lenses may be used, were appropriate, to meet performance requirements.
There have been described preferred embodiments of the invention. However, it will be apparent to those skilled in the art that embodiments other than those which have been expressly described are possible and that these other embodiments will fall within the spirit and scope of this invention as set forth in the following claims. | An electro-optic sensor for precise, direct and continuous measurement of the angular displacement between two bodies. A linear array of photodetectors is disposed on a planar surface mounted on the first body parallel to the axis about which the displacement is to be measured. The line of the array is perpendicular to this axis. A light source disposed on the planar surface near the photodetector array transmits light through optics to a reflecting reference flat mounted on the second body. The optics collimates the transmitted light and causes the reflected image of the light source to be spread into a line on and perpendicular to the photodetector array. This line image moves along the linear array as angular displacement occurs between the two bodies. No mechanical moving parts are required in the sensor. | 6 |
This application is a Continuation patent application of copending U.S. application Ser. No. 12/736,814, filed 12 Nov. 2010.
RELATIONSHIP TO OTHER APPLICATIONS
This application claims priority to and benefits of the following: U.S. Provisional Patent Application No. 60/127,588, filed 13 May 2008, entitled “Fluorescence Detection And Deactivation Of Poison Oak Oil”, International Patent Application number PCT/US2009/002958, filed 13 May 2009, entitled “Fluorescence Detection And Deactivation Of Poison Oak Oil”, and U.S. National Phase patent application Ser. No. 12/736,814, filed 12 Nov. 2010, entitled “Fluorescence Detection And Deactivation Of Poison Oak Oil”, each of which is herein incorporated by reference in its entirety for all purposes.
This invention was made partly using funds from United States National Science Foundation (NSF) research grant No. CHE-0453126. The Federal Government has certain rights to this invention.
FIELD OF THE INVENTION
The invention provides compositions, kits, and methods of using the compositions and kits for detecting, deactivating, degrading, immunogenic compounds from poison oak and poison ivy.
BACKGROUND
Urushiol-induced allergic contact dermatitis in the United States most commonly results from unexpected exposure to oils from plants in the sumac Family Anacardiaceae. Approximately 10 to 50 million Americans suffer from rashes resulting from exposure every year. In particular, the genus Toxicodendron species (which include Western and Eastern poison oak T. diversilobum , poison ivy T. radicans , and poison sumac or dogwood T. vernix ) are distributed widely across North America. Other sources of urushiol include poison wood (in Florida and the Bahamas), and the sap (kiurushi) of the Asian lacquer tree ( Toxicodendron vemiciflua ) used as a varnish in Japanese lacquer ware, and cashew nut shells. (See, for example, Tucker and Swan (1998) NEJM, 339(4): 235.)
Reaction to urushiol is an immunological response to the bio-oxidized form of urushiol (the ortho-quinone). Approximately 50-70% of the U.S. population is either allergic to urushiol, or will become allergic to it upon sensitization by repeated exposure. Symptoms of allergic contact dermatitis from urushiol exposure (often referred to as Rhus dermatitis) vary from a mild annoyance to weeks of irritation and pain. Occasionally, exposure can lead to nephropathy and even to fatal systemic anaphylaxis. The monetary cost due to worker disability from urushiol-induced injuries is substantive: in the states of California, Washington and Oregon, it has been estimated that up to one third of forestry workers are temporarily disabled by poison oak dermatitis each year. In California, the medical costs associated with poison oak injuries accounts for up to 1% of the annual workers' compensation budget. It has been estimated that Toxicodendron dermatitis is responsible for 10% of the total U.S. Forest Services lost-time injuries. In 1988, NIOSH estimated that 1.07-1.65 million occupational skin injuries occurred yearly, with an estimated annual rate of 1.4 to 2.2 cases per 100 workers (8) the costs attributable to lost productivity, medical payments, and disability payments are very high. (See U.S. Centers for Disease Control; Leading work-related diseases and injuries—United States. MMWR, 1986 335:561-563).
Chemically, urushiol is a name given to a collection of related compounds that are 3-substituted catechols (1,2-benenediols), in which the long hydrophobic chain is a linear C 15 or C 17 alkyl chain containing 0-4 degrees of cis unsaturation ( FIG. 1 ). The catechols with two, three, and four carbon-carbon double bonds (2-4 degrees of unsaturation) seem to be the most virulent in eliciting an allergic response. Each of the different members of the Toxicodendron species contain mixtures of the C 15 or C 17 alkyl chains, with various degrees of unsaturation.
They all share the catechol functionality in common, and a long, greasy alkyl chain that facilitates migration into the skin. In addition to direct contact with the toxic plants, exposure commonly occurs by transfer from animal fur, contaminated clothing, garden tools, fire-fighting equipment, forestry and sports equipment. There are a few commercially available products that can be applied prophylactically to protect the skin by creating a physical barrier using organoclays (for example, a lotion containing quaternium-18 bentonite is commercially available as IVYBLOCK from Enviroderm Pharmaceuticals, Inc.). However, the success of this strategy requires advanced planning By far the majority of allergic contact dermatitis cases from urushiol result from unexpected exposure.
A number of methods to treat poison ivy or poison oak have been investigated, including hyposensitization, but this process is involved and can have unfavorable side effects. Studies towards an immunological approach to desensitization have been pursued, but have not yet reached a level of practical application. The best treatment to date is to avoid contact with urushiol. As most patients are unaware that they have had contact with urushiol, a low cost, quick and inexpensive method of detection is warranted. There are many recommended methods to remove urushiol after recent contact, including water, soapy water, organic solvents, and a variety of commercially available solubilizing mixtures including TECHNU, IVYCLEANSE, ALL-STOP, ZANFEL (comprising fatty acid, alcohol, and the surfactant sodium lauroyl sarcosinate), and even DIAL ultra dishwashing soap. Thus the ability to detect urushiol before it transverses the skin will be extremely valuable in mitigating the suffering caused by contact with the various Toxicodendron species. In addition, continued re-exposure (chronic exposure) from repeated introduction of the oil to the patient (from door handles, shoelaces, etc.) is a considerable problem. As little as 0.001 mg of urushiol is enough to cause allergic contact dermatitis.
Treatment of the contact dermatitis usually involves a course of topical and/or enteric treatments with hydrocortisones, β-methasone, and other similar corticosteroids. Repeated exposure to either the original allergen or to a similar allergen can result in a severe hypersensitive immunoreaction, that is often extremely painful and, occasionally, fatal. There is therefore a particular need in the art for compounds and methods of treatment that can remove the allergen(s) prior to induction of an immune and/or allergic response, that can prevent the binding of the allergen(s) to an immunoglobulin or a cell-surface receptor, and/or that can be used to rapidly detect the presence of such allergen(s) so that other precautions may be used to remove the allergen(s) from the area of contact.
There is therefore a need in the art to provide for compositions and methods for detecting the presence of urushiol, inactivating urushiol, and removing urushiol from substrates (including, for example, skin and clothing).
BRIEF DESCRIPTION OF THE INVENTION
The invention is drawn to novel methods, kits, sprays (including aerosol sprays) and compositions for detecting active compounds present in oils that are found in poison oak, poison ivy, poison sumac, cashew nut, and related plants. The methods disclosed herein may also be used to detect other catechols, both synthetic and those found in nature. The invention also is drawn to compositions that may be used to detect said active compounds using fluorescence. In one embodiment the methods of the invention may be used to detect catechols and alkyl-substituted catechols, such as, for example, urushiol, catechin, epicatechin, gallocatechin, epigallocatechin, epigallocatechin-3-gallate, and the like; and chatecholamines, such as, for example, epinephrine, norepinephrine, dopamine, dihydroxyphenylalanine (DOPA), and the like.
The invention provides methods for detecting, treating, and deactivating the antigenic and/or allergenic compounds that induce urushiol-induced contact dermatitis. In one embodiment the method may be used for treating, deactivating, and/or detecting alk(en)yl catechols, and/or alk(en)yl resorcinols.
The invention may be used by clinicians, nursing staff, paramedics, emergency rescue team members, the military, firefighters, forestry personnel, lumberworkers, hunters, mountaineers, hikers, anglers, and the like. In one embodiment, the invention is a kit comprising the elements disclosed herein and a set of instructions of how to use the kit, wherein the kit is used for detecting, treating, and/or deactivating a catechol. The kit can be used, for example, in the home, in the field, in a camp, in a clinic, in a hospital, in an emergency room, and the like.
The invention provides a kit for detecting a catechol, the kit comprising a vessel, the vessel shaped and adapted for confining a composition, the composition further comprising a boron composition, a first nitroxide, and a second nitoxide, and an applicator. In one embodiment the boron composition comprises a hydrophobic alkyl group. In another embodiment the second nitroxide is a profluorescent nitroxide. In a preferred embodiment the applicator is a spray applicator. In a most preferred embodiment the catechol is urushiol. In one alternative embodiment, the kit can also comprise an aerosol propellant. In another embodiment the kit comprises a lamp.
In a preferred embodiment, the invention provides a method for detecting a catechol in a sample, the method comprising the steps of (i) contacting a boron composition and a nitroxide with the sample (ii) allowing the boron composition to react with the catechol in the sample thereby creating a catecholborane; (iii) allowing a first nitroxide to react with the catecholborane thereby generating an alkyl radical and a nitroxide-catecholborane complex; (iv) allowing the alkyl radical to react with a second nitroxide thereby creating an alkoxyamine; (v) measuring the amount of alkoxyamine, nitroxide-catecholborane complex, or an alkoxyamine hydrolysis product so created; the method resulting in detecting the catechol in the sample. In one embodiment the boron composition comprises a hydrophobic alkyl group. In a preferred embodiment, the catecholborane is a B-alkyl catecholborane. In another preferred embodiment the alkyl group is selected from the group consisting of a hydrophobic alkyl group and a hydrophilic alkyl group. In a yet alternative embodiment the nitroxide is a profluorescent nitroxide. More preferably, the nitroxide is tetramethylpiperidinyloxy (TEMPO). In a more preferred embodiment the profluorescent nitroxide is dansyl amino-TEMPO. In another preferred embodiment the sample is selected from the group consisting of an area of a subject's skin, clothing, boots, pets, camping gear, tools, and other outdoor equipment. In another preferred embodiment the sample is selected from the group consisting of a plant tissue, a plant extract, a plant tissue extract, an animal tissue, an animal extract, an animal tissue extract, and an animal fluid. In a more preferred embodiment the plant tissue is from a plant selected from the group consisting of poison oak, poison ivy, poison sumac, mango, cashew nut, and lac tree.
The invention further provides the methods as disclosed herein wherein the nitroxide further comprises a fluorescent compound, the fluorescent compound selected from the group consisting of a hydrophobic fluorescent organic molecule, a hydrophilic fluorescent organic molecule, and a fluorescent quantum-dot nanoparticle.
In one embodiment the method comprises the measuring the amount of alkoxyamine so created using a photon source that results in fluorescence of the alkoxyamine and the nitroxide-catecholborane complex, wherein the fluorescence is visible to the naked eye. In a preferred embodiment the measuring of the amount of alkoxyamine so created is performed using a photon source that induces fluorescence of the alkoxyamine and the nitroxide-catecholborane complex, wherein the fluorescence is detected by a photometer. In a more preferred embodiment the fluorescence comprises photons having a wavelength of between about 250 and 600 nm. In one embodiment the photon source is a lamp. In a preferred embodiment the lamp is a hand-held lamp. In an alternative embodiment the photon source is the sun. The method may also further comprise measuring hydroxylamine complexed with boron or free hydroxylamine created by hydrolysis.
In a preferred embodiment of the invention the catechol is selected from the group consisting of urushiol, catechin, epicatechin, gallocatechin, epigallocatechin, epigallocatechin-3-gallate, and catecholamines epinephrine, norepinephrine, dopamine, and dihydroxyphenylalanine (DOPA). In a more preferred embodiment the catechol is urushiol.
The method may further comprise the step of reacting the alkyl radical with a profluorescent nitroxide having a fluorescent tag, wherein the fluorescent tag is selected from the group consisting of an organic fluorophore and Cd—Se nanoparticle. In another embodiment the method may further comprise the step of measuring the amount of the nitroxide-catecholborane complex. In another embodiment the method further comprises the step of measuring the amount of hydroxylamine hydrolysis product. In a yet other embodiment the method further comprises the step of measuring the amount of alkoxyamine product.
The invention also provides for a method for deactivating a catechol in a sample, the method comprising the steps of (i) contacting a boron composition and an oxygen-containing molecule with the sample (ii) allowing the boron composition to react with the catechol in the sample thereby creating a catecholborane; the method resulting in deactivating the catechol in the sample. In one embodiment the boron composition comprises a hydrophobic alkyl group. In a preferred embodiment, the catecholborane is a B-alkyl catecholborane. In another preferred embodiment the alkyl group is selected from the group consisting of a hydrophobic alkyl group and a hydrophilic alkyl group. In a yet alternative embodiment the nitroxide is a profluorescent nitroxide. More preferably, the nitroxide is tetramethylpiperidinyloxy (TEMPO). In a more preferred embodiment the profluorescent nitroxide is dansyl amino-TEMPO. In another preferred embodiment the sample is selected from the group consisting of an area of a subject's skin, clothing, boots, pets, camping gear, tools, and other outdoor equipment. In another preferred embodiment the sample is selected from the group consisting of a plant tissue, a plant extract, a plant tissue extract, an animal tissue, an animal extract, an animal tissue extract, and an animal fluid. In a more preferred embodiment the plant tissue is from a plant selected from the group consisting of poison oak, poison ivy, poison sumac, mango, cashew nut, and lac tree.
In one preferred embodiment the oxygen-containing molecule comprises a nitroxide. The invention further provides the methods as disclosed herein wherein the nitroxide further optionally comprises a fluorescent compound, the fluorescent compound selected from the group consisting of a hydrophobic fluorescent organic molecule, a hydrophilic fluorescent organic molecule, and a fluorescent quantum-dot nanoparticle.
In one embodiment the method comprises the measuring the amount of alkoxyamine so created using a photon source that results in fluorescence of the alkoxyamine and the nitroxide-catecholborane complex, wherein the fluorescence is visible to the naked eye. In a preferred embodiment the measuring of the amount of alkoxyamine so created is performed using a photon source that induces fluorescence of the alkoxyamine and the nitroxide-catecholborane complex, wherein the fluorescence is detected by a photometer. In a more preferred embodiment the fluorescence comprises photons having a wavelength of between about 250 and 600 nm.
The method may also further comprise measuring hydroxylamine complexed with boron or free hydroxylamine created by hydrolysis.
In a preferred embodiment of the invention the catechol is selected from the group consisting of urushiol, catechin, epicatechin, gallocatechin, epigallocatechin, epigallocatechin-3-gallate, and catecholamines epinephrine, norepinephrine, dopamine, and dihydroxyphenylalanine (DOPA). In a more preferred embodiment the catechol is urushiol.
The invention also provides for a boron composition, the boron composition comprising a reactive moiety that reacts with a catechol with a rate constant, k, of at least 0.2 M −1 s −1 and wherein the reaction produces a stable chatecholborane.
The invention provides for a pharmaceutical composition, the pharmaceutical composition comprising a boron composition, wherein the boron composition comprises a hydrophobic alkyl group. In one embodiment the alkyl group is selected from the group consisting of a hydrophobic alkyl group and a hydrophilic alkyl group. In another embodiment the pharmaceutical composition comprises a boron composition in an effective amount for the treatment of poison oak oil-induced contact dermatitis. In a preferred embodiment the poison oak oil comprises a catechol. In a more preferred embodiment the catechol is urushiol.
The invention provide a topical composition, the topical composition comprising an effective amount of a boron composition and a suitable excipient, carrier, or combination thereof, the boron composition comprising an alkylboronic acid having the general formula R—B(OH) 2 . In one alternative embodiment the boron composition optionally comprises at least one B-alkyl boronic acid derivative. In another embodiment the topical composition optionally containing xanthan gum or gellan gum. In a more preferred embodiment the boron composition is present in an amount selected from the group consisting of from about 99.5% to about 0.001%, from about 95% to about 0.1%, and from about 90% to about 0.5%, by weight, based on the total combined weight of the boron composition thereof, not including other excipient, carrier, or combination thereof. In a most preferred embodiment the topical composition comprises a boron composition in an effective amount for the detection of a catechol in poison oak oil.
The invention further provides a topical medicament, the topical medicament comprising a boron composition, the boron composition comprising an alkylboronic acid having the general formula R—B(OH) 2 , a nitroxide, and a suitable excipient, carrier, or combination thereof, and where R is selected from the group consisting of a hydrophobic alkyl group and a hydrophilic alkyl group. In an alternative embodiment the boron composition optionally comprises at least one B-alkyl boronic acid derivative. In a more preferred embodiment the nitroxide is a profluorescent nitroxide. In a more preferred embodiment the topical medicament comprises a boron composition in an effective amount for the detection of a catechol in poison oak oil to avoid induced contact dermatitis. In another more preferred embodiment the topical medicament comprises a boron composition in an effective amount for the treatment of poison oak oil-induced contact dermatitis.
In one embodiment, the invention provides a method for detecting, treating, and deactivating alk(en)yl catechols, and/or alk(en)yl resorcinols using a boron compound bearing a hydrophobic alkyl group and an at least one equivalent of profluorescent nitroxide are that are mixed in solution or on a substrate. In one preferred embodiment, the profluorescent nitroxide is a nitroxide with a short tether to a fluorescent dye, wherein the dye is quenched in the presence of the free nitroxide. In an alternative embodiment the boron compound further comprises an alkyl boronic acid or alkyl boronic acid derivative. In another alternative embodiment the boron compound further comprises at least one leaving group. In yet another alternative embodiment, the boron compound further comprises two leaving groups.
In one embodiment the invention provides a method for detecting, treating, and deactivating alk(en)yl catechols, and/or alk(en)yl resorcinols, wherein the method results in producing a fluorescent compound that fluoresces when illuminated and wherein the fluorescence is induced by photons having a wavelength of between about 250 and 600 nm. In one embodiment the fluorescence can be, for example, between 250 and 300 nm, between 300 and 350 nm, between 350 and 400 nm, between 450 and 500 nm, between 500 and 550 nm, and between 550 and 600 nm. In the alternative, the method results in producing a fluorescent compound that fluoresces when illuminated with light in the visible spectrum and wherein the fluorescence is induced by photons having a wavelength of between about 600 and 750 nm. In one embodiment the fluorescence can be, for example, between 600 and 650 nm, between 650 and 700 nm, and between 700 and 750 nm.
In another alternative embodiment, the nitroxide can comprise a fluorescent tag such as, for example, a fluorescent organic compound, such as dansyl, 3-hydroxy-2-methyl-4-quinolinecarboxylic ester, a coumarin, a xanthene, a cyanine, a pyrene, a borapolyazaindacene, an oxazine, bimane, 4-acetamido-4′-isothiocyanatostilbene-2,2′-disulfonic acid (SITS) and related stilbene derivatives, and the isothiocyanate of pyrenetrisulfonic acid, fluorescein, acryoldan, rhodamine, dipyrrometheneboron difluoride (BODIPY), acridine orange, eosin, acridine orange, 1-(3-(succinimidyloxycarbonyl)benzyl)-4-(5-(4-methoxyphenyl)oxazol-2-yl)pyridinium bromide (PyMPO), alexa fluor 488, alexa fluor 532, alexa fluor 546, alexa fluor 568, alexa fluor 594, alexa fluor 555, alexa fluor 633, alexa fluor 647, alexa fluor 660 and alexa fluor 680, or the like, or a quantum-dot nanoparticle. In the present invention, a non-limited list of quantum dot nanoparticles includes cadmium sulfide (CdS), cadmium selenide (CdSe), zinc sulfide (ZnS), zinc oxide (ZnO), lead sulfide (PbS), zinc selenide (ZnSe), GaAS, and InP. (Lakowicz et al., Anal. Biochem., 2000, 280: 128-136.
The invention further provides use of a composition comprising a boron composition for the manufacture of a composition for detecting a catechol. In one embodiment the boron composition comprises an alkylboronic acid having the general formula R—B(OH) 2 , a nitroxide, and a suitable excipient, carrier, or combination thereof, and where R is selected from the group consisting of a hydrophobic alkyl group and a hydrophilic alkyl group. In one alternative embodiment the boron composition optionally comprises at least one B-alkyl boronic acid derivative. In a preferred embodiment the nitroxide is a profluorescent nitroxide. In another preferred embodiment the composition comprises a boron composition in an effective amount for the detection of a catechol in poison oak oil.
The invention can be used in a variety of embodiments, for example, for use as chemical sensors and molecular specific deactivating agents. The invention can be used in phototherapy for treatment of an inflammatory response and other disorders. The invention can also be used as a sensor that detects molecules. The invention is of particular use in the fields of clinical diagnosis, clinical therapy, clinical treatment, and clinical evaluation of various diseases and disorders, in the field of consumer goods, for example, over-the-counter medications, balms, ointments, etc., and diagnostic kits, manufacture of compositions for use in the treatment of various diseases and disorders, for use in molecular biology, structural biology, cell biology, molecular switches, molecular circuits, and molecular computational devices, and the manufacture thereof.
In one embodiment, the composition comprises a surface stabilizer. In another alternative embodiment the composition comprises at least two surface stabilizers. In a preferred embodiment, the surface stabilizer is selected from the group consisting of an anionic surface stabilizer, a cationic surface stabilizer, a zwitterionic surface stabilizer, and an ionic surface stabilizer.
In another preferred embodiment, the surface stabilizer is selected from the group consisting of cetyl pyridinium chloride, gelatin, casein, phosphatides, dextran, glycerol, gum acacia, cholesterol, tragacanth, stearic acid, benzalkonium chloride, calcium stearate, glycerol monostearate, cetostearyl alcohol, cetomacrogol emulsifying wax, sorbitan esters, polyoxyethylene alkyl ethers, polyoxyethylene castor oil derivatives, polyoxyethylene sorbitan fatty acid esters, polyethylene glycols, dodecyl trimethyl ammonium bromide, polyoxyethylene stearates, colloidal silicon dioxide, phosphates, sodium dodecylsulfate, carboxymethylcellulose calcium, hydroxypropyl celluloses, hypromellose, carboxymethylcellulose sodium, methylcellulose, hydroxyethylcellulose, hypromellose phthalate, noncrystalline cellulose, magnesium aluminum silicate, triethanolamine, polyvinyl alcohol, polyvinylpyrrolidone, 4-(1,1,3,3-tetramethylbutyl)-phenol polymer with ethylene oxide and formaldehyde, poloxamines, a charged phospholipid, dioctylsulfosuccinate, dialkylesters of sodium sulfosuccinic acid, sodium lauryl sulfate, alkyl aryl polyether sulfonates, mixtures of sucrose stearate and sucrose distearate, p-isononylphenoxypoly-(glycidol), decanoyl-N-methylglucamide; n-decyl β-D-glucopyranoside; n-decyl β-D-maltopyranoside; n-dodecyl β-D-glucopyranoside; n-dodecyl β-D-maltoside; heptanoyl-N-methylglucamide; n-heptyl-β-D-glucopyranoside; n-heptyl β-D-thioglucoside; n-hexyl β-D-glucopyranoside; nonanoyl-N-methylglucamide; n-noyl β-D-glucopyranoside; octanoyl-N-methylglucamide; n-octyl-β-D-glucopyranoside; octyl β-D-thioglucopyranoside; lysozyme, PEG-phospholipid, PEG-cholesterol, PEG-cholesterol derivative, and PEG-vitamin A.
In another alternative embodiment, the cationic surface stabilizer is selected from the group consisting of a polymer, a biopolymer, a polysaccharide, a cellulosic, an alginate, a nonpolymeric compound, and a phospholipid.
In another alternative embodiment, the surface stabilizer is selected from the group consisting of cationic lipids, polymethylmethacrylate trimethylammonium bromide, sulfonium compounds, polyvinylpyrrolidone-2-dimethylaminoethyl methacrylate dimethyl sulfate, hexadecyltrimethyl ammonium bromide, phosphonium compounds, quarternary ammonium compounds, benzyl-di(2-chloroethyl)ethylammonium bromide, coconut trimethyl ammonium chloride, coconut trimethyl ammonium bromide, coconut methyl dihydroxyethyl ammonium chloride, coconut methyl dihydroxyethyl ammonium bromide, decyl triethyl ammonium chloride, decyl dimethyl hydroxyethyl ammonium chloride, decyl dimethyl hydroxyethyl ammonium chloride bromide, C 12-15 dimethyl hydroxyethyl ammonium chloride, C 12-15 -dimethyl hydroxyethyl ammonium chloride bromide, coconut dimethyl hydroxyethyl ammonium chloride, coconut dimethyl hydroxyethyl ammonium bromide, myristyl trimethyl ammonium methyl sulphate, lauryl dimethyl benzyl ammonium chloride, lauryl dimethyl benzyl ammonium bromide, lauryl dimethyl (ethenoxy)4 ammonium chloride, lauryl dimethyl (ethenoxy)4 ammonium bromide, N-alkyl (C 12-18 )dimethylbenzyl ammonium chloride, N-alkyl (C 14-18 )dimethyl-benzyl ammonium chloride, N-tetradecylidmethylbenzy-1 ammonium chloride monohydrate, dimethyl didecyl ammonium chloride, N-alkyl and (C 12-14 ) dimethyl 1-napthylmethyl ammonium chloride, trimethylammonium halide, alkyl-trimethylammonium salts, dialkyl-dimethylammonium salts, lauryl trimethyl ammonium chloride, ethoxylated alkyamidoalkyldialkylammonium salt, an ethoxylated trialkyl ammonium salt, dialkylbenzene dialkylammonium chloride, N-didecyldimethyl ammonium chloride, N-tetradecyldimethylbenzyl ammonium, chloride monohydrate, N-alkyl(C 12-14 ) dimethyl 1-naphthylmethyl ammonium chloride, dodecyldimethylbenzyl ammonium chloride, dialkyl benzenealkyl ammoniumchloride, lauryl trimethyl ammonium chloride, alkylbenzyl methyl ammonium chloride, alkyl benzyl dimethyl ammonium bromide, C 12 trimethyl ammonium bromides, C 15 trimethyl ammonium bromides, C 17 trimethyl ammonium bromides, dodecylbenzyl triethyl ammonium chloride, poly-diallyldimethylammonium chloride (DADMAC), dimethyl ammonium chlorides, alkyldimethylammonium halogenides, tricetyl methyl ammonium chloride, decyltrimethylammonium bromide, dodecyltriethylammonium bromide, tetradecyltrimethylammonium bromide, methyl trioctylammonium chloride, polyquaternium 10, tetrabutylammonium bromide, benzyl trimethylammonium bromide, choline esters, benzalkonium chloride, stearalkonium chloride compounds, cetyl pyridinium bromide, cetyl pyridinium chloride, halide salts of quaternized polyoxyethylalkylamines, quaternized ammonium salt polymers, alkyl pyridinium salts; amines, amine salts, amine oxides, imide azolinium salts, protonated quaternary acrylamides, methylated quaternary polymers, and cationic guar.
The invention also provides for a chemical spray that can be used in the field to allow the detection of urushiol in conjunction with the use of a fluorescent lamp. In one embodiment the amount of urushiol detected is in the range of between about 0.1-100 μg. In a preferred embodiment, the amount of urushiol detected is in the range of between about 1-10 μg.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates the chemical formulae of chatechol and exemplary urushiols.
FIG. 2 illustrates how B-alkyl catechol borane species react with oxygen radicals to expel alkyl radicals (adapted from Darency and Renaud, 2006, Top. Curr. Chem., 263: 71-106; Cadot et al. 2002, JOC, 67: 7193-7202; Baban et al. 1986, J. Chem. Soc., Perkin Trans. 2: 157).
FIG. 3 illustrates a modified Brown and Negishi reaction that may comprise chain transfers with PTOC-OMe for radical acceptors (Brown and Negishi, 1971, J. Am. Chem. Soc. 93: 3777; Suzuki et al. 1969, J. Chem. Soc., Chem. Commun, 17: 1009; Forster 1999, PhD Thesis, University de Fribourg, Switzerland, Diss Nr. 1242; Ollivier and Renaud 1999, Chem. Eur. J., 5: 1468; Kumli and Renaud, 2006, Org. Lett. 8: 5861; Olivier and Renaud, 2000, Angew. Chem. Int. Ed. 39: 925).
FIG. 4 illustrates novel methods for detecting poison oak oil (including poison ivy, sumac oil, and lac tree extracts) that are present upon a substrate by chemical generation of fluorescence.
FIG. 5 illustrates an exemplary reaction between a nitroxide (for example, TEMPO) and a catechol that results in a nitroxide-catecholborane.
FIG. 6 illustrates an exemplary reaction between a profluorescent nitroxide and a catechol that results in a fluorescent nitroxide-catecholborane.
FIG. 7A illustrates details of another exemplary reaction between either a borane compound (top), a catecholborane (middle and bottom), and a nitroxide or profluorescent nitroxide that results in no reaction (top), production of a nitroxide-catecholborane (middle), or production of a fluorescent nitroxide-catecholborane (bottom). FIG. 7B illustrates details of how a reaction between a profluorescent nitroxide in the presence of phenylhydrazine results in production of a fluorescent compound.
FIG. 8 illustrates that addition of an oxygen radical to an alkylcatecholborane forms a perboryl radical 5, visible by ESR
FIG. 9 illustrates that addition of nitroxide to an alkylcatecholborane forms a perboryl radical 6, which fragments to generate an alkyl radical. A second equivalent of nitroxide reacts with the alkyl radical to form alkoxyamine 8.
FIG. 10 shows exemplary profluorescent nitroxides: the free nitroxide quenches fluorescence of a closely tethered fluorophore; fluorescence is restored upon reaction to from the alkoxyamine or hydroxylamine.
FIG. 11 illustrates a reaction sequence that may detect catechol using profluorescent nitroxide addition to alkylcatecholborane 13.
FIG. 12 illustrates use of profluorescent Dansyl amino-TEMPO: preparation, reduction, and formation of radical trapping product 17.
FIG. 13 shows an exemplary reaction of a model alkyl-catecholborane 19 with two equivalents of nitroxide: both alkoxyamine and hydroxylamine 21 were isolated from the reaction mixture.
FIG. 14 illustrates reaction of profluorescent Dansyl amino-TEMPO 16 with n-butylcatecholborane 19 in toluene to give fluorescent n-butylalkoxyamine 22 (A): paper towel spot test shows fluorescence of alkoxyamine 22 (B).
FIG. 15 shows the in situ formation of n-butylcatecholborane 19 and subsequent reaction to form fluorescent 22 (A) in one pot (B).
FIG. 16 illustrates common classes of readily synthesized stable nitroxides.
FIG. 17 illustrates a general synthesis pioneered by Hideg and Keana for the preparation of proxyl nitroxides 42.
FIG. 18 shows the synthesis of the pyrene proxyl profluorescent nitroxide 44.
FIG. 19 illustrates a few representative known profluorescent nitroxides.
FIG. 20 illustrates the excitation and emission spectra of profluorescent nitroxide 12 and fluorescent N-alkoxyamine 28 in DMSO.
FIG. 21 shows a hydroboration route to prepare n-alkylboronic acids 25
FIG. 22 illustrates representative pyrogallols and catechols commonly found in foods such as red wine, tea, and chocolate: note that compounds 48 and 49 are polyols, and are thus aqueous rather than organic soluble.
FIG. 23 illustrates a slow reduction of nitroxide by catechol; rapid reoxidation of the hydroxylamine to the nitroxide with PbO 2 .
FIG. 24 illustrates fluorescence quenching and recovery upon addition of catechol to profluorescent nitroxide 12, with and without addition of PbO 2 as a reoxidant.
FIG. 25 illustrates how exemplary mild oxidants can rapidly oxidize hydroxylamine to nitroxide but that do not oxidize catechol to quinone.
FIG. 26 illustrates detection of urushiol on leaves of poison oak. A: Fresh Poison Oak triad of leaves; B: Print of the same leaves on a paper towel after treatment with Fl-NitO., nBuB(OH) 2 and catalytic PbO 2 in acetone.
DETAILED DESCRIPTION OF THE INVENTION
In order to develop a system to selectively detect catechols in the presence of other alcohols and diols (such as sugars), a reaction that takes place with catechols but not with other alcohols was required. In the field of organic free radical chemistry, alkylcatecholboranes have been used to selectively generate alkyl radicals upon reaction with oxygen radicals. The efficacy of this oxygen radical addition specifically to alkylcatecholboranes is due to de-localization of the unpaired electron of the perboryl species 5 into the aromatic ring ( FIG. 8 ). Direct ESR evidence for this delocalized perboryl radical 5 below 270 K was observed by Roberts (Baban et al., J. Chem. Soc. Perkin Transact. 1986, 2(1): 157-161). A number of very useful synthetic methodologies have been developed from this chemistry. Key to this proposal is the work by Renaud, in which addition of two equivalents of the oxygen radical TEMPO 7, a commercially available persistent nitroxide radical, results in formation of the carbon radical trapping product, alkoxyamine 8 ( FIG. 9 ).
In order to design a visual indicator of the reaction of nitroxides with alkylcatecholboranes, profluorescent nitroxides are used. Profluorescent nitroxides 10 (sometimes referred to as “pre-fluorescent nitroxides”) are nitroxides bearing a short covalent tether to a fluorophore. The free nitroxide quenches the fluorescence. Upon reaction of the nitroxide moiety to form an alkoxyamine 11 or a hydroxylamine (or any other non-nitroxide product), the fluorescence is no longer quenched, restoring fluorescence to the product ( FIG. 10 ). Profluorescent nitroxides have been utilized as sensors of nitric oxide, antioxidants, reactive oxygen species, carbon radicals, cationic metals, viscosity probes, as a chemical logic gate, and in the development of photomagnetic materials. (See Ivan, M. G.; Scaiano, J. C., Photochemistry and Photobiology 2003, 78, (4), 416-419; Hornig, F. S.; Korth, H. G.; Rauen, U.; de Groot, H.; Sustmann, R., Helvetica Chimica Acta 2006, 89, (10), 2281-2296; Lozinsky, E. M.; Martina, L. V.; Shames, A. I.; Uzlaner, N.; Masarwa, A.; Likhtenshtein, G. I.; Meyerstein, D.; Martin, V. V.; Priel, Z., Analytical Biochemistry 2004, 326, (2), 139-145; Meineke, P.; Rauen, U.; de Groot, H.; Korth, H. G.; Sustmann, R., Chemistry—a European Journal 1999, 5, (6), 1738-1747; Meineke, P.; Rauen, U.; de Groot, H.; Korth, H. G.; Sustmann, R., Biological Chemistry 2000, 381, (7), 575-582; Blough, N. V.; Simpson, D. J., Journal of the American Chemical Society 1988, 110, (6), 1915-1917; Lozinsky, E.; Martin, V. V.; Berezina, T. A.; Shames, A. I.; Weis, A. L.; Likhtenshtein, G. I., Journal of Biochemical and Biophysical Methods 1999, 38, (1), 29-42; Tang, Y. L.; He, F.; Yu, M. H.; Wang, S.; Li, Y. L.; Zhu, D. B., Chemistry of Materials 2006, 18, (16), 3605-3610; Hideg, E.; Kalai, T.; Kos, P. B.; Asada, K.; Hideg, K., Photochemistry and Photobiology 2006, 82, (5), 1211-1218; Aspee, A.; Garcia, O.; Maretti, L.; Sastre, R.; Scaiano, J. C., Free radical reactions in poly(methyl methacrylate) films monitored using a prefluorescent quinoline-TEMPO sensor. Macromolecules 2003, 36, (10), 3550-3556; Aspee, A.; Maretti, L.; Scaiano, J. C., Photochemical & Photobiological Sciences 2003, 2, (11), 1125-1129; Ballesteros, O. G.; Maretti, L.; Sastre, R.; Scaiano, J. C., Macromolecules 2001, 34, (18), 6184-6187; Blinco, J. P.; McMurtrie, J. C.; Bottle, S. E., European Journal of Organic Chemistry 2007, 4638-4641; Coenjarts, C.; Garcia, O.; Llauger, L.; Palfreyman, J.; Vinette, A. L.; Scaiano, J. C., Journal of the American Chemical Society 2003, 125, (3), 620-621; Dang, Y. M.; Guo, X. Q., Applied Spectroscopy 2006, 60, (2), 203-207; Fairfull-Smith, K. E.; Blinco, J. P.; Keddie, D. J.; George, G. A.; Bottle, S. E., Macromolecules 2008, 41, 1577-1580; Gerlock, J. L.; Zacmanidis, P. J.; Bauer, D. R.; Simpson, D. J.; Blough, N. V.; Salmeen, I. T., Free Radical Research Communications 1990, 10, (1-2), 119-121; Johnson, C. G.; Caron, S.; Blough, N. V., Analytical Chemistry 1996, 68, (5), 867-872; Maurel, V.; Laferriere, M.; Billone, P.; Godin, R.; Scaiano, J. C., Journal of Physical Chemistry B 2006, 110, (33), 16353-16358; Micallef, A. S.; Blinco, J. P.; George, G. A.; Reid, D. A.; Rizzardo, E.; Thang, S. H.; Bottle, S. E., Polymer Degradation and Stability 2005, 89, (3), 427-435; Nagy, V. Y.; Bystryak, I. M.; Kotelnikov, A. I.; Likhtenshtein, G. I.; Petrukhin, O. M.; Zolotov, Y. A.; Volodarskii, L. B., Analyst 1990, 115, (6), 839-841; Arye, P. P.-B.; Strashnikova, N.; Likhtenshtein, G. I., Journal of Biochemical and Biophysical Methods 2002, 51, (1), 1-15; and Wang, H. M.; Zhang, D. Q.; Guo, X. F.; Zhu, L. Y.; Shuai, Z. G.; Zhu, D. B., Chemical Communications 2004, (6), 670-671.)
The use of a profluorescent nitroxide with an alkylboronic acid derivative 12 is envisioned to react with catechols (such as, but not limited to, for example, urushiol) to form alkylboronate 13: nitroxide addition, radical 14 generation, and nitroxide trapping will generate the fluorescent signal of alkoxyamine 15. Other alkylboronic acid derivatives will be apparent to those of skill in the art.
Catechols are a group of compounds well-known to those of skill in the art having diverse biological activities, whilst at the same time being structurally conservative. The invention contemplates that the compositions and methods disclosed herein may be used to detect, inactivate, or bind to any biologically-active catechol composition. In particular the invention contemplates a catechol selected from the group consisting of urushiol, catechin, epicatechin, gallocatechin, epigallocatechin, epigallocatechin-3-gallate, and catecholamines epinephrine, norepinephrine, dopamine, and dihydroxyphenylalanine (DOPA). One of skill in the art would consider that the structures of catechols are sufficiently similar that they are a well-known chemical class of compounds.
Profluorescent nitroxide is sometimes referred to as a pre-fluorescent nitroxide. In the presence of a catechol such as urushiol and an B-alkylboronic acid derivative, a B-alkyl catecholborionate is formed. Addition of the nitroxide to the catecholborane results in expulsion of an alkyl radical, which is trapped by a second nitroxide, forming two fluorescent species: an alkoxyamine with a fluorescent tag, and fluorescently tagged nitroxide-catecholborane complex. In addition, the nitroxide-catecholborane may degrade to hydroxylamine that is also a fluorescent compound. Use of a hand-held fluorescent lamp shows fluorescence when a catechol such as urushiol is present. This can be used as a method to detect the presence of urushiol. As a treatment, binding of the urushiol into a catecholborane complex will prevent transfer through the skin, preventing oxidation of the catechol and elicitation of an immune response, thus preventing contact dermatitis. For detecting aqueous soluble catechols such as dopamine, epinephrine, and norepinephrine, a water-soluble alkyl group is preferred on the initial boron compound rather than a hydrophobic alkyl group.
Examples of profluorescent nitroxides may be found in the following non-exhaustive list of publications: Blough, 1988, JACS, 110: 1915; Bottle, 2005, Polym. Degrad. & Stability, 89: 427-435; Sciano, 2001, Macromol. 34: 6184; Ibid., 2003, JACS, 125: 620; Ibid., 2003, Photochem. Photobiol. 78: 416; Turro, 2001, Macromol., 34: 8187; Koth, 2000, Biological Chem., 381(7): 575-582; Ibid., 1999, Chem. Eur. J. 5(6): 1738-1747; Ibid., 1997, Ang. IEE, 36: 1501-1503; Ibid., 2006, Hely. Chim Acta, 89: 2281-2296; Hideg 2006, Photochem. Photobiol. 82: 1211; Want, 2006, Chem. Mater., 18: 3605; and Dang and Guo, 2006, Appl. Spectrosc. 60: 203-207,
In the present invention, a non-limited list of quantum dot nanoparticles includes cadmium sulfide (CdS), cadmium selenide (CdSe), zinc sulfide (ZnS), zinc oxide (ZnO), lead sulfide (PbS), zinc selenide (ZnSe), GaAS, and InP. (Lakowicz et al. Analytical Biochemistry, 2000, 280: 128-136). Alternative suitable donor fluorophores will be apparent to those of ordinary skill without undue experimentation. For example, nitroxides tethered to such a quantum dot will quench any fluorescence; when the nitroxides react with a catechol boronate complex, the quenching effect is removed and fluorescence can occur under appropriate conditions.
Use of the Compositions for Detection of Urushiol
A composition prepared according to the present invention may be formulated as an aerosol spray, a topical cream, ointment, medicament, or a solution.
An aerosol containing approximately 0.005% to about 5.0% (w/w) each of the boron composition and nitroxide according to the present invention is prepared by dissolving the compositions in absolute alcohol. The resulting solution is then diluted in an organic solvent or purified water, depending upon the hydrophobicity of the compound. Routine experimentation by those having skill in the art can be used to determine an effective amount for detecting a catechol in a sample.
There are several biologically very important catechols: the catecholamines (including epinephrine, norepinephrine, and dopamine), in addition to epicatechin (common in tea). All of these are water-soluble. Because boron species undergo dynamic exchange of alcohol ligands via their anionic “-ate” species in water, it is likely that this methodology may be extrapolated to detect catechols in an aqueous environment. The key reaction sequence of nitroxide reacting with alkylcatecholborane is well established in non-polar organic solvents. Extension to aqueous conditions would provide a very powerful detection method for catecholamines: success would depend on the lifetimes of the tricoordinate borane species compared to the predominate tetracoordinate boronate species. Water-soluble nitroxides and fluorophores are widely known; nitroxides have been used extensively as an EPR probe in biology. The detection of biologically important catecholamines (including epinephrine, norepinephrine, and dopamine) in aqueous environments could lead to powerful new methods in biomedicine.
Contact dermatitis from exposure of skin to urushiol causes agony and suffering for tens of millions of Americans each year, making this an important human health issue in North America. Urushiol can be effectively removed from skin, clothes and equipment, but only if it is known where this invisible contamination is located. The invention comprises a fluorescence detection method: a spray containing a profluorescent nitroxide and an alkylboronate derivative in an organic solvent will react selectively with urushiol to form a fluorescent N-alkoxyamine. An inexpensive UV light can then be used to pinpoint the presence of urushiol, to prevent or mitigate exposure to skin. Preliminary results with catechol confirm that the key reaction works as expected, and that a highly fluorescent signal is generated. Optimization of the profluorescent nitroxide (both the fluorophore and nitroxide structures), solvent and fine-tuning of the alkyl group on the boronic acid are undertaken. The invention provides a clear benefit to society, including private outdoors enthusiasts, forestry workers, emergency rescue personnel, military personnel, and others who come in contact with poison oak, poison ivy, or sumac.
The invention also may be used to deactivate a chatechol, such as urushiol, using the methods disclosed herein. In certain case the product, such as B-alkyl catecholboronate or alkycatecholborane, may be chemically unstable and the composition may hydrolyse to the products, chatechol and the alkylboronate derivative, for example. It is contemplated that such hydrolysis may be impeded or decelerated in the presence of environmental modulators, such as a hydrophobic composition, a hydrophilic composition, a buffer composition, or the like. Such environmental modulators can be sugars, carbohydrates, proteins, peptides, glycopeptides, glycolipids, and glycophospholipids; organic compositions, such as organic acids, organic salts, organic bases, or the like, lipids, phospholipids, or fatty acids; chemical stabilizers, or the like, or any combination thereof. Such compositions may be used to formulate a topical medicament or topical composition that is used to reduce or eliminate the effects of poison oak oil-induced contact dermatitis.
In addition, the formulation or aerosol can comprise a solvent, the solvent comprising a polar organic solvent, a non-polar organic solvent, an aqueous solvent, or a non-aqueous solvent.
The invention will be more readily understood by reference to the following examples, which are included merely for purposes of illustration of certain aspects and embodiments of the present invention and not as limitations.
