description stringlengths 2.98k 3.35M | abstract stringlengths 94 10.6k | cpc int64 0 8 |
|---|---|---|
TECHNICAL FIELD OF THE INVENTION
[0001] The present invention relates generally to a car seat for infants and toddlers and, more particularly, to a car seat for infants and toddlers which is convertible into a stroller and vice versa.
BACKGROUND OF THE INVENTION
[0002] Car seats which convert into strollers, and vice versa, are generally known in the art. These convertible car seats typically have a retractable wheel assembly comprising four wheels which can be retracted so that the stroller converts into a car seat which can be secured to the fixed car seats of an automobile. In order to convert this type of car seat into a stroller, the seat is unfastened from the fixed car seat of the automobile and the wheel assembly is deployed so that the car seat functions as a baby stroller when the wheels are deployed. One disadvantage of the typical car seat which converts into a stroller, and vice versa, is that the wheel assembly usually adds a relatively large amount of weight to the seat thereby rendering the seat somewhat unwieldy and difficult to attach it to and remove it from the fixed car seat of the automobile. The weight of the wheel assembly is generally attributable to the fact that the wheel assembly comprises four wheels and associated hardware.
[0003] Batten, U.S. Pat. No. 5,595,393, issued Jan. 21, 1997, discloses an infant car seat stroller which can be converted from a car seat into a stroller, and vice versa. This patent discloses that the car seat comprises a first set of wheels which are attached to a flat bar bracket which, in turn, is affixed to a bottom portion of the seat. The patent discloses that the seat includes a retractable pivoting support on the bottom thereof which is modified by drilling a hole through it and by inserting an axle on which a secondary set of wheels is mounted. This allows the second set of wheels to be retracted so that only the first set of wheels is utilized.
[0004] This secondary set of wheels disclosed by Batten corresponds to the back wheels of the car seat. This secondary set of wheels can be retracted to allow the car seat stroller to be pulled across the ground using only the front wheels. One of the primary disadvantages of this design is that it only allows the stroller to be pulled in a rearward direction because pushing the stroller with only front wheels would be very awkward and impractical. This design also requires that the user bear most of the weight of the unit and the infant or toddler while lifting up on the handle since there are no wheels to provide vertical support in the two-wheel drive mode. Also, it appears from the text of this patent that the design is only intended to be used with infants, which typically corresponds to children under the weight of 20 lbs.
[0005] Accordingly, a need exists for a car seat which is convertible into a stroller, and vice versa, which overcomes the weight disadvantages of the four-wheel convertible car seat strollers by utilizing only two wheels, and which overcomes the disadvantages of the known two-wheel strollers associated with the lack of vertical support for the unit and child when the stroller utilizes only two wheels.
SUMMARY OF THE INVENTION
[0006] The present invention provides a car seat stroller assembly which can be converted from a child car seat into a child stroller, and vice versa. The car seat stroller assembly comprises a child car seat which can be removably secured to a fixed car seat of an automobile, a wheel assembly secured to the seat body at a location near the rear end of the bottom portion of the seat body, and a handle assembly secured to the seat body at a location along the back portion of the seat body.
[0007] The car seat stroller assembly preferably consists of two wheels which are rotatably mounted to an axle of the wheel assembly. The wheel assembly can be placed in a retracted position to enable a user to secure the car seat stroller assembly to the fixed car seat of the automobile, or in an extended position in which the wheels extend below the bottom portion of the seat body to enable the car seat stroller assembly to be operated as a child stroller.
[0008] In accordance with a first embodiment of the present invention, the car seat stroller assembly utilizes a child car seat which is currently available on the market. The child car seat is retrofitted with the wheel and handle assemblies of the present invention. One child car seat which is suitable for this purpose is sold by Century Products Company. This seat body of the child car seat is retrofitted by attaching the wheel assembly to a protruding portion of the seat body. This protruding portion, which is known as the “Posilock” feature of the car seat, protrudes from the seat body at a location near the rear end of the bottom portion of the seat body and near the bottom end of the back portion of the seat body.
[0009] The protruding portion of the child car seat is secured to the seat body in a hinging relationship to allow the protruding portion to be retracted and extended. In the extended position, the protruding portion is normally inserted in between the back and bottom cushions of a fixed automobile car seat to assist in securing the child car seat in place in the automobile. The protruding portion can be retracted to allow a user, e.g., a parent, to easily handle the child car seat when it is being removed from and inserted into the automobile. By attaching the wheel assembly to this existing feature on the car seat, the wheel assembly can be easily extended and retracted by extending and retracting the protruding portion of the child car seat.
[0010] Preferably, the front end of the bottom portion of the seat body has a braking mechanism thereon which substantially prevents the car seat stroller assembly from moving when the braking mechanism is in contact with the floor or the ground.
[0011] In accordance with a second embodiment of the present invention, the wheel assembly can be suitably attached to any child car seat, including, but not limited to the above-mentioned Century Products Company child car seat. In accordance with this embodiment, the wheel assembly comprises two side members which are transverse to the axle of the wheel assembly. Each side member has a first end, a second end, a first side and a second side. The first ends of the side members are attached to the axle of the wheel assembly.
[0012] In accordance with this embodiment, when the wheel assembly is placed in the extended position, a first notch formed in each of the second ends of the side members engages a respective pin secured to sides of the seat body. This prevents the wheel assembly from movement in a direction toward the wheels and in a direction away from the bottom end of the back portion. When the wheel assembly is placed in the retracted position, a notch formed in each of the first sides of the side members engages those same pins. This prevents the wheel assembly from movement in a direction away from the back portion of the seat body.
[0013] In accordance with another embodiment of the present invention, which is the preferred embodiment for the wheel and handle assemblies, the handle assembly is linked to the wheel assembly by a linkage in such a way that when the handle assembly is extended, the wheel assembly is extended until the pins secured to the sides of the seat body are engaged in the first notches formed in the ends of the side members. When a user lifts the seat body in an upwards direction away from the wheels, the pins are removed from the notches formed in the ends of the side members. When the handle assembly is retracted, the linkage causes the wheel assembly to be retracted until the pins are engaged in the notches formed in the sides of the side members.
[0014] Other features and advantages of the present invention will become apparent from the following description, drawings and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] [0015]FIG. 1 illustrates the car seat and stroller assembly of the present invention when the assembly is operating in the stroller mode.
[0016] [0016]FIG. 2A is a rear perspective view of the car seat stroller assembly of the present invention in accordance with a first embodiment wherein the wheel assembly and the handle are in the extended positions so that the assembly can be operated in the stroller mode.
[0017] [0017]FIG. 2B is a bottom perspective view of the car seat stroller assembly of the present invention wherein the wheel assembly is retracted such that the car seat stroller assembly is in the car seat mode and can be attached to the fixed car seat of an automobile.
[0018] [0018]FIG. 3A illustrates the car seat stroller assembly of the present invention in accordance with the preferred embodiment wherein the wheel assembly is extended so that the car seat stroller assembly can be operated in the stroller mode.
[0019] [0019]FIG. 3B illustrates the car seat stroller assembly in accordance with the preferred embodiment of the present invention shown in FIG. 4 when the wheel assembly is between the fully extended and fully retracted positions.
[0020] [0020]FIGS. 4A and 4B illustrates the wheel and handle assembly of the car seat stroller assembly of the present invention shown in FIGS. 3A and 3B which demonstrates the manner in which the handle and wheel assemblies operate in conjunction with one another to cause the handle assembly to be extended as the wheel assembly is extended and to cause the handle assembly to be folded as the wheel assembly is retracted.
DETAILED DESCRIPTION OF THE INVENTION
[0021] [0021]FIG. 1 illustrates the car seat stroller assembly 1 of the present invention in accordance with a first embodiment wherein the car seat stroller assembly 1 has been converted from a car seat into a stroller by extending a wheel assembly 2 having two wheels 3 , only one of which is shown in FIG. 1, and by extending a handle assembly 5 . FIG. 1 also illustrates a silhouette 7 of a woman pushing the car seat stroller assembly 1 in which a child 9 is secured. In accordance with this embodiment, a car seat which is sold by Century Products Company has been retrofitted by attaching the wheel assembly 2 and the handle assembly 5 of the present invention thereto.
[0022] [0022]FIG. 2A illustrates a rear perspective view of the car seat stroller assembly 1 shown in FIG. 1 which illustrates the manner in which the wheel assembly 2 of the present invention is secured to the car seat body 6 . The car seat sold by Century Products Company comprises an extension 11 which is intended to be inserted into an opening in the portion of the fixed automobile car seat (not shown) where the vertical backing member of the fixed automobile car seat abuts the horizontal seat member of the fixed automobile car seat. When the car seat body 6 is placed firmly against the fixed automobile car seat and the insert 11 is inserted between the vertical backing member and the horizontal seat member, the insertion member 11 assists in preventing movement of the car seat body 6 .
[0023] The wheel assembly 2 is attached to the insertion member 11 via a fastening device 14 , which may be, for example, screws, bolts, rivets, adhesives, etc. When the wheel assembly 2 is in the extended position, as shown in FIG. 2A, the wheels 3 extend below the bottom surface of the insertion member 11 so that when the wheels are in contact with the ground, they filly support the car seat 6 . The insertion member 11 hinges about a horizontal axis (not shown) to allow it to be extended and retracted. When the wheel assembly 2 is in the extended position, the insertion member 11 to which the wheel assembly 2 is attached locks into place so that the wheels cannot retract when the car seat stroller assembly is operating in the stroller mode.
[0024] The car seat 6 is also retrofitted with a handle assembly 5 which comprises two vertical tube members 12 and 13 , which preferably are telescoping tubes to enable the handle assembly 5 to be extended and retracted. The handle assembly 5 is attached to the car seat via brackets 16 and 17 , which are fixedly attached to the car seat body 6 , and by mating tube portions 19 and 21 which receive the ends of the vertical tube members 12 and 13 at openings 23 and 24 in the mating tube portions 19 and 21 . The brackets 16 and 17 are secured to the body of the car seat 6 via an attachment mechanism such as, for example, bolts 26 and 27 . A horizontal support member 29 secures the vertical tube members 12 and 13 to the upper portion of the back 32 of the car seat body 6 and prevents the vertical tube members 12 and 13 from substantial movement in the directions transverse to the axial directions of the vertical tube members 12 and 13 .
[0025] When operating the car seat stroller assembly 1 in the stroller mode, mechanism comprised of locking members 36 and 37 , which are attached to horizontal support member 29 provide a mechanism for releasing and locking the vertical tube members 12 and 13 . In order to extend the handle, the locking members 36 and 37 are placed in the position parallel to the vertical tube members 12 and 13 and the user exerts an upward force on the handle 41 . Once the vertical tube members 12 and 13 have been lifted to the desired vertical position, the locking mechanisms 36 and 37 are pushed down so that they are substantially transverse to the vertical tube members 12 and 13 and the vertical tube members 12 and 13 are thereby locked into place. It should be noted that different types and configurations of handles may be used with the car seat stroller of the present invention. Therefore, the present invention is not limited to use with any particular type of handle assembly.
[0026] The wheel assembly 2 is extended manually by simply pulling the insertion member 11 or one or more of the wheels 3 in a direction away from the bottom 43 of the seat body 6 to thereby rotate the wheel assembly 2 into the extended position. In order to retract the wheel assembly 2 , the user simply pushes the wheel assembly 2 in a direction toward the bottom 43 of the car seat body 6 . The insertion member 11 is known as the “Posilock” feature of the Century Products Company car seat.
[0027] It will be understood by those skilled in the art that the present invention is not limited to use with any particular type or brand of car seat. The Century car seat was chosen in accordance with this embodiment due to the Posilock Feature, which makes the Century Products Company car seat very suitable for retrofitting with the wheel assembly 2 of the present invention. It will be understood by those skilled in the art that a wheel assembly identical or similar to the wheel assembly 2 shown in FIGS. 1 and 2A can be attached to the bottom and rear portion of any child car seat. However, it should be noted that, regardless of the car seat with which the retrofitting assembly of the present invention is implemented, it is important that the wheel assembly be attached to the bottom and rear portion of the car seat because this location allows the stroller to be pushed or pulled with a high degree of maneuverability.
[0028] [0028]FIG. 2B is a bottom perspective view of the car seat stroller assembly 1 which illustrates the wheel assembly 2 in the retracted position. This view also illustrates the front brakes 44 , which preferably are rubber blocks secured to the front, bottom portion of the car seat body 6 . The brakes 44 prevent the bottom 43 of the car seat body 6 from being scratched when the front, bottom portion of the car seat body 6 is placed against the ground or floor. The brakes 44 allow the assembly to be securely placed at rest.
[0029] In the retracted position, the wheels 3 are flush against the body 6 of the car seat. Two substantially U-shaped support members 45 and 46 are shaped to engage square or rectangular-shaped sections on the body 6 of the seat. By using these U-shaped support members 45 and 46 to couple the wheels 3 with the wheel assembly 2 , the wheels 3 are held snugly against the sides of the car seat body 6 and thus do not substantially extend beyond the sides of the car seat body 6 when the wheel assembly 2 is in the retracted position. This feature of the present invention enables the car seat stroller assembly 1 to be easily handled by a user when securing it to and removing it from the fixed automobile car seat (not shown). Furthermore, in the retracted position, the wheel assembly 2 and the wheels 3 slightly expand the effective base of the seat thereby providing it with additional lateral support when it is secured to the fixed automobile car seat.
[0030] [0030]FIG. 3A illustrates a cross-sectional rear perspective view of the car seat stroller assembly 50 of the present invention in accordance with a second embodiment. In accordance with this embodiment, when the wheel assembly 55 is in the extended position to place the car seat stroller assembly 50 in the stroller mode, the wheels 57 are disposed below the bottom surface 59 of the body 52 of the car seat 52 . In this position, the wheel assembly 55 and the wheels 57 provide total vertical support for the car seat stroller assembly 50 . The handle assembly used in this embodiment is substantially identical to the handle assembly 5 shown in FIGS. 1, 2A and 2 B in that it comprises vertical tubular members 61 and 62 , which preferably are telescoping tubular members, which fit into openings 67 and 68 in vertical tubular mating portions 73 and 74 , respectively. The vertical tubular mating portions 73 and 74 are attached to brackets 78 and 79 by any suitable attachment means such as, for example, welding, bolts, rivets, etc.
[0031] When the car seat stroller assembly 50 is in the stroller mode, i.e., when the wheel assembly 55 is fully extended and locked into place, pins 81 , which are secured to brackets 78 and 79 , mate with a U-shaped slot 85 . The U-shaped slot 85 is of sufficient length to prevent the possibility of the pin 81 coming out of the slot 85 when the car seat stroller assembly 1 is operational in the stroller mode. Also, a bolt and washer assembly 87 is sufficiently tight to maintain a constant amount of pressure and friction between the brackets 78 and 79 and the transverse members 89 of the wheel assembly 55 .
[0032] [0032]FIG. 3B illustrates the car seat stroller assembly 50 with the wheel assembly 55 partially retracted, i.e., between the fully-extended and fully-retracted positions. In order to retract the wheel assembly 55 , the user simply lifts the body 52 of the car seat assembly 50 so that the pin 81 is moved in an upward direction until it is out of the slot 85 and then the wheel assembly 55 is folded in an upward direction until the pins 81 are received in the slots 88 of the transverse members 89 of the wheel assembly 55 . The slots 88 are L-shaped so that once the pins 81 have been received in the slots 88 , the pins 81 are moved vertically relative to the slots 88 until the pins 81 abut the ends of the slots 88 closest to the wheels 57 . The mating of pins 81 with the slots 88 substantially prevents lateral and vertical movement of the pins 81 within the slots 88 when the wheel assembly 55 is in the retracted position. Any movement of the wheel assembly 55 when it is in the retracted position is prevented by the friction fit created by the bolt and nut assembly 87 and 91 .
[0033] When the wheel assembly 55 is in the fully-retracted position (not shown), the wheels 57 are disposed against the sides of the car seat body 52 and are completely unobtrusive. By closely adapting the wheel assembly 55 to the shape of the car seat body 52 , the car seat stroller assembly 50 can be easily handled by the user when the user is placing the assembly in and removing the assembly from the vehicle.
[0034] [0034]FIGS. 4A and 4B illustrate the wheel and handle assembly of the present invention in accordance with the preferred embodiment. In accordance with this embodiment, the wheel assembly and handle assembly are linked together in such a manner that retraction of the handle effectuates retraction of the wheel assembly and extension of the handle assembly effectuates extension of the wheel assembly. The handle assembly 101 is pivotally attached on each end thereof to a linking member 103 by a fastening device 104 . The fastening device 104 allows rotational movement of the handle assembly 101 with respect to the linking member 103 while also securing them together. Those skilled in the art will note that this rotational arrangement can be achieved in a plurality of different ways which are well known to those skilled in the art.
[0035] A linking member 106 is rotationally secured on one end 107 to the wheel assembly 102 and on the other end 108 to the handle assembly 101 . FIG. 4A illustrates the handle assembly 101 , the linking member 103 and the wheel assembly 102 when the handle and wheel assemblies 101 and 102 are in the retracted positions. When the portion 109 of the handle assembly 101 intended to be gripped by the user is rotated in a clockwise and downward direction toward the wheel assembly 102 , the lower end 111 of the handle assembly 101 is rotated upwards away from the wheel assembly 102 thereby exerting an upward force on the end 108 of the linking member 106 . This upward force exerts an upward force on the end 107 of the linking member 106 which, in turn, causes the wheel assembly 102 to be pulled into the retracted position shown in FIG. 4A.
[0036] Conversely, when the wheel assembly 102 is in the fully-retracted position and the end 109 of the handle assembly 101 is rotated upwards in the counter-clockwise direction away from the wheel assembly 102 , the end 111 of the handle assembly 101 is rotated in the downwards in the counterclockwise direction toward the wheel assembly 102 . This causes a downward force to be exerted on the end 108 of the linking member 106 which, in turn, causes a downward force to be exerted on the end 107 of the linking member 106 , thus causing the wheel assembly 102 to be rotated in the downward direction until it is fully extended, as shown in FIG. 4B.
[0037] As with the embodiments shown in FIGS. 2 A- 3 B, in the embodiment shown in FIGS. 4A and 4B, the wheel assembly 102 contains slots 112 and 113 , which serve identical functions to that of the slots 85 and 88 shown in FIGS. 3A and 3B. Also, a nut and bolt arrangement 115 is utilized in the embodiment shown in FIGS. 4A and 4B in the same manner in which the nut and bolt assembly 87 and 91 is utilized in the embodiment shown in FIGS. 3A and 3B to secure the wheel assembly 55 in place.
[0038] It will be understood by those skilled in the art that the present invention is not limited to the particular embodiments discussed above with respect to FIGS. 1 - 4 B. Those skilled in the art will understand that the present invention is not limited to any particular type of arrangement or configuration for the handle and wheel assemblies implemented with the car seat stroller assembly of the present invention. The embodiments discussed above are intended to demonstrate the various advantageous features of the present invention, but those skilled in the art will understand that the invention is not limited to these particular features. Those skilled in the art will understand that other modifications, deletions and adaptations can be made to the embodiments discussed above which are all within the scope of the present invention. | A car seat stroller assembly is provided which can be converted from a child car seat into a child stroller, and vice versa. The car seat stroller assembly comprises a child car seat which can be removably secured to a fixed car seat of an automobile, a wheel assembly secured to the seat body at a location near the rear end of the bottom portion of the seat body, and a handle assembly secured to the seat body at a location along the back portion of the seat body. The car seat stroller assembly preferably consists of two wheels which are rotatably mounted to an axle of the wheel assembly. The wheel assembly can be placed in a retracted position to enable a user to secure the car seat stroller assembly to the fixed car seat of the automobile, or in an extended position in which the wheels extend below the bottom portion of the seat body to enable the car seat stroller assembly to be operated as a child stroller. As a result of the wheel assembly being mounted at a location near the rear end of the bottom portion of the seat body, the car seat stroller assembly is highly maneuverable when it is being operated in the stroller mode. | 1 |
CROSS-REFERENCE TO RELATED APPLICATION
Priority to New Zealand 539554 filed on Apr. 19, 2005 and New Zealand 541464 filed on Jul. 25, 2005 is claimed.
FIELD OF INVENTION
This invention relates to a system of control for a free piston linear compressor and in particular, but not solely, a refrigerator compressor. The control system allow a high power mode of operation in which piston stroke is maximised and collisions deliberately occur.
PRIOR ART
Linear compressors operate on a free piston basis and require close control of stroke amplitude since, unlike conventional rotary compressors employing a crank shaft, stroke amplitude is not fixed. The application of excess motor power for the conditions of the fluid being compressed may result in the piston colliding with the head gear of the cylinder in which it reciprocates.
U.S. Pat. No. 6,809,434 discloses a control system for a free piston compressor which limits motor power as a function of a property of the refrigerant entering the compressor. However in linear compressors it is useful to be able to detect an actual piston collision and then to reduce motor power in response. Such a strategy can be used purely to prevent compressor damage, when excess motor power occurs for any reason or, can be used as a way of ensuring high volumetric efficiency by gradually increasing power until a collision occurs and then decrementing power before gradually increasing power again. The periodic light piston collisions inherent in this mode of operation cause negligible damage and can easily be tolerated.
U.S. Pat. No. 6,536,326 discloses a system for detecting piston collisions in a linear compressor which uses a vibration detector such as a microphone.
U.S. Pat. No. 6,812,597 discloses a method and system for detecting piston collisions based on the linear motor back EMF and therefore without the need for any sensors and their associated cost. This uses the sudden change in period that has been found to occur on a piston collision. Reciprocation period and/or half periods can be obtained from measuring the time between zero-crossings of the back EMF induced in the motor stator windings. The back EMF is a function of motor armature velocity and therefore piston velocity and zero-crossings indicate the points when the piston changes direction during its reciprocation cycles.
When it is desired deliberately to run the compressor at maximum power and high volumetric efficiency it is very important to ensure the collision detection system does not miss the onset of collisions as they will be a regular and expected occurrence in this mode of operation and successive collisions with increasing power will cause damage.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a control system for a free-piston linear compressor which allows for high power operation while obviating piston collision damage.
Accordingly in a first aspect the invention consists in a method of controlling a free-piston linear compressor comprising:
(a) providing a gradually increasing input power function to the compressor; (b) superimposing a transient power function with the power function of step (a) to momentarily increase the input power to the compressor; (c) monitoring for piston collisions; and (d) when a piston collision is detected immediately decrementing said input power.
In a further aspect the invention consists in a method of controlling a linear compressor which includes a free piston reciprocating in a cylinder driven by an electric motor having a stator with one or more excitation windings and an armature connected to said piston comprising the steps of:
(a) supplying an alternating current to said stator winding to cause said armature and piston to reciprocate, (b) obtaining an indicative measure of the reciprocation period of said piston, (c) detecting any sudden reduction of said indicative measure, said sudden reduction indicative of a piston collision with the cylinder head, (d) gradually increasing the power input to said stator windings over many reciprocation periods, (e) superimposing a transient increase in power with the gradually increasing stator power, and (f) reducing the power input to said stator windings on detecting any sudden decrease in piston period.
In yet a further aspect the invention consists in a method of controlling a linear compressor which includes a free piston reciprocating in a cylinder driven by an electric motor having a stator with one or more excitation windings and an armature connected to said piston comprising the steps of:
(a) supplying an alternating current to said stator winding to cause said armature and piston to reciprocate, (b) monitoring the motor back EMF, (c) detecting zero-crossings of said motor back EMF, (d) monitoring the slope of the back EMF waveform in the vicinity of said zero-crossings, (e) detecting discontinuities in said waveform slope, said discontinuities indicative of a piston collision with the cylinder head, (f) gradually increasing the power input to said stator windings over many reciprocation periods, (g) superimposing a transient increase in power with the gradually increasing stator power, and (h) reducing the power input to said stator windings on detecting any back EMF slope discontinuity.
In a further aspect the invention consists in a free piston gas compressor comprising:
a cylinder, a piston, said piston reciprocable within said cylinder, a reciprocating linear electric motor coupled to said piston, a control system configured to monitor motor back, EMF for an indication of piston collisions and set the power input to said motor accordingly, said control system gradually increasing the power input to said motor in the absence of piston collision and rapidly reducing the power input to said motor if a collision is detected, in the absence of piston collision said control system superimposing transient power increases with said gradually increasing power input to induce a low energy collision when said piston is near maximum displacement.
In a further aspect the invention consists in a free piston gas compressor comprising:
a cylinder, a piston reciprocally received within the cylinder, an electric motor coupled to the piston, and a control system configured to control reciprocation of the piston by: (a) gradually increasing input power to the electric motor to cause the piston to reciprocate with increasing displacement; (b) superimposing a transient increase in power with the gradually increasing input power of step (a) to momentarily increase piston displacement; (c) monitoring piston collisions, and (d) when a piston collision is detected immediately decrementing said input power.
To those skilled in the art to which the invention relates, many changes in construction and widely differing embodiments and applications of the invention will suggest themselves without departing from the scope of the invention as defined in the appended claims. The disclosures and the descriptions herein are purely illustrative and are not intended to be in any sense limiting.
BRIEF DESCRIPTION OF THE DRAWINGS
One preferred form of the invention will now be described with reference to the accompanying drawings in which;
FIG. 1 is a longitudinal axial-section of a linear compressor controlled according to the present invention,
FIG. 2 shows a refrigerator control system in block diagram form,
FIG. 3 shows a basic linear compressor control system using electronic commutation with switching timed from compressor motor back EMF,
FIG. 4 shows the control system of FIG. 3 with piston collision avoidance measures,
FIG. 5 shows the control system of FIG. 3 with collision control for high power operation of the compressor,
FIG. 6 shows the control system of FIG. 5 including perturbation of the compressor input power according to the present invention,
FIG. 7 shows a circuit for commutating current to the compressor windings, and
FIG. 8 shows a graph indicative of compressor power input illustrating the perturbated ramp function high power mode (and corresponding piston collisions), together with corresponding piston expansion and compression half cycle periods, and
FIG. 9 shows a linear compressor control system incorporating all of the control features of FIGS. 3 to 6 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention relates to controlling a free piston reciprocating compressor powered by a linear electric motor. A typical, but not exclusive, application would be in a refrigerator.
By way of example only and to provide context a free piston linear compressor which may be controlled in accordance with the present invention is shown in FIG. 1 .
A compressor for a vapour compression refrigeration system includes a linear compressor 1 supported inside a shell 2 . Typically the housing 2 is hermetically sealed and includes a gases inlet port 3 and a compressed gases outlet port 4 . Uncompressed gases flow within the interior of the housing surrounding the compressor 1 . These uncompressed gases are drawn into the compressor during the intake stroke, are compressed between a piston crown 14 and valve plate 5 on the compression stroke and expelled through discharge valve 6 into a compressed gases manifold 7 . Compressed gases exit the manifold 7 to the outlet port 4 in the shell through a flexible tube 8 . To reduce the stiffness effect of discharge tube 8 , the tube is preferably arranged as a loop or spiral transverse to the reciprocating axis of the compressor. Intake to the compression space may be through the head, suction manifold 13 and suction valve 29 .
The illustrated linear compressor 1 has, broadly speaking, a cylinder part and a piston part connected by a main spring. The cylinder part includes cylinder housing 10 , cylinder head 11 , valve plate 5 and a cylinder 12 . An end portion 18 of the cylinder part, distal from the head 11 , mounts the main spring relative to the cylinder part. The main spring may be formed as a combination of coil spring 19 and flat spring 20 as shown in FIG. 1 . The piston part includes a hollow piston 22 with sidewall 24 and crown 14 .
The compressor electric motor is integrally formed with the compressor structure. The cylinder part includes motor stator 15 . A co-acting linear motor armature 17 connects to the piston through a rod 26 and a supporting body 30 . The linear motor armature 17 comprises a body of permanent magnet material (such as ferrite or neodymium) magnetised to provide one or more poles directed transverse to the axis of reciprocation of the piston within the cylinder liner. An end portion 32 of armature support 30 , distal from the piston 22 , is connected with the main spring.
The linear compressor 1 is mounted within the shell 2 on a plurality of suspension springs to isolate it from the shell. In use the linear compressor cylinder part will oscillate but because the piston part is made very light compared to the cylinder part the oscillation of the cylinder part is small compared with the relative reciprocation between the piston part and cylinder part.
An alternating current in stator windings 33 , not necessarily sinusoidal, creates an oscillating force on armature magnets 17 to give the armature and stator substantial relative movement provided the oscillation frequency is close to the natural frequency of the mechanical system. This natural frequency is determined by the stiffness of the spring 19 , and mass of the cylinder 10 and stator 15 .
However as well as spring 19 , there is an inherent gas spring, the effective spring constant of which, in the case of a refrigeration compressor, varies as either evaporator or condenser pressure (and temperature) varies. A control system which sets stator winding current and thus piston force to take this into account has been described in U.S. Pat. No. 6,809,434, the contents of which are incorporated herein by reference. U.S. Pat. No. 6,809,434 also describes a system for limiting maximum motor power to minimise piston cylinder head collisions based on frequency and evaporator temperature.
Preferably but not necessarily the control system of the present invention operates in conjunction with the control system disclosed in U.S. Pat. No. 6,809,434.
To provide context for the linear compressor control system in the present invention a basic control system for a refrigerator is shown in FIG. 2 . A refrigerator 101 incorporating an evaporator 102 and a compressor 103 is set by a user to operate at a desired cabinet temperature through a control which produces a signal 104 . This causes compressor 103 to operate until the refrigerator cabinet temperature monitored by temperature sensor 105 indicates the desired temperature setting has been attained and the error signal 106 driving control amplifier 107 falls below a given threshold. At this point compressor 103 is switched off. When the cabinet temperature exceeds a predetermined threshold the magnitude of error signal 106 exceeds the predetermined value and the compressor is again turned on. This is the conventional non-linear feedback system used in refrigerators.
The control system of the present invention resides within the conventional loop described with reference to FIG. 2 . It receives as an input the output signal from amplifier 107 and controls the compressor 103 which in the present invention will be a free piston linear compressor.
The control system of the present invention operates in conjunction with the basic motor control system of FIG. 3 and preferably, although not necessarily with the system of FIG. 4 . Referring to FIG. 3 , linear compressor 103 A, which may be of the type already described with reference to FIG. 1 , has its stator windings energised by an alternating voltage supplied from power switching circuit 107 which may take the form of the bridge circuit shown in FIG. 7 which uses switching devices 411 and 412 to commutate current of reversing polarity through compressor stator winding 33 . The other end of the stator winding is connected to the junction of two series connected capacitors which are also connected across the DC power supply. The “half” bridge shown in FIG. 7 may be replaced with a full bridge using four switching devices. The control system is preferably implemented as a programmed microprocessor controlling the operation of the power switching circuit 107 . The switching circuit 107 is thus controlled by a switching algorithm 108 executed by the control system microprocessor. The microprocessor is programmed to execute various functions or use tables to be described which for the purposes of explanation are represented as blocks in the block diagrams of FIGS. 3 to 5 .
Reciprocations of the compressor piston and the frequency or period thereof are detected by movement detector 109 which in the preferred embodiment comprises the process of monitoring the back EMF induced in the compressor stator windings by the reciprocating compressor armature and detecting the zero crossings of that back EMF signal. Switching algorithm 108 which provides microprocessor output signals for controlling the power switch 107 has its switching times initiated from logic transitions in the back EMF zero crossing signal 110 . This ensures the reciprocating compressor peaks maximum power efficiency. The compressor input power may be determined by controlling either the current magnitude or current duration applied to the stator windings by power switch 107 . Pulse width modulation of the power switch may also be employed.
FIG. 4 shows the basic compressor control system of FIG. 3 enhanced by the control technique disclosed in U.S. Pat. No. 6,809,434 which minimises piston/cylinder collisions in normal operation by setting a maximum power based on piston frequency and evaporator temperature. Output 111 from an evaporator temperature sensor is applied to one of the microprocessor inputs and piston frequency is determined by a frequency routine 112 which times the time between zero crossings in back EMF signal 110 . Both the determined frequency and measured evaporator temperature are used to select a maximum power from a maximum power lookup table 113 which sets a maximum allowable power P t for a comparator routine 114 . Comparator routine 114 receives as a second input value 106 representing the power demand (P r ) required from the overall refrigerator control. The comparator routine 114 is used by switching algorithm 108 to control switching current magnitude or duration. Comparator routine 114 provides an output value 115 which is the minimum of the power required by the refrigerator P r and the power P t allowed from maximum power table 113 .
Using just the control concepts explained with reference to FIG. 4 will result in the linear compressor 103 A (when active) operating with no or minimal piston collisions in normal operation. However as disclosed in U.S. Pat. No. 6,812,597 linear compressor 103 A may be run in a “maximum power mode” where higher power can be achieved than with the FIG. 4 control system, but with the inevitability of some piston collisions. The control system of the present invention facilitates this mode as will now be described.
Referring to FIG. 5 a power algorithm 116 is employed which provides values to another input to comparison routine 114 . Power algorithm 116 slowly ramps up the compressor input power by providing successively increasing values to comparator routine 114 which causes switching algorithm 108 to ramp up the power switch 107 current magnitude or preferably ON time duration. Power is increased to P a +R every n cycles or piston reciprocations with P a being the power allowed by the collision analyser (see below) and R being a power increment which defines the ramp rate. In practice usually n=1. This ramping continues until a piston collision is detected. Collision detection process 117 is preferably determined from an analysis of the back EMF induced in the compressor windings and the technique used may be either that disclosed in U.S. Pat. No. 6,812,597, which looks for sudden decreases in piston period ( FIGS. 8( a ) and 8 ( b ) show graphs of piston half-periods against time as mentioned below), or that disclosed in U.S. Pat. No. 10/880,389 which looks for discontinuities on the slope of the analogue back EMF signal.
Upon detection of a collision, power algorithm 116 causes a decremented value to be input to comparator routine 114 to achieve a decrease of power. Power algorithm 116 then again slowly ramps up the compressor input power until another collision is detected and the process is repeated.
In order to maximise the probability of detecting the first collision due to increasing peak piston excursions (as continued collisions at what will be increasing power may cause damage) the effective power ramping signal provided by power algorithm 116 is periodically pulsed every m cycles by a perturbation algorithm 119 (see FIG. 6 ) with an increase (R p ) in power for a very short duration. A typical value of m might be 100. In one embodiment this is achieved by increasing the ON time of power switch 107 by 100 μs every 1 second (see FIG. 8( c )). Shorter increases in ON times, say 50 μs, could be used dependent on the collision detection system employed. This amounts to periodic application of an impulse function perturbation R p of the ramp signal as shown in FIG. 8( c ), although it should be appreciated this is graph of power switch 107 ON time and not power as such. Every m cycles the power is increased to P a +R p for one cycle, that is, for one reciprocation to induce a collision if compressor power is such as to nearly be causing peak piston displacements which result in collisions with the cylinder valve gear. This low energy collision is detected and compressor input power immediately reduced by s.R p where s might typically be 20, thus making the proven decrement 20 times the perturbation impulse power. The ramp function resumes to gradually increase compressor power again.
Using the perturbation technique described the linear compressor can be operated at maximum power and volumetric efficiency when required with low energy non-damaging piston collisions in the certainty that continued collisions at increasing power will be avoided.
Desirably, but not necessarily the high power control methodology described is used in conjunction with control for normal operation where collision avoidance is employed as described with reference to FIG. 4 . A control system employing both techniques is shown in FIG. 9 . Here the comparison routine 114 receives three inputs, P r , P t and P a . In the system of FIG. 9 input P a from power algorithm 116 may be decremented by one or both of two collision detection processes 117 and 118 . Process 117 looks for period change and process 118 looks for back EMF slope change as previously mentioned.
With such a comprehensive control system the operation may be summarised by tables I and II shown below.
TABLE I
Logic for normal running of the compressor
where collision avoidance is the objective.
Case
Situation
Description
Output
A
Normal
Output power is the
Pr
running
minimum of;
1- the power required
by the refrigerator,
Pr,
2- the power allowed
by the Collision Table,
Pt or
3- the power allowed
by the Collision
detector, Pa.
B
Collision
If Pr > Pt then power
Pt
Avoidance
is held at Pt. Where Pt
is a function of Running
Frequency and Evaporating
Pressure (or temperature,
as evaporating
temperature is closely
correlated to pressure)
C1
Collision
If a collision is
Pt − Rp or
reaction
detected power is
Pr − Rp
decreased by about Rp
C2
Frequent
If there have been
Pt − nRp or
collisions
more than 1 collision
Pr − nRp
in the last q cycles
then decrease power
by n × Rp
C3
No collisions
If there has been no
Pt − nRp +
recently
collisions in the last
ΔP or
p cycles then increase
Pr − nRp +
Power by ΔP (this can
ΔP
continue until Power
gets to its original
value, Pt).
D
Safety net
If at any time the
Pmin
(only occurs
back emf slope, S,
for a severe
exceeds the reference
collision that is
value, Sr, then
undetected by the
the power is reduced
“collision
to a minimal value,
detection”
Pmin.
algorithm)
Definitions
Pr, Pa, Pt Power levels that are set by altering the commutation time
Rp Power step that reduces the power level.
n No of multiples of power change, normally n = 1
p No of cycles that must be collision free before Power is increased, normally p = 1,000,000
q No of cycles during the collision count, normally q = 10,000
Pmin A preset minimum power, normally about 20 W
TABLE II
Logic for high power running where
low energy collisions are inherent.
Case
Situation
Description
Output
A
Normal
Output power is the
Pr
running
minimum, of the power
required by the
refrigerator, Pr,
and the power allowed
by the Collision
Analyser, Pa.
B
High
If Pr > Pa then power
Pa + R or
Power
is increased to Pa + R
Pa + Rp
every n cycles. After m
cycles the power is
increased to Pa + Rp
for one cycle to produce
a minor collision if
a collision is imminent.
B1
Collision
If a collision is
Pa − s*Rp
reaction
detected power is
decreased by about s*Rp
B2
Frequent
If there have been
Pa + R −
collisions
more than 1 collision
δR
in the last q cycles
then decrease R by δR
(this can continue
until R becomes a large
negative number).
B3
No collisions
If there has been no
Pa + R +
recently
collisions in the last
ΔR
p cycles then increase
R by ΔR (this can
continue until R gets
to its original value).
C
Safety net
If at any time the
Pmin
(only occurs
back emf slope, S,
for a severe
exceeds the reference
collision that
value, Sr, then the
is undetected
power is reduced to a
by the
minimal value, Pmin.
“collision
detection”
algorithm)
Definitions
Pr, Pa Power levels that are set by altering the commutation time
R Power increment that defines the “Ramp Rate”
Rp Power step that perturbates the power level to force a minor collision when the pump is running near its maximum stroke.
M No of cycles between each perturbation, normally m = 100
s Multiple that determines the power decrement after a collision, normally s = 20
p No of cycles that must be collision free before R is increased, normally p = 1,000,000
q No of cycles during the collision count, normally q = 10,000
Pmin A preset minimum power, normally about 20 W
Preferably the collision detection algorithm is one derived from the ascertainment of a sudden decrease in piston period as disclosed in U.S. Pat. No. 6,812,597. An enhanced technique derived from this method will now be described.
The period of the oscillating piston 22 is made up of two half periods between bottom dead centre and top dead centre respectively, but neither successive or even alternate half periods are symmetrical. The half period expansion stroke when the piston moves away from the head (valve plate 5 ) is longer than the half period compression stroke when the piston moves towards the head. Further, because a linear compressor will often run with different periods in consecutive cycles (this becomes very significant if the discharge valve starts to leak), it is useful to separate the period times into odd and even cycles. Thus in the preferred method of piston collision detection four periods are stored and monitored; compression and expansion for the even cycles, plus compression and expansion for the odd cycles. Preferably a sudden change in either of the two shorter half cycles (compression strokes) is assumed in this method to indicate a piston collision. In FIG. 8( b ) typical even short cycle periods are shown whereas FIG. 8( a ) shows typical even expansion stroke half periods.
The process used in the preferred collision detection algorithm 117 is to store the back EMF zero crossing time intervals from detector 109 for the four half periods mentioned above as an exponentially weighted moving average (ewma) to give a smoothed or filtered value for each of the first and second half periods of the odd and even cycles. Preferably, an infinite impulse response (IIR) filter is used with weightings such that the outputted latest estimate of half period time is ⅛ of the last value+⅞ of the previous estimates. These estimates are continually compared with the detected period of the most recent corresponding half cycle and the comparison monitored for an abrupt reduction. If the difference exceeds an amount “A”, algorithm 117 implies a collision. A value for the threshold difference “A” may be 20 microseconds. Other thresholds could be used, especially if the perturbation impulse energy is different from that resulting from a 100 μs ON time.
When a collision is detected the ON time of power switch 107 is reduced by (see for example transition D in FIG. 8( c )) to stop further collisions. In one embodiment the ON period is reduced by 51.2 μs to produce the previously mentioned s.R p decrement. Once the collisions stop, the ON time of power switch 107 is allowed to slowly increase to its previous value over a period of time (see the ramp function R in FIG. 8( c )). A value for the period of time for satisfactory operation may be approximately 1 hour. Of course, power control may be achieved by controlling current magnitude or by pulse width modulation to achieve the same effect as that described.
This is the high power mode of Table II. Alternatively the ON time will remain reduced until the system variables change significantly. In one embodiment where the system in U.S. Pat. No. 6,809,434 is used as the main current control algorithm, such a system change might be monitored by a change in the ordered maximum current. In that case it would be in response to a change in frequency or evaporator temperature. In the preferred embodiment the combination of that algorithm with a collision detection algorithm providing a supervisory role gives an improved volumetric efficiency over the prior art. | A free-piston linear compressor ( 1 ) controlled to achieve high volumetric efficiency by a controller including an algorithm ( 116 ) for ramping up input power until piston-cylinder head collisions are detected using a detection algorithm ( 117/118 ) which then decrements power input whereupon input power is again ramped up by algorithm ( 116 ). Non-damaging low energy collisions are achieved by the controller including a perturbation algorithm ( 119 ) which perturbates the input power ramp with periodic transient pulses of power to ensure piston collisions are provoked during the transient power pulses. | 5 |
FIELD OF THE INVENTION
The present invention relates to a shower system for suction rolls used in papermaking machines.
BACKGROUND OF THE INVENTION
In paper making machines, suction rolls are commonly used to extract water from the wet paper web before it leaves the felt in the wet forming section of the paper making machine. The suction roll comprises a cylindrical metal shell in which a large number of small evenly spaced holes are formed. The suction roll typically rotates in contact with the felt at web speed and direction. Suction is applied to the inside surface of the roll by means of a suction box. The suction box is an elongated tube inside the suction roll and is fixed against rotation. The suction box has a longitudinal slot which is in sealing engagement with the inside surface of the suction roll. As the rotating inside surface of the suction roll passes over the slot, suction is applied through the holes to assist in de-watering the felt and thereby reduce the water content of the wet paper web.
Plugging of the suction roll holes is a commonly encountered problem. The “white water” extracted from the felt contains substantial insoluble components which tend to build up in the suction roll holes. Unless the suction roll is cleaned periodically, this build-up can lead to complete plugging of the suction roll. In such a case, the suction roll must be removed from the paper-making machine and the holes must be manually cleared. This is typically achieved either by manually punching out the obstruction on each hole with a hammer and punch. Given that there are hundreds of thousands of holes in a conventional suction roll, this operation is time consuming and the labour and down-time associated therewith is costly. In addition, such an operation carries with it the risk of damaging the suction roll.
There exist a number of known methods and apparatus which are intended to prevent the build-up of deposits during the paper-making operation and thereby avoid or make less frequent the requirement to manually clear the suction roll holes. For example, in U.S. Pat. No. 4,975,150 Yasuda et al. there is disclosed a method of preventing the plugging of a suction roll with makes use of the conventional fan sprays which are conventionally fitted inside the suction roll. These fan sprays apply a coating of white water to the inside surface of the suction roll to improve sealing and reduce friction between the suction box slot opening and the inside surface of the suction roll. While the pressure of the fan head spray is insufficient to dislodge deposits in the suction roll holes, Yasuda et al. disclose the use of maleic acid in the fan spray as an anti-plugging agent.
It is also known to provide a dedicated high pressure spray head to clean various perforated elements. For example, in U.S. Pat. No. 5,494,227 Costantini, there is disclosed a shower system having an arcuate array of high pressure spray nozzles mounted for lateral reciprocal movement across a screen which functions to separate pulp by size. Similarly, in U.S. Pat. No. 4,167,440 Falk there is disclosed a high pressure reciprocating spray cleaning apparatus for foraminous elements.
It is also known to provide cleaning fluid in a dedicated pressure chamber located inside the suction box for the purpose of cleaning felts. For example, in U.S. Pat. No. 1,840,102 Jespersen, there is disclosed a pressure chamber which extends across the width of the suction roll and applies water under pressure through the suction roll perforations to clean the felt. Similarly, in U.S. Pat. No. 3,190,793 Starke, there is disclosed a pressure chamber employing cleaning fluid subject to high frequency oscillations to clean paper making machine felts.
None of these known systems disclose any means to provide a high pressure cleaning fluid into a suction box for cleaning the perforations in a rotating suction roll.
SUMMARY OF THE INVENTION
In accordance with the present invention, there is provided a high pressure shower system for cleaning perforations in a suction roll. The shower system comprises a header pipe extending longitudinally in the annular space between the suction box and the inside surface of said cylinder; a plurality of spray nozzles disposed along said header pipe in close spaced relation with said inside surface, each spray nozzle having a spray axis aligned on a radius of said cylinder; a means for driving said header pipe in longitudinal reciprocating movement; and a means for supplying high pressure fluid to said header pipe for discharge through said nozzles into said perforations. The header pipe is mounted for reciprocal longitudinal movement on brackets fixed to said suction box and the brackets partially encircle the header pipe with the opening in the brackets permitting reciprocal movement of said nozzle without interfering with the spray discharge. The spray nozzles are uniformly disposed along said header pipe at a spacing equal to or less than the stroke length of said longitudinal reciprocal movement. The bracket can includes a wear resistant low friction material in sliding contact with said header pipe. A conduit means is connected to the header pipe and passes into the interior of the suction chamber through an elongated slot in the side of said chamber adjacent to said header pipe and passes out of the suction chamber through an end plate.
BRIEF DESCRIPTION OF THE DRAWINGS
In drawings which illustrate embodiments of the invention,
FIG. 1 is an elevational view in part cross-section showing a suction roll fitted with the high pressure shower system of the present invention.
FIG. 2 is a transverse cross-sectional view of a suction roll suction roll fitted with the high pressure shower system of the present invention.
FIG. 3 is a plan view showing the spray header and the associated bracket and sealing details of the present invention.
FIG. 4 is a transverse cross-sectional view of the bracket and spray header of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, there is shown in part cross-section, suction roll 2 is an elongated cylinder having stainless steel cylindrical wall 3 and rubber surface 4 bonded to its outer surface.
Perforations 6 are drilled radially through wall 3 and rubber surface 4 in a close set uniform pattern over substantially the entire surface. In conventional papermaking machines, suction roll 2 can be 33 feet wide and 36 inches in diameter with cylindrical wall 3 being about 2½ inches thick. Suction roll 2 is mounted for rotation about its horizontal longitudinal axis. Each end of suction roll 2 is supported for rotation in end assembly 8 at each end, one of which is shown in FIG. 1 .
As shown in FIG. 2, suction box 20 is positioned longitudinally along the central axis within suction roll 2 and is fixed against rotation at each end to bearing end assembly 8 . Vacuum is applied to suction chamber 24 within suction box 20 by means of an appropriate suction line (not shown) which passes through fixed end wall 26 of end assembly 8 . In conventional installations, a vacuum of from about 18 to 23 inches Hg is common.
Walls 32 of suction box 20 are spaced approximately 6 inches inside cylindrical wall 3 of suction roll 2 . Suction chamber 24 has slots 28 , 30 formed longitudinally through walls 32 . Flanges 36 are project radially outward on either side of slots 28 , 30 and carry on their radially outer surfaces elastomeric seals 34 in sliding contact with the inside surface 38 of rotating suction roll 2 . Vacuum in suction chamber 24 is applied to the inside surface 38 of suction roll 2 through slots 28 , 30 and draws water from the felt (not shown) in contact with the rubber surface 4 of suction roll 2 through perforations 6 into suction chamber 24 and out through the suction line.