EXAMPLES
Example I
Preparation and Testing of Fluororescent Compounds
We have prepared the known profluorescent nitroxide Dansyl amino-TEMPO 16. As reported, the free nitroxide quenches fluorescence; the insert of FIG. 12 shows the reaction of the nitroxide to form either the hydroxylamine 17 (vial shown) or the n-butylalkoxyamine 18 (not shown) restores the fluorescence to the naked eye upon irradiation with a long wave-length UV lamp at 366 nm (A hand-held UV lamp typically used for viewing thin layer chromatography plates was utilized in these photographs).
As an initial model, B-n-butylcatecholborane 19 was pre-formed using Dean Stark conditions, and then allowed to react with two equivalents of TEMPO 7 ( FIG. 13 ). The expected N-n-butyloxyamine 20 was formed as a mixture with the hydroxylamine 21, confirming the chemistry developed by Renaud. Hydroxylamine 21 is presumably formed by hydrolysis of the nitroxide boronic ester complex.
This reaction was repeated with the profluorescent Dansyl amino-TEMPO 16 ( FIG. 14A ). The reaction mixture was strongly fluorescent in which a drop of solution was put on a paper towel; illumination with a thin layer chromatography (TLC) long-wavelength lamp clearly showed a strong fluorescent signal for the alkoxyamine 28 (see FIG. 14B ). Similar drops of solution containing the profluorescent nitroxide 16 and a control mixture of the profluorescent nitroxide mixed with n-butylboronic acid gave no detectable signal. Isolation and characterization of the fluorescent n-butylalkoxyamine 22 confirmed that the reaction had occurred as predicted.
Example II
Fluorescence Detection of Catechol
In order to form alkylcatecholborane 13 from free catechol under ambient conditions, we initially believed it would be necessary to convert the hydroxyl groups on an alkylboronic acid to better leaving groups. However, early work by Brown indicated that alkylboronic acids react reversibly with catechol in organic, nonpolar solvents to form the desired catecholboranes. It was determined that the reaction sequence shown in FIG. 15A worked: alkylcatecholborane 19 formed from free catechol and an alkylboroinic acid in situ, and reacted with profluorescent nitroxide 16 in one pot to form 22 with a strongly fluorescent signal ( FIG. 15B ). This was an unexpectedly superior result.
FIG. 26 shows a successful field test of this detection system. The composition was applied onto the surface of poison oak leaves. A paper towel was applied to the surface of the leaves and the paper towel was illuminated using a UV-lamp. As shown in FIG. 26 , the fluorescence was clearly visible to the naked eye.
It has also been observed that the reaction works well in a variety of polar and nonpolar solvents.
Example III
Synthesis and Development of the Components of the Fluorescence-Generation Method: Optimize the Structure of the Nitroxide, Fluorophore, Tether and Alkylboronic Acid
The chemical design of the profluorescent nitroxide is explored, entailing the choice of the optimum nitroxide, fluorescent tag, and tether to prepare a robust, soluble and effective component for this detection system. As fluorescence is a very sensitive method of detection, only very small amounts need react to give a signal visible to the naked eye using an inexpensive hand-held fluorescent lamp. The six-membered ring TEMPO is by far the most common nitroxide scaffold, however there are a number of other common stable nitroxide classes. Considerations in optimization of the nitroxide structure include ease and cost of synthesis, versatility in designing and optimizing the tether between the fluorophore and the nitroxide, stability and solubility. Common stable nitroxide classes include TEMPO (tetramethylpiperidinyl-1-oxyl), proxyl (pyrrolidine analogues), nitronyl, imino and doxyl nitroxides ( FIG. 16 ). The inventor and the inventor's research laboratory has been engaged in the synthesis and applications of nitroxides for over a decade, thus has extensive experience in the synthesis of new nitroxides. In addition, a large number of commercially nitroxides are available from Toronto Research Chemicals, Inc. (North York, Canada).
Recent work by Lozinsky et al. (2004) indicates that profluorescent nitronyl nitroxides quench fluorescence by a different mechanism involving nonbonding electrons of nitrogen and oxygen rather than to the unpaired electron. Thus the fluorescence does not increase upon reduction to the hydroxylamine (and also presumably from the formation of alkoxyamines), making them unsuitable for this study. Given the simple synthetic access ( FIG. 17 ) to proxyl nitroxides following the large body of work pioneered by Hideg, Keana, and many others, proxyl nitroxides 42 are particularly attractive.
The fluorophore can be easily introduced late in the synthetic sequence, encouraging synthetic diversity without having to start the sequence from the beginning. For an example, a Grignard reagent 43 prepared from 1-bromopyrene gives the proxyl nitroxide 44 with a very short tether between the fluorophore and the nitroxide ( FIG. 18 ).
Example IV
Use of Fluorescence Detection
With regard to the choice of fluorophore, preliminary data and results focused on Dansyl amino-TEMPO 12, a well-developed profluorescent nitroxide. One advantage of this compound is that sulfonamides are resistant to hydrolysis, thus minimizing the possibility of hydrolysis to give a free fluorophore and thus a false positive signal. Scaiano (Aliaga et al., Organic Lett., 2003, 5(22): 4145-4148) has developed 4-(3-hydroxy-2-methyl-4-quinolinoyloxy)-TEMPO 45, which shows significantly enhanced fluorescence upon reaction of the nitroxide compared to Dansyl amino-TEMPO 12 (but contains a more easily hydrolyzed ester linkage) ( FIG. 19 ). Bottle (Micallef et al., Polymer Degrad. Stabil., 2005, 89(3): 427-435) has developed the profluorescent nitroxide TMDBIO 46, containing a phenanthrene fluorophore covalently fused into the structure of the nitroxide, making hydrolysis an impossibility. Other fluorophores such as pyrene 47 and coumarins have been utilized, and many more are possible. The use of fluorophores observable in the visible range is also explored. The intensity, wavelength dependence, cost, stability and ease of synthesis will all be taken into consideration in selecting the best fluorophore.
Efficient quenching requires a short tether between the fluorophore and the nitroxide moiety; rotational freedom and flexibility also influence the quenching efficiency. Thus the 5-membered ring nitroxides may provide an advantage in holding the fluorophore in a closer geometry to the nitroxide as compared to the 6-membered ring framework of TEMPO.
Example V
Quenching of Fluorophore
Dansyl amino TEMPO 12 does show a small amount of residual fluorescence, as shown in FIG. 20 . Other profluorescent nitroxides may be even more effective at quenching the fluorescence in the free nitroxide state. The wavelength of excitation and emission can be tuned by selection of the fluorophore.
Example VI
Effect of Charge Upon Fluororescence Detection
Since urushiol is very hydrophobic, apolar organic solvents are investigated for the key reaction sequence, including toluene, hexanes, acetone, ethers, etc. The linear hydrophobic “tail” is optimized for both reactivity with catechol and solubility to match that of the hydrophobic urushiol. B-alkylpinacolboranes 24 are conveniently prepared by iridium-catalyzed hydroboration 78 of the corresponding terminal alkenes using commercially available pinacolborane 23 ( FIG. 21 ). Hydrolysis provides easy access to alkylboronic acids with a variety of chain lengths. Commercially available C 12 -C 17 linear terminal olefins are available, with the C 14 and C 16 being particularly inexpensive. Upon testing with actual urushiol, there may be an advantage to having an odd or even number of carbons in the sidechain, or the exact carbon count may prove to be inconsequential. The stability of the boronic acid is also a consideration. Tertiary alkyl boronic acids are prone to decomposition upon exposure with air. In our preliminary studies, we have used primary n-butyl boronic acid. The sample has remained stable for over a year without taking any precautions to avoid exposure to air. We have determined that aryl boronic acids (very stable, and commercially available) do not take part in the radical reaction sequence, presumably due to failure of the fragmentation step due to the instability of aryl radicals. Thus primary alkyl boronic acids seem to be ideal: they react in the desired radical reaction sequence, but are stable to storage.
Example VII
Optimizing the Detection System with Regard to Stoichiometry, Solvent, Concentration, Reaction Time, and Avoidance of False Positives
Calibration of the fluorescence signal as a function of the concentration of the catechol, boron reagent and nitroxide is carried out. As exposure to 0.001 mg of urushiol can elicit allergic contact dermatitis, very small amounts of urushiol should to be detectable to make this method effective. The optimal stoichiometry to obtain a short reaction time is studied. It is expected that two nitroxides are needed for every boron complex, although one equivalent may be sufficient if the nitroxide catecholboronate complex is hydrolytically unstable. If the fluorescent signal is extremely strong, it may be possible to economize by using a mixture of regular nitroxide mixed with some small percentage of profluorescent nitroxide.
The specificity of this system for catechols is explored. As controls, phenols, resorcinols (1,3-benenediols), alcohols and diols (for example, sugars) are not expected to participate in the key reaction sequence, as no delocalized perboryl radical intermediate similar to 6 will be formed. Reaction with these various alcohols are tested to ensure that this method is indeed selective for catechols. Pyrogallols (1,2,3-benenetriols, for example gallocatechins (ex. 48) and epigallocatechins ( FIG. 22 ) found in red wine, tea and chocolate) are expected to participate in the reaction, depending upon their solubility in the solvents. Likewise, the closely related catechins (ex. 49) and epicatechins (found in foods along with gallocatechins) are true catechols: reaction are again be limited by solubility.
Possible sources of false positives are examined. It is well known that nitroxides react rapidly with ascorbic acid to form hydroxylamines. Our research group has used ascorbate reduction of nitroxide to aid in chromatographic separation of alkoxyamine from unreacted nitroxide. Blough was the first to show profluorescent nitroxides react with ascorbic acid to generate a fluorescent signal. Lozinsky has utilized profluorescent nitroxides to assay the amount of vitamin C in fruit juices, and Wang has used a fluorescent conductive charged polymer nitroxide salt as a sensor for ascorbate and for trolox (a vitamin E mimic). Another side reaction that may interfere with the selective detection of urushiol by this boron catechol sequence is the simple reduction of nitroxides by phenols. Scaiano has studied the kinetics of hydrogen transfer from phenol to nitroxide using a profluorescent nitroxide. The rate constants are very slow: k=0.003 M −1 s −1 in protic solvent for gallic acid and BHT, and k=0.2 M −1 s −1 for TROLOX. Scaiano did not investigate reduction by catechol. In preliminary experiments ( FIG. 23 ), we have shown that addition of catechol to Dansyl amino-TEMPO 12 in toluene does produce a weak fluorescent signal, however this is suppressed by addition of a mild oxidant (PbO 2 ) to convert the tiny amount of hydroxylamine to nitroxide. This removes the false positive from phenol ( FIG. 24 ).
The use of other mild oxidants that will rapidly oxidize hydroxylamine to nitroxide in organic solvents, but not oxidize catechol to quinone, are investigated (See FIG. 25 ). Particularly attractive are Fe (III) salts as less toxic alternatives to lead. We have determined that OXONE is too strong of an oxidizing agent: the nitroxide is oxidized to the oxammonium salt. Interestingly, Bottle has shown that pyrrolidine nitroxides (cyclic 5-membered rings) have higher reduction potentials than piperidine (6-membered ring) nitroxides. Thus use of a pyrrolidine profluorescent nitroxide may inhibit the false positive signal arising from reduction by phenols.
REFERENCES
Addition of Nitroxides to Catecholboranes:
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Darmency and Renaud, (2006) Top. Curr. Chem. 263: 71-106.
Cadot et al., (2002) J. Org. Chem., 67; 7193-7202.
Ollivert et al. (1999) Synlett. 6: 807-809.
Attempted Addition of Nitroxides to Trialkylboranes:
Braslau and Anderson, in Radicals in Organic Synthesis , vol. 2 (Eds. P. Renaud, M. P. Sibi), Wiley-VCH, Weinheim, 2001, p. 129.
Addition of Oxygen Radicals to Catecholboranes:
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Profluorescent Nitroxides:
Blough (1988) J. Am. Chem. Soc. 110: 1915.
Blough (1990) Free Rad. Res. Comm 10: 119-121.
Blough (1996) Anal. Chem. 68: 867-872.
Micallef A S et al. (2005) Polym Degrad. & Stability 89: 427-435.
Foitzik et al. (2008) Macromolecules 41: 1577-1580.
Blinco et al. E. J. Org. Chem. 28: 4638-4641.
Sciano (2001) Macromol. 34: 6184.
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Zhang and Zhu (2004) Chem. Commun 670.
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Dang and Guo (2006) Appl. Spectrosc. 60: 203-207.
Likhtenstein et al. (2007) Photochem. Photobiol. 83: 871-881.
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Those skilled in the art will appreciate that various adaptations and modifications of the just-described embodiments can be configured without departing from the scope and spirit of the invention. Other suitable techniques and methods known in the art can be applied in numerous specific modalities by one skilled in the art and in light of the description of the present invention described herein. Therefore, it is to be understood that the invention can be practiced other than as specifically described herein. The above description is intended to be illustrative, and not restrictive. 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. | The invention herein disclosed provides for compositions, methods for synthesizing said compositions, and methods for using said compositions, wherein the compositions and methods may be used to bind to and/or deactivate a poison oak oil, such as urushiol. The compositions and methods can be used to treat and/or reduce an inflammatory reaction and/or hypersensitivity to natural compounds found in poison oak, poison ivy, poison sumac, mango, lac tree, and cashew nut. | 0 |
FIELD OF THE INVENTION
The present invention relates to mechanical curtains and more particularly to vertically movable partitions for use within buildings, example to cordon off areas, as required, to prevent public access or for crowd control.
BACKGROUND OF THE INVENTION
Security partitions in the form of security gates are well known and may take the form of horizontally sliding bar systems, for example to close off open fronts of shops in shopping centers or to be moved across entrance ways to shops on streets. These types of movable security gates usually require storage space beside the area being protected, to accommodate the gate components when not in use. Conversely, existing “roll-up” security gates are stored in ceiling space when not in use. This type of gate is severely limited in width and height as the roller can only be supported at its ends and cannot deflect under the load of the gate.
U.S. Pat. No. 5,062,464 of Miles Peterson, issued Nov. 5, 1991 describes and illustrates a wall partition, which uses a pantograph type of construction to provide a rigid wall section, which is vertically collapsible and movable to a storage position. Movable wall partition systems have similar problems of storage and structural support requirements and the Peterson vertically movable wall partition avoids those problems by providing ceiling storage for the wall partitions and a single permanent location for all of the panels so that the loads imposed on the building support structure do not vary because of lateral movement of the panels. Further, this design of the wall system allows the partition to be of any width or height as it is lifted and supported at multiple points across its width. This is made possible as the partition is folded up rather than rolled up.
The pantograph structure as suggested by the Peterson construction is similar to that for instance found in baby gates in which a series of elongated members are pivotally linked together in spaced fashion to provide a series of similar diamonds along the length of the gate. In a single (as opposed to multiple) pantograph construction, a pair of members of similar size are pivotally linked at their midpoints. One pair of their ends are pivotally linked to the ends of a further corresponding pair of members of similar length similarly pivoted at their midpoint, and so on. The midpoints of the members are longitudinally aligned and form opposed longitudinal apexes of diamond shapes; the other opposed corners of these diamonds are formed by the pivotally secured ends of adjacent pairs of intersecting members, and are the lateral apexes. The pantograph structure expands and contracts longitudinally. The pantograph structure in such applications is useful because it causes forces applied longitudinally, in the direction of expansion and contraction of the pantograph, to be transmitted evenly throughout all of the members of the pantograph structure. As well, all of the apexes of the diamonds formed by the points of intersection of the members, as the structure is contracted, will arrive at their final, fully contracted position at the same time, meaning that the longitudinal apexes of the diamonds at one end of the pantograph structure, which are moving towards the other end during contraction, will move at a much greater speed than the apexes of the diamonds at the other end.
It is an object of the present invention to provide a mechanical curtain, which is based on these pantograph principles.
SUMMARY OF THE INVENTION
In accordance with the present invention there is provided a mechanical curtain, upwardly movable into open position and downwardly movable into closed position. The curtain comprises a plurality of similarly constructed trains of elongated members, the members of each train arranged to form a single pantograph forming longitudinally aligned rows of diamonds. The trains are spaced laterally to lie within a curtain plane and are oriented so that the pantographs operate in a plane at a 90° angle to that curtain plane. A plurality of bars are secured in parallel spaced fashion to corresponding members of adjacent trains, perpendicular thereto. Means are provided to raise and lower the trains at a similar rate, the pantographs being contracted when the curtain is in open position and being elongated when the curtain is in closed position.
In one embodiment of the present invention, particularly applicable for use as a security gate, the curtain is further provided with locking means to secure the curtain in closed position against unwanted opening.
The curtain according to the present invention has many advantages. When used as a security gate, because its components move vertically rather than horizontally, storage space is not required to the side of the entrance way or other area within which the curtain operates, since the curtain folds and stores above the passageway or area in question. Furthermore, because the curtain does not move horizontally, the loads imposed on the support structure are constant. Also, the height and width restrictions present with conventional roll-up security gates are avoided since the curtain of the present invention may be lifted and supported at multiple points across its width.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other advantages of the invention will become apparent upon reading the following detailed description and upon referring to the drawings in which:
FIG. 1 is a perspective partial view of a mechanical curtain, adapted to be used as a security gate, in a partially closed position;
FIGS. 2 a , 2 b and 2 c are side elevation views of an end train of the curtain of FIG. 1, showing that train respectively in expanded (or closed) position, partially closed position and fully contracted (or open) position;
FIG. 3 is an enlarged side elevation view of a portion of a train of the curtain of FIG. 1, in partially closed position as shown in FIG. 2 b , showing in more detail certain of the components of the train;
FIG. 4 is a plan view from the top of a portion of the curtain of FIG. 1;
FIGS. 5 a , 5 b and 5 c are side elevation views of an end train of an alternative embodiment of the curtain according to the present invention, showing that train respectively in expanded, partially closed and fully contracted positions;
FIG. 6 is a perspective view of an alternative train construction for a mechanical curtain according to the present invention;
FIG. 7 is an enlarged side elevation view of a portion of the train of FIG. 6 in partially closed position showing in more detail certain of the components of the train;
FIG. 8 is a side elevation view of the train of FIG. 7 in fully expanded (or closed) position;
FIG. 9 is a plan view from the top of a portion of the curtain according to the present invention incorporating the construction of FIG. 7;
FIG. 10 is a partial front elevation view showing details of an alternative embodiment of the curtain of the present invention;
FIG. 11 is a perspective view of yet a further alternative embodiment of curtain according to the present invention in partially closed position;
FIG. 12 is a schematic side elevation view of the curtain of FIG. 12 without fabric;
FIG. 13 is a schematic side elevation view of a portion of the curtain of FIG. 12, with fabric.
While the invention will be described in conjunction with illustrated embodiments, it will be understood that it is not intended to limit the invention to such 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 PREFERRED EMBODIMENTS
In the following description, similar features in the drawings have been given similar reference numerals.
Turning to FIG. 1 there is illustrated a mechanical curtain 2 in accordance with the present invention, in partially lowered (closed) position. The curtain as illustrated is particularly useful as a security gate. Curtain 2 is formed from a plurality of similar pantograph trains 4 , longitudinally laterally spaced to form a plane of the curtain. Each train has an upper end 6 and a lower end 8 , and is composed of elongated members 10 , which form, in each train 4 , aligned rows of diamonds 12 . Other than for the last diamond 12 in each train 4 , (at upper end 6 and lower end 8 ), similar pairs of elongated members 10 intersect and are secured pivotally together centrally between their ends as illustrated, to form vertically disposed longitudinal apexes 14 of diamonds 12 . Corresponding ends of these pairs of intersecting members 10 pivotally connect to the ends of other pairs of similar intersecting members 10 to form at these ends laterally disposed apexes 16 . Thus, as can be seen in FIG. 2 a , when trains 4 are elongated in the longitudinal direction, the longitudinal apexes 14 of each diamond 12 are more separated and the laterally disposed apexes 14 are drawn together, while, as can be seen in FIG. 2 c , when the trains are contracted, the longitudinal apexes 14 of each diamond 12 are drawn together and the laterally disposed apexes 16 are more separated.
Cooperating pairs of intersecting elongated members are preferably laterally offset on opposite sides of the apexes 14 and 16 by central spacers 18 (FIG. 4) so that they do not obstruct each other during opening and closing operation of the curtain. A longitudinally oriented aperture 20 , of the longitudinal apexes 14 , the function of which will be described subsequently, may be provided in each spacer 18 .
Each pantograph train 4 operates with its diamonds 12 being in a plane, which is at a 90° angle to the curtain plane, as can be seen in FIG. 1 .
Extending between adjacent trains 4 and secured to corresponding members 10 of adjacent trains are a plurality of spaced bars 22 . Notches 24 (FIG. 3) are provided along interior edges of members 10 in each diamond, to receive portions of corresponding bars in opposite members 10 of the diamonds, when the trains are in their most elongated position.
As can be seen in FIG. 3, as an option, a fabric 25 (chain-line) may be secured about bars 22 over a portion or all of the intended surface area of the curtain, the fabric for example being interwoven through the bars over one side of the diamonds 12 of the trains, as illustrated.
As can be seen in FIG. 1, to move the curtain 2 longitudinally between upper, open position and lower, closed position, a drums 30 are provided with cables 28 , one end of each of which is wrapped around its corresponding drum. Each cable passes over a corresponding sheave or pulley 26 , and its other end may be operatively connected to a lower end 8 of its corresponding train 4 , as illustrated, or to a bar 22 extending between adjacent trains 4 at their lower end 8 . For proper balance, the cables may extend vertically downwardly from sheaves 26 through aperture 20 in spacers of the longitudinal apexes 14 and be secured to the lower. longitudinal apex 14 of its corresponding train 4 .
As can be seen in FIG. 4, bars 22 may be mounted so as to extend outwardly towards adjacent trains at longitudinal apexes 14 . Alternatively, for example, the cables 28 may be looped around a pulley 31 (phantom, FIG. 3) with the free end of the cable appropriately connected above the curtain, to provide a double purchase arrangement for raising and lowering the curtain. An appropriate drive means 33 (FIGS. 2 a , 2 b , 2 c ) for drums 30 is provided so that by unwinding and winding each cable 28 in a similar manner with respect to drums 30 , the pantographs are respectively elongated to close or contracted to open the curtain.
When the curtain is designed as a security gate, an appropriate conventional lock mechanism 32 (FIGS. 2 a and 2 b ) may be provided, for example secured on or in an appropriate portion of the floor below the curtain, to cooperate with lock mechanism 34 secured, to lower end 8 of train 4 .
For purpose of weight balance of the curtain, it is desired that similar numbers of bars 22 be secured to elongated members 10 , preferably in an alternating fashion, on each side of the centre line of the trains (i.e. on each side of the longitudinal axis of the trains running through the longitudinal apexes).
FIGS. 5 a , 5 b and 5 c are schematic side elevation views of an alternative embodiment of curtain 2 in accordance with the present invention. In this case, the trains 4 are pivotally secured to a wall or other support 40 at the upper ends 42 of the upper most elongated members 10 as illustrated. In this manner, as drums 30 wind up cables 28 over their corresponding sheaves 26 , from closed position (FIG. 5 a ) to open position (FIG. 5 c ), the centre line of trains 4 along the longitudinal apexes 14 progressively moves away from support 40 until, when the curtain is in open position as illustrated in FIG. 5 c , those longitudinal apexes 14 have moved their maximum distance away from support 40 and are preferably positioned below sheaves 26 .
Turning to FIGS. 6, 7 and 8 , there is illustrated an alternative construction of curtain 2 in which each elongated member 10 of train 4 is provided with a jog 46 as illustrated. Opposite ends of 48 and 50 of these members, on either side of jog 36 , are parallel. As can be seen in FIGS. 7 and 9, pairs 10 a of such members 10 , on which bars 22 outwardly extend in opposite directions, the members being similarly oriented and positioned, are spaced beside each other and make up one opposing pair of sides of diamonds 12 , while similar elongated single members 10 b , to which no bars 22 are secured make up the other opposing sides. These members 10 b are sandwiched between members 10 a at the apexes where they are connected, and are reversed in their orientation with respect to members 10 a . When the curtain is in elongated, closed orientation, (FIG. 8) this construction permits the bars to be in vertical orientation, albeit, again for reasons of balance, staggered on opposite sides of the longitudinal axis of the curtain trains 4 as illustrated. (The embodiment of curtain illustrated in FIGS. 1 to 5 , prevents the bars from being in vertical alignment.) The embodiment of train construction illustrated in FIGS. 6 to 8 requires inner members 10 b to have no bars secured to them so that the bars secured to members 10 a of a particular diamond 12 will not bear against cooperating, opposed members 10 b in that diamond during the contraction of the trains.
In this embodiment, cables 28 are illustrated as passing through apertures 52 centered in the lowest bars 22 extending between longitudinal apexes 14 of trains 4 .
In FIG. 10, additional horizontally disposed subsets of bars 56 may be provided as required, extending between trains 4 , for aesthetic or functional purposes
In the embodiment illustrated in FIG. 11, a similar extension 60 is laterally disposed in the plane of each diamond 12 , from each laterally disposed apex 16 . The end of each extension 60 is secured by appropriate conventional means to slide up and down within a corresponding track 62 . In this embodiment, cables 28 lie along one edge of each pantograph train 4 , as illustrated, and are secured at its free end to their lowest extension 52 . Track 62 may be supported by existing structures such as walls or posts, or may be free standing.
As illustrated in FIG. 11, a fabric 25 may also be fitted over bars 22 as desired, for purposes such as decoration, obscuring or preventing visibility through the curtain, or other functions. This fabric may for instance be a type of Kevlar (trademark) cloth which is bullet proof or may be solar type cloth which has solar heat control or energy creation applications (i.e. which is made of solar cell material that can convert light energy into electrical energy).
In FIG. 12, an arrangement of curtain, similar to that of FIG. 11 but without any fabric on it, is illustrated in side elevation view, at a position in mid travel between its open and closed positions. In FIG. 13, a more detailed view, again from a side elevation perspective, of the curtain of FIG. 11 is illustrated, on which fabric 58 is illustrated.
The mechanical curtain of the present invention, whether used for security, solar control or otherwise, is relatively simple to construct and operate, and may readily be made visually appealing, while having all of the above mentioned advantages over prior art security gates and the like.
Thus, it is apparent that there has been provided in accordance with the invention a mechanical curtain that fully satisfies the objects, aims and advantages set forth above. While the invention has been described in conjunction with illustrated embodiments thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, it is intended to embrace all such alternatives, modifications and variations as fall within the spirit and broad scope of the invention. | A mechanical curtain, upwardly movable into open position and downwardly movable into closed position, the curtain comprising: a) a plurality of similarly constructed trains of elongated members, the members of each train arranged to form a single pantograph forming longitudinally aligned rows of diamonds, the trains spaced laterally to form a curtain plane and oriented so that the diamonds of the pantographs operate in a plane at a 90° angle to that curtain plane, b) a plurality of bars secured in parallel spaced fashion to corresponding members in adjacent trains, perpendicular thereto, and, c) one or more cables to raise and lower the trains at a similar rate the pantographs being contracted when the curtain is in open position and the pantographs being elongated when the curtain is in closed position. | 4 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation-in-part of U.S. Ser. No. 09/559,993, filed Apr. 27, 2000, which is a continuation of U.S. Ser. No. 09/074,517, filed May 8, 1998, which are hereby incorporated by reference in their entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a method for bleaching pulp. More specifically, the present invention relates to a method of bleaching pulp using high partial pressure ozone in which the ozone is more effectively dispersed and dissolved in a low consistency pulp.
[0004] 2. Brief Description of the Prior Art
[0005] During the past 10-15 years the bleaching of pulp in the Kraft Process has undergone many changes. These changes were mainly prompted by environmental concerns of the quality of the effluent being discharged from paper mills. Of main concern was the bleach plant effluent, which contained polychlorinated dibenzodioxines and dibenzofurans among other compounds. The measurement of AOX was used as an indicator of the concentration of these compounds and the test was quickly adopted as a standard for legislation.
[0006] It was soon determined that the chlorine used in bleaching was a factor in high AOX values, while values could be reduced by lowering the quantity of chlorine used. Chlorine dioxide was substituted for chlorine and reduced AOX values was the result. A typical bleaching sequence became C/D.Eo.D.E.D. with at least 50% of the chlorine being replaced by chlorine dioxide on an equivalence basis. Some paper mills have eliminated chlorine entirely by using, for example, D.Eo.D.E.D. or O.D.Eo.D.E.D. sequences.
[0007] Ozone is a powerful bleaching agent used in many bleach plants throughout the world to bleach Kraft Pulp and recycled fibers. It has recently been discovered that ozone can replace chlorine dioxide and achieve the same brightness and pulp quality. It has been found that 1 kg of ozone can essentially replace 2-4 kg ClO 2 . This results in lower cost bleaching sequences such as O.Z/D.Eop.D.E.D, O.D/Z.Eop.D.X.D, D/Z.Eop.D.E.D. and others. The use of ozone (O 3 ) can become more attractive, however, if a more efficient and cost effective method can be found to better disperse and dissolve O 3 into an existing bleaching sequence. The usual method of bleaching with ozone comprises dispersing ozone into a medium consistency pulp using a pump, mixer and retention tube. This is carried out at a pressure of 150 psig and requires a compressor to add the ozone.
[0008] Medium consistency pulp generally contains a cellulose fiber suspension of from 8-15%, that when exposed to high shear forces acquires fluid properties that permits it to be pumped. High shear mixers enable gases to be dispersed and dissolved in medium consistency pulps.
[0009] A typical medium consistency ozone bleaching process generally consists of pumping pulp to a mixer where ozone is added. The gas dispersion in the pulp is then sent to a vertical retention tube where at least 90% of the ozone dissolves and reacts during a hydraulic residence time of 30 to 60 secs. If the ozone utilization is low, then a second mixer may be added. On discharge from the retention tube, gas is separated from the pulp and the excess ozone in the gas is sent to an ozone destruct unit.
[0010] To achieve high utilization of ozone in medium consistency bleaching, a pump and mixer(s) are used that are driven by high HP motors. Typically pulp is bleached with an ozone charge of about 5 kg ozone/ton pulp, and this is added in a single stage. If higher charges of ozone are required then more than a single stage is necessary, e.g. 10 kg/ton requires two stages. The limiting factor in ozone addition is the volume of gas that can be dispersed and dissolved in the pulp with high ozone utilization. For medium consistency processes it has been found that a high utilization of ozone can be achieved if the volume ratio of gas in the total fluid mixture does not exceed 30%. For ozone generated at a concentration of 10% w/w and operating at a pressure of 150 psig, the maximum charge added is 5 kg of ozone/ton of pulp. If the ozone concentration is raised to 12% this charge can be raised to 6 kg/ton with the same ozone utilization.
[0011] An alternative to medium consistency pulp technology is that of using high consistency pulp. In this process fibers are dewatered to a consistency of 25-40% by passing medium consistency pulp through a press. As well as dewatering the fibers, the pulp is compressed and then fluffed in order to have good contact between gas and fibers. The pulp is then introduced into a reactor where it is contacted with ozone for a period of 1-3 minutes at a pressure of 5 psig. After ozonation, the pulp is degassed and diluted with wash water before passing on to a washing stage.
[0012] When this process was first started there were reports of uneven bleaching, but with improved reactor design this was overcome. An advantage of this process is that it does not require high concentrations of ozone, as using 6.0% w/w works very well. However the high consistency process is not widely accepted because of the mechanical complexity of the equipment and the high power requirement for dewatering the pulp.
[0013] Another possible technique for bleaching pulp involves low consistency pulp. Low consistency pulp employs a cellulose fiber suspension of 1 to less than 5 wt % that has a viscosity greater than water, but can be pumped using conventional pumps without the need of a high shearing effect. Chlorination is generally carried out in a low consistency process and in many processes chlorine dioxide is also added to low consistency pulp slurries. Thus, if an effective process for bleaching pulp with ozone at low consistency was available, one could replace the chlorination stages with such ozone stages easily and without a large capital requirement. However there has been little discussion of ozonation at low consistency.
[0014] Laboratory studies have been carried out on ozonating pulp in bubble columns using pulp slurries around 0.5% concentration. This method worked well, but with columns of a height of 25 m, the gas residence time was very long and ozone utilization low. Furthermore, ozone concentrations in the gas applied were low, 2-3% w/w.
[0015] This low concentration required large volumes of gas to obtain the desired ozone charge. The low concentration also led to low mass transfer rates. The net effect of this was poor ozone utilization, and this together with the dilute pulp slurry has made the consideration of using ozone with low consistency pulp commercially unattractive.
[0016] Up to this point, therefore, there has been no commercial process devoted to ozone bleaching of low consistency pulp. While some laboratory studies have been carried out at consistencies of about 0.5% using unpacked columns and adding the ozone by a diffuser at the bottom, such a process is not considered to be practical for commercial use. Furthermore, there are reports that O 3 consumption increases due to decomposition in water. Also, the favored technology for bleaching uses medium consistency pulps and there have been no reported attempts to carry out low consistency ozone bleaching on an industrial scale.
[0017] Low consistency pulp, however, is easier to pump. Dispersing ozone onto it, because of its low viscosity, would therefore require less power. This can be done before or after a low consistency D stage or a medium consistency D stage. In the latter case this is carried preferably out in a downflow tower and at the bottom of the tower the pulp is diluted to low consistency in order to pump it to the next process step.
[0018] Hence if ozone can be effectively and efficiently dispersed and dissolved in low consistency pulp, the use of low consistency technology with ozonation offers a low cost method which can be used to easily and economically retrofit an existing bleaching process.
[0019] Therefore, it is an object of the present invention to provide a novel process and apparatus for bleaching pulp using ozone.
[0020] Another object of the present invention is to provide a method for more effectively and efficiently dispersing and dissolving ozone into low consistency pulp so as to make low consistency pulp bleaching technology with ozone viable.
[0021] Still another object of the present invention is to provide an efficient process and apparatus for bleaching employing low consistency technology, whereby ozone is used as the bleaching agent.
[0022] These and other objects of the present invention will become apparent to the skilled artisan upon a review of the following disclosure, the Figures of the Drawing, and the claims appended hereto.
SUMMARY OF THE INVENTION
[0023] In accordance with the foregoing objectives, there is provided a novel process and system for bleaching pulp with gaseous mixtures comprising ozone. The process of the present invention comprises first preparing a slurry of cellulosic pulp of a low consistency, i.e., a consistency of fibers of from about 1 to less than 5 weight %. Ozone is then mixed with the pulp slurry in a contacting device under high shear mixing conditions, with the amount of ozone being added to create a partial pressure of ozone in the contacting device greater than atmospheric, and in particular, greater than 1.4 psi. For it has surprisingly been found that when one uses high (greater than 1.4 psi) partial pressure ozone, in combination with a low consistency medium and high shear mixing conditions, improved results are achieved.
[0024] The high shear mixing is achieved using a contacting device or mixer designed for medium consistency pulp bleaching, i.e., a mixer generally used for medium consistency pulps. Such high shear (high-intensity) mixers are well known in the art. Using the high shear mixing conditions has been found to allow the ozone to be effectively and efficiently dispersed and dissolved into the low consistency pulp, even when a high partial pressure of ozone is used. The ozone is then maintained in contact with the cellulosic fibers for a time sufficient to bleach the fibers, before separation occurs.
[0025] What is meant by high shear mixing, i.e., the portions of fluid all moving in the same direction, is known and explained, for example, by Otto Kallmes in his article “On the Nature of Shear and Turbulence, and the Difference Between Them”, 1998 West End Operations . As noted above, high shear mixers are well known in the art, and in a preferred embodiment, such a high shear mixer is used as the contacting device. This would be the easiest way to achieve the high shear mixing conditions.
[0026] The process of the present invention offers one the energy benefits of using low consistency technology, in combination with the benefits of using ozone to bleach the cellulosic pulp. Surprisingly, it has been found that by using a high partial pressure of ozone, i.e., greater than atmospheric, and in particular greater than 1.4 psi, one can actually increase the amount of ozone dissolved in the medium when using low consistency pulp, which cannot be achieved with medium consistency. The more ozone dissolved, of course, allows for a more effective and efficient bleaching process. Also, all of the ozone can be consumed in the high shear mixer so a retention tube is not actually needed, which is unheard of when employing low consistency pulp.
[0027] The ozone bleaching step of the present invention can be combined in an overall bleaching process with other bleaching steps. For example, the ozone bleaching step can be used either before or after a chlorine dioxide bleaching step. The ozone bleaching step can also be followed by a different bleaching step, e.g., with hydrogen peroxide.
[0028] Another advantage of the present invention is that ozone has a short half-life before converting to oxygen, therefore, the present invention with its short mixing time helps ensure more ozone is available for bleaching purposes.
[0029] In another embodiment, there is provided a system for a reactor for bleaching pulp at low consistency with ozone. The reactor comprises a high shear mixer wherein ozone is dispersed into a pulp slurry at high partial pressure having a consistency in the range of from 1 to up to 5 wt %, and a retention tube connected to the mixer which operates at a pressure of from 20 to 80 psig, and wherein the ozone bleaches the pulp in the pulp slurry.
BRIEF DESCRIPTION OF THE DRAWING
[0030] [0030]FIG. 1 of the Drawing depicts a reactor for bleaching pulp at low consistency with ozone, which uses a pressurized ozone generator.
[0031] [0031]FIG. 2 of the Drawing depicts a reactor for bleaching pulp at low consistency with ozone employing an ozone compressor.
[0032] [0032]FIG. 3 of the Drawing depicts a low consistency ozone bleaching process carried out before a chlorine dioxide bleaching step.
[0033] [0033]FIG. 4 of the Drawing depicts an alternative low consistency ozone bleaching process carried out before a chlorine dioxide bleaching step.
[0034] [0034]FIG. 5 of the Drawing depicts a low consistency ozone bleaching process wherein the ozone bleaching step is carried out after a chlorine dioxide bleaching step.
[0035] [0035]FIG. 6 of the Drawing depicts an alternative low consistency ozone bleaching process using an ozone bleaching step that is carried out after a chlorine dioxide bleaching step.
[0036] [0036]FIG. 7 of the Drawing graphically depicts the D/Z delignification efficiency for various reactor/mixers at low consistency (2.5-3.5 wt %).
[0037] [0037]FIG. 8 of the Drawing graphically depicts ozone solubility vs. ozone pressure, in a comparison of low and medium consistency pulp.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0038] The ozone employed in the process of the present invention can be of any source. Preferably, the ozone is generated on-site using an ozone generator, to thereby produce ozone from oxygen at a concentration in the range of from about 4 to 20 wt %, more preferably in the range of from about 10 to 20 wt %, and most preferably in the range of from about 10 to 14 wt %. Ozone generators are well known, and are generally operated at a pressure in the range of from about 20-60 psig, and more preferably in the range of from 30-40 psig.
[0039] The ozone/oxygen mixture is preferably introduced into the contacting device through a valve, which can be used to control the flow of the gas mixture into the high shear mixer or other contacting device. The ozone/oxygen gas mixture can be compressed, if so desired, prior to introduction into the high shear mixer. The ozone compressor generally operates at a pressure ranging from 20-200 psig, and more preferably in the range of from 80-150 psig.
[0040] The ozone is added to the pulp in the contacting device to create a partial pressure by ozone greater than 1.4 psi. More preferably, the partial pressure ranges from greater than 1.4 psi up to 43 psi, and most preferably is in the range of from 9.5 psi to 23 psi. It has been found that the use of such an increased partial pressure of ozone, in combination with the low consistency medium and high shear mixing conditions, results in a significant improvement in the bleaching of the pulp. An improvement of at least 0.2 units lower Kappa number have been observed.
[0041] The high shear mixing conditions in the contacting device can be generated in any known manner, but are preferably, and most easily generated in a high shear mixer. Any high shear mixer well known to the art of pulp bleaching can be used. Such mixers are described, for example, in Pulp Bleaching —Principals and Practice by Carlton W. Dence and Douglas W. Reeve, TAPPI Press, 1996, pages 549-554. In high shear (high intensity) mixers, the pulp and ozone gas mixture are mixed by passage through zones of intense shear. They induce microscale mixing in the entire volume and not only in specific locations as in a continuous stirred reactor. The high shear is created by imposing high rotational speeds across narrow gap, generally between the rotor blades and reactor casing, through which the pulp suspension flows. Although there are design differences among the high shear mixers conventionally known, they all attempt to fluidize the suspension in the mixture working zone. The high shear rate insures flock disruption and good fiber scale mixing.
[0042] The present invention preferably employs a high shear mixer to create the high shear conditions, and many different high shear mixers used for pulp bleaching are known. Some of those known include the Ahlstrom Ahlmix, the Ahlstrom MC pump, the Beloit-Rauma R series, the Ingersoll-Rand Hi-Shear and the Impco Hi-Shear mixer from Beloit Corporation. Others include the Kamry MC, the Kamry MC Pump (Pilot) the Sunds SM and Sunds T mixers. The Quantum mixer is also an acceptable high shear mixer. All such mixers are known in the art and are generally used to mix medium consistency pulp suspensions.
[0043] Mixers can be compared based on energy applied (MJ/ton of pulp) and power dissipation (W/m 3 ). J. R. Bourne in Chem. Eng. Sci., 38(1):5 (1983) states that all devices operated at the same power unit volume will generate the same rate of micromixing. This assumes energy applied equals energy dissipated, which is not true for all mixers. The distribution of power throughout the suspension is as important as its total. Examples of different mixers and the energy and power values for a given pulp consistency are as follows:
Consistency Power Dissipation Energy Mixer Type (wt %) (W/m 3 ) (MJ/ton) Hand Mixing 3 2 × 10 4 120 CSTR 2-3 600 5-9 Quantum (high 5 4.5 × 10 5 63 shear) Mixer High Shear 10 1.8 × 10 6 180
[0044] Using the measured energy dissipation rate and a correlation for the apparent viscosity of a pulp suspension given by Bennington in “Mixing Pulp Suspensions”, PhD. thesis, The University of British Columbia, Vancouver, British Columbia, 1988, τ is 0.02 sec. for a 10% consistency in a typical high shear mixer. In a CSTR operating at 3% consistency, τ=0.4 sec., but varies locally with the mixer. τ represents the mean lifetime of turbulent eddies.
[0045] The pulp suspension of the present invention that is provided to the contacting device, e.g., high shear mixer, is of low consistency. This means that the amount of pulp contained in the suspension ranges from about 1 up to but less than 5 wt %. More preferably, the amount of pulp in the suspension ranges from 2 to 4 wt %. Preferably, the temperature of the pulp slurry entering the mixer is in the range of from about 20-80° C., more preferably from about 40-60° C. The ozone charge added to the pulp is in the range of from about 2-10 kg/ton, more preferably from about 5-6 kg/ton.
[0046] Once in the contacting device, the ozone and pulp suspension are mixed under high shear conditions for a length of time in the range of from about 0.01 second to 1 minute, and more preferably in the range of from about 0.04 second to 1 second. Once the mixing has taken place, the pulp suspension can be passed to a bleaching or reactor station, which is preferably a retention tube, wherein the residence time ranges from about 1 to 10 minutes, more preferably from about 2-5 minutes. It is in the retention tube that the bleaching of the pulp can actually take place by the ozone. Because of the use of the high shear mixing conditions, and the short time in which it takes to dissolve the ozone, as well as the low pressures under which the mixing and retention tube can operate, more ozone is available to do the bleaching of the low consistency pulp. Accordingly, the present invention provides surprising results with regard to excellent bleaching. In fact, the use of a retention tube may not be necessary in spite of using low consistency pulp.
[0047] Referring to FIG. 1, there is illustrated a reactor for bleaching pulp at low consistency with ozone by using a pressurized ozone generator. It consists of a medium consistency mixer where ozone is dispersed in the low consistency pulp followed by a retention tube operating at a pressure between 20-60 psig where ozone gradually dissolves and bleaches the pulp.
[0048] Air is introduced by line 1 into an air separation unit 2 where oxygen is separated from air. Oxygen passes by line 3 into an ozone generator 4 and is converted to ozone, and this passes through line 5 into a control valve 6 that automatically regulates the gas flow by gas flowmeter 7 . Ozone gas is introduced to the mixer 9 by an inlet line 8 and is dispersed into the low consistency pulp. Pulp slurry passes through line 20 into pump 21 where it is pumped into the mixer 9 and mixed with the ozone-oxygen mixture.
[0049] The pulp slurry-gas mixer passes into the column 23 that is held under pressure by a back pressure valve 24 . The ozone-oxygen mixture dissolves and reacts with the pulp slurry before exiting through valve 24 into line 25 .
[0050] The pulp slurry-gas mixture flows into a separator vessel 26 where gases are separated from the pulp and flow through line 27 into an ozone destruct unit 28 , where the ozone is destroyed and the remaining gases leave through line 29 . The pulp slurry leaves the separator through line 30 and flows into pump 31 where it is pumped to the next stage through line 32 .