In order to reduce friction between elastomeric seals 34 and inside surface 38 of suction roll 2 , to improve the vacuum seal there between and to clean out accumulated debris, suction box 20 is fitted with a plurality of fan spray heads 42 which direct water under low pressure against the inside surface 38 of suction roll 2 . Fan spray heads 42 are mounted at uniform intervals along a header pipe (not shown) which extends longitudinally along the outside of suction box 20 . The spacing interval and spray pattern are such as to provide a relatively uniform application of water to inside surface 38 along the length of suction roll 2 . A suitable source of low pressure water (not shown) is piped through fixed end wall 26 of end assembly 8 and is connected to header pipe 43 through wall 32 .
Thus far described, the suction roll arrangement is conventional. In operation, fibres, fillers and other particulate matter present in the white water extracted from the felt tends over time to plug perforations 6 in suction roll 2 . Eventually, the perforations become plugged to such an extent that suction roll 2 must be removed from the papermaking machine and each perforation must be manually cleared, typically by a laborious hammer and punch operation. In accordance with the present invention, there is provided a high pressure spray shower which operates to continuously clean the perforations 6 in suction roll 2 and greatly reduce or eliminate the requirement for manual cleaning.
Referring again to FIG. 1, the high pressure spray shower of the present invention includes header pipe 60 which is mounted longitudinally along the outside of suction box 20 . Header pipe 60 is fitted with a plurality of spray nozzles 62 evenly spaced along its length. Spray nozzles 62 are in close proximity (approx. ¾ to 1 inch) to the inside surface 38 of suction roll 2 and are aligned to direct a needle like jet of fluid in a radial direction into the bore of suction roll perforations 6 as they rotate past the nozzle. Spray nozzles 62 are preferably formed of stainless steel and drilled with a 0.040 inch orifice.
Header pipe 60 is mounted for reciprocating motion along its longitudinal axis to the outside wall 32 of suction box 20 by means of brackets 64 . As best shown in FIGS. 3 and 4, brackets 64 comprise stand-off 68 , collar 70 and bearing sleeve 72 . Header pipe 60 is slidably received in bearing sleeve 72 which is formed of a suitable wear resistant low friction material such as Teflon™ to facilitate the reciprocating movement. Bearing sleeve 72 and collar 70 only partially encircle header pipe 60 so as not to obstruct or interfere with the reciprocating movement or the spray of nozzles 62 .
Header pipe 60 is connected to supply pipe 66 through elongated slot 68 in wall 32 of suction box 20 . Supply pipe 66 passes through pressure seal 65 in fixed end wall 26 of bearing end assembly 8 and is connected to a source of high pressure water (approx. 350 psi) through flexible high pressure feed hose 67 .
Oscillator 80 is fixed to bearing end assembly 8 and is of a conventional hydraulic design. Stroke rod 82 is connected to supply pipe 66 by link arm 84 . Stroke rod 82 is driven in a reciprocating linear action by oscillator 80 which causes supply pipe 66 to move in a reciprocating manner through pressure seal 65 . Elongated slot 68 , pressure seal 65 and flexible high pressure feed hose 67 permit supply pipe 66 to move reciprocally and act as a fixed link to drive header pipe 60 along its longitudinal axis. Angle brace 69 can be used to strengthen corner 70 of supply pipe 66 .
The spacing between spray nozzles 62 is fixed at slightly less than the stroke length of oscillator 80 . This provides at least some overlap in the areas covered by adjacent spray nozzles at the limits of their reciprocal motion thus ensuring that all perforations will be exposed to the high pressure spray. For example, with an oscillator having a stroke length of about 6¼ inches, a centre spacing of about 6 inches between spray nozzles 62 is suitable.
In order to ensure proper operation of suction roll 2 , it is necessary to limit the loss of vacuum in suction box 20 through elongated slot 68 To achieve this, sealing plate 90 is fixed to supply pipe 66 and closely overlies elongated slot 68 . Gasket 92 is fixed to suction box 20 around elongated slot 68 , for example by way of countersunk bolts. Gasket 92 is advantageously formed of a thin sheet of a suitable wear resistant low friction material such as Teflon™. When vacuum is applied inside suction box 20 , sealing plate 90 is drawn into sealing engagement with gasket 92 to reduce vacuum loss. In addition, the low friction nature of gasket 92 facilitates the reciprocating sliding movement of sealing plate 90 over gasket 92 and reduces stress on oscillator 80 and supply pipe 66 . It has been found in practice that gasket 92 can suitably be formed from a sheet of ½ inch thick Teflon™ and extend about 1-2 inches beyond the edges of elongated slot 68 . Sealing plate 90 can suitably be formed from ⅛ inch thick stainless steel plate of a generally rectangular configuration and of sufficient length to maintain coverage of gasket 92 at opposite limits of stroke.
In operation, contaminants in the high pressure spray water tends to accumulate in the ends of header pipe 60 and plug the spray nozzles 62 adjacent the ends. In a preferred embodiment of the present invention, the ends of header pipe 60 are connected to the interior of suction box 20 by flexible bleed lines 100 . Bleed lines 100 are flexible high pressure hydraulic lines of a suitably small diameter, (e,g, ⅜ inch). Bleed lines 100 are attached to high pressure fittings 101 which are threaded into a drilled orifice (e.g., ⅛ inch) in each end cap 102 which closes off the end of header pipe 60 and into a drilled orifice (e.g., ⅜ inch) in wall 32 of suction box 20 . Bleed lines 100 are of sufficient length to flexibly accommodate the entire stroke length of header pipe 60 . The flow of high pressure fluid through bleed line 100 carries contaminant build-up out of the ends of header pipe 60 into suction box 20 , thereby avoiding plugging of the spray nozzles 62 located adjacent the ends of header pipe 60 .
While the above description includes the use of fan spray heads 42 to lubricate the elastomeric seals 34 and inside surface 38 of suction roll 2 , the high pressure spray shower of the present invention itself provides lubrication to the and permits the fan spray heads 42 to be eliminated, if desired.
While the present invention has been described with reference to the embodiment shown in the drawings, it will be understood that many variations are possible and come within the scope of the claims set out below. | A high pressure shower system for cleaning perforations in a suction roll of a paper-making machine is disclosed. An elongated header pipe is mounted to the outside of the suction box and is fitted with a plurality of spaced high pressure nozzles directed at and in close proximity to the inside surface of the suction roll. The header pipe is driven in a longitudinal reciprocating manner providing complete spray coverage of the suction roll perforations. The water supply conduit to the header passes through the inside of the suction box which has a sealed slot opening to accommodate the reciprocal movement of the header. | 3 |
BACKGROUND OF THE INVENTION
[0001] The invention relates to a method for determining a target steering torque for a steering means of a steering device in a vehicle.
[0002] The invention also relates to a controller for controlling a steering device in a vehicle. The invention further relates to a computer program that can be executed on a controller for controlling a steering device in a vehicle.
[0003] In modern steering devices, for example in an electric power steering (EPS) system or in what is referred to as a Steer-by-Wire (SbW) steering system, a target steering torque is determined, which is applied to a steering means, such as a steering wheel, in order to counteract the force applied by the driver or support the force applied by the driver. The target steering torque can also be referred to as the target manual torque. This is intended to convey a driving experience to the driver that corresponds to the current driving situation. In a conventional steering system, in which a mechanical connection exists between the steering means and the wheels to be steered, the target steering torque decisively depends on cornering forces that act on the steering device, and ultimately on the steering means, via a steering linkage.
[0004] In SbW steering systems, the target steering torque is generated, for example, by means of a suitable steering wheel actuator. In an EPS system, in which a mechanical connection exists between the steering wheel and the wheels to be steered, modern control designs allow a target steering torque that corresponds to the target manual torque to be established so as to generate a desired steering feel at the steering wheel. To this end, an electric motor, or an electromechanical servo unit, is actuated or adjusted so that the target steering torque is set in accordance with the desired target manual torque. The target steering torque can specify the torque at the torsion bar, or the torque at the steering wheel.
[0005] Various approaches exist for calculating the target manual torque, or for calculating the target steering torque, for both SbW systems and for EPS systems having a control design for controlling the steering torque. Depending on the type of the steering system, the steering torque corresponds, for example, to the manual torque and/or to what is referred to as the torsion bar torque. The aforementioned approaches are based on various application functions; however, when combined, they do not convey a satisfactory steering feel in some driving conditions, or in some driving situations. For example, the current transverse acceleration, in the form of the toothed rack force, can be taken into consideration in determining the target steering torque. In addition, further variables may be included. Moreover, existing application functions can be included, which take into consideration, for example, additional moments of friction, so that the effect of the transverse acceleration actually experienced at the steering means can be represented more realistically.
[0006] In principle, determining the target steering torque first entails the problem of selecting suitable input variables. These input variables can then be combined in a variety of ways, such that the influence of an individual input variable is frequently no longer fully traceable, and thus it is difficult to correct or improve the target steering torque.
SUMMARY OF THE INVENTION
[0007] It is the object of the present invention to achieve a steering feel, both for SbW systems and for EPS systems having a control design for controlling the steering torque, by generating a target steering torque. The steering feel, or the target steering torque, must be adaptable to various steering systems, vehicle types, or requirements. The resulting steering feel must be a steering feel that is equivalent to, or better than, hydraulic and electromechanical steering systems available on the market today, in all driving conditions and driving situations. This is intended to provide the driver with reliable and precise information, to as great an extent as possible, on current driving conditions and driving situations by way of the target steering torque and by way of the steering means.
[0008] The object is achieved by a method of the type mentioned above, by finding the target steering torque as a function of individual components, with the individual components comprising at least one base steering torque, a damping torque, a hysteresis torque and a centering torque. These individual components can be combined into the target steering torque, for example by way of addition.
[0009] The base steering torque is determined as a function of an externally acting force, this being, for example, the toothed rack force, or a transverse acceleration determined by means of a suitable sensor, and as a function of a vehicle speed. The base steering torque thus generates a base steering force level, in which the current toothed rack force is taken into consideration as a function of the current speed. The base steering force level is preferably generated by characteristic torque curves that can be applied and are dependent on the toothed rack force. There exist various progressions of the characteristic base steering torque curves for various speeds. These various progressions of the characteristic base steering torque curves can be determined, for example, as a function of a certain vehicle, or a comfort level or a steering feel to be achieved. The base steering torque can be used to achieve what is referred to as the servotronic effect known from hydraulic steering systems. According to a different embodiment, the base steering torque is generated by means of a characteristic map, whereby the base steering torque is determined as a function of a current vehicle speed and a current externally acting force.
[0010] The damping torque is determined as a function of a steering speed, such as a steering wheel speed, and the vehicle speed. This generates active damping, which allows the driver to be assisted in the steering process, for example by stabilizing the steering. For this purpose, it may be possible to specify a higher steering torque for a high vehicle speed and a high steering speed so as to reduce the risk of oversteering.
[0011] The hysteresis torque is determined as a function of the current steering speed and the current vehicle speed. The hysteresis torque opposes the steering wheel movement and thus allows friction to be represented. The hysteresis torque is advantageously additionally determined as a function of a current steering torque, whereby the steering experience is improved even further.
[0012] The centering torque is determined as a function of a steering angle and the vehicle speed. The centering torque generates a steering torque in the direction of the straight-ahead position of the steering means, whereby an improved steering feel is achieved. Given the dependence on the vehicle speed, the centering torque can, for example, be raised at high vehicle speeds and reduced at low vehicle speeds. The centering torque is preferably generated so that it depends on a predefinable angular range around the straight-ahead position. As a result, this allows a minor deviation from the straight-ahead position to be easily signaled by way of the contribution to the target steering torque, whereas it can be assumed that a major deviation from the straight-ahead position does not require a particular contribution of the centering torque to the target steering torque because the greater deviation is being sufficiently signaled by other components.
[0013] The method according to the invention thus allows precise determination of individual moments that are intended to contribute to the target steering torque. Moreover, the contribution of each individual components can be adapted particularly well to various steering systems, vehicle types or desired steering feels. To this end, it is particularly advantageous if the contribution of at least one individual component can be applied. This can be achieved, for example, by multiplying each individual component by a factor that can be predefined for this individual component, and by then adding the products thus obtained to the target steering torque. This allows, for example, a component to be entirely suppressed (factor=0) so as to determine a fault, or undesirable behavior, particularly easily and reliably in the determination of the target steering torque. Moreover, the contribution of each component can be amplified (factor>1) or diminished (factor<1). In this way, an application can be executed particularly well, because the influence of the individual components on the entire target steering torque can be predefined or controlled. This further makes it possible to automatically predefine the contributions of the individual components in accordance with a predefinable driving mode. For example, if a rather “spirited” driving mode is desired, the contribution of individual components to the target steering torque can be adapted accordingly. A spirited driving mode can differ from a luxurious driving mode, for example, by transmitting more information about the current transverse acceleration to the driver in the spirited driving mode.
[0014] According to an improved embodiment, a return torque is determined as a function of the steering angle, the vehicle speed and the steering speed and serves as a further individual component. The return torque brings about what is referred to as an active return by generating a steering torque in the direction of the straight-ahead position, so that a target steering speed that is dependent on the steering angle and the vehicle speed is established. Depending on the steering speed, a steering torque component is restoring or damping. This enables even further improved self-alignment.
[0015] According to another preferred embodiment, first a base steering torque with self-alignment is determined as a function of the base steering torque and the centering torque in an intermediate step. Then the target steering torque is found as a function of the base steering torque with self-alignment and the damping torque and hysteresis torque. Moreover, a target steering wheel speed is preferably determined as a function of the vehicle speed and the steering angle, and the base steering torque with self-alignment is additionally determined as a function of the target steering wheel speed that is determined, the steering angle and the steering speed.
[0016] This embodiment implements a quasi-static steering force level solely by way of the base steering torque. Given the dependence on the steering rack force or on the externally acting force, the base steering torque already generates a return behavior that is comparable to the return of a conventional hydraulic steering system. However, to attain improved return behavior and generate an improved target steering torque, a self-alignment torque and a damping torque are taken into consideration, analogously to the aforementioned active return.
[0017] A switch is preferably made from the base steering torque with self-alignment to an undamped self-alignment torque, when a detected actual steering speed is lower than a predefinable target steering speed and when the base steering torque is less than the originally required self-alignment torque. These conditions exist, for example, when the driver takes their hands off the steering wheel while driving, and thus does not transfer any moment to the steering system. This automatically prompts a switch to an undamped self-alignment torque, which effects a self-alignment of the steering into the straight-ahead position and increases safety.
[0018] Advantageously at least one further moment is determined and added to the target steering torque. The additional moment can be, for example, information about the driving conditions, the tire conditions, or the condition or type of the roadway surface. The moment can moreover be part of a drive assist system, by means of which tracking or autonomous driving is implemented. For example, a hazardous situation can be indicated by vibrating the steering means, or advice for a recommended steering direction can be displayed. Such moments are particularly helpful for safely driving a vehicle and can be taken into consideration and applied with particular ease by means of the method according to the invention.
[0019] It is particularly important to implement the method according to the invention in the form of a computer program, which can be executed on a controller for controlling a steering unit in a vehicle, and notably on a microprocessor in the controller, which is programmed to carry out the method according to the invention. In this case, the invention is implemented by the computer program, and thus this computer program represents the invention in the same manner as the method does, the computer program being programmed for the execution thereof. The computer program is preferably stored in a memory element. The memory element used can notably be an optical, electric or magnetic storage medium, for example a random access memory, a read-only memory, a flash memory, a hard drive, or a digital versatile disk (DVD).
[0020] The object is also achieved by a controller of the type mentioned above that comprises the controller means for carrying out the method according to the invention. These means are implemented, for example, in the form of a computer program that is executed by the controller.
[0021] Additional characteristics, application options and advantages of the present invention will be apparent from the following description of exemplary embodiments of the invention, which will be described based on the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 is a steering device comprising a controller according to the invention;
[0023] FIG. 2 is a schematic block diagram of a functionality according to the invention for determining a target steering torque according to a first exemplary embodiment; and
[0024] FIG. 3 is a schematic block diagram of a functionality for determining a target steering torque according to a second exemplary embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] FIG. 1 shows a controller 1 , which is associated with a steering device 2 . A microprocessor 3 is disposed in the controller 1 and is connected via a data line 4 , such as a bus system, to a memory element 5 . The controller 1 is connected, via a signal line 6 , to a motor 7 , such as an electric motor, whereby the controller 1 can control the power of the motor 7 . The motor 7 acts on a torsion bar 9 via a transmission 8 . A steering means 10 , such as a steering wheel, is disposed on the torsion bar 9 and can be used to apply a torque to the torsion bar 9 as a result of a driver actuating the steering means 10 .
[0026] The steering device 2 moreover comprises a steering gear 11 , which is designed, for example, as a rack-and-pinion steering gear. The steering gear can further be designed as a ball-and-nut gear or recirculating-ball gear. The description hereafter primarily assumes a rack-and-pinion steering gear—to the extent necessary—in which the steering gear 11 comprises a pinion 12 a and a toothed rack 12 b . The steering gear 11 is connected to the wheels 14 , for example, by way of the pinion 12 a and the toothed rack 12 b and by a steering linkage 13 .
[0027] The steering device 2 further comprises a torque sensor 15 for detecting a steering torque torSW and a sensor 16 for detecting a steering wheel angle angSW. In the exemplary embodiment shown in FIG. 1 , the sensor 16 is associated with the motor 7 , so that the sensor 16 detects a rotor angle of the motor 7 . This angle corresponds to the steering wheel angle angSW (potentially with the exception of a factor that denotes a gear ratio) because the motor 7 cooperates with the torsion bar 9 , and thus with the steering means 10 , via the transmission 8 . The steering wheel angle angSW can also be detected by means of a sensor that is associated with the steering means 10 or the torsion bar 9 . The sensor 16 disposed on the motor 7 , however, can achieve a higher resolution by detecting the rotor angle.
[0028] The steering device 2 further comprises a sensor 17 , which can be used to determine a toothed rack force torR. The toothed rack force torR corresponds to a transverse acceleration or a cornering force acting on the toothed rack 12 b by way of the wheels 14 and the steering linkage 13 . It would also be possible, of course, to determine the transverse acceleration or toothed rack force torR using other known methods. The toothed rack force torR is transmitted to the controller 1 .
[0029] In an alternative embodiment, the toothed rack force torR is estimated based on other variables. This estimation is also carried out, for example, by means of the controller 1 . In this case, it is, of course, not necessary to detect the toothed rack force torR by means of the sensor 17 and transmit a corresponding signal to the controller 1 .
[0030] The steering torque torSW detected by the torque sensor 15 and the steering wheel angle angSW detected by the sensor 16 are likewise transmitted to the controller 1 . Moreover, a current vehicle speed velV is transmitted to the controller or calculated there based on other variables. A steering speed anvSW is also supplied to the controller 1 . The steering speed anvSW denotes the rotational speed by which the steering means 10 , and thus the torsion bar 9 , can be actuated. The steering speed anvSW can be captured by way of a suitable sensor, for example at the torsion bar 9 . It is also possible for the steering speed anvSW to be found by the controller 1 , for example as a function of the existing steering wheel angle angSW and the time.
[0031] The operating principle of the method for determining a target steering torque which is executed in the controller 1 is shown based on the block diagrams of exemplary embodiments in FIGS. 2 and 3 . The method is realized here in the form of a computer program, in which the individual blocks, or the functionalities corresponding thereto, are suitably implemented. The computer program is stored, for example, in the memory element 5 and is executed on the microprocessor 3 .
[0032] FIG. 2 shows a function 20 , by means of which a base steering torque torB is generated as a function of the toothed rack force torR and the vehicle speed velV. The base torque represents a base steering force level, which is determined, for example, by way of characteristic torque curves that can be applied and that are dependent on the toothed rack force torR. To this end, various progressions of the characteristic torque curves for various speed ranges are stored in the function 20 or are accessible to the function 20 . This allows functions that are known from hydraulic steering systems to be implemented. For example, it may be provided that a higher base steering torque is generated at a higher speed, whereby the servotronic effect known from hydraulic steering systems is achieved.
[0033] Moreover, the use of the toothed rack force results in improved feedback of information about the force conditions for the road-wheel contact. In this way, feedback is implicitly provided for information regarding a friction coefficient, the unevenness of the roadway surface, or a current driving condition, such as understeering or oversteering, for example.
[0034] In a function 21 , a centering torque torCF is generated as a function of the vehicle speed velV and the steering wheel angle angSW. The centering torque torCF presents itself to the driver at the steering wheel 10 as what is referred to as center point feeling. The centering torque torCF ensures that a steering torque in the direction of the straight-ahead position of the steering means 10 is generated as a function of the current steering wheel angle angSW so as to improve the steering feel around the straight-ahead position of the steering wheel.
[0035] In a function 22 , what is referred to as active return torAR is generated as a function of the steering wheel angle angSW, the vehicle speed velV and the steering speed anvSW, with this active return providing a steering torque in the direction of the straight-ahead position of the steering wheel, whereby a target steering speed, which is dependent on the steering wheel angle angSW and the vehicle speed velV, is established. Depending on the actual steering speed anvSW, the moment is restoring or damping.
[0036] In a function 23 , a damping torque torD, or what is referred to as active damping, is generated as a function of the steering speed anvSW and the vehicle speed velV.
[0037] In a function 24 , a hysteresis torque torF is generated as a function of the steering torque torSW, the vehicle speed velV and the steering speed anvSW. The hysteresis torque torF can also be referred to as a moment of friction, because it emulates friction that counteracts the steering wheel movement and the steering speed direction. In this way, the steering feel that is achieved, for example in SbW systems, comes close to that of conventional power steering, in which a mechanical connection exists between the steering gear 11 and steering means 10 .
[0038] The base steering torque torB, the centering torque torCF, the self-alignment torque torAR, the damping torque torD and the hysteresis torque torF are respectively conducted to an element 26 by one of the elements 25 _B, 25 _CF, 25 _AR, 25 _D and 25 _F. In the element 26 , the transmitted moments are superimposed, for example by way of addition, thus generating the target steering torque torTB.
[0039] The value of the respective moments torB, torCF, torAR, torD and torF can be reduced or amplified by means of the elements 25 _B, 25 _CF, 25 _AR, 25 _D and 25 _F. The elements 25 _B, 25 _CF, 25 _AR, 25 _D and 25 _F thus implement the abovementioned factors that make it possible to set the value of an individual moment torB, torCF, torAR, torD and torF, or the contribution of an one or more moments torB, torCF, torAR, torD and torF to the overall target steering torque torTB, to zero. This is advantageous, for example, when a target manual feel or a target steering torque torTB is applied to a particular vehicle. It is therefore particularly easy to check which individual component is the cause of an undesirable or faulty signal, and thus makes an undesirable or faulty contribution to the target steering torque torTB. Undesirable or faulty moments can develop in the system as a result of vibrations. This process thus allows better adaptability of the entire functionality.
[0040] The elements 25 _B, 25 _CF, 25 _AR, 25 _ and 25 _F also allow for easy switching between various steering feels. For this purpose, the elements 25 _B, 25 _CF, 25 _AR, 25 _ and 25 _F are parameterized, for example, so that, by predefining parameters, various steering feels can be directly implemented, for example by selection in a menu in the vehicle. This can be achieved particularly easily if the parameters correspond to the respective factors. According to an advantageous embodiment, at least one parameter is automatically determined as a function of a current driving condition.
[0041] In the exemplary embodiment shown in FIG. 2 , a quasi-stationary steering force level is obtained from the base steering torque torB, the centering torque torCF and the active return or the return torque torAR. In this exemplary embodiment, active steering wheel self-alignment in the direction of the straight-ahead position is influenced not only by the return torque torAR, but also by the centering moment of the centering torque torCF. In addition, functional coupling exists between the return torque torAR and the damping torque torD or the active damping, because these two moments generate a damping torque as a function of the respective application.
[0042] In order to make it even easier to apply the desired steering feel, in the exemplary embodiment shown in FIG. 3 , the moments influencing the quasi-stationary steering force level are functionally decoupled. For this purpose, in the exemplary embodiment shown in FIG. 3 , in a function 30 , first a base steering torque torB is generated, which corresponds to the base steering torque torB shown in FIG. 2 .
[0043] In a function 31 , a target steering wheel speed anvSWS is generated as a function of a current vehicle speed velV and a current steering wheel angle angSW. The significance of the target steering wheel speed anvSWS will be described in more detail hereafter in connection with other functions.
[0044] In a function 32 , a centering torque torF is generated as a function of the current vehicle speed velV and the steering wheel angle angSW. As with the centering torque torCF described in relation to 2 , this centering torque torC is a steering torque that acts in the direction of the straight-ahead position of the steering wheel. The centering torque torC, however, is primarily used as a centering or self-alignment torque, while the centering torque torCF described in relation to FIG. 2 is primarily used to generate a center point feeling. The portion of the target steering torque torTB responsible for self-alignment is implemented in the exemplary embodiment shown in FIG. 2 by means of the return torque torAR or the active return.
[0045] In a function 33 , a damping torque torD is generated, which corresponds to the damping torque torD represented by the function 23 in FIG. 2 . In a function 34 , a hysteresis torque torF is generated, which corresponds to the hysteresis torque torF represented in FIG. 2 and generated by function 24 .
[0046] The damping torque torD and the hysteresis torque torF are conducted to a function 37 by elements 36 _D and 36 -F. The elements 36 _D and 36 _F correspond to the elements 25 _D and 25 _F. As with the function 26 , the function 37 is used to combine the individual moments that are generated, and is achieved by way of addition, for example, whereby the target steering torque torTB to be generated is obtained.
[0047] The moments torB and torC generated by the functions 30 and 32 , and the target steering wheel speed anvSWS generated by the function 31 , are supplied to a function 35 . Using these moments and the steering wheel angle angSW and the steering speed anvSW, the function 35 finds a base steering torque with self-alignment torBC, which is supplied to the function 37 via an element 36 _BC. The element 36 _BC acts analogously to the elements 36 _D and 36 _F and consequently allows the contribution of the base torque with self-alignment torBC to the target steering torque torTB to be reduced, amplified or entirely eliminated.
[0048] The exemplary embodiment shown in FIG. 3 shows improved functional decoupling of the individual application functions 30 , 31 , 32 , 33 and 34 by first implementing the quasi-static steering force level by way of the base steering torque torB. Given the dependence on the toothed rack force torR, the base steering torque torB already generates a return behavior that is comparable to the return of a conventional hydraulic steering system. However, in the same manner as with the active return, or the return moment torAR shown in FIG. 2 , a self-alignment torque torC and a damping torque torC are also required for improved return behavior.
[0049] By means of the function 35 , a switch is made in the exemplary embodiment shown in FIG. 3 from the base steering torque torB to an undamped self-alignment torque, when the current steering speed anvSW is lower than the applicable target steering speed anvSWS, and when the base steering torque torB is less than the required self-alignment torque torC. The switch behavior can, of course, likewise be adjusted, whereby the functionality 35 can also be adapted to various vehicle types or steering feels that are to be achieved.
[0050] The function 35 can be suitably parameterized for this purpose. In addition, or simultaneously, the damping can be influenced or applied by means of the function 33 , and the damping torque torD generated by this function 33 , independently of a current steering force level and a self-alignment torque.
[0051] In principle, existing known electromechanical steering systems supply very little or no roadway feedback. Using the method or application structures according to the present invention, improved roadway feedback can be achieved. Because the information to be fed back, for example a change in the cornering force, is contained in the toothed rack force torR that is employed, this change in toothed rack force results in a corresponding change in the base steering torque, which in turn influences the target steering torque. A change in the cornering force can result, for example, from a change in a friction coefficient, an unevenness of the roadway, or during oversteering or understeering. The power of the implied roadway or driving condition feedback depends on the gradient of an applicable characteristic curve, by means of which the base steering torque is determined.
[0052] As mentioned above, the present example employs the toothed rack force torR on which the base steering torque torB depends. However, the base steering torque torB can, of course, also be applied as a function of another variable representing the cornering forces of the tires. A suitable variable is, for example, the transverse acceleration instead of the toothed rack force.
[0053] Using the proposed application structures, it is further particularly easy to transmit additional information about the target steering torque to the driver. For example, if a sudden change in the toothed rack force torR is detected, prompt amplified feedback can be provided so as to draw the attention of the driver to the drastic change. To this end, for example, an amplification can take place as a function of a current wheel speed, wherein at higher speeds the influence on the target steering torque can be increased. The wheel speeds can be used to detect or plausibilize interference, wherein a current difference in the wheel speeds of various wheels can notably be used.
[0054] Using the proposed application structures, further moments can be added with particular ease. For example, steering wheel rocking can be added by way of simple addition, so as to point out a particular hazard or prompt a driver, who may have become sleepy, to be attentive.
[0055] The proposed application structures can be implemented entirely independently of the underlying steering system. While FIG. 1 shows an electric rack-and-pinion steering gear, the proposed application structures can also be employed in a SbW system. Here, the motor 7 is then actuated, for example, so as to generate the manual steering torque torTB, wherein an additional electric motor, which is not shown, generates the actual steering torque, because no mechanical connection exists between the steering wheel, or the steering means 10 , and the steering gear 11 . The motor 7 can, of course, act on the torsion bar 9 , the toothed rack 12 b , the steering gear 11 or the steering means 10 in the known manner in various locations. | In order to achieve a steering feel for SbW systems and EPS systems having a control design for controlling the steering torque by generating a target steering torque (torTB) that can be adapted to various steering systems, vehicle types, or requirements, in which the resulting steering feel is a steering feel, in all driving conditions and driving situations, which is equivalent to, or better than, hydraulic and electromechanical steering systems available on the market today, according to the invention: a base steering torque (torB) is determined as a function of an externally acting force (torR) and a vehicle speed (velV); a damping torque (torD) is determined as a function of a steering speed (anvSW) and the vehicle speed (velV); a hysteresis torque (torF) is determined as a function of the steering speed (anvSW) and the vehicle speed (velV); a centering torque (torCF; torC) in the direction of the straight-ahead position is determined as a function of a steering wheel angle (angSW) and the vehicle speed (velV); and the base steering torque (torB), the damping torque (torD), the hysteresis torque (torF) and the centering torque (torCF; torC) form individual components, as a function of which the target steering torque (torTB) is determined. | 1 |
BACKGROUND OF THE INVENTION
[0001] The invention concerns shielding for radiation therapy source applicators, especially adjustable shielding for dynamic control of a radiation emission pattern.
[0002] Several forms of ionizing radiation therapy, particularly brachytherapy in which radiation is administered from a radiation source positioned within an anatomical cavity, are delivered using an applicator. Purposes for use of an applicator may include positioning the source within the cavity, mitigating radiation intensity incident on the cavity wall (radiation intensity decays exponentially with distance from the source), or tailoring cavity shape to facilitate radiation delivery in accordance with prescribed therapy parameters. Other purposes may also exist. The anatomical cavity may be a natural cavity, or may result from surgical intervention, for example as in the case of removal of a cancerous lesion.
[0003] Some applicators are essentially solid and of fixed configuration in that their shape doesn't vary during therapy. A typical fixed configuration applicator might comprise a catheter or wand, fashioned for placement within a body cavity, and into which a source, usually contained within a catheter, can be positioned. Such an applicator can be inserted into the body either through a natural orifice, or through a surgical incision or entry. Other forms of applicators may incorporate extensible elements which can be caused to alter shape after insertion into the body. A common form of the latter is a balloon applicator. Proxima Therapeutics Inc. of Alpharetta, Ga. (now part of Cytyc Corporation of Marlborough, Mass.) offers extensible applicators incorporating balloons. These applicator balloons are generally inflated with saline solution so as to attenuate radiation intensity near the source itself. With such an applicator, the source is ideally confined within a tube or channel within the balloon such that the position of the source within the outer skin or surface of the balloon is controlled and known. Preferably the shape of the inflated, extensible surface is coordinated with the radiation field of the source such that the intensity of radiation delivered just outside the surface of the balloon is uniform, below dangerous levels, but still strong enough to provide effective therapy.
[0004] Traditionally, the strength of the balloon, i.e. its rigidity or conformability, is chosen such that it shapes or tends to conform the tissues surrounding the cavity to the desired shape of the balloon as well to the radiation field expected from the source. When these factors can be simultaneously achieved, a uniform or isodose prescription can be delivered to the inner-most tissues forming the cavity. When this is the case, the therapist can be assured of a uniform therapy throughout the target tissue adjacent the cavity. All too often, however, this condition cannot be produced. Sometimes the cavity cannot be reshaped such that the radiation intensity outside the balloon is insufficiently uniform. Should this situation arise, a balloon which conforms to the existing cavity might be employed, but then different measures must be taken to assure delivered dose uniformity. In other instances, nearby tissue structures may lie within the therapeutic range of the radiation outside the balloon, and so would be injured were a therapeutic dose of radiation delivered. In these instances, the therapist cannot deliver a preferred treatment unless measures are taken to avoid over-treatment of at-risk tissue. It is these measures to which this invention is addressed.
[0005] The radiation source is usually positioned within or near the distal tip of a catheter to facilitate handling of the source and positioning it within the applicator. The radiation source may be isotopic in nature or it may be electronic, producing x-rays which can be utilized to produce a therapeutic effect similar to isotopes. Isotope sources pertinent to use with balloon applicators are generally referred to as high dose sources and may be in the form of point sources, comprising a single isotope “seed”, or they may be linear sources, comprising a series of seed sources, or a wire. When the source is a seed, multiple seeds or a wire, it is generally positioned in a catheter for insertion into the applicator in order to access the anatomical cavity to be treated. In other applications, the radiation source can be a fluid comprising radioactive material in suspension. This fluid can be used to inflate the extensible element of the applicator, rather than saline.
[0006] Radiation from radioisotopes is emitted in a known manner with a decaying intensity measured by the isotopes' half-life—the time at which half of their original intensity remains. Within practical time constraints, these parameters for a given radioisotope are fixed and they cannot be altered thus offering no possibilities for control. Furthermore, radioisotopes emit radiation at a few distinct energy bands, radiation from each band having its own ability to penetrate tissue and deliver dose. For example, the high-energy band of radiation emitted from 192 Ir, the most common high dose-rate brachytherapy isotope, penetrates through large thicknesses of shielding materials. In addition, isotopes are always “on”, so controlling the output with on/off switching is not possible. Other common and medically relevant radioisotopes also have emission spectra containing high-energy components that make selective shielding within a body cavity impractical due to space considerations. The radiation from these isotopes will penetrate any practical thickness of shielding material. This high-energy radiation easily penetrates well beyond the target site requiring therapy, thus delivering radiation to healthy parts of the body and risks injury. It also puts the therapist at risk, necessitating “bunker” type installations within which therapy can be conducted in the absence of attending personnel. This is a major disadvantage to the use of isotopic radiation in therapy.
[0007] In contrast, with electronically controlled radiation sources, the shape of the anode and its structure, and any minimal shielding utilized, determines the directionality of the x-rays emitted. Such an x-ray source is described in U.S. Pat. No. 6,319,188, the specification of which is incorporated herein in its entirety by reference. The emitted x-rays from such a source may be emitted isotropically, they may be directed radially, axially, or a combination thereof. Anode shaping is well known by those skilled in the art of x-ray generation apparatus. Anode shape, target thickness and target configuration can be used to change the radiation profile emitted from the miniature x-ray source. Also, miniature x-ray sources capable of producing the therapeutic effects of high dose rate isotopes only require thin radiation shields to selectively block emitted radiation, thus producing a directionally shaped radiation field. With electronically produced x-rays, the acceleration voltage determines the energy spectrum of the resulting x-rays. The penetration of the x-rays in tissue is directly related to the energy of the x-rays. The cumulative radiation dose directed at a point of the lesion may be controlled by x-ray source beam current or by “on” time within the body of the patient. Control of these parameters may be applied manually, or it can be automated in real-time based on matching output to a prescribed dose based on sensor feedback to a controller. An exemplary controlled system is described in co-pending patent application Ser. No. 11/394,640, filed Mar. 31, 2006, the disclosure of which is herein incorporated by reference in its entirety. This ease of control with x-rays and their minimal safety requirements are significant advantages to the therapist and the patient.
[0008] Therefore, in order to provide the therapist the ability selectively to protect radiation-sensitive or normal tissue structures from therapeutic dosages prescribed to treat diseased tissue, convenient apparatus and methods are needed which can be adapted to selectively shield these at-risk normal tissues while allowing prescribed dosages to adjacent, diseased tissue. The apparatus and methods of this invention provide the therapist this ability.
SUMMARY OF THE INVENTION
[0009] This invention comprises an array of shielding apparatus and methods which can be applied to solid (non-extensible) radiation therapy applicators. The invention further comprises apparatus and methods for use with applicators which incorporate an extensible element or elements, for example balloons. Some shielding embodiments are applicable to both types of applicator. Furthermore, in addition to being applicable to use of miniature x-ray sources for radiation therapy, they can be used with low dose rate isotopic sources where the emitted radiation can be effectively blocked by application of the shielding embodiments described.
[0010] As mentioned above, solid applicators may comprise flexible tubular sheaths or rigid wands, comprised of materials with minimal radiation attenuating properties, through the lumen of which a radiation source can be introduced and advanced into proximity of the tissue to be irradiated. If it is desired to shield a portion of the radiation output, radiation attenuating members may be incorporated into the catheter or applicator design, for example by providing an additional lumen or lumina within the sheath or wand shaft, through which a radiation attenuating member or members may be positioned adjacent the radiation source. By careful placement, the member or members may therefore be positioned to lie between the source and the tissue structures to be protected. The radiation attenuating members may be in fixed positions within the applicator relative to the catheter and/or source, or they may be moveable. Furthermore, if a plurality of attenuating members is employed, the members can be individually controlled or collectively controlled. If, for example, the members extend to the proximal end of the catheter or wand, control can be by hand manipulation, or by automatically actuated manipulation. Equally, manipulation can be indirect, for example by hydraulic actuation with pressure acting within the member lumen and acting against the proximal end of the member, assuming adequate seal between the member and lumen to achieve a piston effect.
[0011] If a single, tubular attenuating member is used, it can slide over the sheath or wand, or slide within the radiation source lumen, between the source and interior surface of the sheath. The attenuating member can be truncated angularly, or otherwise shaped, including comprising a window at its distal tip so as to produce the radiation output desired. If multiple attenuating members are employed, they can pass through individual lumina in the sheath or wand, or can be arrayed within an annular space inside the sheath lumen and outside of the source catheter. Each member may be shaped at its distal end in order to cooperate with adjacent members to produce the shielding effect desired. An exemplary shape of interest is both elongate and arcuate such that collectively, an array of adjacent members can be arranged to form a tube-like shield of attenuating material about the source within. Such an arrangement will substantially direct the radiation forward in the distal direction, with perhaps a lesser amount proximally toward the therapist (depending on applicator configuration), and very little radially. Alternatively, one or more of the attenuating “paddles” or finger-like shield segments can be individually retracted to produce circumferentially limited radiation output, directed radially. Such retraction can be constant, either open or closed. Equally, it can be cyclic, manually driven or automated, and can generate a rotating radiation path if desired.
[0012] Such an array, and the catheter and source, can extend beyond the distal end of the applicator sheath if desired. Proximal of the distal end of the sheath, the members or shield sections can transition from elongate arcuate paddles into round, wire-like extensions passing through applicator lumina and reaching the proximal end of the sheath, thereby permitting manipulation of the distal “paddles”. The entire assembly could be operable within the sheath wall. With this arrangement, the distal end of the sheath or wand could optionally be closed, rather than open to the cavity. If distally, axially directed radiation is undesirable in such a case, the distal end of the sheath can be capped with radiation attenuating material which is heavily absorptive of radiation.
[0013] Another embodiment of interest is a pair of nesting, attenuating tubes operating within the lumen of the sheath, and surrounding the source catheter. The distal ends of the two tubes are castellated with sections cut from the ends such that when properly aligned, the circumferential shield is complete, blocking radial emission. Relative rotation of the tubes can produce a radial beam or beams of radiation. Alternatively, the tubes can have cooperating windows such that relative rotation opens a desired window or windows for release of radiation. Or, the tubes may be translated axially relative to one another, such that the axial length of the windows can be varied. If the relative position of the tubes is arranged to form a fixed window, the tubes may be translated and rotated to collectively irradiate a desired portion of the cavity tissue. See copending application Ser. No. 11/323,346, filed Dec. 30, 2005, the disclosure of which is included herein by reference, describing relatively movable windows in concentric tube shields.
[0014] In the embodiments discussed above, the shielding apparatus described is generally movable relative to the sheath body or shaft, comprised of a singular or a plurality of cooperating components and is independent of, but coordinated with, movement of the source catheter and source. The shield can be stationary, with the source movable axially.
[0015] In another embodiment, a solid applicator is comprised at least partially attenuating material, at least at the distal end of the sheath, so fashioned as to permit a radiation field having preferred shapes and characteristics dependent on the location of the source within the sheath. As a simple example, a tubular, attenuating shielding extension can be affixed to the distal end of the applicator sheath. The internal diameter of the extension can correspond to that of the sheath such that the source may be moved freely through the internal lumen of the assembly. The outer diameter of the extension, however, may be tapered or stepped, diminishing distally, such that the radiation delivered radially may be attenuated somewhat when the source is positioned distally, but more heavily attenuated when the source is positioned more proximally within the sheath assembly. Similarly, the solid tubular shield extension may be circumferentially notched or incomplete such that relatively unattenuated radiation emanates radially where portions of the shield are thin or missing, but purposely attenuated where they are all present. In such a fixed construction, the distal tip may or may not be blocked by attenuating material as suits the situation.
[0016] As stated earlier, attenuation apparatus may be fashioned for applicators with extensible or balloon elements, through which the therapeutic radiation passes. Most, if not all, of the shielding embodiments described above for use with solid applicators may be applied to balloon applicators as well, with the attenuating members functioning within or about the sheath or shaft onto which the balloon is affixed. In other respects, the description of these embodiments is similar, but the shielding portions of the embodiments operate within and are enclosed by the balloon. The balloon itself provides additional shielding opportunities, including opportunities to more precisely shape the intensity of the radiation field selectively.
[0017] When a balloon is being used as part of an applicator, the target zone for therapeutic radiation is generally a tissue volume all around the inflated balloon extending about one centimeter radially outwards from the surface of the balloon. It is this tissue which is generally thought to be most susceptible to recurrence of disease, especially cancer. For therapeutic purposes, a minimum intensity is required for cell destruction, and this minimum forms the basis for the prescription dose one centimeter outward from the surface of the balloon. As is known to those of skill in the art, radiation intensity decays exponentially as it passes through matter, therefore the intensity at the surface of the balloon will be greater than at the one centimeter target depth. It is important that the intensity at the balloon surface not be substantially greater than at target depth, however, since that would be overly destructive, and might risk injury to adjacent healthy tissue. At the surface of the source or source catheter, the intensity of the radiation is usually too high for therapeutic use.
[0018] Balloon applicator design utilizes the attenuating properties of the inflation medium in the balloon and the balloon membrane itself to attenuate radiation intensity from a high level at the source catheter to manageable intensity at the outer surface of the balloon. This is achieved by manipulation of attenuating properties of the inflation medium and balloon, and/or by the geometrical size and shape of the balloon. The useful effect of this technique is that the ratio of radiation intensity incident on the tissue at the balloon surface to the intensity one centimeter outward from the balloon is reduced, implying a more uniform dose throughout the target tissue. This phenomenon is called “beam hardening”.
[0019] The absorption properties of the balloon membrane itself can be varied to tailor to suit the overall design situation. Balloon materials are usually polymers and are commonly polyurethane, PET, silicone rubber, or similar materials well known to those of skill in the art. The material of most balloon membranes is normally quite transparent to radiation, but their radiation attenuating properties can usually be tailored by loading them with attenuating fillers. Attenuating fillers such as barium sulfate and metallic particulates can be compounded into these balloon materials. Other fillers are also well known to those skilled in the art. The higher the filler loading generally, the more attenuating the resultant material, and the more rapid the exponential decay of the radiation incident upon it. In the end, total attenuation of a material is a function of both its attenuation properties as well as the thickness over which those properties block the path of the radiation. Therefore, a weakly attenuating but thick material may be equally effective at shielding tissue from radiation as a thin but strongly attenuating material.
[0020] In addition to material composition modifications to the balloons, their construction can be altered as well. For example, the wall thickness of the balloon membrane can be varied selectively during the manufacturing process. Thickness variations can result from molding design, or they can result from fabrication of balloon using materials of dissimilar thicknesses. Fabrication of materials of similar thickness, but different filler loadings may also be used to selectively shield specific balloon areas. See also copending applications Ser. No. 10/683,885 (filed Oct. 13, 2003) and Ser. No. 10/962,247 (filed Oct. 8, 2004) regarding attenuating balloons. The disclosures of both copending applications are included herein by reference.
[0021] As described above, the balloon may serve the further purpose of mechanically shaping the cavity by virtue of the pressure within the balloon. If the shaped cavity corresponds to the source intensity pattern, uniform dosage as prescribed is a relatively simple matter. In instances where the cavity either has a free-form shape or cannot be formed into a preferred shape, a balloon having elastic behavior (cavity filling) may be preferred in order to avoid air gaps outside the balloon adjacent the tissue forming the cavity. Such balloons may be of many of the same but the more elastic of the membrane materials outlined above, but probably with lesser wall thicknesses. Fillers can be similarly compounded into the material, or fabrication techniques can again be used to tailor attenuation. What is not under control where balloon behavior is elastic is the distance to target tissue from the source. Care must be taken to assure that the intensity of delivered radiation remains between the prescribed level and the danger level over the total balloon surface. Thicknesses may also be varied, but the problem becomes very complex because irregular expansion of the balloon alters the membrane thickness as well as its loading of filler per unit area, and hence its attenuating properties. Generally, the greater the distance the balloon expands, the thinner the membrane in that area.
[0022] In use of either solid or balloon applicators, either those of the invention, or prior art applicators, it may be desirable to provide shielding for the therapist in the proximal direction along the shaft of the wand or catheter. Particularly when the applicator is in use near a body opening, radiation may escape proximally along the shaft out of the patient toward where the therapist is likely to be positioned. When such exposure is likely, a local shield may be employed which is mounted on the applicator shaft to shield in the proximal direction. This embodiment may be solid sort of flange, and overlap the body opening sufficiently to block any such radiation effectively. Alternatively, it may fit within the body opening, forming a radiation seal in concert with the opening. Further, it may comprise an inflatable element independent of or integral with the main inflatable element of the applicator. Still further, on a balloon applicator, it can comprise a shielding member or attenuating segment at the proximal end of the primary applicator balloon such that it is automatically deployed when the applicator is put into use, and is of adequate scope or projection to prevent outwardly directed radiation toward the therapist.
[0023] These and other features and advantages of the present invention will become apparent from the following detailed description of preferred embodiments which, taken in conjunction with the accompanying drawings, illustrate by way of example the principles of the invention.
DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1 a is a perspective view of the tip of a solid applicator with an open tip, and having a source catheter positioned within emitting axially directed radiation at the tip.
[0025] FIG. 1 b is a perspective view of the embodiment of FIG. 1 a , but with the source catheter advanced and emitting radiation isotropically.
[0026] FIG. 1 c is a perspective view of the tip of the embodiment of FIG. 1 a , but with a closed tip which can be opened by advancement of the source catheter of FIG. 1 a.
[0027] FIG. 1 d is a perspective view of the tip of the embodiment of FIG. 1 c , but with the source catheter advanced and emitting radiation.
[0028] FIG. 2 a is a perspective view of the tip of a solid applicator having “paddle” shaped shielding elements deployed circumferentially at the tip of the applicator sheath, and showing proximal extensions of the shielding members for axial manipulation of the elements from outside the patient, and with an axially shielded source catheter positioned within the shielding members.
[0029] FIG. 2 b is a perspective view of the applicator tip of the embodiment of FIG. 2 a with two of six shielding elements retracted and partially exposing the top side of the source catheter in order to emit radiation radially over a portion of the applicator circumference.
[0030] FIG. 2 c is a section taken through the shaft of the applicator of the embodiment of FIG. 2 a.
[0031] FIG. 3 a is a perspective view of the tip of a two-part, coaxial attenuation embodiment to be positioned over the source catheter but within the sheath lumen, having castellated ends that in this view are so rotated as to act in concert to shield radial radiation completely.
[0032] FIG. 3 b is a perspective view of the embodiment of FIG. 3 a , but with the two parts so rotated as to permit two opposed beams of radiation radially.
[0033] FIG. 4 a is a perspective view in partial section of the tip of a two-part attenuation embodiment, with open tip, to be positioned over the source catheter, each part having a window and the windows shown so rotated as to block all radial radiation emission.
[0034] FIG. 4 b is a perspective view of the embodiment of FIG. 4 a , but with one window rotated and translated such that the window is partially open.