[0051] [0051]FIG. 2 illustrates a reactor for bleaching pulp at low consistency with ozone by using an ozone compressor. It comprises generally of a medium consistency mixer where ozone is dispersed in the low consistency pulp, followed by a retention tube operating at a pressure between 20-60 psig where ozone gradually dissolves and bleaches the pulp.
[0052] Air is introduced by line 100 into an air separation unit 102 where an oxygen rich stream is separated from air. Oxygen passes by line 103 into an ozone generator 104 and is converted to ozone and this passes through line 105 into an ozone compressor 110 where the gas mixture is compressed. From here it flows to a control valve 106 that automatically regulates the gas flow by gas flowmeter 107 . Ozone gas is introduced to the mixer 109 by an inlet line 108 and is dispersed into the low consistency pulp. Pulp slurry passes through line 120 into pump 121 where it is pumped into the mixer 109 via line 122 and mixed with the ozone-oxygen mixture.
[0053] The pulp slurry-gas mixture passes into the column 123 that is held under pressure by a back pressure valve 124 . The ozone-oxygen mixture dissolves and reacts with the pulp slurry before exiting through valve 124 into line 125 . The pulp slurry-gas mixture flows into a separator vessel 126 where gases are separated from the pulp and flow through line 127 into an ozone destruct unit 128 , where the ozone is destroyed and the gases leave through line 129 . The pulp slurry leaves the separator through line 130 and flows into pump 131 where it is pumped to the next stage through line 132 .
[0054] [0054]FIG. 3 illustrates a low consistency ozone bleaching process in accordance with the present invention that includes an ozone bleaching stage before a chlorine dioxide bleaching stages. This uses a pressurized ozone generator to compress ozone before adding it to a mixer. This method avoids the use of a compressor to add compressed ozone to the mixer.
[0055] In the process, pulp of medium consistency is pumped through line 252 into a storage tank 251 . The pulp flows down the tank into a dilution zone 250 where it is diluted to a low consistency with dilution water added through nozzles 246 and 247 . Agitators 248 and 249 ensure that mixing is complete. The pulp slurry of consistency about 3% passes through line 220 into pump 221 where it is pumped into the mixer 209 and mixed with the ozone-oxygen mixture. Air is introduced by line 201 into an air separation unit 202 where oxygen is separated from air. Oxygen passes by line 203 into a pressurized ozone generator 204 and is converted to ozone and this oxygen-ozone mixture passes through line 205 into a control valve 206 that automatically regulates the gas flow by gas flowmeter 207 . The ozone-oxygen gas mixture is introduced to the mixer 209 by an inlet line 208 and is dispersed into the low consistency pulp.
[0056] The pulp slurry-gas mixture passes into the column 223 , that is held under pressure by a back pressure valve 224 . The ozone-oxygen mixture dissolves and reacts with the pulp slurry before exiting through valve 224 into line 225 . The pulp slurry-gas mixture flows into a separator vessel 226 , where gases are separated from the pulp and flow through line 227 into an ozone destruct unit 228 , where the ozone is destroyed and the resulting gases leave through line 229 . The pulp slurry leaves the separator 226 through line 230 and flows into pump 231 , where it is pumped through line 232 into a mixer 234 where chlorine dioxide is added through line 233 before flowing by line 235 into the bottom of the bleaching tower 236 . The pulp rises to the top of the tower and overflows through line 237 into line 238 to a washer 239 . The pulp is washed with wash water added through line 240 and the washed pulp leaves the washer through line 241 . The dilution water separated from the pulp is collected in storage tank 242 , where it is removed through line 243 by pump 244 and is pumped through line 245 to the nozzles 246 and 247 , where it is added to the dilution zone 250 of the storage tank 251 .
[0057] [0057]FIG. 4 illustrates a low consistency ozone bleaching process involving an ozone bleaching stage in accordance with the present invention that is carried out before a chlorine dioxide bleaching stage. The process uses a compressor to compress ozone before adding it to the mixer.
[0058] In the Figure, pulp of medium consistency is pumped through line 352 into a storage tank 351 . The pulp flows down the tank into a dilution zone 350 where it is diluted to a low consistency with dilution water added through nozzles 346 and 347 . Agitators 348 and 349 ensure that mixing is complete. The pulp slurry of consistency about 3% passes through line 320 into pump 321 where it is pumped through line 322 into the mixer 309 and mixed with the ozone-oxygen mixture. Air is introduced by line 301 into an air separation unit 302 where oxygen is separated from air. Oxygen passes by line 303 into an ozone generator 304 and is converted to ozone, and this oxygen-ozone mixture passes through line 305 into an ozone compressor 310 where it is compressed. From here it flows to a control valve 306 that automatically regulates the gas flow by gas flowmeter 307 . The ozone gas mixture is introduced to the mixer 309 by an inlet line 308 and is dispersed into the low consistency pulp.
[0059] The pulp slurry-gas mixture passes into the column 323 , which is held under pressure by a back pressure valve 324 . The ozone-oxygen mixture dissolves and reacts with the pulp slurry before exiting through valve 324 into line 325 . The pulp slurry-gas mixture flows into a separator vessel 326 where gases are separated from the pulp and flow through line 327 into an ozone destruct unit 328 , where the ozone is destroyed and the gases leave through line 329 . The pulp slurry leaves the separator through line 330 and flows into pump 331 where it is pumped through line 332 into a mixer 334 where chlorine dioxide is added through line 333 before flowing by line 335 into the bottom of the bleaching tower 336 . The pulp rises to the top of the tower and overflows through line 337 into line 338 to a washer 339 . The pulp is washed with wash water added through line 340 and the washed pulp leaves the washer through line 341 . The dilution water separated from the pulp is collected in storage tank 342 . It is removed through line 343 entering pump 344 and is pumped through line 345 to the nozzles 346 and 347 , where it is added to the dilution zone 350 of the storage tank 351 .
[0060] [0060]FIG. 5 depicts a low consistency ozone bleaching process stage in accordance with the present invention that is carried out after a chlorine dioxide bleaching stage. The process uses a pressurized ozone generator to produce compressed ozone before adding it to a mixer. This method avoids the use of a compressor to add compressed ozone to the mixer.
[0061] Pulp of medium consistency is pumped through line 452 into a storage tank 451 . The pulp flows down the tank into a dilution zone 450 where it is diluted to a low consistency with dilution water added through nozzles 446 and 447 . Agitators 448 and 449 ensure that mixing is complete. The pulp slurry, now of low consistency about 3%, passes through line 420 into pump 421 that discharges through line 422 into a mixer 424 where chlorine dioxide is added through line 423 . The pulp slurry-chlorine dioxide mixture passes through line 425 into the bottom of tower 426 , where it flows upwards consuming chlorine dioxide and bleaching the pulp. It overflows from the tower 426 in line 427 flowing into pump 428 , which discharges into mixer 409 where the oxygen-ozone mixture is added.
[0062] Air is introduced by line 401 into an air separation unit 402 where oxygen is separated from air. Oxygen passes by line 403 into an ozone generator 404 and is converted to ozone and this passes through line 405 into a control valve 406 that automatically regulates the gas flow by gas flowmeter 407 . Ozone gas is introduced to the mixer 409 by an inlet fine 408 and is dispersed into the low consistency pulp. The pulp slurry-gas mixture passes into the column 429 , which is held under pressure by a back pressure valve 430 . The ozone-oxygen mixture dissolves and reacts with the pulp slurry before exiting through valve 430 into line 431 . The pulp slurry-gas mixture flows into a separator vessel 432 , where gases are separated from the pulp and passed through line 433 into an ozone destruct unit 434 , in which the ozone is destroyed and the resultant gases leave through line 438 . The pulp slurry leaves the separator through line 436 and flows into pump 437 , where it is pumped to the washer 439 through line 460 . The pulp is washed with wash water added through line 440 and leaves through line 441 . The washings are collected in tank 442 and leave through line 443 entering pump 444 and discharges via line 445 through nozzles 446 and 447 into the dilution zone 450 of the medium consistency storage tank 451 .
[0063] [0063]FIG. 6 illustrates a low consistency ozone bleaching process in accordance with the present invention that is carried out after a chlorine dioxide bleaching step. The process uses a compressor after the ozone generator to compress ozone before adding it to a mixer.
[0064] Pulp of medium consistency is pumped through line 552 into a storage tank 551 . The pulp flows down the tank into a dilution zone 550 where it is diluted to a low consistency with dilution water added through nozzles 546 and 547 . Agitators 548 and 549 ensure that mixing is complete. The pulp slurry, now of consistency about 3%, passes through line 520 into pump 521 and discharges through line 522 into a mixer 524 where chlorine dioxide is added through line 523 . The pulp slurry-chlorine dioxide mixture passes through line 525 into the bottom of tower 526 , where it flows upwards consuming chlorine dioxide and bleaching the pulp. It overflows from the tower in line 527 flowing into pump 528 and discharges into mixer 509 where the oxygen-ozone mixture is added. Air is introduced by line 501 into an air separation unit 502 where oxygen is separated from air. Oxygen passes by line 503 into an ozone generator 504 and is converted to ozone, and this passes through line 505 into a compressor 510 where the gas is compressed. The oxygen-ozone mixture passes through control valve 506 , which automatically regulates the gas flow by gas flowmeter 507 . The ozone gas mixture is introduced to the mixer 509 by an inlet line 508 , and is dispersed into the low consistency pulp.
[0065] The pulp slurry-gas mixture passes into the column 529 , which is held under pressure by a back pressure valve 530 . The ozone-oxygen mixture dissolves and reacts with the pulp slurry before exiting through valve 530 into line 531 . The pulp slurry-gas mixture flows into a separator vessel 532 , where gases are separated from the pulp and flow through line 533 into an ozone destruct unit 534 , wherein the ozone is destroyed and the resultant gases leave through line 535 . The pulp slurry leaves the separator through line 536 and flows into pump 537 where it is pumped to the washer 539 through line 538 . The pulp is washed with wash water added through line 540 and leaves through line 541 . The washings are collected in tank 542 and leave through line 543 entering pump 544 and discharges via line 545 through nozzles 546 and 547 into the dilution zone 550 of the medium consistency storage tank 551 .
[0066] The invention will be illustrated in greater detail by the following specific example. It is understood that the example is given by way of illustration and is not meant to limit the disclosure or the claims to follow. All percentages in the examples, and elsewhere in the specification, are by weight unless otherwise specified.
EXAMPLE 1
[0067] It has been found that most pulps bleach well giving increased brightness with little strength loss for an ozone charge of 5 kg of ozone/ton pulp. Taking this is as the basis of a design for a reactor, and assuming ozone is generated at a concentration of 12% w/w, the oxygen requirement is estimated as follows:
[0068] O 2 required=100*5/12=41.7 kg/ton of pulp.
[0069] This produces a mixture of O 2 +O 3 =5 kg O 3 +36.7 kg O 2 .
[0070] The volume of the gases at a pressure of 760 mms Hg, and temperature of 0° C. is 2.76 m 3 O 3 +30.40 m 3 O 2 .
[0071] Total gas volume=33.16 m 3 /ton of pulp.
[0072] If this is to be dispersed and dissolved in a pulp slurry having a consistency of 3%, volume of pulp slurry=100/3 m 3 /ton of pulp=33.3 m 3 /ton of pulp.
[0073] This consists of 1.0 m 3 pulp+32.3 m 3 of dilution water.
[0074] Hence it is required to dissolve and disperse 33.16 m 3 of gas in 33.3 m 3 of pulp slurry.
[0075] The ratio of gas to pulp slurry=33.16:33.3=about 1:1.
[0076] If all the O 3 dissolved in the dilution water, the solubility of the O 3 would have to be 5 kg/32.3 m 3 , or 155 g/m 3 .
[0077] If this reaction takes place at 50° C., the solubility of 12% w/w O 3 in water is as follows:
Total Pressure Partial Pressure 0 3 Solubility 0 3 (psia) (psia) (g/m 3 ) 14.7 1.22 13.2 24.7 2.05 22.2 164.7 13.67 147.9
[0078] If this is compared to dispersing ozone in medium consistency pulp having a consistency of 10%:
[0079] Volume=1.0 m 3 pulp+9.0 m 3 dilution water=10.0 m 3 pulp slurry.
[0080] If 5 kg O 3 ton of pulp is dispersed and dissolved in the dilution water, O 3 applied=5 kg/9 m 3 =555 g/m 3 .
[0081] The gas to liquid ratio at a pressure of 760 mms Hg and 0° C. is 33.16:9, which is 3.7:1.
[0082] At a pressure of 150 psig, this ratio becomes 0.33:1
[0083] If this medium consistency equipment disperses ozone satisfactorily at a ratio of 0.33:1 for medium consistency pulp, it will be able to do the same for low consistency. Hence to reduce the gas:slurry ratio from 1:1 to 0.33, the gas volume must be reduced by a ratio of 1/0.33 m 3 . This corresponds to a pressure of 30 psig.
[0084] Based on the above calculations, it was decided that medium consistency equipment can be used for dispersing ozone into low consistency pulp at a pressure of 30 psig. This was confirmed by testing carried out in the Laboratory as follows:
[0085] Laboratory Studies
[0086] Trials were carried out in a Quantum Mark-5 Laboratory Mixer/Reactor. This was originally designed and operated with medium consistency pulp. For each run 90 grams of pulp having Kappa No=25.5 was used and a first bleaching stage at a temperature of 40° C. with a constant chlorine dioxide dosage of 14.5 kg/ton was carried out. Following this, 4.0-5.5% w/w ozone-oxygen mixture was then introduced at a pressure of 50-70 psig at a temperature of 40° C. During the ozone addition, the pulp was mixed for 5 seconds at high intensity using a Quantum mixer followed by subsequent intermittent mixing at a lower intensity (using a CSTR) for 5 minutes. The results are shown in Table 1 below:
TABLE 1 0 3 Charge 0 3 Consumed 0 3 Reacted Retention Time Pressure (kg/t) (kg/t) (%) (mins) (psig) 2.4 2.2 93.0 5 46 4.0. 3.9 95.0 5 55 6.1 5.8 95.1 5 52 7.3 7.0 95.9 5 65
[0087] This illustrates that equipment designed for dispersing gases in medium consistency pulp can also be used successfully for O 3 bleaching of low consistency pulp with high ozone utilization.
EXAMPLE 2
[0088] Tests were carried out on a Pilot Plant that was originally designed to use ozone to bleach a medium consistency pulp slurry. It consists of a pump that pumps the pulp into a pressurized high shear mixer. Ozone of concentration 12% w/w is compressed and added to the pulp slurry at the inlet of the mixer. The ozone gas mixture is dispersed in the pulp slurry where it reacts with the lignin. The slurry-gas mixture discharges into a column where the remaining ozone is consumed.
[0089] Results for a Softwood Pulp having Kappa No 31, carried out at temperature 40° C. and a pulp consistency of 3.5%, are shown in Table 2 below:
TABLE 2 Pressure Ozone Ozone Charge Ozone Pressure Bottom Consumed Ozone Consumed to pulp inlet Mixer Tower in Mixer top Tower (kg/t) (psig) (psig) (%) (%) 6.3 30 20 87 99 6-3 90 80 94 99 6-3 110 100 99 99
[0090] These results demonstrate that a Mixer designed for dispersing ozone into a medium consistency pulp slurry can be used successfully for a low consistency pulp slurry and that it is possible to operate at lower pressures with good results.
EXAMPLE 3
[0091] Two runs of an ozone stage were performed on a brown stock kraft pulp at low consistency in a Pilot plant using a high intensity mixer. The runs were made to verify if the ozone stage efficiency (degree of delignification) and the consumption were equivalent for low and medium consistency pulp. The pulp used was a softwood kraft with an initial kappa number of 30.8 and ISO brightness of 27.9%.
[0092] In each run, the washed pulp was received at 33% consistency and diluted to 3.8% consistency in an agitated feed tank. Pulp slurry was then preheated to 40° C. with the injection of steam in the feed tank. At that temperature, concentrated (98%) sulphuric acid was added to the tank to adjust the pH of the pulp suspension to 2.5 before the ozone stage. Pulp slurry was pumped directly to the hopper of the positive displacement pump. This pump introduced pulp in the high pressure section of the pilot plant, where ozone gas was mixed with the pulp in a Impco high intensity mixer. The flow of the pulp into the high pressure section and the ozone charge and concentration were kept constants.
[0093] After compression, the ozone gas stream was introduced into the pulp suspension trough a sintered metal sparger (20 micron porosity) located between the feed pump discharge and the Impco high intensity mixer inlet. The residence time in that mixer was approximately 0.05 second. The conditions for each run are described in Table 3.
[0094] The pulp was sampled approximately 1 meter from the ozone injector point after passing through the high intensity mixer. Gas samples were removed at the exit of the high intensity mixer, at the medium consistency pulp sampling point and at the top of the tower. Each gas sample was analyzed for residual concentration by gas chromatography. The ozonated pulp for the second run was analyzed for kappa number (CPPA standard, G.18) and ISO brightness (CPPA standard, E.1). The results are shown in Table 4 below.
[0095] The efficiency of delignification was approximately 1 kappa number drop per kg ozone. This observation is comparable to the efficiency observed at medium consistency and demonstrates the successful and efficient use of a high shear mixer with ozone and low consistency pulp.
TABLE 3 Z-stage conditions Conditions First Run Second Run Consistency, % 3.8 3.8 Temperature, ° C. 40 40 pH 2.4 2.4 Ozone charge, % o.d. pulp 0.551 0.566 Ozone concentration, % 12.85 13.21 Pressure 30 90 Residence time, min 6.4 6.4
[0096] [0096] TABLE 4 Results First Run Second Run Results Bottom Top Bottom Top Ozone residual, % on o.d. pulp 0.072 0.001 0.037 0.001 Ozone consumed, % on o.d. pulp 0.479 0.550 0.530 0.565 Kappa 27.0 24.1 Brightness ISO, % 31.4 32.2 Viscosity, CP 25.3 23.3
EXAMPLE 4
[0097] The performance of continuously stirred tank reactors (CSTR) of different types was compared to a high shear mixer for delignification efficiency in a D/Z process at low consistency. The performances were compared on the basis of OXE (oxidation equivalent, with 1 OXE=quantity of substance which receives 1 mole electrons when the substance is reduced. ClO 2 =74.12 OXE/Kg and O 3 =125.00 OXE/Kg). All of the CSTRs considered were similar in setup in terms of ozone pressure, concentration and duration.
[0098] The various reactors/mixers run, with the results are as follows.
[0099] CRL:(D/Z)Ep, SKP, initial kappa No. 23.3, final kappa No. 3.6, 14.0 kg ClO 2 ton for 6.3 kg O 3 /ton
[0100] AL:(D/Z)Eop, SKP, initial kappa No. 24.0, final kappa No. 7.9, 8.0 kg ClO 2 /ton, 6.33 kg/O 3 /ton
[0101] ECONOTECH:(D/Z)Ep, SKP, initial kappa No. 23.3, final kappa No. 3.6, 14.0 kg ClO 2 /ton, 6.0 kg O 3 /ton
[0102] CTP:(D/Z)Ep, SKP, initial kappa No. 25.4, final kappa No. 5.1, 15.0 kg ClO 2 /ton, 5.3 kg O 3 /ton
[0103] QUANTUM:(D/Z)Ep, SKP, initial kappa No. 25.5, final kappa No. 4.5, 10.0 kg ClO 2 /ton, 4.0 kg O 3 /ton
[0104] ROBIN:(D/Z)Ep, SKP, initial kappa No. 25.4, final kappa No. 9.0, 9.3 kg ClO 2 /ton, 8.1 kg O 3 /ton
[0105] The delignification efficiency for the various reactors is graphically depicted in FIG. 7. The results clearly demonstrate the superiority of using a high shear mixer in connection with ozone at low consistency, as compared to other reactors which are conventionally used with low consistency pulp.
EXAMPLE 5
[0106] Runs were made comparing ozone solubility at different pressures in low consistency and high consistency pulps. The results are graphically depicted in FIG. 8. As can be seen therefrom, the combination of high partial pressure ozone with a high shear mixer can provide better results using low consistency pulp than those even possible with medium consistency pulp. For example, the graph of FIG. 8 shows that one can achieve an ozone solubility of 6 kg/metric ton of pulp at low consistency at 70 psig O 3 , which one cannot achieve when using medium consistency pulp.
EXAMPLE 6
[0107] Runs were made to show the Kappa number drop when high partial pressure O 3 is used in combination with low consistency pulp and a high shear mixer. The results are shown in Table 5 below:
TABLE 5 Pilot Plant D/Z Trial DZ DZEp Ozone O 3 charge Partial O 3 Total Ozone ISO ISO %, od Pressure Gas Conc. Pressure uptake %, Kappa Brightness Kappa Brightness Run pulp (psi) (% wt) psi Location od pulp number % number % 1 0.49 10.3 12.85 80 Top tower N.A. 8.1 50.4 4.2 56.5 Bottom 0.43 8.4 2 0.615 10.4 13 80 Top tower 0.600 7.8 49.5 4.0 57.5 Bottom 0.555 7.9 3 0.575 3.9 13 30 Top tower 0.56 9.0 47.8 5.0 55.3 Bottom 0.536 9.1 4 0.44 3.9 13 30 Top tower 0.400 9.6 45.4 5.3 54.3 Bottom 0.36 9.9 5 0.434 10.6 13.2 80 Top tower 0.40 8.5 48.7 4.5 56.9 Bottom 0.43 8.8
[0108] Generally, a Kappa drop of up to at least 0.2, and preferably, one unit is possibly achieved by using high partial pressure ozone.
[0109] While the invention has been described with preferred embodiments, it is to be, understood that variations and modifications may be resorted to as will be apparent to those skilled in the art. Such variations and modifications are to be considered within the purview and the scope of the claims appended hereto. | Provided is a process for bleaching pulp with ozone. The process involves preparing a slurry of cellulosic pulp having a consistency in fibers of from 1 up to 5 weight %. Such a low consistency slurry is then mixed with high partial pressure ozone under high shear conditions. The ozone is then maintained in contact with the cellulosic fibers to effect bleaching of the fibers. The present process offers the advantages of bleaching using a low consistency slurry, with the added advantages of employing ozone. | 3 |
FIELD OF THE INVENTION
This invention concerns curable coating compositions, especially compositions for high-gloss topcoats, particularly for clearcoats of color-plus-clear composite coatings.
BACKGROUND OF THE INVENTION
Curable, or thermosettable, coating compositions are widely used in the coatings art, particularly for topcoats in the automotive and industrial coatings industry. Color-plus-clear composite coatings are particularly useful as topcoats for which exceptional gloss, depth of color, distinctness of image, or special metallic effects are desired. The automotive industry has made extensive use of these coatings for automotive body panels.
Single-layer topcoats and the clearcoats of color-plus-clear composite coatings, however, require an extremely high degree of clarity and gloss to achieve the desired visual effect. Such coatings also require a low degree of visual aberrations at the surface of the coating in order to achieve the desired visual effect such as high distinctness of image (DOI). As such, these coatings are especially susceptible to a phenomenon known as environmental etch. Environmental etch manifests itself as spots or marks on or in the finish of the coating that often cannot be rubbed out. It is often difficult to predict the degree of resistance to environmental etch that a high gloss topcoat or color-plus-clear composite coating will exhibit. Many coating compositions known for their durability and/or weatherability when used in exterior paints, such as known high-solids enamels, do not provide the desired level of resistance to environmental etch when used in high gloss coatings such as the clearcoat of a color-plus-clear composite coating.
Curable coating compositions utilizing carbamate- or urea-functional materials are described, for example, in U.S. Pat. Nos. 5,756,213; 5,760,127; 5,770,650, 5,792,810; and 5,827,930, each of which is incorporated herein by reference. These patents describe coating compositions including a carbamate-functional or urea-functional compound prepared by a ring-opening reaction with a lactone. While such compounds have proven useful in coatings, particularly coatings for flexible substrates, it has been found that even a modest number of lactone units in the compounds give rise to problems of solidification during storage at room temperature and the need to employ higher amounts of solvent than desired in order to obtain suitable viscosities. On the other hand, decreasing the average number of lactone units per compound leads to less than optimum properties in the cured coating, such as poorer durability, less resistance to environmental etch, and less resistance to scratching and marring.
SUMMARY OF THE INVENTION
The present invention provides a curable coating composition that includes at least three components: a component (a), a component (b), and a component (c). The present invention also provides a composition comprising component (a) and component (b) that has improved stability against crystallization or solidification as compared to compositions without the component (b).
The component (a) has at least one carbamate group or urea group and has a lactone or hydroxy carboxylic acid moiety. When used in connection with the invention, the term “carbamate group” refers to a group having a structure
in which R is H or alkyl. Preferably, R is H or alkyl of from 1 to about 4 carbon atoms, and more preferably R is H. When used in connection with the invention, terminal urea group refers to a group having a structure
in which R′ and R″ are each independently H or alkyl, or R′ and R″ together form a heterocyclic ring structure. Preferably, R′ and R″ are each independently H or alkyl of from 1 to about 4 carbon atoms or together form an ethylene bridge, and more preferably R′ and R″ are each independently H. The terminal urea group of the invention is distinguished from urea linking groups for which R″ would be other than alkyl.
Preferred compounds (a) may be represented by the structures
in which R, R′, and R″ are as previously defined; R 1 is alkylene or arylalkylene, preferably alkylene, and particularly preferably alkylene of 5 to 10 carbon atoms; R 2 is alkylene or arylalkylene, preferably alkylene and particular preferably alkylene of about 5 to about 10 carbon atoms; R 3 is alkylene (including cycloalkylene), alkylarylene, arylene, or a structure that includes a cyanuric ring, a urethane group, a urea group, a carbodiimide group, a biuret structure, or an allophonate group, preferably alkylene (including cycloalkylene) or a structure that includes a cyanuric ring; n is from 1 to about 10, preferably from 1 to about 5; m is from 2 to about 6, preferably 2 or 3; and L is O, NH, or NR 4 , where R 4 is an alkyl, preferably an alkyl of 1 to about 6 carbon atoms.
The compound (a) may be prepared by a process that involves a step of reacting together a lactone or a hydroxy carboxylic acid and a compound comprising a carbamate or urea group or a group that can be converted to a carbamate or urea group and a group that is reactive with the lactone or hydroxy carboxylic acid. In the case of a group that can be converted to a carbamate or urea group, the group is converted to the carbamate or urea group either during or after the reaction with the lactone or hydroxy carboxylic acid. The process for preparing compound (a) may include a further step in which a hydroxyl-functional product of the first step is reacted with a compound having at least two isocyanate groups.
The second component (b) is a branched polyol having a lactone or hydroxy carboxylic acid moiety. The branched polyol has at least two hydroxyl groups and at least one branch point. By “branch point” we mean a carbon atom having carbon-carbon bonds with at least three other carbon atoms. Preferred compounds of the second component (b) may be represented by the structure
in which R 1 , n, and m are as previously defined, R 5 is an m-valent moiety having at least one branch point, and X is a moiety having an active hydrogen group. Preferably, R 5 is alkylene, more preferably with one branch point, and particularly preferably R 5 has from 2 to about 12 carbon atoms. Preferably, X is OH or X is a moiety having a carbamate or terminal urea group, more preferably X is OH.
The third component (c) of the coating composition is a curing agent that is reactive with the first two components.
Additionally, the invention provides a process for increasing the solids content of a coating composition that includes a component (a) as described above having at least one carbamate group or urea group and having a lactone or hydroxy carboxylic acid moiety. In the process of the invention, a small amount of a polyol (b)(1) having at least one branch point, preferably from about 0.2 to about 10% by weight based on the total weight of the components (a) and (b), is incorporated into the composition, preferably during a step in which a compound (a)(1) is reacted with a lactone or hydroxy carboxylic acid to form the component (a). Preferred polyols (b)(1) may be represented by the structure R 5 (OH) m , where R 5 and m are as defined previously.
The invention further provides an article having a substrate, in particular a flexible substrate, upon which substrate is a cured coating derived from a coating composition according to the invention and a method of producing such a coating on a substrate.
DETAILED DESCRIPTION
The composition according to the present invention includes as a first component a compound (a) having at least one carbamate group or terminal urea group and having a lactone or hydroxy acid moiety. By “lactone or hydroxy acid moiety” it is meant a structure resulting from incorporation of a lactone or hydroxy acid into the compound. For example, a lactone or hydroxy acid could be incorporated into compound (a) as an ester or polyester segment by reaction with a hydroxyl or a primary or secondary amine group on a precursor to compound (a). Preferred compounds (a) may be represented by the structures
in which R, R′, and R″ are as previously defined; R 1 is alkylene or arylalkylene, preferably alkylene, and particularly preferably alkylene of 5 to 10 carbon atoms; R 2 is alkylene or arylalkylene, preferably alkylene and particular preferably alkylene of about 5 to about 10 carbon atoms; R 3 is alkylene (including cycloalkylene), alkylarylene, arylene, or a structure that includes a cyanuric ring, a urethane group, a urea group, a carbodiimide group, a biuret structure, or an allophonate group, preferably alkylene (including cycloalkylene) or a structure that includes a cyanuric ring; n is from 1 to about 10, preferably from 1 to about 5; m is from 2 to about 6, preferably 2 or 3; and L is O, NH, or NR 4 , where R 4 is an alkyl, preferably an alkyl of 1 to about 6 carbon atoms.
The compound (a) may be prepared by a process that involves a step of reacting together a lactone or a hydroxy carboxylic acid and a compound (a)(1) comprising a carbamate or terminal urea group or a group that can be converted to a carbamate or terminal urea group and a group that is reactive with the lactone or hydroxy carboxylic acid. Preferably, the compound (a)(1) has a carbamate or terminal urea group or, in an alternative preferred embodiment, it has a carbamate group or a group that can be converted to a carbamate group. In a particularly preferred embodiment, the compound (a)(1) has a carbamate group.
Suitable functional groups reactive with the lactone or hydroxyl carboxylic acid include, without limitation, hydroxyl groups, carboxyl groups, isocyanate groups, and primary and secondary amine groups. Preferably, the compound (a)(1) has a hydroxyl group or an amino group as the group reactive with the lactone or hydroxyl carboxylic acid. The compound (a)(1) has at least one group that is reactive with the lactone or hydroxy carboxylic acid, and preferably it has from 1 to about 3 of such groups, and more preferably it has one such reactive group. In a preferred embodiment, the compound (a)(1) has a carbamate group and a hydroxyl group. One preferred example of such a compound is a hydroxyalkyl carbamate, particularly a β-hydroxyalkyl carbamate. In another preferred embodiment, the compound (a)(1) has a terminal urea group and a hydroxyl group.
Suitable compounds (a)(1) include, without limitation, any of those compounds having a carbamate or terminal urea group and a group reactive with lactone or hydroxyl carboxylic acid that are known in the art. Hydroxypropyl carbamate and hydroxyethyl ethylene urea, for example, are well known and commercially available. Amino carbamates are described in U.S. Pat. No. 2,842,523. Hydroxyl ureas may also be prepared by reacting the amine group of an amino alcohol with hydrochloric acid and then urea to form a hydroxy urea compound. An amino alcohol can be prepared, for example, by reacting an oxazolidone with ammonia. Amino ureas can be prepared, for example, by reacting a ketone with a diamine having one amine group protected from reaction (e.g., by steric hindrance), followed by reaction with HNCO (e.g., as generated by thermal decomposition of urea), and finally reaction with water. Alternatively, these compounds can be prepared by starting with a compound having the group that can be converted to carbamate or terminal urea, which groups are described below, and converting that group to the carbamate or urea prior to beginning the reaction with the lactone or hydroxy carboxylic acid.
In a particularly preferred embodiment, the compound (a) is prepared by a process that involves a step of reacting together a lactone or a hydroxy carboxylic acid and the compound (a)(1) in the presence of a minor amount of a compound (b)(1). The compound (b)(1) is a polyol that may be represented by the structure R 5 (OH) m , where R 5 , n, and m are as defined previously.
The compound (b) is included in an amount that is sufficient to stabilize the composition including components (a) and (b) for a period of time of at least about six months. In particular, the compound (b) is included in an amount that is sufficient to prevent the solidification at about 20° C. of the component (a) for at least about six months. Component (b) is included in an amount sufficient to keep component (a) fluid for at least about six months. If, during the at least six-month period the mixture including components (a) and (b) is cooled to a temperature below about 0° C. at which temperature the mixture solidifies, then when heated again to about 20° C., the mixture should again liquefy.
In another aspect of the invention, the preparation of compound (a) includes a further step in which the product of the reaction of compound (a)(1) is reacted with the lactone or carboxylic acid with a polyisocyanate. Preferably, the product of compound (a)(1) and the lactone or hydroxy carboxylic acid has a hydroxyl group at the end of the lactone or hydroxy carboxylic acid segment that is reacted with the polyisocyanate. Suitable examples of polyisocyanate compounds include both aliphatic polyisocyanates and aromatic polyisocyanates. Useful polyisocyanates include monomeric isocyanates, for example aliphatic diisocyanates such as ethylene diisocyanate, 1,2-diisocyanatopropane, 1,3-diisocyanatopropane, 1,6-diisocyanatohexane (hexamethylene diisocyanate or HMDI), 1,4-butylene diisocyanate, lysine diisocyanate, 1,4-methylene bis-(cyclohexyl isocyanate) and isophorone diisocyanate (IPDI), and aromatic diisocyanates and arylaliphatic diisocyanates such as the various isomers of toluene diisocyanate, meta-xylylenediioscyanate and para-xylylenediisocyanate, 4-chloro-1,3-phenylene diisocyanate, 1,5-tetrahydro-naphthalene diisocyanate, 4,4′-dibenzyl diisocyanate, and 1,2,4-benzene triisocyanate. In addition, the various isomers of α, α, α′, α′-tetramethyl xylylene diisocyanate can be used. Isocyanate-functional oligomers or low molecular weight reaction products of the monomeric isocyanates, which may have from 2 to about 6 isocyanate groups, may also be used. Examples of these include isocyanurates and the reaction products of excess isocyanate with polyols, such as the product of three moles of diisocyanate with a mole of a triol (e.g., 3 moles of IPDI with one mole of trimethylolpropane or two moles of IPDI with one mole of neopentyl glycol); reaction products of isocyanate with urea (biurets); and reaction products of isocyanate with urethane (allophanates). The polyisocyanate preferably has two to four isocyanate groups, and more preferably the polyisocyanate has 2 or 3 isocyanate groups per molecule. Isocyanurates such as the isocyanurates of isophorone diisocyanate or hexamethylene diisocyanate are particularly preferred. In a particularly preferred embodiment, a β-hydroxyalkyl carbamate is reacted with epsilon-caprolactone and the product of this reaction is then reacted with a polyisocyanate, preferably the isocyanurate of IPDI. It should be appreciated that the order of the various reaction steps may in many cases be varied in the synthesis of the compounds of the invention.
When a compound (a)(1) that has a group that can be converted to carbamate or terminal urea is used, conversion of the group to a carbamate or urea can be accomplished during or after the reaction with the lactone or the hydroxy carboxylic acid to produce the first component. Groups that can be converted to carbamate include cyclic carbonate groups, epoxy groups, and unsaturated bonds. Cyclic carbonate groups can be converted to carbamate groups by reaction with ammonia or a primary amine, which ring-opens the cyclic carbonate to form a β-hydroxy carbamate. Epoxy groups can be converted to carbamate groups by first converting to a cyclic carbonate group by reaction with CO 2 . This can be done at any pressure from atmospheric up to supercritical CO 2 pressures, but is preferably under elevated pressure (e.g., 60-150 psi). The temperature for this reaction is preferably 60°-150° C. Useful catalysts include any that activate an oxirane ring, such as tertiary amine or quaternary salts (e.g., tetramethyl ammonium bromide), combinations of complex organotin halides and alkyl phosphonium halides (e.g., (CH 3 ) 3 SnI, Bu 4 SnI, Bu 4 PI, and (CH 3 ) 4 PI), potassium salts (e.g., K 2 CO 3 , KI) preferably in combination with crown ethers, tin octoate, calcium octoate, and the like. The cyclic carbonate group can then be converted to a carbamate group as described above. Any unsaturated bond can be converted to a carbamate group by first reacting with peroxide to convert to an epoxy group, then with CO 2 to form a cyclic carbonate, and then with ammonia or a primary amine to form the carbamate.
Other groups, such as hydroxyl groups or isocyanate groups can also be converted to carbamate groups. However, if such groups were to be present on the compound (a)(1) and it is desired to convert those groups to carbamate after the reaction with the lactone or hydroxycarboxylic acid, they would have to be blocked or protected so that they would not react during the lactone reaction. When blocking these groups is not feasible, the conversion to carbamate or terminal urea would have to be completed prior to the lactone reaction. Hydroxyl groups can be converted to carbamate groups by reaction with a monoisocyanate (e.g., methyl isocyanate) to form a secondary carbamate group (that is, a carbamate of the structure above in which R is alkyl) or with cyanic acid (which may be formed in situ by thermal decomposition of urea) to form a primary carbamate group (i.e., R in the above formula is H). This reaction preferably occurs in the presence of a catalyst as is known in the art. A hydroxyl group can also be reacted with phosgene and then ammonia to form a primary carbamate group, or by reaction of the hydroxyl with phosgene and then a primary amine to form a compound having secondary carbamate groups. Another approach is to react an isocyanate with a compound such as hydroxyalkyl carbamate to form a carbamate-capped isocyanate derivative. For example, one isocyanate group on toluene diisocyanate can be reacted with hydroxypropyl carbamate, followed by reaction of the other isocyanate group with an excess of polyol to form a hydroxy carbamate. Finally, carbamates can be prepared by a transesterification approach where a hydroxyl group is reacted with an alkyl carbamate (e.g., methyl carbamate, ethyl carbamate, butyl carbamate) to form a primary carbamate group-containing compound. This reaction is performed at elevated temperatures, preferably in the presence of a catalyst such as an organometallic catalyst (e.g., dibutyltin dilaurate). Other techniques for preparing carbamates are also known in the art and are described, for example, in P. Adams & F. Baron, “Esters of Carbamic Acid”, Chemical Review , v. 65, 1965 and in U.S. Pat. No. 5,474,811, issued to Rehfuss and St. Aubin.
Groups such as oxazolidone can also be converted to terminal urea after reaction with the lactone or hydroxy carboxylic acid. For example, hydroxyethyl oxazolidone can be used to react with the lactone or hydroxy carboxylic acid, followed by reaction of ammonia or a primary amine with the oxazolidone to generate the urea functional group.
One preferred class of compounds (a)(1) having a group reactive with the lactone or hydroxy carboxylic acid and a group that can be converted to carbamate is the hydroxyalkyl cyclic carbonates. Hydroxyalkyl cyclic carbonates can be prepared by a number of approaches.
Certain hydroxyalkyl cyclic carbonates like 3-hydroxypropyl carbonate (i.e., glycerine carbonate) are commercially available. Cyclic carbonate compounds can be synthesized by any of several different approaches. One approach involves reacting an epoxy group-containing compound with CO 2 under conditions and with catalysts as described hereinabove. Epoxides can also be reacted with β-butyrolactone in the presence of such catalysts. In another approach, a glycol like glycerine is reacted at temperatures of at least 80° C. with diethyl carbonate in the presence of a catalyst (e.g., potassium carbonate) to form a hydroxyalkyl carbonate. Alternatively, a functional compound containing a ketal of a 1,2-diol having the structure:
can be ring-opened with water, preferably with a trace amount of acid, to form a 1,2-glycol, the glycol then being further reacted with diethyl carbonate to form the cyclic carbonate.
Cyclic carbonates typically have 5- or 6-membered rings, as is known in the art. Five-member rings are preferred, due to their ease of synthesis and greater degree of commercial availability. Six-membered rings can be synthesized by reacting phosgene with 1,3-propanediol under conditions known in the art for the formation of cyclic carbonates. Preferred hydroxyalkyl cyclic carbonates used in the practice of the invention can be represented by the formula:
in which R (or each instance of R if n is more than 1) is a hydroxyalkyl group of 1-18 carbon atoms, preferably 1-6 carbon atoms, and more preferably 1-3 carbon atoms, which may be linear or branched and may have substituents in addition to the hydroxyl group, and n is 1 or 2, which may be substituted by one or more other substituents such as blocked amines or unsaturated groups. The hydroxyl group may be on a primary, secondary, or tertiary carbon. More preferably, R is —(CH 2 ) p —OH, where the hydroxyl may be on a primary or secondary carbon and p is 1 to 8, and even more preferably in which the hydroxyl is on a primary carbon and p is 1 or 2.
The compound (a)(2) may be a lactone or a hydroxy carboxylic acid. Lactones that can be ring opened by an active hydrogen are well-known in the art. They include, for example, ε-caprolactone, γ-caprolactone, β-butyrolactone, β-propriolactone, γ-butyrolactone, α-methyl-γ-butyrolactone, β-methyl-γ-butyrolactone, γ-valerolactone, δ-valerolactone, γ-nonanoic lactone, γ-octanoic lactone, and pentolactone. In one preferred embodiment, the lactone is ε-caprolactone. Lactones useful in the practice of the invention can also be characterized by the formula:
wherein n is a positive integer of 1 to 7 and R is one or ore H atoms, or substituted or unsubstituted alkyl groups of 1-7 carbon atoms.
The lactone ring-opening reaction is typically conducted under elevated temperature (e.g., 80-150° C.). The reactants are usually liquids so that a solvent is not necessary. However, a solvent may be useful in promoting good conditions for the reaction even if the reactants are liquid. Any non-reactive solvent may be used, including both polar and nonpolar organic solvents. Examples of useful solvents include toluene, xylene, methyl ethyl ketone, methyl isobutyl ketone, and the like. A catalyst is preferably present. Useful catalysts include proton acids (e.g., octanoic acid, Amberlyst® 15 (Rohm & Haas)), and tin catalysts (e.g., stannous octoate). Alternatively, the reaction can be initiated by forming a sodium salt of the hydroxyl group on the molecules that react will react with the lactone ring.
A hydroxy carboxylic acid can also be used as compound (a)(2). Useful hydroxy carboxylic acids include dimethylhydroxypropionic acid, hydroxy stearic acid, tartaric acid, lactic acid, 2-hydroxyethyl benzoic acid, and N-(2-hydroxyethyl)ethylene diamine triacetic acid. The reaction can be conducted under typical esterification conditions, for example at temperatures from room temperature up to about 150° C., and with catalysts such as calcium octoate, metal hydroxides like potassium hydroxide, Group I or Group II metals such as sodium or lithium, metal carbonates such as potassium carbonate or magnesium carbonate (which may be enhanced by use in combination with crown ethers), organometallic oxides and esters such as dibutyl tin oxide, stannous octoate, and calcium octoate, metal alkoxides such as sodium methoxide and aluminum tripropoxide, protic acids like sulfuric acid, or Ph 4 SbI. The reaction may also be conducted at room temperature with a polymer-supported catalyst such as Amerlyst-15® (available from Rohm & Haas) as described by R. Anand in Synthetic Communications, 24(19), 2743-47 (1994), the disclosure of which is incorporated herein by reference. The reaction may be performed with an excess of the compound having the group reactive with the hydroxy carboxylic acid.
The reaction with the compound (a)(2) can provide chain extension of the compound (a)(1) molecule if sufficient amounts of the compound (a)(2) are present. The relative amounts of the (a)(1) compound and the (a)(2) lactone and/or hydroxy acid can be varied to control the degree of chain extension. The reaction of the lactone ring or of the hydroxy carboxylic acid with a hydroxyl or amine group results in the formation of an ester or amide and an OH group. The resulting OH group can then react with another available lactone ring or molecule of hydroxy carboxylic acid, thus resulting in chain extension. The reaction is thus controlled by the proportion of the compound(s) (a)(2) to the amount of initiator compound (a)(1). In the preferred embodiments of the present invention, the ratio of equivalents of lactone and/or hydroxy carboxylic acid to equivalents of active hydrogen groups on compound (a)(1) is preferably from 0.1:1 to 10:1, and more preferably from 1:1 to 5:1. When the reaction product has an acid group, the acid group can then be converted to a hydroxyl group by well-known techniques such as reaction with ethylene oxide.
The coating composition further includes a component (b). Component (b) can be prepared according to the process outlined above in which compound (a)(1) are polyol (b)(1) are simultaneously reacted with the lactone or hydroxy carboxylic acid compound (a)(2). Alternatively, the components (a) and (b) can be formed separately and combined in the coating composition.