[0035] FIG. 4 c is a perspective view of the embodiment of FIG. 4 a , but with the tip of the inner part capped to prevent radiation emissions distally.
[0036] FIG. 5 is a perspective view of a one-part attenuation embodiment to operate within the applicator sheath and over the source catheter, having an angularly truncated distal tip, and with a source catheter shown within, such that directional radiation is provided.
[0037] FIG. 6 is a perspective view of another one-part embodiment as in FIG. 5 , but having a window through which radiation can emanate so as to provide directional radiation.
[0038] FIG. 7 is a cross sectional view of the tip of a one-part attenuating sheath having a tapered distal tip to provide varied attenuation.
[0039] FIG. 8 is a cross sectional view of the tip of a one-part attenuating sheath having a stepped distal tip to provide varied attenuation.
[0040] FIG. 9 is a perspective view of an applicator similar to that of FIG. 1 b but including a balloon.
[0041] FIG. 10 is a perspective view of an applicator similar to that of FIG. 2 b but including a balloon with the applicator affixed to the balloon at two points.
[0042] FIG. 11 is a side elevation view with partial sectioning showing a balloon applicator having a shielding apparatus similar to that of FIG. 4 b and with the applicator sheath affixed to the balloon at two points.
[0043] FIG. 12 is a side elevation view of a balloon applicator having a one-part shield similar to that of FIG. 5 .
[0044] FIG. 13 is a side elevation view of a balloon applicator having a one part shield similar to that of FIG. 6 with the applicator sheath affixed to the balloon at two points.
[0045] FIG. 14 is a side elevation view showing two axially shielding embodiments to attenuate proximally directed radiation, the one at right being a shielding section molded as part of the balloon or affixed on the balloon during or after balloon manufacture, and the embodiment at left being a solid attenuating flange with hub mounted slidably on the shaft of the applicator.
[0046] FIG. 15 is a side elevation view of a balloon applicator having an inflatable, attenuating balloon collar as an integral part of and proximal to the main applicator balloon.
[0047] FIG. 16 is a side elevation view of a balloon applicator and source having an independently inflatable collar mounted on the shaft of the applicator.
[0048] FIG. 17 is a schematic view of a balloon applicator positioned within breast tissue in the vicinity of a bone (rib) wherein the balloon has a shielding segment positioned adjacent to the bone so as to protect the bone from radiation.
[0049] FIG. 18 is a schematic view of an applicator and source positioned within breast tissue and having a solid flange shield as in FIG. 14 positioned on the applicator shaft at the entry into breast tissue.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0050] The figures generally illustrate the shielding embodiments of the present invention wherein the shielding serves to selectively protect certain tissue structures while not interfering with prescribed radiation therapy. In the drawings, the straight sheath or shaft of the applicators illustrated are shown shorter than they would in fact be. Furthermore, balloons are depicted as being transparent in order to more clearly illustrate apparatus within the balloons.
[0051] FIG. 1 a shows a simple, solid, tubular attenuating applicator 10 having an open end 11 , into the lumen of which is inserted a source catheter 12 . Depending on the source and catheter characteristics, radiation can be emitted from the distal end. The degree of collimation will depend on the depth of the source within the applicator lumen. Such an applicator can be fashioned from a polymer like polyurethane, polypropylene, or a metal like stainless steel. In general, at least with electronic radiation sources, most metallic shielding totally absorbs any incident radiation in the range of interest for brachytherapy. If polymeric, attenuation can be controlled by filler additions into the material from which the applicator is made. Typical fillers might include barium sulfate or tungsten or stainless steel powder. Generally, the greater the filler component, the greater the degree of attenuation in the resulting filled material. In design, this applicator need be nothing more than a tube, perhaps extruded if polymeric, and drawn or machined if metallic.
[0052] FIG. 1 b illustrates how such an applicator 10 as shown in FIG. 1 a might function when the source 13 is advanced to a position distal of the end of the applicator shaft. In this case, the radiation is shown as if the source is essentially isotropic, emitting radiation throughout generally a spherical envelope.
[0053] FIG. 1 c shows a variation of the applicator 10 of FIG. 1 a , but with a closed tip which is separated into segments 14 which can hinge out of the way of the source catheter 12 as it is advanced. In this way, the embodiment shown is self-closing and can completely close off radiation when the catheter is withdrawn within the applicator rather than emitting radiation distally out of an open tip as in FIG. 1 a . When the source and catheter are advanced, however, the tip opens by the segments hinging as shown in FIG. 1 d , permitting radiation emission as in FIG. 1 b . This can be accomplished with a polymeric material that tends to retain and to return to a preferred shape as in FIG. 1 c.
[0054] FIGS. 2 a - 2 e show an applicator 20 having a central lumen 21 for positioning the source catheter 12 centrally within the applicator 20 . The applicator 20 also has satellite lumina 24 for positioning and manipulating paddle-like attenuation members or fingers 22 positioned in slots 23 within the wall of the shaft or sheath of the applicator tip, into which the paddles can be partially or completely retracted. Paddles 22 have rod-like proximal extensions 25 operating in lumina 24 which can be used to manipulate the paddles or fingers from outside the patient's body, as indicated by the axial arrows. Alternatively, the paddles 22 and source 13 can function completely within the envelope of the applicator, never emerging axially from the tip of the applicator. In this embodiment, the applicator sheath 20 is fashioned from a polymer as described above, but with minimal attenuating filler, and more preferably without filler. The paddles are made of filler loaded, attenuating polymer such as that described above. They could also be metallic. In operation, retraction of selective paddles as shown in FIG. 2 b will allow radiation emission in selective sectors around the circumference of the applicator. When positioned to act in concert, all radial emissions can be blocked or absorbed. Radiation can be swept rotationally by active use of the shielding members.
[0055] FIG. 2 c shows a cross section through the shaft or sheath of the applicator 12 . The lumina 24 for operating the paddles 22 are arranged as satellites around the central lumen 21 through which the source and its catheter are passed. It must be appreciated that other than paddle shapes can be employed without departing from the scope this invention.
[0056] FIG. 3 a depicts a pair castellated tubes 31 and 32 designed to operate within the central lumen of the applicator (not shown), but generally surrounding the source catheter (not shown). When the tubes are positioned as shown in FIG. 3 a , all radial emission is blocked. When positioned as shown in FIG. 3 b , circumferential segments 33 of the applicator emit radiation. At intermediate relative rotations, those segments are narrower than when fully open, as shown. In the embodiment shown, the castellation notches are rectilinear. They could equally be other shapes to suit a given situation without departing from the invention. The materials for the two tubes is preferably metallic, or alternatively attenuating polymers containing fillers as described previously.
[0057] The embodiment shown in FIGS. 4 a and 4 b generally corresponds to that of FIGS. 3 a and 3 b , but rather than notches in the ends of the tubes, each tube 41 , 42 has a window 43 , 44 which can be positioned to cooperatively restrict the beam of radiation allowed to exit the applicator. The beam can be restricted axially by axial adjustment of one tube relative to the other, and it can be limited circumferentially by relative rotation (see arrows). Depending on the attenuation properties chosen, the beam can be partially blocked (one tube thickness of attenuation) or not attenuated (open window). By blocking the end of one or both tubes, by a disc 45 integral with tube 42 for example, axial (distal) radiation can be blocked as well.
[0058] FIGS. 5 and 6 show one-part shield embodiments 50 , 60 that comprise tubes which can be manipulated (see arrows) to operate within the applicator lumen (not shown) and outside of the source catheter 12 , or alternatively outside the applicator shaft or sheath, or still further, can comprise the applicator sheath itself. The end can be shaped arbitrarily to suit the situation at hand. FIG. 5 shows a truncated, obliquely angled tip 51 whereas FIG. 6 shows a window 61 which can optionally have a sealed tip 62 (as shown). With such a shielding apparatus, the materials of construction are preferably attenuating.
[0059] FIGS. 7 and 8 show applicator tips 71 , 81 which have graduated levels of shielding attenuation along their length by virtue of their geometry—the more distal, the less attenuating. In the embodiments shown, one tip 72 is tapered ( FIG. 7 ), and the other tip 82 stepped ( FIG. 8 ). If the source is positioned near the distal tip of the applicator, the radial radiation is more intense. if more proximal, the radiation is less intense. The tip may be open (as shown) or optionally sealed to prevent axial emission.
[0060] FIG. 9 depicts a balloon applicator apparatus corresponding in part to the applicator described in FIGS. 1 a, b , but having a balloon 100 affixed to the shaft or sheath of the applicator 103 at point 102 . A conventional hub 101 is affixed to the proximal end of the applicator shaft or sheath in order to provide for both source catheter 12 introduction through the in-line port which is fitted with seals (not shown) to prevent balloon leakage past the catheter shaft, and for inflation of balloon 100 through the auxiliary port, a connecting lumen within the wall of the applicator shaft, and through a port in the shaft into the balloon. The elements of the inflation circuit are not detailed since they are standard within the industry.
[0061] FIG. 10 depicts a balloon applicator apparatus corresponding in part to the applicator described in FIGS. 1 a, b , but having a balloon 100 affixed to the shaft or sheath of the applicator 103 at point 102 . A conventional hub 101 is affixed to the proximal end of the applicator shaft or sheath in order to provide for both source catheter 12 introduction through the in-line port which is fitted with seals (not shown) to prevent balloon leakage past the catheter shaft, and for inflation of balloon 100 through the auxiliary port, a connecting lumen within the wall of the applicator shaft, and through a port in the shaft into the balloon. The elements of the inflation circuit are not detailed since they are standard within the industry.
[0062] FIG. 11 depicts a balloon applicator apparatus incorporating shielding elements similar to those of FIGS. 4 a, b , but having a balloon 120 affixed to the applicator shaft at point 121 on applicator shaft 122 . Within applicator shaft lumen, but outside the source catheter 12 , are the two tubular shielding tubes 41 and 42 each having windows 43 and 44 , and extending distally to be received by cup 124 , providing rotating fixation of the balloon 120 relative to the applicator axis at two points. At the proximal end of the applicator shaft is a conventional hub 123 . The source catheter and shielding tubes all pass concentrically through the straight port, with conventional seals (not shown) between adjacent parts to prevent balloon leakage. The auxiliary port is for inflation of the balloon 120 through a connecting lumen within the wall of the applicator shaft, and a port in the shaft into the balloon. The elements of the inflation circuit are not detailed since they are standard within the industry.
[0063] FIG. 12 depicts applicator apparatus having a truncated, oblique shield sleeve 131 similar to that described in FIG. 5 , but with a balloon 130 affixed to applicator sheath 133 at a point 132 . A conventional hub 134 is affixed to the proximal end of applicator sheath 133 to provide for introduction of the source catheter 12 and the shield sleeve 131 , each of which must be properly sealed. The auxiliary port is for inflation of balloon 130 through this port, a connecting lumen within the wall of the applicator shaft, and through a port in the shaft into the balloon. The elements of the inflation circuit are not detailed since they are standard within the industry.
[0064] FIG. 13 depicts applicator apparatus having a shield sleeve 141 with window, similar to that described in FIG. 6 , but with its distal tip extended, and a balloon bonded or otherwise affixed to the applicator shaft 143 at a point 142 . The distal extension of shield sleeve 141 cooperates with a balloon mounted cup 145 to provide a rotational fixation between sleeve 141 and balloon 140 , thus providing two point balloon fixation as previously described. A conventional hub 144 is affixed to the proximal end of applicator shaft 143 to provide for introduction of the source catheter 12 and the shield sleeve 141 , each of which must be properly sealed. The auxiliary port is for inflation of balloon 140 through this port, a connecting lumen within the wall of the applicator shaft, and through a port in the shaft into the balloon. The elements of the inflation circuit are not detailed since they are standard within the industry.
[0065] FIG. 14 depicts a balloon applicator 148 having two alternate shielding apparatus for preventing, or at least attenuating, radiation directed along the applicator shaft 159 , proximal of a balloon 150 . To the right is an attenuating portion 151 of the balloon itself. This portion can be an integral portion of the balloon, with a hub as shown, or alternately without a hub, either molded in place or bonded to the balloon after or as part of fabrication, or as a segmental part of the balloon itself and included in the fabrication process. Preferably it is of polymer and filled with attenuating filler as previously described and sufficiently flexible so as to expand with the balloon upon inflation. To the left in FIG. 15 is a stand-alone flange 152 with collar 153 to affix the flange to the applicator shaft, as an alternate embodiment. The flange is solid and is optionally movable along the applicator shaft 159 (see arrow) by a sliding fit tight enough to retain its set position, or alternately having a conventional clamp or bonded fastening. The flange material is preferably a filled polymer, but could be metallic.
[0066] FIG. 15 depicts a balloon applicator 158 having a balloon 160 which in turn has an integral inflatable torus 161 located on an applicator shaft 169 proximal of the main balloon 160 . The torus 161 is preferably a filled polymer, acting as a radiation shield that is deployed as the balloon 160 is inflated.
[0067] The embodiment 168 of FIG. 16 is similar to that of FIG. 15 , but in this instance, the torus 171 mounts on an applicator shaft 169 proximal of main balloon 170 . With appropriate accommodation for inflation, as for example by a separate tube outside the applicator shaft, the torus 171 can be movable on shaft 169 . It could also be fixed axially, and have an internal inflation as has been described for the main balloons. This torus is also preferably of a filled polymer.
[0068] FIG. 17 shows an applicator 178 similar to the apparatus described in FIGS. 1 a , 1 b and FIG. 10 , except that a segment 181 of the balloon 180 is made attenuating by adding attenuating material to one portion of the balloon. The applicator is shown within breast tissue 178 , and adjacent to a bone, in this example, a rib 182 , with the attenuating material situated between the source 179 and the rib.
[0069] FIG. 18 shows an applicator 188 with balloon 190 and source 192 within breast tissue 19 and having a solid flange 189 as described in FIG. 14 (to the left) mounted on the applicator shaft 191 . The flange 189 in this embodiment is shown slightly cupped to conform to the breast surface. In other applications, the flange may optionally be shaped to accommodate different anatomy.
[0070] An important feature of most of the above embodiments is that a radiation shield is included on an applicator, the shield having radiation attenuating properties that vary with position. Such variation with position includes positions beyond the shield, where no attenuation occurs, and includes positions where a hole may occur in a shield, for zero attenuation at that hole or window. Thus, variation with position is intended to include a simple shield wherein the x-ray source is positioned so as to have its radiation attenuated by the shield or positioned so as not to have its radiation attenuated.
[0071] The above described preferred embodiments are intended to illustrate the principles of the invention, but not to limit its scope. Other embodiments and variations to these preferred embodiments will be apparent to those skilled in the art and may be made without departing from the spirit and scope of the invention as defined in the following claims. | Brachytherapy applicators incorporate various forms of selective shielding devices for controlling the direction and intensity of radiation directed at a patient's tissue. In some forms the applicators include a retractable sheath, in some a series of retractable fingers. In other forms the applicator, having an inflatable balloon, has a shield which is retractable from a position adjacent to the balloon or retracted from the balloon, or a shield can itself be inflatable, separately or together with the balloon. | 0 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates generally to reusable medical apparatuses and, more particularly, to thermometry devices with memories and post-sale servicing of such medical apparatuses.
[0002] Many reusable medical apparatuses have a finite lifetime based on usage after which they either fail or become more prone to failure than is considered safe or effective for its intended purposes. In the case of a thermometry device, for example, the active components such as the temperature-measuring probe may fail after excessive use. In some cases, the life of these devices has been found to be more a function of the usage cycles or number of procedures than the cumulative usage time.
[0003] Therefore, in order to keep these devices in good working condition, users need to keep track of either or both: the cumulative usage time, and the usage cycles. Often times, a reusable device gets used well beyond its intended lifetime without being noticed, which compromises its accuracy in the case of a measuring or diagnostic device, or efficacy in the case of a therapeutic device. Record keeping, however, requires constant diligence and obviously can be burdensome to nurses, doctors, and other healthcare providers especially for devices that are often used in routine patient visits such as thermometers. Even if the user keeps good record of usage, significant delays still occur when records indicate it is time for replacement. The delay could happen at the user level, for example, due to effort to match a particular piece of device with its warranty information in order to find out the cost of replacement or repair. The delay could happen at the distributor level. Distributors sometimes wait for a significant amount of orders or returns to accumulate before they contact the manufacturer.
[0004] When a device actually malfunctions or fails, the repair or replacement task faces similar delays. Warranty information needs to be located, and there is still the question whether the distributor will act promptly. Further, without on-site diagnosis of the problem, it is often hard to order the right part or send for the right repair-crew.
[0005] On the manufacturer side, RMA (Return Merchandise Authorization) calls are often the service call with the highest call volume. If these calls can be shortened or eliminated, for example, by allowing the user easy access to the right warranty information, much saving can be achieved.
[0006] Therefore, there is a need, unfulfilled by current products in the market, for a device or apparatus that assists in record-keeping of reusable medical apparatuses, in error diagnosis, and for expediting and simplifying the servicing and billing procedure for reordering parts or entire devices.
BRIEF SUMMARY OF THE INVENTION
[0007] In general, the present invention provides a platform for medical device manufacturers, suppliers, and service-providers to better service previously sold medical devices. The invention enables a reusable medical apparatus or device, for example, an electronic thermometer, to record information on the device that can be accessed and processed for service, repair and billing purposes, e.g., with regard to replaceable parts. At least three kinds of service information can be recorded and updated automatically this way:
[0008] (1) Number of uses: a record of usage cycles enables the device to alert the user when it is time to replace the device or parts of it;
[0009] (2) Warranty information: knowing whether the device is still under warranty can expedite the return/reorder process and to automate the generation of RMA numbers;
[0010] (3) Error codes: enables the user to identify the exact problem in the device and initiate more effective service calls or orders.
[0011] In one aspect, the present invention provides a novel electronic thermometer that is capable of storing, processing and displaying various service information by itself, i.e., on a stand-alone basis. The electronic thermometer includes a controlling base that houses controlling electronics programmed to at least calculate a sensed temperature, a probe assembly having a heat-conducting probe removably attached to the controlling base to communicate electrically with the controlling electronics, and an electronic memory associated with the probe assembly programmed to store at least one piece of the probe-specific service information.
[0012] In one embodiment, the electronic memory is an electrical erasable programmable read-only memory (EEPROM) that is disposed in a connector connected to the probe. The connector provides removable electrical connection between the probe assembly and the controlling electronics in the base unit of the thermometer. In one feature, the thermometer further includes a counter that generates the probe's usage count—that information is updated, after each use of the probe, and stored in the EEPROM. When the usage count reaches a predetermined number, which is programmable, an indicator generates a signal. The signal can be a user-actionable message, e.g., a message prompting the user to take certain action such as reordering a replaceable probe. In another embodiment, the electronic memory is disposed in the controlling base of the thermometer. Other probe-specific service information may include information related to a probe warranty or error codes.
[0013] In another aspect, the present invention provides a system for servicing a reusable medical apparatus. The system utilizes a remote processing facility which makes it possible to automate or otherwise expedite many post-sale services as the service providers can be connected directly to the end user through this system. The system of the present invention includes a reusable medical apparatus that has a reusable part and an electronic memory associated with the reusable part—the electronic memory being programmed to store at least one piece of service information specific to the reusable part—and a remote processing system programmed to process the service information for servicing the reusable medical apparatus.
[0014] In various embodiments, at least part of the remote processing system is disposed in a local computer or a handheld module, or connectable to the electronic memory in the medical apparatus through a network. In one feature, the network connection is the Internet, an intranet or an extranet. In another feature, the reusable medical apparatus is configured or adapted to plug into a Universal Serial Bus (USB) port. The reusable medical apparatus can be a medical sensor apparatus, e.g. a vital signs monitor. In one embodiment, the apparatus is a thermometer, spirometer, pulse oximeter, digital scale, sphygmomanometer, electronic stethoscope or a combination of any of the above. In another embodiment, the apparatus is an instrument for interrogating a sensory organ, such as the eye, ear, nose, throat, oral tract and skin. For example, the apparatus can be an otoscope, ophthalmoscope, retinoscope, autorefractor, tympanometer, audiometer, illuminator, laryngoscope, or rhinolaryngoscope.
[0015] In an embodiment, the remote processing system is programmed to initiate an order for the reusable part or the entire apparatus when a usage count of the reusable part stored in the electronic memory in the medical apparatus reaches a predetermined number. In another embodiment, based on information related to a warranty stored in the electronic memory, the remote processing system is programmed to generate a return merchandise authorization number if the warranty is in effect. In yet another embodiment, based on error codes stored in the electronic memory, the remote processing system is programmed to provide error information or initiate a service call.
[0016] In one embodiment, the present invention provides a system for servicing an electronic thermometer that includes:
an electronic thermometer having:
(a) a controlling base that houses controlling electronics programmed to at least calculate a sensed temperature; (b) a probe assembly comprising a heat-conducting probe; and (c) a connector in electrical communication with the heat-conducting probe and providing removable electrical connection between the probe assembly and the controlling electronics, the connector comprising an electrical erasable programmable read-only memory (EEPROM) that stores at least one piece of service information selected from the group consisting of usage count of the probe, probe warranty information, and probe error codes; and
a remote processing system accessible through an internetwork and programmed to process the at least one piece of service information for servicing the electronic thermometer.
[0022] In another aspect, the present invention provides a method of manufacturing a reusable medical apparatus such as a thermometer. The method includes the steps of programming an electronic memory to store at least one piece of service information specific to a reusable part (e.g., a thermometer probe) and connecting the electronic memory to the reusable medical apparatus. In one embodiment, the electronic memory is made to be accessible locally, e.g., through other parts of the apparatus and data is displayed locally. In another embodiment, the electronic memory is made to be accessible through a remote processing system described herein. In one example, the manufacturing method includes connecting the electronic memory to a connector, e.g., a USB plug, for access by the remote processing system.
[0023] A further aspect of the invention is a method for servicing a reusable medical apparatus. The method includes the steps of programming an electronic memory to store a service information specific to a reusable part of the apparatus, programming a remote processing system to process the information for servicing the reusable medical apparatus, and connecting the electronic memory to the remote processing system, e.g., through a network. The electronic memory can be associated with the medical apparatus, e.g., by being disposed in the reusable part or in a connector outside the reusable part.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1 is a perspective view of a thermometer embodiment.
[0025] FIG. 2 is a block diagram of a thermometer embodiment that has incorporated the present invention.
[0026] FIG. 3 is a block diagram of a second thermometer embodiment that has incorporated the present invention.
[0027] FIG. 4 is a block diagram of a remote processing embodiment of the present invention.
[0028] FIG. 5 is a block diagram of another embodiment of the present invention.
[0029] FIG. 6 is a front view of a connector assembly for the thermometer of FIG. 1 .
[0030] FIGS. 7 and 8 are exploded view of the connector assembly of FIG. 6 .
DETAILED DESCRIPTION OF THE INVENTION
[0031] The invention is herein described, by way of example only, 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 embodiments of the present invention only, and are presented in the course 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 several forms of the invention may be embodied in practice.
[0032] The principles of the invention are illustrated through examples of electronic thermometers, but should not be construed to be limited to such. In general, the present invention provides a memory device associated with a reusable medical apparatus where the memory stores service information related to a reusable (and typically replaceable) part of the device. In one feature, the medical apparatus is a medical sensor apparatus that has at least one sensor for sensing one or more physical parameters relating to the object of the medical interrogation (human or animal). Examples of such sensor apparatus include vital signs monitors which measure vital signs including body temperature, blood pressure, pulse rate, respiratory rate, lung functions, intracranial pressure, weight, and blood oxygen saturation levels. Such monitors include thermometers, sphygmomanometers, spirometers, electronic stethoscopes, digital scales, pulse oximeters, and so on. They can be devices dedicated to the detection or monitoring of a single vital sign or of a multiple vital signs. For example, one embodiment of such a device is the Spot Vital Signs® Monitor manufactured by Welch Allyn of New York, which measures body temperature, blood pressure, and blood oxygen saturation. In another feature, the medical apparatus of the present invention interrogates conditions in the sensory organs including eye, ear, nose, throat and the rest of the oral tract. Examples of such devices include otoscopes, ophthalmoscopes, retinoscopes, autorefractors, tympanometers, audiometers, illuminators, rhinolaryngoscopes, and laryngoscopes.
[0033] For illustration purpose, the medical apparatus of the present invention can be an electronic thermometer of the type disclosed in co-owned U.S. Pat. No. 6,971,790, the entire content of which is herein incorporated by reference. As disclosed therein and illustrated here in FIG. 1 , an electronic thermometer 10 includes a controlling base (or controller) 12 contained in a housing 14 , and a probe assembly 20 that is tethered to the base 12 by means of a flexible electrical cord 22 , shown partially and in phantom in FIG. 1 . The cord 22 has a probe end 24 and an opposite end 30 that couples to the base 12 , which, in term, houses controlling electronics (not shown) programmed to control the operation of the thermometer and to calculate temperatures from outputs received from the probe assembly 20 . The base 12 also includes a user interface 36 that includes a display 35 , as well as a plurality of actuable buttons 38 for operating the thermometer 10 . The thermometer 10 , in one embodiment, is powered by batteries (not shown) that are contained within the housing 14 . Obviously, it can also be powered by an external electric source. The probe assembly 20 includes a heat-conducting, temperature probe 18 tethered to the base housing 14 by the flexible cord 22 and is retained within a chamber 44 which is releasably attached to the base housing 14 . The chamber 44 includes a receiving cavity 46 that provides a fluid-tight seal around the probe 18 , once inserted, with respect to the remainder of the housing 14 's interior. Details of the chamber 44 is separately described in co-owned U.S. Ser. No. 10/268,844, the entire contents of which are herein incorporated by reference. The probe 18 is sized to fit within a patient body site (e.g., sublingual pocket, rectum, etc.). The probe assembly 20 , alternately, the probe 18 , is described herein as an example of a reusable part.
[0034] The present invention provides a mechanism for storing and updating probe-specific service information in a memory device associated with the thermometer 10 . In a preferred embodiment and as illustrated by the block diagram in FIG. 2 , the memory device 50 is disposed in the reusable part, in this case, the probe assembly 20 , so that the memory device physically goes with the reusable part and there is no risk of associating the memory and its stored data with a wrong piece of reusable part. However, one skilled in the art can readily appreciate that the memory device can be physically located in a more permanent part of the medical apparatus such as base 12 of the thermometer 10 , and be within the scope of the present invention.
[0035] Still referring to FIG. 2 , the thermometer's controlling base 12 includes a user interface 36 electrically connected to controlling electronics that includes a microprocessor 56 . In one embodiment, a read only memory (ROM) 57 , which holds the algorithm performed by the microprocessor 56 , and a random access memory (RAM) 59 for operation of the algorithm, are electrically connected to the microprocessor 56 . Optionally, a real-time clock 65 that has an output electrically connected to an input of the microprocessor 56 . The probe assembly 20 and the controlling base 12 connect to each other electrically through two mating connections 52 and 54 . Once connected, the processing circuitry in the base 12 can interrogate the memory device 50 for the stored probe-specific service information. That information can be displayed directly, or after being processed, through the user interface 36 . The displayed information can include a warning for the need for service (parts replacement, repair, recalibration, etc.). Alternatively, an indicator 58 can be actuated when such a need is detected. The indicator 58 , in one embodiment, is disposed in the probe assembly 20 , but can be disposed elsewhere in the thermometer 10 .
[0036] In a preferred embodiment, the memory device 50 comprises a non-volatile memory which does not lose its data after power is terminated. Examples of suitable memory devices include electrical erasable programmable read-only memory unit (EEPROM), RAM, and so on.
[0037] The probe-specific service information that the memory device 50 records can include warranty-related information and error codes. Examples of warranty-related information include the manufacturing date of the probe, probe identification, warranty number, customer number, date of purchase/delivery, the expiration date of the warranty, and a formula for calculating the warranty. Some warranties expire after elapse of a time period from an event, e.g., manufacturing, purchase or first use. Other warranties expire after an amount of use cycle has been performed by the replaceable part, the probe in this case. As is described herebelow, the thermometer can be configured to count and record how many times the probe has been used. Storage of warranty-related information allows a user, through the user interface 36 , to inquire about the warranty. Further, it allows a processing circuitry such as the microprocessor 56 in the thermometer base 12 to calculate if a warranty is still valid and still covers the probe. This information is important in a user's decision on servicing the thermometer and can eliminate unnecessary delays in initiating replacement orders, providing added safety and quality assurance for patients. If the warranty is determined to be valid and in effect, a request for a RMA number or label may be automatically submitted to the manufacturer.
[0038] Error codes stored in the memory device 50 provides a source for the processing circuitry in the thermometer to look up the exact problem when malfunction is detected. Instructions for further testing, if needed, and simple repair instructions may be displayed through the user interface. However, if repair by a professional service crew is needed, the correct contact information for the crew and the error code can be displayed so that a service call can be quickly and efficiently made. Other information that may be recorded on the memory device 50 includes probe identification (e.g., serial number), probe type, calibration data, date of last calibration, and so on.
[0039] Another type of information that the memory device 50 can store is a usage count of the probe 18 , and that information can be automatically updated each time the probe is used. Referring to FIG. 3 , a counter 60 is preferably disposed in the probe assembly 20 , but can be disposed elsewhere, e.g., in the thermometer base 12 , as long as the counter 60 is electrically connected to the memory 50 during operation of the thermometer 10 . The counter 60 is preferably a non-volatile counter that functions as an arithmetic unit to either add to a usage count or subtract from a preset value. Accordingly, a user may be able to view either the number of usage or the remaining amount of recommended usage for the installed probe. During use, the counter 60 is electrically connected to receive the same drive signals that actuate the probe 18 , and accordingly, is able to count each use cycle. For example, the counter 60 may be programmed to add a count every time it detects electric currency for longer than, say, 5 seconds. Depending on the specific use pattern of the medical apparatus, the counter 60 can be further programmed to avoid overcounting. For example, in using a thermometer, a user may have to adjust the placement of the probe several times before getting a reliable reading. During such adjustment, the user may turn on the probe for short intervals. To avoid counting each of such interval as a complete usage cycle, the counter 60 may be programmed to undergo a waiting period, say, of 3 minutes, after each addition before it can start adding again. In one embodiment, the optional indicator 58 emits a signal, e.g., two seconds of flashing red light, when use cycle approaches or reaches a preset value. The signal can be programmed to progress to become more persistent as the probe stays in use. The signal serves as a reminder to the user that replacement parts should be sought or ordered. This can be very effective because the patient will likely receive the signal with uneasiness. Optionally, there can be an additional interlocking device, a power-off switch, or a similar device that disables the probe 18 when the usage exceeds a preset value. In one embodiment of the present invention, whether the warning signal has been emitted or not, the user can, through the user interface 36 , access the data stored in the memory device 50 to find out how many times the probe has been used, how many use cycles are recommended by the manufacturer as the upper limit, or how much usage is left within the recommended parameter.
[0040] While the thermometer 10 , standing alone, may be able to perform all the processing functions described above, the required processing power may add too much burden on the size, the weight and/or the cost of the thermometer. Accordingly, part of or the entire processing power can be supplied remotely, e.g., through a network connection. This approach may also alleviate the amount of memory required of the on-probe memory device 50 and results in a smaller and less expensive chip. For example, as long as the on-probe memory device 50 stores a serial number for the warranty, the details of the warranty and related information needed to calculate the validity of the warranty may be stored in a remote memory device.
[0041] According to this aspect of the invention and referring now to the block diagram provided in FIG. 4 , the right half of both FIGS. 2 and 3 can be replaced with a remote processing system 70 that is separate from and outside the electronic thermometer when the user decides to review service options regarding the thermometer. The processing circuitry connection 54 can be a network port that mates with the connection 52 of the probe assembly 20 ( FIGS. 2 and 3 ). In a preferred embodiment, connection 54 is a universal serial bus (USB) port and connection 52 is a mating USB plug. Alternatively, a separate module or adapter (not shown) can be used to bridge between the probe assembly connection 52 and the processing circuitry connection 54 .
[0042] The processing circuitry connection 54 may be part of a first local computer 72 , in which case this computer may provide part or the entire processing needed. For example, from the first computer 72 , the user may download an applet from a website, e.g., one maintained by the manufacturer, to accomplish extracting the probe-specific service information from the on-probe memory device 50 . A dongle or another security device may be required for the access. The local computer 72 is located relatively close to where the thermometer is located, for example, in the same unit of the healthcare facility. In another embodiment, the first computer 72 is further connected to a second computer 74 through a network 76 . The network 76 can be an internetwork (e.g., the Internet/World Wide Web, an extranet, or an intranet), a global area network (GAN), a wide area network (WAN), a metropolitan area network (MAN), a Local area network (LAN), or a personal area network (PAN). Further, the network 76 can be connected through wires using, e.g., Ethernet technology, or wireless using, e.g., Bluetooth technology. The second, more remote, computer 74 may include a processor 75 , a memory 77 , a display 78 and a data-input device 79 (e.g., keyboard). In a particular embodiment, the network 76 is the Internet/World Wide Web or an extranet.
[0043] In one embodiment, the more remote computer 74 is located at the thermometer manufacturer's facility and connected to its own database in order to expedite servicing of the thermometer. The advantage of such a connection is that many of the service calls can be automated or substantially sped up. For example, as described above, the present invention enables determination whether a warranty for the replaceable part (probe) is still valid and in effect. If so, and since the user is able to connect to the manufacturer, an RMA number or label can be automatically generated at any time, eliminating the need for such a call to the manufacturer during business hour. As another example, when malfunction is detected, a service call can be automatically sent to the manufacturer or the contracting repair crew, and the applicable error code is supplied with the call to make the repair more efficient.
[0044] Alternatively, referring to FIG. 5 , the processing circuitry connection 54 , instead of being connected to a remote processor, may be part of a portable, preferably handheld, module 90 that has the processing power and any additional memory that is needed, and is installed with any special software needed for accomplishing the extracting and processing tasks. The portable module 90 should include a power source (e.g., battery) or connected to an external power source such that it can power up the memory chip on the probe.
[0045] Referring now to FIGS. 6-8 , an embodiment of the on-probe memory device is illustrated. In particular, the flexible cord 22 has one end 24 connected to the probe (see FIG. 1 ) and an opposite end 30 that leads into a connector 80 which houses the memory. The connector 80 includes an overmolded cable assembly 82 including a ferrule 85 for receiving the cable end 30 as well as a printed circuit board 84 having an EEPROM 88 and a counter 60 attached thereto. The connector 80 further includes a cover 92 which is snap-fitted over a frame 96 , which is in turn snap-fitted onto the cable assembly 82 . As such, the body of the EEPROM 88 and the counter 60 are shielded from the user while the programmable leads 89 extend from the edge and therefore become accessible for programming and via the base housing 14 ( FIG. 1 ) for input to the processing circuitry when a probe 18 is attached to the probe end 24 of the cord 22 . In other words, the programmable leads 89 can serve as the probe-side connection 52 depicted in FIGS. 2 and 3 . The frame 96 includes a detent mechanism, which is commonly known in the field and requires no further discussion, to permit releasable attachment with an appropriate mating socket (not shown) on the base housing 14 ( FIG. 1 ) and to initiate electrical contact therewith.
[0046] The probe-specific service information discussed above, such as error codes, and warranty number, can be added to the memory of the EEPROM 88 prior to assembly into the probe connector 80 through access to the leads 89 extending from the cover 92 . Date of purchase and other service-related information may be added to the memory of the EEPROM 88 at the point of purchase or the first time the connector 80 is connected to a processing circuitry, whether the circuitry is inside the thermometer base unit 12 ( FIGS. 2 and 3 ), a remote computer 74 ( FIG. 4 ) or a handheld module 90 ( FIG. 5 ). These data can then be accessed by the thermometer processing circuitry when the connector 80 is attached to the base housing 14 ( FIG. 1 ).
[0047] While the present invention has been particularly shown and described with reference to the structures and methods disclosed herein and as illustrated in the drawings, it is not confined to the details set forth and this invention is intended to cover any modifications and changes as may come within the scope and spirit of the following claims. | The present invention provides a platform for a manufacturer of reusable medical apparatuses to provide timely post-sale service for replaceable parts. In one embodiment, the probe assembly of an electronic thermometer has a connector that is equipped with a memory device, e.g., EEPROM, that stores a variety of probe-specific service information including usage count of the probe, probe warranty information and error codes. The user can plug the connector, e.g., through an adapter module, to a local computer's USB port and submit the stored service information to a website maintained by the probe manufacturer to check up and get service for the specific probe in a timely fashion. Automatic alert for replacement probe orders depending on the amount of usage, automatic generation of RMA numbers when the probe warranty is determined to be in effect, and automatic service calls for malfunctioning thermometers can all be accomplished accordingly without the need for manual record-keeping. A healthcare provider can simply set aside a day at a scheduled interval to check all of its reusable medial apparatuses equipped with the invented system to keep them safe and effective. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a utility application which claims benefit of U.S. Provisional Application No. 61/820,271, filed 7 May 2013. The entireties of the aforementioned application are incorporated herein by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
BACKGROUND OF THE INVENTION
[0003] The present invention generally relates to apparatuses to make tooling panels (boards) capable of acting as a template to make prototypes as well as parts to be manufactured on an on-going basis.
[0004] This invention relates to the field of machinable, synthetic tooling panels. More specifically, the invention comprises a medium for making machinable tooling panels by using air permeable core structures singly, stacking them in layers and/or side-by-side as well as methods for making the tooling panels. The individual air permeable components may have suitable coatings on selected outside surfaces as well as between segments.
[0005] The rapid production of prototypes by using tooling punch (boards) is a task frequently required in modern manufacturing. Furthermore, techniques to make prototypes using tooling panels can often be applied to the manufacturing process itself in various occasions.
[0006] Tooling panels are molds used to make parts from composites, thermo-formable sheets, resin infused fibers and the like. The top part of a tooling panel which will be in contact with the part to be manufactured is often formed into the shape required to make the prototype or part by machining it into the desired configuration. Tooling panels usually remain in intimate contact with the part to be made throughout the manufacturing process. Thus they mast undergo the same processing conditions such as thermal care that the part does.
[0007] Tooling panels have been made from a variety of substances such as wax, ceramic, wood and metal. In addition, polymers such as polyurethanes, epoxy resins and other polymeric substances have been used.
[0008] One provider of wax to make tooling panels is the Freeman Manufacturing & Supply Company. This wax can be readily machined to provide tooling panels from which parts can be formed. However, wax has a relatively low melting point and can only be used to make parts that do not require more than a moderate temperature cure cycle. In addition, the manufacturing process must not impose large forces on the wax tool panel or it will be destroyed.
[0009] Ceramic used to make tooling panels can be obtained from Advanced Ceramic manufacturing among other suppliers. Ceramic tooling panels overcome the low melt point associated with wax. However, ceramics tend to be brittle and dense. They are not rapidly responsive to dynamic temperature changes in ovens and autoclaves that are commonly used to make parts. Accommodation this sluggish temperature response by using slow temperature ramps may unnecessarily lengthen production time. Ceramic tooling panels are heavy and are difficult to use when large parts are to be made.
[0010] Wood has been used to make tooling panels and it can be shaped by various well-understood methods to make a tooling panel upon which to cure parts. However, wood is susceptible to dimensional changes when relative humidity changes. Its dimensions frequently change more in response to changing relative humidity than the part which will be formed from it. Wood is also relatively dense resulting in heavy tooling panels.
[0011] Metal can be used as to make tooling panels. Its dimensional stability is not affected by changes in relative humidity and it can be readily machined. However, metal is dense and gives heavy tooling boards. In addition, metals have relatively large thermal expansion coefficients that will exceed those from plastic parts being made using metal tooling panels. This can cause the metal tooling panel to have different dimensions that a curing part during a thermal cure leading to detective parts.
[0012] Plastics/resins can be used to make tooling panels. One such is described in U.S. Pat. No. 7,906,063 where by resin particles are formed layer-by-layer via selective melting and hardening to make tooling panels. Resins such as polyurethane foams and epoxy resins are available from Rampf Molds Canada. Polymeric tooling panels generally have slow responses to temperature changes. They can be dense resulting in heavy tooling panels.
[0013] All existing tooling panel materials have limits to their practical size resulting in compromises when large parts are required to be manufactured.
[0014] Response to temperature change is a key property of tooling panels. During the heat-up phase of a cure process used to make a part, the tooling panel has a higher temperature on the outside than on the inside. Matching the dimensional change of the part being manufactured and the tooling panel is huge factor determining part quality. When the tooling panel/part is cooled the interior part of the tooling panel as hotter than the outer surface. Dimensional changes are important even after the heating part of the cure cycle is completed. In addition, the cooling at different temperatures can cause the tooling panel to crack limiting its reusability.
[0015] It was therefore an object of the present invention to provide a tooling panel that overcomes the disadvantages of current tooling panels. The disadvantages of current tooling panels are 1) poor temperature response, 2) difficulty of making tooling panels for large parts, 3) heavy weight to make tooling panels for large parts, 4) exaggerated susceptibility to changes in relative humidity; and 5) difficulty of operating at high temperatures.
BRIEF SUMMARY OF THE INVENTION
[0016] Surprisingly, it has now been found, as described in the claims, that the present invention comprises materials to make tooling panels and methods to make the tooling panels that overcome the disadvantages seen in current tooling panel materials. The disadvantages of existing products include 1) poor temperature response, 2) difficulty of making tooling panels for large parts, 3) heavy weight to make tooling panels for large parts, 4) exaggerated susceptability to changes in relative humidity and 5) difficulty of operating at high temperatures.
[0017] This invention provides a tooling panel that is light weight yet able to be formed into shapes of almost unlimited size. The invention can also make tooling panels that have superior temperature response and operating temperature and are virtually unaffected by changes in relative humidity.
[0018] Tooling panels described in the present invention can be based on a non-woven core structure. The non-woven core is made from fibers that are coated after the non-woven has been made. Suitable choice of the material used to coat the fibers can allow superior temperature workability. The coating also imparts strength to the material. The core structure can be coated with materials that are machinable thus converting the core material plus coating into a tooling panel that has a good response to temperature changes, is light-weight, insensitive to changes in relative humidity. Air permeable tooling panels can be based on materials other than non-wovens by puncturing a core material to make it air permeable. A core material can be made from a foam; however, foams commonly used as core panels are not air permeable. The foam would need to be perforated to provide necessary air permeability. A mold used to make the air permeable core material could be designed in a manner that the core is made containing perforations.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0019] FIG. 1 . Shows the construction of the various layers of a fiber incorporated into the non-woven.
[0020] FIG. 2 . Shows the construction of the non-woven part.
[0021] FIG. 3 . Shows the construction of multiple layers of the non-woven part.
[0022] FIG. 4 . Shows several non-woven parts with coatings from an edge view.
[0023] FIG. 5 . Shows a top view of an air permeable core structure with several holes to allow air passage.
[0024] FIG. 6 . Shows the temperature response of tooling board material of the present invention compared to polymeric tooling boards. The plot is expressed in a percent change in temperature for a tooling board vs. oven temperature. Oven temperature is plotted on a second Y axis.
DETAILED DESCRIPTION OF THE INVENTION
[0025] The invention is based on improving tooling panels by making their core structure air permeable and able to function at higher temperatures. One aspect of the invention is a non-woven core structure. The non-woven can be made from fibers which can be made from synthetic polymers, natural polymers or inorganics such as glass or a combination of any of these fibers. The fiber may or may not be treated with an adhesion promoting material such as a latex. The fiber is then treated with an outer-coat to provide most of the physical properties of the non-woven construction. The outer-coat may be a curable system sued as a phenol-formaldehyde resin. After forming the nonwoven structure and curing the outer-coat, almost all of the physical properties of the non-woven core material such as compression and temperature stability likely come for the cured outer-coat resin. However, the invention does not depend on this mechanism being correct.
[0026] The non-woven core material may be constructed in various widths, lengths and thicknesses limited only by the capability of the machinery used to make the non-woven and the ability to transport the non-woven material. The tooling panel material produced in this manner may be bonded with another to form a larger tooling panel. In addition, an outer surface of the tooling panel may be coated with a material such as a rigid foam that can be machined to a pattern and used to make a part.
[0027] FIG. 1 shows a perspective view of one of the fibers comprising a segment of non-woven tooling board. The base fiber 3 provides the initial structure of the non-woven material. This fiber may be made from synthetic or natural materials. In addition, the fiber may be composed or organic polymers or inorganic materials. Representative examples of materials used to make synthetic fibers are polypropylene, various nylons and aromatic polyimides and polyesters. Representative examples of materials used to make natural fibers are cotton, wool, flax and wool. Hybrids of natural and synthetic fibers can be used seen as Rayon which is made by chemically modifying cellulose. Inorganic fibers could be made from glass or carbon among other materials. The individual fiber may be made from fibers of various thicknesses. In addition, the non-woven may be made from a mixture of fiber types and thicknesses.
[0028] The base fiber may be coated with an adhesive promoter, 2 . The adhesive promoter, if needed, will be selected on the basis of its performance with the fiber chosen and the outer layer 1 . The adhesion promoter may be latex, solvent based or 100% solids materials. A latex adhesion promoter could be based on rubber latexes or various other materials. The same base monomers used to make latex or others could make a polymer that is dissolved in a solvent and used for the same function as the latex. Furthermore, one hundred percent solids materials such as hot melt adhesive could be used as the adhesion promoter. The adhesion promoter could be radiation cured for example with electron beam radiation.
[0029] The outer coat 1 likely provides much of the physical properties of the non-woven tooling board. Representative examples of the outer coat are phenol-formaldehyde resins, urea-formaldehyde resins and epoxy resins. Proper choice of the outer coaling allows the core structure to perform for extended times up to 250° F. and for brief periods at temperatures up to 300° F. These examples are one hundred percent solids, heat cured resins but other resins such as hot melt resins and solvent or water based resins may be used. The outer layer could be radiation cured tor example with electron beam radiation.
[0030] It is likely that once the outer coat is applied and cured, if necessary, that this layer provides most of the structural properties of the non-woven structure. Furthermore, the coating process may leave some of the resin in interstitial spaces among the fibers. This model relegates the base fiber and adhesion promoter to relatively unimportant status once the outer coat is fully functional. The applicability or not applicability of this model does not influence the applicability of the invention.
[0031] FIG. 2 illustrates an element of the non-woven material. The arbitrary outer boundary 5 contains fibers 4 . The arbitrary outer boundary does not necessarily define the contours of the non-woven since it may be configured into various shapes. An individual fiber 4 is intertwined amongst numerous other fibers to form a non-woven structure.
[0032] The non-woven elements may be various sizes limited only by constrains of the equipment used to manufacture and ship them. The size of the non-woven component may be altered, FIG. 3 . Two individual elements 6 and 7 are stacked to form a thicker element. The individual components may be stacked on top of one another as shown in FIG. 3 or may be placed beside each other or a combination of stacking and placing beside each other.
[0033] Individual non-woven components may be adhered to one another as well as coated, FIG. 4 . The individual elements 10 may be adhered to each other by a layer 8 . This layer may be continuous or non-continuous. Layer 8 may be applied by brush, spray, roller applicator or any other method that successfully applies it. Layer 8 may be composed of a two component polyurea or polyurethane sprayed onto one of both of the surfaces prior to placing them together. A hot melt adhesive, epoxy adhesive, silicone adhesive, water based adhesive are representative examples of other coatings that may be used to bond non-woven structures together. In addition, the non-woven structures may not need an adhesive to bond them together. The choice of the adhesive or whether to use an adhesive will depend on the structure of the non-woven and the application in which it will be used.
[0034] A coating, 9 , may be applied to the outer surface or surfaces of the non-woven structure. The coating can be applied by the same processes used to apply 8 . Components 8 and 9 may be applied by the same or by different methods and may be composed of the same or different materials. The coating on an outer surface may be formed into a configuration needed to manufacture a part. For example, the outer surface coating may be a rigid foam that can be machined.
[0035] The improved, air permeable core structure can be based on non-fibrous materials. For example, the invention can be made from any materials or configuration of materials that make a high air permeability core structure. A material may be made permeable by perforating it multiple times with a drill or other suitable tool. The top surface of a non-fibrous core structure is shown in FIG. 5 . The top surface is denoted by 11 and examples of holes by 12 . The holes can be a variety of sizes and shapes. The number of holes and their size/shape depends on the amount of air permeability needed to maintain the temperature response needed to make good parts from the resultant tooling panel. The perforated material could be coated with a material that can be machined. However, depending on the material, size of the perforations and amount of perforations the core structure may serve without the need for a coating.