The compound (b) may be prepared by a process including a step of reacting together a compound (b)(2) that is a lactone or a hydroxy carboxylic acid with a compound (b)(1). The compound (b)(1) is a polyol having at least one branch point. Examples of suitable lactones and hydroxy carboxylic acids include those already mentioned above. Examples of polyols suitable as the compound (b)(1) include, without limitation, neopentyl glycol, 2-ethyl-1,3-hexanediol, 2,5-dimethyl-2,5-hexanediol, 2,2,4-trimethyl-1,3-pentanediol, 2,2-diethyl-1,3-propanediol, 2-methyl-2-propyl-1,3-propanediol, 2,4-dimethyl-2,4-pentanediol, 3,3-dimethyl-1,2-butanediol, 1-ethyl-2-propyl-1,5-pentanediol, 2-ethyl-2-methyl-1,3-propanediol, 2-methyl-2,4-pentanediol, 1,2-cyclohexanedimethanol, 1,4-cylcohexanedimethanol, and so on. Particularly preferred are 2-ethyl-1,3-hexanediol, 2,2,4-trimethyl-1,3-pentanediol, 2-ethyl-2-methyl-1,3-propanediol, and 1-ethyl-2-propyl-1,5-pentanediol.
The amount of polyol (b)(1) having at least one branch point is preferably from about 0.2 to about 10% by weight based on the total weight of the components (a) and (b).
Component (b) preferably has a structure
in which R 1 , n, and m are as previously defined, R 5 is an m-valent moiety having at least one branch point, and X is a moiety having an active hydrogen group. Preferably, R 5 is alkylene or substituted alkylene, more preferably with one branch point, and preferably R 5 has from 2 to about 12 carbon atoms. Preferably, X is OH or X is a moiety having a carbamate or terminal urea group, more preferably X is OH.
Compound (b)(1) may be represented by the structure R 5 -(OH) m , in which R 5 and m are as defined previously.
In a one preferred embodiment, the component (b) has a structure as shown above in which X is OH. In other cases, it may be advantageous to modify the hydroxyl functional compound as described in U.S. Pat. No. 5,827,930, the entire disclosure of which is incorporated herein by reference, to provide a component (b) that has carbamate or terminal urea functionality as defined hereinabove. The hydroxyl group resulting from the reaction of the compound (b)(1) with the compound (b)(2) lactone or hydroxy carboxylic acid can be reacted with a compound (b)(3) to supply a carbamate or terminal urea functionality. Compound (b)(3) has a group that is reactive with the hydroxyl group of the of the product of the reaction of (b)(1) with (b)(2) to provide a group that will be reactive with crosslinker compound (c), preferably a carbamate or urea group or group that can be converted to carbamate or urea.
A number of compounds may be used as compound (b)(3) to convert a hydroxyl group on the product of (b)(1) and (b)(2) to a carbamate group. Hydroxyl groups can be converted to carbamate groups by reaction with a monoisocyanate such as methyl isocyanate or with cyanic acid (which may be formed by the thermal decomposition of urea) to form a primary carbamate group. A catalyst may be used. A hydroxyl group can also be reacted with phosgene and then ammonia to form a compound having primary carbamate functionality (R is hydrogen) or with phosgene and then a primary amine to form a compound having secondary carbamate functionality (R is alkyl).
In another method, alkyl carbamates such as methyl carbamate or butyl carbamate or substituted alkyl carbamates such as hydroxypropyl carbamate can be transesterified with the hydroxyl group. This reaction is carried out with heating and, preferably, in the presence of a catalyst such as an organometallic catalyst like dibutyl tin dilaurate. Additionally, a methylol acrylamide compound can be reacted with the hydroxyl group and then converted to carbamate by reaction of the unsaturated acrylamide bond with peroxide, then CO 2 , then ammonia or a primary amine. It is also possible to react the hydroxyl with a partially blocked diisocyanate, then unblock the isocyanate and react the regenerated isocyanate group with a hydroxyalkyl carbamate or hydroxy urea (i.e., hydroxypropyl carbamate or hydroxyethyl ethylene urea). A diisocyanate in which the isocyanate groups have differing reactivities, such as toluene diisocyanate, is particularly suitable for half-blocking. Similarly, the half-blocked polyisocyanate can be reacted first with the hydroxy functional carbamate or urea compound and then unblocked and reacted with the hydroxy functional product of (b)(1) and (b)(2).
The coating composition further includes a component (c) that is a curing agent or curing agents reactive with components (a) and (b). Each curing agent should be reactive with functionality on one or both of components (a) and (b). For example, curing agent or agents of component (c) could be reactive with carbamate groups, urea groups, and/or hydroxyl groups, depending on the functionalities of components (a) and (b). Useful curing agents include materials having active methylol or methylalkoxy groups, such as aminoplast crosslinking agents or phenol/formaldehyde adducts; curing agents that have isocyanate groups, particularly blocked isocyanate curing agents, curing agents that have epoxide groups, amine groups, acid groups, siloxane groups, cyclic carbonate groups, and anhydride groups; and mixtures thereof. Examples of preferred curing agent compounds include, without limitation, melamine formaldehyde resin (including monomeric or polymeric melamine resin and partially or fully alkylated melamine resin), blocked or unblocked polyisocyanates (e.g., TDI, MDI, isophorone diisocyanate, hexamethylene diisocyanate, and isocyanurates of these, which may be blocked for example with alcohols or oximes), urea resins (e.g., methylol ureas such as urea formaldehyde resin, alkoxy ureas such as butylated urea formaldehyde resin), polyanhydrides (e.g., polysuccinic anhydride), and polysiloxanes (e.g., trimethoxy siloxane). Another suitable crosslinking agent is tris(alkoxy carbonylamino) triazine (available from Cytec Industries under the tradename TACT). The curing agent may be combinations of these, particularly combinations that include aminoplast crosslinking agents. Aminoplast resins such as melamine formaldehyde resins or urea formaldehyde resins are especially preferred. Combinations of tris(alkoxy carbonylamino) triazine with a melamine formaldehyde resin and/or a blocked isocyanate curing agent are likewise suitable and desirable.
The coating composition used in the practice of the invention may include a catalyst to enhance the cure reaction. For example, when aminoplast compounds, especially monomeric melamines, are used as a curing agent, a strong acid catalyst may be utilized to enhance the cure reaction. Such catalysts are well-known in the art and include, without limitation, p-toluenesulfonic acid, dinonylnaphthalene disulfonic acid, dodecylbenzenesulfonic acid, phenyl acid phosphate, monobutyl maleate, butyl phosphate, and hydroxy phosphate ester. Strong acid catalysts are often blocked, e.g. with an amine. Other catalysts that may be useful in the composition of the invention include Lewis acids, zinc salts, and tin salts.
A solvent may optionally be utilized in the coating composition used in the practice of the present invention. Although the composition used according to the present invention may be utilized, for example, in the form of substantially solid powder, or a dispersion, it is often desirable that the composition is in a substantially liquid state, which can be accomplished with the use of a solvent. This solvent should act as a solvent with respect to the components of the composition. In general, the solvent can be any organic solvent and/or water. In one preferred embodiment, the solvent is a polar organic solvent. More preferably, the solvent is selected from polar aliphatic solvents or polar aromatic solvents. Still more preferably, the solvent is a ketone, ester, acetate, aprotic amide, aprotic sulfoxide, aprotic amine, or a combination of any of these. Examples of useful solvents include, without limitation, methyl ethyl ketone, methyl isobutyl ketone, m-amyl acetate, ethylene glycol butyl ether-acetate, propylene glycol monomethyl ether acetate, xylene, N-methylpyrrolidone, blends of aromatic hydrocarbons, and mixtures of these. In another preferred embodiment, the solvent is water or a mixture of water with small amounts of co-solvents.
In a preferred embodiment of the invention, the solvent is present in the coating composition in an amount of from about 0.01 weight percent to about 99 weight percent, preferably from about 10 weight percent to about 60 weight percent, and more preferably from about 30 weight percent to about 50 weight percent.
Coating compositions can be coated on the article by any of a number of techniques well-known in the art. These include, for example, spray coating, dip coating, roll coating, curtain coating, and the like. For automotive body panels, spray coating is preferred.
Additional agents, for example surfactants, fillers, stabilizers, wetting agents, dispersing agents, adhesion promoters, UV absorbers, hindered amine light stabilizers, etc. may be incorporated into the coating composition. While such additives are well-known in the prior art, the amount used must be controlled to avoid adversely affecting the coating characteristics.
The coating composition according to the invention is preferably utilized in a high-gloss coating and/or as the clearcoat of a composite color-plus-clear coating. High-gloss coatings as used herein are coatings having a 20° gloss (ASTM D523) or a DOI (ASTM E430) of at least 80.
When the coating composition of the invention is used as a high-gloss pigmented paint coating, the pigment may be any organic or inorganic compounds or colored materials, fillers, metallic or other inorganic flake materials such as mica or aluminum flake, and other materials of kind that the art normally includes in such coatings. Pigments and other insoluble particulate compounds such as fillers are usually used in the composition in an amount of 1% to 100%, based on the total solid weight of binder components (i.e., a pigment-to-binder ratio of 0.1 to 1).
When the coating composition according to the invention is used as the clearcoat of a composite color-plus-clear coating, the pigmented basecoat composition may any of a number of types well-known in the art, and does not require explanation in detail herein. Polymers known in the art to be useful in basecoat compositions include acrylics, vinyls, polyurethanes, polycarbonates, polyesters, alkyds, and polysiloxanes. Preferred polymers include acrylics and polyurethanes. In one preferred embodiment of the invention, the basecoat composition also utilizes a carbamate-functional acrylic polymer. Basecoat polymers may be thermoplastic, but are preferably crosslinkable and comprise one or more type of crosslinkable functional groups. Such groups include, for example, hydroxy, isocyanate, amine, epoxy, acrylate, vinyl, silane, and acetoacetate groups. These groups may be masked or blocked in such a way so that they are unblocked and available for the crosslinking reaction under the desired curing conditions, generally elevated temperatures. Useful crosslinkable functional groups include hydroxy, epoxy, acid, anhydride, silane, and acetoacetate groups. Preferred crosslinkable functional groups include hydroxy functional groups and amino functional groups.
Basecoat polymers may be self-crosslinkable, or may require a separate crosslinking agent that is reactive with the functional groups of the polymer. When the polymer comprises hydroxy functional groups, for example, the crosslinking agent may be an aminoplast resin, isocyanate and blocked isocyanates (including isocyanurates), and acid or anhydride functional crosslinking agents.
The coating compositions described herein are preferably subjected to conditions so as to cure the coating layers. Although various methods of curing may be used, heat-curing is preferred. Generally, heat curing is effected by exposing the coated article to elevated temperatures provided primarily by radiative heat sources. Curing temperatures will vary depending on the particular blocking groups used in the cross-linking agents, however they generally range between 90° C. and 180° C. The first compounds according to the present invention are preferably reactive even at relatively low cure temperatures. Thus, in a preferred embodiment, the cure temperature is preferably between 115° C. and 150° C., and more preferably at temperatures between 115° C. and 140° C. for a blocked acid catalyzed system. For an unblocked acid catalyzed system, the cure temperature is preferably between 80° C. and 100° C. The curing time will vary depending on the particular components used, and physical parameters such as the thickness of the layers, however, typical curing times range from 15 to 60 minutes, and preferably 15-25 minutes for blocked acid catalyzed systems and 10-20 minutes for unblocked acid catalyzed systems.
The invention is further described in the following examples. The examples are merely illustrative and do not in any way limit the scope of the invention as described and claimed. All parts are parts by weight unless otherwise noted.
EXAMPLES
Example of the Invention
A mixture of 136.9 parts by weight of hydroxypropyl carbamate, 459 parts by weight of ε-caprolactone, and 1.0 parts by weight of stannous octoate was heated in a suitable reactor under an inert atmosphere to 130° C. After three hours at 130° C., 14.9 parts by weight of 2-ethyl-1,3-hexanediol, 34.8 parts by weight of ε-caprolactone, and 4.6 parts by weight of aromatic 100 solvent were added to the reactor. The reaction mixture was then held at 130° C. for an additional four hours, then cooled to room temperature.
Comparative Example
A mixture of 136.9 parts by weight of hydroxypropyl carbamate, 459 parts by weight of ε-caprolactone, and 1.0 parts by weight of stannous octoate was heated in a suitable reactor under an inert atmosphere to 130° C. After three hours at 130° C., the reaction mixture was cooled to room temperature.
Testing of Examples
The Example of the Invention and the Comparative Example were kept at room temperature. After three days, the Comparative Example solidified to a hard, waxy solid. The Example of the Invention remained liquid.
The Example of the Invention was then tested further in a freeze/thaw cycle test by storing the sample at −5° C. freezer to bring the sample to −5° C., then allowing the sample to return to room temperature. The freeze/thaw cycle was repeated nine times. Each time, the sample returned to its original liquid state without formation of any solid material.
The invention has been described in detail with reference to preferred embodiments thereof. It should be understood, however, that variations and modifications can be made within the spirit and scope of the invention. | The present invention provides a curable coating composition that includes at least three components. The coating composition includes a component (a) having at least one carbamate group or urea group and having a lactone or hydroxy carboxylic acid moiety. The second component (b) of the coating composition is the reaction product of a polyol having at least one branch point, i.e., carbon bonded to at least three other carbons, with a lactone or hydroxy carboxylic acid. The third component of the coating composition is a curing agent that is reactive with the first two components. Preparation of coated articles using the compositions of the invention is also disclosed. | 2 |
TECHNICAL FIELD OF THE INVENTION
The present invention concerns a support element for the human body.
More in particular, the present invention concerns a support element such as for example a saddle for means of transport like cycles or motorcycles, a seat, a grip, a handle for the handlebar of cycles, motorcycles, sport equipment and the like, an armrest, a back support, a headrest, sport and leisure equipment, and the like.
DESCRIPTION OF RELATED ART
In some manufacturing sectors, such as those for manufacturing means of transport like cycles, motorcycles and the like, or also in other fields, like for example the fields of manufacturing various kinds of devices, or furniture elements, or sport and leisure equipment, human body support elements are used, of course for the most wide ranging purposes.
For example, in the field of manufacturing cycles and motorcycles, such support elements can consist of saddles, or handles for resting the hands, and the like.
In other fields, such as for example the fields of manufacturing devices of various kind with human actuation or sport equipment, for example rowing machines, weight benches, etcetera, such support elements can consist of seats, back supports, headrests, arm rests, grips, or the like, which allow man to interact with machine in a comfortable manner, for example sitting down, resting his hands, arms or head, actuating the machine controls, etc.
Such support elements generally comprise—think for example of a saddle or a handle—a rigid core, partially or completely covered with a layer of soft and yieldable material such as a polyurethane foam, an elastomeric material or the like.
The soft and yieldable layer of material can also in turn be partially covered by a further cover for example made from leather, or from other natural or synthetic material with suitable characteristics in terms of appearance or function, obviously variable in relation to the specific type of application.
It is known that in some specific applications it is necessary to have support elements having, on the surface, one or more portions—in number, shape and function that of course vary in relation to their application—with different appearance with respect to the rest of the surface of the support element.
These portions with different appearance can be, for example, inserted in the support element with the purpose of improving the visibility of the element itself—for example by using different looks or colourings—so as to allow the user to instantaneously identify the support surfaces in the device with which he must interact, or which he must manage or manipulate.
In other applications, such portions with different appearance can have the purpose of improving the visibility of logos, drawings, or other types of information, messages or more.
For example, Italian patent n. 1207441 to the same Applicant describes a process for making a saddle, in which the felt, the padding and the covering of the saddle itself are assembled in a single machining step, exploiting the adhesion characteristics that the polyurethane of the padding exerts, during its foaming reaction, both on the felt and on the covering material, thus obtaining a perfect joining of the three components.
In European patent n. EP 0903321, to the same Applicant, a support structure is described with ornamental elements, comprising a filler made from an elastically yieldable material, comprising at least one layer of transparent polyurethane gel and a layer of elastomeric foamed material, and covered by a covering layer made from flexible sheeted material, in which said filler comprises, inside it and between the two layers, at least one ornamental element. The covering layer has at least one area that is optically transparent through which the ornamental element itself is visible.
The production steps of this support structure, however, are very laborious and require further treatments in order to make the gel transparent, a subsequent arrangement of the ornamental element over the layer of partially polymerised gel and a further subsequent laying the elastomeric material layer, which must in turn polymerise and expand.
At the current state of the art, in some applications the portions having different appearance are directly connected to the surface of the support element, in areas that are suitably arranged.
In other applications, such portions with different appearance are obtained through tampography, or pad printing, directly on the surface of the support element, on the desired areas.
These known techniques do not ensure products having optimal resistance over time to be obtained, since they tend, for example, to deteriorate, separate, get scratched, crumble, by action of the repeated contact with the parts of the human body involved or by action of weather conditions, or for yet other reasons.
SUMMARY OF THE INVENTION
The technical task of the present invention is therefore that of improving the state of the art, by devising a support element for the human body with portions having different appearance without the drawbacks mentioned above.
In such a technical task, one purpose of the present invention is to devise a support element for the human body that is equipped with portions having different mechanical and functional properties with respect to the remaining part of the support element.
A further purpose of the present invention is to devise a process for making a support element for the human body that is equipped with portions that are more wear resistant and resistant to weather conditions, and against other actions that are potentially dangerous for the integrity of the resting surface thereof.
Another purpose of the present invention is to devise a process for making a support element for the human body, that is equipped with portions with properties in terms of appearance and functions that are improved with respect to the rest of the support element, that can be actuated with an optimisation of the production costs, a greater efficiency of the process and with the use of materials which can reduce impact on the environment.
Such a technical task and such purposes are achieved with the support element for the human body according to the present principles, and with the process for making such a support element according to the present principles.
The support element according to the invention has portions with different appearance consisting of surface elements having high surface quality, which are capable of offering a different approach in terms of appearance and a localised functionality that is differentiated thanks to an integrated process that joins materials having high compatibility which can reduce the impact on the environment, ensuring, at the same time, a greater duration of use and a greater resistance to weather conditions and the like, without becoming damaged.
Moreover, such surface elements constitute areas having different characteristics in terms of comfort of resting of the user, for example preferably areas with greater yield, softness, or even with high grip.
The support element is moreover made in a single moulding step, which can be actuated with equipment and technology that is known and available in the field.
Further advantageous characteristics are described in the dependent claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The characteristics of the invention shall become clearer to any man skilled in the art from the following description and from the attached drawing tables, given as a non limiting example, in which:
FIG. 1 is a plan view of a support element according to the invention, consisting of a saddle;
FIG. 2 is a rear view of the support element of FIG. 1 ;
FIG. 3 is a partially sectioned rear view of the support element of FIGS. 1 , 2 ;
FIG. 4 is a plan view of another embodiment of the support element according to the invention, consisting of a handle;
FIG. 5 is a side view of the support element of FIG. 4 ;
FIG. 6 is a partially sectioned side view of the support element of FIGS. 4 , 5 ;
FIG. 7 is a partially sectioned rear view of another embodiment of the support element according to the invention;
FIG. 8 is a partially sectioned side view of a step of a version of the process for making the support element according to the invention;
FIG. 9 is a partially sectioned rear view of a further version of the support element of FIGS. 1 , 2 ;
FIG. 10 is a partially sectioned side view of a further version of the support element of FIGS. 4 , 5 ; and
FIG. 11 is a partially sectioned side view of a step of a further version of the process for making the support element according to the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
With reference to the attached FIG. 1 , a support element for the human body according to the present invention is wholly indicated with reference numeral 1 .
The support element 1 comprises a surface that is suitable for coming into contact with the user.
In FIG. 1 , the support element consists of a saddle for cycles, motorcycles and the like.
It should however be noted that the support element according to the invention can consist of any other element in which at least one part of the human body rests or adheres, for example in the field of means of transport, various kinds of devices, sport equipment and the like, without any limitation.
As illustrated in the partially sectioned view of FIG. 3 , the support element 1 , consisting of a saddle, comprises, in a known manner, a core 2 , known in the field also with the name felt, made for example from metal, plastic or from any other material with suitable characteristics. In this version of the invention, the core 2 is rigid, but it could also be semi-rigid or elastic.
The core 2 of the saddle 1 has shapes and sizes that are conventional and known in the field.
The core 2 comprises means for coupling to means of transport, machinery, known devices (not illustrated), sport equipment, furniture elements, and the like, or to any other means or device in which the support element according to the invention is foreseen.
In the present embodiment, the core 2 comprises in particular coupling means, that are not represented in the figures and that are of the type known in the field, with the seatpost of the saddle of cycles, motorcycles and the like.
At least one portion of the core 2 is covered with one layer 3 of soft and yieldable material.
In the present embodiment, the entire upper surface of the core 2 is covered with the layer 3 made from soft and yieldable material.
In other embodiments, only one or more portions of the core 2 can be covered with one layer 3 of soft and yieldable material.
The soft and yieldable material with which the layer 3 is made consists of a polyurethane foam, of an elastomeric material, of similar material or of combinations thereof.
For example, the polyurethane foam can be of the self-skinning type, i.e. it is capable of forming an outer surface having characteristics that are optimal in terms of the surface quality and of the resistance to wearing.
The layer 3 made from soft and yieldable material can also be covered by a possible further protective surface film that is applied through spraying, painting, or through another technique that is suitable for the purpose.
The layer 3 made from soft and yieldable material comprises at least one surface insert 4 having different characteristics in terms of appearance and/or comfort with respect to the rest of the surface of the support element 1 or of the layer 3 .
The at least one insert 4 comprises a visible surface 6 that is in contact with the user.
The layer 3 made from soft and yieldable material comprises an outer surface that substantially corresponds to the surface of the support element 1 that is suitable for coming into contact with the user.
The surface of the support element 1 that is suitable for coming into contact with the user is made up of the visible surface 6 of the at least one surface insert 4 and of the outer surface of the layer 3 .
The layer 3 surrounds the at least one surface insert 4 . As shall become clearer from the rest of the description, the support element 1 comprising at least one surface insert 4 is made in a single moulding step.
More in detail, in the present embodiment of the support element 1 , made up of a saddle, the layer 3 comprises at least one surface insert 4 .
In particular, the outer surface of the layer 3 is interrupted by the presence of the at least one surface insert 4 .
The surface insert 4 is arranged at the surface of the support element 1 suitable for coming into contact with the user.
Each surface insert 4 can have a different colour from that of the layer 3 , or it can have a different surface finishing, or it can have other characteristics, which concern its outer appearance, which differentiate it with respect to the rest of the surface of the support element 1 .
In one version of the invention, such other characteristics can consist of logos, indications, graphical elements, prints, screen printing, pad printing, transfers, combinations thereof and all other graphical and ornamental elements which can be useful to differentiate the support element 1 or to make it more appealing or visible. Such characteristics cannot be directly made in the layer 3 of the support element 1 . Such characteristics can be directly contained in the surface insert 4 or they can be conveyed by it in various ways.
In some cases, the visible surface 6 of the surface insert 4 can have high grip, for a better handling.
Each surface insert 4 also has a shape such as to ensure optimal and comfortable resting of the involved part of the body, for example a suitably studied ergonomic shape or a surface finishing with characteristics that are different from those of the rest of the support element 1 , as shall become clearer from the present description.
Each surface insert 4 can be made from a polyurethane foam and/or from an elastomeric material and the like or it can also be made from a different material with respect to that from which the layer 3 is made, for example leather, fabric, synthetic material, metal, rubber, three-dimensional material of a different kind, self-modelling material, transpiring material, material with low friction coefficient, etcetera, combinations thereof or of other material suitable for conferring different appearance and/or comfort characteristics to the surface insert 4 .
More in particular, each surface insert 4 can be made from a different material having characteristics that are different in terms of comfort when resting the part of body involved and in terms of appearance, with respect to the layer 3 or to the remaining surface of the support element 1 .
In particular, thanks to the at least one surface insert 4 , it is possible to vary material in each area, for example so as to differentiate the prostate area or other areas of the body of the user that are particularly sensitive, so as to confer different mechanical, functional, appearance, comfort, etcetera properties to the support element 1 .
For example, in one embodiment, each surface insert 4 can be made from a soft material.
In another version of the invention, the surface insert 4 can be made from a material having a thinner thickness with respect to the leather formed by the self-skinning polyurethane foam of the layer 3 , conferring in such a way a greater sensation of comfort.
In a further version of the invention, the surface insert 4 is made from metal material or another material that is resistant to scratching and impact, and arranged, for example, in the side portions of the support element 1 , which can be subject to impact or scratching or through which the support element 1 can rest against a wall or against another resting surface. In such a way, the surface insert 4 confers a greater life span and integrity to the support element 1 . In the case in which a metal material is used, the surface insert 4 is made from a thin metal sheet, which has flexible characteristics that are suitable for responding to the manufacturing requirements necessary for making the present invention, as described in the present description. It should be clear that, in the case in which metal and/or rigid materials are used, the edges thereof shall be rounded so as to not hurt or be an annoyance to the user.
The metal or resistant material or any other material forming the surface insert 4 can be previously overinjected with a polyurethane or elastomeric material.
In yet another version of the invention, the surface insert 4 is made from a particularly flat material or a material with low friction, and is arranged for example in the side portions of the support element 1 , at the rubbing areas of the leg or of the body of the user during, for example, pedalling. In such a way, the surface insert 4 determines an area with lower friction coefficient, capable of not annoying or wasting energy of the user.
In one version of the invention, the surface insert 4 is made from a transpiring material or a material that in any case limits sweating of the part of body of the user with which it comes into contact, improving his sensation of comfort.
The surface insert 4 , therefore, can be arranged at the prostatic area and/or at the ischiatic area, and/or at side portions of the support element 1 , in which it is necessary to have greater wear resistance, or at the areas undergoing rubbing of the leg of the user, where it is necessary to have less friction, and/or in other positions that are suitable for conferring greater comfort and functionality or a different appearance with respect to the rest of the support element 1 . In other embodiments, each surface insert 4 , for example, can be made up of a plurality of elements that are arranged over one another or coupled in another manner, made from different materials with different characteristics in terms of resting comfort. For example, a coupling of yieldable materials can be obtained with other more rigid ones, or yet other combinations, arranged in different ways in relation to the specific requirements.
In one version of the invention, the surface insert 4 can comprise an outer shell, sealed, in soft material, inside which is arranged at least one of: a self-modelling material, a natural element, cork, silica, a similar material, a synthetic element, micro-beads, grain materials of any origin, polystyrene, or similar material, a viscoelastic material, a gel, a liquid gel, or combinations thereof.
The outer shell can be made from polyethylene or from any material suitable for the purpose.
In such a way, the surface insert 4 , thanks to the self-modelling material contained in the outer shell, is able to distribute the pressure exerted by the body of the user, while simultaneously conferring a greater sensation of comfort to the latter.
In one version of the invention, the surface insert 4 can comprise a polyurethane gel or an elastomeric material.
Each surface insert 4 can be made, for example, through thermoforming methods.
In one version of the invention, each surface insert 4 is provided with a portion 5 that is enclosed in the layer 3 of soft and yieldable material. The portion 5 enclosed in the layer 3 is made up of at least one side flap.
In one version of the invention, the portion 5 is peripheral.
More in detail, the side flap 5 is foreseen along the entire perimeter of the surface insert 4 , in particular of its visible surface 6 , as explained in greater detail in the rest of the description.
Moreover, the side flap 5 projects from the visible surface 6 of the surface insert 4 .
The side flap 5 can be made with quite a thin thickness, for example of some tens of millimeters.
As visible, for example, in FIG. 3 , the peripheral side flap 5 that projects from the visible surface 6 makes it possible to achieve a coupling between the layer 3 and the surface insert 4 which prevents any possible relative movement between the two parts.
Such a coupling, as previously mentioned, is made in a single moulding step.
Through such a coupling, the surface insert 4 is thus fixedly held and locked within the layer 3 of soft and yieldable material and cannot become detached from it.
In a further version of the invention, represented in FIGS. 9 and 10 , each surface insert 4 does not have a portion 5 , such as for example a side flap, enclosed in the layer 3 of soft and yieldable material. In this version of the invention, the surface insert 4 adheres to the layer 3 of soft and yieldable material through a compatibility interface between the materials that form the surface insert 4 and the layer 3 , respectively. Such an adhesion, therefore, is made thanks to the interaction existing between the materials that form the surface insert 4 and the layer 3 , which are compatible with one another and therefore adhesive to one another.
As a non limiting example, in the case in which there is a layer 3 made from polyurethane foam, the surface insert 4 , in order to be compatible and therefore adhere to the layer 3 , can be made from a polyurethane material, such as, for example, a film or layer of thermoplastic material, or from any material that is pre-emptively treated with a compatibilising material, such as for example a primer suitable for the purpose.
On the other hand, in the case in which there is a layer 3 made from elastomeric material, the surface insert 4 , in order to be compatible and therefore adhere to the layer 3 , can be made from a polyurethane based material, such as for example a film or layer of thermoplastic polyurethane material or a material impregnated with polyurethane, or from any material that has been pre-emptively treated with a compatibilising material, such as for example a primer suitable for the purpose.
In such a way, the contact surface between the surface insert 4 and the layer 3 makes a compatibility and adhesion interface between them.
In such a way, a coupling between such materials is created thanks to which the surface insert 4 is fixedly held and locked within the layer 3 of soft and yieldable material with the impossibility of detaching from the latter.
At the joining area of the outer surface of the layer 3 and the visible surface 6 of each surface insert 4 there can be a peripheral throat 7 with a small section, for reasons that shall become clearer in the rest of the description. The invention thus conceived makes it possible to achieve important technical advantages.
Firstly, according to the invention it is possible to make, in a single moulding step, elements for supporting the human body comprising, at the surface in contact with the user, surface elements having different characteristics in terms of appearance that ensure optimal resistance and duration in the use, to weather conditions, and the like.
Moreover, the invention makes it possible to obtain, in a single moulding step, elements for supporting the human body comprising, at the surface in contact with the user, surface areas that are differentiated in terms of their function and/or of the resting comfort, so as to foresee, for example, areas with characteristics of greater yielding or softness at the regions in which there is a higher specific pressure of the body on the support element itself.
Having a single moulding step results in obvious advantages in terms of cost and production time and also leads to a greater compatibility between the materials.
Moreover, such a step can be obtained with equipment that is essentially known and conventional, already available to men skilled in the art.
Another embodiment of the support element according to the invention is illustrated in FIGS. 4 , 5 , 6 .
In this embodiment we have used, to indicate same parts, the same reference numerals as the previous embodiment, increased by 100.
In this embodiment, the support element is made up of a handle 101 for the handlebar of means of transport such as cycles, motorcycles and the like and/or sport equipment.
The handle 101 comprises a core 102 . Such a core 102 can be rigid or semi-rigid or elastic.
The core 102 is made, for example, from plastic material, metal material, or from any other material with characteristics that are suitable for this type of application.
In a non-limiting embodiment, the core 102 is in the form of a tube. Such a core 102 can be in the form of a sleeve.
In a further non limiting embodiment the core 102 is made, for example, through a covering layer, possibly soft, or made through a spray paint of any material suitable for the purpose.
The core 102 defines an area of rigidity that is differentiated with respect to the remaining portion of the support element 101 .
The core 102 is suitable for being coupled, for example, to a handlebar of a bicycle and/or of sport equipment, with the aid of locking means that are known in the field and that are not object of the present invention.
The core 102 is covered, for at least one portion of the outer surface with a layer 103 of soft and yieldable material, the characteristics of which have been illustrated in the description of the previous embodiment.
In this embodiment, the core 102 is completely covered by the layer 103 except for, possibly, an end section 108 , which can be functional to the locking onto the handlebar through locking rings or other known means.
Consequently the layer 103 also has a substantially tubular shape, for example slightly convex, closed at a base, like in the case of the present embodiment.
The handle 101 also comprises a surface insert 104 , with different characteristics in terms of appearance and/or of comfort with respect to the remaining part of the covering layer 103 .
The surface insert 104 can have an oval shape, as illustrated, or different shapes, without for this reason departing from the scope of protection of the present invention.
The surface insert 104 can be foreseen in the resting area of the palm of a hand or it can be foreseen in different areas in contact with the user, without for this reason departing from the scope of protection of the present invention.
Moreover, it could be foreseen for there to be many surface inserts 104 on a same handle.
The specific characteristics of the surface insert 104 of the handle 101 , both in terms of the appearance and in terms of the functionality and of the resting comfort, and in terms of production technology, are the same described in relation to the previous embodiment, with the already described technical effects and advantages.
Yet another embodiment of the support element according to the present invention is represented, in a partial section, in FIG. 7 .
In this embodiment, the same reference numerals as in the previous embodiment have been used to indicate same parts, increased by 100.
This embodiment is the same as that of FIGS. 1-3 , i.e. the support element 201 is, as an example, made up of a saddle. The support element 201 comprises an outer cover 209 . The outer cover 209 is substantially positioned at at least one of the surface inserts 204 and/or, possibly, near to them. In this embodiment, the support element 201 has surface characteristics that can be personalised more with respect, for example, to the embodiment of FIGS. 1-3 , since the at least one surface insert 204 and, possibly, at least one part of the layer 203 made from soft and yieldable material arranged near to the at least one surface insert 204 , are covered with the most suitable material for the specific application.
For example, the outer cover 209 can be made from leather, natural or synthetic fabric, or the like. The outer cover 209 can be made from transparent material.
In the rest of the description we shall describe, in its main steps, a process for making a support element for the human body according to one version of the present invention. The process steps are applied in an absolutely general manner, i.e. irrespective of the specific type of support element made, which in the specific case consists, for example, of a handle.
The process initially comprises a step of providing at least one surface insert 104 .
The surface insert 104 can be made, as previously mentioned, for example through thermoforming.
Once the surface insert 104 has been inserted in a suitable number in relation to the specific application, the process comprises a step of arranging such a surface insert 104 inside a first half-shell S of a mould.
The mould is of the type typically known in the field. The visible surface 106 of the surface insert 104 is in direct contact with the inner surface of the first half-shell S of the mould.
The surface insert 104 is housed at a protruding ribbing N that is foreseen in the inner surface of the first half-shell S of the mould.
The perimeter of such a ribbing N substantially corresponds to that of the visible surface 106 of the surface insert 104 .
In such a way, in the insertion of the surface insert 104 , the side flap 105 is slightly folded towards the inside of the mould with effects that shall be described in more detail in the rest of the description.
At this stage, the process foresees a step of placing the visible surface 106 of the surface insert 104 in communication with a vacuum source.
This is obtained thanks to the presence of holes F in the first half-shell S, which are placed in communication with a vacuum source of the type known in the field, not further described and not represented in the figures.
In such a way the optimal adhesion of the visible surface 106 of the surface insert 104 to the inner surface of the first half-shell S is obtained, without the risk of accidental movements or displacements.
The possibility of putting only the inner surface of the mould in communication with a vacuum source at the visible surface 106 of the at least one surface insert 104 , with respect to the prior art in which the entire inner surface of the mould is put in communication with such sources, confers the technical advantage of positioning elements in a localised manner. In such a way, the element that must be held in vacuum does not necessarily correspond to the entire inner surface of the mould, but it can be limited only to some portions thereof, obtaining therefore a specific localisation of such at least one element.
Subsequently, the mould is closed with a second half-shell, not represented in the figures.
Then there is a step of injecting, inside the mould, a material of the polyurethane foam type and/or an elastomeric material or the like, thus obtaining the layer 103 of soft and yieldable material.
Subsequently, the mould is closed with a male of the same mould, which is not represented in the figures.
The injection modalities of such a material inside the mould are known in the field and are not further described.
This step is schematically represented in FIG. 8 , in which the support element obtained consists of a handle like that of FIGS. 4-6 .
As visible in FIG. 8 , the injection of material achieves an optimal coupling with the surface insert 104 , so that the material injected is arranged exclusively around its inner surfaces and around the side flap 105 , but not between the insert itself and the surface of the first half-shell S of the mould.
The penetration of material in this area is indeed prevented by the presence of the portion or of the side flap 105 folded at the ribbing N. The pressure of the material on the flap 105 indeed carries out a perfect seal closure that prevents any leakage. The injected material of the layer 103 , therefore, presses and hermetically closes the portion or the side flap 105 against the ribbing N.
The ribbing N folds the portion or side flap 105 . The folding occurs towards the area in which the material of the layer 103 will be injected.
The ribbing N creates a sort of dike for the material of the layer 103 injected which is arranged exclusively around the inner surfaces of the surface insert 104 and around the portion or the side flap 105 , but not between the surface insert 4 itself and the surface of the first half-shell S of the mould.
Moreover, the arrangement of the material of the layer 103 around the side flap 105 determines an optimal locking of the surface insert 104 within the foam.
There is a step in which the material injected inside the mould polymerises, in the case of a polyurethane foam, or it reacts, in the case of an elastomeric material, cross-linking or hardening and compacting; then the male and the half-shells are opened and the final product is obtained.
As it can be understood, the peripheral throat 107 between the surface of the layer 103 and the visible surface 106 of the surface insert 104 is indeed determined by the presence of the ribbing N in the first half-shell of the mould.
In a further version of the invention, schematically illustrated in FIG. 11 , in which there is no portion 105 , such as for example a side flap, enclosed in the layer 103 of soft and yieldable material, the process for making a support element for the human body foresees the aforementioned steps. However, differently from what has been described above, in this version of the invention the surface insert 104 adheres to the layer 103 made from soft and yieldable material thanks to the compatibility of the materials which respectively form the surface insert 104 and the layer 103 , and not because, as described previously, the side flap 105 is slightly folded inwards with respect to the mould and enclosed in the injected material.
In this version of the invention, the coupling created by the adhesion between the materials and the layer 103 and the surface insert 104 , obtained thanks to the presence of a compatibility and adhesion interface, as previously described, defines an optimal locking of the surface insert 104 within the layer 103 , with the impossibility of detaching from the latter.
The penetration of injected material in the area corresponding to the surface insert 104 is prevented by the presence of the ribbing N, when it is present.
In another embodiment of the process, it can also be foreseen for there to be a step of arranging an outer cover 209 inside the first half-shell S of the mould, in direct contact with its inner surface substantially at the at least one surface insert 204 and before the injection step of the material which will form the layer 3 , at one or more ribbings N foreseen in the mould.
It has thus been seen how the invention achieves the proposed purposes.
The present invention has been described according to preferred embodiments but equivalent variants can be conceived without departing from the protection offered by the following claims. | A support element (e.g., a seat, a saddle or a handgrip) for the human body including a layer made from soft and yieldable material and at least one surface insert with different characteristics in terms of appearance and/or comfort, in which said surface insert includes a visible surface to be in contact with the user, wherein said visible surface has a smaller size than said layer and wherein said surface insert includes at least one portion embedded in said layer. A process for making the support element is also presented. | 1 |
FIELD OF THE INVENTION
The present invention relates to fluid pumps and particularly to a wireless remote controlled fluid pump.
BACKGROUND OF THE INVENTION
Fluid pumps, particularly hydraulic oil pumps, for actuating vehicle repair equipment are well known. Fluid pumps are used to raise and lower vehicle repair and alignment racks and to provide power to tension members used with force applying structures such as shown in U.S. Pat. Nos. 4,313,335 and 4,794,783. Such fluid pumps are typically powered by compressed air which drives an air motor connected to a pumping mechanism. An operator of the fluid pump controls the pump by a series of valves which are connected to the air motor and pump and actuated manually by levers. Some applications of a fluid pump can also be powered by an electric motor connected to the pumping mechanism. In either case, the air over hydraulic pump or the electric over hydraulic pump, the valve controls are on the pump housing and are actuated by foot levers. In some cases the valve controls are operated by extended actuators attached to the pump house by a length of hose or wire. An example of such control system is shown in the sales brochure of Enerpac, a Unit of Applied Power, Inc. (a copy of which is in the attached appendix).
In most cases the operator of the pump must be close to the work area in which the tool powered by the hydraulic fluid being pumped, is located. Such placement can expose the operator to dangers of equipment malfunctions, part breakage and part projectiles. Although manufacturers of such equipment provide instructions and warnings, events of property damage and personal injury do occur. The present invention removes the operator from such locations by allowing the operator to operate a fluid pump at a distance remote from the fluid pump and the immediate work area.
SUMMARY OF THE INVENTION
The present invention provides a wireless remote control apparatus mounted on a fluid pump for controlling the pump and release functions of such fluid pump. The wireless remote control apparatus includes at least one, two position, three way solenoid valve in fluid communication with a fluid supply and actuators for controlling the pump and release valves of the fluid pump. The solenoid is energized by an electrical power source and is operatively connected to a signal receiving device also connected to the electrical power source. The signal receiving device is operatively associated with a signal transmitting device which signal transmitting device is remotely located from the fluid point. A frequency for the transmitted and received control signal must be the same however the frequency can be different for each fluid pump associated with the vehicle repair system, i.e., one fluid pump can be used to raise and lower the vehicle repair rack and a different fluid pump may be used to operate each of the force applying structures. The use of one transmitter capable of transmitting different control signals is well known such as in a hobbyist's remote control vehicle.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the wireless, remote control pump embodying the present invention.
FIG. 2 is a perspective view of the present invention as shown in FIG. 1 rotated 90°.
FIG. 3 is a schematic illustration of the present invention.
FIG. 4 is a top view of the valve block 12 illustrating the principal elements of the present invention and the fluid conduit network 71.
FIG. 5 is a side view of the present invention showing the piston position and lever position in the pump mode.
FIG. 6 is a side view of the present invention illustrating the pistons position and the lever position in the release mode.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A wireless remote control apparatus 1 mounted on a fluid pump 4, as shown in FIGS. 1 and 2 generally includes a valve block 12 mounted on the fluid pump 4. The wireless remote control apparatus 1 also includes a control box 14 which includes the electric power source, which in the preferred embodiment is a battery pack 20, and the relays and signal receiver (described below). Operatively associated with the signal receiver 16 and a part of the present invention is the signal transmitter 2. The illustrated embodiment of the present invention discloses a hydraulic oil pump that is operated with compressed air, which is supplied to the pump through the supply hose 9. The hydraulic oil exits the pump 4 through the hose 5 with the hydraulic oil pressure registered on the pressure gauge 3.
The fluid pump typically operates by an operator depressing a pump button 6. The pump button activates a motor (not shown) either air powered or electric powered, which drives the pump mechanism (not shown) and pumps the hydraulic fluid from a reservoir to a hydraulic cylinder (not shown). Pressure in the fluid pump is released by the operator depressing a release button 10 on the fluid pump, which allows the hydraulic fluid to return, from the hydraulic cylinder, to the pump reservoir. A typical fluid pump, presently used in the vehicle repair business, utilizes a pivoting rocker lever that an operator may manipulate with either a hand or foot. The lever engages the pump button 6 and the release button 10 as determined by the operator to operate the pump.
The vehicle repair business also utilizes an electric over hydraulic pump which operates in a similar manner as the above described air over hydraulic pump. The principal difference is that the electric over hydraulic pump uses an electric motor to operate the pump and is controlled by electrical components rather than a pivoting rocker lever. The present invention may be embodied in an apparatus to control both types of the above described fluid pumps in the vehicle repair business.
FIG. 3 is a schematic illustration of the present invention in relation to an air/hydraulic pump 4. The pump 4 is provided with a pump button 6 having a return spring 7, an air supply port 8 and a release button 10 which also has a return spring 7.
As shown in FIG. 4 the valve block 12 includes a fluid conduit network 71 in fluid communication with a lever piston cavity 60, a pump button piston cavity 72, and a valve channel 22. The fluid conduit network 71 comprises the air supply conduit 74, the working air conduit 76 and the up air conduit 78. A pump valve 24 and release valve 26 are mounted in the valve channel 22 and in fluid communication with the fluid conduit network 71. The pump valve 24 and release valve 26 each have an electrical connector, 25 and 27 respectively. The electrical connectors 25 and 27 are connected to the control box 14 by wires 46. Electrical power is supplied to the pump valve 24 and release valve 26, through the wires 46, from the battery pack 20 as selectively controlled by a first relay 18 connected to the release valve 26 and a second relay 19 connected to the pump valve 24 in response to a signal sent by a remote signal transmitter 2 to a signal receiver 16 mounted in the control box 14. The battery pack 20 provides the electrical energy to the first relay 18, the second relay 19, the pump valve 24, the release valve 26 and the receiver 16. The utilization of a battery pack 20 for the power source for the various components, eliminates a power cord from the immediate work area in which the vehicle repair process is taking place.