[0036] Although the preceding description contains significant detail, it should not be construed as limiting the scope of the invention but rather as providing illustrations of the preferred embodiments of the invention. As an example, sprayed polyurea coatings illustrated here to form the coating on an outer surface could be made from various other materials. One alternative is to use polyurethane coatings. Such a variation would not materially affect the nature of the invention.
[0037] The following examples are intended to describe the invention without restricting the invention to the examples.
EXAMPLE 1
Preparation of the Non-Woven Fabric
[0038] The nonwoven core material is a resin bonded, highloft nonwoven. It was produced by processing 200 denier polyester staple, 1.5″ cut length (Wellstrand PET, Poole Company, Greenville, S.C.), through a Rando Webber system (Rando Machine Corporation, Macedon, N.Y.) The airlaid webber was 84″ wide.
[0039] The lofty airlaid web from the webber was sprayed on side one with a mixture of 95% styrene butadiene emulsion (Noveon Stycar 1177, Noveon, Inc, Cleveland, Ohio) and 5% melamine (ResimeneAO-7551, Ineos Melamines, LLC, Springfield, Mass.). The mixture contained black pigment. The web was processed through an oven set at 300° F. to cure the mixture. The web was turned over upon exiting and the other side was sprayed with the same mixture and processed back through the same oven. The web was turned again upon exiting and passed a third time through the oven.
[0040] The cured web was passed through a dip and squeeze padder where phenolic resin (resole, Fenolica de Monterrey) was saturated into the web with the excess squeezed away. The wet web was sprayed on side one with the phenolic resin and passed through an oven at 400° F. to cure the resin. The web was turned over upon exiting the oven and sprayed on the other side with the phenolic resin. The web passed through the oven a second time, was turned over upon exiting and passed back through the oven a third time. The cured web was cut into sheets (78×49 inches) after exiting the second oven. The final thickness was approximately 1.5 inches.
EXAMPLE 2
[0041] A material that can be applied to the surface of the tooling board and can be machined is given below. The materials in the curative are blended together and then mixed in a spraying apparatus in a 1:1 by volume ratio with the isocyanate and deposited on the surface of the tooling board. The thickness of the sprayed layer is dependent on the needs of the tooling board. The sprayed layer may be machined to accommodate contours needed for the part to be prototyped or manufactured. The material can be sprayed using a E-XP-2 Reactor manufactured by Graco.
[0000]
Material
CAS Number
Weight
Supplier
Curative
Polyol 30-240
25791-96-2
75.7
Monument Chemical
1,4-Butanediol
110-63-4
17.6
Sigma Aldrich
Water
3.5
Triethylene diamine
280-57-9
1.7
Gulbrandsen
Bis-(2-dimethylami-
3033-62-3
1.0
Huntsman
noethyl)ether
Silstab 2100
0.5
Siltech Corp.
Isocyanate
PM 200
9016-87-9
135
Hanson Group
101-68-8
EXAMPLE 3
[0042] A material that can be used to adhere the layers together is given below. The D 2000 and DETDA are blended and then sprayed in a 1:1 volume ration with the PM 200.
[0000]
Material
CAS Number
Weight
Supplier
D 2000
9046-10-0
25
Hanson Group
DETDA
68479-98-1
60
Hanson Group
PM 200
9016-870-9
100
Hanson Group
101-68-8
EXAMPLE 4
[0043] The temperature response of the material in this invention is compared to responses for commercial tooling board materials, FIG. 6 . The density of the commercial samples is listed on the plot legend. The commercial tooling boards are made from rigid polyurethane foam. All samples were 4 inches long×2 inched wide×1.5 inches thick. A thermocouple was placed 1.5 inches inside each sample into the length dimension and the half point for the height dimension.
[0044] The second Y axis of the plot shows the oven temperature for the test. The first Y axis shows the percent difference between the oven temperature and the thermocouple in each sample of tooling board. It can be seen that the difference between the oven temperature and the interior of a tooling board is always much smaller for the tooling board of the invention.
Definitions
[0045] Tooling panel (board) are molds or shapes used to manufacture parts
[0046] Highlofts are low-density fibrous structures with a high ratio of thickness to mass per unit area. This is done by bonding or interlocking fibers using mechanical, chemical, thermal and/or solvent means.
[0047] Denier is a unit of measurement that describes the linear mass density of the material, calculated by the mass in grams of a single 9,000 meter strand.
[0048] Staples is a fiber of standardized length and may be of any composition.
[0049] Staple length is a property of staple fibers. It refers to the average length of a group of fibers of any composition. Staple length depends on the fiber. For example, the staple length of natural fibers such as cotton or wool has a range of lengths in each sample and is an average value. Staple length for synthetic fibers which have been cut to a certain length is essentially the same far every fiber in the group.
[0050] Airlaid refers to manufacturing technology that produces a web of fibers. In this specific case, the process used staple fibers that are coated with bonding agents such as latex emulsions, thermoplastics or some combination of both.
[0051] Web is a continuous sheet of material. | The invention describes making core structures for tooling panels air permeable and resistant to higher temperatures. Core structures may be a non-woven made from fibers that may be treated with an adhesion promoter. The fiber is then treated with an outer-coating. Proper choice of outer coating allows the tooling panel to function at higher temperatures. The non-woven core may be constructed in various dimensions. Air permeability allows tooling panels to show superior response to changing temperatures. The non-woven may be bonded with another to form a larger tooling panel. The outer surface of the tooling panel may be coated with a material such as rigid foam that can be machined to a pattern placed in contact with material in manufacture a part. The permeable core structure can be made from permeated plastic, wood, metal, ceramic and the like. | 3 |
TECHNICAL FIELD
[0001] The present invention relates to a process for manufacturing deep well junction structures.
BACKGROUND OF THE INVENTION
[0002] As is known, a new type of junction structure, of the so-called deep well type, has been proposed, for forming MOS power transistors with a high inverse breakdown voltage, and simultaneously low resistance values. A junction structure of this type is described for example in U.S. Pat. No. 5,216,275 issued Jun. 1, 1993, according to which the junction structures with deep wells comprise a plurality of deep wells of doped semiconductor material, extending in an epitaxial layer downwards as far as close to a substrate, substantially parallel to one another. In particular, the deep wells have a prevalent vertical dimension (for example between 40 μm and 100 μm), and have an opposite conductivity to the epitaxial layer. When the junction structure is inversely biased, as the inverse voltage increases, the equipotential lines associated with two adjacent deep wells extend in the epitaxial layer, firstly parallel to the walls of the deep wells, and then join together so that the portions of epitaxial layer contained between the two adjacent deep wells are depleted.
[0003] The particular geometry of the junction structure gives rise to high inverse breakdown voltages even in the presence of quite high doping levels of the epitaxial layer and of the deep wells (approximately 10 15 atoms/cm 3 ).
[0004] At present, the described junction structures are formed according to two manufacturing processes.
[0005] In a first case, taught in the aforementioned patent, the epitaxial layer, for example of N type, is grown to a required thickness. Subsequently, trenches are formed in the epitaxial layer having a preset depth substantially equal to the conduction regions to be formed. Using a second epitaxial growth, the trenches are then filled with semiconductor material with an opposite conductivity to the epitaxial layer (for example P type conductivity), such as to form the deep wells substantially within the trenches.
[0006] However, the present technological limits in performing epitaxial growth processes make the step of filling the trenches problematic, and it does not yield acceptable results.
[0007] According to a different solution, the epitaxial layer and the deep wells are formed by iterating a sequence of process steps that involve partial epitaxial growth, a photo technique for defining the areas to be doped, and ionic implantation. For example, at each iteration, a partial epitaxial layer 20 μm thick is grown, and wells with an opposite conductivity are formed in the epitaxial layer. The wells extend throughout the thickness of the partial epitaxial layer, until corresponding aligned wells, formed in a previous iteration.
[0008] The described method allows forming junction structures wherein the deep well regions extend to a substantial depth (of as much as 100 μm, as already stated). However, in order to obtain this depth, it is necessary to carry out numerous cycles of epitaxial growth, photo technique and ionic implantation, and this is disadvantageously complex and costly.
SUMMARY OF THE INVENTION
[0009] The embodiment of the present invention provides a process for manufacturing deep well junction structures, which overcomes the described disadvantages.
[0010] According to the present invention, a process for manufacturing deep well junction structures is provided, the process including forming trenches in a semiconductor material body and forming deep conductive regions surrounding the trenches and having a second conductivity type opposite to the conductivity type of the semiconductor material body, the deep conductive regions extending from the trenches towards the interior of the semiconductor material body, and implanting a doping species along directions inclined with respect to a perpendicular to a surface of a semiconductor material body.
[0011] In accordance with another aspect of the foregoing embodiment of the invention, the trenches are then filled with a filling material and contacts are formed on the surface of the semiconductor material body that are in electrical contact with the deep conductive regions.
[0012] In accordance with another embodiment of the invention, the process for manufacturing deep well junctions includes, in succession, on a first substrate having a first conductivity type and a first doping level, growing an epitaxial layer having the first conductivity type and a second doping level lower than the first doping level; and isotropically etching the epitaxial layer using a mask to form trenches; forming deep conductive regions surrounding the trenches and having a second conductivity type opposite to the first conductivity type and the second doping level; and filling the trenches. Ideally, the deep conductive regions are formed by angular ionic implantation and subsequent diffusion of a doping ion species within the epitaxial layer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] In order to assist understanding of the invention, an embodiment is now described purely by way of non-limiting example, and with reference to the attached drawings, wherein:
[0014] FIGS. 1 - 6 show cross-sections of a wafer of semiconductor material, in successive manufacture steps, carried out according to the present invention;
[0015] [0015]FIG. 7 shows the plot of quantities relative to a junction structure formed using the process according to the present invention; and
[0016] FIGS. 8 - 12 show cross-sections of a wafer of semiconductor material, in successive manufacture steps, in which a device comprising a junction structure according to the present invention is formed.
DETAILED DESCRIPTION OF THE INVENTION
[0017] With reference to FIGS. 1 - 6 , a wafer 1 of semiconductor material, for example monocrystalline silicon, comprises a substrate 2 of N+ type, with a first doping level, for example, of 10 19 atoms/cm 3 .
[0018] An epitaxial layer 3 O is initially grown (FIG. 1) in the substrate 2 , and has a second doping level, lower than the first doping level, for example, of 10 15 atoms/cm 3 . In addition, the epitaxial layer 3 has a thickness comprised preferably between 20 μm and 100 μm.
[0019] On top of the epitaxial layer 3 , a trench mask 5 is then formed, and covers the entire surface 6 of the substrate 2 , except at apertures 8 (FIG. 2). These apertures 8 have a first width L 1 , comprised preferably between 1 μm and 5 μm, and are spaced from one another by a predetermined distance (for example 10-30 μm). In order to form the trench mask 5 , thermal oxidation of the substrate 2 for example is firstly carried out, and silicon oxide is then deposited. A resist mask 9 is then formed through a photolithographic process, and selective etching of the silicon oxide exposed is carried out, to form the apertures 8 . The resist mask 9 is then removed.
[0020] As shown in FIG. 3, an anisotropic etch of the epitaxial layer 3 (trench etch of the silicon) is then carried out, in order to form trenches 10 , which have a width equal to the first width L 1 , and have lateral walls 11 that are substantially vertical, and extend at apertures 8 , for a pre-determined depth D. In particular, the depth D of the trenches 10 is selected on the basis of the inverse breakdown voltage to be obtained, in a manner known to persons skilled in the art, and is generally slightly less than the thickness of the epitaxial layer 3 , such that the trenches 10 extend as far as near the substrate 2 . In addition, the trench etch is preferably a dry, plasma etch.
[0021] By thermal oxidation, a pre-implant oxide layer 14 is then formed, which covers the vertical walls 11 and the base walls 13 of the trenches 10 , and has a thickness of, for example, 150-500 nm, as shown in FIG. 4.
[0022] Subsequently, a predetermined quantity of a doping ion species (for example boron) is implanted, as represented schematically in FIG. 4 through arrows 12 . The quantity of implanted ion species is selected such that, subsequently, regions are formed (deep wells 16 in FIG. 5), which have a substantially same doping level as the second doping level of the epitaxial layer 3 (approximately 10 15 atoms/cm 3 ).
[0023] In this step, the wafer is rotated such that the implantation takes place along directions inclined by an angle α with respect to the perpendicular to the surface 6 of the epitaxial layer 3 . In particular, this can be obtained by tilting the wafer 1 by an angle α with respect to a plane perpendicular to the implantation direction (arrows 12 ), and then rotating the wafer 1 .
[0024] The angle α depends on the ratio between the width L 1 of the apertures 8 and the depth D of the trenches 10 , and is such that the doping ion species is implanted both on the lateral walls 11 , and on the base walls 13 of the trenches 10 . Thus, implanted regions 15 are formed, which surround the trenches 10 , and have a conductivity opposite to the epitaxial layer 3 (for example P type conductivity).
[0025] Subsequently, as shown in FIG. 5, the implanted ion species is diffused in an inert environment, so that, on the basis of the implanted regions 15 , deep wells 16 are formed, which have a second width L 2 , preferably between 5 μm and 20 μm, and are separated from one another by intermediate zones 18 of the epitaxial layer 3 (with a width comprised between 10 μm and 20 μm).
[0026] The trench mask 5 is then removed, and the trenches 10 are filled, as illustrated in FIG. 5. In particular, the trenches 10 are filled by depositing a thick oxide layer 17 (for example TEOS—TetraEthylOrthoSilicate).
[0027] Now, a junction structure 20 is formed, comprising the epitaxial layer 3 and the deep wells 16 . In detail, interface regions 21 between the deep wells 16 and the epitaxial layer 3 form PN junctions, which extend substantially at right-angles to the surface 6 of the epitaxial layer 3 .
[0028] The deep wells 16 can have different shapes, for example the shape of a cup (such as to have a circular crown or polygonal shape in plan view), or they can form elongate trenches, which extend in parallel, in a direction perpendicular to the plane of the plate.
[0029] With reference to FIG. 6, the process can be completed by further, known, processing steps, comprising for example partial removal of the thick oxide layer 17 on top of the deep wells 16 (etch back), and metallization, in order to form contacts 22 .
[0030] It is apparent from the foregoing description that the method according to the present invention advantageously allows junction structures to be formed with deep wells, using a limited number of processing steps. In particular, it is sufficient to carry out a single photolithographic process (for defining the trench mask 5 ), and a single ionic implant.
[0031] The used processing steps are also of a standard type, and thus the process, which is simple and economical to carry out, yields, with a high output, junction structures with high performance levels. In particular, FIG. 7, relative to experimental tests carried out on a junction structure formed according to the invention, shows that the presence of dielectric (silicon oxide region 17 ) within the deep wells 16 does not affect the distribution of the electrical field lines, in presence of strong inverse biasing (750 V).
[0032] The described process can advantageously be used to form power devices, for example DMOS transistors with a vertical current flow. In this case, when the junction structure 20 in FIG. 5 has been obtained, the portion of the thick oxide layer 17 which projects from the trenches 10 is removed, for example using a chemical-mechanical action (CMP—Chemical-Mechanical Polishing), and a gate oxide layer 25 is thermally grown and covers the surface 6 of the epitaxial layer 3 , FIG. 8. A conductive layer 26 , for example of polycrystalline silicon, is then deposited on top of the gate oxide layer 25 .
[0033] Through a photolithographic process and a subsequent chemical etch, portions of the conductive layer 26 are selectively removed, such as to define gate regions 27 , extending over respective intermediate zones 18 of the epitaxial layer 3 , as shown in FIG. 9.
[0034] Then a doping ion species of P type, for example boron, is implanted, as indicated schematically here through arrows 29 , such as to form first enriched regions 30 , of P+ type.
[0035] Subsequently, a resist mask 31 is formed over the trenches 10 and extends in part laterally to the same trenches (FIG. 10). Thereby, implant windows 34 are defined between the resist mask 31 and the gate regions 27 .
[0036] A doping ion species of N type, for example phosphorous, is then implanted, as indicated here schematically through arrows 32 , to form second enriched regions 33 of N+ type, at the implant windows 34 .
[0037] With reference to FIG. 11, the resist mask 31 is removed, and the implanted doping species are diffused. In detail, exploiting the different diffusion speeds of the P and N type species, body regions 35 of P+ type, and source regions 36 of N+ type are formed starting respectively from the first and second enriched regions 30 , 33 . By virtue of the diffusion process, the body regions 35 extend partially below the gate regions 27 .
[0038] Subsequently (FIG. 12), an oxide layer 38 (for example VAPOX—Vapor Oxide) is formed on top of the entire wafer 1 , and is then selectively etched to open contact windows 40 and uncover adjacent portions of the body regions 35 and source regions 36 .
[0039] Source contacts 42 are then formed using a metallization step. These source contacts 42 fill the contact windows 40 , and reach both the body regions 35 and the source regions 36 .
[0040] Finally, a gate contact 43 , shown here only schematically, is formed, and an MOS power transistor 45 is completed.
[0041] Finally, it is apparent that modifications and variants can be made to the described process, without departing from the scope of the present invention. For example, any suitable material can be used to fill the trenches 10 , including a non-isolating material; in addition, the conductivity of the active layers can be opposite that described. Thus, the invention is to be limited only by the claims appended hereto and the equivalents thereof. | A process for manufacturing deep well junction structures that includes in succession, the steps of: on a first substrate having a first conductivity type and a first doping level, growing an epitaxial layer having the first conductivity type and a second doping level lower than the first doping level; anisotropically etching the epitaxial layer using a mask to form trenches; forming deep conductive regions surrounding the trenches and having a second conductivity type, opposite to the first conductivity type and the second doping level; and filling the trenches. The deep conductive regions are formed by angular ionic implantation and subsequent diffusion of a doping ion species within the epitaxial layer. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to disc braking systems and more particularly to a distortion reducing technique for affixing a disc brake rotor to a rotatable wheel hub.
2. Description of the Related Art
Many motor vehicles include disc brake systems having a circular metal disc brake rotor with opposed braking surfaces that are clamped by brake pads carried by a brake caliper to exert a braking effect. The wheel hub incorporates an anti-friction wheel bearing assembly in which one race of the bearing is coupled to the vehicle suspension and the other rotationally mounts the brake rotor and wheel. Ordinarily the rotating components of the rotor, wheel and hub assembly are manufactured separately and assembled together by a plurality of bolts and lug nuts which clamp the wheel to the hub flange with a so-called hat or mounting flange portion of the rotor clamped therebetween. In order to enhance performance of the braking system it is desired to carefully and accurately control the dimensional characteristics of the rotor braking surfaces as the rotor rotates. The thickness variation of the disc and the lateral run-out or lateral deflection of the surfaces as they rotate needs to be held to minimum tolerances. The desire to control lateral run-out of braking surfaces of a disc rotor are well known and rotor manufacturing techniques have been improved to reduce such run-out.
For example, U.S. Pat. No. 5,988,761 teaches a wheel end hub assembly for a motor vehicle incorporating mechanical retention features which accurately and positively orient the motor vehicle brake component, such as a disc brake rotor or brake drum with respect to its wheel hub. With this approach, the machining operations for the brake component braking surfaces can be accurately based from a datum surface of the hub. The assembly incorporates a retention nut threaded onto the wheel mounting bolts which exerts a clamping force on the brake component, e.g., a rotor mounting flange, and further establishes the relative positions of the hub and brake component. In this patented arrangement, the wheel is fixed to the hub with lug nuts engaging the mounting bolts and clamping the wheel against the braking component.
U.S. Pat. No. 6,988,598 points out that in conventional disc brake systems, the rotor is generally rigidly attached to the wheel or hub. With this type of attachment method, the rotor run-out must be generally controlled within approximately 0.003 inches to 0.005 inches. Some racing vehicles, such as used in some classes of drag racing, utilize specialized racing aluminum wheels and the rotor must be mounted directly to such wheels. However, these wheels often do not have a mounting surface that runs true enough to mount the rotor within the permissible range of run-out without additional machining. This additional machining requires additional work time and expense and can reduce the strength of the wheel. To solve this problem, the patented device allows the rotor to slide axially during brake application assuming a new axial location not dictated by the wheel face after release of the braking pressure. This patent suggests a disc brake rotor mounting system that enables self-alignment of the rotor without the need for a precision mounting surface on the wheel. In a preferred embodiment, a generally circular wheel adapter is adapted for mounting to a surface of a hub or wheel with fasteners engaging the hub or wheel through a plurality of wheel attachment bores spaced around a circumference of the wheel adapter. The wheel adapter includes a plurality of drive pin bores spaced around its circumference through which drive pin attachment bolts can be inserted to threadingly engage a like plurality of drive pins. The drive pin attachment bolts securely fasten the drive pins to the wheel adapter. The brake rotor includes a plurality of radially aligned drive slots positioned to align with the plurality of drive pins. Alignment bushings mount between each of the rotor drive slots and a corresponding drive pin. The alignment bushings include a central channel and a pair of flanges. The raised flanges slidingly engage opposing sides of the brake rotor and axially retain each alignment bushing with respect to its corresponding drive slot.
In operation during braking, calipers press on the brake rotor causing torque on the brake rotor resistant to the rotation of the wheel to which the brake rotor is attached. This torque is transmitted as force through the alignment bushings to the drive pins and so on to the wheel itself. As the calipers grip on the brake rotor, any misalignment of the brake rotor will result in the calipers exerting greater force on one or the other side of the brake rotor. In such a case, once the net force on the brake rotor overcomes the resistance of the drag rings, the brake rotor will slide in or out on the drive pins until located such that the calipers exert the same force on both sides of the brake rotor. Once the braking operation subsides and the calipers no longer exert any force on the brake rotor, the brake rotor stays fixed in its new location and orientation due to the drag rings. Neither of these patented arrangements recognizes that rotor brake plate run-out can increase on the vehicle due to mounting flange distortions that occur when the wheel contacts the rotor flange as it attaches to the hub, let alone suggesting any solution to such a problem.
It is desirable to minimize mounting induced rotor lateral run-out along with other sources of lateral run-out.
SUMMARY OF THE INVENTION
The present invention provides solutions to these problems by fixing the rotor to the hub flange outside the wheel-to-hub flange bolted joint to reduce mounted rotor distortion induced by wheel clamp load.
The invention comprises, in one form thereof, a vehicle wheel assembly including a conventional vehicle wheel with a plurality of generally equiangularly spaced mounting bolt receiving apertures, a disc brake rotor having a mounting flange, and a journaled wheel hub having a generally planar wheel contact area for receiving the wheel. There is a generally planar rotor flange contact area for receiving the rotor mounting flange. The rotor flange contact area extends generally parallel to and axially spaced from the wheel contact area. The wheel contact area has a plurality of generally equiangularly spaced radially extending axially raised lobes, one for each wheel mounting bolt aperture, for receiving a corresponding wheel mounting bolt and the rotor flange contact area comprises a like plurality of recesses interleaved with the lobes for receiving generally equiangularly spaced radially inwardly extending rotor fingers each shaped to fit within a corresponding recess.
An advantage of the present invention is that the rotor is securely clamped to the hub independently of the clamping of the wheel to the hub providing a desirable rigid coupling of rotor to wheel without any direct physical contact between the wheel and rotor.
A further advantage of this invention resides in the barrel mounting of the rotor and as a result, any hub deflections occurring in this area are minimized and would not be translated into rotor brake plate lateral run out. Further, since the rotor is outboard mounted, it can be serviced or replaced without removing the hub.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of a portion of a wheel mounting assembly accordingly to the prior art;
FIG. 2 is a cross-sectional view of a portion of a wheel mounting assembly accordingly to the present invention;
FIG. 3 is an isometric view of the assembly of FIG. 2 with the wheel removed;
FIG. 4 is an exploded isometric view of the assembly of FIG. 3 ;
FIG. 5 is an exploded isometric view similar to FIG. 4 , but illustrating a modified form of the present invention; and
FIG. 6 is a cross-sectional view of a portion of the wheel mounting assembly of FIG. 5 .
Corresponding reference characters indicate corresponding parts throughout the several drawing views.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings and particularly to FIG. 1 , there is shown a cross-sectional view through a wheel mounting assembly 11 according to U.S. Pat. No. 5,988,761. The assembly includes hub 13 , brake rotor 15 , a cartridge type wheel bearing assembly 17 mounted to hub 13 , and wheel 19 mounted against rotor 15 . The outer race 69 of bearing assembly 17 is a unitary assembly, that forms the outer race surfaces for the sets of tapered roller bearings and includes flange 71 and bore 73 enabling it to be mounted to a suspension component of the vehicle. The wheel bearing assembly 17 may also include a toothed tone wheel which provides a signal for wheel speed sensor 75 related to wheel speed. These components are used as part of a vehicle anti-lock brake system or traction control system. Rotor 15 is spanned by caliper supported braking pads 41 and 43 . Hub 13 includes a generally cylindrical barrel section 21 and a radial protruding rotor annular mounting flange 23 . Flange 23 forms a number of wheel mounting bolt bores 25 which receive wheel mounting bolts 27 . Brake rotor 15 includes a generally circular mounting flange 29 including a plurality of bolt clearance holes 31 which are in registry with wheel mounting bolt bores 25 . Rotor mounting flange 29 defines an inboard surface 33 and an opposed outboard surface 35 . Mounting flange 29 surface 33 is clamped against the outboard surface of the mounting flange 23 of the hub 13 by nuts such as 37 . Wheel 19 is clamped against the outboard surface 35 of rotor flange 29 by nuts such as 39 . Tightening nuts 39 to secure the wheel 19 to hub 13 with the rotor flange 29 captive therebetween may induce deformation in rotor flange 29 causing undesired lateral rotor run-out as illustrated by dimension A. The clamping may also induce some radial run-out as indicated by dimension B in FIG. 1 , however, the present invention is primarily concerned with lateral run-out.
In FIGS. 2-4 analogous parts bear reference numerals one hundred greater than corresponding reference numerals of FIG. 1 . The joined hub 113 , brake rotor 115 and wheel 119 rotate together about a common axis 153 . Rotor 115 has a mounting flange 129 with inboard 133 and outboard 135 surfaces. Inboard surface 133 is clamped against the flange of hub 113 by threaded fasteners 145 of FIG. 3 which pass through corresponding rotor flange holes 181 ( FIG. 4 ) and threadedly engage hub apertures 183 . The hub surface 151 (best seen in FIG. 4 ) to which the rotor face 133 is clamped is, however, quite different from the outboard surface of flange 23 . The wheel hub 113 has a generally planar wheel mounting face or contact area comprising the plurality of generally equiangularly spaced radially extending axially raised lobes 155 for receiving the wheel 119 inboard surface. The separated wheel mounting flanges allow localized wheel clamp load distortion significantly reducing the impact on the rotor. The generally planar rotor flange contact area 151 comprises the intervening recesses such as 165 and 167 for receiving the rotor mounting flange 129 . FIG. 4 shows the rotor mounting flange 129 as a plurality (here five) of generally equiangularly spaced radially inwardly extending fingers 177 each shaped to fit within a corresponding recess between adjacent lobes. The rotor flange contact area 151 extends generally parallel to the wheel contact area and is axially spaced therefrom a distance C as shown in FIG. 2 . In order for this clearance distance to exist, the maximum axial dimension of the fingers 177 within the corresponding recesses 165 should be less than the axial space between the wheel contact area 155 and the rotor flange contact area 151 . A typical number of wheel mounting lugs for passenger vehicles is four or five while somewhat larger pickup trucks or vans may employ eight or more. Five wheel mounting bolts 185 , one for each wheel mounting bolt aperture such as 191 are illustrated. Like numbers of lobes 155 , recesses 165 , fingers 177 , and rotor mounting bolts 145 are shown.
FIGS. 5 and 6 illustrate one of many possible alternate embodiments of the present invention. This embodiment may be employed when a full three hundred sixty degree support of the wheel is desired. As before, components analogous to those discussed earlier bear reference numerals one hundred greater than those previously used. Thus, a vehicle wheel 219 has mounting bolts such as 289 passing through wheel mounting bolt aperture such as 291 for fixing the wheel to a brake rotor, and journaled hub 297 with the assembly rotatable about a common axis 253 . The hub 297 again has barrel 299 and flange portions which rigidly couple the wheel and rotor for co-rotation about a that common axis and functions as an intermediate member for supporting both the rotor and the wheel while precluding direct contact therebetween. The most striking dissimilarities between FIGS. 4 and 5 are the presence in FIG. 5 of an extra annular ring 303 and a quite different shape of the rotor hat portions 193 and 301 . In FIGS. 5 and 6 , the hat portion is now frustoconical tapering inwardly toward the attachment flange and its rotor flange holes such as 281 , and the surface to which the wheel 219 clamps is now composed of two separable members, the outboard surface 313 of ring 303 and the hub surfaces formed by axially raised lobes. Closer inspection reveals these lobes have two axially spaced plane surfaces or faces 307 and 309 for receiving the wheel and rotor respectively. The ring 303 rests on surface 309 while the wheel 219 engages ring surface 313 and surface 307 . Semicircular notches 311 receive the outer halves of the mounting bolts 289 . Hub face 307 is axially outboard of the second face 309 relative to the vehicle. As in the earlier embodiment, the first face 307 comprises a plurality of generally equiangularly spaced radially extending petals and the rotor includes a like plurality of generally equiangularly spaced radially inwardly extending tabs interleaved between the petals, however, only a portion of the rotor tabs lies between adjacent petals since part of each tab forms the frustoconical portion which provides the clearance for the mounting ring 303 . However, the axial extent of the petals still exceeds the thickness of the intervening rotor tabs. The ring 303 pilots onto the recess formed by the flange or petal portions 309 and lies between the hub petals or fingers so there is still a gap or separation 305 between the rotor flange and the wheel 219 similar to distance or space C in FIG. 2 . As before, a first plurality of wheel mounting bolt 289 and lug fasteners couple the wheel to the hub 297 and second plurality of fasteners 283 rigidly couple the hub and rotor.
Thus, while a preferred embodiment has been disclosed, numerous modifications will occur to those of ordinary skill in this art. Accordingly, the scope of the present invention is to be measured by the scope of the claims which follow. | A vehicle wheel assembly includes a vehicle wheel, a disc brake rotor, and a rotatable hub in which the rotor is securely clamped to the hub independently of the clamping of the wheel to the hub providing a desirable rigid coupling of the rotor and wheel without any physical contact between the wheel and rotor. The hub functions as an intermediate member for supporting both the rotor and the wheel while precluding direct contact therebetween to reduce any rotor deformation which might be induced by the more conventional technique of clamping of the rotor between the wheel and the hub. | 5 |
This application for a utility patent is a conversion of Provisional Application 61/131,228.
BACKGROUND OF THE INVENTION
It is common practice for persons in construction, building, and maintenance trades to use work platforms and scaffolding to access elevated work areas. The safety and productivity of workers using these portable work platforms or scaffolds requires that the platforms or scaffolds be physically stable, be easy to position, be substantially level, and be readily moved from place to place.
The majority of portable work platforms or scaffolds currently in use in the construction and maintenance trades are supported by four legs or points of contact with the ground (i.e., support elements). In some instances, these legs are to be fitted with stem casters to facilitate relocation between workplaces.
The ground or floor surface at many construction sites and other work locations is often irregular and uneven. In current field practice, significant time and effort may be required to level the scaffolding by placing wooden blocks or other cribbage under the platform support legs, wheels, or casters. It is common for many portable scaffolds, such as those fitted with wheels, to be inadequately blocked or leveled due to the unavailability of proper cribbage and/or hasty installation.
Often the best points of support (i.e., solid, level surfaces) for a work platform do not correspond with the location of the work platforms vertical support elements. This requires the users to either move the platform to a less than ideal location to perform the overhead task, or tolerate an unstable (and often unsafe) work platform.
It is common practice for existing scaffolding to be constructed from tubular structural members. However, the geometry of traditional tubular scaffolding members provide high load bearing capacities, but do not provide torsional rigidity. As a result, traditional scaffolding must be fitted with diagonal braces. However, diagonal braces often interfere with tasks such as painting, tuck pointing or other maintenance or construction activities.
In many applications the use of scaffolding or work platforms could enable workers to perform their tasks more efficiently and safely than is possible working from an extension or step ladder. However, the use of scaffolding may be limited because, in most application, traditional scaffolding is too large or cumbersome to fit through a narrow door way or similar obstruction. As such, valuable work time is often wasted ascending, descending, and/or repositioning ladders.
BRIEF SUMMARY OF THE INVENTION
In one aspect, a carriage assembly is provided. The carriage assembly includes a carriage frame, a caster, and a first jack body coupled to the carriage frame and the caster. The first jack body has a longitudinal axis. The first jack body is configured to selectively move the caster with respect to the carriage frame along the longitudinal axis.
In another aspect, a carriage assembly is provided. The carriage assembly includes a carriage frame that includes a first frame member having a first axis. A first jack body is coupled to the first frame member and a caster. The first jack body has a longitudinal axis that is substantially perpendicular to the first axis. The first jack body is configured to selectively move the caster with respect to the carriage frame along the longitudinal axis.
In yet another aspect, a carriage assembly is provided. The carriage assembly includes a carriage frame that includes a first frame member defining a first receiver opening. The first frame member has a first axis. A first jack assembly includes a jack attachment member sized to fit within the first receiver opening such that the first jack assembly is movable along the first axis. A jack body is coupled to the jack attachment member. A foot includes a caster and a shaft extending from the caster. The jack body defines a jack opening. The jack body has a longitudinal axis. The shaft is sized to fit within the jack opening. The first jack body is configured to selectively move the caster with respect to the carriage frame along the longitudinal axis.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 —An isometric assembly drawing that depicts a unique and original arrangement of a stabilizing jack, a locking caster, and perforated mounting tube.
FIG. 2 —An isometric assembly drawing depicting a carriage framework intended to support a scaffold or work platform. In addition, (four) mechanical jack assemblies, as detailed in Drawing 1 , are depicted in various states of attachment or insertion into the carriage.
FIG. 3 —An oblique view drawing depicting a scaffold or work platform carriage and claimed leveling system, and depicting the claimed system's ability to compensate for irregularities in the environmental terrain or floor upon which it is transported or supported.
FIG. 4 —A front view drawing detailing a scaffold or work platform carriage and claimed leveling system, and depicting the claimed system's ability to compensate for irregularities in floor elevation or ground conditions.
FIG. 5 —An isometric assembly drawing depicting the claimed scaffold or work platform, carriage, and leveling system.
FIG. 6 —An isometric assembly detail drawing depicting the claimed engagement of square and rectangular tube elements.
Item A—The jack body or stationary portion of a typical stabilizing jack, such as those often used to support or lift the tongue of an automotive trailer. (See note below)
Item B—The telescoping foot of a typical stabilizing jack assembly, such as those often used to support of lift the tongue of an automotive trailer.
Item C—The hand crank as typically rotated by the user to raise or lower a stabilizing jack, with major components depicted in entirety as items A, B, and C.
Item D—A typical commercially available fully locking floor caster. When activated by the user, the casters integral brake prevents rotation of both the wheel as well as rotation of the caster.
Item E—A jack attachment tube consists of a length of commercially available steel or aluminum box tube as extruded in a square or rectangular hollow profile.
Item F—Locating holes or similar through perforations as punched or drilled through item E which allows the insertion of pins or similar retaining hardware.
Item G—A carriage which supports the work platform which is fabricated from commercially available steel or aluminum box tube as extruded in a square or rectangular hollow profile.
Item H—Modular, interchangeable H members constructed from square or rectangular tubing which form the vertical elements and ends of the portable scaffold or work platform.
Item I—Modular, interchangeable I members constructed from square or rectangular tubing which form the vertical elements and sides of the portable scaffold or work platform.
Item J—Receivers or similar openings at each end and on the major axis of the carriage, G.
Item K—Receivers or similar openings at each side and on the minor axis of the carriage, G.
Item L—Locating holes or similar through perforations as punched or drilled through the carriage, G which allows the insertion of pins or similar retaining hardware.
Item M—A commercially available retaining pin, which could be a hitch pin, device pin, spring pin or similar common means of attachment.
Note: The stabilizing jack (items A, B, and C), locking caster (item D), and retaining pin (item L) depicted herein are common, commercially available components. These items are not claimed, but rather their use in part of a unique and original combination which, when incorporated together with other depicted components, provides an improved method of leveling and stabilizing portable work platforms.
DETAILED DESCRIPTION OF THE INVENTION
It is common and accepted practice in the building, maintenance, and construction trades to use portable work platforms or scaffolds to perform tasks in elevated locations.
It is common for the floor, ground surface, or other environmental terrain of many construction and maintenance sites to be irregular, rough, or strewn with debris or other errant, random objects.
It is desirable that workers engaged in construction and maintenance trades be able to readily move portable scaffolds or work platforms from one location to another in order to expeditiously perform various tasks at various locations.
It is common and accepted current practice to fit wheels and stem casters to the vertical members of certain existing, commercially available scaffolds and work platforms to accommodate locomotion as outlined above.
It is advantageous that those engaged in various construction and maintenance trades be provided with portable scaffolds and work platforms which are more stable than those currently commercially available through an improved and more versatile means of leveling and supporting such work platforms.
The Applicant claims a substantial improvement over the current art and practice of manufacturing and configuring portable scaffolds and work platforms is achieved when certain jack, caster, and other commercially available components are combined in his unique and original modular work platform as described herein.
Feature 1 provides convenient movement of the portable scaffold or work platform between work sites upon locking caster wheels.
Feature 2 readily changes or adjusts the position of each point of support of the portable scaffold so to improve access and transit through narrow doorways, aisles, or other physical obstacles.
Feature 3 readily changes or adjusts the position of each point of support of the portable scaffold so to optimize or improve platform stability.
Feature 4 provides hand-operated jacks to compensate for variations in floor elevation or obstructions beneath the portable scaffold or work platform.
Feature 5 provides an interlocking structural design to allow relocation of each individual point of support without requiring scaffold disassembly or causing the platform to tip or become temporarily unstable.
Feature 6 eliminates the need for diagonal supports which obstruct and interfere with tasks being performed by users of the portable scaffold or work platform.
Feature 7 provides a simple and reliable method of dismantling and reassembling the portable scaffold or work platform for compact transportation or storage.
Please reference Drawing One which depicts a typical, commercially available stabilizing jack assembly consisting of three principle external components; a fixed body A, a telescoping member B, and a hand crank C. A commercially available locking floor caster, D, is bolted or similarly attached to the lower, telescoping portion of the stabilizing jack B.
Feature 1 provides convenient movement of the portable scaffold or work platform is achieved by combining the jack assembly (sum of items A, B, and C) with that of the locking floor caster, item D, as described above.
The benefit of improved platform stability as described above is enhanced by incorporation of the locking feature commonly found on certain commercially available locking floor casters, D. Locking floor casters are integrated with the jack assemblies as described above. This feature allows the user to set the caster brakes when at the desired work location. Upon completing the task, the user releases the caster brake to facilitate rolling the entire work platform to another desired location.
The body of the stabilizing jack A is welded, or similarly securely joined, to a length of steel box tube or similar square or rectangular structural material to provide a jack mounting tube which is depicted as item E.
Each jack mounting tube, E is perforated on its vertical axis through both faces of the square or rectangular tubing. These perforations, depicted as item F are located at one or more locations along the length of the jack mounting tube. In Drawing One, the perforations F are depicted at three locations on each jack mounting tube E.
Please reference Drawing Two which depicts a carriage as item G. The carriage frame is fabricated from steel box tube or similar hollow rectangular or square tubing in such a manner that openings, or receivers as depicted as items J and K are located at each corner of the carriage, G. Item J receivers are located on the major axis of the carriage while item K receivers are located on the minor axis of the carriage.
A running fit is formed between the internal opening of each receiver, J and K and the outside faces of each jack mounting tube, item E, thus allowing the engagement of a jack mounting tube E into any desired receiver J or K.
Feature 2 readily changes or adjusts the position of each point of support of the portable scaffold or platform so as to improve access and transit through narrow doorways, aisles, or other physical obstacles is achieved when the user elects to insert the jack mounting tubes E into the major axis receivers K in the method as described above. Thus configured by the user, the portable scaffold assumes a narrow profile and is easily maneuvered through a narrow doorway or aisle.
Feature 3 readily changes or adjusts the position of each point of support of the portable scaffold so to improve platform stability is achieved when the user elects to insert the jack mounting tubes E into the minor axis receivers K in the method as described above. Thus configured by the user, the portable scaffold assumes a wide profile and provides the stability required by workers to safely ascend the platform.
Feature 4 provides an advantage to compensate for variations in floor elevation or obstructions beneath the portable scaffold or work platform. For example, in an environment of irregular clutter, mud holes, or other random obstacles, the user may choose to insert the E portion of certain jack assemblies into any combination of receivers J and/or K which correspond with those areas perceived by the user to offer the best support.
Drawing Three provides an oblique view of a configuration of the claimed work platform in which the telescoping portion of a stabilizing jack assembly B−1 has been retracted by the user to compensate for an obstacle while the remaining jack assemblies B remain in an extended configuration.
Drawing Four provides a front view of a configuration of the claimed work platform in which the telescoping portion of a stabilizing jack assembly B−1 has been retracted by the user to compensate for an obstacle while the remaining jack assemblies B remain in an extended configuration.
The carriage, G, is perforated on a vertical axis with through holes L at points adjacent to each major axis receiver J, and each minor axis receiver K. These holes lie on a shared centerline with the jack attachment tubes, E.
After inserting a jack attachment tube E at a desired location as described above, the user inserts a retaining pin L to secure the jack attachment tube E, and assure platform stability.
In summary, the user may elect to readily adjust the elevation of each corner of the portable scaffold or work platform by rotating the jack hand crank C and readily adjust the location of support for the platform by selecting an appropriate receiver] and/or K into which to insert each jack attachment tube, E.
It is common and accepted practice for existing, commercially available scaffolds and portable work platforms to be fitted with stem casters or wheels. However, these casters cannot be readily removed or relocated unless the scaffolding is disassembled.
Feature 5 allows relocation of each individual point of support without requiring scaffold disassembly or causing the platform to tip or become temporarily unstable is achieved by a user procedure as described in more detail below.
Assuming jack assemblies positioned in locations as depicted in Drawing Four, the operator may wish to remove and relocate the south stabilizing jack assembly. The user would operate the hand crank C on the north jack assembly so as to retract the telescoping foot B.
Following retraction of the north jack assembly as described above, the weight of the portable scaffold or work platform is primarily upon the east and west jack assemblies.
The operator may then elect to remove the retaining pin M on the south jack assembly and withdraw the jack assembly and jack attachment tube E from the receiver.
The operator may insert the jack attachment tube E into the adjacent receiver K on carriage G. The operator subsequently reinserts retaining pin M through perforation L.
Following the procedures outlined above, the user may elect to adjust the elevations of the north and south jacks until the desired platform level is achieved.
Alternatively, the operator may elect to repeat the relocation procedure as described above at one or more of the remaining corners of the carriage G until the desired balance, stability and/or width of the platform is achieved.
It is the current and accepted practice to utilize round tubing as the primary structural elements in commercially available scaffolding and work platforms. While round steel pipe is typically less expensive than similar gauge square or rectangular tubing, round tubing does not provide the torsional rigidity when inserted within another tube as can be obtained by two intersecting lengths of square tubing.
Please reference Drawing Five. Scaffolding components are assembled to the carriage to form a useful work platform. The ends of the platform include H-members as depicted as item H. The horizontal elements of the platform are comprised of cross members as depicted as item I.
The engagement of the claimed square or rectangular geometry of the mating areas of H-members H with the square or rectangular geometry or the mating areas of cross members I, and carriage G provides a substantial increase in torsional rigidity to the assembled platform.
Feature 6 eliminates diagonal supports which obstruct and interfere with tasks is realized by the utilization of square and rectangular elements as described above in lieu of round tubing as is the current practice and described above.
Feature 7 provides a simple and reliable method of dismantling and reassembling the portable scaffold or work platform for compact transportation or storage is realized by the use of modular, interchangeable components and interlocking design. | A carriage assembly includes a carriage frame, a caster, and a first jack body coupled to the carriage frame and the caster. The first jack body has a longitudinal axis. The first jack body is configured to selectively move the caster with respect to the carriage frame along the longitudinal axis. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application for patent is related to the following applications for patent:
PRE-FETCHING DATA FROM MEMORY ACROSS PAGE BOUNDARIES, U.S. patent application Ser. No. 08/529,470;
CACHE CONTROLLED INSTRUCTION PRE-FETCHING, U.S. patent application Ser. No. 08/531,948;
PROGRESSIVE DATA CACHE, U.S. patent application Ser. No. 08/519,031;
MODIFIED L1/L2 CACHE INCLUSION FOR AGGRESSIVE PRE-FETCH, U.S. patent application Ser. No. 08/518,348;
STREAM FILTER, U.S. patent application Ser. No. 08/519,032;
CACHE DIRECTORY FIELD FOR INCLUSION, U.S. patent application Ser. No. 08/518,347; and
HIGH SPEED MULTIPLE PORT INTERLEAVED CACHE WITH ARBITRATION OF MULTIPLE ACCESS ADDRESSES, U.S. patent application Ser. No. 08/638,655 (Attorney Docket No. AT9-94-210).
These applications for patent are hereby incorporated by reference in the present disclosure as if fully set forth herein.
TECHNICAL FIELD
The disclosure relates in general to data processing systems and, in particular, to processing systems that can fetch more than one instruction at a time from different sub-arrays within the same cache memory.
BACKGROUND INFORMATION
In modern microprocessor systems, processor cycle time continues to decrease as technology continues to improve. Also, design techniques of speculative execution, deeper pipelines, more execution elements and the like, continue to improve the performance of processing systems. The improved performance puts a heavier burden on the memory interface since the processor demands data and instructions more rapidly from memory. To increase the performance of processing systems, cache memory systems are often implemented.
Processing systems employing cache memories are well known in the art. Cache memories are very high-speed memory devices that increase the speed of a data processing system by making current programs and data available to a processor (also referred to herein as a "CPU") with a minimal amount of latency. Large on-chip caches (L1, or primary, caches) are implemented to help reduce the memory latency, and they are often augmented by larger off-chip caches (L2, or secondary, caches).
The primary advantage behind cache memory systems is that by keeping the most frequently accessed instructions and data in the fast cache memory, the average memory access time of the overall processing system will approach the access time of the cache. Although cache memory is only a small fraction of the size of main memory, a large fraction of memory requests are successfully found in the fast cache memory because of the "locality of reference" property of programs. This property holds that memory references during any given time interval tend to be confined to a few localized areas of memory.
The basic operation of cache memories is well-known. When the CPU needs to access memory, the cache is examined. If the word addressed by the CPU is found in the cache, it is read from the fast memory. If the word addressed by the CPU is not found in the cache, the main memory is accessed to read the word. A block of words containing the word being accessed is then transferred from main memory to cache memory. In this manner, additional data is transferred to cache (pre-fetched) so that future references to memory will likely find the required words in the fast cache memory.
The average memory access time of the computer system can be improved considerably by use of a cache. The performance of cache memory is frequently measured in terms of a quantity called "hit ratio." When the CPU accesses memory and finds the word in cache, a cache "hit" results. If the word is found not in cache memory but in main memory, a cache "miss" results. If the CPU finds the word in cache most of the time, instead of main memory, a high hit ratio results and the average access time is close to the access time of the fast cache memory.
Pre-fetching techniques are often implemented to try to supply memory data to the on-chip L1 cache ahead of time to reduce latency. Ideally, data and instructions are pre-fetched far enough in advance so that a copy of the instructions and data is always in the L1 cache when the processor needs it. Pre-fetching of instructions and/or data is well-known in the art. However, existing pre-fetching techniques often pre-fetch instructions and/or data prematurely. The problem with pre-fetching and then not using the pre-fetched instructions and/or data is two-fold. First, the pre-fetched data may have displaced data needed by the processor. Second, the pre-fetch memory accesses may have caused subsequent processor cache reloads to wait for the pre-fetch accesses, thus increasing the latency of needed data. Both of these effects lower the efficiency of the CPU.
Furthermore, when aggressively pre-fetching data to an L1 cache, speculatively pre-fetched data can displace lines in the L2 cache that may be needed in the near future. This may occur even when the pre-fetched line may not be frequently used, may not be modified with a store operation, or may not be used at all by the program (in the case of a bad guess pre-fetch). Also, data pre-fetched to the L1 cache in an aggressive pre-fetch scheme can thrash with (displace) data in the L2 cache.
In state-of-the-art cache memories, more than one memory access is usually performed in a single cycle. This is accomplished by implementing the cache memory in multiple arrays or "sub-arrays". If multiple addresses arrive at the cache memory together, the address originating from the highest priority source is selected for each sub-array. If only one address is destined for a sub-array, no priority determination is needed.