A pump button piston 70 moves up and down in the pump button piston cavity 72 in response to fluid moving into the cavity 72 through the working air conduit 76 from the pump valve 24. The pump button piston 70 pushes against the pump button 6 to operate the pump 4. Concurrently, fluid passes through the working air conduit 76 into a down air chamber 66 contained in a lever piston cavity 60. The lever piston cavity contains a lever piston 58 which is shaped to form two chambers, an up air chamber 64 and a down air chamber 66. The lever piston 58 is operatively connected to a lever 50 with a lever/piston connector 68. The lever is pivotly connected to the valve block 12, in a lever slot 56 by a lever pivot 52 with one end of the lever 50 in operative connection with the release button 10 of the pump 4. The release button 10 is free to open when fluid enters the down air chamber 66 through the working air conduit 76. The fluid pushes the lever piston 58 down thereby pulling the lever 50 down about the lever pivot 52. When the operator desires to release the hydraulic pump pressure, the operator operates the release valve 26 thereby opening the working air conduit 76 to the atmosphere and conveying fluid from the air supply conduit 74 through the release valve 26 to the up air conduit 78 into the up air chamber 64 of the lever piston cavity 60. The fluid in the up air chamber 64 pushes the lever piston 58 up and pushes the lever 50 down about the lever pivot 52 against the release button 10 thereby releasing the hydraulic pressure in the pump 4. Fluid seals are maintained in the up air chamber 64, the down air chamber 66 and the pump button piston cavity 72 by suitable annular seals 62. By selectively operating the pump button 6 and the release button 10, the operator can pump and release the hydraulic pressure of the pump 4. The lever can be maintained in a position with a lever detente 53 engaging a ball 82 held in a ballholder 81 located in the valve block 12 and accessed through a ball access hole 80.
The operator sends a signal, to pump or release, with a signal transmitter 2 to a receiver 16 in the control box 14. The signal may be selected from an electromagnetic frequency group consisting of radio, ultraviolet and infra red frequencies and can also be operated on an audio signal. The preferred signal is in the radio range and is received by an antenna 17 located in the control box 14. In the event that battery power is lost or diminished to the point of not operating the electronics in the control box 14, the remote control apparatus is provided with a manual pump button 38 and a manual release button 42 operatively associated, respectively, with the pump valve 24 and the release valve 26.
The remote control pump of the present invention may also be provided with a suitable housing and handle to improve the aesthetics and portability of the pump.
Thus, it should be apparent that there has been provided in accordance with the present invention a wireless remote control pump for use with vehicle repair equipment that satisfies the objectives and advantages set forth above. Although the invention has been described in conjunction with the specific embodiment thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, it is intended to embrace all such alternatives, modifications and variations that fall within the spirit and broad scope of the appended claims. | A wireless remote control apparatus mounted on a fluid pump for controlling the pump and release functions of such fluid pump. The wireless remote control apparatus includes valves in fluid communication with a fluid supply, actuators for controlling the pump and release valves of the pump, a signal transmitting and signal receiving device operatively associated with the fluid pump. The wireless remote control apparatus can operate on a frequency selected from radio, ultraviolet and infra red frequencies and is further provided with a manual operating mechanism. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a portable universal serial bus (USB) memory device, and more specifically to a memory device that is thin so it can be easily adapted to mounted in pieces of a body, such as a frame of a belt, pendant, etc.
2. Description of Related Art
Small and portable memory products have a variety of configurations, such as CF card, MS card, SD card and SM card to adapt to corresponding electronic devices. One portable memory product that is thumb shaped is an improved memory device for an electronic device, such as a computer.
With reference to FIG. 8, the thumb shaped memory device with a large memory capacity includes a housing ( 60 ), a cap ( 63 ), a driver IC (not shown) on a first PCB ( 70 ), a memory IC ( 81 ) on a second PCB ( 80 ) and a USB plug ( 90 ). The USB plug ( 90 ) is a standard and fixed size, and the thumb shaped memory device is five times the size of the USB plug ( 90 ).
The housing ( 60 ) has an upper shell ( 61 ), a bottom shell ( 62 ) and an opening ( 64 ). The first, second PCBs ( 70 , 80 ) and the USB plug ( 90 ) are mounted in the housing ( 10 ). The second PCB ( 80 ) is mounted on the first PCB ( 70 ). The USB plug ( 90 ) is horizontally connected to a side of the first PCB ( 70 ) and a part of the USB plug ( 90 ) protrudes through the opening ( 64 ) in the housing ( 60 ). The USB plug ( 90 ) of the thumb shaped memory device inserts into a USB socket on a computer (not shown), and then the memory IC ( 81 ) and the computer (not shown) execute a dual storing procedure through the driver IC. The thumb shaped memory device is small than a 1.44M floppy disk so that the thumb shaped memory device is easily carried. In addition, most computer systems can support the USB protocol so that the thumb memory device can be read directly by the computer without specific driver software. The cap ( 63 ) covers and protects the USB plug ( 90 ) from dust.
The USB plug ( 90 ) protrudes from the housing ( 60 ) and increases the length of thumb shaped memory device. Further, stacking the first and second PCBs increases the thickness of the thumb shaped memory device. Although the thumb shaped memory device is smaller than a 1.44M floppy disk, the memory cards previously mentioned are smaller than the thumb shaped memory device. Whereby, the thumb shaped memory device is not small enough to carry easily. Furthermore, the cap ( 63 ) must be removed before the USB plug ( 90 ) can be inserted into the computer. Removing the cap ( 63 ) from the thumb shaped memory device may not be simply, and the cap ( 63 ) can be lost easily.
The present invention provides a portable memory device that is small and has many others additional functions to mitigate or obviate the aforementioned problems.
SUMMARY OF THE INVENTION
An objective of the present invention is to provide a portable memory device for a computer that is only three times than a USB plug so that the portable memory can be easily carried.
Another objective of the present invention is to provide a portable memory device with a dustproof cap that is convenient and easy to use will not be lost easily.
Other objectives, advantages and novel features of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a first embodiment of a portable memory device in accordance with the present invention;
FIG. 2 is a perspective view of a second embodiment of a portable memory device in accordance with the present invention;
FIG. 3 is an operational perspective view of the portable memory device in FIG. 2;
FIG. 4 is an exploded perspective view of a third embodiment of a portable memory device in accordance with the present invention in use;
FIG. 5 is a top plan view of the portable memory device in FIG. 4;
FIG. 6 is an exploded perspective view of a fourth embodiment of a portable memory device in accordance with the present invention in use;
FIG. 7 is a top plan view of the portable memory device in FIG. 6; and
FIG. 8 is a partially exploded perspective view of a conventional thumb shaped portable memory device.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to FIG. 1, a first preferred embodiment of a portable memory device comprises a housing ( 10 ), a memory and driver board ( 20 ) and a USB plug ( 30 ). The USB plug ( 30 ) has distal end (not numbered) and a proximal end (not numbered). The memory device including the housing ( 10 ) and the USB plug ( 30 ) is 3 times larger than the USB plug ( 30 ) or less.
The forgoing components are mounted in the housing ( 10 ), and the housing ( 10 ) has an upper shell ( 11 ), a bottom shell ( 12 ), two short sides (not numbered) and two long sides (not numbered). An opening ( 13 ) is defined in one short side of the housing ( 10 ). A window ( 14 ) is defined in the upper shell ( 11 ).
The memory and driver board ( 20 ) mounted in the housing ( 10 ) includes a memory IC (not shown), a driver IC ( 21 ), an oscillator ( 22 ), an LED ( 23 ), discrete electric components and four edges (not numbered). The memory IC is mounted under the memory and driver board ( 20 ). One edge of the memory and driver board ( 20 ) facing the opening ( 13 ) and the proximal end of the USB plug ( 30 ) are combined together with a soldering process. Most of the USB plug ( 30 ) protrudes through the opening ( 13 ) in the housing ( 10 ). The LED ( 23 ) is mounted on the memory and driver board ( 20 ) and corresponds to the window ( 14 ) to indicate the operating state of the driver IC ( 21 ). The memory unit can be any memory size.
The memory device as described only uses one PCB with the memory unit and the driver IC ( 21 ) mounted on the PCB so the memory device is thin. Therefore the portable memory device is small.
With reference to FIG. 2, a second preferred embodiment of the portable memory device in accordance with the present invention includes a dustproof cap ( 40 ) and a flexible strap hinge ( 41 ). The dustproof cap ( 40 ) is covered on the to the USB plug ( 30 ) protruded from the housing ( 10 ). The flexible strap hinge ( 41 ) is connected between the dustproof cap ( 40 ) and the long side of the housing ( 10 ). With reference to FIG. 3, the dustproof cap ( 40 ) still is connected to the housing ( 10 ) when the dustproof cap ( 40 ) is open so that the dustproof cap ( 40 ) is not lost. The dustproof cap ( 40 ) and the flexible strap hinge ( 41 ) can be formed as a single piece.
With reference to FIG. 4, a third preferred embodiment of the portable memory device in accordance with the present invention comprises an external housing ( 50 ) to hold the housing ( 10 ) and the USB plug ( 30 ) protruding from the housing ( 10 ). The external housing ( 50 ) includes two narrow sides (not numbered), two broad sides (not numbered), a closed end (not numbered), an open end ( 52 ) and an end plate ( 53 ). Two keyways ( 51 ) are respectively defined in the two broad sides. Two keys ( 100 ) corresponding to the keyways ( 51 ) are formed on the upper and bottom shells ( 11 , 12 ). With reference to FIG. 5, the end plate ( 53 ) on the housing ( 10 ) covers the open end ( 52 ) when the portable memory device is inserted into the open end ( 52 ) of the external housing ( 50 ). The external housing ( 10 ) can be further connected to a chain ( 54 ) with a key ring ( 55 ).
With reference to FIG. 6, a fourth preferred embodiment of the portable memory device in accordance with the present invention is similar to the third preferred embodiment. Two keyways ( 51 a ) are formed in the two narrow sides respectively of the external housing ( 50 a ). The keyways ( 51 a ) communicate with the open end ( 52 ) of the external housing ( 50 a ). Two keys ( 100 a ) corresponding to the two keyways ( 51 a ) are formed on the two long sides of the housing ( 10 ). The closed end of the external housing ( 50 a ) is further connected to a belt ( 56 ). With reference to FIG. 7, the portable memory device is easily pulled out of the external housing ( 50 a ) by the two keys ( 100 a ) to separate the portable memory device from the external housing ( 50 a ).
The memory unit and the driver unit are deposited on the same PCB to reduce the thickness of the memory device that is only 3 times larger than the USB plug or less. Therefore, the memory device can be adapted to use a small dustproof cap to decorate the memory device and keep dust off the USB plug.
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 to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed. | A portable USB memory device has a housing, a memory and driver board and a USB plug. The memory and driver board has a memory IC, a driver IC and some electronic components so that the thickness of the memory device is decreased and the memory device is only 3 times larger than the USB plug. The memory device is small enough small to adapt to mount in an external housing, which further is adapted to attach to other devices like key chains, belts, etc. | 0 |
This is a division of application Ser. No. 934,729, filed Aug. 18, 1978 (which is a division of Ser. No. 810,578 filed June 27, 1977--now U.S. Pat. No. 4,123,879, granted Nov. 7, 1978).
BACKGROUND AND SUMMARY
The present invention relates to panel wall systems of the type which are used in offices to provide work stations, storage, filing, counter space and the like. There are systems which are commercially available which are modular in concept in that the panels may be interconnected and that a number of different components may be assembled to and supported by the panels.
The present invention, it is believed, represents significant improvements in systems of this type wherein costs of manufacture, flexibility in use, and aesthetic appearance are important characteristics of the system. One feature of the present invention provides for interchangeability of insert assemblies onto the panel frames. These insert assemblies provide the exterior facing for the panel, and with the present system of interchangeability, many different kinds of insert assembly, such as painted metal, wood veneer, plastic or fabric may be provided with the same frame. These insert assemblies may be removed and changed, if desired, after a period of use.
Another feature of the invention resides in the structure of the frames for the individual panels. Systems are known which use a series of vertically spaced slots for assembling the components to the panels. In the past, some such systems have permitted "light leaks"--that is, the ability for light on one side of the panel to be seen through the panel from the other side. This has occurred both at the locations at which the panels are interconnected and at the locations of the slots just mentioned. One of the objects of the vertically spaced slots is to provide flexibility in the vertical positioning of the components. However, the greater number of slots that are provided in such systems, the greater is the amount of light leaking through to the other side. Not only do such light leaks distract from the appearance of the system, but if the slots or openings are large enough, they actually reduce privacy of an office or work area because persons walking down an aisle, for example, may see directly into the enclosed area. To overcome these objections, the present invention provides a novel panel frame wherein the vertical members of the frame are tubular members with an inwardly projecting flange located between the sets of vertically spaced slots, thereby preventing light leaks through the frame. Further, in order to prevent light leaks between adjacent panels, the edge of each panel is provided with a doubly-curved upright connector. The connectors on adjacent panels cooperate to prevent light leaks between the panel irrespective of the angular orientation of the panels over the useful range at which the panels might be oriented.
Another feature of the present invention is that a full line of shelving and cabinets are included, and they may be assembled to the panel and built up using only a limited number of interchangeable components. Thus, not only is the system modular in the sense that discrete panel assemblies may be interconnected to provide any desired layout, but each panel may be built up to provide storage area, counter area, shelving, desks, if desired, and so on.
In the case of cabinets, a flipper door is used which includes mechanism to prevent rocking of the door when it is opened or closed. The flipper door slides beneath the top of the cabinet in the open position; yet, its edges are flush with the top and bottom of the cabinet in the closed position.
Other features and advantages of the present invention will be apparent to persons skilled in the art from the following detailed description of a preferred embodiment of the system accompanied by the attached drawing wherein identical reference numerals will refer to like parts in the various views.
THE DRAWING
FIG. 1 is a frontal perspective view of a completed work area incorporating the present invention;
FIG. 2 is a rear perspective view of the system of FIG. 1;
FIG. 3 is a close-up frontal perspective view of the upper portion of the system of FIG. 1 with the side panels slightly more open to show the cabinet;
FIG. 4 is a view similar to FIG. 3 with the flipper door of the cabinet opened;
FIG. 5 is a fragmentary lower perspective view of the left side portion of the cabinet of FIG. 4;
FIG. 6 is a fragmentary perspective view, taken at a higher perspective than FIG. 5, of the right side of the cabinet of FIG. 4 with a portion of the flipper door cut away to show the rack slide;
FIGS. 7, 8 and 9 are perspective views of a panel shown in various stages of completion;
FIG. 10 is a perspective exploded view of a completed panel assembly as seen in FIG. 8 without inserts;
FIG. 11 is a cross sectional view of the upper frame channel seen through the sight line 11--11 of FIG. 10;
FIG. 12 is a horizontal cross sectional view of a side tubular frame member seen through the sight line 12--12 of FIG. 10;
FIG. 13 is a horizontal cross sectional view of an end connector as seen through the sight line 13--13 of FIG. 10;
FIG. 14 is a perspective view of the inside of a panel insert;
FIG. 15 is a close-up elevational fragmentary view of a connector tab for the insert of FIG. 14;
FIG. 16 is a cross sectional view of a reinforcement channel for the panel insert of FIG. 14 taken through the sight line 16--16 of FIG. 15;
FIG. 17 is a perspective view of a top cap for a completed panel;
FIG. 18 is a perspective view of a top cap of FIG. 17 turned over;
FIG. 19 is a horizontal cross sectional view of the top cap of FIG. 17;
FIG. 20 is a perspective view of a universal connector bracket for two adjacent panels;
FIG. 21 is a fragmentary upper perspective view of the connection between two adjacent panels at right angles to each other without the top caps of the panels;
FIG. 22 is a view similar to FIG. 21 but with the top caps assembled to the respective panels;
FIG. 23 is a view similar to FIG. 24 with the panels slightly more open;
FIG. 24 is a view similar to FIG. 23 but with the panels aligned;
FIG. 25 is an upper perspective view showing the shelving and separators on the left side of the cabinet of FIGS. 3 and 4;
FIG. 26 is a perspective view of an envelope divider lying on its side;
FIG. 27 is a perspective view of a divider partition lying on its side;
FIG. 28 is a lower perspective view of the intermediate shelf of FIG. 25;
FIG. 29 is a vertical cross sectional view with the center broken away, of the shelf of FIG. 28 looking toward the right side thereof;
FIG. 30 is a fragmentary top view, with the center portion broken away, of the right side of the shelf of FIG. 28;
FIG. 31 is an upper frontal perspective view of a vertical support assembly shown in FIG. 25;
FIG. 32 is a horizontal cross sectional view of the vertical support of FIG. 31 with the center portion cut away;
FIG. 33 is a fragmentary plan view, with the center portion cut away, of the right side of the lower shelf of the cabinet of FIG. 4;
FIG. 34 is a vertical cross sectional view taken through the sight line 34--34 of FIG. 33;
FIG. 35 is an upper rear perspective view of the top of the cabinet of FIG. 3;
FIG. 36 is a perspective view of the cabinet top of FIG. 35 turned over;
FIG. 37 is a side view of the cabinet top of FIG. 35;
FIG. 38 is an upper frontal perspective view of a flipper door with a cabinet of FIG. 3 with portions of the upper and lower left edge of the front panel cut away;
FIG. 39 is a rear perspective view of a flipper door of FIG. 38;
FIG. 40 is a side view of the flipper door of FIG. 38 shown in the horizontal position;
FIG. 41 is a cross sectional view, with the center portion cut away, taken through the sight line 41--41 of FIG. 40;
FIG. 42 is a fragmentary vertical cross sectional view taken front to rear of the cabinet of FIG. 3, looking toward the right with the door in the fully open position;
FIG. 43 is a view similar to FIG. 42 with the door partially opened;
FIG. 44 is a fragmentary close-up view of the upper right-hand corner of the cabinet of FIG. 3 with the door in the closed position;
FIG. 45 is a side, frontal perspective view of a cabinet end panel shown as a left side end panel for a cabinet;
FIG. 46 is a right frontal perspective view of the cabinet side panel of FIG. 45;
FIGS. 47 and 48 are front and rear elevational views of the panel of FIG. 45;
FIGS. 49 and 50 are side views of the locking tongue of the cabinet side panel of FIG. 45 shown without and with a center spring respectively;
FIG. 51 is a right end view of the tongue of FIG. 50;
FIG. 52 is a top view of the tongue of FIG. 50;
FIG. 53 is a close-up fragmentary horizontal cross sectional view of the rear end of the panel of FIG. 45 showing the assembled structure of the locking tongue;
FIG. 54 is a complete horizontal cross sectional view of the cabinet side panel of FIG. 45;
FIG. 55 is a frontal perspective view of a right side slipper door rack for the cabinet of FIG. 3;
FIG. 56 is a cross sectional view taken through the sight line 56--56 of FIG. 55;
FIG. 57 is a close-up fragmentary horizontal cross sectional view similar to FIG. 56 showing the slipper door rack assembled to the cabinet of FIG. 3;
FIG. 58 is a view similar to FIG. 57 illustrating the unlatching of the flipper door from the cabinet;
FIG. 59 is a perspective diagrammatic view illustrating the coupling of the tongues of the cabinet side panels to the recessed hanging slots;
FIGS. 60, 61 are frontal left and rear right side perspective views respectively of a handle for the flipper door of FIG. 38;
FIGS. 62-65 are plan views of the adjacent portions of two panels arranged in different angular orientations;
FIG. 66 is a perspective view of a series of cabinets arranged one above the other and supported by a panel wall;
FIG. 67 is a vertical cross sectional view of the apparatus of FIG. 66 taken through the sight line 67--67 thereof;
FIG. 68 is a frontal diagrammatic view of a single cabinet illustrating the flexibility in vertical and horizontal spacing that may be attained with the system of the present invention;
FIG. 69 is a fragmentary perspective view, with the parts in exploded relation, of the cantilever mounting for a work station, using the recessed hanging slots;
FIG. 70 is a perspective view of a three-piece drawer slide adapted to be incorporated into the present invention;
FIG. 71 is an upper perspective view of a pull-out work surface or shelf which might be incorporated in the present invention;
FIG. 72 is an upper left perspective view of a pull-out shelf which might be incorporated into the system, having laterally spaced slots for compartmentalizing; and
FIG. 73 is an upper perspective view of a frame, mounted on drawer slides, which might be incorporated into the system for providing pocket file space.
DETAILED DESCRIPTION
Referring first to FIGS. 1 and 2, reference numeral 10 generally designates a work area in the form of an alcove including a back panel 11, first and second side panels 12, 13, and a cabinet generally designated 14. A cantilevered work surface 17 is supported by the back panel 11 in a manner to be disclosed more fully below. The panels 11, 13 are of similar construction, except that the horizontal extension of the side panel is less than the horizontal extension of the back panel. Thus, the structure of only one panel may be discussed for a complete understanding of the invention.
The panels 11-13 are shown in FIGS. 1 and 2 as completed assemblies, and the word "panel" is used herein to refer to complete panel assemblies. Referring particularly to FIG. 2, the panels 11 and 13 are connected together by means of a bracket which will be disclosed more completely below. However, the adjacent edges of the panels 11, 13 are each provided with a vertically elongated end connector member, designated respectively 15, 16 which cooperate in a manner, also to be disclosed more completely below, so as to prevent the leaking of any light between the panels. A universal connector bracket is shown in FIG. 20 and designated by reference numeral 18, and it connects the tops of the two adjacent panels. A similar bracket connects the bottoms of the same panels.
The bracket 18 includes an aperture 18A and an elongated slot 18B. Referring to FIG. 21, a bolt 18D is received in the slot 18A and threaded into an aperture on a plate 41 of the back panel 11. Similarly, a bolt 18E is received in the slot 18B and threaded into an aperture on a similar plate 41 on the side panel 13. The angular disposition of the two panels is maintained by threading the two bolts tightly onto the connector bracket 18.
When it is desired to maintain a fixed angular relationship between two panels, a fixed connector bracket might be used with two apertures sized to receive the bolts 18D, 18E while maintaining the panels in the desired relation.
If it is desired to open the alcove so that the side panels form oblique angles with the back panel, this is accomplished by loosening the bolt 18D and 18E, changing the panels and tightening the bolts. It will be observed that for all such adjustments, there still is no light leak between adjacent panels; and this is true for a wide range of angular relationships, and it is considered to be an important feature of the invention.
Such an "open" alcove is shown in FIGS. 3 and 4; and in these figures the cabinet 14 can be seen to include a flipper door 20 (seen closed in FIG. 3 and opened in FIG. 4), first and second cabinet side panels 21, 22, a bottom shelf 23, and a top 24. The cabinet end panels 21, 22 are interchangeable--that is, the same structure can be used either as a left cabinet end panel or a right cabinet end panel simply by turning it over, as will be clear from an understanding of subsequent description.
PANEL ASSEMBLY
Referring now to FIGS. 7-16, the panel assembly 11 (FIG. 9), includes a frame generally designated 26 in FIG. 7. Referring now to FIG. 10, the frame 26 includes an upper channel 27, a lower channel 28, and first and second side tubular members 29, 30.
The upper and lower channels 27, 28 are interchangeable, and they are seen in cross section in FIG. 11 as having a generally U-shape with inwardly turned flanges 31, 32.
Similarly, the side tubular members 29, 30 are interchangeable, and they are seen in cross section in FIG. 12 as including a rectangular tube formed from a single sheet of metal, one of the ends of which is turned inwardly to form a flange 33. The tubular side frame member 30 includes a plurality of vertically spaced round apertures 35 on the inner side, and first and second sets of vertically elongated rectangular slots 37, 38, at a much closer spacing. The slots 37, 38 are seen to be located adjacent the outboard edge of the tubular frame member 30, and the flange 33 is interposed between the sets of slots to form a barrier so that light will not pass through the tube (front to rear) even though the slots 37, 38 (which are referred to as "adjustment" or "hanging" slots) are aligned.
The upper and lower channels 27, 28 are welded to the tubular side frame elements 29, 30 to form the solid frame 26 shown in FIG. 7. The outermost edges (those which contain the inwardly turned flanges 31, 32) of the channel frame members 27, 28 extend beyond the limits of the tubular frame members 29, 30. Each end of each tubular frame member 29, 30 has welded to it a plate 41 which includes a first pair of tapped apertures 42 for securing the connector bracket 18, as described, and a third tapped aperture 43 which is located within the channel frame member adjacent the innermost edges of the inwardly turned flanges 31, 32. Conventional levelers 45 are threadedly received in the apertures 43 for the bottom channel frame member 28, as best seen in FIG. 8, in summary, the plate 41 has two functions. The apertures 42 are used for the attachment of upper and lower connector brackets (or an end spacer member such as the ones shown at 47 in FIG. 10), and the tapped apertures 43 are used at the bottom of the frame to receive the levelers 45. Toward this end, the channels are provided with a pair of apertures 49 through which the levelers may extend (see FIG. 8).
At the top of each frame, when the connector bracket 18 or end spacer 47 are assembled to the plates 41, their upper surfaces are flush with the top of the upper channel member 27 (again, referring to FIG. 8).
First and second end connector elements 49, 50, which are identical to each other, are welded respectively to the outboard edges of the vertical frame support members 29, 30. Referring now to FIG. 13, the end connector 49 includes a central flat web 51, a first curved end portion 52, and a second curved end portion 53. The curvature of the end portions are such that the outer convex surface of the portion 53 conforms to the inner concave surface of the portion 52; and the elements are arranged on adjacent panels in inverted relation so as to achieve mating conformation, as will be described further below.
Referring now to FIGS. 7 and 10, the upright support tubes 29, 30, are each provided with an upper and a lower rectangular slot, designated 56 and 57 for the tube 29 and 58, 59 for the tube 30. These slots are spaced inwardly of the adjustment or "hanging" slots 37, and they are sometimes referred to as the "insert slots" because an insert assembly generally designated 60 and seen in FIG. 14 is hung in these slots. A second pair of similar slots is provided on the other side of each of the upright support tubes 29, 30 for hanging a second, similar insert assembly. Each of the inserts may include different facing material, if desired.
Turning now to FIGS. 14-16, the insert assembly 60 includes a flat panel 61 with inwardly turned upper and lower flanges 62, 63 and side flanges 64, 65 which are doubled over for additional strength. Upper and lower reinforcement channels 66, 67 are provided for hanging the insert assembly to the frame 26 by means of the panel slots, just described.
Referring now to FIG. 16, the reinforcement channel 66 includes first and second welding flanges 68, 69, as well as a raised center web 70. At each end of the web 70, a hook 72 is stamped. Comparing FIGS. 15 and 16, the hook is seen to include an outwardly curved and pointed guide portion 73 to facilitate assembly of the insert assembly to the frame. After all four hooks on the reinforcing members engage the insert slots 56-59 on the frame, the panel is slid down, and the hooks will be seen to include a generally flat spring portion 74 for securing tight engagement with the associated frame. The other panel assembly may be similarly mounted to the frame.
When the inserts are assembled to the frames, the innermost edges of the peripheral flanges 62, 65 of the insert are flush with the tubular frame members 29, 30; so that the hanging slots 37 are recessed in the final panel assembly. The combination of recessing and the light barrier helps to obscure the hanging slots from view, but they are nonetheless readily accessible.
INTERCONNECTION OF PANELS
At the top of each panel, as seen in FIG. 9, there is a top cap generally designated 75, and seen in better detail in FIGS. 17-19. The top cap may be made from plastic or metal, and it includes an upper cover member 76 and first and second legs 77, 78 which are corrugated as at 79, 80 respectively. The lower end of each of the legs further is curved upwardly and outwardly at 81, 82 respectively so as to form catches for the flanges 31, 32 on the upper channel members.
Referring now to FIGS. 17 and 18, the length of the cover 76 extends from one end connector 49 to the other end connector 50 when the top cap is assembled to a panel. However, the length of the legs 77, 78 are shorter by a distance which will permit the top cap to be raised and moved to one side (see FIG. 22) in order to uncover the connecting bracket 18, if desired. This facilitates rearranging the wall panels when desired, without removing the top caps. When the top caps are raised, the catches 81, 82 engage the downwardly turned edges 31, 32 of the upper channel member 27 of the frame (see FIGS. 7 and 11). This also permits the inserts to be raised and removed if desired for replacement or changing.
In order to assemble two panels together, the bracket 18 (and a corresponding one at the bottom) is secured to the respective panels by means of bolts 18D and 18E which are threaded into the apertures 42 on the plates 41 in the respective panels 11, 13.
It will also be seen from FIG. 21 that for this orientation of the panels, the two end connector strips 50 (for panel 11) and 49A (for panel 13) cooperate to prevent light transmission through the connection. Specifically, in this orientation, the smaller rounded edge 88 of the connector 50 is received in the larger rounded portion 89 of the end connector 49A. If the panel 13 were turned 180°, the same connector brackets could be used, but the smaller rounded edge 90 of the connector 49A would then be received in and turned within a larger rounded edge 91 of the connector 50.
After the two panels are thus secured together, the end caps 75 are put in place as seen in FIG. 22. If it is desired to have further access to the connection, the end caps may be raised so that the latches on the end caps engage the inwardly and downwardly turned edges of the associated top channel; and the end caps may then be slid to the side. If it is desired to completely remove the end cap 75, they are lifted upwardly, and the legs 77, 78 are pushed inwardly until the catches 81, 82 clear the curved edges of the upper channel 27 of the panel frame.
If it is desired to change the inclination of the panels, the top caps 75 are lifted and slid to the side to the access position, and the threaded studs 18D and 18E are loosened from the plates 41. The panels may then be adjusted with the stud 18E sliding in the slot 18B until the desired position is achieved, such as a 120° angle (FIG. 23) or a 180° angle (FIG. 24). The bolts are then re-tightened at top and bottom. After the brackets are secured, the top caps 75 are repositioned on their associated panels.
As already indicated, by raising the top cap to its upper position, while still in engagement with the upper channel of the frame, it is possible to lift and remove the panel insert without completely removing the top cap from the panel. This is desirable, for example, for replacing an insert assembly or for changing it to a different color or material or replacing it.
SHELF COMPONENTS
Referring now to FIG. 25, the cabinet side panel 21, flipper door 20, cabinet top 24 and cabinet bottom shelf 23 have already been identified.
The cabinet side panel 21 is shown individually in FIGS. 45-48. The cabinet side panel includes an outer flanged facing 95, and an inner metal sheet 96 (FIG. 46). The inner element 96 includes a pair of spaced parallel grooves 98, 99, which extend vertically. As illustrated, the grooves or channel recesses, as they are sometimes are referred to are preferably located so that one is located toward the front of the panel and the other is located toward the rear of the panel. Both grooves have rear vertical surfaces which have adjustment slots designated respectively 103 (for the groove 98) and 104 (for the rear groove 99). These slots permit the mounting and adjustment of shelves on one-inch increments.
At the rear of the cabinet side panel 21, there are three upper tabs 105 and three lower tabs 106. The tabs 105, 106 are spaced according to the spacing of the recessed hanging slots 37 in the vertical tubular supports 29, 30 of the panel frame (FIGS. 7 and 10). Further, the tabs 105, 106 each have symmetry and define upwardly and downwardly projecting fingers for engaging the hanging slots on the panel frame. Thus, the cabinet side panel 21 may be used either as a left panel side or a right panel side by turning it over.
Between the tabs 105, 106 there is a spring-biased locking member 110 projecting from the rear of the panel 21 and in vertical alignment with the slots 105, 106.
Referring now to FIGS. 49, 54 and 59 the locking (or "latch") member 110 includes a bifurcated tongue generally designated 114 having first and second projections 115, 116. These projections are spaced so as to straddle the material separating two of the hanging slots 37 on the left side of the panel frame. Conversely, when the cabinet side panel is used on the right side, the projections 115, 116 fit within the same slot 37, but in both cases, the coupling prevents vertical movement of the side panel once the locking member is in place. At the center of the latch member 110 there is a protruding straight portion 117, and at the end there is an outwardly projecting stamped offset 118. A spring 119 is received on the straight portion 117 (see FIGS. 50-52).
Referring now to FIGS. 53 and 54, the latch member 110 is received in a U-shaped bracket 121 mounted within the cabinet end panel on the flat portion of the rear groove 99. The spring 119 is in compression and bears against the adjacent side of the bracket 121, thereby urging the latch member outwardly. Its outward motion is inhibited by the offset 118 which interferes with the other side of the bracket 121, as seen in FIG. 53. Referring back to FIG. 46, an aperture 128 is formed in the inner side material 96 of the panel, and if an object such as a key is inserted in this slot, as illustrated by the arrow 113 in FIG. 53, the projection offset 118 will be returned to its original position and the latch member may be removed from the bracket 121. As best seen in FIG. 46, a slot 129 is formed in the base of the groove 99, and this permits a key or screwdriver to be inserted and engage the central slot on the latch member 110 to pull it rearwardly and thereby disengage the latch to remove the cabinet side panel, if desired.
In order to install the side panel in the hanging slots on the panel frame, the latch member 110 is retracted as just disclosed, further compressing the spring 119. The sets of tabs 105, 106 are then aligned with the hanging slots in the panel frame 26, and the cabinet side panel 21 is moved downwardly so that the lower fingers of the tabs engage the slots. Next, the latch member 110 is permitted to extend outwardly and the bifurcated tongue 114 engages the material between adjacent slots or to fit into a slot, depending on whether it is used as a left or right side panel, as illustrated in FIG. 59. Thus, the panel is "locked" into the panel frame and cannot be inadvertently removed, nor can it be raised without retracting the locking member 110 through the slot 129.
Referring now to FIG. 25, an intermediate shelf 130 is supported between the cabinet side panel 21 and a vertical support assembly generally designated 131. The intermediate shelf 130 is shown in FIGS. 28-30 as including a flat portion 133 which provides the shelf space, a downwardly turned forward edge 134, and an upwardly turned rear edge 135. At each end of the shelf there is an end mounting bracket and these are designated 137 and 138 in FIG. 28. Each bracket is similar, and referring to the bracket 138 in FIGS. 29 and 30, a forward tab projection 141 and a rear tab projection 142 are stamped from the bracket. It will be observed that the rear tab is notched at 144 (FIG. 29) for securing the shelf in place. The left side tabs, of course, fit into the cabinet side panel 21, and the right side tabs fit into a similar structure on the vertical support assembly 131, to be discussed presently.
The shelf includes three sets of slots designated respectively 150, 151 and 152 and located respectively along the forward edge of the flat shelf portion 133, the rear edge thereof, and on the upwardly turned rear flange 135. The slots of each set are aligned forward to rear, and they are used to secure separators such as the file separator 160 in FIG. 27 or the envelope pouch 161 of FIG. 26. The file separator 160 includes a forward locking tab 163, a lower rear projection 164 and an upper rear tab 165 for fitting respectively into one of the slots 151 and 152. The envelope holder 161 includes only forward locking tabs 166 which fit into the forward slots 150.
Turning now to the bottom shelf 23 as seen in FIGS. 33 and 34, it also includes three sets of slots designated respectively 190, 191 and 192 similar to the corresponding sets of slots for the intermediate shelf. The bottom shelf also includes side mounting brackets, one of which is shown at 195, which includes forward and rear mounting tabs 197, 198 for mounting the shelf to the cabinet side panels 21, 22 (FIG. 4).
Turning now to FIGS. 31 and 32, the vertical separator assembly can be seen to include first and second pieces of sheet metal 170, 171 which form a pair of forward grooves 173, 174 similar to the vertical grooves 98, 99 shown in FIG. 46 of the cabinet side panel 41. A pair of rear adjustment grooves 175, 176 are formed in the vertical separator assembly. Each of the grooves is provided with adjustment slots designated 180 and 181 for the respective grooves. Similarly, the assembly is provided with a forward locking tab 182 for fitting into one of the slots 190, a lower rear projection 183 for being received in one of the slots 191, and an upper rear tab 184 for fitting into one of the slots 192 in the lower shelf 23 (see FIG. 33). The tabs 182, 183 and 184 are formed in only one of the sheet metal pieces 170, 171, as seen in FIG. 32.
Turning now to FIGS. 35 and 36, the cabinet top panel 24 includes a covering sheet 200 which is provided on its underside with first and second channel reinforcement elements 201, 202 in FIG. 36, and first and second side mounting brackets 203, 204. These brackets include forward and rear mounting tabs 205, 206 similar to the ones discussed in connection with the shelves, and they permit the cabinet top to be mounted into the cabinet side panels 21, 22. It will be observed that the rear edge of the top is curved at 207, whereas the forward edge 208 is more sharply bent to cooperate with the flipper door, to be described presently. In both cases, the edges are bent back on themselves to avoid sharp edges.
FLIPPER DOOR ASSEMBLY
Referring now to FIGS. 38-41, the flipper door 20 includes a covering sheet 220 which is fitted with a recessed handle 221, seen better in FIGS. 60 and 61. The handle is mounted from the rear by inserting screws in the two mounting blocks designated 222 in FIG. 61. A finger grip is shown at 223.
Returning now to FIGS. 38, 39, a reinforcing channel 225 is provided at the bottom of the flipper door 20 on the rear side of the facing sheet 220. First and second side channels 226, 227 are mounted on their stiffeners to the rear of the door, and they extend transversely of the channel 225. The the top of the door there is a transverse rod 230, at the ends of which are mounted nylon pinions 231, 232. The rod is rotatably mounted to the back of the flipper door by means of brackets 233, 234. Also mounted on the rods between the brackets and the pinions is a pair of sliding clips 236, 237 which take the form, as seen in FIG. 41 as an inverted U-shaped channel with outwardly projecting lower flanges 236A and 237A respectively. Interposed between the brackets and the clips are first and second coil springs 240, 241 for urging the clips outwardly relative to the fixed brackets.
The flipper door is mounted to a pair of tracks, one of which is shown in FIG. 55 and designated 250. The tracks are shown, in their mounted position in FIGS. 5 and 6, and they are designated 250 and 250A respectively. Turning now to FIG. 55, the track 250 includes a rack 251 which is integrally formed with an upright wall 252, and supported by a pair of intermediate braces 253, and first and second larger end braces 254 (see FIG. 56). On the back of the upright wall 252, there is a pair of spacers, one of which is shown at 256 for fitting into the grooves 98, 99 of the cabinet side panel. The tracks are mounted by screws, as seen in FIGS. 57 and 58.
With the tracks in place within the cabinet as shown in FIGS. 5 and 6, the flipper door may be inserted by urging the clips 236, 237 on the rod 230 toward the center (compare FIGS. 57 and 58), until the clips clear their respective tracks. The pinions are then set to engage the racks 251 on the tracks, and in the fully inserted position, the distal flanges of the channels 226, 227 rest on the track, as seen in FIG. 57, to support the forward portion of the flipper door in the horizontal position. The rear portion is supported, of course, by the pinion and rod. When the clips 236 are released, the coil springs 240, 241 urge them outwardly and into engagement with their associated tracks, and the door is held in place by the lower flanges 236A, 237A as they are received beneath the tracks. It will be observed from FIG. 57 that the clip 236 prevents complete withdrawal of the flipper door because it would interfere with the larger brace 254 at the forward position. This is further indicated in FIG. 43 which shows the flipper door in a partially open position. The flipper door is shown fully open in FIG. 42.
Referring now to FIG. 43, it will be seen that the forward edge 208 of the cabinet top 24 does not extend completely to the front of the cabinet but terminates short of that position so that when the flipper door is fully extended horizontally, it may be rotated about the rod 230, and the rearwardly bent upper portion 220A of the sheet metal 220 will be flush with the top of the cabinet and appear to be an extension of it, as best illustrated in FIGS. 1 and 3.
Turning now to FIGS. 62-65, there is illustrated the cooperation between end connector elements 49, 50 which prevent light leaks between adjacent panels 11, 12 for the various positions of the two panels. For example, in FIG. 62, the panels are in line or define an angle of 180°. In FIG. 63, the panels are arranged in an obtuse included angle. In FIG. 64 they are formed at a 90° angle, and in FIG. 65 they form an angle between 180° and 270°. In the straight position of FIG. 62, both edges of the elements 49, 50 form light seals, whereas in FIGS. 63 and 64 only the upper edges cooperate. in FIG. 65, the lower edges cooperate to form a light seal.
Referring now to FIGS. 66 and 67, the system is shown in a set-up including four individual cabinets 260, 261, 262 and 263 in a vertical stack, all hung in the recessed hanging slots on a rear panel 264, and including first and second side panels 266, 267. As best seen in FIG. 67, this arrangement includes a cabinet top 270, and four cabinet bottom shelves designated respectively 271-274. The top 270 and bottom shelves 271 are mounted in their associated side panels as previously disclosed, and this arrangement thus permits vertical stacking of cabinets which eliminates a separate top panel for each of the cabinets except the uppermost one.
Turning now to FIG. 68, there is illustrated one arrangement of vertical support assemblies and partitions demonstrating the horizontal and vertical modularity which may be incorporated into the system. Thus, a bottom shelf 280 and cabinet top 281, together with first and second cabinet side panels 282, 283 are assembled as already disclosed. A plurality of vertical separator assemblies 287 are then mounted to the bottom shelf 280, and partial shelves are inserted as desired. Individual separator plates or envelope bins are then installed on the shelving as desired.
Referring now to FIG. 69, there is disclosed one manner of mounting the work surface 17 in a cantilever manner including a cantilever bracket 290 which includes first and second slotted brackets 291, 292 through which screws 293 are placed for securing to the underside of the work surface 17. To the rear of the bracket 290 there is welded a bracket 295 provided with a plurality of hooked tabs of the type already described for fitting into the recessed hanging slots. The other side of the work surface may be mounted similarly, and structures other than the particular mounting brackets shown may be used to secure the work surface, such as a slide and drop arrangement of slots and pins.
Referring now to FIGS. 70-73, another feature of the invention is that it is readily adapted for the incorporation of drawer slides and such slides may be used to mount work surfaces (as seen in FIG. 71), shelves (FIG. 72) or files (FIG. 73).
In FIG. 70, there is shown a three-piece drawer slide having an outer section 301, and intermediate section 302 and an inner section 303. This is a conventional drawer slide except that the outer section 301 is provided with a first tab 304 and a hooked tab 305 to fit into and be secured to the upright channels in a cabinet side panel or similar structure.
In FIG. 71, two drawer slides are shown and designated 300, and a work surface 307 is mounted to the innermost sections of the slides so that it may be pulled out as desired.
In FIG. 72, a bottom shelf 309 is secured to the inner sections of the drawer slides 300, and it includes laterally spaced forward slots 310 and a set of aligned rear slots 311 formed in an upright rear flange 312.
In FIG. 73, the drawer slides 300 are used for mounting a frame 320 including first and second frame members 321, 322 parallel to the drawer slides and spaced for mounting legal size pocket folders such as the one designated 323. The frame 320 includes first and second transverse frame members 324, 325, which are spaced for mounting a letter size pocket folder 328.
It will thus be appreciated that the invention has wide adaptability in providing vertical and horizontal modularity and cabinet space, and it is also adapted for pullout work surfaces, shelves and file folders.
Having thus disclosed in detail preferred embodiments of the invention, persons skilled in the art will be able to modify certain of the structure which has been illustrated, and to substitute equivalent elements for those disclosed while continuing to practice the principle of the invention; and it is, therefore, intended that all such modifications and substitutions be covered as they are embraced within the spirit and scope of the appended claims. | An improved panel wall system is disclosed with means for interconnecting the panels in any desired angular relationship while providing a sight barrier through the joint. As many of the panels may be connected as are desired; and they may be placed in any desired configuration. Each panel includes an insert assembly to provide its exterior face; and these may be removed and changed, if desired. A full line of shelving and cabinets may be assembled to the panels with a limited number of interchangeable components. The cabinets include a flipper door which will not rack when opened or closed, and which slides beneath the top of the cabinet in the open position, yet has its edges flush with the top and bottom of the cabinet in the closed position. | 4 |
FIELD OF THE INVENTION
This invention relates generally to large appliances, such as washers or dryers, and particularly to those used in close proximity to dwelling enclosure walls.
BACKGROUND OF THE INVENTION
In the majority of laundry room or utility room situations found both in residential use as well as those in commercial use, the washer and dryer appliances are situated with their respective back surfaces facing a dwelling wall. In most circumstances, the various connections and couplings made to the washer and dryer appliances, such as those for electrical, gas, water or ventilation, make their respective connections at the back surface of the appliance. As a result, the typical washer or dryer appliance is not usually found with its back surface against the nearby dwelling wall, but is generally required to be spaced from the dwelling wall a sufficient distance to permit clearance between the various connections and couplings to the machine. In addition, laundry or utility rooms frequently have one or more sets of pipes extending across the wall surface which further precludes the positioning of the washer or dryer appliance tightly against the wall. As a result, in the typical washer or dryer arrangement there exists a space of approximately 6 to 10 inches between the rear surface of the washer or dryer appliance and the closest dwelling wall.
In use, a problem frequently arises in that objects being places within, removed from or collected on top of the washer and dryer appliances often fall behind the appliance due to the above-described spacing between its rear surface and the wall. Because washer and dryer appliances are extremely heavy and therefore difficult to move, they may not be readily pulled from the wall to permit retrieval of these articles or objects without considerable effort and inconvenience. In addition, the typical utility room or laundry room environment often includes overhead cabinets, shelves or the like which further exaserbate the problem of retrieving such objects by making it even more difficult to gain access to the space between the appliance and the dwelling wall.
In addition to the problems of objects being inadvertantly dropped behind the washer or dryer appliance during the transfer of clothing articles and the like to and from the appliance, the typical washer or dryer is designed with a raised control panel at the rear of the machine which in turn often defines a small flat upper surface. This small upper surface often becomes a convenient surface upon which to place various articles associated with the laundering process or otherwise related to it, such as material removed from garmet pockets and so on. Such articles placed upon this rear upper surface also tend to be inadvertently knocked bacwardly and fall into the spacing between the rear of the washer or dryer and the dwelling wall.
There arises therefore a need in the art for a convenient system for retrieving such articles which inadvertently fall between the washer or dryer appliance and the adjacent wall surface.
SUMMARY OF THE INVENTION
Accordingly, it is a general object of the present invention to provide for the easy retrieval of objects inadvertently falling between the rear surface of a washer or dryer or the like and the adjacent dwelling wall. It is a more particular object of the present invention to provide for the easy retrieval of such objects while avoiding the difficulty and inconvenience of moving the washer or dryer appliances.
In accordance with the present invention there is provided a catch basket for use in combination with a large appliance wherein the appliance is spaced from an adjacent dwelling wall. The catch basket includes a substantially rigid three-sided frame member together with expansion means for securing the frame member within the space between the appliance and the adjacent wall and to the appliance. Flexible basket means are attached to the rigid frame and extend across the spacing between the appliance and the wall. Means are further provided whereby the flexible basket means may adjust for and accommodate existing irregularities of the adjacent wall.
BRIEF DESCRIPTION OF THE DRAWINGS
The features of the present invention, which are believed to be novel, are set forth with particularity in the appended claims. The invention, together with further objects and advantages thereof, may best be understood by reference to the following description taken in conjunction with the accompanying drawings, in the several figures of which like reference numerals identify like elements and in which:
FIG. 1 is a perspective view of the present invention catch basket as used in combination with a conventional washing machine;
FIG. 2 is a partially sectioned top view of a catch basket constructed in accordance with the present invention;
FIG. 3 is a partial section view of a catch basket constructed in accordance with the present invention taken along section lines 3--3 in FIG. 1;
FIG. 4 is a section view of a portion of the present invention catch basket taken along section lines 4--4 in FIG. 2; and
FIG. 5 is a partially sectional view of an alternate embodiment of the expansion means of the present invention catch basket.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a perspective view of a typical installation of the present invention catch basket 10 in which a washing machine 11, constructed in accordance with well known washing machine fabrication techniques, includes a top surface 13, a rear surface 12 and an access door 20 defined in top surface 13. Washing machine 11 further includes a control housing 14, generally situated along the rear portion of top surface 13, and including a control panel 15 and a control panel top 16. In the situation shown in FIG. 1, washer 11 is installed in a position generally parallel to, but spaced from wall surface 32 such that a space between rear surface 12 and wall surface 32 exists.
A catch basket 10 constructed in accordance with the present invention is supported in the intervening space between rear surface 12 of control housing 14 and wall surface 32. Catch basket 10 includes a generally U-shaped frame 21 formed of a rigid material which in turn defines a straight portion 35 resting against rear surface 32 and extending across a substantial portion of the span of control panel top 16 and a pair of rearwardly extending legs 22 and 23. The latter terminates in a foot 24 and a foot 25 respectively which, as described below in greater detail, contact wall surface 32 and frictionally engage the wall surface. A pair of tabs 31 and 32 are attached to straight portion 35 and extend forwardly therefrom to position U-frame 21 with respect to control panel top 16. By means described below in greater detail, a flexible basket 26 is secured to U-frame 21 and extends downwardly therefrom and spans the majority of the above-described space between rear surface 12 and wall surface 32.
In accordance with the invention, the support of basket 26 between rear surface 12 of washer 11 and wall surface 32 provides a receptacle within which objects which otherwise fall to the floor between rear surface 12 and wall surface 32 and are difficult to retrieve, are instead caught within basket 26 and maintain therein and are thus readily retrievable without the need of moving washer 11 or requiring access to the space between rear surface 12 and wall surface 32.
The means by which catch basket 10 is supported in the manner indicated in FIG. 1 are described below in greater detail. However, suffice it to state here that the cooperation of foot 24, foot 25 and tabs 30 and 31 are operative to secure U-frame 22 without the use of fasteners of any kind in either wall surface 32 or washer 11. In accordance with the descriptions in greater detail set forth below, it should also be noted that catch basket 10 includes means which accommodate substantial variation in the space between rear surface 12 and wall surface 32. As a result, catch basket 10 is capable of use in a variety of positions of washer 11. It should also be noted that while the illustration set forth in FIG. 1 is that relating to the use of the present invention catch basket in combination with a washing machine, it will be apparent to those skilled in the art that the present invention catch basket is equally capable of use in combination with other large appliances, such as dryers or stoves or the like.
FIG. 2 shows a top view of the present invention catch basket in which U-frame 21 is formed of a metal tube and defines a straight portion 35 which terminates in a pair of bends 33 and 34 at each end and a pair of rearwardly extending legs 22 and 23. Legs 22 and 23 are coupled to a pair of expansion joints 39 and 40 respectively which in turn are coupled to a foot 24 and a foot 25 respectively. A tab 31 is secured to straight portion 35 of U-frame 21 by a loop 42 and extends outwardly from U-frame 21. Similarly, a tab 30 is secured to straight portion 35 of U-frame 21 by a loop 47. The structure of tab 31 and loop 42 is set forth in greater detail in FIG. 3. However, suffice it to note here that tabs 30 and 31 are spaced apart a sufficient distance to provide a stable pair of resting surfaces upon which catch basket 10 may rest upon control panel top 16 of washer 11. Foot 24 and foot 25 are formed of a rubber or resilient plastic-like material and function to create a frictional contact with wall surface 32. As mentioned above, and in accordance with an important aspect of the present invention, foot 24 and foot 25 engage wall surface 32 without the use of any fastener or permanent attachment to the wall surface. Therefore, the present invention catch basket may readily be removed from wall surface 32 without having caused any damage thereto. Similarly, it should be noted that tabs 30 and 31 rest upon the engaging surface of the appliance, such as control panel top 16 of washer 11 shown in FIG. 1, without the use of any permanent attachment to the appliance, thereby avoiding any potential damage or disfigurement of the machine and further facilitating the easy removal of the present invention catch basket for cleaning or other reasons. In accordance with structures set forth below in greater detail, expansion joints 39 and 40 are operative to provide an expandable coupling between legs 22 and 23 respectively and foot 24 and foot 25 respectively to exert an expanding force against wall surface 32 which further enhances the frictional contact between foot 24 and foot 25 against wall surface 32. Basket 26 is formed of a flexible cloth-like or net material in its preferred form and extends from U-frame 21 rearwardly and terminates on its back edge at an elastic 36. Elastic 36 is stretched between expansion joint 39 and 40 and is formed of a resilient material having sufficient elasticity to support the rear portion of basket 26. In accordance with an important aspect of the present invention, the use of elastic 36 to provide the back support means of basket 26 permits basket 26 to conform to irregularities in wall surface 32, such as would occur in the presence, for example, of plumbing fixtures, pipes or electrical conduits being secured to wall surface 32. In such case, elastic 36 rests against such wall surface irregularities and is deformed inwardly from the straight line position shown in FIG. 2 to permit basket 26 to accommodate such wall surface irregularities.
FIG. 3 is a section view of the present invention catch basket taken along section lines 3--3 in FIG. 1 and shows the details of the attachment of the present invention catch basket to control panel top 16 of washer 11. Accordingly, tab 31 extends across a portion of control panel top 16 and by attachment of loop 42, tab 31 is secured to straight portion 35 of U-frame 21. In addition, the present invention catch basket defines a downwardly extending tab 41 attached to loop 42 and secured to straight portion 35 in a similar manner to that of tab 31. Tab 41 rests against rear surface 12 of washer 11 and is maintained in contact therewith by the expansion force created by expansion joints 39 and 40 (seen in FIG. 2). Basket 26, which, as described above, is preferrably formed of a flexible cloth-like material, defines an elongated trough in the interior of U-frame 21 and extends downwardly therefrom. Basket 26 defines a basket side 46 extending downwardly from straight portion 35 and terminates in a basket bottom 45 which spans substantially all of the space between rear surface 12 of washer 11 and wall surface 32. While any number of means of attachment for basket 26 to U-frame 21 may be utilized without departing from the spirit and scope of the present invention. It has been found advantageous to secure basket 26 to U-frame 21 by folding the upper portion of basket side 46 in a peripheral fold and securing the lower portion of the fold thus formed to basket side 46 beneath U-frame 21 and thus form a sheath 50 about the perimeter of basket 26 which encloses U-frame 21 and elastic 36. It should be understood that tabs 30 and 31 are of substantially identical construction and that tab 30 includes a downwardly extending tab identical to tab 41 which is not seen in the figures, but which cooperates with tab 30 in the same manner as tab 41 cooperates with tab 31 to secure the position of U-frame 21 with respect to control panel top 16 and rear surface 12 of washer 11. Tabs 31 and 41 are covered by resilient sleeves 44 and 43 respectively which in the preferred form comprise a layer of rubber or elastic material suitable for producing a frictional engagement with the underlying surfaces of washing machine 11 and thereby enchancing the attachment of catch basket 10 shown in FIG. 1. Similarly, tabs 31 and the downwardly extending tab therefrom (not shown) also support resilient sleeves identical to resilient sleeves 43 and 44 in FIG. 3.
FIG. 4 shows a section view of expansion joint 40 in which foot 25 which, as mentioned, is formed of a rubber or resilient plastic material, is in contact with wall surface 32 and defines an interior cup 55. A hollow tube 51 is received on one end within cup 55 and maintained therein by the frictional engagement of the interior of cup 55 and the outer surface of tube 51. Tube 51 comprises a rigid wall 53 and an interior passage 54 which is sized to receive the end portion of leg 23. Leg 23 further defines a cylindrical wall 52 which in turn defines a reduced neck 60 extending inwardly. A spring 56 is compressively captivated between the bottom portion of cup 55 and neck 60. In the attached position, such as that shown in FIG. 1, expansion joint 40 is initially contracted by forcing leg 23 toward foot 25 such that leg 23 travels within interior passage 54 of tube 51. The inward motion of leg 23 within tube 51 during this contraction is resisted by compressed spring 56 which exerts an expanding force against cup 55 and neck 60 which tends to drive leg 23 outwardly from tube 51.
Expansion joint 39, foot 24 and leg 22 are identical in construction to expansion joint 40, foot 25 and leg 23 respectively and are operated in the same manner. Thus, the attachment of catch basket 10 in the position shown in FIG. 1, is carried forward by initially placing foot 24 and foot 25 against wall surface 32 and forcing U-frame 21 toward wall surface 32 to contract expansion joints 39 and 40. Thereafter, and with expansion joints 39 and 40 sufficiently contracted, tabs 30 and 31 are positioned in the manner shown in FIG. 1 and the contracting force against U-frame 21 is relaxed, which permits expansion joints 30 and 40 to force U-frame 21 against rear surface 12 of washer 11. This expanding force is provided by the compressed spring 56 and simultaneously forces tab 41 and the corresponding downwardly extending tab associated with tab 30 against rear surface 12 of washer 11 and foot 24 and foot 25 against wall surface 32 to secure catch basket 10.
FIG. 5 shows an alternate embodiment of the present invention in which foot 25 is replaced by a suction cup 62 which engages wall surface 32 in a manner similar to foot 25 in the embodiment of FIG. 4 and which defines a collar 63 on its reverse side. Leg 23 defines an interior passage 65 extending inwardly from one end and a reduced neck 60 which constricts passage 65. A cylindrical rod 61, which is sized to be received within passage 65, extends into collar 63 and passage 65. A compressed spring 64, similar to spring 56 in the embodiment of FIG. 4, is compressively maintained within rod 61 and imparts an expansion force between suction cup 62 and neck 60 which tends to force rod 61 outwardly from passage 65. The operation of the expansion joint shown in FIG. 5 is substantially the same as that shown in FIG. 4. The additional function of suction cup 62 is to provide a more secure attachment to wall surface 32 in the event such surface has an extremely glossy or slippery finish.
As can be seen by the foregoing descriptions, the present invention catch basket provides an advantageous solution to the problems of articles falling behind large appliances, such as a washing machine or a dryer. The catch basket shown in readily secured in place without the use of fasteners or attachments to either the appliance or the wall surface and is readily removeable therefrom for cleaning or for placement in use elsewhere.
While particular embodiments of the invention have been shown and described, it will be obvious to those skilled in the art that changes and modifications may be made without departing from the invention in its broader aspects. Therefore the aim in the appended claims is to cover all such changes and modifications as fall within the true spirit and scope of the invention. | A catch basket for use in combination with a large appliance wherein the appliance is spaced from an adjacent dwelling wall. The catch basket includes a substantially rigid three-sided frame member together with expansion means for securing the frame member within the space between the appliance and the adjacent wall and to the appliance. Flexible basket means are attached to the rigid frame and extend across the spacing between the appliance and the wall. Means are further provided whereby the flexible basket means may adjust for and accommodate existing irregularities of the adjacent wall. | 3 |
CROSS-REFERENCE TO RELATED PATENT APPLICATION(S)
[0001] This application is a 35 U.S.C. § 371 National Phase Entry Application from PCT/KR2006/000600, filed Feb. 22, 2006, and designating the United States. This application also claims the benefit of Korean Patent Application No. 10-2005-0016168, filed on Feb. 25, 2005, in the Korean Intellectual Property Office, the disclosure of which is incorporated herein in its entirety by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a layered metal hydroxide-retinoic acid (LMH-RA) hybrid and its anticancer efficacy. More particularly, the present invention relates to a pharmaceutical composition for the treatment of cancers, including a hybrid of RA and LMH which is an inorganic carrier.
[0004] 2. Description of the Related Art
[0005] Generally, layered inorganic compounds can include various materials in their interlayers. For example, various functional guest materials can be intercalated into the interlayers of aluminosilicates, metal phosphates, etc., using layer charges generated by isomorphous substitution of metal ions constituting host lattice layers or physicochemical adsorption capability induced by layer surface modification. In addition, it is known that a pore size of crosslinked clay, MCM-41, etc. are adjusted to physically adsorb molecules of a predetermined size. Among these layered inorganic compounds, layered double hydroxides (LDHs), also called “anionic clays”, are composed of positively charged metal hydroxide layers, interlayer anions capable of compensating for the positive charges, and interlayer water. It is known that various anions can be easily introduced into the interlayers of LDHs using ion-exchange reaction or coprecipitation. These LDHs and their derivatives have received much interest due to the technical importance of layered nano-hybrids in catalytic reactions, separation technology, optical industry, medical engineering, pharmaceutical industry, etc., and thus, research thereon has been actively conducted.
[0006] For example, the structures of interlayer anions (carbonate) and water in hydrotalcite ([Mg 3 Al(OH) 8 ]+[0.5CO 3 .mH 2 O] − — a mineral name of a compound having a magnesium (Mg)-aluminum (Al)-based LDH structure—were elucidated using 1 H and 13 C NMR spectra [“Ordering of intercalated water and carbonate anions in hydrotalcite—An NMR study”, A. van der Vol. et al., Journal Physical Chemistry, 1994, 98, 4050-4054].
[0007] Sang-Kyeong Yun et al. [“Layered double hydroxides intercalated by polyoxometalate anions with Keggin(α-H 2 W 12 O 40 6− ), Dawson(α-P 2 W 18 O 62 6− ), and Finke(CO 4 (H 2 O) 2 (PW 9 O 34 ) 2 10− ) structures”, Inorganic Chemistry, 1996, 35, 6853-6860] disclosed the pillaring of Mg 3 AI LDH by polyoxometalate (P 2 W 18 O 62 6− or CO 4 (H 2 O) 2 (PW 9 O 34 ) 2 10− ) using ion exchange reaction of LDH-hydroxide and -adipate precursors with the polyoxometalate, and evaluation results of structural and thermal properties of the resultant LDH. Ji-Won Moon et al. [“Crystal structures of some double hydroxide minerals”, Mineralogical Magazine, 1973, 39[304], 377-389] disclosed the structural characteristics of some LDHs, and the types and structures of metal cations and interlayer anions available for the LDHs.
[0008] F. Cavani et al. [“Hydrotalcite-type anionic clays: Preparation, properties and applications”, F. Cavani et al., Catalysis Today, 1991, 11, 173-301] comprehensively reviewed the historical background, available components (e.g., types of metal cations and interlayer anions), structural properties, and applications of LDHs. In contrast, the incorporation of biological materials into LDH is not much known except for those phosphate ion-containing biological materials, such as DNAs or RNAs (Korean Patent No. 10-0359716).
[0009] Recently, retinoid derivatives (e.g., retinols, retinoic acids, etc.) have received much interest as materials of functional cosmetic products for skin whitening, the removal or prevention of pigmented lesions such as melasma and freckles, and anti-wrinkle effect due to intrinsic antioxidative activity. However, these retinoid derivatives are very unstable to be destroyed in the air, which causes great restriction in handling of them and their applicability. In particular, retinoids such as vitamin A (retinol), known as anticancer materials, cause serious side effects, such as skin irritation, when administered in high dosage for anticancer therapy, and thus, are practically inapplicable. U.S. Pat. No. 4,310,546 discloses an N-(4-acyloxyphenyl)-all-trans-retinamide compound, U.S. Pat. No. 4,323,581 discloses N-(4-hydroxyphenyl)-all-trans-retinamide, and U.S. Pat. No. 4,665,098 discloses N-(4-hydroxyphenyl)retinamide (known as fenretimide).
[0010] It is known that retinoids are involved in cell differentiation and development by inducing dimerization of nuclear receptors, RAR (retinoic acid receptor) and RXR (retinoid X receptor) to promote the entry of RAR/RXR into cell nuclei [Dino moras et al., Nature, 1995, 375, 377-382]. It is also known that retinoids exhibit anticancer effects by indirectly regulating the activity of a transcriptional activation factor participating in tumorigenesis and metastasis, i.e., AP-1 (activation protein-1), so that the expression of a target gene of AP-1 is suppressed [Yang-Yen H. F. et al., New Biol. 3: 1206-1219, 1991]. It is also known that retinoids including retinol can inhibit uncontrolled cell proliferation and induce differentiation or apoptosis, and thus, can be effectively used for the treatment or prevention of cancers [Hong W. K. and Itri L. M., Biol. Chem. Med., 2nd ed. edited by Sporn et al., New York: Raven Press; 597-630, 1994]. However, the use of retinoids may produce side effects, such as skin irritation, toxicity in organ systems, and deformation, by some proteins which are activated by the interaction between the retinoids and their receptors [Hathcock J. N. et al., Am. J. Clin. Nutr., 52, 183-202, 1990]. Recently, some retinoid derivatives with better anticancer effects and fewer side effects than existing retinoids have been reported. However, when these retinoid derivatives are administered in the form of retinoid-based drugs in high dosage for anticancer therapy, irritation to tissues may be caused. Thus, it is necessary to reduce a dosage of the retinoid derivatives, which limits the use of the retinoid derivatives as anticancer drugs. Retinoids exhibit low tissue distribution due to low solubility, and thus, the use of high-dose retinoids is needed. In view of this problem, LDH-retinoic acid (RA) was suggested.
[0011] Currently available drugs for the treatment of liver cancer include injectable forms of 5-fluorouracil (5-FU), cytarabine, and alkyloxane, which are described in the Korean pharmacopoeia. However, these drugs contribute to prevent the proliferation of cancer cells, rather than to induce the death of cancer cells, and thus, are not effective for the fundamental treatment of liver cancer. With respect to a holmium-166-chitosan complex (DW-166HC), known as a potent treatment of liver cancer, its clinical safety and effects have not been completely evaluated, and thus, long-term clinical trials with many patients must be performed. Furthermore, in a case where two or more tumor masses are distributed over several organs, tumors spread to distant organs (metastasis), patients suffer from abdominal dropsy or jaundice, or several blood vessels extend into a tumor mass, chemotherapy with DW-166HC cannot be used. In addition, the chemotherapy with DW-166HC must be prescribed and managed by a medical doctor.
[0012] There are a few foreign and domestic patents which are more or less associated with LDH-based nanocomposites, in particular, LDH-RA. LDH may be a natural or synthetic LDH. A method of synthesizing LDH is disclosed in U.S. Pat. Nos. 3,539,306 and 3,650,704. In particular, Korean Patent Application No. 10-2002-0047318 discloses a hydrozincite-3-benzoyl-α-methylbenzene acetic acid hybrid, Korean Patent Application No. 10-2001-0046774 discloses a vitamin-LDH hybrid wherein anionic vitamins or their derivatives are intercalated into interlayers of LDHs which works as inorganic carriers, and the method of preparing the same, and Korean Patent Application No. 10-1993-0002369 discloses a UV-screening composition suitable for human skin. However, these patent documents are silent about the anticancer efficacy of LDH-RA.
[0013] It is very difficult to develop a treatment for liver cancer considering the fact that the liver participates in all metabolisms of the human body. Thus, a LDH-RA hybrid, developed by the present inventors, which is a selective anticancer active material capable of exhibiting minimal toxicity in normal cells and maximal anticancer activity in liver cancer cells, can be used as a potent treatment of liver cancer.
SUMMARY OF THE INVENTION
[0014] In view of the above problems, the present invention provides a pharmaceutical composition for the treatment of liver cancer, including a retinoic acid-layered metal hydroxide (RA-LMH) hybrid as a novel drug delivery system which shows few side effects of RAs, good drug stability, sustained drug release, and improved drug delivery efficiency.
[0015] The present invention is directed to prepare a retinoic acid-layered metal hydroxide (RA-LMH) hybrid wherein RA is intercalated into the interlayer of LMH by anion exchange reaction. RA is very unstable and toxic, and thus, involves problems such as antigenic effects in immune response. Thus, a novel drug delivery system for RA has been required. LMH is soluble in an acidic condition but very stable in a neutral or basic condition. In this regard, LMH is expected to be a novel drug delivery system capable of conferring stability and sustained release property to RA. Metal hydroxide used in the RA-LMH hybrid according to the present invention is harmless to human body, and the release of RA from LMH can be appropriately adjusted. The RA-LMH hybrid according to the present invention has a significant meaning since it is a first attempt to apply to a pharmaceutical composition for cancer treatment. Therefore, it is an objective of the present invention to provide a RA-LMH hybrid which stabilizes unstable retinoid derivatives, extends effect of RA through sustained-release of it, and induces the apoptotic cell death of tumor cells.
[0016] According to an aspect of the present invention, there is provided a pharmaceutical composition for the treatment of a cancer, including an LMH-RA hybrid as an effective ingredient. The pharmaceutical composition can be used for the treatment of various cancers due to the anticancer activity of RA [Yang-Yen H. F. et al., New Biol. 3: 1206-1219, 1991, Hong W. K. and Itri L. M., Biol. Chem. Med., 2nd ed. edited by Sporn et al., New York: Raven Press; 597-630, 1994]. However, the following working examples of the present invention have demonstrated that the pharmaceutical composition of the present invention is particularly useful for the treatment and prevention of liver cancer.
[0017] The LMH may be layered double hydroxide (LDH) or hydroxy double salt (HDS). Although the LDH and HDS are similarly prepared by titrating a metal salt-containing solution with a base solution, the HDS contains a single metal element such as a divalent metal element, whereas the LDH contains two or more metal elements of different valencies, usually divalent and trivalent metal elements. Thus, the LMH-RA hybrid of the present invention may be a LDH-RA hybrid or a HDS-RA hybrid.
[0018] The LDH-RA hybrid or the HDS-RA hybrid may be prepared by intercalating RA into the interlayer of LDH or HDS using ion exchange, coprecipitation, or adsorption. According to the coprecipitation method, RA is added as a reactant during synthesis of LDH or HDS, and the intercalation of RA into the interlayer of LDH or HDS occurs simultaneously with synthesis of LDH or HDS. According to the ion exchange method, anion species in the interlayer of previously synthesized LDH or HDS are substituted by RA. According to the adsorption method, anions in the interlayer of LDH or HDS are removed by thermal treatment, and RA is then intercalated into the interlayer of LDH or HDS.
[0019] The LMH-RA hybrid may be represented by Formula 1 below:
[0000] [M 2+ 1−x N 3+ x (OH) 2 ][RA n− ] x/n .y H 2 O [Formula 1]
[0020] wherein M 2+ is a divalent metal cation selected from the group consisting of Mg 2+ , Ni 2+ , Cu 2+ , and Zn 2+ , N 3+ is a trivalent metal cation selected from the group consisting of Al 3+ , Fe 3+ , V 3+ , Ti 3+ , and Ga 3+ , x is a value ranging from 0.1 to 0.5, RA is a retinoic acid or its derivative, n is a charge number of RA, and y is a positive number.
[0021] The LMH-RA hybrid may also be represented by Formula 2 below:
[0000] [M 2+ (OH) 8 ][RA n− ] 2/n .y H 2 O [Formula 2]
[0022] wherein M 2+ is a divalent metal cation selected from the group consisting of Mg 2+ , Ni 2+ , Cu 2+ , and Zn 2+ , RA is a retinoic acid or its derivative, n is a charge number of RA, and y is a positive number.
[0023] In Formula 1, the x value is related to a metal composition ratio and may range from 0.1 to 0.5, and more preferably, from 0.25 to 0.33. If the x value is outside the range, the encapsulation of RA into an inorganic LDH carrier, i.e., the intercalation of RA between the hydroxide layers of the LDH carrier may not occur, which renders the production of a desired LDH-RA hybrid difficult.
[0024] The LMH-RA hybrid of the present invention may be used in a hydrate form. The degree of hydration can be expressed as the y value. The y value can be changed according to various factors, such as moisture content in air. Generally, the y value can be represented by a positive number.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] 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 in which:
[0026] FIG. 1 is a diagram illustrating a retinoic acid-layered double hydroxide (RA-LDH) hybrid (a) and a retinoic acid-hydroxy double salt (RA-HDS) hybrid (b);
[0027] FIG. 2 is X-ray diffraction patterns of a NO3-LDH hybrid (a), a RA-LDH hybrid (b), and a RA-HDS hybrid (c);
[0028] FIG. 3 is ultraviolet-visible (UV-Vis) spectra of a RA and a RA-LDH hybrid, and dissolution data of RA with time (UV-Vis absorbance with time when 5 mg of a RA-LDH hybrid is dispersed in an aqueous solution);
[0029] FIG. 4 shows a morphological change of hepatocarcinoma cell line, CHX, by a RA-LDH hybrid;
[0030] FIG. 5 shows the expression of fluorescein isothiocyanate (FITC) with time in the CHX hepatocarcinoma cell line;
[0031] FIG. 6 shows endocytosis of an LDH-FITC hybrid in the CHX hepatocarcinoma cell line;
[0032] FIG. 7 shows a distribution of an LDH-FITC hybrid in the Golgi region of the CHX hepatocarcinoma cell line;
[0033] FIG. 8 shows a distribution of an LDH-FITC hybrid in the lysosomes of the CHX hepatocarcinoma cell line;
[0034] FIG. 9 is a graph illustrating the activity of lactic acid dehydrogenase in the CHX hepatocarcinoma cell line;
[0035] FIG. 10 shows an effect of a RA-LDH hybrid on DNA fragmentation;
[0036] FIG. 11 is Western blotting analysis results showing an effect of a RA-LDH hybrid on protein expression;
[0037] FIG. 12 shows an effect of a RA-LDH hybrid on tumor development in xenografted nude mice; and
[0038] FIG. 13 is haematoxylin-and-eosin (H/E) staining results showing an effect of a RA-LDH hybrid on tumor development in xenografted nude mice.
DETAILED DESCRIPTION OF THE INVENTION
[0039] The present invention will now be described more fully with reference to the accompanying drawings, in which exemplary embodiments of the invention are shown.
[0040] The present invention provides an inorganic layered metal hydroxide-retinoic acid (LMH-RA) hybrid wherein a retinoic acid or its derivative is intercalated into the interlayer of layered double hydroxide (LDH) or hydroxy double salt (HDS) used as an inorganic carrier, its anticancer effect, and a pharmaceutical composition using the LMH-RA hybrid. The LMH-RA hybrid of the present invention exhibits a pharmaceutical efficacy for tumor treatment by inducing apoptotic cell death of tumor cells.
[0041] The LMH-RA hybrid according to the present invention includes RA intercalated into the interlayer of a layered inorganic compound, such as LDH or HDS (see Examples 1 and 2). Various functional guest materials can be intercalated into the interlayer of the layered inorganic compound using layer charges generated by isomorphous substitution of metal ions constituting host lattice layers or physicochemical adsorption capability induced by layer surface modification. LDH, also called “anionic clay”, is composed of positively charged metal hydroxide layers, interlayer anions capable of compensating for the cations, and interlayer water. A LDH-RA hybrid may be represented by [M2+1−xN3+x(OH)2][An−]x/n yH2O where M2+ is a divalent cation, N3+ is a trivalent cation, and An− is an n-valent anion. The layer charge density of the LDH-RA hybrid can be adjusted by changing the ratio of the divalent cation to the trivalent cation. The n-valent anion can be easily intercalated into the interlayer of LDH using ion exchange or coprecipitation. LDH and its derivatives have received much interest due to the technical importance of layered nano-hybrids in catalytic reactions, separation technology, optical industry, medical industry, engineering, etc.
[0042] As used herein, the term “LMH-RA hybrid” is not a simple mixture but is a hybrid complex synthesized by chemical or physical interaction between components. For example, cationic LMH and an anionic active ingredient for a cosmetic product can be chemically bound by electrostatic interaction. Ion exchange and coprecipitation are methods based on chemical interaction. According to the ion exchange method, ions such as nitrate (NO3−), chlorine (Cl—), or carbonate (CO32−) in the interlayer of LMH are substituted by ionized drug molecules. According to the coprecipitation method, ionized drug molecules are added to a metal-containing solution during titration, and the encapsulation of the drug molecules occurs simultaneously with formation of LMH. Meanwhile, an adsorption method is based on physical interaction, i.e., van der Waals force between an organic material (e.g., tocopherol succinate) previously incorporated in LMH and an active component (e.g., retinol). The above-illustrated preparation examples are only for illustrative purpose, and thus not intended to limit the scope of the present invention. In practical, both electrostatic interaction and van der Waals force may exist in the LMH-RA hybrid according to components or preparation conditions.
[0043] The LMH-RA hybrid of the present invention can be formulated into pharmaceutically acceptable dosage forms in combination with a pharmaceutically acceptable additive, such as an excipient, an adjuvant, a diluent, an isotonic solution, a preservative, a lubricant, and a solubilizing aid.
[0044] A pharmaceutical composition of the present invention can be administered in the form of an adult dosage of 1 μg/kg/day to 400 mg/kg/day of the LMH-RA hybrid used as an active ingredient. An adequate dosage is determined according to the degree of disease severity.
[0045] The pharmaceutical composition of the present invention can be administered in the form of tablets, foam tablets, capsules, granules, powders, sustained-release tablets, sustained-release capsules (single unit formulations or multiple unit formulations), intravenous or intramuscular injectable ampules, suspensions, or suppositories, or in other suitable dosage forms.
[0046] In order to prepare pharmaceutical formulations using the pharmaceutical composition, the LMH-RA hybrid can be used in a pharmaceutically effective amount, in combination with a physiologically tolerated excipient and/or diluent and/or adjuvant, according to an appropriate preparation method.
[0047] Hereinafter, the present invention will be described more specifically with reference to the following working examples. The following working examples are for illustrative purposes and are not intended to limit the scope of the present invention.
EXAMPLE 1
[0048] RA-inorganic hybrids were synthesized by coprecipitation as follows.
[0049] (1) A solution of a RA derivative in 0.2 M NaOH was dropwise added to a mixture of metal cations Zn(II) and AI(III) (1<Zn/Al<4). The resultant precipitate was centrifuged and washed to give a RA-inorganic hybrid. The entire processes were performed in a nitrogen atmosphere to prevent contaminations with CO 2 in air. The resultant compound was represented by the following formula:
[0000] M II 1−x Al III x (OH) 2 (C 20 H 27 O 2 ) x .m H 2 O
[0050] M II : Mg, Zn, Ni, . . . 0.1<x<0.5)
[0051] (2) A solution of a RA derivative in 0.2 M NaOH was dropwise added to a metal cation Zn(II)-containing solution. The resultant precipitate was centrifuged and washed to give a RA-inorganic hybrid compound. The entire processes were performed in a nitrogen atmosphere to prevent contaminations with CO 2 in air. The resultant compound was represented by the following formula:
[0000] M II 5 (OH) 8 (C 20 H 27 O 2 ) 2 .m H 2 O
[0052] (M II : Zn, Ni, . . . )
[0053] The X-ray diffraction patterns of the RA-inorganic hybrids are shown in FIG. 2 and the UV-Vis spectra of the RA-inorganic hybrids are shown in FIG. 3 . Referring to FIGS. 2 and 3 , the interlayer distance of the RA-inorganic hybrids corresponds to 2-fold of the molecular length of RA, and the UV-Vis spectral absorption peaks of the RA-inorganic hybrids are identical to those of RA. These results show that RAs are stabilized and vertically arranged in the interlayer of metal hydroxide layers. Based on these results, the probable arrangement of RAs between inorganic lattice layers is as shown in FIG. 1 .
EXAMPLE 2
[0054] A dispersion solution of 5 mg of a LDH-RA hybrid in 40 mL of distilled water was added to seven test tubes, incubated at 35° C. in a thermostat system rotating at 270 rpm, and centrifuged at predetermined time intervals. The UV-Vis spectra of the resultant supernatants were measured, and the results are shown in FIG. 3 . Absorbance with time at the maximum absorption wavelength (288 nm) is also shown in FIG. 3 . Referring to FIG. 3 , 60% RA was released for 2 hours after the reaction was initiated. After then, a small amount of RA was released continuously. These results show that RA stabilized between LDH lattice layers is delivered continuously and acts on a target site.
EXAMPLE 3
[0055] In order to examine the morphological change of tumor cell line, CHX, by LDH-RA treatment, about 10 4 cells were seeded in each of four wells of a 6-well plate and incubated in a 5% CO 2 incubator at 37° C. One of the four wells was used as a control group with no drug treatment. The remaining three wells were treated with 40 μg/ml of LDH, 250 μg/ml of RA, and 1,000 μg/ml of LDH-RA, respectively. At 12 hours after the treatment, the morphological change of the cells in each well was observed, and the results are shown in FIG. 4 . Referring to FIG. 4 , in the control group, significant augmentation of cell proliferation was observed. In the LDH-dose group and the RA-dose group, cell proliferation was slightly retarded but no apoptotic cell death was observed. In the LDH-RA dose group, cell proliferation was greatly suppressed and apoptotic cell death was greatly increased. Meanwhile, in order to determine the programmed time of apoptotic cell death by LDH-RA treatment, Tunel assay was performed, and the results are shown in FIG. 5 . Referring to FIG. 5 , the strongest fluorescence was observed at 2-3 hours after the treatment. This result shows that LDH-RA-mediated cell death occurs at 2-3 hours after the LDH-RA treatment.
EXAMPLE 4
[0056] In order to evaluate an effect of a LDH-RA hybrid synthesized according to the present invention on cells, the endocytosis of LDH with time in the CHX tumor cell line was observed. For this, the CHX tumor cells were plated on cover glasses and cultured. Then, the cells were treated with previously prepared LDH-FITC (Fluorescein Isothiocyanate) so that endocytosis occurred. At this time, the cells were washed with a phosphate buffer saline (PBS) at 0, 1, 2, and 3 hours after the LDH-FITC treatment, and fixed with methanol for 10 minutes. The cover glasses were placed on slide glasses, and cellular change was observed in a dark room using a laser-scanning confocal microscope (Bio-Rad). The results are shown in FIG. 6 . Referring to FIG. 6 , at an initial stage (0 hours), no green fluorescence was observed in the tumor cells as well as their surroundings. However, green fluorescence started to appear at 1-2 hours after the LDH-FITC treatment, and the strongest green fluorescence was observed at 3 hours after the LDH-FITC treatment. In particular, strong green fluorescence was observed in nuclear membranes and the surroundings of endoplasmic reticula. This can be explained by the release of FITC from LDH in acidic small organelles (<pH 6) around nuclear membranes, such as endoplasmic reticula, Golgi, and lysosomes. Thus, it is thought that FITC easily reaches small organelles through LDH and is then released from LDH due to the acidic environment of the organelles.
EXAMPLE 5
[0057] In order to determine which organelle participates in release of FITC from LDH, the distribution of FITC in the organelles of cells was observed, and the results are shown in FIG. 7 . Referring to FIG. 7 , LDH-FITC first reached Golgi and lysosomes around nuclear membranes after endocytosis. Thus, it is thought that FITC is released from LDH in acidic (pH<6) Golgi and lysosomes, and distributed in the small organelles and nuclear membranes of cells.
[0058] In order to determine if the release of FITC from LDH occurs in Golgi, the Golgi was stained with Alexa Fluor anti-golgi-97 antibody, and lateral fluorescence distribution was observed. As a result, green fluorescence was observed in the Golgi and the surroundings. This result shows that LDH-FITC is first ingested into the cell membrane by endocytosis and then reaches the nuclear membrane and the surrounding organelle, Golgi. This can be explained by the release of FITC from LDH due to the acidic environment of the Gogi. On the other hand, the release of FITC from LDH in lysosomes was also evaluated using lysoTracer Red DND-99. As a result, red fluorescence was observed in the lysosomes. Like in the Golgi, it is thought that after endocytotic uptake of LDH-FITC into the cells, FITC is released from LDH in lysosomes due to the acidic environment (pH<6) of the lysosomes (see FIGS. 7 and 8 ).
EXAMPLE 6
[0059] In order to evaluate an anticancer effect of a LDH-RA hybrid obtained according the present invention, activity of lactic acid dehydrogenase associated with apoptotic cell death was measured. For this, the CHX tumor cells were seeded into each well of a 96-well plate. The CHX tumor cells were divided into 6 groups: normal group with no treatment, LDH-dose group with 1,000 μg/ml of LDH, RA-dose group with 250 μg/ml of RA, LDH-RA low-dose group with 25 μg/ml of LDH-RA, LDH-RA mid-dose group with 50 μg/ml of LDH-RA, and LDH-RA high-dose group with 100 μg/ml of LDH-RA. All groups were cultured for 12 hours. 20 μl of pyruvate substrate (NADH 1 mg/ml) was added to each group, and the cultures were mixed at room temperature for 2 minutes and stirred at 37° C. for 30 minutes. 20 μl of a color reagent (Sigma 505-2) was added to each culture, and the resultant cultures were mixed at room temperature for 20 minutes. 100 μg of 0.4N NaOH was added to each culture, and the resultant cultures were mixed at room temperature for 15 minutes. Absorbance (A570/A630) of each culture was measured using an ELISA reader, and the results are shown in FIG. 9 . Referring to FIG. 9 , the activities of lactic acid dehydrogenase of the normal group, the LDH-dose group, and the RA-dose group were 6±1.5%, 13±2%, and 42±5%, respectively. The activities of lactic acid dehydrogenase of the LDH-RA low-dose group, the LDH-RA mid-dose group, and the LDH-RA high-dose group were 41±2%, 76±6%, and 86±5%, respectively. In particular, the activity of lactic acid dehydrogenase of the LDH-RA dose groups was 2-fold or more higher than that of the RA-dose group in the same concentration. This might be because LDH facilitates the introduction of RA into cells, and thus, a RA-mediated apoptotic pathway is increasingly activated, thereby inducing a higher apoptotic cell death than the RA-dose group.
EXAMPLE 7
[0060] In order to determine whether a LDH-RA hybrid induces DNA fragmentation, the CHX tumor cells were seeded at 1×10 4 cells/well in a 6-well plate and cultured for 12 hours. A LDH-dose group, a RA-dose group, and a LDH-RA dose group were treated with 1,000 μg/ml of LDH, 250 μg/ml of RA, and 40 μg/ml of LDH-RA, respectively, for 1-2 days, and cells were then collected. The cells were treated with 200 μg of a lysis buffer (10 mM Tris-HCl, pH 7.5, 1 mM EDTA, 0.2% Triton X-100) and incubated on ice for 30 minutes. Then, proteinase K (100 μg/ml) was added to the cells, followed by incubation in a 50° C. water bath for 5 hours. The resultant cultures were thoroughly mixed with a 1:1 phenol/chloroform mixture and centrifuged at 15,000 rpm for 15 minutes. The supernatants were collected and treated with 100% EtOH. The precipitates were dried, and 35 μg of RNase (50 μg/ml)-containing dH 2 O was added thereto. The resultant solutions were analyzed by 1.5% agarose gel electrophoresis to qualitatively determine DNA fragmentation, and the results are shown in FIG. 10 . Referring to FIG. 10 , in the normal group, no apoptotic cell death was observed due to active cell proliferation (see FIG. 4 showing the morphological change of the normal cell group). In the LDH-dose group, no or few DNA fragmentation was observed. On the other hand, the RA-dose group and the LDH-RA dose group formed discontinuous ladder patterns (200-400 bp in length) by cleavage of genomic DNA into DNA fragments by endonuclease activated during apoptosis. Here, based on the observation of a 1 kb or less DNA ladder pattern, it is thought that apoptosis is induced by RA released from LDH.
EXAMPLE 8
[0061] The CHX tumor cells were seeded at 1×10 4 cells/well into four wells of a 6-well plate, and cultured for 12 hours. The four wells were used for a normal group, an LDH-dose group, a RA-dose group, and a LDH-RA dose group, respectively. The normal group was an untreatment group. The LDH-dose group, the RA-dose group, and the LDH-RA dose group were treated with 1,000 μg/ml of LDH, 250 μg/ml of RA, and 40 μg/ml of LDH-RA, respectively, for 12 hours, and cells were then collected. Then, the cells were treated with a lysis buffer (50 mM Tris-HCl pH 7.5, 1% (v/v) Triton X-100, 150 mM NaCl, 10% (v/v) glycerol, 2 mM dithiothreitol, 10 mM MgCl 2 ). 30 μg of each extract was loaded onto 10% polyacrylamide SDS gel (SDS-PAGE) and transferred to Immobilon-P membrane (Amersham). Protein expression was detected using enhanced chemiluminescence (ECL) assay. For this, β-actin which was standard protein commonly present in all cells, Caspsase-3 associated with apoptotic cell death, and AKT and Bcl-2 associated with cell survival were labeled with primary antibody (Santa Cruz, 1:1,000 dilution). Then, the membrane was washed with PBS and treated with a blotting solution to prevent a side reaction. Then, the membrane was incubated in a blocking solution containing Horseradish Peroxidase-conjugate anti-goat IgG (HRP) as a secondary antibody and then incubated with an ECL blotting reagent for 3 minutes. Chemiluminescence was detected using an X-ray film from 30 seconds to 20 minutes, and the results are shown in FIG. 11 . Referring to FIG. 11 , β-actin was expressed in all groups, whereas AKT and Bcl-2 associated with cell survival were expressed only in the normal group and the LDH-dose group. Caspase-3 associated with apoptotic cell death was strongly expressed in the RA-dose group and the LDH-RA dose group. This can be explained by RA-induced RXR/RAR dimerization. That is, a RXR/RAR dimer, formed by RA, is attached to an AP-1 binding site of genomic DNA during AP-1-mediated transcription and facilitates the transcription of interferon (IFN) localized in the downstream of the genomic DNA, thereby inducing apoptosis. Thus, even when LDH-RA is administered in a small dose, the entry and release of RA into cells through LDH can be facilitated, thereby enabling an effective pharmacological action of RA on the cells. This demonstrates the possibility of using LDH-RA as a promising anticancer drug.
EXAMPLE 9
[0062] The CHX tumor cells were collected at 1×10 7 cells/well and administered subcutaneously to the hind legs of athymic nude mice. Appearance of tumor mass was observed every week. Tumor masses appeared 3 weeks after the subcutaneous administration, and, when a tumor size was increased to 5 mm, one group of the mice was untreated (control group), and the other groups of the mice were treated as follows: a LDH-dose group with LDH (1 mg/ml), a RA-dose group with RA (0.5 mg/ml), and a LDH-RA dose group with LDH-RA (50 μg/ml). The LDH-dose group, the RA-dose group, and the LDH-RA dose group were further treated with LDH, RA, and LDH-RA, respectively, every two weeks for 8 weeks. The macro photographic images of tumor growth are shown in FIG. 12 . Referring to FIG. 12 , in the control group, a tumor size was increased to 30 mm after 8 weeks. In the LDH-dose group, a size reduction in tumor mass was slightly observed but tumor growth was not adversely affected. In the RA-dose group, a tumor size was reduced by about 20%. In the LDH-RA dose group, a tumor size was reduced by 80% or more. After then, the mice were anesthetized. Tumor tissues were cut, fixed in formalin, and cut into sections (5 μm thick) on a microtome. The sections were stained with hematoxylin/eosin (H/E) and examined with a microscope (50× magnification), and the results are shown in FIG. 13 . Referring to FIG. 13 , in the control group, tumor masses were found in almost all tissues, thereby causing growth retardation of tumor, resulting in necrosis. In the LDH-dose group, necrotic tumor tissues were observed, like in the control group. On the other hand, in the RA-dose group, necrosis was retarded due to slight inhibition of proliferation of tumor tissues, thereby resulting in a 15% reduction in tumor tissues. In the LDH-RA dose group, a tumor size was greatly reduced due to apoptosis of tumor tissues, and 85% or more tissue necrosis was observed, showing the prevention of tumor proliferation or growth. From the above results, it can be seen that LDH mediates the introduction of a LDH-RA hybrid into cells and the transport of the LDH-RA hybrid to small organelles, such as Golgi or lysosome, and when RA is released from LDH in an acidic pH of the small organelles, IFN synthesis is induced during transcription, thereby inducing the apoptotic cell death of tumor cells.