Some impediments to aggressive fetching are related to the method of address generation. In many architectures, addresses are generated for a memory access by operating on address operands arithmetically. For example, a load operation may require that two operands be added together to form the effective address of the memory data to be fetched. One address operand may be one read from General Purpose Register (GPR) A and the other from GPR B. The add operation must be performed in order to obtain the effective address (EA) in memory.
The address generation, however, is a cycle limiter in an aggressive implementation. If two such load operations are attempted together, two separate addition operations (EA0=GPR A+GPR B and EA1=GPR C+GPR D) have to be performed to obtain the two EAs and then the EAs must be examined to determine if the same sub-array in the cache is being accessed by each EA. If the same sub-array is being accessed, then the EAs must be arbitrated to determine which receives priority. It is advantageous to minimize the amount of time it takes to arbitrate between cache sub-arrays.
SUMMARY OF THE INVENTION
The present invention receives the operand data involved in the sub-array selection and duplicates the arithmetic operation on the operands within the arbitration circuitry. An embodiment of the present invention comprises a sub-array arbitration circuit for arbitrating between at least two memory accesses received by the cache memory. The sub-array arbitration circuit comprises a first adder for receiving a first address and a second address and generating a first effective address associated with a first memory location in the cache memory and a second adder for receiving a third address and a fourth address and generating a second effective address associated with a second memory location in the cache memory. The sub-array arbitration further comprises a priority circuit for determining if the first memory location and the second memory location reside in separate sub-arrays of the cache memory. If the first memory location and the second memory location do reside in separate sub-arrays, the sub-array arbitration circuit sends the first effective address to a first sub-array and sends the second effective address to a second sub-array.
In another embodiment of the present invention, there is disclosed an arbitration circuit for arbitrating between a first memory access request and a second memory access request received by a cache memory containing a plurality of sub-arrays, the arbitration circuit comprising a first adder for receiving a first address and a second address associated with the first memory access request and generating a first effective address associated with a first memory location in the cache memory; circuitry for receiving a third address associated with the second memory access request for accessing a second memory location in the cache memory; and priority determination circuitry for determining if the first memory location and the second memory location are located in separate sub-arrays of the cache memory. The sub-array arbitration further comprises a priority circuit for determining if the first memory location and the second memory location reside in separate sub-arrays of the cache memory. If the first memory location and the second memory location do reside in separate sub-arrays, the sub-array arbitration circuit sends the first effective address to a first sub-array and sends the third address to a second sub-array.
The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the cache sub-array arbitration circuit that follows may be better understood. Additional features and advantages of the cache sub-array arbitration circuit will be described hereinafter which form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and the specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims.
BRIEF DESCRIPTION OF THE DRAWING
For a more complete understanding of the present invention, and the advantages thereof, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a block diagram of a processing system in accordance with the present invention;
FIG. 2 is a high level block diagram of a cache sub-array arbitration circuit in accordance with the present invention;
FIG. 3 is a high level block diagram of cache sub-arrays in accordance with the present invention; and
FIGS. 4-6 are a detailed block diagram of a cache sub-array arbitration circuit in accordance with the present invention.
DETAILED DESCRIPTION
The principles of the present invention and their advantages are best understood by referring to the illustrated embodiments depicted in FIGS. 1-6 of the drawings, in which like numbers designate like parts.
Referring now to FIG. 1, a processing system which advantageously embodies the present invention is depicted. Multiprocessor system 10 includes a number of processing units 20, 30 and 40 operatively connected to system bus 45. Note that any number of processing units may be utilized within multiprocessor system 10. Also connected to system bus 45 is memory controller 50, which controls access to main memory store 60. Memory controller 50 is also coupled to input/out (I/O) controller 52, which is coupled to I/O device 54. Processing units 20, 30 and 40, I/O controller 52, and I/O device 54 may all be referred to as bus devices herein. As shown, each processor unit 20, 30 and 40 may include a processor and L1 caches 110, 72, and 82, respectively. The L1 (primary) caches may be located on the same chip as the respective processor. In one embodiment, the L1 caches contain sub-array arbitration circuits according to the present invention. Coupled to processing units 20, 30 and 40 are L2 (secondary) caches 120, 74 and 84, respectively. Each L2 cache is connected to system bus 45 via the processor to which it is attached.
Each L1 and L2 cache pair are normally serially related. The L1 cache may be implemented as store-in or write-through, while the larger and slower L2 cache is implemented as a write-back cache. Both the L1 and L2 cache controllers are physically implemented as part of the processing unit, and are connected via buses internal to the processing unit. Alternatively, the L2 cache controller could be off-chip.
FIG. 2 depicts cache sub-array arbitration logic circuit 220 contained in L1 cache 110. The pending line of instructions is scanned for load operations that may require the addition of the contents of two registers to determine the effective address (EA) of the data to be fetched. In the example shown, two such instructions are found and two pairs of address operands, EA0A, EA0B, EA1A and EA1B, are received from the general purpose registers GPR W, GPR X, GPR Y and GPR Z, respectively (not shown). In some cases, the two pairs of address operands may have common general purpose registers, rather than two different pairs of general purpose registers.
GPR W and GPR X contain 64-bit operands, EA0A(0:63) and EA0B(0:63), that must be added together by adder 205 to form the effective address (EA0). GPR Y and GPR Z contain 64-bit operands, EA1A(0:63) and EA1B(0:63), that must be added together by adder 210 to form the effective address (EA1). Both sets of operands are sent to L1 cache 110 simultaneously. Cache sub-array arbitration logic circuit 220 contains adders that replicate a portion of the addition performed by adders 205 and 210. Cache sub-array arbitration logic circuit 220 also contains logic gates that arbitrate between address bits of EA0, EA1 and EA MISS. Also shown in FIG. 2 are control lines indicating the presence of a valid address operation for each EA (EA0 Valid, EA1 Valid), a third address source, EA MISS, and an EA MISS VALID line. The EA MISS address source is an address bus that can contain the address for a cast-out operation. EA MISS and other address sources are obvious extensions to the basic EA pair. The present invention grants priority to a cache miss (EA MISS) over EA0 and EA1 cache accesses to the same cache sub-array.
In a preferred embodiment, L1 cache 110 is 4-way interleaved. It is well known in the art that a data cache can be addressed by an effective address (EA) and a real address (RA) in the same cycle. EA(55:56) and RA(31:32) select the sub-array. If both the EA and the RA are active and EA(55:56) equal RA(31:32), then the two addresses are said to be in conflict. When both the EA and the RA are accessing the same sub-array, the sub-array arbitration circuit blocks the lower priority address and grants priority address and grants the higher priority address access to the sub-array. The constraint that a sub-array can be accessed by only one address is due to the fact that there is only one pair of bit lines for each memory cell. Consequentially, only one word line per sub-array can be enabled in the sub-array during a single cycle.
In one embodiment of the present invention, the architecture definitions for the Effective Address are: EA(0:35) is the effective segment ID; EA(36:51) is the effective page index; and EA(52:63) is the 4K effective page offset. The effective address is used in the data cache array as follows:
______________________________________ ECAM Subarray Double Byte OffsetNot Used Tag Select Word Select Not Used______________________________________EA(0:43) EA(43:54) EA(55:56) EA(57:60) EA(61:63)______________________________________
EA(60) selects even or odd double word. EA(57:59) select 1 of 8 even or odd double words.
In one embodiment of the present invention, the architecture definitions for the Real Address are: RA(0:27) is the real page number; and RA(28:39) is the 4K real page offset. The real address is used in the data cache array as follows:
______________________________________RCAM Subarray Double Byte OffsetTag Select Word Select Not Used______________________________________RA(0:30) RA(31:32) RA(33:36) RA(37:39)______________________________________
RA(36) selects even or odd double word. RA(33:35) select 1 of 8 even or odd double words.
In one embodiment, three EAs can access the cache array in the same cycle. There are two levels of subarray arbitration control. The first level of arbitration controls the EA MUX. The EA MUX selects one of the three EA addresses, EA0, EA1, or EA MISS, to access one of the cache sub-arrays. The second level of arbitration controls the word line access. If the subarray conflict exists between the EAs, the subarray arbitration logic will grant access to the higher priority request and deny the lower priority request.
FIG. 3 depicts in greater detail the arrangement of four cache sub-arrays, Sub-Array 0-Sub-Array 3. Each sub-array contains a portion of the L1 cache 110 memory array and the arbitration logic (Sub-Array Arbitration Logic 220a-220d) for that sub-array. Each Sub-Array Arbitration Logic 220a-220d controls a multiplexer (EA MUX 225a-225d) that gates one of the effective addresses to the proper cache sub-array. EA0(0:63) and EA1(0:63) are thus presented to the sub-arrays of L1 cache 110 and the correct sub-array of Sub-Array 0-Sub-Array 3 is enabled. EA0 is given priority if both EA0 and EA1 address the same sub-array.
In one embodiment of the invention, L1 cache 110 is 16-way set associative and the line size is 32 bytes. Therefore, the lower 9 address bits, bits 55:63 are used to address a select one of the (16×32)=512 individual bytes. Bits 55 and 56 select the sub-array, bits 57 and 58 select the cache line within each sub-array, and bits 59 through 63 select an individual byte within the 32 bytes of the line. In order to perform sub-array arbitration, only the resulting bits from the addition of bits 55 and 56 (including the carry-in for bit 56) are needed. This present invention utilizes those bits and performs the calculation within the sub-array arbitration logic 220a-d.
As the text accompanying FIGS. 2 and 3 demonstrates, the delay caused by serially performing EA calculation in adders 205 and 210 and then selecting the address to be gated to the sub-array is reduced by calculating in sub-array arbitration logic 220 only the small part of the EA involved in sub-array selection within each sub-array. This calculation produces a selective signal to the EA selector (i.e., EA MUX 225a-225d) in parallel with the full EA address calculation.
FIGS. 4 and 5 depict in detail the arithmetic logic for selecting EA0 and EA1. In FIG. 4, the two address operands to be added to obtain EA0 are EA0A(0:63) and EA0B(0:63). A partial sum, X0, is created in adder 410 for EA0 if EA0 is valid. Carry predict logic 405 predicts the bit 56 carry-in, C0. C0 and X0 are used to determine to which sub-array EA0 is directed. EA1 has lower priority than EA0. Therefore, the EA0 sub-array enable signals, EA0 Enable Sub-A1 through EA0 Enable Sub-A3, are used to disable the EA1 sub-array enable signals. In FIG. 4, EA Miss logic circuits 420 and 435 are shown, since a cast-out operation would take priority over both EA0 and EA1 operations.
FIG. 6 depicts AND and OR logic used to generate the enable signals for EA MUX 225a-d are generated along with the sub-array enable line. For Sub-Array 1 for instance, multiplexer EA MUX 225b uses the signals EA0 ENABLE SUB-A1 or EA1 ENABLE SUB-A1 to generate EA0 ENABLE 1 or EA1 ENABLE 1. The sub-array is enabled by Enable Sub-A1. FIG. 6 describes only EA0 and EA1 bus arbitration for clarity, the EA Miss bus is omitted.
Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims. | A cache sub-array arbitration circuit for receiving a plurality of address operands from a pending line of processor instructions in order to pre-fetch data needed in any memory access request in the pending instructions. The sub-array arbitration circuit compares at least two addresses corresponding to memory locations in the cache, and determines in which sub-arrays the memory locations reside. If the two memory locations reside in the same sub-array, the arbitration circuit sends the higher priority address to the sub-array. If a received address operand is the real address of a cache miss, the arbitration circuit sends the cache miss address to the sub-array before other pre-fetch memory access request. | 6 |
BACKGROUND OF THE INVENTION
This invention relates to processing machines with rolls in general and more particularly to an improved pressure control device for processing machines having at least one roll which has a stationary core, around which a hollow roll revolves which forms the roll proper, radially spaced from the core, and supported directly on the core at its ends and supported in the radial direction in between the ends through a fluid pressure medium which is disposed in a chamber formed at the core.
In such a device the pressure medium generates a force acting on the inside of the hollow roll and, thereby, controls the operating pressure of the roll. Such processing machines typically have a loading device which is operated by a fluid pressure medium and applies a force at the roll or a counter roll. In this way the loading device or the roll form the controlling element and there is derived from the pressure prevailing therein a control pressure, by means of which, in the respective other controlled element a pressure can be adjusted which is in a definite, predetermined pressure ratio to the pressure in the controllable element. The invention is applicable particularly to processing machines, in which the loading device is the controlling element.
From U.S. Pat. No. 2,908,964, an embodiment of such a pressure control device for a pair of rolls is known. In the disclosed device the rolls are designed as so-called "swimming rolls". In such rolls, a seal extends along the core between the latter and the inside of the hollow roll. This seal together with transversal seals provided at the ends of the hollow roll, subdivides the space between the core and the hollow roll into two lengthwise chambers which are filled with hydraulic oil which constitutes the fluid pressure medium. The lengthwise chamber situated on the side of the roll gap receives the higher pressure. The pressure difference determines the working pressure, i.e., the line pressure in the roll gap. The hydraulic oil acts directly against the inside of the hollow roll.
The present invention, however, is also applicable to other types of rolls in which pressure is transmitted to the inside of a hollow roll by mechanical intermediate members such as pressure shoes or roller arrangements. Such rolls are described, for instance, in U.S. Pat. No. 2,395,915, German Offenlegungsschrift No. 2 230 139 and German Auslegeschriften Nos. 1 193 792 and 1 561 706.
In the device described in U.S. Pat. No. 2,908,964, one of the so-called "swimming rolls" is fixedly supported, while a loading device which comprises two hydraulic piston/cylinder units, which transmits their force to the ends of the core of the counter roll, acts, in the case of the other roll, on the ends of the core which form the journals of the roll and protrude from the hollow roll.
The important point is that the pressures in the floating rolls and in the loading device are very accurately matched to each other. If, for instance, the pressure in a floating roll is too high, i.e., higher than the counter forces require, then the floating roll will be bent, since its hollow roll is supported on the core at the ends and the excessive pressure in the center strives to push the hollow roll away from the core toward the counter roll or, in any event, will cause a non-uniform line pressure in the roll gap. All this is true not only for the so-called "swimming roll" but also for the other types of rolls known from the above-mentioned references.
It is a further disadvantage, if the pressure in the rolls is not accurately matched to the situation, that the bearings at the ends of the hollow roll are then subject to an excessively high load. In the ideal case, i.e., if the pressure in the roll is accurately matched, the counterforce should be in equilibrium with the force exerted by the fluid pressure medium and the bearings at the end will have only a guiding function. But if the pressures do not balance, then the bearings must take up the pressure difference, which leads to an unbalanced force between the hollow roll and the core. The same is true if the force of the loading device does not exactly correspond to the pressure in the roll. If, for instance, a very low pressure in the roll occurs at the same time as a very high pressure at the loading device, the forces exerted thereby are fully conducted onto the bearings in the roll.
For monitoring the pressure ratio in the roll and in the loading device, a pressure ratio control is provided in the embodiment described in U.S. Pat. No. 2,908,964. This pressure ratio control regulates the pressure at the loading device so that the force exerted by a web of material passing between the rolls is just cancelled by that pressure due to the hydraulic oil in the lengthwise chamber of the "swimming roll". Then, all pressure is transmitted by the hydraulic oil, while the bearings at the ends of the hollow roll remain free of the forces acting in the roll gap. In the embodiment described in U.S. Pat. No. 2,908,964, the controlling variable is the pressure in the "swimming roll".
However, it is also well known in the art to provide the control in such a processing machine in the inverse manner, i.e., to choose the pressure in the loading device as the controlling variable and to set the pressure in the roll accordingly.
It is a condition for the functioning of such a pressure control device that the pressure in the controlled element can actually reach the pressure which the controlling element demands. However, this is not always the case in practice; rather, the pressure in the controlled element sometimes cannot follow the controlling variable fast enough or cannot follow it at all, be it because of a lack or excessive sluggishness of the pressure supply or because of pressure losses occurring at certain points.
In a processing machine with rolls of the type in question, in which the pressure in the loading device is the control input, this can occur in two cases in particular. First, it occurs if the loading pressure rises faster than the pressure in the roll can follow. Such an increase of the loading pressure is necessary if, after inserting a web into the processing machine, the line pressure must be increased to the full operating pressure. Secondly, the desired pressure ratio is not obtained if the pressure in the roll does not ever come up to its normal magnitude for whatever reason. This may be due to an insufficient capacity of the pump system, continuous leakage losses because of a faulty condition of the seals in the roll, defective connections in the control lines, etc.
Similar problems can occur if the pressure in the roll is the controlling input.
SUMMARY OF THE INVENTION
It is the object of the present invention to develop a pressure control device of the type mentioned at the outset in such a manner that deviations of the pressures in the loading device or in the roll resulting in a deviation from the desired pressure ratio are prevented.
As a solution to this problem, the invention provides a pressure ratio monitoring device which compares the control pressure with the actual pressure in the controlled element (roll or loading device) and, if the pressure in the controlling element is too high in relation to the predetermined pressure ratio, decreases the former to this pressure ratio.
The control pressure is a pressure which is derived from the pressure on the controlling element. This control pressure calls for a pressure of definite magnitude in the controlled element. The pressure ratio monitoring device now monitors whether the actual pressure in the controlled element meets this requirement. Should this not be the case, a change is not made on the side of the controlling element in the form of an even greater increase of the control pressure, but the control is, so to speak, conducted in reverse and now, the pressure in the controlled element is reduced until the predetermined pressure ratio prevails again.
While through this measure, the working pressure may possibly not be able to be increased above a defined value, it is ensured that at least at the attainable pressure the correct relationship between the pressures in the roll and in the loading device prevails and the processing machine operates at a pressure equilibrium approaching the ideal condition, where excessive loading of the bearings and, in particular, non-uniform line pressure do not come about.
Arrangements are known in which a separate and, in particular, pneumatic system is provided for controlling the pressure ratio, which generates, among other things, in particular, a pneumatic control signal for adjusting the pressure in the controlling element. German Pat. No. 1 523 351 shows a roll arrangement with "swimming rolls" and a hydraulically operated loading device, in which a pneumatic control system is provided.
In such a pressure control device, the pressure ratio monitoring device can comprise, according to one embodiment of the present invention, a control element which is acted upon by pressures representative of the pressures in the roll or in the loading device and which lets the control signal pass through unchanged as long as the ratio between the controlling pressure and the controlled pressure is equal to or below a predetermined value, but throttles the control signal down as soon as the ratio exceeds the value.
The point of intervention of the pressure monitoring device is therefore in the separate system for setting or controlling the pressures in the roll and in the loading device. As long as the pressure ratio corresponds to the desired value, nothing happens. As soon, however, as the pressure to be controlled does not follow, an intervention is made in that the control signal in the separate system and, correspondingly, also the pressure in the controlling element are reduced.
In detail, the design may be such that the control element comprises a diaphragm arrangement which actuates a throttling valve arranged in the line carrying the control signal for the controlling element and to which the control pressure is applied on the one side, a force formed from the actual pressure in the controlled element on the other side.
In normal operation, an equilibrium results from this actual pressure and the control pressure. In the case of a deviation, the diaphragm is displaced and the throttling valve is actuated in the desired manner.
In an arrangement, in which two oppositely disposed chambers which contain hydraulic pressure fluid of different pressures are provided at the core of the roll and in which the differences of these pressures determines the working pressure of the roll, as is the case, for instance, with a so-called "swimming roll", it is advisable to provide an arrangement known per se having two coaxially opposite bellows which are acted upon by the pressures in the chambers and which act, on the sides facing each other, on a lever, and are firmly supported on the other sides which face away from each other, and to provide mechanical transmission members for transmitting displacement of the lever to the diaphragm of the control element.
In this manner, a pressure representative of the working pressure in the roll is brought to bear and can be compared with the control pressure.
Such an element with two oppositely disposed bellows is described in German Pat. No. 1 460 632.
Roll arrangements are known, in which the selectable setting of the hydraulic pressure for the controlling elements takes place using pneumatically controlled regulators for the hydraulic pressure. These set a hydraulic pressure dependent on the pneumatic control signal and an adjusting valve in the feed line carrying the pneumatic control signal supplies an adjustable portion of a fixed pneumatic pressure as a control signal.
In such an arrangement, it is advisable to arrange the pressure monitoring device in the line which carries the fixed pneumatic pump pressure to the adjusting valves.
Then, when the pressure monitoring device has become operative, instead of the full pneumatic pump pressure, the adjusting valves receive only a reduced pressure, from which the adjusting valves then also form an accordingly reduced control signal for the controlling element.
The pressure ratio monitoring device compares the control pressure for the controlled element, developed in a separate system, with the actually prevailing pressure. If, however, the system generating the control pressure itself fails for any reason, the pressure in the controlled element could drop without the pressure ratio monitoring device going into action, just because the control pressure is also not "raised" in such a case. In spite of this, the pressure in the controlling element could be too high.
In order to also provide for such a failure of a separate pneumatic control system, a further embodiment of the present invention consists of arranging a pneumatic control element in the line carrying the fixed pneumatic pump pressure to the adjusting valves, ahead of the pressure ratio monitoring device. A pneumatic pressure representing the pressure in the controlling element and the fixed pneumatic pump pressure are applied to the pneumatic control element. If the first-mentioned pressure increases, the control element only lets a correspondingly rising portion of the fixed pneumatic pressure pass.
The control signal for setting the pressure in the controlling element can therefore rise only if a previous rise has been "reported back" by the pneumatic system. Thus, the pressure in the controlling element also can only rise under these conditions. In the event of a failure of the pneumatic system, such "reporting back" naturally is omitted and no pressure rise can occur. The pressure then remains at a lower base value which is set at the hydraulic-pneumatic control element.
Finally, a pressure limiter can also be arranged in the line for the control pressure to the controlled element.
Thereby, the pressure in the controlled element can never increase beyond a permissable amount. This is particularly important if the controlling element is designed as a double acting pressure cylinder, where part of the weight of the roll resting thereon is relieved by a pressure on the side of the piston opposite to the direction of the loading, this relief pressure likewise being used for controlling the controlled element in the sense that the pressure in the controlled element becomes lower with increasing relief pressure. If now the relief pressure drops out for any reason, the loading in the roll gap thereby increases and the control increases the pressure in the controlled element accordingly. Thus, there is the danger that the permissable load of the rolls will be exceeded. The pressure limiter in the line of the control pressure to the controlled element not prevents a further increase of the pressure in the controlled element. This renders the pressure ratio monitoring device operative and accordingly reduces the pressure in the controlling element.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a pneumatic-hydraulic circuit diagram of a roll arrangement in which the present invention is realized.
FIG. 2 is a cross section through the pressure ratio monitoring device according to the present invention.
FIG. 3 is an enlarged partial view of the lower end of the device according to FIG. 2.
FIG. 4 is a cross section through a pneumatic control element contained in the pressure control device.
DETAILED DESCRIPTION OF THE INVENTION
In the drawings, hydraulic lines are shown as solid lines and pneumatic lines as broken lines.
In FIG. 1, a processing machine 100, with a floating roll 1, e.g., a "swimming roll", and any counter roll 2, is shown. The floating roll comprises a hollow roll 3, which is supported at its ends on a core 4. The core 4 goes through the hollow roll 3 lengthwise and its ends protrude from the hollow roll 3, the ends forming the roll journals. As is evident from the small cross section of the floating roll, designated as a whole with 5, the core leaves a certain spacing from the inside of the hollow roll 3. The space in between is subdivided into two longitudinal chambers 7 and 8 which are arranged opposite to each other in the direction of the roll pressure, by two longitudinal seals 6 arranged at the core. At the ends of the longitudinal chambers 7 and 8, transversal seals are provided inside of the bearings, so that the longitudinal chambers are substantially closed and a hydraulic pressure can be built up in them. In the longitudinal chamber 7 facing the roll gap, a higher pressure is generated, which results in taking up the load in the roll gap. In revolving, the hollow roll 3 slides past the seals 6 and is supported between the bearings only via the hydraulic pressure fluid in the longitudinal chamber 7.
While the floating roll 1 in the illustrated embodiment is supported firmly, the counter roll 2 has a loading device 10 which comprises two hydraulic piston/cylinder units 9, which exert pressure directed against the floating roll 1 on the roll journals 11 of the counter roll 2.
The hydraulic pressure medium for the pressure supply of the floating roll 1 is furnished by the pressure supply unit 12, which contains essentially a pump generating a constant pressure.
The pressure for the hydraulic piston/cylinder units 9 is supplied by the pressure supply unit 13. Unit 13 makes a constant hydraulic pressure available from which the controlled pressure for actuating the hydraulic piston/cylinder units 9 in pressing the counter roll 2 against the floating roll 1 is produced in a manner yet to be explained. A certain amount of hydraulic pressure PE is also present on the piston rod side of the piston/cylinder units 9 and is conducted there via the lines 14. The working pressure therefore is the difference between the pressures prevailing on the two sides on the piston/cylinder units 9. If the roll arrangement is to be raised, i.e., the counter roll 2 is to be lifted from the floating roll 1, then the pressure brought to the piston rod side is raised beyond the pressure prevailing on the closed side.
The pressure in the floating roll is controlled by a difference pressure control 16 which maintains a certain portion of the full pressure, brought out via the line 17 from the pressure supply unit 12, in the longitudinal chamber 7. There is also a hydraulic pressure in the longitudinal chamber 8, which is brought about, among other factors, by the hydraulic pressure medium leaking through at the seals 6. The pressure medium escaping into the longitudinal chamber is led off continuously into the sump via line 18, so that no excessive pressure can build up, or so that the pressure remains at the regulated value.
The control of the portion of the full pressure of the pressure supply unit 12 prevailing in the line 17 maintained in the longitudinal chamber 7 takes place through a separate pneumatic system. The pneumatic control pressure 50 is brought in via the lines 19 and 20. The pressure in the longitudinal chamber is set depending on how high this control pressure 50 is.
The pressure in the loading device 10 are the control input for determining the control pressure 50. The lines 21 and 22 leading to the closed sides of the piston/cylinder units 9 as well as the lines 23 and 24 leading to the piston rod sides are tapped via branch lines 25 and 26 and 27 and 28, respectively. The pressures from the closed sides go to a converter 29, which generates a pneumatic signal corresponding to the average of the two pressures at its output. Similarly, the pressures of the piston rod sides are conducted to a hydraulic-pneumatic converter 31, which produces a pneumatic signal representing the average value at its output 32.
Since the force actually exerted by the loading device depends on the difference of these pressures, the signals at the outputs 30 and 32 are fed to a pneumatic summing member 33 which compares the signals with each other and forms therefrom the pneumatic control pressure 50, which appears at the output 34 and is fed via the lines 20 and 19 to the difference pressure control 16, and thus controls the pressure in the floating roll 1. The pneumatic pressure for the devices 29,31 and 33 is made available by the air supply unit 35 and fed to the inputs of the devices 29,31 and 33 designated with the small arrows.
The pressure in the piston/cylinder units 9 forming the loading device 10 must be adjustable independently. This pressure adjustment again takes place by means of a separate pneumatic system. A pump 36 generates a constant pneumatic pressure, which is fed via the lines 37,38 and 39 to two adjusting valves 40 and 41 which can be operated from the outside and, which feed, depending on how they are actuated, a certain portion of the pneumatic pressure supplied to two pneumatic-hydraulic converters 44 and 45 via the lines 42 and 43. The converters 44 and 45 receive constant hydraulic pressure from the pressure supply unit 13 via the line 46. Depending on the magnitude of the pneumatic pressure in the lines 42 and 43, a certain portion of the full pressure in the line 46 is now passed on to the lines 47 and 48 which open into the lines 21 and 22, respectively, and furnish the pressure fluid for the closed side of the piston/cylinder units 9. The pressure of the loading device 10 is therefore determined by setting the adjusting valves 40 and 41.
The pressure in the loading device 10 again determines, in the manner already described, the control pressure 50 prevailing in the lines 20 and 19, which controls the pressure in the floating roll 1 in such a manner that it is in a definite ratio to the pressure in the loading device 10.
It may now occur that the pressure in the floating roll 1 does not reach the value which is called for by the control pressure 50. If for instance, the seals 6 pass too much pressure fluid, sufficient pressure cannot build up in the longitudinal chamber 7. Defects in the hydraulic feed line to the floating roll 1 also may prevent sufficient pressure build up. As a result, the force exerted by the loading device 10 is too large in relation to the counterforce of the hydraulic pressure medium in the longitudinal chamber 7. This force is taken up by the bearings at the end of the hollow roll 3, which are thereby heavily stressed. In this situation, non-uniform line pressure is also obtained.
In order to prevent this, a pressure ratio monitoring device 60 is built into the pressure control device.
In principle, it would be possible, in order to obtain the heretofore described function of controlling pressure in the floating roll 1 in dependence on the pressure in the loading device 10, to let the line 38 open directly into the adjusting valves 40 and 41 and the line 20 directly into the line 19. According to FIG. 1, however, these lines are brought through the pressure ratio monitoring device 60, and in addition, the pressures in the longitudinal chambers 7 and 8 are tapped via lines 61 and 63 and fed to a pneumatic-hydraulic control element 62, which is part of the pressure ratio monitoring device 60.
The control pressure 50 in the line 20 is present at the input 64 of the control element 62, and the pressure in the lines 61 and 63, at the inputs 65 and 66. The control signal 51 present in the line 38 arrives at the input 67 and is passed at the output 68 into the line 39. The output 68 is furthermore connected to the input 69.
In the control element 62, the control pressure 50, which represents the pressure in the loading device 10, is now compared with the actual pressure prevailing in the floating roll 1. If the ratio between these two pressures is not more than a predetermined value, then the control element 62 remains inactive and lets the control signal 51 present in the line 38 pass through without change from the input 67 to the output 68 and from there, via the line 39 to the adjusting valves 40 and 41.
If, however, the pressure in the floating roll 1 cannot reach the value called for by the control pressure 50 and the pressure is therefore larger than the predetermined value, then only a certain portion of the control signal 51 is passed to the adjusting valves 40 and 41, which then also let only pneumatic pressure accordingly reduced from the set value through via the lines 42 and 43 to the converters 44 and 45, whereby the hydraulic pressure in the lines 21 and 22 and therefore, in the loading device 10, is lowered, so that the correct pressure ratio readjusts itself.
In FIG. 1, the control element 62 is only shown schematically; a practical embodiment will now be described in conjunction with FIGS. 2 and 3.
It can now happen that due to some defect, the mechanism generating the pneumatic control pressure 50 fails. In such an event, the pressure ratio monitoring device 60 would not respond, since the pneumatic control pressure cannot be too high relative to the pressure in the floating roll. Nevertheless, the ratio of the pressure of the loading device 10 and the floating roll 1 can be considerably disturbed.
To provide protection in such a case, the pneumatic systems for the control pressure 50 and the control signal 51 are coupled via the line 73. At the output 30 of the converter 29, a pressure representative of the pressure on the closed sides of the piston/cylinder units 9 is taken off and fed to the inputs 71 and 72 of a pneumatic control element 70, which passes on from the input 74 to the output 75 the pressure present in the line 37 only in accordance with the pressure increase in the line 73. Thus, only if the pneumatic system reports a pressure increase in the piston/cylinder units 9 can an accordingly increased portion of the pressure in the line 37 pass into the line 38 as a control signal. Thus, it cannot happen that the pressure in the loading device 10 will be increased, while the control pressure 50 for the floating roll fails to appear and the pressure ratio monitoring device 60 is inactive, the purpose of which is to exactly ascertain that the pressure in the loading device 10 does not become too high.
Further protection is provided by a pressure limiter 80 in the line 20. The pressure limiter 80 prevents, for instance, due to a failure of the relief pressure on the piston rod sides of the piston/cylinder units 9, a very peaked control pressure 50 from suddenly getting to the difference pressure control 16 and raising the pressure in the floating roll 1 beyond the permissable value.
In FIGS. 2 and 3, the pneumatic/hydraulic control element 62 is shown in detail. On a base plate 162, two bellows 165 and 166 are arranged on the same axis; they are firmly supported on their sides facing away from each other and into which lead the lines 65 and 66, respectively, which carry the pressure in the two chambers 7 and 8 of the floating roll 1. With their sides facing each other, the bellows engage a two arm lever 161 which is fulcrumed at 163 and transmits its movement via a roller 164 to a one arm lever 167 which in turn acts on a pin 168 which is subjected to an upward or downward force, according to FIG. 2, if the ratio of the pressure in the bellows 165 and 166 changes.
The pin 168 rests on a diaphragm body 171 mounted in a housing 170, which is connected to the base plate 162. The diaphragm body 171 is held at the housing 170 by several diaphragms 150 which are lined up in the direction of the axis of the pin 168 and can move in the axial direcction. The displacement is transmitted via a pin 172 to the closing body 174 of a throttling valve 173. The upper edge of the closing body 174 cooperates with a conical sealing surface 175 of the throttling valve 173 to form a control edge 178. If the pin 172 and therefore, the closing body 174 move downward, then the upper edge of the closing body moves away from the seating surface 175, and a passage from left to right as per FIGS. 2 and 3 is opened up. Normally, the closing body 174 is held in contact with the sealing surface 175 by the spring 176.
The inputs corresponding to the presentation in FIG. 1 are drawn in FIGS. 2 and 3. Accordingly, the control pressure 50 is present at the input 64; it also prevails in chamber 177. In the chamber 178 of the same size, the signal pressure 51 of the output 68 is present, which is also conducted via the input 69 to the chamber 178, so that the diaphragm body 171 is partially pressure-relieved by the pressures prevailing in the chambers 177 and 78.
If now the pressure in the longitudinal chamber 7 facing the roll gap in the floating roll 1 drops during operation, this pressure drop propagates via input 65 in the bellows 165, which accordingly will collapse somewhat. The right hand side of the two arm lever 161 as shown on FIG. 2 will move downward and the roller 164 upward. Correspondingly, the one arm lever 167, the pin 168, the diaphragm body 171, the pin 172 and the closing body 174 also move upward. In cooperation with the sealing surface 175, the control edge 179 is closed and the air steam flowing from the input 67 to the output 68 is throttled. Thereupon, the pressure in the loading device 10 and the control pressure 50, representing the former, are lowered. This means that the pressure in the chamber 177 drops and the diaphragm body 171 moves downward according to FIG. 2. This creates a larger opening at the control edge 179, so that the control signal can pass again from 67 to 68 less attenuated, or with no change at all. Then, equilibrium occurs matching the conditions.
In FIG. 4, the control element 70 is shown, the design of which corresponds in substance to the lower part of the control element 62 in FIG. 2. Instead of the pin 169, merely a chamber 180 is provided. Chamber 180 contains a spring 181 and, within chamber 180, the pressure of the line 73, present at the input 71, prevails, which represents the pressure in the loading device 10. The same pressure also prevails in the chambers 183 and 184, so that the diaphragm body 182 is pressure relieved.
If now, for instance, due to a disturbance, the air supply, the output signal of the device 29 and therefore, the pressure line 73 or the chamber 180 drop off, then the diaphragm body 182 moves upward, and the control edge 179 closes. The passage from the input 74 to the output 75 is reduced down to a small predetermined base pressure for the loading device 10. Thus, an increased loading pressure can occur in no case. | A pressure control device for processing machines having at least one roll which has a stationary core around which a hollow roll which forms the roll proper revolves with radial spacing from the core, the hollow roll supported at its ends on the core and supported on the core in between in the radial direction by a fluid pressure medium disposed in a chamber formed at the core, the fluid pressure medium generating a force acting on the inside of the hollow roll to provide the operating pressure of the roll, with a loading device operated by a fluid pressure medium also applied either to the roll or a counter-roll, either the loading device or roll forming a controlling element, with a control pressure which is derived from the pressure prevailing therein used to adjust a pressure in the other controlled element which has a definite predetermined pressure ratio to the pressure in the controlling element, which pressure control device includes a pressure ratio monitoring device having as inputs the control pressure and the actual pressure in the controlled element and compares the inputs and, if the pressure in the controlling element becomes to high relative to a predetermined pressure ratio, reduces the pressure to the controlled element in order to reestablish the desired predetermined pressure ratio. | 3 |
TECHNICAL FIELD
The present disclosure relates to multi-channel controls, and particularly to multi-channel protection logic.
BACKGROUND OF THE INVENTION
Many control systems have independent protection devices. For example. engine control systems, and particularly multi-channel engine control systems, include overspeed detection systems that detect the occurrence of an overspeed within an engine and trigger an action in response to detecting an overspeed to mitigate the overspeed condition.
Protection systems often include redundancy, such that no single point failure in the protection system causes the plant to be unable to protect against an event. Furthermore, protection systems are also designed such that no single point failure inadvertently shuts down the plant. Typically plant control systems use two dedicated plant control-function independent hardware overspeed devices to detect and respond to overspeed conditions. These systems can fail to protect against overspeed if one of the two protection devices fails.
In other systems that use a primary control to supplement the protection devices, the protection devices are hardware devices that lack flexibility in self-testing or in changing the implementation. Furthermore, the prior art shared a microprocessor bus between the primary controller and the protection device.
SUMMARY OF THE INVENTION
A multi-channel controller has a first control channel having a first primary controller with a first protection output signal and a first protection device with a first protection output signal. A second control channel has a second primary controller with a second protection output signal and a second protection device with a second protection output signal. A plurality of logic gates connect each of the first primary control output signal, the first protection device output signal, the second primary control output signal, and the second protection device output signal to a controlled device.
A method for controlling a multi-channel solenoid includes the steps of detecting an event using at least one of a first protection device, and a second protection device, outputting an event detected signal from each of the first protection device, and the second protection device detecting the event, and activating at least one channel of a multi-channel solenoid.
Also disclosed is a method for controlling a multi-channel solenoid by monitoring the current through an overspeed solenoid, and thereby determining the health of a controller and the health of multiple logic gates using a protection device.
These and other features of the present invention can be best understood from the following specification and drawings, the following of which is a brief description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a multi-channel engine controller controlling a stepper motor that adjusts engine fuel flow.
FIG. 2 illustrates an example logical configuration for connecting the multi-channel controller of FIG. 1 to an overspeed protection solenoid.
FIG. 3 illustrates the primary operation mode of the example of FIG. 2 .
FIG. 4 illustrates a first example failure mode of the example of FIG. 2 .
FIG. 5 illustrates a second example failure mode of the example of FIG. 2 .
FIG. 6 illustrates a third example failure mode of the example of FIG. 2 .
FIG. 7 illustrates a fourth example failure mode of the example of FIG. 2 .
DETAILED DESCRIPTION
FIG. 1 illustrates an example electronic multi-channel engine controller 10 , controlling a stepper motor 20 within a hydromechanical metering unit 19 . The solenoid 22 actuates an overspeed shutoff valve to an engine (not pictured) that reduces or eliminates fuel supply to the engine when a certain condition exceeds a threshold. In the illustrated example, the condition is an engine speed, and the system is referred to as an overspeed protection system. However, it is understood that a similar system could protect against excessive temperature, or other conditions, and fall within the below disclosure.
The multi-channel controller 10 includes two channels 12 , 14 each of which includes a primary controller 30 that controls the engine while the primary controller 30 is healthy (fully functioning). Furthermore, each channel 12 , 14 includes a microprocessor protection device 40 that includes a backup controller function that assumes control if the primary controller 30 becomes unhealthy. The protection device 40 also provides an overspeed protection control independent of the primary controller 30 . Specifically an overspeed solenoid 22 is activated and shuts off or reduces fuel to the engine when an overspeed condition is detected, thereby eliminating the overspeed condition. When the overspeed condition ends, the overspeed solenoid 22 is deactivated and allows fuel to reach the engine. The illustrated overspeed solenoid 22 is a two coil or two channel solenoid, and either coil activating is sufficient to reduce or eliminate fuel flow to the engine.
Between the two primary channels is a cross-channel data link 15 that provides data communications between channels 12 , 14 . Each channel 12 , 14 includes an overspeed detection output signal 16 from the corresponding primary controller 30 and the protection device 40 corresponding to the overspeed protection solenoid 22 . Also, each channel 12 , 14 has a stepper motor output signal 17 from the primary controller 30 and the protection device 40 corresponding to the stepper motor 20 within the hydromechanical metering unit 19 . A cross-channel overspeed vote signal 18 communicates between one channel's 12 , 14 protection device 40 and the other channel's 12 , 14 primary controller 30 .
FIG. 2 illustrates an example logical configuration for connecting the multi-channel controller 10 of FIG. 1 to the overspeed solenoid 22 while allowing continued overspeed protection in a number of failure modes. Each channel 12 , 14 of FIG. 1 has a pair of corresponding sensor inputs 122 , 124 , 132 , 134 . Two sensor inputs 122 , 124 are accepted by both controllers 30 , 40 in channel 14 and the other sensor inputs 132 , 134 are accepted by both controllers 30 , 40 in channel 12 . The overspeed solenoid 22 has two channels 22 a , 22 b , each of which has two inputs 142 , 144 , 146 , 148 . When each of the two inputs 142 , 144 , 146 , 148 corresponding to a single channel 22 a , 22 b of the overspeed solenoid 22 instructs the overspeed solenoid 22 to restrict fuel to the engine, the overspeed solenoid 22 activates and restricts fuel flow.
Also included in the configuration of FIG. 2 are multiple logic gates 160 - 174 . The logic gates 160 - 174 combine the outputs of the controllers 30 , 40 thereby ensuring that no single controller 30 , 40 failure causes the overspeed detection system to fail. The logic gates 160 - 174 are implemented using solid state digital logic circuits. Primary OR gates 168 , 170 each accept one input from a corresponding primary controller 30 and one input from an alternate OR gate 164 , 166 (alternately referred to as the cross-channel Overspeed Vote Signal) and output an “activate overspeed solenoid” signal whenever the corresponding primary controller 30 or the alternate OR gate 164 , 166 indicates an overspeed condition. The overspeed solenoid 22 accepts the output of the primary OR gate 168 , 170 at each of the primary control inputs 142 , 148 .
Each of the alternate OR gates 164 , 166 has three inputs 190 , 192 , 194 . The first alternate OR gate input 190 is an overspeed detection output of the primary controller 30 in the same channel 12 , 14 as the alternate OR gate 164 , 166 and is high whenever the primary controller 30 detects an overspeed. The second alternate OR gate input 192 is an overspeed detection output signal from the protection device 40 of the same channel 12 , 14 as the alternate OR gate 164 , 166 and is high whenever an overspeed is detected by the corresponding protection device 40 . The third alternate OR gate input 194 is an output of a channel health control AND gate 172 , 174 in the same channel 12 , 14 as the alternate OR gate 164 , 166 .
Each of the channel health control AND gates 172 , 174 accepts and inverts a primary controller health input 182 and a protection device health input 184 , with each of the inputs being high when the corresponding controller 30 , 40 is healthy. Due to the inverting of the inputs 182 , 184 , the output of the channel health control AND gate 172 , 174 is high only when both the protection device 40 and the primary controller 30 for the corresponding channel 12 , 14 are unhealthy. Thus, when both controllers 30 and 40 within the same channel are unhealthy, the local channel protection system defaults to a failsafe state of detecting an overspeed in the remote channel.
The protection device inputs 144 , 146 of the overspeed solenoid 22 are connected to the output of backup OR gates 160 , 162 . Backup OR gates 160 , 162 accept an overspeed detected input 192 corresponding to the overspeed detection of the protection devices 40 . When the protection device 40 detects an overspeed condition, the overspeed detected input 192 is high. Thus, the backup OR gates 160 , 162 instruct the overspeed solenoid 22 to activate whenever the protection device 40 detects an overspeed condition.
In order to test protection device inputs 144 , 146 prior to operation backup OR gates 160 , 162 have inputs 161 from their respective protection devices that allows the channel 14 to activate switch 144 without activating switch 148 and the channel 12 to activate switch 146 without activating switch 142 .
Since the protection device 40 is a microprocessor, it is capable of reading and intelligently reacting to self-test signals. A current sensor 200 transmits an analog signal 203 that permits the protection device 40 to monitor current through the overspeed solenoid 22 to determine the health of the protection device and the plurality of Boolean logic gates 160 - 170 .
Optionally, it is possible output LSS signals 161 or 192 such that the LSS signals 161 , 192 pulse width modulate the current command thereby creating a closed loop.
Also, the LSS voltage is monitored using signal 202 . Signal 202 is pulled up to a voltage 201 that is less than the voltage required to energize the overspeed solenoid through the switch commanded by input 148 . Thus, the health of the switches controlled by commands 146 and 148 , and the health of the plurality of Boolean logic gates 160 - 170 can be determined by the protection device 40 .
Furthermore, for self-test capability for determination of the health of the Boolean logic gates 160 - 170 by the protection device 40 , the following Boolean logic gate signals are monitored by the protection device 40 : switch input 148 , output of the local OR gate 166 (alternately referred to as the local overspeed vote signal), output of the remote OR gate 164 (alternately referred to as the remote overspeed vote signal) and both outputs out of primary controller 30 (the input to primary OR gate 170 and the input to alternate OR gate 166 ). Both outputs from primary controller 30 are passively buffered to prevent faults from propagating from the primary controller 30 to the protection device 40 and the plurality of Boolean logic gates 160 - 170 .
In order to announce the results of self-testing, protection device 40 has a data link 32 for reporting self-test results. Primary controller 30 passes the self-test results to an operator of the protected device (alternately referred to as a plant operator). Alternatively, protection device 30 can have a second data link or equivalent output (fault lamp drivers, etc) that announces faults to a plant operator.
The data link 32 is also used for coordinating special self-tests during control power-up and plant shutdown with the primary controller 30 . The software is written in the protection device 40 such that the protection device's 40 normal operating protection algorithm is unchanged by any data transmissions from the primary controller 30 .
During a shutdown, the overspeed system 10 can verify its own health by using either channel or both channels 12 , 14 to shutdown the plant. Such a mode is referred to as a self-test mode. In the self-test mode, the primary controller 30 activates the input to primary OR gate 170 and the protection device 40 activates the self-test overspeed vote signal 161 . Testing both channels ensures that the overspeed solenoid 22 is not wound incorrectly such that the magnetic field of one channel cancels the magnetic field of the other channel.
The signal from primary controller 30 to primary OR gate 170 is only used during the self-test mode to prevent a single in-range failure within the plant sensor inputs 132 , 134 inadvertently activating the overspeed solenoid 22 during normal operations.
The microprocessor systems of the primary controller 30 and the protection device 40 include disable signals from independent monitors within the microprocessors. Whenever a microprocessor-based monitor detects a fault, the outputs from that microprocessor are disabled such that the microprocessor does not detect for an overspeed. The disable signals are used to generate primary controller health signal 182 and protection device health signal 184 . As stated earlier, when both controllers 30 and 40 within the same channel are unhealthy, the local channel protection system defaults to a failsafe state of detecting for an overspeed in the remote channel.
Operation of the two channel 12 , 14 , four controller 30 , 40 system is disclosed in greater detail below with regards to FIGS. 3-7 , each of which describes a particular operation mode of the example configuration of FIG. 2 .
FIG. 3 illustrates the primary operation protection mode of the multi-channel controller 10 with all four of the controllers 30 , 40 being healthy. In FIG. 3 , each of the protection devices 40 detects an overspeed condition based on the sensor inputs 122 , 124 , 132 , 134 and outputs an overspeed detected signal 192 to the backup OR gates 160 , 162 , causing the backup OR gates 160 , 162 to output an overspeed detected signal to the protection device inputs 144 , 146 .
The overspeed detected input 192 is also sent to the alternate OR gates 164 , 166 . Since each of the alternate OR gates 164 , 166 has at least one signal indicating that the overspeed solenoid 22 should be activated, the alternate OR gates 164 , 166 each also output a high signal indicating that the overspeed solenoid 22 should be activated. The outputs of the alternate OR gates 164 , 166 are received by the primary OR gates 168 , 170 , causing the primary OR gates 168 , 170 to output a signal activating the overspeed solenoid 22 to the overspeed solenoid inputs 148 , 142 .
Thus, when all four controllers 30 , 40 are operating and healthy and an overspeed condition is detected, the overspeed solenoid receives an input signal at two inputs 142 , 144 , 146 , 148 at each of the channels 22 a , 22 b instructing activation of the overspeed solenoid 22 .
While it is desirable that all four of the controllers 30 , 40 are operating, and therefore at least two of the four controllers 30 , 40 detect any event, it is understood that during standard operation, controllers can fail. The below descriptions illustrate how the system can continue functioning in a number of failure modes.