[0063] A layered metal hydroxide-retinoic acid (LMH-RA) hybrid according to the present invention stabilizes RA and guarantees the sustained-release property of RA (see the following Examples 1-2). The LMH-RA hybrid of the present invention also exhibits a higher anticancer efficacy than RA (see the following Examples 5-6). This is possible because LMH effectively facilitates RA delivery to a tumor cell. Furthermore, since RA toxicity problem, which may be caused when RA is used in a high dose, can be alleviated, the LMH-RA hybrid of the present invention has fewer RA-mediated side effects. Therefore, the LMH-RA hybrid of the present invention is very useful for a pharmaceutical composition for the treatment of cancers.
[0064] While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, it will be understood by those of ordinary skill in the art that various changes in form and details may be made therein without departing from the spirit and scope of the present invention as defined by the following claims. | Provided is a pharmaceutical composition for the treatment of liver cancer, including a layered metal hydroxide-retinoic acid (LMH-RA) hybrid as a novel drug delivery system which shows few side effects of retinoic acid, good drug stability, sustained drug release, and improved drug delivery efficiency. | 0 |
BACKGROUND OF INVENTION
1. Field of the Invention
The invention relates to a fiber optic helmet mounted display system. More specifically, the invention relates to such a display system which uses a wide angle eyepiece.
2. Description of Prior Art
Helmet mounted display systems are known in the prior art as illustrated in, for example, U.S. Pat. Nos. 4,315,240, Spooner, Feb. 9, 1982, 4,315,241, Spooner, Feb. 9, 1982, 4,340,878, Spooner et al, July 20, 1982, 4,347,507, Spooner, Aug. 31, 1982, 4,347,508, Spooner, Aug. 31, 1982, 4,348,185, Breglia et al, Sept. 7, 1982, 4,348,186, Harvey et al, Sept. 7, 1982, 4,349,815, Spooner, Sept. 14, 1982, 4,439,157, Breglia et al, Mar. 27, 1984, 4,439,755, LaRussa, Mar. 27, 1984. In all of the above systems, except the one described in the '157 patent, an image is projected onto a screen. The requirement for a domed screen provides disadvantages as is well known in the art. In any case, none of the systems of the cited references, or any others known to Applicant, use a wide angle eyepiece as in the present application.
SUMMARY OF INVENTION
In accordance with the invention there is provided a fiber optic helmet mounted display system for producing a replica of an image derived from an image source for observation by an observer. The system includes a wide angle eyepiece mounted on the helmet in the line of sight of the observer. The fiber optic cable means transmit the image from the image source to the eyepiece. Whereby, a replica of the image is produced in the line of sight of the observer, the replica appearing to originate at infinity.
BRIEF DESCRIPTION OF DRAWINGS
The invention will be better understood by an examination of the following description, together with the accompanying drawings, in which:
FIG. 1 illustrates the helmet components;
FIG. 2 is an optical schematic for each eye; and
FIG. 3 is a typical field of view illustration in accordance with the invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to FIG. 1, the display system, illustrated generally at 1, is mounted on a helmet 3 worn by an observer 5. The observer can be the pilot, or any other crew member, of a flight simulation device. Alternatively, it could be the crew member or an observer in an operational vehicle such as a helicopter, fixed wing aircraft, space shuttle, tank or ship.
The display system comprises an optical assembly 7, a wide angle eyepiece 9 and a beam splitter 11. The wide angle eyepiece can comprise a PANCAKE WINDOW™ as described in U.S. Pat. No. 3,443,858, LaRussa, May 13, 1969 or a wide field optical viewer with concave eyepiece as described in U.S. Pat. No. 3,432,219, Shenker et al, Mar. 11, 1969. The image sources are coupled to the wide angle eyepiece by coherent fiber optic cables 13. Other features of the invention may include an accelerometer package 15 and a diode array 17.
Turning now to FIG. 2, the image is provided by image source 19. In a simulator situation, the image would be generated by a computational device capable of transforming a digital data base into a real world scene. Alternatively, the image could originate from a film, model board, video disc or any other medium capable of storing a representation of the environment which would surround the observer in the real world.
In the case of operational vehicles, the image would be provided by a remote sensor such as a television camera or a thermal imaging device or a computational device capable of generating the required imagery.
In accordance with a preferred embodiment, the image transmitted by the fiber optic cable is enhanced either by wavelength multiplexing or dynamic scanning. Wavelength multiplexing is described in Fiber Optics Principles and Applications in Medicine, Siegmund, W. P. et al, Annals of the New York Academy of Sciences, Vol. 157, 1969, while dynamic scanning is described in Fiber-Optics Principles and Applications, Kapany, N. G., Academic Press, New York, 1967. In both techniques, a single picture element or pixel is distributed over many individual fibres at the input end of the cable and is recombined at the output end of the cable. Both techniques increase the resolution of the fiber optic cables and reduce the visibility of the fiber optic structure.
Relay lens 21 is provided to re-image the output of the image source onto the input of the fiber optic cable 13. Relay lens 23 produces an serial image 24 of the output of the fiber optic cable. The aerial image 24 is viewed by the eyepiece 9 to form a collimated image to the eye of the observer. The image appears to originate at a distance as shown by dotted lines 26. As is known in the art, a relay lens is a lens which re-images an input to a different location.
The output relay lens 23 forms a part of the optical assembly 7, and, as seen in FIG. 1, both the optical assembly and the eyepiece are mounted on the observer's head. The image source 19 and the input relay lens 21 are mounted a short distance from the observer and, as seen in FIG. 2, are coupled to the observer's head by the fiber optic cable 13.
In the preferred mode of operation, the beam splitter 11 of FIG. 1 is inserted in the optical path between the wide angle eyepiece 9 and the optical assembly 7. The beam splitter permits the optical assembly to be placed out of the direct line of sight of the observer whereby the collimated view of the replica of the image carried by the fiber optic cable can be combined with the direct view of objects seen through the eyepiece, and the replica of the image still appears to originate at a distance. Such an arrangement allows the observer to see his immediate environment, such as a cockpit instrument panel for a pilot, as well as the replica of the image.
The diode array 17 and the accelerometer package 15 determine the position of the head of the observer. Alternative schemes, well known in the art, can also be used.
In order to provide as wide a field of view as possible the optical axis of each eyepiece is inclined outward such that the displayed field of view is as shown in FIG. 3. The amount of overlap can be varied for particular applications.
Due to the difficulty and cost of providing high resolution imagery over the entire displayed field of view, a small high resolution inset is normally used as shown in FIG. 3. In the simplest mode of operation, this inset is fixed in the central portion of the field of view such that an observer, by turning his head towards an object of interest, will see it in high resolution.
An alternative mode of operation causes the inset to be slaved to a particular item of interest.
In a third, and most advantageous, mode the inset is slaved to the observer's eye position. In this mode, due to the characteristics of the human visual system, the entire displayed field of view is perceived by the observer as if it were all displayed in high resolution. An occulometer, capable of measuring the observer's eye position with sufficient accuracy and speed of response, is mounted on the helmet for this mode of operation in addition to the diode array and accelerometer package which monitor the position of the helmet.
The inset image may be obtained from a separate image source which, after appropriate magnification, would be optically combined with the background image either at the input end of the fiber optic cable or, if a separate fiber optic cable is used for the inset, in the optical assembly 7 of FIG. 1. Alternatively, a single image source, having the ability to display that part of the image corresponding to the inset in higher resolution than the remainder of the image, may be used. In the modes where the inset is slaved to either the eye position or an object of interest, a servo mechanism, or an electronic technique, may be used to move the inset in an appropriate manner.
It is noted that the operation of the system herein is described in The Proceedings of the 1984 Image Conference III, May 30-June 1, 1984 at page 345, et. seq., Welch and Shenker and The Proceedings of the 1984 SID (Society for Information Display) International Symposium, Section 8.2, page 112, Hanson and Longridge, ISSN 0097-966X, the contents of which documents are incorporated herein by reference.
Although particular embodiments have been above-described, this was for the purpose of illustrating, but not limiting, the invention. Various modifications, which will come readily to the mind of one skilled in the art, are within the scope of the invention as defined in the appended claims. | A fiber optic helmet mounted display system produces a replica of an image derived from an image source for viewing by an observer. The system includes a wide angle eyepiece mounted on the helmet in the line of sight of the observer. Fiber optic cable means transmit the image from the image source to the eyepiece whereby to produce the replica of the image in the line of sight of the observer, the replica appearing to originate at a distance. | 6 |
[0001] This application is a Non-Provisional Application based upon U.S. Patent Application 60/728,945, filed Oct. 21, 2005, incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates generally to mounting systems. More particularly, the present invention relates to adjustable mounting systems for mounting devices such as flat panel televisions and displays on a surface.
BACKGROUND OF THE INVENTION
[0003] In recent years, flat-panel television units have become enormously popular in both the commercial and the residential sectors. As the prices for plasma and liquid crystal display (LCD) flat panel displays have continued to fall, and as the quality for the same devices have improved, more and more businesses and individuals have purchased such devices both for business and home entertainment purposes.
[0004] One of the advantages of flat-panel television units that customers have found particularly appealing is their relatively low thickness. Because conventional “tube” televisions have a relatively large depth, the display options for such devices are quite limited. In the residential setting, most users require a television stand or large entertainment center to store the television. Such stands or entertainment centers can take up significant floor space, which is often undesirable. In the commercial or educational setting, users will often install large overhead mounting systems that can contain the television. However, these systems usually require professional installation and, once the television is secured in the mount, it is often very difficult to access and adjust due to its height.
[0005] With flat-panel televisions, on the other hand, users are presented with a relatively new option: mounting the television directly to a wall or similar surface. By mounting the television to a wall, a person can eliminate the need to take up potentially valuable floor space with a television stand or entertainment unit. Furthermore, individuals and entities can mount the television at a sufficiently low height to be able to adjust the television's orientation with little difficulty.
[0006] Although the introduction of flat-panel televisions on a wide scale has presented new opportunities to both residential and commercial customers, it has also presented new challenges. Over the past few years, a number of wall mounting systems have been developed for use with flat panel televisions, but each has their own drawbacks. For example, U.S. Pat. No. 6,402,109 discloses a wall mounting system that permits a flat panel television to have a limited range of motion once it is mounted to the wall. The products described in these disclosures rely upon the use of a set of curved slots to form a rotatable connection between a mounting bracket and a support bracket. Although moderately useful, a rolling connection among the slots is required for the smooth tilting movement of the mounting bracket relative to the support bracket. Unfortunately, the curved slots themselves can cause the mounting systems' rolling pins to slip during the tilting process, which can lead to the mounting bracket, and therefore the attached television or display, to move in an abrupt, non-smooth fashion relative to the support bracket. Such movements can make it difficult for one to precisely position the television or display in the desired position. Additionally, gravity can, on occasion, cause the rolling pins to fall within the slots, which can cause the system to bind. In such a situation, it becomes more difficult to adjust the orientation of the flat panel display. Furthermore, with some newer plasma and LCD televisions being more sensitive and delicate than conventional tube televisions, such sudden slippage could also damage the devices.
[0007] U.S. Application Publication No. 2004/0245420 discloses a mounting system where a plurality of arc-shaped glides are used in place of the rolling pins. However, such glides may be more expensive to manufacture than rolling pins, are more difficult to assemble into the curved slots than the rolling pins, and are prone to suffering wear to the frictional sliding of the glides against the sides of the slots.
[0008] It therefore would be desirable to develop an improved rotatable connection for tilt mounting systems that addresses the above-identified shortcomings.
SUMMARY OF THE INVENTION
[0009] The present invention comprises a self-balancing flat panel television or display mounting system. The mounting system is tiltable through the use of a plurality of substantially straight guide paths or surfaces formed with a mounting bracket and an adapter bracket, where carrier mechanisms are used to effectuate a smooth, rolling connection between the mounting bracket and the adapter bracket. In this arrangement, the resultant forces on the carrier mechanisms are oriented substantially perpendicular to the direction of the carrier mechanisms' travel, balancing the forces created by the supported load. By using a plurality of sets of guide paths with each support plate/mounting bracket combination, the guide paths create a “scissoring” action which diminishes sliding and promotes the smooth movement of the carrier mechanisms with the guide paths, as well as helping to ensure that the carrier mechanisms do not slip when a user or installer lifts and removes the television from the remainder of the mount.
[0010] These and other advantages and features of the invention, together with the organization and manner of operation thereof, will become apparent from the following detailed description when taken in conjunction with the accompanying drawings, wherein like elements have like numerals throughout the several drawings described below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a perspective view of a tilt mounting system constructed in accordance with one embodiment of the present invention;
[0012] FIG. 2 is a side view of the mounting system of FIG. 1 when in a first position;
[0013] FIG. 3 is a magnified view of the interaction among a carrier and a set of guide paths on the mounting bracket and support plate when in the position shown in FIG. 2 ;
[0014] FIG. 4 is a side view of the mounting system of FIG. 1 when in a second position;
[0015] FIG. 5 is a side view of the mounting system of FIG. 1 when in an intermediate position;
[0016] FIG. 6 is a magnified view of the interaction among a carrier mechanism and a set of guide paths on the mounting bracket and support plate when in the position shown in FIG. 5 ; and
[0017] FIG. 7 is a side view of a mounting system constructed according to an alternative embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] FIGS. 1-6 show an adjustable mounting system 10 constructed in accordance with one embodiment of the present invention. The mounting system 10 of FIGS. 1-6 comprises a mounting bracket 12 which is configured to attach to a flat surface such as a wall. The mounting bracket includes a mounting bracket contact portion 11 and a pair of mounting bracket flanges 13 on each side thereof. In the embodiment shown in FIGS. 1-6 , a plurality of mounting bracket holes 18 are strategically placed and sized within the mounting bracket contact portion 11 to attach the mounting bracket 12 to the wall. It should also be noted, however, that the mounting bracket 12 can be part of a larger support system, and that the attachment of the mounting bracket 12 to the wall does not have to be direct. Instead, the mounting bracket 12 can be connected to the wall via a plurality of intermediate components, such as an articulating arm (not shown) or other brackets or plates. These various components can be used to translation an attached electronic device away from or towards the wall, to tilt the electronic device to the left or right, or for other purposes.
[0019] In the embodiments shown in FIGS. 1-6 , an adapter bracket 14 is rotatably coupled to the mounting bracket 12 . Like the mounting bracket 12 , the adapter bracket 14 includes an adapter bracket contact portion 15 bounded by a pair of adapter bracket flanges 17 on each side thereof in one embodiment of the invention. In the embodiment shown in FIGS. 1-6 , a display bracket 16 is secured to the adapter bracket contact portion 15 and is configured to attach to a flat panel display or other electronic device via a plurality of display bracket holes 20 . However, it should also be noted that, in other embodiments of the invention, the display bracket 16 is not necessary and the adapter bracket 14 can attached directly to the respective electronic device.
[0020] As shown in FIGS. 1-6 , the mounting bracket 12 includes a plurality of mounting bracket guide paths 24 , and the adapter bracket 14 includes a plurality of adapter guide paths 26 . FIGS. 1-6 show and describe the mounting bracket guide paths 24 and adapter guide paths 26 as slots that are formed completely within the mounting bracket 12 and adapter bracket 14 , respectively. However, it should be understood that the present invention is not strictly limited to the use of slots. Instead, guide paths for the mounting bracket 12 and the adapter bracket 14 can comprise items such as rails and outer surfaces that define a path of travel, as well as other structures that provide guide paths. The present invention should therefore not be strictly limited to the use of slots.
[0021] The mounting bracket guide paths 24 are located on the mounting bracket flanges 13 , and the adapter bracket guide paths 26 are located on the adapter bracket flanges 17 . In one embodiment of the invention, each mounting bracket flange 13 includes two mounting bracket guide paths 24 , and each adapter bracket flange 17 includes two adapter bracket guide paths 26 , each of which are configured to align with a respective mounting bracket guide slot 24 .
[0022] Importantly, both the mounting bracket guide paths 24 and the adapter bracket guide paths 26 is substantially straight in nature. In particular, each individual mounting bracket guide slot 24 and adapter bracket slot 26 does not possess any discemable radius of curvature along the longer edges of the slots that are closer to where the electronic device is mounted. In a preferred embodiment, the longer inner and outer edges of both the mounting bracket guide paths 24 and the adapter bracket guide paths 26 are substantially straight and possess no discemable radius of curvature. Both the mounting bracket guide paths 24 and the adapter bracket guide paths 26 are sized to accept a carrier 22 therethrough. FIGS. 1-6 show the carrier mechanisms 22 as comprising rolling pins. However, other types of carriers, such as gliders or other items, could also be used. In one particular embodiment of the invention, two rolling pins are used, with one rolling pin passing through the uppermost mounting bracket guide paths 24 and adapter bracket guide paths 26 on each of the respective flanges, and another rolling pin passing through the lowermost mounting bracket guide paths 24 and adapter bracket guide paths 26 on each of the respective flanges.
[0023] The different positions of the mounting system 10 shown in FIGS. 2-6 show the relative movement of the adapter bracket 14 , and therefore any attached electronic device, relative to the mounting bracket 12 . FIGS. 2 and 3 show the adapter bracket 14 in a first position, where the adapter bracket 14 (and the electronic device) are angled upward to the greatest extent permitted by the mounting system 10 . Conversely, FIG. 4 shows the adapter bracket 14 in a second position, where the adapter bracket 14 (and the electronic device) are angled downward to the greatest extent permitted by the mounting system 10 . FIGS. 5 and 6 show the adapter bracket 14 in an intermediate position, about half way between the position shown in FIGS. 2 and 3 and the position shown in FIG. 4 .
[0024] In the position shown in FIGS. 2 and 3 , the carriers 22 are positioned at the top most regions of the respective adapter bracket guide paths 26 and the lower most regions of the respective mounting bracket guide paths 24 . In contrast, when the adapter bracket 14 is positioned as shown in FIG. 4 , the carriers 22 are positioned at the lower most regions of the respective adapter bracket guide paths 26 and the top most regions of the respective mounting bracket guide paths 24 . At all times during the motion process, the adapter plate 14 and attached electronic device exert a normal force against the carrier 22 in the uppermost slots, with the force being normal to a major axis of the respective mounting bracket guide paths 24 . In a preferred embodiment of the invention, the mounting bracket guide paths 24 on each mounting bracket flange 13 are oriented such that lines normal to the major axes of each mounting bracket guide slot 24 will intersect at a point within the vicinity of the center of gravity of a flat panel display or television when properly secured to the adapter bracket 14 . As a result of this arrangement, the flat panel display or television does not tend to tilt on its own without the imposition of outside forces (typically imposed by a user who wants to change the orientation of the flat panel display.)
[0025] During the process of adjusting the tilt of the adapter bracket 14 relative to the mounting bracket 12 , the position of the adapter bracket guide paths 26 is adjusted relative to the position of the corresponding mounting bracket guide paths 24 . This movement can be described as a “scissors style” movement, with the interaction of the slots resembling the interaction of two scissor blades during a cutting process. As a result of this scissors style relative motion, the forces that are exerted on the carriers 22 promotes the rolling of the carriers 22 within the respective slots and works to help prevent any sliding action of the carriers 22 . As any sliding of the carriers 22 within the slots can lead to an uneven and/or unbalanced movement of the adapter bracket 14 and electronic device relative to the mounting bracket 12 , the use of straight slots, and therefore the resultant scissors style movement, aids in permitting a smooth and consistent adjustment process. This makes it easier for the user to place the electronic device at a desired orientation. Additionally, the improved rolling action also prevents slippage and instability when a user attempts to remove the electronic device/adapter bracket 14 combination from the mounting bracket 12 when necessary or desired.
[0026] In alternative embodiments of the present invention, it is not necessary for each mounting bracket guide slot 24 to have a corresponding adapter bracket slot 26 . For example, it is possible, instead of having adapter bracket guide paths 26 at all, the adapter can include a plurality of holes just large enough to permit the carrier 22 roll therein, with each hole corresponding to a mounting bracket guide slot 24 . Alternatively, this arrangement can be reversed, where the mounting bracket flanges 13 each possess a hole that corresponds to a respective adapter bracket slot 26 .
[0027] The embodiment of the invention shown in FIGS. 1-6 also includes a friction member 30 for adjusting the level of resistance that is met during the adjustment process. In one particular embodiment, the friction member 30 includes an adjustment screw that passes through both an adapter plate friction slot 28 and a hole (not shown) in the corresponding mounting plate flange 13 . It should be noted that the hole and slot can also be reversed, such that the friction slot appears on the mounting bracket 12 . A plurality of washers (not shown) may also be used along with the adjustment screw. In this embodiment of the invention, a clockwise rotation of the adjustment screw causes the respective adapter bracket flange 17 and mounting bracket flange 13 to come into closer contact with each other, which results in an increased level of friction when the user moves the flat panel display (and therefore the adapter bracket 14 ) relative to the mounting bracket 12 . A counterclockwise rotation of the adjustment screw correspondingly reduces the friction level between the mounting bracket 12 and the adapter bracket 14 . It should be understood that other types of friction devices may also be used, and that these friction devices may or may not include an adjustment screw of the type described herein.
[0028] FIG. 7 shows an additional embodiment of the present invention, where the adapter bracket 14 includes a guide path 26 which is an open-back rolling surface instead of a slot. In this particular embodiment, if a user needs to perform an action under the television or display such as accessing cables, he or she can rotate the adapter bracket 14 relative to the mounting bracket 12 about an axis defined by the upper carrier mechanism 22 . This action provides a user with improved access to the back side of the device without having to completely remove the adapter bracket 14 .
[0029] The foregoing description of embodiments of the present invention have been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the present invention to the precise form disclosed, and modifications and variations are possible in light of the above teachings or may be acquired from practice of the present invention. The embodiments were chosen and described in order to explain the principles of the present invention and its practical application to enable one skilled in the art to utilize the present invention in various embodiments and with various modifications as are suited to the particular use contemplated. | An improved adjustable mounting system for mounting a flat panel display to a surface. A mounting bracket is configured to attach to the surface, while an adapter bracket is operatively connected to the mounting bracket and is configured to operatively connect to the flat panel display. At least one carrier mechanism operatively connects the mounting bracket and the adapter bracket, the first carrier mechanism positioned with a set of substantially straight guide paths or surfaces to couple the adapter bracket to the mounting bracket. When the flat panel display is operatively connected to the adapter bracket and the mounting bracket is attached to the surface, the flat panel display is generally selectively rotatably positionable about an axis substantially parallel to the surface as a result of the interaction of the first carrier mechanism with the set of substantially straight guide paths or surfaces. | 8 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a novel serum-free tissue culture medium useful for cultivation of a virus producer cell, in particular a retrovirus producer cell required for production of a recombinant retrovirus vector, which is used for studies of gene therapy or clinical gene therapy, and a method for producing a virus, in particular a recombinant retrovirus vector, using the medium.
[0003] 2. Description of Related Art
[0004] Gene therapies in which virus vectors are used have been developed and many clinical tests have been carried out aiming at treatment of congenital genetic diseases as well as cancers and infectious diseases. In particular, a large number of trials have been conducted for gene therapy utilizing a retrovirus vector or a adenovirus vector.
[0005] Examples of DNA vectors used for production of recombinant retrovirus vectors which are used for integrating genes of interest include MFG and LXSN (GenBank Accession No. M28248) in which genes for virus particle structural proteins (gag, pol, env) are eliminated from the wild-type Moloney murine leukemia virus (MoMLV)) genome. Other vectors having further modification have been used in clinical tests for human subjects.
[0006] A recombinant retrovirus vector is produced by cultivating a producer cell which is derived from transfection of a DNA vector inserted with a gene of interest into a packaging cell (Psi-Crip, GP+E86, GP+envAm12, PG13, etc.), and collecting a supernatant which contains the virus vector of interest. A producer cell clone that stably produces a retrovirus vector for stable expression of a gene of interest may be selected, for example, from infected cells obtained by further infecting a packaging cell using the supernatant. Through such steps, a master cell bank (MCB) and a working cell bank (WCB) are prepared, and a recombinant retrovirus vector for gene therapy is stably produced.
[0007] Cultivation of a retrovirus producer cell is very important for stable retrovirus production. Usually, a retrovirus producer cell is cultivated in a serum-containing medium, and a virus-containing supernatant is collected from the culture. A case of successful cultivation under serum-free conditions has been reported. In this case, a cell capable of growing under serum-free conditions is selected in a step called adaptation in which the serum concentration in the medium is gradually decreased. However, it is generally very difficult to produce a retrovirus using a serum-free medium (Mol. Biotechnol., 15:249-257 (2000)).
SUMMARY OF THE INVENTION
[0008] Use of an animal serum has great risk, for example, because it may contain an unknown virus. Therefore, it is desirable to use a serum-free medium for cultivation of a retrovirus producer cell. Thus, a serum-free medium which does not contain an animal serum is used only in the final virus production step upon production of a recombinant retrovirus vector to be clinically administered to humans in many cases. Furthermore, selection of the lot of a serum to be used is very important because productivity of a recombinant retrovirus vector greatly varies among serum lots. On the other hand, such variation in productivity can be suppressed if a serum-free medium is used. Therefore, the use of a serum-free medium is highly necessary. Several serum-free media for virus production are commercially available although none of them can serve as a substitute for a serum-containing medium. Attempts have been made for preparing a retrovirus vector free of a serum as follows. In one method, after cultivation in a serum-containing medium, the medium is exchanged for a serum-free medium such as X-VIVO15 (Cambrex) in the final virus collection step and a virus supernatant is then collected from the culture. In another method, a cell that can be cultivated under serum-free conditions is selected by adaptation. However, they still are not sufficiently effective.
[0009] As a result of intensive studies, the present inventors have shown that a retrovirus producer cell can grow well in a serum-free medium containing serum albumin. The present inventors have further found that a high-titer retrovirus supernatant can be collected using the medium. Thus, the present invention has been completed.
[0010] In summary, the present invention relates to the following.
[0011] [1] A serum-free medium used for cultivation of a virus producer cell, which contains serum albumin.
[0012] [2] The medium according to [1], wherein the serum albumin is human serum albumin.
[0013] [3] The medium according to [1], which contains the serum albumin at a concentration of 0.05 to 1% by weight.
[0014] [4] The medium according to [1], which contains interleukin-2.
[0015] [5] The medium according to [4], which contains interleukin-2 at a concentration of 10 to 1000 JRU/ml.
[0016] [6] The medium according to [1], which contains calcium at a concentration of 1.35 to 6.31 mmol/L.
[0017] [7] The medium according to [1], which contains epidermal growth factor.
[0018] [8] The medium according to [1], wherein the virus producer cell is a recombinant retrovirus vector producer cell.
[0019] [9] A method for producing a substance of interest, the method comprising cultivating a cell capable of producing a substance of interest in the medium defined by [1].
[0020] [10] The method according to [9], wherein the cultivation is initiated by inoculating a stock of the cell capable of producing a substance of interest into the medium defined by [1].
[0021] [11] The method according to [9], wherein the substance of interest is a recombinant retrovirus vector.
[0022] Using the medium of the present invention, it is possible to readily prepare a recombinant retrovirus vector free of a serum and a therapeutic composition containing the vector. The composition is very useful in the field of gene therapy.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0023] FIG. 1 illustrates the efficiency of gene transfer into CEM cells with retroviruses obtained using the complete medium or the medium A.
[0024] FIG. 2 illustrates the efficiency of gene transfer into HT1080 cells with retroviruses obtained using the complete medium or the medium A.
[0025] FIG. 3 illustrates the efficiency of gene transfer into CEM cells with retroviruses obtained using the medium A or the medium B.
[0026] FIG. 4 illustrates the efficiency of gene transfer into human PBMCs with retroviruses obtained using the medium A or the medium B.
[0027] FIG. 5 illustrates the efficiency of gene transfer into CEM cells with retroviruses obtained using Opti-ProSFM or Opti-ProSFM +HSA (at a final concentration of 0.2%).
[0028] FIG. 6 shows the morphologies of the cells on Day 3 of virus collection.
[0029] FIG. 7 illustrates the efficiency of gene transfer into CEM cells with retroviruses obtained using the medium I, the medium II or the medium III.
[0030] FIG. 8 illustrates the efficiency of gene transfer into CEM cells with retroviruses obtained using the medium I or the medium IV.
[0031] FIG. 9 illustrates the efficiency of gene transfer into CEM cells with retroviruses obtained using the medium A or the medium V.
DETAILED DESCRIPTION OF THE INVENTION
[0032] The first aspect of the present invention relates to a serum-free medium which is suitable for cultivation of a virus producer cell.
[0033] This medium is one prepared by adding serum albumin to a basic medium free of a serum that is prepared by mixing components necessary for cultivation of a virus producer cell.
[0034] The components of the basic medium include: energy sources such as amino acids, saccharides and organic acids; vitamins; buffer components for pH adjustment; and inorganic salts. The medium may contain a pH indicator such as phenol red. A known medium free of a serum such as DMEM, IMDM or Ham's F12 medium may be used as the basic medium. These media are available as commercial products from Invitrogen, Sigma and the like. Commercially available serum-free media such as Opti-ProSFM, VP-SFM and 293SFMII (all from Invitrogen), and HyQ SFM4MegaVir (HyClone) may also be used.
[0035] The medium of the present invention can be prepared by adding serum albumin to the above-mentioned medium free of a serum. Although it is not intended to limit the present invention, human serum albumin as a plasma fractionation product (e.g., a human albumin formulation) is preferably used according to the present invention. The final concentration of the added serum albumin is 0.05 to 1%, preferably 0.1 to 0.3%. Some commercially available human serum albumin formulations contain sodium N-acetyl-tryptophan and sodium caprylate as stabilizing agents. They may be contained in the serum-free medium although it is not intended to limit the present invention. The content of sodium N-acetyl-tryptophan is 10 to 200 mg/L, preferably 40 to 50 mg/L. The content of sodium caprylate is 10 to 100 mg/L, preferably 25 to 30 mg/L. Furthermore, interleukin-2, preferably recombinant human interleukin-2, is preferably added to the medium of the present invention. The final concentration of the added interleukin-2 is 10 to 1000 JRU/mL, preferably 50 to 500 JRU/mL. In addition, the medium of the present invention can contain calcium at a concentration of 1.35 to 6.31 mmol/L, preferably 2.70 to 4.51 mmol/L. The above concentrations correspond to 150 to 700 mg/L and 300 to 500 mg/L, respectively, when calcium chloride is used as calcium.
[0036] A purified protein (natural or recombinant) such as transferrin, insulin or epidermal growth factor, oleic acid, progesterone or the like may be added to the medium of the present invention to increase the cell growth and/or the titer of produced virus. If epidermal growth factor is to be added to the medium, the concentration is 2 to 30 mg/L, preferably 5 to 20 mg/L.
[0037] Although there is no specific limitation concerning the virus producer cell to be cultivated using the medium of the present invention, the medium of the present invention is preferably used for cultivating a retrovirus vector producer cell.
[0038] The second aspect of the present invention relates to a method for producing a substance of interest such as a virus vector. In a preferred embodiment of the present invention, a frozen stock (e.g., a MCB or a WCB) of a virus producer cell for producing a recombinant virus vector is thawed using an appropriate means, it is directly inoculated into the serum-free medium of the present invention to initiate cultivation, and it is then possible to allow the cell to grow. For preparation of a recombinant virus vector in large quantities, it is preferable to comprise a step of adapting a virus producer cell to the serum-free medium of the present invention. For example, for adapting a cell that has been cultivated in a medium containing a serum at a concentration of 10% to the serum-free medium, this step is carried out as follows: cultivation is carried out using a serum-free medium to which a serum is added at a concentration of 5%; the cell is passaged 2 to 4 times for adaptation; and adaptation cultivation is similarly carried out using a serum-free medium to which a serum is added at a concentration lowered to 2%. The cell is adapted finally to the serum-free medium by decreasing the serum concentration in a stepwise manner as described above.
[0039] Although there is no specific limitation concerning the virus vector produced according to the present invention, a particularly preferable example is a retrovirus vector or a recombinant retrovirus vector.
[0040] There is no specific limitation concerning the retrovirus vector produced according to the present invention. A replication-defective retrovirus vector with which unlimited infection or gene transfer is prevented is usually used according to the present invention. Examples of known replication-defective retrovirus vectors include retrovirus vectors (e.g., MFG vector, α-SGC vector (WO 92/07943), pBabe (Nucleic Acids Research, 18:3587-3596 (1990)), pLXIN (Clontech) or pDON-AI (Takara Bio)), lentivirus vectors (human immunodeficiency virus (HIV)-derived vectors, simian immunodeficiency virus (SIV)-derived vectors, etc.) and modifications thereof.
[0041] The retrovirus vector may carry an arbitrary foreign gene. Examples of the foreign genes include genes encoding polypeptides (enzymes, growth factors, cytokines, receptors, structural proteins, etc.), antisense RNAs, ribozymes, decoys, and RNAs that cause RNA interference. An appropriate promoter, an enhancer, a terminator or other transcription regulatory elements may be inserted into the vector for controlling the expression of the foreign gene.
[0042] According to the present invention, a retrovirus vector is produced by cultivating, in the medium of the present invention, a retrovirus producer cell which is constructed by transferring a DNA encoding the retrovirus vector into a retrovirus packaging cell line.
[0043] There is no specific limitation concerning the packaging cell line. A known packaging cell line such as PG13 (ATCC CRL-10686), PA317 (ATCC CRL-9078), GP+E-86 or GP+envAm-12 (U.S. Pat. No. 5,278,056) or Psi-Crip (Proc. Natl. Acad. Sci. USA, 85:6460-6464 (1988)) can be used. Alternatively, a retrovirus producer cell can be constructed by transferring a packaging plasmid carrying genes necessary for production of retrovirus particles (Retrovirus Packaging Kit (Takara Bio), etc.) into 293 cell or 293T cell of which the transfection efficiency is high.
[0044] A retrovirus producer cell can be cultivated under normal cultivated conditions. For example, cultivation may be carried out with humidity of 95% and CO 2 concentration of 5% although it is not intended to limit the present invention. For example, cultivation can be carried out at a temperature of 30 to 37° C. The cell may be cultivated at a temperature out of this range provided that the desired cell growth and retrovirus vector production can be achieved. According to the present invention, a retrovirus is produced by collecting a supernatant from the thus obtained culture. A retrovirus vector may be prepared as the supernatant as it is, a filtrate obtained by filtrating the supernatant through a filter, or a retrovirus vector obtained by concentrating or purifying the supernatant according to a known method. It is stored until use using an appropriate means (e.g., freezing). A retrovirus vector at a higher titer than a conventional one can be obtained by cultivating a retrovirus producer cell using the medium of the present invention as described above.
EXAMPLES
[0045] The following Examples illustrate the present invention in more detail, but are not to be construed to limit the scope thereof.
Example 1: Preparation of Medium
[0046] A medium A was prepared by adding 8 mL of 25% human serum albumin (Buminate 25%, Baxter) which contained 2 g of human serum albumin, 42.92 mg of sodium N-acetyl-tryptophan, and 26.6 mg of sodium caprylate to 1 L of a commercially available medium GT-T503 (Takara Bio). A medium B was prepared by further adding interleukin-2 (Proleukin, Chiron) at a final concentration of 175 JRU/mL to the medium A.
Example 2
[0047] 1. Cultivation of retrovirus producer cell
[0048] A working cell bank (WCB) of a mouse retrovirus producer cell expressing a gene for human low-affinity nerve growth factor receptor lacking its intracellular domain (ΔLNGFR) constructed using GP+envAm-12 as a packaging cell was thawed in a water bath at 37° C. The thawed cell suspension was transferred into a 15-mL centrifuge tube. 10 mL of a complete medium (DMEM medium (Cambrex) containing 10% fetal calf serum (JRH)) was further added thereto. The mixture was centrifuged at 500×g for 5 minutes at 20° C. After centrifugation, a supernatant was removed, the cells were suspended in the complete medium (DMEM medium containing 10% fetal calf serum), and the cells were counted. After counting, 1×10 6 of the cells were dispensed into each of 15-mL centrifuge tubes. The tubes were centrifuged at 500×g for 5 minutes at 20° C. After centrifugation, a supernatant was removed. The cells were then suspended in the medium A, and cultivated using T25 cell culture flasks (CELLBIND, Corning) in a CO 2 incubator (temperature: 37° C.; humidity: 95%; CO 2 concentration: 5%). Cultivation using the complete medium was carried out as a control for comparison. For both the complete medium and the medium A, cells were passaged at intervals of three days by seeding at a cell density of 2×10 4 /cm 2 . The cells were passaged three times under the conditions.
[0049] 2. Collection of retrovirus supernatant
[0050] The cells were cultivated for three days after the third passage, and passaged for retrovirus collection in a similar manner. The cells were seeded at a cell density of 4×10 4 /cm 2 . Cultivation was carried out from day 0 to day 1 in a CO 2 incubator (temperature: 37° C.; humidity: 95%; CO 2 concentration: 5%). On day 1, the complete medium or the medium A was removed, and exchanged for a fresh medium. The volume was adjusted to 0.1 mL/cm 2 for virus collection. Cultivation was carried out while lowering the temperature of the CO 2 incubator to 33° C. On day 2, a supernatant was collected from each culture flask. The flask was supplemented with the complete medium or the medium A, and cultivation was carried out. The collection was carried out for successive three days. The collected culture supernatants (Day 1, Day 2 and Day 3) were filtrated through filters with a pore size of 0.22 μm (Millipore) to obtain retrovirus supernatants, which were divided into aliquots and stored at −80° C.
[0051] 3. Assessment of retrovirus supernatant for gene transfer
[0052] Gene transfer efficiency was measured using the retrovirus supernatants obtained by cultivation and collection using the complete medium or the medium A as described above. The undiluted supernatants, 4-fold dilutions and 8-fold dilutions were prepared for the respective retrovirus supernatants collected using the complete medium or the medium A. Protamine (Mochida Pharmaceutical) was further added at a final concentration of 4 μg/mL, respectively. The complete medium or the medium A was used for dilution. 0.5×10 6 cells of human leukemia cell CEM were added to and suspended in 500 μL of the dilution. The suspension was transferred into a 24-well cell culture plate (Asahi Techno Glass). The 24-well cell culture plate was centrifuged at 32° C. at 1000×g for 2 hours. After centrifugation, a supernatant was removed from each well, and a medium for CEM (RPMI1640 medium containing 10% serum, Cambrex) was added to each well. After suspending, the cells were cultivated in a CO 2 incubator (temperature: 37° C.; humidity: 95%; CO 2 concentration: 5%) for three days. After cultivation, the efficiency of gene transfer with the retrovirus was determined by examining the expression of the gene for human low-affinity nerve growth factor receptor (ΔLNGFR) as a marker gene of the retrovirus vector using a fluorescently labeled antibody that recognizes LNGFR. After infection and cultivation, 0.5×10 6 of the cells were transferred into an Eppendorf tube, and precipitated by centrifugation at 4° C. at 500×g for 5 minutes. After removing a supernatant, 100 μL of PBS solution containing 0.5 μg of a monoclonal antibody that recognizes ΔLNGFR (Chemicon) as a primary antibody was added to the precipitated cells. The suspension was allowed to stand on ice for 20 minutes. A sample was prepared using mouse IgG (Becton-Dickinson) as an isotype control for determining nonspecific binding (background). Then, 900 μL of a pre-chilled phosphate buffer solution (PBS, Gibco) was added thereto, and the cells were precipitated by centrifugation at 4° C. at 500×g for 5 minutes. After removing a supernatant, 100 μL of phycoerythrin (PE)-labeled anti-mouse IgG antibody (Dako) as a secondary antibody that recognizes the primary antibody was added to the precipitated cells. The suspension was allowed to stand on ice for 20 minutes. Then, 900 μL of a pre-chilled phosphate buffer solution (PBS, Gibco) was added thereto, and the cells were precipitated by centrifugation at 4° C. at 500×g for 5 minutes. After removing a supernatant, a 3% formaldehyde solution was added to the precipitated cells for fixation. After fixation, flow cytometry analysis (FCM) was carried out.
[0053] The flow cytometry analysis was carried out using FACS Caliber (Becton-Dickinson) according to the instructions attached to the instrument. The ratio of ΔLNGFR expression was determined as follows: a region of fluorescence intensity for cells not expressing ΔLNGFR in the histogram of PE detection parameters (x axis: intensity of fluorescence from PE; y axis: cell number) was confirmed using the isotype control; a region of fluorescence intensity for cells expressing ΔLNGFR without the above region was determined; and the ratio (%) was determined. After the determination, the transfer efficiency (GT (%) Gene Transduction efficiency) was calculated according to the following equation:
[0054] GT(%)=measured value for each sample—measured value for isotype control (background)
[0055] The results of gene transfer efficiency measurements are shown in FIG. 1 .
[0056] As shown in FIG. 1 , the gene transfer efficiency observed using the retrovirus supernatant collected on each day after cultivation using the medium A was equivalent to or higher than the gene transfer efficiency with the complete medium. Thus, it was shown that a virus at a higher titer than that obtained using the complete medium was obtained. These results show that passaging and virus collection can be sufficiently carried out by cultivation from a working cell bank without adaptation.
Example 3
[0057] 1. Preparation of retrovirus vector
[0058] A retrovirus vector plasmid pDOG-polII was constructed as follows. First, an rsGFP expression vector pQBI25 (Qbiogene Inc.) was cleaved with restriction enzymes NheI and NotI to obtain a 775-bp GFP gene fragment. Next, pQBI polII (Qbiogene Inc.) was cleaved with restriction enzymes NheI and NotI to remove an rsGFP-NeoR fusion gene. The previously obtained 775-bp rsGFP gene fragment was inserted thereinto to obtain a vector pQBI polII(neo-) in which the rsGFP gene is expressed under the control of polII promoter. pQBI polII(neo-) was digested with a restriction enzyme XhoI to obtain a DNA fragment containing a GFP expression unit under the control of polII promoter. The termini were blunted using DNA blunting kit (Takara Bio). Termini of a 4.58-kbp vector fragment obtained by digesting a retrovirus vector plasmid pDON-AI (Takara Bio) with restriction enzymes XhoI and SphI were blunted using DNA blunting kit (Takara Bio), and then dephosphorylated using alkaline phosphatase (Takara Bio). The previously blunted DNA fragment containing the rsGFP expression unit under the control of polII promoter was inserted into this blunted vector using DNA Ligation Kit (Takara Bio) to obtain an rsGFP expression recombinant retrovirus vector pDOG-polII.
[0059] Transient virus production was carried out using the vector pDOG-polII and Retrovirus Packaging Kit Eco (Takara Bio) to obtain an ecotropic virus DOG-polII. The thus obtained ecotropic virus DOG-polII was used to infect a GaLV retrovirus packaging cell PG13 (ATCC CRL-10686) in the presence of RetroNectin (Takara Bio) to obtain a gene-transferred cell PG13/DOG-polII.
[0060] 2. Assessment of retrovirus vector productivity
[0061] PG13/DOG-polII cell was cultivated using the medium A or the complete medium according to the method as described in Example 2 to prepare a retrovirus supernatant. The thus obtained retrovirus supernatant was used to carry out gene transfer into human fibrosarcoma cell HT1080.
[0062] The undiluted supernatants, 4-fold dilutions, 20-fold dilutions and 100-fold dilutions were prepared for the retrovirus supernatants collected using the complete medium or the medium A on day 3. Protamine (Mochida Pharmaceutical) was further added at a final concentration of 4 μg/mL. The complete medium or the medium A was used for dilution. After removing the culture, 1 mL of the dilution was added 1×10 5 cells of human fibrosarcoma cell HT1080 which had been inoculated on the day before the infection. The cells were allowed to stand in a CO 2 incubator (temperature: 37° C.; humidity: 95%; CO 2 concentration:. 5%) for six hours. A sample was prepared by adding only the medium as a negative control. Then, a virus supernatant was removed from each well, a medium for HT1080 cell (DMEM medium containing 10% serum) was added thereto, and the cells were cultivated for three days.
[0063] After cultivation, intracellular rsGFP expression was measured by flow cytometry (FCM) in order to determine the efficiency of gene transfer with the retrovirus. The flow cytometry analysis was carried out using FACS Caliber according to the instructions attached to the instrument. The ratio of rsGFP expression was determined as follows: a region of fluorescence intensity for cells not expressing rsGFP in the histogram of FITC detection parameters (x axis: intensity of fluorescence from rsGFP; y axis: cell number) was confirmed using the negative control; a region of fluorescence intensity for cells expressing rsGFP without the above region was determined; and the ratio (%) was determined. After the determination, the transfer efficiency was calculated according to the following equation:
[0064] GT(%)=measured value for each sample—measured value for negative control (background)
[0065] The results of gene transfer efficiency measurements are shown in FIG. 2 .
[0066] As shown in FIG. 2 , also using the gibbon ape retrovirus producer cell, the gene transfer efficiency observed for the retrovirus supernatant collected from the culture obtained using the medium A was comparable to that with the complete medium. These results show that passaging and virus collection can be sufficiently carried out by cultivation directly in a serum-free medium from a working cell bank without adaptation.
Example 4
[0067] A virus supernatant was prepared using a mouse retrovirus producer cell expressing a gene for ΔLNGFR according to the method as described in Example 2. The medium A or a medium B which was prepared by adding IL-2 to the medium A at a concentration of 600 JRU/mL was used. Cultivation was carried out as described in Example 2-1 except that the cells were passaged five times. Virus collection was carried out as described in Example 2-2 except that the cells were seeded at a cell density of 6×10 4 /cm 2 . For assessment of gene transfer efficiency, in addition to CEM cells, human peripheral blood mononuclear cells (PBMCs) were subjected to gene transfer and FACS measurement in a similar manner.
[0068] The results of cell growth ratios are shown in Table 1. For both of the medium A and the medium B, the growth ratios in P0 (passage 0, and so on) and P1 were about 3-fold probably because the cells were gradually adapting. The growth ratios were 5-fold or more during and after P3. Among the media, a better growth ratio of 7469-fold (P0-P5) was observed using the medium B which contained IL-2 as compared with the growth ratio of 5228-fold (P0-P5) with the medium A.
TABLE 1 Cell growth ratio Medium P0 P1 P2 P3 P4 P5 P0-P5 A 2.69 3.28 4.18 5.24 4.68 5.78 5228 B 2.75 3.28 4.96 4.64 6.84 5.26 7469
[0069] The results of gene transfer efficiency using the undiluted retrovirus supernatants are shown in FIGS. 3 and 4 . Equivalent gene transfer efficiency was observed using the medium A and the medium B upon both the gene transfer into CEM cells ( FIG. 3 ) and the gene transfer into human PBMCs ( FIG. 4 ).
Example 5: Comparison with Commercially Available Serum-free Media
[0070] The medium A of the present invention was compared with various commercially available serum-free media using a mouse retrovirus producer cell expressing a gene for ΔLNGFR according to the method as described in Example 2. Cultivation was carried out in two ways, i.e., direct adaptation and indirect adaptation.
[0071] (1) Direct adaptation: A working cell bank was passaged twice in the complete medium. The medium was then exchanged directly for the medium A or a commercially available serum-free medium. The cells were passaged four times.
[0072] (2) Indirect adaptation: A working cell bank was passaged twice in the complete medium. Adaptation cultivation was carried out while lowering the fetal calf serum concentration in a stepwise manner (the fetal calf serum concentration: 6.6%→3.3%→1.5%→0%).
[0073] The following four media were used:
[0074] 1. The medium A
[0075] 2. AIM-V (Invitrogen)
[0076] 3. HyQ SFM4MegaVir (HyClone)
[0077] 4. Opti-ProSFM (Invitrogen)
[0078] The recommended amounts of glutamine were added to the media 3 and 4.
[0079] Virus collection was carried out as described in Example 2-2. Gene transfer was carried out using CEM cells. Gene transfer efficiency was assessed as described in Example 2-3.
[0080] (1) According to the direct adaptation, the cells could be passaged four times only using the medium A or Opti-ProSFM. In particular, the growth during the fourth passage with the medium A was superior. The cells could not be cultivated in other commercially available serum-free media. The cultivation with the medium AIM-V or the medium HyQ SFM4MegaVir was terminated during the second passage.
[0081] (2) According to the indirect adaptation, the fetal calf serum concentrations could be lowered to 0% with the medium A or Opti-ProSFM. The fetal calf serum concentration could be lowered only to 1.5% with the medium AIM-V and to 6.6% with the medium HyQ SFM4MegaVir. Thus, cultivation under serum-free conditions could not be accomplished.
[0082] Next, gene transfer efficiency was assessed for the cases of the medium A and Opti-ProSFM with which virus collection could be carried out according to the indirect adaptation. The results are shown in Table 2. The gene transfer efficiency observed with the medium A was about 2-fold higher than that observed with Opti-ProSFM.
[0083] Based on these results, it was confirmed that the medium A of the present invention is superior in respect of cultivation of a retrovirus producer cell to commercially available serum-free media, and retrovirus production can carried out clearly with high efficiency.
TABLE 2 Gene transfer efficiency (GT (%)) 4-fold 16-fold Undiluted dilution dilution Medium A 50.82% 12.25% 1.92% Opti-ProSFM 31.53% 6.62% 1.1%
Example 6: Improvement in Cell Growth due to Addition of Serum Albumin
[0084] Cell cultivation was carried out using a mouse retrovirus producer cell expressing a gene for ΔLNGFR according to the method as described in Example 2. After cell cultivation was initiated using the medium A, cells were cultivated from the first passage using the medium A or a commercially available medium GT-T503 (Takara Bio). The cells were passaged once more using the same medium, and the cell growth ratios were compared with each other.
[0085] The results of cell growth ratios are shown in Table 3. The cell growth ratio observed using the medium A which contained human serum albumin was about 2-fold higher than that observed using the medium GT-T503. The conditions of the cells in the medium GT-T503 were not well because many cells were aggregated or detached.
TABLE 3 Cell growth ratio 1st to 2nd 2nd to 3rd passage passage Medium A 4.18 5.24 Medium GT-T503 2.5 2.14
Example 7: Assessment of Effect of Serum Albumin added to Commercially Available Serum-free Medium
[0086] A virus supernatant was prepared using a mouse retrovirus producer cell expressing a gene for ΔLNGFR according to the method as described in Example 2. A commercially available serum-free medium Opti-ProSFM (Invitrogen) and a medium prepared by adding 25% human serum albumin (Buminate 25% (HSA), Baxter) to result in a final concentration of 0.2% by weight to Opti-ProSFM were used in this Example. The recommended amount of glutamine was added to Opti-ProSFM.
[0087] Cultivation was carried out as described in Example 2-1 except that the cells were passaged five times. Virus collection was carried out as described in Example 2-2. Collection on day 4 was carried out also as described in Example 2-2.
[0088] Gene transfer was carried out using CEM cells. Gene transfer efficiency was assessed as described in Example 2-3.
[0089] The results of gene transfer efficiency observed with 4-fold dilutions of the retrovirus supernatants are shown in FIG. 5 .
[0090] As shown in FIG. 5 , the virus titer was increased by the addition of human serum albumin (HSA).
Example 8: Examination of Calcium Concentration in Medium
[0091] A virus supernatant was prepared using a mouse retrovirus producer cell expressing a gene for ΔLNGFR according to the method as described in Example 2. A medium I in which transferrin was eliminated from the medium A, as well as a medium II and a medium III in which the calcium concentration in the medium I was adjusted from 165 mg/L (the original concentration) to 330 mg/L and 495 mg/L, respectively, by adding calcium chloride according to Pharmacopeia of Japan were used in this Example. Cultivation was carried out as described in Example 2-1 except that the cells were passaged five times. Virus collection was carried out as described in Example 2-2. Gene transfer was carried out using CEM cells. Gene transfer efficiency was assessed as described in Example 2-3.
[0092] FIG. 6 is a photograph that shows the morphologies of the cells on Day 3 of virus collection. The results of gene transfer efficiency are shown in FIG. 7 . In the preliminary test, equivalent gene transfer efficiency was observed using the medium I and a medium in which the calcium concentration in the medium I was adjusted to 640 mg/L. By increasing the calcium concentration from 165 mg/L (the original concentration) to 330 or 495 mg/L, the number of aggregated or detached cells of the mouse retrovirus producer cell expressing a gene for ΔLNGFR was reduced ( FIG. 6 ) and virus collection could be carried out for three successive days. The virus titers reflected the conditions of the cells. That is, the collected virus tended to decrease (Day 1>Day2>Day3 of virus collection) using the medium I, while the collected virus tended to increase using the medium II and the medium III ( FIG. 7 ). Thus, the successive collection which is necessary for retrovirus collection could be carried out by increasing the calcium concentration. Furthermore, the reduction in cells detached in the virus supernatant eliminated clogging upon subsequent filtration and facilitated the procedure.
Example 9: Assessment of Effect of Added Epidermal Growth Factor
[0093] A virus supernatant was prepared using a mouse retrovirus producer cell expressing a gene for ΔLNGFR according to the method as described in Example 2. The medium I in which transferrin was eliminated from the medium A and a medium IV prepared by adding epidermal growth factor (Wako Pure Chemical Industries) to the medium I at a final concentration of 10 mg/L were used in this Example. Cultivation was carried out as described in Example 2-1 except that the cells were passaged five times. Virus collection was carried out as described in Example 2-2. Gene transfer was carried out using CEM cells. Gene transfer efficiency was assessed as described in Example 2-3.
[0094] The results of gene transfer efficiency are shown in FIG. 8 .
[0095] As shown in FIG. 8 , the virus titer was increased by the addition of epidermal growth factor.
Example 10: Assessment of Synergistic Effect of Modified Calcium Concentration and Added Epidermal Growth Factor
[0096] A virus supernatant was prepared using a mouse retrovirus producer cell expressing a gene for ΔLNGFR according to the method as described in Example 2. The medium A and a medium V in which the calcium concentration in the medium A was adjusted from 165 mg/L (the original concentration) to 330 mg/L by adding calcium chloride according to Pharmacopeia of Japan and to which epidermal growth factor was added at a final concentration of 10 mg/L were used in this Example. Cultivation was carried out as described in Example 2-1 except that the cells were passaged five times. Virus collection was carried out as described in Example 2-2. Gene transfer was carried out using CEM cells. Gene transfer efficiency was assessed as described in Example 2-3.
[0097] The results of gene transfer efficiency are shown in FIG. 9 . The virus titer was increased by 3-fold by modifying the calcium concentration from 165 mg/L (the original concentration) to 330 mg/L and adding epidermal growth factor. Furthermore, the successive collection which is necessary for retrovirus collection could be carried out. In addition, the reduction in cells detached in the virus supernatant eliminated clogging upon subsequent filtration and facilitated the procedure.
[0098] The present invention provides a serum-free medium that is suitable for cultivation of a virus producer cell. Using the medium of the present invention, a virus producer cell can be efficiently cultivated under serum-free conditions, and a virus vector free of a serum can be produced with a procedure more convenient than a conventional one. | A method for obtaining a virus vector free of a serum, and a serum-free medium for cultivation of a virus producer cell which can be used for the method are provided. By cultivating a virus producer cell using a serum-free medium containing serum albumin, it is possible to cultivate the cell in a state equivalent to that in a serum-containing medium to produce a virus vector at a sufficient titer. The virus vector prepared from the virus producer cell cultivated in the medium exhibits gene. transfer efficiency comparable to that of a conventional vector. The medium is useful for gene therapy and studies thereof. | 2 |
FIELD OF THE INVENTION
This application is directed to a means for delivering pharmaceuticals, nutraceuticals and the like to a mammal and more specifically, the control of the water activity of a food product matrix for use in the incorporation of a pharmaceutical, nutraceutical or other bioactive compound into the matrix.
BACKGROUND OF THE INVENTION
Pharmaceutical and nutraceutical products intended for oral administration are typically provided in tablet, capsule, pill, lozenges and caplet form. These products are swallowed whole or chewed in the mouth for delivery of the active ingredient into the alimentary system of a body. Such oral delivery systems are sometimes made chewable to ease drug administration in pediatric and geriatric patients. Such concerns with ease of administration may be amplified when dealing with pets and other animals.
As a result, several approaches have been utilized in formulating oral delivery systems, including gums and candy bases. The use of such delivery systems is limited by the reaction of the active ingredient, whether it be pharmaceutical, nutraceutical or other ingredients, to the existence of water in the system.
SUMMARY OF THE INVENTION
Therefore, an object of the subject invention is a method of controlling water activity in an oral delivery system and the product thereof.
These and other objects are attained by the subject invention wherein there is provided a carrier or product formed of a matrix having starch, sugar, fat, polyhydric alcohol and water in suitable ratios such that there exists a water activity of 0.6-0.75. The water activity of the product matrix is adjusted up or down so that the availability of water in the finished product is not detrimental to the included active ingredient, be it pharmaceutical, nutraceutical, or vitamin mineral complex.
A further object of the subject invention is a oral delivery system for pharmaceuticals, nutraceuticals or other active ingredient which matches the water activity of the carrier to the included active ingredient.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
By the subject invention, a soft chewable oral delivery system is provided. The dosage form may be in tablet form and may contain one or more active ingredients. The active ingredients are incorporated into the system which is described in further detail below and which includes a starch component, a fat or oil, a sugar component, a polyhydric alcohol, water and other minor ingredients. Into this mixture is placed the active ingredient. After mixing and extruding these ingredients, the extrudate is formed into the appropriate shape. The relative proportions of the mixture are as follows.
Starch
10-50%
Fat or Oil
0-40%
Sugar
5-25%
Polyhydric Alcohol
10-50%
Water
5-20%
Salt (NaCl)
1-5%
Active Ingredient
0.1-5%
Generally speaking, the starch component of the matrix comprises 10 to 50 percent by weight of the matrix. More particularly, the starch component of the matrix comprises 15 to 40 percent by weight of the matrix.
While starch for use in the matrix can be of any suitable type, it is most preferred that at least part of the starch in the matrix be a highly derivatized or pregelatinized starch. If a highly derivatized starch is present in the matrix, it should be present in an amount of about ½ percent by weight of the total starch and the balance of the starch being non-derivatized. More preferably, about 20-40 percent by weight of the total matrix and about 45% of the total starch should be the derivatized starch. An example of a preferred pregelatinized starch is A. E. Staley's NU-COL 4227 or SOFT-SET.
Other amylaceous ingredients may be used in combination with the derivatized starch or alone, provided the starch limits are not exceeded. The amylaceous ingredients can be gelatinized or cooked before or during the forming step to achieve the desired matrix characteristics. If gelatinized starch is used, it may be possible to prepare the product of the subject invention or perform the method of the subject invention without heating or cooking of any sort. However, if ungelatinized (ungelled) or uncooked starch is used, the matrix must be cooked sufficiently to gel or cook the starch to reach the desired content.
Starches that can serve as a base starch for derivatization include regular corn, waxy corn, potato, tapioca, rice, etc. Such types of derivatizing agents for the starch include but are not limited to ethylene oxide, propylene oxide, acetic anhydride, and succinic anhydride, and other food approved esters or ethers, introducing such chemicals alone or in combination with one another. Prior crosslinking of the starch may or may not be necessary based on the pH of the system and the temperature used to form the product.
By “amylaceous ingredients” is meant those food-stuffs containing a preponderance of starch and/or starch-like material. Examples of amylaceous ingredients are cereal grains and meals or flours obtained upon grinding cereal grains such as corn, oats, wheat, milo, barley, rice, and the various milling by-products of these cereal grains such as wheat feed flour, wheat middlings, mixed feed, wheat shorts, wheat red dog, oat groats, hominy feed, and other such material. Also included as sources of amylaceous ingredients are the tuberous food stuffs such as potatoes, tapioca, and the like.
Another component of the matrix is a fat component such as fat or oil of animal or vegetable origin. Typical animal fats or oils are fish oil, chicken fat, tallow, choice white grease, prime steam lard and mixtures thereof. Other animal fats are also suitable for use in the matrix. Vegetable fats or oils are derived from corn, soy, cottonseed, peanut, flax, rapeseed, sunflower, other oil bearing vegetable seeds, and mixtures thereof. Additionally, a mixture of animal or vegetable oils or fats is suitable for use in the matrix. The fat component of the matrix is about 0 to about 40% by weight of the matrix. More specifically, the fat component of the matrix is about 20 percent by weight of the matrix.
The polyhydric alcohol component of the matrix can be selected from glycerol, sorbitol, propylene glycol, 1.3-butanediol, and mixtures thereof with each other and other polyhydric alcohols. Generally the polyhydric alcohol comprises about 10 to about 50 percent by weight of the matrix. More specifically, the polyhydric alcohol comprises about 20 to about 40 percent by weight of the matrix.
The sugar component can be employed in a dry or crystalline condition or can be an aqueous syrup having a sugar concentration of from 50 to about 95, preferably from 70 to about 80, weight percent. The sugar used can be lactose, sucrose, fructose, glucose, or maltose, depending on the particular application and price or availability of a particular sugar. Examples of various well established sources of these sugars are, corn syrup solids, malt syrup, hydrolyzed corn starch, hydrol (syrup from glucose manufacturing operations), raw and refined cane and beet sugars, etc.
Water must be present in the matrix at least about 5 percent by weight of the matrix. More specifically, water is present in the matrix about 5 percent to about 20 percent by weight of the matrix. The matrix thus formed usually has a water activity of 0.60 to 0.75.
While water must be at least 5 percent by weight of the matrix, when the matrix is used in a food product, the moisture of the food product must be adjusted. Generally the moisture content of the matrix is such to give a moisture content of 5-15 percent to the final soft dry food product. More preferred is a moisture content of 5 percent to 14 percent. Most preferred is a moisture content of 8 percent to 13 percent. The desired moisture content may be achieved in any suitable fashion. Normal processing may produce the moisture content desired. A standard drying step is optional and may be used if necessary.
The active ingredient may be any drug, nutrition agent, or the like which can be orally administered. Exemplary of such active ingredients are the following: nutraceuticals, such as chromium picolinate, potassium gluconate and methionine amino acid; prescription drugs, such as ivermectin, fenbendazole, piperazine, magnesium hydroxide, stranozole, furosemide, penicillin, amoxicillin, prednisolone, methylprednisolone, acepromazine; and, other pharmaceutical products, such as aspirin, prozac, zantac, and benedryl. Minor amounts of flavorants, colorants, glycerin, flavor enhancers, sweeteners, emulsifiers, antibitterness agents, taste masking agents, stabilizers, preservatives, or combinations thereof may be added.
To form the matrix, the starch system, fat, polyhydric alcohol, corn syrup and water are mixed with a screw extruder, permitting addition of ingredients and variable heating at different points along the barrel. Other mixing apparatus, such as a sigma mixer, swept wall heat exchanger or the like may be used. If a coloration is desired in the final product, cooked or pregelled starches are used to form the matrix. The use of these starches avoids high cooking temperatures which would destroy the desired coloration and/or active ingredient. If coloration active temperature sensitivity is not a problem, it is possible to use an uncooked or ungelatinized starch to form the matrix and cook or gel the starch as the process is carried out. The incorporation of a derivatized starch in the product more clearly guarantees the softness of the product for a longer period of time. Softness is also provided by the fats and oils. In this fashion a suitable matrix is provided for use with a wide variety of active ingredients.
Having fully described the invention, the following examples are presented to illustrate the invention without limitation thereof. In these examples all parts percentages are by weight unless otherwise specified.
EXAMPLE 1
Carrier
INGREDIENT
PARTS
Regular Corn Starch (Purefood GMI)
18.0
Pregel Starch (SOFT SET)
15.0
Corn Syrup (Star Dri Corn Syrup Solids)
15.0
Corn Oil
20.0
Sorbitol
20.0
H 2 O
10.0
Salt
2.0
TOTAL
100.0
The above ingredients are mixed at temperatures of about 125° F., extruded and cut into a suitable tablet size. This product has an oily, bubbly appearance suggesting cutting back on the oil content. Temperature was also adjusted during each of the following examples to eliminate puffing of the product as it exits the extruder.
EXAMPLE 2
Guaifenesin
INGREDIENT
PARTS
Regular Corn Starch (Purefood GMI)
17.9
Pregel Starch (SOFT SET)
15.0
Corn Syrup (Star Dri Corn Syrup Solids)
15.0
Sorbitol
39.3
H 2 O
10.0
Salt
2.0
Guaifenesin*
0.8
TOTAL
100.0
*Available from Arrow Chemical Co., N.J.
EXAMPLE 3
Vitamins
INGREDIENT
PARTS
Regular Corn Starch (Purefood GMI)
17.9
Pregel Starch (SOFT SET)
15.0
Corn Syrup (Star Dri Corn Syrup Solids)
15.0
Sorbitol
35.1
H 2 O
10.0
Salt
2.0
Vitamin and Mineral Mix*
5.0
TOTAL
100.0
*Commercially available mixture available from Archer Daniels Midland.
EXAMPLE 4
Flax
INGREDIENT
PARTS
Regular Corn Starch (Purefood GMI)
17.9
Pregel Starch (SOFT SET)
15.0
Corn Syrup (Star Dri Corn Syrup Solids)
15.0
Sorbitol
35.1
H 2 O
10.0
Salt
2.0
Flax*
5.0
TOTAL
100.0
*Available from Enreco Flax.
EXAMPLE 5
Acetaminophen
INGREDIENT
PERCENT
Regular Corn Starch (Purefood GMI)
17.9
Pregel Starch (SOFT SET)
15.0
Corn Syrup (Star Dri Corn Syrup Solids)
15.0
Sorbitol
39.1
H 2 O
10.0
Salt
2.0
Acetaminophen*
0.8
Red Coloring #40
0.1
Flavoring (Cherry)
0.1
TOTAL
100.0
*Available from Mallincrodt as Compap
EXAMPLE 6
Carrier
INGREDIENT
PARTS
Regular Corn Starch (Purefood GMI)
17.9
Pregel Starch (SOFT SET)
15.0
Corn Syrup (Star Dri Corn Syrup Solids)
15.0
Sorbitol
40.1
H 2 O
10.0
Salt
2.0
TOTAL
100.0
TABLE 1
Example
Active
Oil/Sugar
A w
Extrusion Temp.
1
Premix
Corn Oil/Sorbitol
N/A
125
2
Guaifenesin
100% Sorbitol
0.656
115
3
Vitamin Mix
100% Sorbitol
0.651
115
4
Flax
100% Sorbitol
0.673
115
5
Acetaminophen
100% Sorbitol
0.666
115
6
Premix
100% Sorbitol
0.61
115
By the above examples and Table 1 it is apparent that an oral delivery system for the administration for pharmaceuticals, nutraceuticals, vitamins and minerals and other active ingredients may be provided in a chewable form by the subject invention. If the active ingredient is water sensitive such as aspirin, then the amount of polyhydric alcohol is increased, the water activity is depressed to about 0.65 and the stability and texture of the resultant product is maintained. If the active ingredient requires or can tolerate the presence of free water for its activity, such as in the case of Guaifenesin, the amount of polyhydric alcohol may be decreased, while maintaining the level of such polyhydric alcohol such that a soft texture of the resulting tablet is maintained. In the case of Guaifenesin, then an A w of 0.70 may be utilized and a softer, more chewable texture achieved. An effective oral delivery system in which the texture and stability of the product and activity of the active ingredient is controllable, is the result.
While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments and equivalents falling within the scope of the appended claims.
Various features of the invention are set forth in the following claims. | The subject invention is a carrier or product formed of a matrix having starch, sugar, fat, polyhydric alcohol and water in suitable ratios such that there exists a water activity of 0.6-0.75. The water activity of the product matrix may be adjusted up or down so that the availability of water in the finished product is not detrimental to the included active ingredient, be it pharmaceutical, nutraceutical, or a vitamin mineral complex. | 0 |
CROSS REFERENCE TO RELATED APPLICATION
The present application is based on and claims the benefit of priority of Japanese Patent Application No. 2008-54958, filed on Mar. 5, 2008, the disclosure of which is incorporated herein by reference.
FIELD OF THE INVENTION
The present disclosure generally relates to a navigation apparatus for use in a vehicle.
BACKGROUND INFORMATION
Conventionally, a navigation apparatus such as the one disclosed in Japanese patent document JP-A-H07-91974 allows the user to “draw” or “trace” a desired navigation route from the current position to the destination on a displayed map on the screen, when the map is displayed on a touch-sensitive display screen. The traced roads on the displayed map are then recognized by the navigation apparatus as a navigation route, thereby enabling the user to specify a complicated route as a user-desired navigation route.
However, the above navigation apparatus forces the user to draw the desired navigation route from the scratch if the recognized route derived from the first route setting turns out to be different from a user-intended route. That is, in other words, even when the user desires to change just a portion of the recognized route, the entire route from the start point to the destination has to be re-drawn on the displayed map, in a manner that is similar to the first route setting for drawing the intended route. Thus, re-routing and partially modifying the recognized route are not easy for the user of the navigation apparatus.
SUMMARY OF THE INVENTION
In view of the above and other problems, the present disclosure provides a navigation apparatus that allows a user to easily modify a navigation route for use in a vehicle.
In an aspect of the present disclosure, the vehicle navigation apparatus having a storage unit for storing map information and displaying a travel route from a current position to a destination based on the map information includes: a display unit for displaying a map and the travel route based on the map information; a set unit for setting an edit start point and an edit end point respectively to one of edit points on the travel route according to a user operation; a move unit for moving, according to the user operation, a reference point selectively set to one of the edit points on the travel route being displayed on the display unit, on the map being displayed on the display unit; and a revision unit for revising the travel route that is defined by the edit start point and the edit end point, based on a position of the reference point having been moved by the move unit on the map, the edit start point and the edit end point respectively set by the set unit, a move direction of the movement of the reference point, and the map information.
The navigation apparatus of the present disclosure thus allows the user to modify a line of the already-set travel route in an easy and novel manner, based on the position of the reference point on the map, the edit start/end points, the reference point move direction, and the map information.
BRIEF DESCRIPTION OF THE DRAWINGS
Objects, features, and advantages of the present disclosure will become more apparent from the following detailed description made with reference to the accompanying drawings, in which:
FIG. 1 is a block diagram of a navigation apparatus in an embodiment of the present disclosure;
FIG. 2 is an illustration of a start point and a destination displayed on a screen of the navigation apparatus;
FIG. 3 is an illustration of a travel route displayed on the screen of the navigation apparatus;
FIG. 4 is another illustration of the travel route displayed on the screen of the navigation apparatus;
FIG. 5 is yet another illustration of the travel route displayed on the screen of the navigation apparatus;
FIG. 6 is still yet another illustration of the travel route displayed on the screen of the navigation apparatus;
FIGS. 7A and 7B are illustrations of the travel route displayed on the screen of the navigation apparatus;
FIG. 8 is a flow chart of route edit control processing in a first embodiment of the present disclosure;
FIGS. 9A to 9C are illustrations of the travel, route displayed on the screen of the navigation apparatus; and
FIG. 10 is a flow chart of route editing processing in a second embodiment of the present disclosure.
DETAILED DESCRIPTION
The vehicle navigation apparatus according to an embodiment of the present disclosure is described as follows with reference to the drawing.
(First Embodiment)
1. Explanation of the Drawing
FIG. 1 is an outline of the navigation apparatus according to the present embodiment, and FIGS. 2 to FIG. 7 are examples of a travel route displayed on a display unit 10 , and FIG. 8 is a flow chart of route edit control processing.
2. Outline of the Navigation Apparatus of the Present Embodiment
The navigation apparatus of the present embodiment includes a position detector 1 , a map data input unit 6 , an operation unit 7 , a memory 9 , the display unit 10 , a transceiver 11 , a voice controller 12 , a speaker 13 , a voice recognizer 14 , a microphone 15 , a remote controller sensor 16 , a remote control terminal (Hereafter, it is called as a remote-controller) 17 , and a control unit 8 having all these parts connected thereto.
The control unit 8 is a device for controlling the above identified parts. That is, the control unit 8 is a well-known type computer having a CPU, a ROM, a RAM, an I/O, and a bus line for interconnecting these components.
The control unit 8 receives information inputs from the position detector 1 , the map data input unit 6 , the operation unit 7 , the memory 9 , the display unit 10 , the transceiver 11 , the voice controller 12 , the speaker 13 , the voice recognizer 14 , and the remote controller sensor 16 , for performing various processing such as the map scale change, menu display and selection, destination setting, route search, route guide start, current position correction, display screen change, sound volume adjustments, and the like.
As for the position detector 1 , a GPS receiver 5 for receiving a radio wave from GPS (Global Positioning System) satellites, as well as a geo-magnetism sensor 2 , a gyroscope 3 , a distance sensor 4 and the like are incorporated. The position detector 1 uses those components 2 to 5 in a mutually-compensating manner for detecting a position of a vehicle.
Further, the position detector 1 may selectively use only a part of the components 2 to 5 , or may incorporate other sensors such as a steering rotation sensor, a tire rotation sensor or the like.
The map data input unit 6 is a device for inputting map information from a memory medium (not shown in the drawing) to the navigation apparatus (i.e., to the memory 9 ). The memory medium used by the input unit 6 provides various kinds of data, including so-called map matching data for improvement of the position detection accuracy, as well as map data, landmark data and the like.
The map data input unit 6 is capable of reading data from various recording media, such as an optical medium (e.g., a CD-ROM, a DVD-ROM and the like) as well as a semiconductor medium of memory cards and a magnetic medium of a HDD.
The operation unit 7 is a user interface having either or both of a touch switch (touch panel function) that is integrally disposed on the display unit 10 as well as a mechanical switch or the like. The operation unit 7 is used to provide an instruction from the user to the control unit 8 , for the purpose of utilizing various functions such as map scale change, menu display and selection, destination setting, route search, route guide start, current position correction, display screen change, sound volume adjustments, and the like.
Further, the remote controller 17 has operation switches (not shown in the drawing) for transmitting instruction signals respectively corresponding to above-described functions. The instruction signal generated by one of the switches is input to the control unit 8 through the remote controller sensor 16 .
The memory 9 is a large volume storage device such as a hard disk drive (HDD). The memory 9 stores data having the large data volume as well as data that should not be lost while the power supply is turned off. Further, the memory 9 may store frequently used data after copying the data from the map data input unit 6 . The memory 9 may also be a small volume, removable memory medium.
The display unit 10 is a display device capable of displaying a navigation map, a destination selection menu and the like in full-color, by using the liquid crystal display, an organic electro-luminescence (organic EL) display, or the like.
The transceiver 11 is a device receiving and sending information from/to an outside of the vehicle. The information may include traffic information, weather information, facilities information, advertising information, etc. provided from the outside resources (VICS (Vehicle Information and Communication System implemented in Japan), for example), and may also include vehicle information, user information, etc. sent to the outside of the vehicle. The information received and sent through the transceiver 11 is processed by using the control unit 8 .
The speaker 13 is a sound notification device that provides sound guidance and/or notification based on voice output signals from the voice controller 12 . The sound guidance includes guidance voice for navigation and menu operations as well as voice recognition result by the voice recognizer. The microphone 15 is a device for inputting user's voice as an electric signal to the voice recognizer 14 .
The voice recognizer 14 inputs a recognition result into the voice controller 12 after comparing the input voice derived from the microphone 15 and the vocabulary data in the internal dictionary (not shown in the drawing) that serves as a comparison reference pattern and determining the best matching recognition result. On the other hand, the voice controller 12 controls the voice recognizer 14 to talk-back, through the speaker 13 , to the user who has provided the voice input (i.e., to provide voice output to the user), and transmits the recognition results by the voice recognizer 14 to the control unit 8 .
Further, the control unit 8 executes prescribed processing such as, for instance, map scale change processing, menu display and selection processing, destination setting processing, route search processing, route guide start processing, current position correction processing, display change processing, volume adjustments processing, and the like, according to voice of the user on the basis of information from the voice recognizer 14 . In this case, at the time of performance of the route guide start processing, for example, the processed information such as route guidance voice information processed by the control unit 8 is notified from the speaker 13 through the voice controller 12 .
3. Featured Operation of the Navigation Apparatus According to the Present Embodiment
3.1 Outline of the Operation
When the destination is defined, as shown in FIG. 2 , by the user's operation of either of the remote controller 17 or the operation unit 7 , the control unit 8 automatically searches and sets, as a guidance route, an optimum travel route toward the defined destination on the basis of the present location detected with the position detector 1 . The automatic setting method of the optimum travel route is based on, in the present embodiment, the technique known as Dijkstra method from among various kinds of method.
Then, the control unit 8 displays, on the display unit 10 , an image of the travel route (a thick solid line in FIG. 3 , designated as a recommended route hereinafter) set as the guidance route on the map together with the marks respectively indicating the current position and the destination, after combining the map information stored in the map data input unit 6 or the memory 9 with the travel route. In FIGS. 2 and 3 as well as other drawings, the image showing the map is omitted.
When the travel route intended by the user (i.e., a broken line in FIG. 3 ) is different from the recommended travel route that is found by the control unit 8 , the recommended route is modified (or amended) in the following manner.
That is, when a route edit mode is selected by the user with the operation of the operation unit 7 while the recommended route is drawn on the display unit 10 , the line representation of the recommended route is changed for indicating that the route edit mode is currently set in operation, and edit points (i.e., nodes) on the currently-displayed recommended route that can be edited are shown (see FIG. 4 ). In FIG. 4 , the line type of the recommended route is changed, with the edit points represented as round marks. However, the line type and the edit point marking are not limited to those representations.
The edit point is a point on the travel route shown on the map, which can be “edited” (i.e., changed) directly by the user operation. The edit points are respectively different on each of multiple map information layers. That is, due to the different scale of map display on each of those map information layers, the edit points on each of the layers are differentiated, and one map information layer is associated with another layer through a link defined between the edit points.
More practically, the number of edit points decreases as the map scale increases to the larger scale, or the number of edit points increases as the map scale is reduced to the smaller one. In the present embodiment, the edit points are set and displayed on the display unit 10 by using a map scale that is used to display the map at a time of selection of the route edit mode by the user.
Then, the edit points are displayed and the guidance voice/guidance image is provided for prompting the user to select the edit start point and the edit end point (see FIG. 5 ). Therefore, the user selects the edit start point and the edit end point from among the edit points currently displayed on the display unit 10 upon receiving the guidance.
The edit start point and the edit end point represent edges of the desired edit section (i.e., change section) on the recommended route (e.g., a solid line in FIG. 6 ). The edit start point is one edge on the current position side of the edit section, and the edit end point is another edge on the destination side of the edit section.
Then, an edit point is selected as a reference point when the user touches one of the edit points being displayed on the display unit 10 . That is, for example, with the edit start/end points in a selected condition, the control unit 8 determines which one of the edit points is touched by the user by utilizing the touch panel function, and the selected reference point is exclusively displayed on the display unit 10 as shown in FIG. 6 .
In this case, the reference point is a point on the travel route displayed on the display unit 10 , and the reference point can be moved based on a direct instruction from the user. Therefore, as described later, the control unit 8 basically searches for the travel route that passes the reference point on the map indicated by the user.
In the above-described manner, the map information layer (i.e., the map scale) having the recommended route to be edited thereon as well as the edit start and end points are determined, and the reference point on the map is moved according to the movement of the user finger that is touching the reference point on the display unit 10 as shown in FIGS. 7A and 7B . That is, the reference point is moved (edited) by the user simultaneously with the amendments (i.e., editing) of the line representing the travel route based on the position of the moved reference point on the map as well as the map information.
The reference point is, at the time of route editing, always displayed on the map until the edit start/end points and edit points are re-defined. On the other hand, the line representing the travel route after amendments is displayed on the display unit 10 only after the discovery of the new travel route relevant to the after-move reference point. That is, in other words, the line representing the after-amendments travel route is not displayed before the after-amendments travel route is found.
3.2. Details of the Operation
FIG. 8 is a flow chart that shows the control (hereafter, mentioned as “route edit control”) to be executed in the above-mentioned outline operation. This route edit control is performed by the control unit 8 , and the program to execute the route edit control is memorized in the ROM of the control unit 8 .
When the destination is set by the user, a recommended route to the destination is searched for on the basis of the current position as mentioned above, and then the searched recommended route is displayed on the display unit 10 (S 1 ).
Next, whether the route edit mode is selected by the user or not is determined (S 5 ), and if the edit mode is not selected (S 5 :NO), the process concludes itself.
On the other hand, if the edit mode is selected (S 5 :YES), the operation mode of the navigation apparatus shifts to the route edit mode (S 10 ), and the edit points on the recommended route currently displayed on the display unit 10 is displayed (S 15 ).
Then, it is determined whether user-intended edit points are displayed or not by providing the user with a query either in the vocal message or in the text message. The edit points are determined either as the intended one or not based on the answer from the user for the query (S 20 ).
If it is determined that the user-intended edit points are not displayed (S 20 :NO), the map information layer is changed to the smaller scale layer than the current scale (S 25 ), and the edit points according to the changed scale are then displayed along the recommended route on the display unit 10 (S 25 ).
If, on the other hand, it is determined the user-intended edit points are displayed (S 20 :YES), an edit start point, an edit end point, together with the reference point are set according to the instruction from the user (S 30 ,S 35 ), and the reference point is moved and displayed based on the user operation (S 40 ).
At this point, the travel route passing through either the reference point or the proximity of the reference point (i.e., designated as an “indication point” hereinafter) indicated by the user is searched for, and then it is determined whether the travel route passing through the indication point has been found (S 45 ).
Then, if it is determined that the travel route passing through the indication point has not been found (S 45 : NO), another query for determining if it is required for the travel route to pass through the indication point is provided for the user (in voice or in text). Then, the user's intention whether the travel route should pass through the indication point is determined (S 50 ).
At this point, if it is determined that the user desires for the travel route to pass through the indication point (S 50 :YES), the currently-displayed map information layer is changed to the smaller scale (S 55 ), and whether the travel route passing the indication point has been found or not is re-determined on the map information layer with the changed scale (S 45 ).
In this case, because the map information layer having the smaller scale is determined through the link that is associated with the node, that is, the indication point currently displayed, the travel route search can be continued after the change of the map information layer.
Then, the reference point is, again, moved and displayed on the basis of the user operation, if it is determined that the travel route may not pass through the indication point (S 50 :NO).
Then, if it is determined that the travel route passing through the indication point (S 45 :YES), the alternative route that has been found is displayed on the display unit 10 (S 60 ), and a query for inquiring the user whether the displayed alternative route should be used as the guidance route in the voice/text is provided for the user. Then, according to the user response to the query, use of the alternative route is determined (S 65 ).
If it is determined that the alternative route is not used as the guidance route (S 65 :NO), the reference point is moved and displayed according to the user operation again (S 40 ). On the other hand, the current route is changed to the alternative route (S 70 ), if it is determined that the alternative route has been selected by the user (S 65 :YES).
4. Advantageous Effects of the Navigation Apparatus According to the Present Embodiment
In the present embodiment, the reference point on the travel route displayed on the map on the display unit 10 is moved according to the user operation (S 40 ), and the travel route is amended based on the position of the reference point on the map and the map information. Therefore, the travel route once set and displayed on the map is amended/re-routed/re-defined according to the reference point on the map, the edit start/end points, the move direction of the reference point, and the map information.
As a result, the set-and-displayed route (i.e., a first recommendation of the travel route) can be modified in a manner that has flexibility of a rubber band, which is user-friendly, as well as novel and un-obvious from the conventional art.
Further, in the present embodiment, the navigation apparatus displays the newly-found travel route on the display unit 10 only after the new route is discovered. That is, before the discovery of the new route, the travel route is not displayed on the display unit 10 (S 60 ). Therefore, the user can easily recognize that the travel route after the amendment has been discovered or not, thereby being enabled to have an improved usability.
Furthermore, in the present embodiment, the reference point is always displayed on the display unit 10 , thereby enabling the user to easily recognize the positional change of the reference point, that is, for example, where the reference point is located on the map. That is, the usability of the navigation apparatus is improved due to the ease of locating the route change.
Furthermore, the process time for finding the modified route is reduced due to the use of the map scale that is used at the time of starting the route edit mode. That is, when the route edit mode is set in operation, the map information having the currently displayed map scale for allowing the selection of the edit points is used to modify the travel route, thereby leading to the reduced operation time.
In other words, if the map information having a different map scale is used to locate the reference point, the process time will be increased due to the process load for considering the scale conversion, even when the map information is available in a couple of different scales.
However, in the present embodiment, the map information used to modify the travel route is having the same scale as the one used to display the map on the display unit 10 , thereby making it un-necessary to consider the scale conversion that leads to the increase of the process time.
Furthermore, under an instruction from the user, the modification of the travel route may be based on the different map scale that is different from the currently-used map scale (S 20 , S 50 ), thereby leading to the travel route amendment that appropriately reflects the user's intention.
Furthermore, the amended travel route may once again be amended based on the map information and the reference point on the amended route (S 65 :NO), thereby enabling the user to repeat the amendment/modification of the travel route until the amended route satisfies the user.
5. Relationship Between the Specificity of the Embodiment and Claim Language
In the present embodiment, the display unit 10 corresponds to a display unit recited in the claims, S 30 and S 35 , etc. correspond to a set unit recited in the claims, S 40 etc. correspond to a move unit recited in the claims, and S 60 etc. correspond to a correction unit recited in the claims.
(Second Embodiment)
In the present embodiment, the alternative route is calculated as a smooth line, as shown in FIGS. 9A to 9C , without considering the map information. That is, the alternative route is first defined and displayed as a smoothly curved line defined by the reference point and the edit start/end points, and the line is then approximated by the actual routing on the map information for determining the alternative route.
That is, a smooth line that passes through the edit start point, the reference point, and the edit end point without considering the map information is calculated and displayed as shown in FIGS. 9A and 9B . Then, in FIG. 9C , the searched travel route based on the smooth line for approximating the new route and the map information at the time when the user released his/her hand or finger from the reference point on the display unit 10 .
FIG. 10 shows a flow chart of the route edit control according to the present embodiment.
In the edit control process, the recommended route toward the destination is searched for and displayed on the display unit 10 , on the basis of the current position when the destination is set by the user, as mentioned above (S 100 ).
Then, whether the route edit mode has been selected by the user or not is determined (S 105 ). If the route edit mode has not been selected (S 105 :NO), the currently displayed travel route (i.e., the recommended route) is set as the guidance route (S 145 ), and the process concludes itself.
On the other hand, if the route edit mode has been selected (S 105 :YES), the operation of the navigation apparatus shifts to the route edit mode (S 110 ), and the edit points on the currently-displayed recommended route are shown on the display unit 10 (S 115 ).
Then, the reference point as well as the edit start/end points are set according to the user instruction (S 120 , S 125 ), and a smoothly curved line connecting the edit start/end points and the reference point is calculated and displayed as the reference point is moved according to the user operation (S 130 ).
Next, whether the user has released his/her hand or finger from the reference point is determined (S 135 ), and if the user has released his/her hand from the reference point (S 135 :YES), the travel route that approximates the line shape displayed on the display unit 10 at the time of the release of the hand is searched for based on the map information, and then displayed on the display unit 10 (S 140 ).
When it is determined that the user has not released his/her hand from the reference point (S 135 :NO), the smooth line between the edit start/end points and the reference point is re-calculated and displayed (S 130 ).
Then, the selection of the route edit mode by the user is re-determined (S 105 ), and, if the edit mode has not been selected (S 105 :NO), the process concludes itself after setting the currently-display recommended route is as the guidance route (S 145 ).
(Other Embodiments)
The above embodiments displaying travel route on the display unit 10 only after the discovery of the new/amended route does not confine the present invention. That is, the new route may be presented differently before/after the discovery.
Further, the reference point basically being shown on the map in the route edit mode may be altered.
Furthermore, the user input required for determining the passing of the route through the indication point (S 50 ) may be omitted. That is, the map information layer may be automatically changed to the smaller scale layer from the current one.
Furthermore, in one of the above embodiments, the same map information layer is used throughout the route edit mode. However, the map information layer may be changed after the route edit mode has been started. That is, a step for switching the layer may be incorporated as the other one of the above embodiments.
Such changes, modifications, and summarized scheme are to be understood as being within the scope of the present disclosure as defined by appended claims. | The navigation apparatus has a display unit ready to accept a user operation that moves a reference point of a navigation route already being defined on a map by the apparatus. The move of the reference point of the navigation route according to the user operation, together with map information, defines a new navigation route that incorporates route amendments. The navigation apparatus thus allows the user to easily and responsively modify an already-defined navigation route in a novel manner, which enables a rubber-banding of the already-defined navigation route. | 6 |
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