FIG. 4 illustrates an alternate operation mode of the multi-channel controller 10 with all four of the controllers 30 , 40 being healthy. Additionally, the operational mode of FIG. 4 functions when the primary controller 30 in one channel 12 and/or the protection device 40 in the other channel 14 are unhealthy (non-functional). In FIG. 4 , the primary controller 30 that is healthy outputs an overspeed detected signal to the alternate OR gate 164 corresponding to the healthy primary controller 30 . The alternate OR gate 164 then outputs an overspeed detected signal to the primary OR gate 170 corresponding to the opposite channel 12 having an unhealthy primary controller 30 , causing the primary OR gate 170 to output an overspeed detected signal to the overspeed solenoid input 148 .
Likewise, the protection device 40 that is healthy outputs an overspeed detected signal 192 to the backup OR gate 162 in the channel 12 corresponding to the healthy protection device 40 . The backup OR gate 162 outputs an overspeed detected signal to the backup overspeed solenoid 22 input 146 , thus ensuring that both inputs in a single channel 22 a of the overspeed solenoid 22 receive an activation input in response to the detection of an overspeed event. The overspeed solenoid 22 is fully operational as long as a single channel 22 a is operational, the primary overspeed solenoid input 148 and the backup overspeed solenoid input 146 are sufficient to activate the overspeed solenoid 22 .
FIG. 5 illustrates an alternate operation mode of the multi-channel controller 10 where both speed sensors for one of the channels 14 ceases operating. When both speed sensor inputs 122 , 124 cease operating, and the primary controller 30 is healthy, the primary controller 30 assumes an overspeed condition in order to force a failsafe mode. The primary controller 30 of the channel 14 with the failed speed sensors outputs an overspeed detected signal to the alternate OR gate 164 corresponding to the channel 14 with the failed speed sensor. Since at least one of the alternate OR gate's 164 inputs indicates an overspeed condition, the alternate OR gate 164 outputs an overspeed detected signal to the primary OR gate 170 in the opposite control channel 12 . The primary OR gate 170 then continuously outputs an overspeed detected signal to the overspeed solenoid 22 via the primary overspeed solenoid input 148 as long as the speed sensor is in a failure state.
The protection device 40 in the channel 12 corresponding to the healthy speed sensor only outputs an overspeed detected signal when an actual overspeed event is detected. The overspeed detected signal is output to the backup OR gate 162 , which then outputs an overspeed detected signal to the overspeed solenoid 22 input 146 . Once two overspeed detected signals are received at a single channel 22 a of the overspeed solenoid 22 , the overspeed solenoid 22 activates, and the overspeed event is protected against. In this failure mode, the overspeed solenoid 22 receives two overspeed detected signals to a single channel 12 , 14 when an overspeed condition exists, despite the overspeed sensors being dead to the other channel 12 , 14 .
FIG. 6 illustrates an alternate mode of operation of the multi-channel stepper motor controller 10 where one control channel 14 enters a dual failure mode and entirely ceases operation. When the channel 14 enters failure mode, both the primary controller health input 182 and protection device health input 184 to the channel health control AND gate 174 cease indicating that the corresponding controller 30 , 40 is healthy. Both of the inputs to the channel health control AND gate 174 are inverted, and the AND gate sees two positive signals and outputs an overspeed detected signal to the alternate OR gate 164 corresponding to the failed channel 14 . The overspeed detected signal is the default signal for a failure channel 12 , 14 .
As the alternate OR gate 164 has at least one input indicating an overspeed condition, the alternate OR gate 164 outputs a signal indicating an overspeed condition to the primary OR gate 170 corresponding to the currently healthy control channel 12 . The primary OR gate 170 then outputs an overspeed detected signal to the overspeed solenoid 22 input 148 . As with the example of FIG. 5 , the overspeed solenoid 22 only activates when both the primary input 148 and the backup input 146 of a single channel 22 a indicate an overspeed condition.
When the protection device 40 in the functional channel 12 detects an overspeed condition, the protection device 40 outputs an overspeed detected signal to the corresponding backup OR gate 162 . The backup OR gate 162 then outputs an overspeed detected signal to the backup overspeed detected input 146 of the overspeed solenoid 22 , thus providing both needed inputs 146 , 148 to activate the overspeed solenoid 22 in the case of an overspeed event.
An alternate failure mode to one of the controllers 30 , 40 or one of the control channels 12 , 14 failing is that cross-channel overspeed vote signal between the two channels 12 , 14 is disrupted due to a severed electrical connection. FIG. 7 illustrates an example where the communication between one of the control channels 14 is severed from the other control channel 12 . As can be seen in FIG. 7 , the link between alternate OR gate 164 corresponding to control channel 14 and the primary OR gate 170 is severed. The primary OR gate 170 is configured such that when the link to the input corresponding to the alternate OR gate 164 of the opposite control channel 14 is severed, the input defaults to an overspeed detected input, thus causing the primary OR gate 170 to output an overspeed detected signal to the primary overspeed protection solenoid input 148 .
Similarly, if power is lost to one channel 14 causing a gross failure in that channel, then the primary OR gate 170 's input in channel 12 from channel 14 's alternate OR gate 164 defaults to an overspeed event.
The input for the protection device input 146 to the overspeed solenoid 22 is provided in an identical fashion as was previously described with regards to the dual or gross failure mode example of FIG. 6 . Thus, at least one channel receives the two inputs 146 , 148 needed to activate the overspeed solenoid 22 .
As can be seen in the illustrations of FIGS. 4-7 , the failure modes in each example Figure are symmetrical, with opposite failures from the ones described resulting in the same functionality.
Although an example of this invention has been disclosed, a worker of ordinary skill in this art would recognize that certain modifications would come within the scope of this invention. For that reason, the following claims should be studied to determine the true scope and content of this invention. | A multi-channel controller uses multiple logic gates and multiple control channels to provide fault tolerant protection against undesired events. | 6 |
CROSS REFERENCES TO RELATED APPLICATIONS
[0001] The present application claims priority to U.S. Provisional Patent Application No. 60/710,308, filed Aug. 22, 2005.
[0002] This invention was made in the performance of a Cooperative Research and Development Agreement with the Department of the Air Force. The Government of the United States has certain rights to use the invention.
FIELD OF THE INVENTION
[0003] The present invention relates to nanocomposites formed from the combination of repeat sequence protein polymers and layered silicates. The invention also provides for methods for the synthesis of such nanocomposite materials.
BACKGROUND OF THE INVENTION
[0004] The combination of polymers and inorganic filler materials is known for the production of nanocomposite materials with improved mechanical, thermal and barrier properties as compared to the unmodified polymer. A detailed discussion of nanocomposites can be found in Ajayan, P. M., Nanocomposite Science and Technology (Wiley, 2003).
[0005] The combination of polymers with layered silicates, also known as smectite clays or phyllosilicates, has been exploited as a means for the synthesis of nanocomposites. Comprehensive reviews on the subject are Alexandre and Dubois (2001) and Pinnavaia, T. J.; Beall, G. W. Polymer Clay Nanocomposites Wiley New York, 2000. Smectite clays are described in Grim, R. E. Clay Mineralology 2 nd edition; McGraw-Hill: New York 1968.
[0006] Several methods for the synthesis of polymer clay nanocomposites have been described in the art, for example Nylon/clay composites first described by Usuki et al. (1993). A. Usuki, et al., “Synthesis of nylon 6-clay hybrid”, J. Mater. Res., vol. 8, No. 5, May 1993, pp. 1179-1184. In this process nylon and montmorillonite are combined at high temperature to give an exfoliated nanocomposite with improved material properties relative to the polymer alone.
[0007] A biodegradable thermoplastic material comprising a natural polymer, a plasticizer and an exfoliated clay having a layered structure and a cation exchange capacity of from 30-350 milliequivalents per 100 grams is described in U.S. Pat. No. 6,811,599 B2. The natural polymer is a polysaccharide.
[0008] A smectite clay modified with an organic chemical composition and a polymer is described in U.S. Pat. No. 6,521,690.
[0009] Nanocomposites formed from phyllosilicates and the synthetic homopolymer poly-L-lysine have been described. (Krikorian, V. et al. J. Polym. Sci. B: Polym. Phys. 2002, 40, 2579). Soy protein isolate has also been incorporated into nanocomposites containing sodium montmorillonite clay (Chen, P. and Zhang, L. Biomacromolecules, 2006, 7, 1700).
[0010] Proteins make up the main structural elements of most organisms, using complex sequences of amino acids that lead to wide arrays of functionalities. One of the most intensely studied structural proteins, Bombyx mori silkworm silk, has generated significant interest because of its remarkable mechanical properties, which rival even spider silk. Elastin, another well-known structural protein, is found predominantly in the body's arterial walls, the lungs, intestines, and skin. Silk elastin like protein (SELP) is a recombinant protein consisting of alternating blocks of silk-like and elastin-like amino acids. The mechanical properties of recombinant proteins like SELP are often inferior to structural proteins found in nature.
[0011] The use of recombinant proteins in in-vivo applications and in applications outside of the body may demand improvements and alterations in a wide variety of properties, including high temperature mechanical behavior.
SUMMARY OF THE INVENTION
[0012] The invention is directed to compositions comprising nanocomposites of a phyllosilicate and one or more repeat sequence protein polymers. In one embodiment of the invention, the phyllosilicate is Na + Montmorillonite (MMT), a smectite clay and the repeat sequence protein polymer is a co-polymer comprising sequences derived from silk and elastin termed SELP. In yet another embodiment of the invention the repeat sequence protein polymer is a chemically modified SELP analogue whereby the protein is reacted with succinic anhydride. In another embodiment of the invention the phyllosilicate is attapulgite. In yet another embodiment of the invention, an additive, for example, a plasticizer, or a protein cross linking agent, or a plasticizer and a cross linking agent is added to the phyllosilicate and the repeat sequence protein polymer.
[0013] The compositions of the present invention are nanocomposites that demonstrate material property alterations and/or enhancements relative to the RSPP alone.
[0014] The nanocomposites are dispersions of phyllosilicate sheets within a protein matrix. The dispersion, or exfoliation, is achieved by interactions between the positively charged lysine residues of the protein and the negatively charged phyllosilicate sheets, in addition to other polar functionalities within the protein structure.
[0015] Without wishing to be bound by any particular theory, it is believed that the electrostatic character of the protein dominates long-range particle-particle interactions, and that the hydrogen bonding character of the protein dominates local interactions between the protein and the phyllosilicate material. Specifically, cationic charged proteins result in an exfoliated morphology, while the presence of anionic protein residues affects the morphology of the nanocomposite by generating repulsive interactions with MMT sheets that may result in a weak clustering or agglomeration of MMT in solution that manifests as at least some non-uniformity in the solid state.
[0016] The nanocomposites of the present invention may be tailored to have altered and/or improved elasticity as shown by elastic modulus values that are at least 10%, at least 20%, at least 30%, at least 40%, at least 50%, at least 60%, at least 70%, at least 80%, and at least 90% greater than the elastic modulus values of the RSPP alone. The nanocomposites also may be designed to have altered tensile properties, altered morphology, altered zeta potential, and or altered coefficient of thermal expansion.
[0017] The protein-based nanocomposite of repeat sequence protein polymer and phyllosilicate produces a repeat sequence protein polymer with mechanical properties suitable for use of the composite as suture material, as a tissue scaffold, artificial tissue, or biodegradable structural material, including industrial materials.
[0018] The nanocomposites of the present invention may also retain variable percentages of the water, or other solvents used to make the nanocomposites as well as other additives selected to tailor properties of the nanocomposites.
[0019] This invention also describes methods for the formation of nanocomposites consisting of a phyllosilicate and a repeat sequence protein polymers. The method comprises suspending a phyllosilicate in deionized water or buffered water, with or without an additional solvent; and adding a repeat sequence protein polymer to the phyllosilicate suspension with mixing and/or sonication. The resulting mixture may be cast into a vessel and allowed to dry.
[0020] The amount of SELP material added to the phyllosilicate suspension may be selected to provide a nanocomposite with desired material properties. For example, a nanocomposite with desired elastic modulus values, or tensile strength values, may be made by varying the amount of SELP in the composite.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is a graph showing X-ray scattering curves for nanocomposites of the present invention.
[0022] FIG. 2 is low and high magnification transmission electron microscopy (TEM) images of nanocomposites of the present invention.
[0023] FIGS. 3A and 3B are, respectively, graphs showing the elastic modulus and the coefficient of thermal expansion (CTE) of nanocomposites of the present invention.
[0024] FIG. 4 is a graph showing the zeta potential for aqueous suspensions of a phyllosilicate having increasing concentrations of repeat sequence protein polymer.
[0025] FIG. 5 is low and high magnification TEM images of nanocomposites of the present invention.
[0026] FIG. 6 is a graph showing stress-strain curves for nanocomposites of the present invention, with a table listing the elastic modulus (GPa) and percent elongation to break (%) calculated from the curves.
DETAILED DESCRIPTION OF THE INVENTION
[0027] The present invention is directed to compositions that are nanocomposites of a phyllosilicate material and one or more repeat sequence protein polymers. In one embodiment of the invention, the phyllosilicate material is a smectite clay, for example, montmorillonite (MMT) clay, and the repeat sequence protein polymer is a co-polymer having sequences derived from silk and elastin, termed SELP. In yet another embodiment of the invention the repeat sequence protein polymer is a chemically modified SELP analogue whereby the protein is reacted with succinic anhydride.
[0028] The nanocomposites of the present invention are highly exfoliated materials produced under controlled conditions. The invention further includes methods for the formation of nanocomposites of a phyllosilicate and a repeat sequence protein polymer. The method suspends a phyllosilicate clay in water with or without a solvent; adds a repeat sequence protein polymer to the phyllosilicate suspension with mixing and/or sonication. The resulting mixture may be cast into a vessel and dried, retaining varying amounts of water or other solvent. Additives may be used and added to select properties of the nanocomposites.
DEFINITIONS
[0029] For purposes of this invention, the following definitions shall apply:
[0030] “Elastic modulus”, or modulus of elasticity means a measurement that expresses the ability of a material to return to its original dimension after the removal of stresses, calculated by the formula E=S/δ, where S is the unit stress and δ is the unit strain. The nanocomposites of the present invention have an elastic modulus that is at least 10%, at least 20%, at least 30%, at least 40%, at least 50%, at least 60%, at least 70%, at least 80%, and at least 90% greater than the elastic modulus of the RSPP without the addition of the phyllosilicate material.
[0031] An “Exfoliated nanocomposite” means a composite morphology where the layers of the phyllosilicate component are dispersed or displaced from the generally intercalated layered structure found in the starting phyllosilicate material. A “highly exfoliated nanocomposite” exhibits a morphology that is generally homogeneous because substantial layer dispersion has occurred so that the composite cannot be shown to have distinct phyllosilicate and RSPP phases.
[0032] Without wishing to be bound by any particular theory, it is believed that the electrostatic character of the protein dominates long-range particle-particle interactions, and that the hydrogen bonding character of the protein dominates local interactions between the protein and the phyllosilicate material. Specifically, cationic charged proteins result in an exfoliated morphology, while the presence of anionic protein residues affects the morphology of the nanocomposite by generating repulsive interactions with MMT sheets that may result in a weak clustering or agglomeration of MMT in solution that manifests as at least some non-uniformity in the solid state.
[0033] “Material properties” means tensile strength, elastic modulus, morphology, and altered and/or improved thermal properties.
[0034] The nanocomposites of the present invention demonstrate an alteration and/or improvement, when compared to repeat sequence protein polymers alone, of one or more material properties.
[0035] A “nanocomposite” means a composite composed of two or more physically distinct materials in close contact, where at least one of the two or more phases exhibits at least one dimension that is in the nanometer size range (i.e. smaller than 100 nanometers). The close contact between phases in a nanocomposite underlies the unique properties of this class of materials relative to conventional composite materials. Ajayan, P. M., Nanocomposite Science and Technology (Wiley, 2003).
[0036] “Tensile Strength” as applied to a composite film means the maximum stress which can be applied in a tension test prior to breakage (failure) of the film. Tensile strength is expressed in Pascals (MPa) or pounds per square inch (psi).
[0037] “Percent elongation-to-break”, sometimes referred to as strain to break, is the strain on a material when it breaks and is expressed as a percent. Tensile properties includes tensile strength and percent elongation-to-break.
[0038] “Zeta potential” means the electrical potential that is generated by the accumulation of ions at the surface of a colloidal particle.
Repeat Sequence Protein Polymers
[0039] The repeat sequence protein polymer (RSPP) can be any modified polypeptide with at least one distinct domain repeated throughout the entire sequence two or more times.
[0040] The at least two distinct repeating domains of the RSPPs suitable for the present invention may be derived from a natural, chemically synthesized and/or modified, recombinant protein, or mixtures thereof. For example, the repeating sequence units may be derived from modifying a natural structure supporting materials such as silk, elastin, and collagen. Alternatively, the repeating sequence units may be derived from synthetic structures.
[0041] One skilled in the art will appreciate the various naturally occurring proteins containing repeating sequence units, which can be modified and used for designing and producing the repeat sequence protein polymers of the present invention, any of which may be employed herein. Specifically, there are more than six hundred repeating amino acid sequence units known to exist in biological systems. The natural OR synthetic protein repeating amino acid sequence units are derived by making modifications to elastin, collagen, abductin, byssus, extensin, flagelliform silk, dragline silk, gluten high molecular weight subunit, titin, fibronectin, leminin, gliadin, glue polypolypeptide, ice nucleating protein, keratin mucin, RNA polymerase II, resilin or a mixture thereof.
[0042] RSPP repeating sequence units for the natural or synthetic materials listed above are described and the amino acid sequences are shown in WO 04080426A1, which is incorporated herein in its entirety.
[0043] The repeat sequence protein polymer (RSPP) formula comprises:
[0000] T y [(A n ) x (B) b (A′ n ′) x ′(B′) b′ (A″ n ″) x ″] i T′ y ′
[0000] wherein: T and T′ each comprise an amino acid sequence of from about 1 to about 100 amino acids, wherein the amino acid sequence of T′ is the same as or different from the amino acid sequence of T; y and y′ are each an integer from 0 to 1, wherein the integer of y′ is the same as or different from the integer of y; A, A′ and A″ are each individual repeating amino acid sequence units comprising from about 3 to about 30 amino acids, wherein the amino acid sequence of A′ and the amino acid sequence of A″ are the same as or different from the amino acid sequence of A; n, n′, and n″ are each integers of at least 2 and not more than 250; x, x′ and x″ are each 0 or an integer of at least 1, wherein each integer varies to provide for at least 30 amino acids in the A′, A′ and A″ individual amino acid sequence repeating units, and wherein the integer of x′ and the integer of x″ are the same as or different from the integer of x and x, x′, and x″ cannot all be zero; B and B′ each comprise an amino acid sequence of from about 4 to about 50 amino acids, wherein the amino sequence of B′ is the same as or different from the amino acid sequence of B; b and b′ are each an integer from 0 to 3, wherein the integer of b′ is the same as or different from the integer of b; and i is an integer from 1 to 500.
[0044] The repeating amino acid sequence units may comprise identical repeating sequence units or may comprise different repeating sequence unit combinations, which join together to form a block copolymer or an alternating block copolymer. Additionally, the individual repeating amino acid sequence units of the repeat sequence protein polymer comprise from about 3 to about 30 amino acids or from about 3 to about 8 amino acids. Moreover, the same amino acid may appear at least twice in the same repeating sequence unit.
[0045] It will be further understood by those having skill in the art that the repeat sequence protein polymers of the present invention may be monodispersed or polydispersed. For purposes of defining and describing the present invention, “monodispersed” polymers are polymers having a single defined molecular weight. For purposes of defining and describing the present invention, “polydispersed” polymers are polymers that have been subjected to proteolysis or other means of subdivision, or were produced or modified in such a manner as to give rise to a distribution of molecular weights.
[0046] In one embodiment, the copolymers are combinations of silk units and elastin units to provide silk-elastin copolymers having properties distinctive from polymers having only the same monomeric unit.
[0047] A silk-elastin polymer, SELP47K, may be used as the repeat sequence protein polymer of the present invention. The SELP47K is a homoblock protein polymer that consists exclusively of silk-like crystalline blocks and elastin-like flexible blocks. SELP47K is a modified material of 70% proline, valine, and alanine, and has hydrophobic characteristics. The repeat sequence protein polymer may also comprise SELP 47-E13, SELP 47R-3, SELP 47K-3, SELP 47 E-3, SELP 67K, and SELP 58.
[0048] In one embodiment of the invention, the structure of the silk elastin-like protein is Head-(S 2 E 3 EKE 4 S 2 ) 13 -Tail, where S is the silk-like sequence of amino acids GAGAGS, E is the elastin-like sequence GVGVP, and EK is the elastin like sequence modified with a lysine residue GKGVP. The head sequence of amino acids is MDPVVLQRRD WENPGVTQLN RLAAHPPFAS DPM and the tail sequence is AGAGSGAGAM DPGRYQDLRS HHHHHH. The copolymer contains 886 amino acids, with 780 amino acids in the repeating sequence unit. The SELP47K has a molecular weight of about 70,000 Daltons, and a pI of 10.5. The properties of other SELP variants are shown below in Table 1.
[0000]
TABLE 1
SELP variants, properties.
Number of
Lysine
Molecular
Isoelectric
Variant Name
Subunits
Substitution
Weight (Da)
Point
SELP47E
13
Glutamic
70,212
4.16
Acid
SELP47K-3
3
none
20,748
9.52
SELP47R-3
3
Arginine
20,960
10.5
SELP47E-3
3
Glutamic
20,879
5.9
Acid
SELP27K
13
none
59,401
10.53
SELP37K
13
none
64,605
10.53
SELP58
13
none
74,765
6.7
SELP67K
13
none
80,347
10.53
[0049] One skilled in the art will appreciate the various methods for producing the repeat sequence protein polymers of the present invention, any of which may be employed herein. For example, the repeat sequence protein polymer may be produced by generally recognized methods of chemical synthesis, for example, L Andersson et. al., Large - scale synthesis of peptides , Biopolymers 55(3), 227-50 (2000)); genetic manipulation (for example, J. Cappello, Genetically Engineered Protein Polymers, Handbook of Biodegradable Polymers, Domb, A. J.; Kost, J.; Wiseman, D. (Eds.), Harvard Academic Publishers, Amsterdam; pages 387-414); and enzymatic synthesis (for example, C. H. Wong & K. T. Wang, New Developments in Enzymatic Peptide Synthesis , Experientia 47 (11-12), 1123-9 (1991)). For example, the repeat sequence protein polymers of the present invention may be produced using the methods described in U.S. Pat. Nos. 5,243,038; 6,355,776; and WO 07080426A1 the disclosures of which are incorporated by reference herein. In another example, the repeat sequence protein polymers may be produced utilizing non-ribosomal peptide synthase (for example, H. V. Dohren, et al., Multifunctional Peptide Synthase, Chem. Rev. 97, 2675-2705 (1997).
[0050] The E. coli strains containing a specific silk-elastin repeat sequence protein copolymer SELP47K, SELP37K and SELP27K recombinant DNA were also obtained from Protein Polymer Technologies, Inc. of San Diego, Calif. SELP67K, SELP58, SELP37K and SELP27K variant proteins were produced in 14 L fed batch culture using standard SELP47K production protocols, as described above. Proteins were purified and characterized as follows: 40 grams of cell pastes collected from 14L cultures were lysed via French-press followed by the addition of polyethyleneimine (0.8 w/v %). Centrifugation was used to separate the cellular debris from the cell extract. SELP polymers were precipitated from the cell extract using ammonium sulfate (30% saturation), collected by centrifugation and reconstituted in water.
[0051] The protocol used for the genetic engineering of variants SELP47E, SELP47K-3, SELP47R-3, and SELP47E-3 is a modification of a commercially available kit designed to create single base pair changes in multiple sites along a particular DNA sequence (QUIKCHANGE® Multi (Site-Directed Mutagenesis Kit), Stratagene cat #200513). The standard protocol involves the construction of single direction 5′ phosphorylated primers that will hybridize to plasmid template regions of interest and incorporate point mutations. Thermocycling is employed that includes a ligation reaction designed to link the multiple primers during each round of synthesis.
Phyllosilicates
[0052] The layered silicate materials suitable for the present invention are phyllosilicates, frequently referred to as smectite clays. Phyllosilicates have a multiple layer structure with the layers having a thickness of between about 3 Angstroms to about 10 Angstroms. Each two-dimensional layer is made up of two silica tetrahedra sheets arranged on either side of an octahedral alumina sheet. The multiple layers are separated by cations. A number of phyllosilicates have a cation exchange capacity of between 20 and 250 mEq per 100 g.
[0053] The layered phyllosilicates are swellable clays in that they expand when exposed to liquids such as water, or other solvents with the ability to act as hydrogen bond acceptors and/or donors, thereby increasing the space between the layers. Examples include, but are not limited to montmorillonite, bentonite, hectorite, saponite, beidellite, attapulgite, and stevensite.
[0054] In one embodiment, the phyllosilicate is sodium montmorillonite, or its ion exchanged form, which may be obtained in the sodium form by utilizing naturally occurring clay. Sodium montmorillonite consists of negatively charged, 1 nm thick aluminosilicate layers with exchangeable sodium cations on the surface. The sheets are approximately 100 nm in diameter. In another embodiment of the present invention, the phyllosilicate is attapulgite.
[0055] Those skilled in the art will recognize that phyllosilicate clays that have been processed to remove non-clay materials can be converted to the sodium form if desired by either running a clay slurry through a cation exchange resin; or, by forming a mixture of clay, water and a water-soluble sodium compound and subjecting the mixture to shear.
[0056] The concentration by weight of phyllosilicate used in the present nanocomposite invention is about 0.1 to about 9-9%, about 0.1 to about 50%, about 1% to about 20%, about 1% to about 10%, and about 4% to about 6%.
[0057] The nanocomposites may retain variable amounts of the water or other solvents used to make the composites. For instance, the nanocomposites may retain from about 0.1% to about 90%, about 1% to about 50%, about 1% to about 25%, about 1% to about 15%, about 1% to about 10%, about 5% to about 20%, and about 5% to about 10% of water or other solvents.
[0058] The nanocomposites may include additives to tailor and vary properties. For instance, additives may be salts, onium ions, plasticizers, anti-microbials, reinforcing agents, protein cross linking agents, growth factors, preservatives, nanoparticles, nanofibres, chaotropic agents and electrolytes.
[0059] Plasticizers decrease the glass transition temperature of nanocomposite films and improve film flexibility, particularly at room temperature. The concentration of such plasticizers is from about 2 wt % to about 10 wt % of the total solids in suspension. Suitable plasticizers include polyethylene glycol (PEG) and a mono-, poly-, or di-saccharide, for example, trehalose. Common families of molecules that may also be used to plasticize nanocomposite films include adipic acid derivatives, azeic acid derivatives, benzoic acid derivatives, diphenyl derivatives, citric acid derivatives, epoxides, glycolates, isophthalic acid derivatives, maleic acid derivatives, phosphoric acid derivatives, phthalic acid derivatives, polyesters, trimelitates, etc. Specifically, water soluble plasticizers can be used such as citrate esters, triethyl citrate, triacetin, diethyl phthalate, glycerol, polyalkylene glycols such as polyethylene glycol, trehalose, polysaccharaides, polysuccinimide and poly aspartate.
[0060] Protein crosslinkers such as glutaraldehyde can be used to stabilize the films from solvent attack, as well as increase the effective molecular weight. Concentrations of approximately 0.6% to approximately 4% are typically used for glutaraldehyde crosslinking. Other homofunctional and heterobifunctional protein crosslinkers that react primarily with protein amines, sulfhydryls and carboxyl groups may be used. Homobifunctional protein crosslinkers that react with sulfhyhryl groups include 1,4-bis[3-(2-pyridyldithio)propionamido]butane (DPDPB), bis[2-(N-succinimidyl-oxycarbonyloxy)ethyl]sulfone(BSOCOES), ethylene glycol disuccinate di(N-succinimidyl)ester (EGS). Dimethyl 3,3′-dithiopropionimidate dihydrochloride is a homobifunctional reagent which typically reacts with primary amines to form amidine bonds. Bis[2-(4-azidosalicylamido)ethyl]disulfide (BASED) is a photoactive crosslinker with amine reactivity. Sebacic acid bis(N-succinimidyl)ester (DSS) is a homobifunctional crosslinker with amine reactivity. Sulfosuccinimidyl 4-(N-maleimidomethyl)cyclohexane-1-carboxylate) (SulfoSMCC) is a heterobifunctional crosslinker that interacts with amine and sulfhydryl groups. Dithiobis(succinimidylpropionate) (DSP) is homobifunctional and reactive towards amino groups. Spacer arms can be used in these molecules if the distance between reactive groups in the protein is unknown. Intermediate crosslinkers such as ethyl-3-(dimethylaminopropyl)carbodiimide (EDC) can also be used to modify reactive groups for later crosslinking or functionalization.
[0061] The following examples are included to illustrate embodiments of the invention and are not intended to be limiting thereof.
EXAMPLES
Example 1
Production of Silk-Elastin Like Protein (SELP)
[0062] Monodispersed silk-elastin protein polymer SELP47K was produced by fermenting a recombinant E. coli strain to produce a cell-paste containing monodispersed SELP47K as described in US2004/0180027A1. The cell-paste is placed in ice cold water and homogenized to make the cell extract. The cell-extract is mixed with polyethyleneimine and a filter-aid and allowed to sit at 7° C. for one hour. The polyethyeleneimine causes precipitation of cell debris and a significant amount of E. coli proteins. The SELP47K containing reaction mixture is then filtered using a Rotary Drum Vacuum Filter (RVDF). The filtered SELP47K solution is then mixed with ammonium sulfate to 25% saturation, which leads to precipitation of SELP47K. Precipitated SELP47K and mother liquor is mixed with a filter-aid and again filtered using RVDF. The RVDF cake containing SELP47K and filter-aid is mixed with cold water to dissolve the SELP47K. This precipitation and solubilization step is repeated to improve the purity profile of the SELP47K. Purified monodispersed SELP47K is then water-exchanged until the conductivity of SELP solution reached 50 μS/cm 2 . The monodispersed SELP solution was then concentrated to 10% wt/vol and then lyophilized to make powdered monodispersed SELP47K protein polymer. The material was stored at −70° C. until needed for application testing.
Example 2
Preparation of Succinylated SELP
[0063] Succinylated SELP was prepared from a solution of SELP (0.7 g) in 25% aqueous acetonitrile (10 mL) that was treated with succinic anhydride (152 mg) at room temperature. Sodium hydroxide solution (3M) was added dropwise in order to maintain the pH between 7 and 8 during the course of the reaction. After 3 hours an aliquot was found to be unreactive towards ninhydrin indicating the derivatization of the available amino functionalites. The sample was dialyzed against water (3×2L) overnight and then freeze dried to give a spongy white solid (0.62 g).
Example 3
Preparation of the RSPP/Phyllosilicate Solutions and Films
[0064] Cloisite® Na+ Montmorillonite (MMT) phyllosilicate in powder form (Southern Clay, cation exchange capacity [CEC] 92 meq/100 g) was added to deionized water to form 0.1-1.0 wt % suspensions. The water/MMT suspensions were then sonicated using a probe sonicator for approximately 10 minutes. For zeta potential measurements, SELP in powder form was slowly added to the MMT suspensions. For preparation of thin films, SELP was dissolved in deionized water to form a 5 wt % solution, and was added to the MMT suspension. The mixtures were then cast into polystyrene weighing dishes and dried for several days. The resulting films were freestanding, optically clear, approximately 5 cm in diameter, and the total amount of solid in each film was approximately 100 mg. The final amounts of MMT in the nanocomposite material were 0%, 2%, 4%, 6%, 8% and 10% on a dry weight basis.
[0065] Nanocomposites using the phyllosilicate attapulgite in powder form were also prepared by adding the attapulgite to deionized water and then mixing the suspension with SELP. Films were prepared as described above.
Example 4
Methods for Characterizing Material Properties of the Nanocomposite
Zeta Potential
[0066] Zeta potential measurements of the nanocomposite liquid solvent mixtures were performed on a ZetaPALS instrument (Brookhaven Instruments Corp., NY) at room temperature. At each MMT concentration, the average value was taken from 10 measurements. 0.01 wt % and 0.1 wt % MMT in water suspensions were stirred overnight, and then allowed to settle for several days. Samples for zeta potential measurements were then taken from the supernatant of the settled suspensions. SELP or succinylated SELP powder was added to the suspensions in various amounts. The zeta potential results were generally similar for both the 0.01 and 0.1 wt % suspensions at the same relative concentrations.
X-Ray Diffraction Profiles
[0067] Small angle x-ray scattering profiles were collected at beamline X27C of a National Synchrotron Light Source instrument with an evacuated beam path, a camera length of 1870 mm, an x-ray wavelength of 0.1366 nm, and a Mar-CCD (Charge coupled device) large area detector (Mar USA, Evanston, Ill.). Wide angle scattering was done using a Rigaku™ rotating anode operating at 50 kV with a Statton camera (camera length 73 mm), imaging plates held under vacuum, and an x-ray wavelength of 0.15418 nm. Two-dimensional patterns were analyzed using the Fit2D software (A. Hammersley, European Synchrotron Radiation Facility).
Transmission Electron Microscopy (TEM)
[0068] Transmission electron microscopy was performed on a Philips™ CM200-FEG instrument operating at 200 kV. Films were cut into ˜25 mm 2 size sections, embedded in Spurr (Electron Microscopy Sciences, Hatfield, Pa.) epoxy and cured at room temperature overnight. Cross sectional microtomy was done in on a RMC PowerTome™ with a diamond knife at room temperature. Section thickness was 100-150 nm.
Tensile Tests
[0069] Films were cut into strips approximately 5×35 mm for tensile strength testing. Five tests were run on each sample concentration. The slope of the stress-strain curve at 0.25% strain was used to calculate the elastic modulus. The percentage elongation to break, or strain to break was also measured as a percentage value.
Thermal Mechanical Analysis
[0070] In thermal mechanical analysis, the coefficient of thermal expansion (CTE) was measured as the slope of the sample's length at constant stress vs. temperature curve, divided by the original length of the sample. This slope was measured over a 2° C. temperature span in the rubbery regime (>200° C.)
Example 5
Material Properties of the Nanocomposites
X-Ray Diffraction
[0071] FIG. 1 b shows scattering curves in the small-angle and wide-angle regimes. There was no interlayer spacing near 1.2 nm, as is seen in the MMT powder control. Peaks arising from the interatomic (intra-sheet) MMT spacings as well as the broad peaks from the SELP can be seen at scattering vector (q) values greater than 1 nm −1 . In the small angle regime (q<1 nm −1 ) there is a very uniform scattering profile with no evidence for peaks at these larger length scales.
[0072] The results indicate that there is no intermediate structure, where the protein chains are intercalated between the MMT sheets in an ordered fashion. The WAXS regime (q>1 nm −1 ) shows that the SELP is not crystalline, as shown be the absence of the characteristic silk I peak at d=0.72 nm as well as the lack of any clear silk II β-sheet peaks.
TEM
[0073] FIG. 2 shows TEM micrographs from 150 nm thick cross-sections of 2%, 4% and 8% MMT in SELP nanocomposite samples. The high magnification micrographs (2b, d, f) show that the MMT is dispersed well in the SELP matrix, with the individual, 1 nm thick, MMT sheets visible. The density of MMT also appears to be quite uniform across the films from top to bottom, and along their length for several hundreds of microns ( FIGS. 2 a, c, e ).
[0074] The TEM and X-ray diffraction data both support the findings of a highly exfoliated structure.
Tensile Properties
[0075] Film tensile tests showed an elastic modulus for the SELP alone control films of 2 GPa ( FIG. 3 a ) and tensile strengths greater than 50 Mpa (Data not shown). As MMT concentration increased, an increase in the elastic modulus to nearly 3 GPa was seen up to loadings of 4-6%. At MMT loadings above 4-6%, the modulus dropped. While the modulus of the films was increased at 4% MMT, the films were found to be more brittle, with the percent elongation to break, or strain to break, decreasing from 0.044 (4.4%) at 0% MMT to 0.012 (1.2%) at 4% MMT.
Differential Scanning Calorimetry
[0076] Differential Scanning Calorimetry (DSC) showed no significant shift in the SELP glass transition with the addition of MMT. The T g remained near 180° C. regardless of the amount of MMT present, and this value is similar to the T g measured from dry films and fibers of silk and elastin.
Thermal Properties
[0077] Thermal mechanical analysis (TMA) was used to determine the coefficient of thermal expansion (CTE) in the rubbery region (>200° C.). The CTE showed a decrease with increasing amounts of MMT from 94×10 −3 ° C. −1 in the SELP only control to as low as 49×10 −3 ° C. −1 at 8% MMT loading ( FIG. 3 b ). While DSC showed no evidence for a T g shift, the temperature at which the samples transitioned from glassy to rubbery behavior, as measured from the intersection of the slopes of the sample length vs. temperature curves in the glassy and rubbery regions, was seen to increase significantly with increasing MMT concentration. This temperature increased from 193° C. in the SELP to 213° C. in the 10% MMT/SELP samples.
Zeta Potential
[0078] FIG. 4 shows a plot of zeta potential at various weight ratios of SELP/MMT. The zeta potential of the pure MMT suspension and the SELP solution are plotted on the log-linear plot at SELP/MMT relative concentrations of 0.0001 and 10000, respectively. The zeta potential of sodium MMT in water, at a concentration of 0.1 wt %, is −42 mV (Southern™ Clay Na + , 92 meq/100 g). The size of the MMT sheets, as measured by the median in the log-normal distribution of sizes measured from light scattering, was 90 nm. As SELP is added into the suspension in higher concentrations, the effective size and surface charge of the MMT sheets remains relatively unaltered until the weight ratio of SELP/MMT reaches about 1. The surface charge decreases in magnitude as SELP is adsorbed onto the MMT, the zeta potential goes toward zero, and is then neutralized at a SELP/MMT weight ratio of 8:1. The zeta potential of the system does not go far into the positive regime with the continued addition of SELP, because of the low overall positive charge of the protein (only 13 positively charged lysines out of 886 total residues). The zeta potential of the SELP solution (0.5-1 wt %) was measured to be +3 mV. The exfoliated composites had SELP/MMT weight ratios varying from 10:1 to 50:1, and it can be seen in FIG. 4 that the MMT charge is neutralized by the adsorbed protein at these ratios.
[0079] In the SELPsucc nanocomposites we see good dispersion at the nanometer length scale, as we saw in the SELP nanocomposites. X-ray scattering shows no MMT interlayer spacing and no intercalation peak. On larger length scales, however, some macroscopic phase separation in the SELPsucc can be seen, especially in low magnification TEM images. FIG. 5 shows electron micrographs of the SELPsucc samples and clear regions of MMT-rich and protein rich regions can be seen.
[0080] In aqueous solution, absorption of SELP on MMT sheets seems to readily occur, irrespective of a small fraction of ionic residues. However, these residues play a dominate role in determining the morphology of the nanocomposite because the anionic residues generate repulsive interactions with MMT sheets resulting in a weak clustering or agglomeration of MMT in solution that manifests in non-uniformity in the solid state.
Example 6
Preparation of Plasticized RSPP Nanocomposite Films
[0081] Plasticizers, including polyethylene glycol (PEG) and trehalose were used to decrease the glass transition temperature of the films and to improve film flexibility at room temperature. SELP solutions with MMT in deionized water were prepared as in example 3, and PEG (molecular weight 200 g/mol) was added in concentrations ranging from 2-10 wt % of the total solids in suspension. Samples were made containing 3% w/w of MMT, 2% w/w of PEG, and 95% w/w SELP were made and the tensile strength of these samples were compared to the tensile strength of SELP alone, as shown in FIG. 6 . Common families of molecules that may also be used to plasticize these nanocomposite films include adipic acid derivatives, azeic acid derivatives, benzoic acid derivatives, diphenyl derivatives, citric acid derivatives, epoxides, glycolates, isophthalic acid derivatives, maleic acid derivatives, phosphoric acid derivatives, phthalic acid derivatives, polyesters, trimelitates, etc. Specifically, water soluble plasticizers can be used such as citrate esters, triethyl citrate, triacetin, diethyl phthalate, glycerol, polyalkylene glycols such as polyethylene glycol, trehalose, polysaccharaides, polysuccinimide and poly aspartate.
Example 7
Preparation of Cross-Linked RSPP Nanocomposite Films
[0082] Protein crosslinkers were used to stabilize the films from solvent attack, as well as increase the effective molecular weight. After SELP/MMT films made according to Example 3 were dried, they were submerged in a 2.5 vol. % glutaraldehyde solution to crosslink for 18 hours. Concentrations of approximately 0.6%-4% were typically used for glutaraldehyde crosslinking. The films were then submerged in DI water for 2 hours for rinsing and subsequently dried. Concentrations of approximately 0.6% to approximately 4% are typically used for glutaraldehyde crosslinking. | Nanocomposites of repeat sequence protein polymers and phyllosilicates demonstrated improved material properties, for example, improved elasticity, and are useful as suture, tissue scaffolding, and biodegradable composite materials. | 0 |
BACKGROUND OF THE INVENTION
The present invention pertains to sealed bearing assemblies, which are particularly useful in forming trolley wheels.
Trolley systems are employed extensively as overhead or in-floor motive arrangements in manufacturing processes. Typically, semi-precision bearings are utilized in this environment to rollingly support a trolley adapted to transport workpieces, tools, etc., for movement along a track. Semi-precision bearings are well suited to this task due to the inherent clearance or "play" or looseness incorporated in their construction. More specifically, the looseness of the bearing enhances its ability to maneuver curves, pass smoothly over debris that may be on the track, and accommodate element expansion in processes involving large temperature gradients.
Yet, despite the number of advantages gained, the construction thereof providing the desired looseness has also been responsible for several notable shortcomings. Firstly, loose bearings are difficult to seal due to the relatively large radial and axial excursions of the rotating components. Most seals have a comparatively limited ability to follow such excursions and continue sealing. Secondly, because of the loose construction and the difficulty of conventional seals to remain in sealing contact, the grease contained within semi-precision bearings does, on occasion, seep out, drip onto and spoil the goods being manufactured. Thirdly, semi-precision bearings include a relatively large amount of enclosed open space which is filled with the lubricating grease. In the past, the consumption of such large amounts of grease has been inconsequential due to the low cost of conventional greases. However, technologically advanced greases--offering increased lubrication capabilities, longer lifespans, increased usefulness in high temperatures, etc.--are very expensive and have, heretofore, been essentially limited economically to precision bearings.
SUMMARY OF THE INVENTION
The aforementioned problems are overcome in the present invention, wherein bearing assemblies having unique seal arrangements alleviate the risk of dripping grease and facilitate the economic use of the new, expensive greases.
The sealed bearing assembly of the present invention includes a raceway, a closure member positioned along the side thereof and a seal assembly which forms a leak-resistant pocket about the raceway for enclosing and retaining the grease. Hence, the risk of dripping grease from the bearing is effectively obviated. Also, the grease is confined to only the specific area where bearing lubrication is needed. This facilitates the economical use of modern greases. Further, the present seal assembly is of a resilient nature which not only effects easy mounting within the bearing without fastener members, but also accommodates the inherent radial clearance and "end play" of the semi-precision bearing without jeopardizing the desired seal.
Preferably, the seal assembly includes at least one annular, resilient body formed from a fluoroelastomer having a cup-shape, an inwardly extending flange supporting the body on a shoulder of the inner race, and a pair of spaced, sealing/end faces which engage the sidewalls of one of the closure members. Notches may be included on the sealing faces to prevent vacuum formation between the seal and the closure member, and consequent grease siphoning/pumping from the lubrication pocket. These and other objects, advantages and features of the present invention will be more fully understood and appreciated by reference to the written specification and appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of a bearings assembly of the present invention;
FIG. 2 is a cross-sectional view of a second embodiment of the present invention;
FIG. 3 is an enlarged, fragmentary, cross-sectional view of one-half of the bearing assembly of
FIG. 4 is an end view of the seal;
FIG. 5 is a cross-sectional view of a seal of the present invention taken along line IV--IV of FIG. 4; and
FIG. 6 is a fragmentary, perspective view of the seal.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In the preferred embodiment, sealed bearing assembly 10 includes a plurality of balls 45 bordered on opposite sides by shield or seal assembly 14 (FIGS. 1 and 3) Seal assembly 14 is formed by a pair of identical annular seals 15 which collectively define therebetween an annular pocket 16 designed to confine the lubricating grease only to the path traveled by the balls 45. This construction enables use of costly commercially available greases providing an extended life and high temperature resistance.
Bearing assembly 10, in the preferred embodiment, further includes a mounting structure, by which it is coupled to a trolley or carriage (not shown), comprised of a hub 19, a collar or spacer 27 and a seal member 31 (FIGS. 1 and 3). Hub 19 has an annular configuration which defines a central aperture 21 adapted to receive therethrough a bolt, rivet, axle or the like for coupling assembly 10 to the trolley or carriage (not shown). Central aperture 21 is divided into two adjacent portions 23, 25; first portion 23 is cylindrical in shape to matingly receive th fastening member and second portion 25 is frustoconically shaped to taper outwardly away from first portion 23 and abut the head of the fastening member for its retention. Annular collar 27 is in abutment with side 29 of hub 19, opposite second portion 25, so as to be positioned in tight frictional engagement between hub 19 and a trolley brace (not shown). Rigid, metallic seal member 31, also annular in shape, is contiguously wrapped about collar 27 to alleviate the risk of entrapping and accumulating dirt and debris within bearing assembly 10.
Outer peripheral surface 32 of hub 19 includes a substantially U-shaped groove 33 adapted to receive, mount and retain together therein a pair of inner race elements 35, 37 collectively forming the inner race 39. More specifically, each inner race element 35, 37 defines an annular arcuate hollow 41, which cooperates with each other to form the arcuate inner race 39 adapted to receive and rollingly support a plurality of balls 45. Preferably, assembly 10 is a full complement bearing having balls 45 spaced around raceway elements 35, 37 and 39 generally immediately adjacent one another. Inner race 39 further includes a marginal peripheral surface or shoulder 46 on each side thereof to effect mounting of seals 15, as will be described below.
Positioned concentrically around inner race 39 is a corresponding outer race 47. Outer race 47 includes a complementary outer channel 49, opposed to inner race 39, to receive and rotatably confine balls 45 within bearing assembly 10. Preferably, outer peripheral surface 51 thereof functions to form the trolley wheel which is rollingly supported for movement along a track or rail (not shown).
Securely attached to opposite sides of bearing assembly 10 is a pair of closure members 55, 57. Closure members 55, 57 perform the dual role of integrally cooperating with shield assembly 14 to form a portion of the grease containing pocket 16, and enclosing the sides of bearing 10 to substantially bar the accumulation of dirt and debris from collecting therein. Annular recesses 59, 61 are formed in the sides of outer race 47 to securely mount closure members 55, 57 into place. Preferably, closure member 55, also known as a welsh plug, initially has a dome-shaped disk configuration, which is flexed or "oil-canned" within recess 59 to press and urge its outer periphery tightly into recess 59 for secure retention. Closure member 57 is an annular member having a central aperture 58 securely press-fit into recess 61 via its outer periphery for mounting.
Shield assembly 14 includes a pair of identical, annular seals 15 (FIGS. 4-6) which are mounted on opposite sides of balls 45 to thereby define an annular pocket 16 (FIGS. 1-3 . To ensure a secure sealing arrangement in spite of the inherent "play" of a semi-precision bearing, seal 15 is preferably composed of a fluoroelastomer which is flexible and has excellent memory and resiliency, high temperature resistance, toughness, tear and chemical resistance, such as VITON (trademark of E.I. DuPont de Nemours & Co., Inc.). However, other suitable materials could also be utilized. Moreover, the resilient nature of seals 15 enable their mounting within assembly 10 without the need for any fastening members.
Each seal 15 includes an annular, substantially cup-shaped body 65 having a pocket segment 67 and a stabilizing segment 69 (FIGS. 1-6). Segments 67, 69 collectively form a smooth continuous body 65, and are discussed as segments only to reflect their functional differences, as will be described further below. Pocket segment 67 defines a radially outermost sealing face 71 which, when assembled within bearing 10, is directed laterally outwardly and in flush engagement with an inside surface 95, 97 of one of closure members 55, 57 (FIGS. 1-3). When seal 15 is at rest and in an unassembled condition, sealing face 71 is oriented such that angle α (FIG. 5) is approximately eight degrees (preferably 7°40'). Stabilizing segment 69 defines, in like manner, a free, radially innermost end face 73 which, when assembled within bearing 10, is directed substantially radially inwardly toward rotational axis 75 (FIGS. 1-3). When seal 15 is at rest and in an unassembled condition, free end face 73 is oriented such that angle β is approximately ten degrees (FIG. 5).
Projecting laterally outwardly from the midsection of convex surface 76 is a flange 77 which demarcates body 65 into segments 67, 69 (FIGS. 1-6). Flange 77 extends only a short distance and defines a distal end face 79 oriented at an inclination angle φ. Angle φ is preferably approximately twenty degrees (FIG. 5). Flange 77 further includes a radially inner surface 81 adapted for mounting seal 15 onto shoulder 46 of inner race 39 and a radially outer surface 83 which forms a portion of the boundary for pocket 16.
In assembled condition, seals 15 are placed on inner race 9 by tautly wrapping annular flanges 77 about shoulders 46 (FIGS. 1-3). More specifically, this arrangement tightly presses each inner surface 81 of flange 77 against a shoulder 46 of inner race 39 to form a first sealing interface 91 and prevent rotation of seals 15 with respect to inner race 39. Each flange 77 extends inwardly along one shoulder 46 until distal end face 79 nearly engages balls 45. Spacing is normally maintained between balls 45 and distal end face 79 so as to avoid additional frictional forces in the bearing and premature wearing of flange 77. To enhance the sealing arrangement thereby formed, the length of inner surface 81 is maximized by inclining distal end face 79 at angle φ, such that inner surface 81 extends across nearly the entire corresponding shoulder 46.
A second sealing interface 93 is formed by pocket segment 67 extending arcuately outward so that sealing face 71 is slidingly engaged with the interior sidewall 95, 97 of one of the closure members 55, 57. Closure members 55, 57 are secured to bearing 10 such that they rotate with outer race 47, and are in a rotatable relationship with seals 15 (FIGS. 1-3). Sealing face 71 is flush with sidewall 95, 97 to form a wiper seal therewith and thereby preclude the seepage of grease. Similar to flange 77, pocket segment 67 is spaced radially a small distance from the rotating outer race 47 to, likewise, avoid additional frictional forces in the bearing and premature wearing of seal 15.
Stabilizing segment 69 acts to stabilize seal 15 within bearing assembly 10 and to position flange 77 properly on shoulder 46 of inner race 39. More specifically, convex surface 76 along stabilizing segment 69 adjacent flange 77 is pressed against sidewall 101 of inner race 39, to limit and set the projection of flange 77 inwardly toward balls 45 so as to provide a fail-safe positioning means therefor. From this position, stabilizing segment 69 bends arcuately outward until tip 103 engages the interior surface 95, 105 of closure member 55 or rigid seal member 31, respectively, although such an engagement is not essential.
Tip 103 of stabilizing segment 69 may be provided with a plurality of notches 107 (FIGS. 4-6). Notches 107 create passages designed to ensure the free flow of air between space 109 and cavity 11, when tip 103 engages closure member 55. Notches 107 act to obviate the risk of creating a vacuum in space 109, due to the movement of parts and seals 15 of a semi-precision bearing, which could siphon or pump the grease out of pocket 16 and cause premature spoiling of the bearing assembly 10.
As clearly seen in FIGS. 1 and 2, seals 15 are applicable to a variety of different types of semi-precision bearings. As an example, seals 15 are shown in use with the two illustrated embodiments 10, 10' which are designed for different coupling arrangements. Moreover, seals 15 may also be used in bearings of the caged or retainer type.
Seals 15 are particularly adapted for use in semi-precision bearings, such as illustrated in FIGS. 1 and 2, which possess an inherent looseness in their construction. More specifically, the resilient nature of seals 15 are able to absorb and compensate for the various bearing movements including radial play/diametric clearance, end play/axial movement and "free rock" or rocking motion between inner and outer races 39, 47 and ball members 45 to maintain a low-friction sealing contact at all times. Sealing interfaces are formed along shoulder 46 by flange 77 and closure members 55, 57 by sealing face 71, and are oriented and stabilized through the provision of segment 69 engaging side 101 of inner race 39 and interior surfaces 95, 105 so that the lubricating grease is confined in pocket 16. This construction, then, precludes grease seepage and requires only a small amount of grease to greatly enhance the economic use of modern greases.
Of course, it is understood that the above are merely preferred embodiments of the invention, and that various other embodiments as well as many changes and alterations may be made without departing from the spirit and broader aspects of the invention as defined in the claims. | A sealed bearing assembly including an inner race, an outer race, and a plurality of balls forming therewith a bearing, a pair of closure members along the sides thereof, and a pair of identical annular seals positioned between the bearing and the closure members, is constructed such that an annular pocket is formed by the seals about the rolling elements. The seals act to confine lubricating material within the pocket to only the specific volume where it is needed. The seals not only preclude seepage of the lubricating material, but also facilitate the economical use of modern greases. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a divisional application of U.S. patent application Ser. No. 13/825,124 filed on May 31, 2013 which is a national phase application of PCT/CN2011/078742 filed Aug. 23, 2011, which claims benefit from a Chinese patent application number 201010287822.4 filed Sep. 20, 2010, and the disclosures of which are incorporated herein by reference in their entirety.
TECHNICAL FIELD
[0002] The present invention relates to manufacturing of a sensor, more particularly, to a process and tool for manufacturing a fabric pressure sensor.
BACKGROUND ART
[0003] Pressure sensors have a wide range of applications for industrial and personal use, but most pressure sensors are not suitable for the users to wear due to drawbacks such as large in size, high weight, hard touch feeling and inconvenience to use. Thus, their applications for personal use are highly limited, for example, sports clothing, smart clothing, footwear, etc, which are on the occasion in close contact with human body for pressure measurement. Fabric pressure sensor is a new type of pressure sensor. As it is mainly composed of resistance-type fabric sensing element and flexible structural material, it has many advantages, such as soft touch, light weight, long life span, and suitability for three-dimensional and large-area measurement. Fabric pressure sensor and its products have a wide range of applications in clothing and footwear, health care and rehabilitation, clinical medicine, sports, safety and protection, automobiles, aerospace, construction and other fields.
[0004] FIG. 1 and FIG. 2 show the schematic views of two fabric pressure sensors respectively. The fabric pressure sensor adopts a sandwich structure, which comprises a resistance-type fabric sensing element 1 - 1 in the middle, an upper conversion layer based on silicone 2 - 1 or silicone-fabric composite (silicone 2 - 2 , fabric 2 - 3 ) on the top, a lower conversion layer based on silicone 3 - 1 or silicone-fabric composite (silicone 3 - 2 , fabric 3 - 3 ) at the bottom, an adjustment column 4 - 1 and a connecting wire 5 - 1 of the sensing fabric. The external pressure exerted on the upper and lower conversion layers convert into the deformation of the sensing fabric in the middle, thereby causing the change in resistance of the sensing fabric and output. The contour in the middle of the upper and lower conversion layers may adopt the toothed shape as shown in the figures or other shapes according to the application requirements. The stiffness of the material used for the adjustment column 4 - 1 can be adjusted to adapt to the different measurement requirements. The fabric pressure sensor in FIG. 1 uses silicone-based upper and lower conversion layers, and the fabric pressure sensor in FIG. 2 uses the conversion layers based on silicone-fabric composite.
[0005] Different from conventional silicone-based and film-type pressure sensors, the fabric pressure sensors are made of flexible materials, which deform easily in the manufacturing process. Therefore, it is necessary to develop and establish a corresponding process, equipment and tool for manufacturing flexible pressure sensors.
SUMMARY OF THE INVENTION
[0006] In respect of the technical problems which include the difficulties in manufacturing fabric pressure sensors using the conventional technologies and lack of the corresponding manufacturing tools, the present invention provides a process and the corresponding tools for manufacturing the fabric pressure sensors which enable simple manufacturing and control over the processing quality and product yield.
[0007] The technical solutions conferred by the present invention to solve the above-mentioned technical problems is a process for manufacturing fabric pressure sensors which comprises the following steps:
[0008] S1. Cut a sensing fabric to a pre-determined size, and connect a flexible electric wire with a wire of said sensing fabric by sewing;
[0009] S2. Fix said sensing fabric by a clamping positioner at a predetermined tension;
[0010] S3. Bond a lower conversion layer with said sensing fabric by a lower conversion layer positioning box;
[0011] S4. Bond an adjustment column with said sensing fabric by an upper conversion layer positioning box, and bond the upper conversion layer with said adjustable column by the upper conversion layer positioning box.
[0012] In the process for manufacturing a fabric pressure sensor according to the present invention, the following steps are included between step S1 and step S2:
[0013] S11. Use an electrical property measuring device to measure the conductivity and sensitivity of said sensing fabric;
[0014] S12. Use a wire connecting tool to connect said sensing fabric with a wire;
[0015] S13. Use a resistance meter to determine the quality of the connection between said sensing fabric and said wire according to the conductivity and the sensitivity of said sensing fabric.
[0016] In the process for manufacturing a fabric pressure sensor according to the present invention, the following steps are additionally included after step S4:
[0017] S5. Apply pressure to the bonding areas among the lower conversion layer, the sensing fabric, the adjustable column and the upper conversion layer through a positioning bonding weight plate.
[0018] The present invention also provides an electrical property measuring device for measuring the electrical properties of the sensing fabric, which comprises adjustable test electrodes ( 11 ) configured to contact with both ends of said sensing fabric, a resistance meter ( 12 ) for reading the resistance value of said sensing fabric, a sample station ( 13 ), and a clamper ( 17 ) for fixing said sensing fabric on the sample station and applying a pulling force and predetermined strain to both ends of said sensing fabric.
[0019] The electrical property measuring device according to the present invention further comprises an adjustment block ( 14 ) for applying pressure to said test electrodes ( 11 ), and said pressure is used to change the contact between said test electrodes ( 11 ) and said sensing fabric.
[0020] The present invention also provides a wire connecting tool for connecting the sensing fabric with a wire, and said wire connecting tool includes a wire distance control hole ( 21 ) located in the middle of said wire connecting tool, and a fixed platform ( 22 ) for fixing said sensing fabric and connecting said sensing fabric with said wire through sewing.
[0021] In the wire connecting tool according to the present invention, the surface of said fixed platform ( 22 ) also includes a wire indicating line ( 23 ) for indicating the position of said wire.
[0022] The present invention also provides a sensor structural component assembling tool for assembling the fabric pressure sensor, and said sensor structural component assembling tool comprises a clamping positioner ( 31 ) for fixing said sensing fabric at a pre-determined tension, a lower conversion layer positioning box ( 32 ) for bonding a lower conversion layer with said sensing fabric, and an upper conversion layer positioning box ( 33 ) for bonding an adjustment column with said sensing fabric and bonding an upper conversion layer with said adjustment column.
[0023] The sensor structural component assembling tool according to the present invention further comprises a positioning bonding weight plate ( 34 ) which applies pressure to the bonding area among said lower conversion layer, said sensing fabric, said adjustment column and said upper conversion layer.
[0024] In the sensor structural component assembling tool according to the present invention, the said positioning bonding weight plate ( 34 ) includes a plurality of raised heads ( 341 ) for applying pressure to the selected bonding area.
[0025] The process for manufacturing a fabric pressure sensor according to the present invention has the following advantages: it is not only an easier and more convenient process in manufacturing of the fabric pressure sensor but is also capable of monitoring the manufacturing quality, and enhancing the manufacturing precision and product yield of the flexible fabric pressure sensor.
[0026] Prior to the manufacture, the conductivity and sensitivity of the sensing fabric can be measured in order to better control the quality of the pressure sensor while suitable sensing fabric can be selected according to application requirements of the pressure sensor. The electrical property measuring device is used to quantify the relationship between resistance and tensile strain of the sensing fabrics in different lengths. The adjustment block is used to quantify the relationship between strain and resistance of the sensing fabric under different contact pressures, so as to calculate the sensitivity of the sensing fabric. The wire connecting tool is capable of well controlling the distance between two ends of the sensing fabric under testing and ensuring that the distance between the two ends of the sensing fabric under testing is consistent. The wire indicating line improves the parallelism and spacing accuracy of the wires in the connection process, thus ensuring the connection quality and consistency. The sensor structural component assembling tool ensures that the sensing fabric is fixed and placed in the pressure sensor in a specified position and at a pre-determined tension, so that the layers of the fabric pressure sensor can be well connected and accurately positioned. A plurality of raised heads enables accurate positioning of the bonding area, and applies the pressure for positioning. The positioning bonding weight plate ensures that the connection between the upper conversion layer, the sensing fabric and the lower conversion layer is firmer to avoid dislocation movement.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] Below is a further illustration of the present invention by using a combination of figures and embodiments. Brief description of the figures is as follows:
[0028] FIG. 1 is a schematic diagram showing the structure of one embodiment of the fabric pressure sensor.
[0029] FIG. 2 is a schematic diagram showing the structure of another embodiment of the fabric pressure sensor.
[0030] FIG. 3 is a flow diagram of the process for manufacturing a fabric pressure sensor according to a first embodiment of the present invention.
[0031] FIG. 4 is a flow diagram of the process for manufacturing a fabric pressure sensor according to a second embodiment of the present invention;
[0032] FIG. 5 is a flow diagram of the process for manufacturing a fabric pressure sensor according to a third embodiment of the present invention.
[0033] FIG. 6 is a schematic diagram showing the structure of the electrical property measuring device according to an exemplary embodiment of the present invention.
[0034] FIG. 7 is a schematic diagram showing the structure of the wire connecting tool according to an exemplary embodiment of the present invention.
[0035] FIG. 8 is a schematic diagram showing the structure of the sensor structural component assembling tool according to an exemplary embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0036] To better illustrate the purpose, technical solutions and advantages of the present invention, the present invention is further described below with an aid of both figures and examples together. It should be understood that the examples described hereinafter are only for the purpose of illustrating the present invention, but not for limiting the scope of the present invention.
[0037] As shown in FIG. 3 , that is, the flow diagram of the process for manufacturing a fabric pressure sensor according to a first embodiment of the present invention, the process starts from step 300 which provides an unmodified sensing fabric followed by step 301 which cuts the unmodified sensing fabric to a pre-determined size, and subsequently connects a flexible electric wire with a wire of said sensing fabric by sewing. In a subsequent step 302 , a clamping positioner is used to fix said sensing fabric at a pre-determined tension. Following 302 is step 303 which bonds a lower conversion layer with said sensing fabric by a lower conversion layer positioning box. It is then followed by step 304 which bonds an adjustment column with said sensing fabric by an upper conversion layer positioning box, and also bonds the upper conversion layer with said adjustment column by the upper conversion layer positioning box. Finally, step 305 results in the fabric pressure sensor manufactured by the process as described in this embodiment. Using the process according to the present invention makes the manufacture of the fabric pressure sensor more easily and conveniently than any of the conventional methods.
[0038] As shown in FIG. 4 , that is, the flow diagram of the process for manufacturing a fabric pressure sensor according to a second embodiment of the present invention, the process starts from step 400 which provides an unmodified sensing fabric, followed by step 401 which cuts the unmodified sensing fabric to a pre-determined size, and subsequently connects a flexible electric wire with a wire of said sensing fabric by sewing. In a subsequent step 402 , an electrical property measuring device is used to measure the conductivity and sensitivity of said sensing fabric. Following 402 is step 403 where a wire connecting tool and the sewing method are employed to connect said sensing fabric with a wire. It is then followed by step 404 where a resistance meter is used to determine the quality of connection between said sensing fabric and said another wire according to the conductivity and the sensitivity of said sensing fabric. In a subsequent step 405 , a clamping positioner is used to fix said sensing fabric at a pre-determined tension. Following 405 is step 406 which bonds a lower conversion layer with said sensing fabric by a lower conversion layer positioning box. The subsequent step 407 bonds an adjustment column with said sensing fabric by an upper conversion layer positioning box, and also bonds the upper conversion layer with said adjustment column by the upper conversion layer positioning box. Finally, step 408 results in the fabric pressure sensor manufactured by the process as described in this embodiment. Using the process for manufacturing a fabric pressure sensor according to the present invention makes the manufacture of the fabric pressure sensor more easily and conveniently than any of the conventional methods. Prior to the manufacture, the measurement of the conductivity and sensitivity of the sensing fabric enables better connection among the sensing fabric, the upper conversion layer and the lower conversion layer, and an excellent contact with the wire.
[0039] As shown in FIG. 5 , that is, the flow diagram of the process for manufacturing a fabric pressure sensor according to a third embodiment of the invention, the process starts from step 500 which provides an unmodified sensing fabric, followed by step 501 which cuts the unmodified sensing fabric to a pre-determined size, and subsequently connects a flexible electric wire with a wire of said sensing fabric by sewing. In a subsequent step 502 , an electrical property measuring device is used to measure the conductivity and sensitivity of said sensing fabric. Following 502 is step 503 where a wire connecting tool and the sewing method are employed to connect said sensing fabric with a wire. It is then followed by step 504 where a resistance meter is used to determine the quality of connection between said sensing fabric and said another wire according to the conductivity and the sensitivity of said sensing fabric. In a subsequent step 505 , a clamping positioner is used to fix said sensing fabric at a pre-determined tension. Following 505 is step 506 which bonds a lower conversion layer with said sensing fabric by a lower conversion layer positioning box. The subsequent step 507 bonds an adjustment column with said sensing fabric by an upper conversion layer positioning box, and bond the upper conversion layer with said adjustment column by the upper conversion layer positioning box. It is followed by step 508 which applies a pressure to the bonding area through a positioning bonding weight plate. Finally, step 509 results in the fabric pressure sensor manufactured by the process described in this embodiment. Applying said pressure to the bonding area through the positioning bonding weight plate ensures that the connection between the upper conversion layer, the sensing fabric and the lower conversion layer be firmer to avoid dislocation movement.
[0040] As shown in FIG. 6 , that is, the schematic diagram showing the structure of the electrical property measuring device according to an exemplary embodiment of the present invention. The device comprises a resistance meter 12 , a sample station 13 and test electrodes 11 . The test electrodes 11 are used to contact both ends of said sensing fabric; the resistance meter 12 is used to read the resistance value of said sensing fabric; and the sample station 13 is used to fix said sensing fabric and apply pulling force to both ends of said sensing fabric. During testing, a resistance-type sensing fabric sample 15 to be tested is placed on the sample station and kept flat throughout the entire process, followed by applying a pulling force to both ends of the sensing fabric to reach the pre-determined strain of the fabric which the value of the strain can be read from the measuring scale of the sample station 13 . By adjusting the pulling force at both ends of the sensing fabric, the strain applied on the sensing fabric can be adjusted. Subsequently, clamps 17 located at both sides of the sample station are used to clamp and fix the sensing fabric. The test electrodes 11 are placed on the conducting layer 16 of the sensing fabric to test the resistance of the sensing fabric. The spacing of the test electrodes 11 can be adjusted to test the resistance of the samples in different lengths. Through adjusting the adjustment block 14 which is used to apply pressure on the top of the test electrodes 11 , the contact pressure between the test electrodes 11 and the conducting layer 16 of the sensing fabric can be adjusted. The resistance of the sensing fabric is read from the resistance meter 12 . According to the rate of the change in resistance and strain of the fabric sample 15 , the sensitivity coefficient of the sensing fabric can also be calculated by the following formula:
[0000] K =(Δ R/R 0)/ε (1)
[0041] where K is the sensitivity coefficient of the sensing fabric, R0 is the initial resistance of the sensing fabric, ΔR is the resistance change amount of the sensing fabric, and ε is the strain applied to the sensing fabric. The electrical property measuring device can quantify the relationship between resistance and tension strain for the sensing fabrics of different lengths; the presence of adjustment block 14 can allow quantifying the relationship between strain and resistance of the sensing fabric under different contact pressures, so as to calculate the sensitivity of the sensing fabric.
[0042] As shown in FIG. 7 , that is, the schematic diagram showing the structure of the wire connecting tool of an exemplary embodiment of the present invention. The wire connecting tool comprises a wire distance control hole 21 , a fixed platform 22 and a wire indicating line 23 . The wire distance control hole 21 is located in the middle of said wire connecting tool which is used to control the spacing of a wire; the fixed platform 22 is used to fix the sensing fabric and connect the sensing fabric with the wire through sewing; and the wire indicating line 23 is situated on the surface of the fixed platform 22 which is used to indicate the position of the wire. During wire connection, the sensing fabric is firstly placed on the fixed platform 22 at a certain pre-determined tension and kept flat throughout the entire process. Secondly, both ends of the sensing fabric are fixed on the fixed platform 22 across the wire distance control hole 21 so that the sensing fabric is not easy to be deformed during the connection thereof with the wire through sewing and the consistency of the connection can be well maintained. The wire indicating line 23 is used to hold the fabric conducting strip perpendicular to the wire when the sensing fabric is being placed on the fixed platform, and to determine the connection position of the wire on the sensing fabric. The wire indicating line 23 can also improve the parallelity and spacing accuracy of two wires connected with each other in the connection process, thus ensuring the connection quality and consistency. The connection between the flexible electrical wire and the wire of the sensing fabric is achieved by sewing, which ensures reliable connection and does not affect the flexibility of the sensing fabric.
[0043] As shown in FIG. 8 , that is, the structural schematic diagram of the sensor structural component assembling tool of a preferred embodiment of the present invention, the sensor structural component assembling tool comprises a clamping positioner 31 , a lower conversion layer positioning box 32 , an upper conversion layer positioning box 33 and a positioning bonding weight plate 34 . The clamping positioner 31 is used to fix said sensing fabric at a pre-determined tension; the lower conversion layer positioning box 32 is used to bond a lower conversion layer with said sensing fabric; the upper conversion layer positioning box 33 is used to bond an adjustment column with said sensing fabric, and to bond a upper conversion layer with said adjustment column; and the positioning bonding weight plate 34 is used to apply pressure to the bonding areas among said lower conversion layer, said sensing fabric, said adjustment column and said upper conversion layer, so as to ensure firm connection between them. During the assembling of the pressure sensor, the sensing fabric 35 is placed and fixed on the clamping positioner 31 in a determined position and at a pre-determined tension. Clamps situated at both sides of the clamping positioned are used to clamp two opposite sides of the sensing fabric. The connecting wire positioning slot 37 is used to position the connecting wire of the sensing fabric when the sensing fabric is placed and fixed on the clamping positioner 31 . Meanwhile, the lower conversion layer is placed in the lower conversion layer positioning box 32 of the sensor structural component assembling tool, following with applying the proper amount of bonding agent to both ends of the lower conversion layer and the sensing fabric for connection. Then, the clamping positioner 31 and the lower conversion layer positioning box 32 are assembled together in a way to place the sensing fabric 35 on the lower conversion layer and ensure accurate positioning of the sensing fabric. The upper conversion layer positioning box 33 is placed on the lower conversion layer positioning box 32 and the sensing fabric 35 while the positioning of the sensing fabric should be accurate. A suitable amount of bonding agent is applied on the bonding areas of the adjustment column and upper conversion layer by placing the bonding agent according to sequence in different slots of the upper conversion layer positioning box. Then, the positioning bonding weight plate 34 is placed on the upper conversion layer positioning box followed by applying a pressure to corresponding bonding areas of the upper conversion layer, lower conversion layer, sensing fabric and the adjustment column in order for proper bonding. The positioning holes 36 , 38 and 39 located on the upper conversion layer positioning box, the lower conversion layer positioning box and the positioning bonding weight plate 34 respectively are used for accurate positioning of various components of the sensor structural component assembling tool. The fabric pressure sensor of the present invention can be manufactured by the tools and process as described herein. The sensor structural component assembling tool ensures good connection between different layers of the fabric pressure sensor.
[0044] As shown in FIG. 8 , according to an exemplary embodiment of the sensor structural component assembling tool of the present invention, the positioning bonding weight plate 34 includes a plurality of raised heads 341 for applying pressure to the selected bonding area. When the positioning bonding weight plate 34 is placed on the upper conversion layer positioning box, the raised heads 341 of the positioning bonding weight 34 are used to apply positioning pressure on the bonding area among the upper conversion layer, the lower conversion layer, the sensing fabric and the adjustment column for the purpose of proper bonding. The raised heads 341 enable accurate positioning of the bonding area through applying the pressure.
[0045] Below is a description of the entire manufacturing process of a fabric pressure sensor in combination with a specific embodiment.
[0046] 1) Produce a resistance-type sensing fabric;
[0047] 2) Test and evaluate the conductivity and sensitivity of the sensing fabric using the electrical property measuring device of the present invention;
[0048] 3) Cut the sensing fabric to a pre-determined size;
[0049] 4) Use the wire connecting tool of the present invention and the sewing method to connect the sensing fabric with the wires;
[0050] 5) Use a resistance meter to determine the quality of connection between the sensing fabric and the wires;
[0051] 6) Produce the upper conversion layer, lower conversion layer and adjustment column of the pressure sensor, and evaluate their appearance quality;
[0052] 7) Place and fix the sensing fabric on the clamping positioner 31 of the sensor structural component assembling tool at a pre-determined tension;
[0053] 8) Place the lower conversion layer in the lower conversion layer positioning box 32 of the sensor structural component assembling tool, and apply bonding agent to both ends of the lower conversion layer;
[0054] 9) Place the clamping positioner 31 with the lower conversion layer positioning box 32 in an inlaid manner;
[0055] 10) Place the upper conversion layer positioning box 33 on the lower conversion layer positioning box 32 and the sensing fabric, and apply bonding agent on the bonding area of the adjustment column and upper conversion layer, and place them in the lower conversion layer positioning box 32 in sequence;
[0056] 11) Use the positioning bonding weight plate 34 to apply pressure to the bonding area among the sensing fabric, the lower conversion layer, the adjustment column and the upper conversion layer for proper bonding;
[0057] 12) Finish the production of the fabric pressure sensor and evaluate its performance.
[0058] The embodiments described above are only some of the embodiments of the invention, which are not intended to limit the scope of the invention patent. Any equivalent structural transformation using the specification or its accompanying drawing of the invention, or any direct or indirect use thereof in other related technical fields shall fall within the scope of protection of the invention patent. | A process for manufacturing a fabric pressure sensor comprises cutting a sensing fabric to a pre-determined size, connecting a flexible electric wire with a wire of the sensing fabric by sewing, fixing the sensing fabric by means of a clamping positioner at a pre-determined tension, bonding a lower conversion layer with the sensing fabric by means of a lower conversion layer positioning box, bonding an adjustable column with the sensing fabric by means of an upper conversion layer positioning box, and bonding the upper conversion layer with the adjustable column by means of the upper conversion layer positioning box. A tool for manufacturing the sensor comprises an electrical property measuring device, a wire connecting tool, and a sensor structural component assembling tool. The present invention provides an easy and convenient way of manufacturing a fabric pressure sensor, monitoring the quality of manufacture, and enhancing the manufacturing precision and product yield. | 6 |
TECHNICAL FIELD
[0001] The present invention relates generally to computer network environments and, in particular, to optimizing the processing of client requests to a network server.
BACKGROUND ART
[0002] In a computer network environment, a server may process data requests from hundreds or thousands of clients. For example, a web server may receive a request for data which, when received by the requesting client, allows the client to view a web page. The server places the request into a thread (or multiple threads) previously allocated by the server. The thread provides instructions for the flow of work required to obtain the requested data and return it to the client. Typically, the server reads the request from the server's network connection with the client in one of three ways. The read may be a “synchronous blocking read” in which the thread is blocked while waiting for the retrieval of the requested data and must complete before being released to another request. Because no thread switching is involved, synchronous blocking reads may be fast. However, because no other process may use the thread while the thread is waiting to complete, the number of network connections which may be processed at a time is limited to the number of threads allocated.
[0003] Alternatively, the read may be a “synchronous non-blocking read” in which the thread periodically attempts to read the data from the connection. Between attempts, the thread is not blocked and may perform other tasks. While efficiency may be improved relative to a synchronous blocking read, scalability (the number of network connections which may be processed at a time) remains limited.
[0004] In the third possible method, the read is an “asynchronous non-blocking read” in which the network connection is registered with a service to monitor the connection. When the requested data is ready to be read, the monitoring service calls a callback on another thread to allow the requesting client to retrieve the data. Although scalability is improved from synchronous reads, the required thread switching for every request may adversely affect performance.
[0005] Typically, another read request from the client follows data sent in response to a previous request. However, the subsequent request may follow immediately, such as when multiple requests are sent for pieces of a web page, or may follow after a considerable delay, such as when the client's user is thinking about what web page to go to next. Thus, a blocking read may be the most efficient for the former situation but a non-blocking read may be the most efficient for the latter situation.
[0006] Consequently, a need remains for improved processing of read requests from a client to a server.
SUMMARY OF THE INVENTION
[0007] The present invention provides a server protocol to process read requests from clients. Rather than all read requests being processed synchronously or all read requests being processed asynchronously, an attempt is first made to perform a synchronous read. If the synchronous read is unsuccessful, the connection through which the request was received by the server is registered with a monitoring service. When the data is ready to be read, an appropriate callback is called and the data transmitted.
[0008] An optional delay may be imposed before the synchronous read is attempted to increase the likelihood that the attempt will be successful. A series of delays/read attempts may also be employed in order to increase the likelihood still further that an attempt will be successful. The delays may be of the same length of time or may be different. In one aspect of the present invention, a first delay is set to approximate the expected time required for a successful synchronous read request to be completed. A second delay is set to a different, shorter time. The first delay may be determined by logging the average delay while processing a previous request and adaptively adjusting the first delay.
[0009] The risk of stack overflows may also be reduced by forcing the stack to unwind if more than a predetermined number of synchronous reads are successful.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a block diagram of a network environment in which the present invention may be implemented;
[0011] FIG. 2 is a block diagram of a server adapted to implement the present invention;
[0012] FIG. 3 is a flow chart of one aspect of the present invention in which a synchronous attempt to read data is followed by an asynchronous read;
[0013] FIG. 4 is a flow chart of another aspect of the present invention in which a delay is imposed before the synchronous read of FIG. 3 is attempted; and
[0014] FIG. 5 is a flow chart of a further aspect of the present invention in which the delay/read attempt sequence of FIG. 4 is performed up to a predetermined number of times;
[0015] FIG. 6 is a flow chart of a further aspect of the present invention in which the delay/read attempt sequence of FIG. 4 is performed twice; and
[0016] FIG. 7 is a flow chart of a further aspect of the present invention in which the stack is unwound to prevent an overflow.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0017] FIG. 1 is a block diagram of a network environment 100 in which the present invention may be implemented. The environment 100 includes numerous client units 110 and a server 200 , interconnected through a network 120 . As illustrated in FIG. 2 , the server 200 includes a processor 202 and a memory 204 for, among other functions, storing instructions executable by the processor 202 . The server 200 is connected to a data source 206 , such as a data storage drive, through an interface 208 . Connections 210 to network clients 110 are made through interfaces 212 . Threads 220 1 - 220 n are allocated, such as out of the memory 204 and used to direct the sequential flow of work, such as processing read requests. As will be described below, the server 200 further includes a service monitor 216 to monitor asynchronous reads, a stack (generally a dedicated portion of the memory 204 ) and, optionally, an iteration counter 218 .
[0018] Referring to FIG. 3 , a method of the present invention will be described. After a request is received by the server 200 from a client over a connection 210 (step 300 ), a thread is created and an attempt is made to read the requested data in a non-blocking, synchronous manner (step 302 ). If the read attempt is successful (step 304 ), the server calls a callback on the same thread (step 306 ). After the server transmits the data to the client (step 308 ), the thread is released for subsequent re-use (step 310 ).
[0019] If, on the other hand, the synchronous read attempt is unsuccessful (step 304 ), the connection over which the request was received is registered with the monitoring service 216 (step 312 ) and the thread is released (step 314 ). The monitoring service 216 monitors the connection (step 316 ) and, when the data is ready (step 318 ), the server calls a callback on a different thread (step 320 ). After the server transmits the data to the client (step 322 ), the thread is released for subsequent re-use (step 324 ). Thus, a synchronous read is employed initially and an asynchronous read is automatically employed if the synchronous read fails.
[0020] Frequently, data is not available immediately after a response to a request has been sent due to network delays as well as the time required by the client to process a response and send the next request. Thus, the attempted synchronous read (step 302 ) will frequently, but unnecessarily, fail, sending the process into the asynchronous mode (beginning with step 312 ) and reducing the performance of the server. As illustrated in FIG. 4 , one embodiment of the present invention addresses the inefficiency by introducing a predetermined delay before the synchronous read is attempted. After the read request is received by the server 200 (step 400 ), the server waits for the predetermined delay period, such as 50 milliseconds (step 404 ). The synchronous read attempt is then made (step 302 ) and the process continues (at step 304 ) as illustrated in the balance of FIG. 3 . Thus, the imposed delay accommodates network and other delays and increases the likelihood of a successful synchronous read. However, if the total chosen is too long, the thread may be tied up for an unnecessarily long time. And, if the total chosen is too short, the likelihood of a successful synchronous read may decrease.
[0021] The embodiment of FIG. 5 introduces flexibility into the delay to increase the likelihood of a successful read without tying up the thread for an unduly long period. In this embodiment, after the read request is received by the server 200 (step 500 ), the iteration counter 218 is set to a value, such as five (step 502 ), and the server waits for a predetermined delay period, such as 10 milliseconds (step 504 ). The synchronous read attempt is then made (step 506 ). If the attempt is unsuccessful (step 508 ), the counter is decremented (step 510 ); if the counter has not yet reached zero (step 512 ), the process loops back and waits again for the delay period (step 504 ) before making another attempt to read the data (step 506 ). The process continues until the read is successful, in which case the callback is called (step 306 , FIG. 3 ), or until the counter 218 reaches zero. If the counter 218 reaches zero, the connection is registered with the service monitor 216 (step 312 , FIG. 3 ) to initiate the asynchronous read process. Thus, the imposed delay accommodates network and other delays and increases the likelihood of a successful synchronous read. The total delay time is based upon the length of each individual delay selected and the number of iterations selected. It will be appreciated that the scope of the present invention does not depend upon the choice of the counter 218 . The counter 218 may thus be the described count-down counter, a count-up counter, which is incremented until it reaches a predetermined value, or any other kind of counter. Alternatively, a timer may be employed which runs (up or down) for the total predetermined delay period in which case the step 502 of setting and starting the counter would be replaced with a comparable step of setting the timer and the step 510 of decrementing the counter would be eliminated.
[0022] The embodiment of FIG. 5 may be refined further, as illustrated in FIG. 6 . After the request has been received (step 600 ), the process pauses for a first delay (step 604 ) before the synchronous read is attempted ( 606 ). If the read is successful (step 608 ), the callback is called as in the other embodiments (step 306 , FIG. 3 ). Otherwise, a second delay is encountered (step 610 ) after which a second synchronous read attempt is made (step 612 ). If this attempt is successful (step 614 ), the callback is called (step 306 , FIG. 3 ). If not, the connection is registered as in the other embodiments (step 312 , FIG. 3 ). The first delay period may be manually selected to be a period, such as 40 milliseconds, which is the approximate average of the total delay required process other requests over the connection. The second delay may be a shorter delay, such as 10 milliseconds, to provide one more opportunity for the synchronous read before resorting to the asynchronous read.
[0023] Referring again to FIG. 5 , if the synchronous read is successful during any of the iterations, the total delay period may be logged (step 514 ) and later imposed as the first delay during subsequent requests. Preferably, the server 200 will process a first request over a connection in the manner described with respect to FIGS. 3 and 5 , recording the total delay required for a successful read. The server 200 then switches to the process described with respect to FIGS. 3 and 6 . Before processing subsequent requests, the server 200 adaptively adjusts the first delay (step 604 ) to be approximately the same as the total delay recorded while the first request was processed. For example, if the first request was successful after 4 iterations of 10 milliseconds each, the first delay period would be automatically set to 40 milliseconds. The second delay may be set to, for example, 10 milliseconds, thereby providing a potential of 50 milliseconds for two synchronous read attempts before the connection is registered for an asynchronous read.
[0024] When a read request is received and placed in a thread, a return address as well as information about the state of the system are added to the top of the stack 222 . If an attempt at a synchronous read is successful, the callback typically processes the request, sends the response and tries to read the next request, all without “popping” the previously added information from the stack 222 . The next request may also result in a successful synchronous read and a callback called on the same thread, also without popping the new information off of the stack 222 . If this sequence is repeated too often, the stack 222 may not be able to unwind, resulting in an overflow situation and possible loss of data and/or system crash. Stack operations are described in more detail in commonly-assigned U.S. Pat. No. 6,779,180, entitled “Apparatus and Method for Preventing Stack Overflow from Synchronous Completion of asynchronous Functions”, which patent is incorporated herein by reference in its entirety.
[0025] The risk of a stack overflow may be reduced in the present invention by implementing an optional stack “unwinding” subroutine as illustrated in the flow chart of FIG. 7 . When a synchronous read attempt is successful (step 304 ) and a callback is to be called on the current thread, a counter is incremented (step 700 ). If the counter has reached a predetermined value (step 702 ), indicating that the stack depth has reached a maximum safe level, an indicator in the thread may be set to delay the call to the callback (step 704 ). The stack 222 is then unwound (step 706 ) and the callback called (step 306 , FIG. 3 ). Alternatively, rather than calling the callback, the request may be registered immediately with the monitoring service 216 , triggering the unwinding of the stack 222 . The counter is then reset ( 708 ) and the next read request will proceed with a fresh stack.
[0026] The objects of the invention have been fully realized through the embodiments disclosed herein. Those skilled in the art will appreciate that the various aspects of the invention may be achieved through different embodiments without departing from the essential function of the invention. The particular embodiments are illustrative and not meant to limit the scope of the invention as set forth in the following claims. | In a computer network environment, a server protocol is provided to process read requests from clients. Rather than all read requests being processed synchronously or all read requests being processed asynchronously, an attempt is first made to perform a synchronous read. If the synchronous read is unsuccessful, the connection through which the request was received by the server is registered with a monitoring service. When the data is ready to be read, an appropriate callback is called and the data transmitted. An optional delay may be imposed before the synchronous read is attempted to increase the likelihood that the attempt will be successful. A series of delays/read attempts may also be employed in order to increase the likelihood still further that an attempt will be successful. | 7 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a division of co-pending U.S. patent application Ser. No. 11/185,734 which is a division of U.S. Pat. No. 6,948,757 which is a 371 of PCT/EP01/15368.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to a windshield for motorcycles which is adjustably mounted by a holding means on the motorcycle and can be adjusted by a drive means into different positions.
[0004] The invention furthermore relates to a windshield for motorcycles which is adjustably mounted by a holding means on the motorcycle, the holding means having two non-parallel guides for setting different vertical and/or inclined positions of the windshield as it moves along the guides.
[0005] Finally, the invention relates to a drive means for an adjustably supported motor vehicle component, especially a windshield for motorcycles.
[0006] 2. Description of Related Art
[0007] German Patent DE 39 41 875 C1 discloses a windshield which is mounted on a motorcycle so as to be adjustable in its height and its angular orientation by an adjustment means. The adjustment means contains at least two guide rails arranged at different angles and on each of which a respective sliding piece is movably supported. The windshield is connected to the two sliding pieces to be able to pivot around the transverse axis of the vehicle. An electric motor is located in the area of the front, lower guide rail and via a threaded rod transfers linear drive motion to the sliding piece which is supported on the front guide rail. The driving of the sliding piece via the threaded rod or a comparable dimensionally stable drive element limits the possible locations of the electric motor in the vicinity of the front guide rail.
SUMMARY OF THE INVENTION
[0008] A primary object of the present invention is to provide a windshield of the initially mentioned type with a drive device which is improved with respect to its arrangement and functionality.
[0009] Another object of the invention is to provide a windshield of the initially mentioned type with a holding means with two guides which is adjustably supported by a durable holding means with a simple structure.
[0010] A further object of the invention is to provide a drive means of simple structure for an adjustable vehicle component.
[0011] The initially mentioned object is achieved in accordance with the invention in that the drive means for the windshield has a cable line connection between the drive motor of the drive means and the adjustable windshield. A cable line connection which is formed, for example, in the manner of a Bowden cable, can be installed flexibly with bends or curvatures so that the drive means can be attached in the vicinity of the windshield or also farther away from it on the motorcycle without major structural limitations which entail rigid connecting elements, such as spindles or the like.
[0012] The initially mentioned object is also achieved in the initially mentioned windshield in accordance with the invention in that the drive means for the windshield has a lever means with at least one pivotally mounted drive lever between the drive motor of the drive means and the adjustable windshield. Rigid coupling by means of a pivotable drive lever enables reliable, play-free actuation and adjustment of the windshield. The lever ratios on the drive lever can be designed such that none of the drive movements applied to the drive lever are stepped up into large driven motions of the drive lever. This yields a compact execution of the drive unit.
[0013] If the drive means for the windshield has a lever means with two symmetrically arranged drive levers which are each connected on the outside end to a carriage, which is supported in the middle for pivoting in opposite directions, and which on the inner end are connected to one another by means of a movable coupling part, a uniform drive motion can be applied to two movable bearing parts of the windshield which are spaced apart from one another.
[0014] The second object is achieved by the first guide is mounted on the vehicle and the second guide being located on the windshield and by a driven carriage which is connected to the windshield on the first guide which is mounted on the vehicle and a vehicle-mounted part on the second guide located on the windshield being drive-engaged. Thus, both the vehicle-mounted part and also the windshield or the part connected to the windshield assume a guide function. Functionally, the carriage is connected via a cable line connection to the drive means. Here, the aforementioned advantages of the flexible arrangement of the drive means apply. A cable line connection is defined as any connections which are resistant to extension and compression, but which are flexible, and which can be flexible installed on the motorcycle, for example, in the manner of a Bowden cable.
[0015] Preferably, the windshield is mounted on the windshield bearing part which contains the second guide and which is connected to the carriage. In this configuration, the windshield bearing part forms a unit of the holding means and the windshield is interchangeably attached to the windshield bearing part and the holding means without effort.
[0016] If each cable line is guided to a respective one of a right-side and a left-side windshield bearing part or on two spaced mounting points on the windshield itself by the drive means, reliable adjustment of the windshield is ensured by this double driving.
[0017] Functionally, the drive means contains a rope pulley on which the cable or the rope of at least one cable or rope line can be wound and unwound. This pulley can have two adjacent peripheral grooves on which two cable lines can be wound and unwound at the same time and in the same direction so that the two cables, and thus the two windshield bearing parts, are synchronously activated. By means of one of the two cable line connections, at least one other movable part of the motorcycle can be adjusted synchronously to the motion of the windshield.
[0018] In one preferred embodiment, the guides are made as links in which stationary bearing elements, such as pins or the like, are guide-engaged. If the guides or links are formed to be linear, depending on the mutual assignment, a uniform adjustment motion is enabled. When the guides or links have at least one curved section, a pivoting motion of the windshield can be superimposed on the linear adjustment motion. Instead of the curved section, any shape of the guide or the link deviating from the linear section can make provide a pivoting motion of the windshield which deviates from the straight adjustment motion.
[0019] Preferably, the first guide or link is made in at least one longitudinal part of the holding means. This longitudinal part can be a central part of the holding means. Alternatively, there are two longitudinal parts in the right-side and left-side arrangement for the two windshield bearing parts.
[0020] Preferably, the longitudinal part is formed from at least two combined components which can be divided along the guide. This configuration facilitates the production of guides and the installation of the assigned components of the holding means, such as, for example, the carriage.
[0021] In the drive means for an adjustably supported vehicle component, especially a windshield for motorcycles, it is provided in accordance with the invention that the drive means has a cable line connection between the drive motor of the drive means and the vehicle component and a rope pulley on which at least one cable line can be wound and unwound and is guided by the drive means to the vehicle component or to a right-side and to a left-side vehicle component bearing part.
[0022] Furthermore, it is provided that the drive means has a lever means with at least one pivotally supported drive lever between the drive motor of the drive means and the adjustable vehicle component.
[0023] Further details of the configuration and advantages of the invention will become apparent from the following description taken together with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1 is a side view the front part of a motorcycle with an adjustable windshield;
[0025] FIG. 2 is a perspective view of the holding means of the windshield with a drive device in the initial position;
[0026] FIG. 3 is a view similar to that of FIG. 2 showing the drive device with the covering removed;
[0027] FIG. 4 is a view similar to that of FIGS. 2 & 3 showing the holding and drive device in the end position;
[0028] FIG. 5 is a perspective view of an inner side of the left-side part of the holding means;
[0029] FIG. 6 is a top view of the left-side part of the holding means and the drive device;
[0030] FIG. 7 shows in an inside view as shown in FIG. 5 , but with the holding means in the end position as shown in FIG. 4 ;
[0031] FIG. 8 is a perspective view from above of a second embodiment of a holding means of the windshield with a modified drive device in the initial position;
[0032] FIG. 9 is a view corresponding to that of FIG. 8 , but with the holding and drive device in the intermediate position;
[0033] FIG. 10 is a view corresponding to that of FIG. 8 , but with the holding and drive device in the end position;
[0034] FIG. 11 is a plan view of the holding means of the second embodiment in the initial position according to FIG. 8 ;
[0035] FIG. 12 is a plan view of the holding means in the intermediate position according to FIG. 9 ; and
[0036] FIG. 13 is a plan view of the holding means in the end position according to FIG. 10 .
DETAILED DESCRIPTION OF THE INVENTION
[0037] The partially depicted motorcycle 1 of FIG. I has a cowling 2 and a windshield 3 which is mounted above the cowling 2 by a holding means 4 such that it can route the slipstream past the motorcycle driver 5 . If necessary, the windshield 3 can be adjusted in its height and/or its angle of inclination by the holding means 4 out of a most vertical set position (shown schematically in FIG. I in broken lines) into a highly inclined position (shown in solid lines).
[0038] The holding means 4 contains a holding frame 6 (only the part of the left part of which is shown in FIGS. 2 to 7 ) with mounting or screw openings 7 (see, FIG. 5 & 8 ) for fixing the holding frame 6 on the frame of the motorcycle 1 or on the cowling 2 . A drive means 8 is mounted on the central transverse part 9 of the holding frame 6 . On the longitudinal side parts 10 (only the left longitudinal part 10 being shown), a linear link guide 11 (see, FIG. 4 ) with a, for example, rectangular cross section is formed in which an elongated carriage 12 is movably held. A front bearing pin 13 extends through a side oblong hole opening 14 of the link guide 11 into the bearing hole 15 of a windshield bearing part 16 . The carriage 12 is drive-engaged with a part, e.g., a stationary rear bearing pin 18 that projects on the back end 17 of the longitudinal part 10 , laterally to the outside, and fits into the link guide 19 of the windshield bearing part 16 which is formed as an oblong hole. The guides 11 , 19 are non-parallel with respect to each other, as is apparent from the drawings, for varying the position of the windshield 3 in terms of height and/or inclination, when it is moved along the guides. The rear bearing pin 18 is located above the link guide 11 , and the link guide 19 of the windshield bearing part 16 runs underneath the front bearing pin 13 so that the windshield bearing part 16 is swung up around the bearing pin 13 if it is pushed lengthwise by means of the driven carriage 12 and the bearing pin 13 . The windshield bearing part 16 has mounting openings 20 for attaching the windshield 3 .
[0039] Next to the link guide 11 and parallel to it, a channel 21 is formed, which connects with the opening 14 of the link guide 11 (see FIG. 5 to 7 ) and in which a drive cable 22 , which is connected to the carriage 12 , is movably held. The drive cable 22 is movably guided in jacketing 23 from the windshield bearing part 16 , via a bend 24 , to the pulley 25 of the central drive means 8 . The pulley 25 is mounted on the gear shaft of the force transmission mechanism 27 driven by the electric motor 26 (see especially FIG. 3 ), and has a peripheral groove 28 in which the drive cable 22 can be wound and unwound and which is resistant to tension and compression. By means of a retaining pin 29 which is mounted on the end of the drive cable 22 and which is inserted in a recess of the rope pulley 25 , the drive cable 22 is attached to the pulley 25 in the peripheral direction, resistant to extension. The pulley 25 has a second peripheral groove 30 next to the first peripheral groove 28 in which, in the same direction of rotation, a second drive cable 31 for the opposing, right-side windshield bearing part (not shown) is located. The covering 32 (see FIG. 2 ) covers and seals the pulley 25 .
[0040] Next to the link guide 11 and parallel to it, a channel 21 is formed, which connects with the opening 14 of the link guide 11 (see FIG. 5 to 7 ) and in which a drive cable 22 , which is connected to the carriage 12 , is movably held. The drive cable 22 is movably guided in jacketing 23 from the windshield bearing part 16 , via a bend 24 , to the pulley 25 of the central drive means 8 . The pulley 25 is mounted on the gear shaft of the transmission 27 driven by the electric motor 26 (see especially FIG. 3 ), and has a peripheral groove 28 in which the drive cable 22 can be wound and unwound and which is resistant to tension and compression. By means of a retaining pin 29 which is mounted on the end of the drive cable 22 and which is inserted in a recess of the rope pulley 25 , the drive cable 22 is attached to the pulley 25 in the peripheral direction, resistant to extension. The pulley 25 has a second peripheral groove 30 next to the first peripheral groove 28 in which, in the same direction of rotation, a second drive cable 31 for the opposing, right-side windshield bearing part (not shown) is located. The covering 32 (see FIG. 2 ) covers and seals the pulley 25 .
[0041] When the electric motor 26 is actuated, for example, via a hand switch on the handlebars or via a speed-dependent or slipstream-dependent control, the drives cables 22 , 31 are taken up at the same time from the position shown in FIG. 1 in which the two windshield bearing parts 16 are located in the front position and hold the windshield 3 in the lower vertical position with a slight upward inclination, via rotation of the cable pulley 25 so that, via rearward displacement of the respective carriage 12 , the windshield bearing parts 16 , and thus the windshield 3 , are raised and inclined more dramatically against the slipstream. The end position is shown in FIGS. 4 & 7 .
[0042] The opposing drive motion of the electric motor 26 moves the windshield 3 back again into the reclined position or into an intermediate position.
[0043] If the link guide 11 is positioned so that it rises over its length relative to the lengthwise axis of the motorcycle, the front bearing pin 13 , and thus the windshield bearing part 16 and the windshield 3 , are additionally raised in its vertical position.
[0044] One or both link guides 11 , 19 can have angled or curved sections so that a certain swinging behavior of the windshield 3 which is dependent on the lengthwise displacement can be fixed.
[0045] The largely flexibly installable drive cables 22 , 31 of the drive means 8 enable a comparatively free arrangement of the drive means 8 relative to the movable holding means 4 or to the windshield 3 so that the electric motor 26 with the transmission 27 and the pulley 25 can also be located away from the holding means 4 and at angular positions to it, which is something which could be accomplished by a conventional mechanical coupling only with high construction cost.
[0046] In another embodiment of the windshield (see, FIGS. 8 to 13 ), with a modified drive means, the holding means 4 contains a drive pulley 33 (see FIG. 11 ) which is located on the central transverse part 9 in the middle between the two side longitudinal parts 10 (only the left longitudinal part 10 is shown) and is pivotally supported on it and is coupled to rotate with the electric motor 26 via the transmission mechanism 27 . The drive wheel 33 is covered by a cover 34 which is mounted on the transverse part 9 . The carriage 12 of the windshield bearing part 16 is U-shaped and sits movably on the guide 11 which is formed as a rail. On the two brackets 35 , which project inward from the carriage 12 , a pin 36 is mounted on which a left drive lever 37 is pivotally supported. The drive lever 37 extends roughly to the middle of the transverse part 9 , resting directly on the cover 34 , and supported to move and pivot on a pin 38 which projects upward, for example, from the cover 34 and which is held to be able to move into an elongated hole 39 in the drive lever 37 .
[0047] A right drive lever 40 for driving the right windshield bearing part or its carriage is located symmetrically to the left drive lever 37 and is supported in the corresponding manner by means of a pin 42 which fits into the longitudinal slot 41 . The right drive lever 40 has an inner end 43 which is bent up such that this end 43 rests on the inner end 44 of the left drive lever 37 . The inner ends 43 , 44 of two drive levers 37 , 40 , each contain a longitudinal guide slot 45 , 46 in which is held a movable coupling part, e.g., the guide pin 47 which is mounted on a sliding piece 48 which is movably supported in a longitudinal guide 49 on the cover 34 . A drive part, e.g., a guide pin 50 which is eccentrically mounted on the drive wheel 33 extends through an arc-shaped slot 51 in the cover 34 (which defines a circular path) up into the longitudinal guide slot 45 in the drive lever 37 (as shown) or into the lengthwise hole 46 of the right drive lever 40 .
[0048] A right drive lever 40 for driving the right windshield bearing part or its carriage is located symmetrically to the left drive lever 37 and is supported in the corresponding manner by means of a pin 42 which fits into the longitudinal slot 41 . The right drive lever 40 has an inner end 43 which is bent up such that this end 43 rests on the inner end 44 of the left drive lever 37 . The inner ends 43 , 44 of two drive levers 37 , 40 , each contain a longitudinal guide slot 45 , 46 in which is held the guide pin 47 which is mounted on a sliding piece 48 which is movably supported in a longitudinal guide 49 on the cover 34 . A pin 50 which is eccentrically mounted on the drive wheel 33 extends through an arc-shaped slot 51 in the cover 34 up into the longitudinal guide slot 45 in the drive lever 37 (as shown) or into the lengthwise hole 46 of the right drive lever 40 .
[0049] To change the position of the windshield 3 , the drive means 8 causes the drive wheel 33 to rotate and swings the windshield 3 , for example, by an angle of a maximum roughly 130° clockwise as shown in FIGS. 8 to 13 . In doing so, the pin 50 , which slides in the longitudinal guide slot 45 , pivots the left drive lever 37 around the pin 38 so that the drive lever 37 moves the carriage 12 , and thus, the left windshield bearing part 16 to the rear via the middle intermediate position shown in FIGS. 9 & 12 into the end position which is shown in FIGS. 10 & 13 and in which the windshield 3 is raised to have a greater inclination.
[0050] As a result of the pin 50 which couples the two drive levers 37 , 40 to one another, the drive motion is transferred to the two drive levers 37 , 40 for their synchronous movement.
[0051] This embodiment has a small installation depth of the drive, since the drive motion takes place via the drive lever which pivots through only a comparatively small angle. The rotary motion of the pin 50 in the vicinity of the two end positions causes only minor pivoting of the two drive levers 37 , 40 , so that starting and braking take place gently in the vicinity of the two end positions.
[0052] The drive means 8 is controlled via Hall sensors in the drive motor and/or via microswitches which are triggered via the drive wheel 33 . There can also be a comparable control in the first embodiment. | A windshield for motorbikes which can be variably positioned at various angles of inclination on the motorbike by a holding device ( 6 ) and a drive device ( 8 ). The drive device ( 8 ) has a cable or a cable pull connection ( 22, 23, 24, 25 ) between a drive motor ( 26 ) of the drive device ( 8 ) and a support element ( 16 ) for the adjustable windshield. The holding device ( 6 ) can also be formed by two non-parallel guides ( 11, 19 ) for varying the position of the windshield ( 3 ) in terms of height and/or inclination, when it is moved along the guides ( 13, 19 ). The first guide ( 11 ) is fixed to the vehicle and the second guiding mechanism ( 19 ) is arranged on the windshield ( 3 ). A driveable carriage ( 12 ) which is connected to a support element ( 16 ) for the adjustable windshield and is situated on the first guide ( 11 ) engages a part ( 18 ) which is fixed to the vehicle and is situated on the second guide ( 19 ). | 1 |
FIELD OF THE INVENTION
The present invention relates to apparatus for preheating substrates prior to inserting them into a processing chamber for conducting a semiconductor manufacturing process step.
BACKGROUND OF THE INVENTION
Semiconductor processing chambers are used to provide process environments for the fabrication of integrated circuits and other semiconductor devices on wafers. Wafers are sequentially processed through a series of many different processing steps which include depositions of various layers (metal, insulator and dielectric) on the wafer, each of which may be followed by masking and etching process steps with or without planarization steps also being involved. By selective repetition of the deposition and processing of these layers, integrated circuits may be fabricated on the wafer or substrate.
Deposition and etching processes may be accomplished by various techniques, including various chemical vapor deposition (CVD) processes, physical vapor deposition (PVD) processes, such as sputtering, and plasma processes, to name a few. Most processing chambers used in conducting these processes include a vacuum chamber containing a wafer support member upon which the wafer is placed to be processed. A gas inlet having a mass flow controller, and a throttled exhaust coupled to a vacuum pump through a gate valve communicate with the vacuum chamber to provide the process gas flow and the vacuum conditions required for processing the wafer. A slit valve is provided in the vacuum chamber which allows access by a robot blade used to load the wafer on the wafer support for processing, as well as to remove the wafer from the wafer support and chamber after the process step has been completed.
Many such processes require elevated temperatures for best results. Although it is possible that the wafer support may start out at room temperature initially for processing of a first wafer, this is certainly not the usual case, since there is very little cooling of the wafer support, and certainly not cooling to room temperature during the time that a first wafer is removed and another wafer is loaded to be processed. When a wafer at room temperature is loaded onto a wafer support that is at operating temperature, a phenomenon has been observed where the wafer tends to “chatter” or “dance” on the wafer support initially after placement there. This phenomenon is believed to be caused when the pins, which support the wafer to allow the robot arm to slide out from between the wafer and wafer support, withdraw to allow the wafer to contact the wafer support. It is believed that cold (i.e., relative to the operating temperature) air is trapped between the wafer and wafer support, and as that air is heated it expands and causes the wafer to chatter as it escapes from between the wafer support and the wafer. This phenomenon, although observed with 200 mm wafer processing, was not as severe a problem as it has become with 300 mm wafer processing, where the chattering is much more pronounced, due to the larger surface area of the wafer, and this is likely to cause misalignment of and/or damage to the wafer.
One way of eliminating the chattering is to leave the wafer on the lift pins for a significant period of time (e.g., about 45 seconds) after placing it in the processing chamber to allow it to heat up prior to contacting it with the chuck. However, this additional time requirement seriously impacts the throughput of the processing. The chattering phenomenon can also be eliminated by preheating the wafers to a temperature significantly above room temperature, although they do not need to be heated all the way up to operating temperature. Such preheating also increases throughput in the processing chamber, since it then takes less time to get the wafer up to processing temperatures. A conventional heater may be used to preheat a wafer substrate. Conventional heaters are generally thick plates, having a thickness of at least 0.5″ up to about 1″, and are often made of cast aluminum or aluminum alloy and having a tube heater filament or embedded metal electrode running through the plate to heat the overall plate. A general idea of such construction can be gained from a reading of the description of the susceptor plate described in U.S. Pat. No. 5,633,073. Although the susceptor plate in the patent is described for use within a processing chamber, a similar construction can be used for preheating.
Conventional heaters have certain drawbacks including the fact that they are relatively thick and bulky, which limits their effectiveness if they are to be used in a stack arrangement for heating of multiple wafers simultaneously. This thickness also translates to a relatively large mass to be heated, and therefor the response time for initial heating up of the heater or changing the steady state temperature of a heater is relatively large (i.e., slow response time). Still further, conventional heaters are relatively heavy and expensive, costing on the order of $4,000 to $5,000 per heater plate.
In view of the foregoing, there remains a need for a heater system that has better response time, is more adaptable to stacked usage, and is less expensive.
SUMMARY OF THE INVENTION
A heating chamber assembly is provided with a stack of at least two thick film heater plates forming at least one slot configured to receive a wafer therein. A chamber surrounds the stack and has a door therethrough which opens to allow insertion of wafers and withdrawal of wafers from the assembly. Each slot is alignable with the door for receiving a wafer, or allowing a robot arm to access a wafer already in the slot and withdraw it.
Multiple slots can be provided by stacking enough thick film heater plates to form the desired number of slots. A slot is formed between two thick film heater plates, so that for “n” slots, “n+1” heater plates are required.
A drive shaft may be mounted to the stack, and the drive shaft extends through the chamber and engages a driver or motor which drives the drive shaft and stack for the purpose of aligning each of the slots with said door as desired. When the door is closed, it forms a pressure seal with the chamber. A sealing mechanism forms a pressure seal around the drive shaft and with the chamber, such that the chamber is capable of maintaining positive pressure. A gas inlet may be provided in the chamber, to enable the passing of a purge gas into the chamber to positively pressurize said chamber.
Each of the thick film heater plates comprises a pair of electrodes through which power is inputted to a resistive circuit to generate heat. A pair of supports underlies and supports each thick film heater plate in the stack, with one of each pair of supports aligning with the pair of electrodes on the respective thick film heater plate. The supports not only support the stack, but separate each adjacent pair of thick film heater plates to form the slots therebetween. The supports which align with the electrodes of the heater plates electrically interconnect the plates. Each of the electrically connecting supports includes a pair of electrodes for extending therethrough which align with and contact the electrodes in thick film heater plates on opposite sides thereof. An electrical power supply can than be connected at any location along the interconnected circuit of supports and heater plates, to supply power to the entire stack. Although the heater plates could be individually connected to separately controlled power supplies, such an arrangement is more expensive and cumbersome given the greater number of electrical line and power supplies that would be required, and as such is not considered as practical commercially.
The supports comprise a nonconducting material to prevent electrical conduction from the power source to any wafer in a slot. A nonconductive sleeve may surround a portion of each of the electrodes passing through the supports to further insulate the power from the wafers.
A controller may be provided to automatically and remotely control the chamber door led to open and close. The controller may also be connected with the driver or motor and the electric power supply to control their functions.
At least one thermocouple may be provided within the chamber and electrically connected to the controller to provide feedback regarding a temperature inside of the chamber. A more preferred arrangement is to provide three thermocouples 78 , 80 , 82 , one probing the top heater plate, one probing the bottom heater plate, and one probing the middle heater plate or one of a pair of heater plates nearest the middle of the stack if an even number of heater plates is employed. The middle thermocouple is used to provide feedback for temperature control purposes. The top and bottom thermocouples are used for comparison with the reading generated by the middle thermocouple. If a difference between the reading from the middle thermocouple and either one or both of the top and bottom thermocouples becomes more than a predetermined amount, this is an indicator of an operational problem, at which time the operation would be shut down.
Further, a sensor may be mounted on the chamber to detect when a wafer has been placed out of position in the chamber, and the sensor may be electrically connected to the controller to input a message to the controller when a misaligned wafer has been detected.
A heater subassembly for a wafer heating chamber is provided which includes a stack of thick film heater plates electrically interconnected with one another and defining slots therebetween. The slots are dimensioned for receiving wafers. At least a pair of supports are positioned between each pair of interfacing surfaces of the plates.
A support base may be provided to underlie the bottom thick film heater plate of the stack, to further support the stack. A drive shaft extending from the bottom of the stack or support base and is adapted to be driven to traverse the stack.
The supports comprise nonconductive blocks, at least a portion of which have a thickness that defines a height of the slots. Another portion of each nonconductive block is thinner than the thickness defining the height of the slots and forms a portion of a pedestal adapted to support a wafer.
The supports may include spring loaded connectors in combination with a rigid shaft passing therethrough.
These and other objects, advantages, and features of the invention will become apparent to those persons skilled in the art upon reading the details of the heat chamber assemblies and subassemblies as more fully described below.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic sectional view of a heater according to the present invention.
FIG. 2 is top view of an example of a thick film heater plate used in a heater according to the present invention.
FIG. 3 is an isolated, perspective view of a bake chamber assembly isolated from the chamber of the heater.
FIG. 4 is a partially exploded view of a bake chamber assembly, absent the drive shaft.
FIG. 5 is an exploded partial view of a bake chamber assembly showing electrical connections between the thick film heater plates.
FIG. 6 is an exploded partial view of a bake chamber assembly detailing electrical connection components between the thick film heater plates.
FIG. 7 is a partial assembly view of a dual chamber heater assembly, absent the chambers.
FIG. 8 is a perspective view of a dual chamber heater assembly, absent a top plate.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Before the present invention is described, it is to be understood that this invention is not limited to particular examples or embodiments described, as such may, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting, since the scope of the present invention will be limited only by the appended claims.
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.
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 capacitor” includes a plurality of such capacitors reference to “the layer” includes reference to one or more layers and equivalents thereof known to those skilled in the art, and so forth.
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.
Referring now to the figures, wherein like reference characters denote like or corresponding parts throughout the views, examples of the present invention are explained. The major components of a heater 1 according to the present invention are diagrammatically illustrated in the sectional view of FIG. 1 . Heater 1 includes a bake chamber assembly 10 that is movably mounted within a heater chamber 30 . Bake chamber 30 is pressure sealed and may be formed of cast aluminum (preferably Al 6061 T6). Preferably a block of cast aluminum is machined to form a twin heater chamber, as shown in FIG. 8, for receiving a pair of side by side stacked heater plates, although a single chamber, such as chamber 30 in FIG. 1 can be machined similarly. Aluminum is a preferred material, since it has good heat transfer properties, is easy to machine, and contains no nickel which could be attacked and corroded by O 3 . Aluminum is also chemically compatible with other processing gases used in the related processes that the present invention is to be used for. The chamber is preferably a single piece, as noted above. A top plate 30 a seals against the chamber 30 .
A bake chamber according to the present invention may be formed to assume a position where one of a plurality of processing chambers would otherwise reside, for use in a multichamber system such as The Producer, available from Applied Materials, Santa Clara, Calif. As noted above, a bake chamber may be similarly arranged for use in conjunction with a single processing chamber. In yet another arrangement, a heating or bake chamber assembly may be incorporated into a load lock of one or more processing chambers, for direct preheating in the load lock.
The bake chamber assembly 10 includes a plurality of thick film heater plates 12 mounted in a stack on support plate 14 . Support plate 14 is mounted on drive shaft 16 . Support plate 14 and drive shaft 16 may be formed of aluminum (Al 6061 T6), for example. The support plate 14 and heater plates 12 are dimensioned to be freely slidable within chamber 13 . The bake chamber assembly 10 is assembled within the chamber 30 with drive shaft 16 passing through opening 32 in the bottom 30 b of chamber 30 . A flexible sealing member 34 , e.g., a bellows or other sealing member, is secured to the bottom 30 b to surround the entire perimeter of the hole 32 and to form a pressure seal with the bottom 30 b . The flexible sealing member also encapsulates the drive shaft 16 , or at least forms a pressure seal with the bottom of the drive shaft 16 , so that the drive shaft can traverse in and out of the chamber 30 with no loss of pressure within the chamber 30 .
The top lid 30 a of the chamber includes a gas inflow valve 36 through which nitrogen or other purging gas (such as helium or oxygen, for example) is inputted to pressurize the chamber, which is generally pressurized to about 700±50 Torr at the bake pressure. Pressurization of the chamber insures a positive pressure always exists during heating processes, so that when a wafer is placed into or removed from the chamber, there is an outflow of the purge gas which prevents possible inflows of contaminants. Also, the pressurized purge gas increases the efficiency of heat transfer within the chamber. A sensor 38 , which may be an infrared transmitter or other optical type of sensor, is also provided in the top lid 30 a and is aligned with holes in the supports interconnecting the heater plates 12 . In the case of an infrared transmitter 38 , an infrared receiver 40 is aligned therewith on the bottom 30 b of the chamber. This sensor system is used to detect when a wafer is out of alignment with its intended position in the heater, and is discussed in more detail below.
A motor 50 having an extendable and retractable motor drive shaft 52 is provided for traversing the bake chamber assembly. The motor is actuated and controlled by a computer controller 60 so that motor drive shaft 52 engages the drive shaft 16 and extends to raise the position of the bake chamber assembly 10 with respect to the chamber 30 , while retracting to lower the position of the bake chamber assembly 10 relative to the chamber 30 . In the configuration of FIG. 8, the motor 50 is mounted in the lift bracket 51 , to simultaneously actuate both bake chamber assemblies. The motor 50 may be a stepper motor, such as a five phase stepper motor available from Oriental Motors, 291 Beach Road, Singapore, where precise positioning of the bake chamber assembly can be controlled by the stepper motor without the need for any additional position sensor. Alternatively, other motors or drivers may be employed along with a position sensor that may be placed on the motor drive shaft 52 or drive shaft 16 , or anywhere else on the movable bake chamber assembly, with feedback to the controller 60 , which would then control inputs to the motor 50 for precise positioning of the bake chamber assembly 10 .
The chamber 30 includes a robot door 42 , which may be a remotely controlled slit valve or the like as is generally known in the art. The robot door 42 is controlled by controller 60 to open to allow an insertion or removal of a wafer, and then to close after that operation is complete, to reseal the chamber 30 and allow the purge gas to repressurize the interior of the chamber 30 .
Turning to FIG. 2, a top view of a thick film heater plate 12 is shown. Heater plate 12 includes a substrate or plate 12 a that forms the base of the plate. A thick film heater 12 b is printed on the plate 12 a to form the thick film heater plate. (Thick film heaters are available from Watlow Industries, Hannibal Missouri). The thick film heater 12 b includes an electrically resistive circuit which covers a substantial portion of the surface of the plate 12 a , and a pair of electrodes 12 d connected to the circuit 12 c , which are adapted to connect with a power source. Since no embedding or additional layer to house a tube type of electrode is required with this arrangement, the thick film heater plates can be manufactured about one order thinner than conventional heater plates. For example, conventional aluminum or ceramic heater plates are generally on the order of greater than 0.50″ and usually at least around 0.7″ thick. In contrast, thick film heater plates for purposes of this invention can be produced having a thickness of less than 0.5″ and typically about 0.125″ and thinner. For heating applications at about 400° C., the thickness may be as little as about 0.08″, and for heating at about 200° C., the thick film heater plates 12 may be even thinner, as thin as about 0.05″.
The fact that the thick film heater plates 12 are substantially thinner than conventional heater plates results in several advantages of the present invention over conventional bake chambers. Being one order thinner also translates into a one order smaller heat mass. Thus, the response time for temperature control and temperature changes is much faster than that of ordinary heater plates. Also, the heat loss and power consumption of thick film heater plates 12 is substantially lower than conventional heater plates. This leads to a reduction in the cost of production, increased throughput, and less energy consumption. Thick film heaters can be printed on many different substrates, including, but not limited to, stainless steel, aluminum, alumina, ceramics, quartz, etc. This increases design flexibility in the ability to meet different temperature and chemical compliance requirements.
Since the thick film heater plates 12 are substantially thinner than conventional heater plates, more of them can be stacked in the same chamber than could conventional plates, thereby providing an increased number of slots 18 to receive wafers 22 and increasing throughput. For example, a chamber that can contain enough conventional heater plates to form only three slots can contain enough thick film heater plates to form six slots. On a slot to slot comparison (a slot is a compartment for receiving a wafer, formed by stacking one heater plate on top of another) a stack of thick film heater plates has a much lower height and the distance between slots is much smaller, compared to the conventional arrangement. This reduces the travel requirements for the drive mechanism required to align each slot with the robot door. The result is increased accuracy, for any time the drive is out of alignment in the least, the degree of misalignment is amplified as the travel distance increases. Additionally, a shorter travel drive unit is less space consuming and less expensive to produce than what is needed for the conventional arrangement. Also, the elongation requirements of the bellows 34 are less stringent, reducing the number of folds in the bellows needed, thereby reducing the opportunity for failure of this component. The lower mass of the thick film heater plates lowers the amount of power required for the motor/driver 50 , which also lowers costs. The cost of producing a thick film heater plate itself is significantly lower than the cost of a conventional heater plate, costing around $1,000 or less compared to $4,000-$5,000 for a conventional heater plate.
FIG. 3 is an isolated, perspective view of a bake chamber assembly 10 isolated from the chamber of the heater. The thick film heater plates 12 are stacked one on top of another and interconnected by supports 70 , which may be ceramic iso blocks, or other substantially non-conductive and structurally supporting material. The thickness of the supports 70 establishes a slot 18 in between each adjacent pair of thick film heater plates for receiving a wafer therebetween. A heater base 16 ′ is provided at the free end of drive shaft 16 for engaging the drive shaft 52 of the drive motor 50 . Although an arrangement of seven thick film heater plates 12 is shown (thereby forming six slots 18 ), it is noted that the present invention is not limited to such number, as fewer or greater numbers of thick film heater plates can be stacked in a bake chamber assembly 10 to form the desired number of slots. A cutout 26 is provided in each thick film heater plate 12 to facilitate the circulation of the purge gas through the chamber. The cutouts 26 are preferably arranged in an alternating manner, such that a cutout 26 of any plate 12 appears on an opposite side (e.g., is diametrically opposed) to the cutouts 26 of the plates 12 immediately adjacent it. This type of arrangement acts to direct the flow of the purge gas across the surfaces of the plates 12 (and thus also any wafers 22 in slots 18 ), forming a much more effective purge.
FIG. 4 is a partially exploded view of a bake chamber assembly 10 , absent the drive shaft 16 . Supports 70 are formed in a stepped, or “L-shaped” design, where the thicker portion 70 a of the support contacts thick film heater plates 12 on both sides and establishes the spacing between the plates 12 to form the slots 18 . The thinner portion 70 b of each support 70 forms a support or pedestal 70 b upon which the wafer 22 is supported when it is inserted into the slot 18 . This maintains the wafer 22 out of direct contact with the underlying heater plate 12 and at a desired distance between both heater plates 12 above and below the wafer so that heating and temperature control operations are much more consistent and are applied through convection and radiant heat, rather than a direct heat transfer. Another benefit is that a pin lift system is not needed to raise the wafer to allow access by the robot blade, as the pedestal supports 70 b leave enough space underlying the wafer to allow the robot blade to access the slot and then pick the wafer 22 off the pedestal supports 70 b , and remove the wafer through the robot door 42 , without the need for any mechanism to lift the wafer for access clearance. Conversely, the robot arm can also insert a wafer 22 into a slot 18 (after having gained access through robot door 42 ), lower the wafer 22 onto the pedestal supports, thereby separating contact between the robot arm and wafer 22 , and withdraw from the chamber through the robot door, again without any need for a mechanism to receive the wafer 22 and lower it onto a support.
FIG. 5 is a blown up partial view of the bake chamber assembly in FIG. 4, showing the area outlined in FIG. 4, V. An assembly which provides the electrical connections between the thick film heater plates 12 is shown. Bores 72 are provided in the insulating supports 70 and are dimensioned to receive terminals 74 with a close fit. Terminals 74 may be formed of copper or other relatively good conducting metal or material which is also nonreactive in the environment for which it is designed. The large diameter end 74 a lies substantially flush with the surface of the support 70 , or extends minimally therefrom, to contact a terminal 12 d of a thick film heater plate when is assembled on top of the supports 70 . An insulator sleeve 76 fits over a portion of the reduced diameter part 74 b of terminal 74 to continue the insulation provided by supports 70 . The end portion of the reduced diameter part 74 b extends beyond the insulator sleeve and is dimensioned for a close, contacting fit with bore 74 c provided in the large diameter end 74 a (of another terminal 74 ). Thus, the terminals form a continuous, electrically conducting column when assembled upon one another, by the contact provided between a reduced diameter end 74 b of an overlying terminal 74 , with a large diameter end 74 a of an underlying terminal 74 via bore 74 c . This “peg in hole” interfit at the same time provides lateral structural support to the stack. Upon assembly of the entire stack, the plates are further secured together using a conventional clamping mechanism. For example, a rod can be passed through each side of the stack and a wave washer can be applied against the plates at both (or only one of) the top and bottom of the stack, with a nut or other compression fixture applying a clamping pressure against the wave washer(s) to maintain a compressive force against the plates and supports to maintain them as a unit.
Alternatively, the thick film heater plates may be provided with Luvatech™ connectors (available from AMP, Cupertino, Calif.) fixed to terminals 12 d . This type of an arrangement allows easy assembly of the stack, as the Luvatech connectors are spring loaded and clamp to an electrically conductive rod that can be passed through the connectors to form the stack. This way, one or more heater plates may be added, removed or exchanged without dismantling the entire stack.
FIG. 6 is a further exploded partial view of a bake chamber assembly which shows that the supports 70 are provided with pegs 70 c , extending from the bottom surface of the support, that are dimensioned to pass through holes 12 e in plates 12 and interfit with holes 70 d in an underlying support 70 (or, in the case of the supports 70 which sit directly on the support plate 14 , in holes provided in the support plate 14 (not shown) to provide further structural stability as well as to insure proper placement of the plates 12 with respect to the supports 70 .
FIG. 7 is a partial assembly view of a dual chamber heater assembly 100 , absent the chambers. The construction of the bake chamber assemblies 10 is essentially the same as that described above, however, two assemblies are ganged together in this arrangement, so that a single robot having a pair of arms can service twice as many process chambers in tandem, for increased production. A single drive motor 50 is mounted in lift bracket 51 for raising a lowering the pair of stack assemblies in tandem. Each chamber is provided with a robot door 42 for access thereto to input and extract substrates. Although not shown, a single controller may be connected to both bake chamber assemblies for the tandem operation thereof. Of course, separate and independent controllers, motors and robots could be provided, if one so desired, although it would be commercially less cost effective.
FIG. 8 is a perspective view of a dual chamber heater assembly 100 ′, absent a top plate. The assembly 100 ′ varies slightly from assembly 100 in design, in that the robot doors 42 are oriented at a slight angle to one another. Both bake or heater chambers 30 are pressure controlled by a single pump input which normalizes the pressure in both chambers. The two chamber are preferably machined from a single block of aluminum to form the two assembly, “ganged” unit. Only one bellows 34 is shown in FIG. 8, for contrast with the drive shaft 16 , shown without the bellows. Of course, each drive shaft, during operation, would be surrounded by a bellows 34 or other flexible sealing mechanism.
The following example is 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 is not intended to limit the scope of what the inventors regard as their invention nor is it intended to represent that the arrangement below is the only arrangement experimented with. 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
A multi-slot bake chamber is assembled with a stack of seven thick film heater plates, separated by six sets of supports to form six slots. Another set of supports separates the bottom thick film heater plate from a support base which is mounted to a drive shaft that extends through the chamber. A remotely controlled robot arm is provided to access each of the slots as the slots are aligned, via a motor and the drive shaft, with a robot door in the chamber. The controller opens the door to allow such access. Three processing chambers (in this example, CVD chambers) are also accessible by the robot arm. Therefor the robot arm can move wafers between any of the three processing chambers and the bake chamber.
Six wafers, originally at room temperature (e.g., about 25° C.) are loaded into the bake chamber, which has been set to heat to about 300° C. After a period of less than or equal to about 30 seconds, the wafers will have achieved a steady state temperature of about 300° C. and can be further processed. The robot door is opened and the robot arm is activated to remove a wafer from the bake chamber and transfer it to one of the CVD chambers. The same process is carried out for the other two CVD chambers which may be programmed to perform the same process step, or a different process step from the first CVD chamber. The chambers use a process temperature of about 480° C. in this example. When the wafers are placed on the chucks of the CVD chambers, they come to rest stably in their intended positions, and do not “dance” because the wafers are already in a preheated state.
Upon completion of a process step in one of the CVD chambers, the robot arm is activated to remove the wafer from the CVD chamber and return it to an empty slot in the bake chamber, where it will await further processing, or from where it can be removed after it has returned to about 300° C. Because the bake chamber has six slots, it will always have another wafer ready for processing in the CVD chamber from which it receives a wafer, thereby greatly enhancing throughput of the CVD chambers.
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. | A heating chamber assembly for heating or maintaining the temperature of at least one wafer, employs thick film heater plates stacked at an appropriate distance to form a slot between each pair of adjacent heater plate surfaces. The heating chamber assembly may be employed adjacent one or more processing chambers to form a preheat station separate from the processing chambers, or may be incorporated in the load lock of one or more such processing chambers. The thick film heater plates are more efficient and have a better response time than conventional heat plates. A chamber surrounding the stack of heater plates is pressure sealable and nay include a purge gas inlet for supply purge gas thereto under pressure. A door to the chamber opens to allow wafers to be inserted or removed and forms a pressure seal upon closing. The slots in the stack are alignable with the door for loading and unloading of wafers. The stack is mounted on a drive shaft that extends through the chamber where it interfaces with a drive that traverses the drive shaft in and out of the chamber to align various slots as desired. | 2 |
BACKGROUND
[0001] The present invention relates to a routing system of the type used for both primitive and temporary displays, sets, installations, and so forth wherein a light source is placed behind a panel or other transparent or translucent medium.
[0002] In the field of lighting systems, particularly those used for theater, television, film, and other sets, trade shows, building and outdoor displays, and the like, certain known and reliable systems have been used for many years. For example, a backdrop is commonly used, which may comprise a rigid or flexible panel on which graphics or pictures are printed. Such panels may be hung behind a scene or set. In other applications, such as tradeshows, posters and panels may be hung or mounted in various locations in a display structure or installation. In theater, television, and film lighting, lights and systems that are sometimes referred to as “sky pans”, “cyclorama or cyc lights” or floodlights may be disposed behind the panel, and powered to illuminate all or a portion of the panel. In many applications the panel is transparent or translucent to allow the graphics or image to be brightly illuminated by the backlighting. Such lighting is generally quite effective, but has definite drawbacks. For example, sky pan lights may need to be placed as much as 10 to 12 feet behind the panel. Moreover, depending upon the size of the light and the area illuminated, power ratings may range to approximately 4 kA or higher. The resulting lighting is thus hot, energy intensive, and space-consuming.
[0003] Moreover, such lighting systems are somewhat difficult to handle and tedious to displace and store after use or between uses. Where periodic changes are made to scenes or backdrops, or where the entire application may need to be moved to another location, current lighting systems must be carefully packed, along with supporting cords and structures, moved to a storage or new location, and carefully unpacked and set up. The systems tend to be large and heavy, making all of these operations more difficult.
[0004] There is a need, in this field, for improvements in lighting systems and methods that may at least partially address the drawbacks of current technologies.
BRIEF DESCRIPTION
[0005] The present disclosure sets out a new form or lighting system designed to respond to such needs. The system may include a flexible support configured to be suspended from a support structure, a plurality of tubular light sources held generally horizontally and parallel to one another by the flexible support, and electrical cabling coupled to the plurality of light sources to provide power to the light sources during operation.
[0006] In accordance with other aspects, the system may include a plurality of tubular light sources arranged in a ladder-like arrangement and held generally horizontally and parallel to one another by a flexible support that is configured to be suspended from a support structure during use, and collapsed for storage or movement. Electrical cabling is coupled to the plurality of light sources to provide power to the light sources during operation, the cabling comprising a first connector adjacent to a first point of the lighting system and configured to receive incoming power for the tubular light sources, and a second connector adjacent to a second point of the lighting system and configured to allow power to be passed along to another lighting system.
[0007] In accordance with still further aspects, the lighting system may comprise a plurality of modular lighting assemblies. Each modular lighting assembly comprises a plurality of tubular light sources arranged in a ladder-like arrangement and held generally horizontally and parallel to one another by a flexible support that is configured to be suspended from a support structure during use, and collapsed for storage or movement. Electrical cabling is coupled to the plurality of light sources to provide power to the light sources during operation. The cabling comprises a first connector adjacent to a first point of the lighting system and configured to receive incoming power for the tubular light sources from a power source or from another of the modular lighting assemblies, and a second connector adjacent to a second point of the lighting system and configured to allow power to be passed along to another of the modular lighting assemblies.
DRAWINGS
[0008] These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
[0009] FIG. 1 is an illustration of exemplary set or display lit in accordance with aspects of the present techniques;
[0010] FIG. 2 is a diagram of the same display from a rear side;
[0011] FIG. 3 is a side view of the display illustrating a front panel and a rear light assembly in accordance with aspects of the present techniques;
[0012] FIG. 4 is a diagrammatical representation of a series light tubes used in the system, illustrating exemplary physical configurations and arrangements for lighting a panel;
[0013] FIGS. 5-11 are diagrammatical representations of different modular configurations in which the light assemblies may be used;
[0014] FIGS. 12 and 13 are detailed views of an exemplary arrangement for holding and orienting light tubes in a collapsible assembly; and
[0015] FIG. 14 is an illustration of a straightforward manner in which the lighting system may be packed and unpacked for storage and relocation.
DETAILED DESCRIPTION
[0016] Turning now to the drawings, FIG. 1 illustrates a lighting system 10 that may be suitable for applications such as television and theater sets, film sets, tradeshows, and any one of the range of permanent, semi-permanent and temporary settings. In the illustrated embodiment a light assembly 12 is disposed behind a panel 14 . The panel may be transparent or translucent, and may have components, graphics, scenes, or any desired feature drawn, applied, printed, painted or otherwise disposed on one or both sides thereof. The panel may also be colored or formed so as to provide any desired effect when light traverses or falls on the panel from the light assembly 12 . The light assembly itself includes a series of parallel light tubes 16 , in this case arranged horizontally behind the panel. As discussed in more detail below, each of the light tubes may comprise a series of light emitting diodes that create and project light towards the panel when powered. The light source or sources within the tubes may be powered by one or more circuits (e.g., transformers, drive circuits, power converters, etc.) either within the tubes or external to the tubes. The light tubes are supported on a flexible support structure indicated generally by reference numeral 18 . In the embodiment illustrated in FIG. 1 , two flexible supports extend upwardly from the light assembly and may be secured to a mechanical support 20 , such as a bar over which the flexible support structures pass. Also visible in FIG. 1 is one or more power cables or harnesses 22 that allow for application of power to the light tubes.
[0017] The same structure is illustrated in FIG. 2 from a rear side. As noted above, the light assembly 12 comprises a series of light tubes 16 supported in a parallel arrangement by a flexible support structure 18 . The panel 14 is placed adjacent to the light assembly and light from the assembly shines onto the panel as described more fully below. In the illustrated embodiment the flexible support structure comprises flexible vertical components that receive and support light tubes. These elements may be made of fabric, webbing, or any suitable flexible (i.e., collapsible) material, or a series of segments that can be easily hung and collapsed. Moreover, these elements of the support structure may include pockets that receive and support the light tubes, parallel webs with bridge-type members that are disposed under the light tubes, slots through which the light tubes pass, or any other suitable support. Effectively, then, the light assembly 12 is a hanging structure that is held by the bar 20 or any suitable upper mechanical support, with the light tubes being positioned in the flexible support structure 18 and held in place, in the generally parallel arrangement by gravity. One or more weights or other lower supports could also be used to maintain the system taut or stable once deployed. Accordingly, the entire arrangement is fully flexible, collapsible, easily packaged, and so forth as discussed below. In the currently contemplated embodiment, the power cables or harnesses provide power to the light tubes and may terminate in one or more corners of the light assembly with a male and/or female connector. For example, in a currently contemplated embodiment, at a lower corner of the light assembly a male electrical plug is provided that can be plugged into a grid outlet or extension cord (or other power source). Moreover, a female receptacle may be provided at a corner of the light assembly and coupled to the power cable so that power may be passed to one or more other light assemblies in a pass-through manner as discussed below.
[0018] FIG. 3 is a side view of the light assembly and panel of the previous figures. The light system 10 here again includes the light assembly 12 disposed adjacent to the lit panel 14 . In general, as discussed above, the light assembly will be placed in back of the panel 14 , although in some embodiments similar light assemblies may be placed in front of, between, on top of or below similar panels, or in various curved configurations with respect to the panels. As mentioned above, the light assembly may form a module that may be used singly or with other similar modular light assemblies. In this modular approach, while the light assemblies may be different, they are conveniently identical, having the same number of light tubes and dimensions. In the illustrated embodiment, for example, 14 parallel light tubes are provided at equal spacings as indicated by reference numeral 26 in FIG. 3 . Typical spacings may be, for example, between 6 inches and 12 inches. Unlike conventional high powered spotlights, moreover, the light assembly may be placed relatively close to the panel as indicated by dimension 28 in FIG. 3 . By way of example, in currently contemplated embodiments, the light assembly is placed between 6 inches and 24 inches from the panel (rather than distances on the order of 4 to 8 feet for conventional lighting systems).
[0019] FIG. 4 is a detailed illustration of exemplary spacing and illumination by the light tubes. As noted above, while any suitable light tube may be employed, in currently contemplated embodiments each light tube comprises a cluster of light emitting diode (LED) chips (not separately shown) with a backing 30 . The LED chips are configures so that light is effectively directed toward a forward face of the light tube. In the light tubes used in current embodiments, one or more electrical circuits are provided for converting AC power fed to the power cable to DC power for the individual light chips. These light chips may be designed to be powered, for example by 12 or 24 vDC, although any suitable power rating may be employed. Suitable light tubes may be obtained, for example, from Mac Tech LED under the designation TL6036WW. Moreover, the light tubes used in present embodiments have a luminous flux rating of approximately 3200 k lumen and a beam angle of approximately 120 degrees.
[0020] As shown in FIG. 4 , the spacing 26 between the light tubes, along with the spacing 28 between the light assembly and the panel 14 preferably allow for some degree of overlap between the illuminated regions 32 of each light tube. That is, to provide even and consistent lighting of the panel, each light tube emits a region of illumination 32 that overlaps in adjacent area 34 as they approach the panel. In presently contemplated embodiments the overlap may comprise the full or nearly full combination of two adjacent light tubes, or more than two light tubes may contribute to overlapping regions.
[0021] FIGS. 5-11 illustrate diagrammatically a series of embodiments in which the lighting system is used in a modular fashion with different arrangements of panels, typically for different settings and sizes. FIG. 5 , for example, shows a single modular arrangement with a flat panel. This simple arrangement, designated by reference numeral 36 , corresponds to the embodiments of FIGS. 1 and 2 . In FIG. 6 , a curved arrangement 38 includes a panel 14 that is arched or curved with respect to the light assembly. This curve could be convex with respect to the light assembly as shown in FIG. 6 or concave, or the panel could be arranged in a wavy fashion. FIG. 7 illustrates a modular arrangement 40 in which two light assemblies 12 are used to light a single panel 14 . As noted above, in such arrangements, the light assemblies may be identical to one another in size, configuration, and lighting capacity, or could be different. FIG. 8 is shows a similar but larger arrangement 42 in which a series of four light assemblies are used to light a large curved panel.
[0022] FIGS. 9 , 10 and 11 show various ways in which modular panels may be interconnected to facilitate installation and powering. In FIG. 9 , a side-by-side arrangement 44 comprises two identical light assemblies 12 . Powers supplied at a lower corner of a first light assembly as indicated by reference numeral 46 (e.g., via a male plug as discussed above) and at an upper corner of the same panel power is transmitted to an adjacent panel as indicated by reference numeral 48 . This may be accomplished, for example, by a female connector at the top of the first panel that joins a male connector at the top of the second. In this same arrangement, a lower connector may be provided for passing power through a subsequent panel, as indicated by reference numeral 50 . It should be noted, however, that the placement and type of electrical connections may be varied, and these may be provided along the top, bottom, mid-points, or at any suitable location in the light assembly.
[0023] FIG. 10 illustrates a similar arrangement in which two panels 12 are provided in upper and lower positions. Here again, power is received in a first panel as indicated at reference numeral 46 , and is passed to a second panel by an interconnection 48 . In FIG. 11 a matrix or array of light assemblies is provided, with incoming and interconnecting power as discussed above. It should be noted that in upper and lower, and matrix-type arrangements, the support structures of the light tubes may be such that one entire light assembly may be simply hung onto an upper light assembly without additional mechanical supports being required.
[0024] In presently contemplated configurations, the light tube support structure 18 is made of webbing material with loops to receive and secure the light tubes as generally illustrated in FIGS. 12 and 13 . As shown in FIG. 12 , a length of webbing 54 has loops 56 secured to a face, such as via stitching 58 . The webbing may be made of any suitable material, such as a durable fabric. The loops 56 may be made of the same or another material, but in a present embodiment, they are made of an elastic fabric. A loop portion 60 forms an opening 62 through which the light tubes may be inserted, as shown in FIG. 13 . The resulting structure will not only hold the light tubes in place, but will provide a secure orientation of the tubes so that the light sources within each tube will remain properly directed as described above. It has been found that tension on the webbing and loops as the system is raised into position aids at securely holding and orienting the light tubes.
[0025] As noted above, the lighting system allows for easily collapsing the entire flexible structure for disassembly, storage and transport. As illustrated in FIG. 14 , for example, one or more of the light assemblies may be positioned in a collapsed arrangement 64 within a storage or transport crate or trunk 66 . The entire assembly will then be self-contained, and could be extracted, mounted and used following very straightforward removal as indicated by arrow 68 in FIG. 14 . In presently contemplated embodiments, all circuitry and power cabling is pre-assembled in the light assembly, as discussed above, so that take-down and set-up are greatly facilitated. Moreover, importantly, rather than the complex special shipping arrangements required for transport of conventional lighting systems, the collapsible structure described allows for much smaller and simple packaging that can be transported more compactly and via commercial carriers.
[0026] While only certain features of the invention have been illustrated and described herein, many modifications and changes will occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention. | A lighting system comprises a flexible support, such as a pair of fabric or web-like strips, and a plurality of tubular light sources supported by the flexible support. The flexible support may be hung from a support structure, and the tubular light sources will hang generally parallel to one another. Each tubular light source may include a plurality of LED chips, and power supply or conversion circuitry may also be disposed in the tubular light sources. Power cabling extends to the light sources, and may be adapted to provide pass-through power to other, similar assemblies to form a modular system. The assemblies may be easily deployed and repacked for storage and movement. The system is suitable for large area lighting, particularly with panels used for theater, television, and film sets, or with displays, trade show installations, and so forth. | 5 |
This is a Continuation of application Ser. No. 08/520,186, filed Aug. 28, 1995 now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to improvements in a method and apparatus for surface-grinding of a workpiece or workpieces, for example, ceramic wafers, quartz wafers, semiconductor wafers and the like (hereinafter also referred simply to as wafers).
2. Description of the Prior Art
A conventional processing method used for a workpiece or workpieces, for example wafers, comprises, as shown in FIG. 6:
a slicing step A, in which a cylindrical semiconductor ingot or cylindrical semiconductor ingots are cut (or sliced) into wafers, each in the shape of a thin plate, by a wire saw, a circular inner peripheral blade or the like;
a chamfering step B, in which the peripheral edge portions of each sliced wafer are removed in order to prevent chipping along the periphery;
a lapping step C, in which both sides of each chamfered wafer are lapped for correcting the thickness and flatness;
an etching step D, in which the whole surface of each lapped wafer is etched by dipping it into an etching solution in order to eliminate the work damage; and
a polishing step E, in which each etched wafer is mirror-polished across one side or the two sides to improve the surface roughness and flatness.
The cross-sectional views of wafers processed in the conventional method shown in FIG. 6 are shown, in sequence of the processing steps, in FIG. 9(a) to FIG. 9(d).
In the figure,
SW denotes a sliced wafer just after completion of the slicing step,
LW denotes a lapped wafer just after completion of the lapping step,
EW denotes an etched wafer just after completion of the etching step, and
PW denotes a polished wafer just after completion of the polishing step.
The surface irregularity and curvatures of wafers in FIG. 9(a) through FIG. 9(d) are respectively the waviness and bows drawn in their stressed forms.
The wafer SW just after completion of the slicing step has a form including waviness and bow. This occurs by the reason that a cutting edge does not necessarily advance in a straight line due to delicate imbalance of cutting resistances on either side of the cutting edge.
The contour of a relatively large cycle like those of a bowl or an S character is called Bow and that of repeated irregularity with a small cycle on the order of several mm is called Waviness.
When a wire saw or a circular inner peripheral blade is used, waviness and bow occurs in both cases. But waviness is easier to occur and becomes a problem especially when a wire saw is used. A wafer just after slicing has a chance to have bow due to work damage. At this time it is necessary to slightly etch the wafer surface.
In the current general wafer processing method as shown in FIG. 6, the lapping step C has a function to improve waviness but it has been difficult to correct bow because of easy elastic deformation of a wafer (FIG. 9(a) to FIG. 9(d)).
As the integration levels of semiconductor devices have recently risen, the semiconductor wafers as substrates have had the demand for a higher flatness level.
In order to obtain a wafer or wafers each with a high precision form of this higher flatness level, it is necessary to put surface-grinding into the process.
When this surface-grinding is desired, the following methods may be used, which are:
a processing method shown in FIG. 7 (a slicing step A--a surface-grinding step H--a chamfering step B--a polishing step E.) or
another processing method shown in FIG. 8 (a slicing step A--a chamfering step B--a lapping step C--an etching step D--a surface-grinding step H--a chamfering step B2--a polishing step E).
Here the surface-grinding step H is the one in which a publicly known surface-grinding apparatus 20 as shown in FIG. 12 is used.
In FIG. 12, 22 denotes a grinding stone, 24 denotes a fixedly supporting means and W denotes a workpiece such as a wafer.
In the processing method shown in FIG. 7, the lapping step is omitted and the method is better in terms of processing due to the simplification in processing steps.
If surface-grinding is conducted, however, with a surface-grinding apparatus adopting a conventional way for fixedly supporting a wafer or wafers (for example, the way in which the wafer or wafers are vacuum-sucked onto a rigid chuck table like a porous ceramic plate or the like), there was a problem that waviness and bow of each wafer are almost never improved due to elastic deformation during suction.
A conventional surface-grinding technique applied to the processing method of FIG. 7 comprises, for example as shown in FIG. 10(a) to FIG. 10(i):
(a) a step, in which a wafer SW just after completion of a slicing step (FIG. 10(a)) is fixed by chucking to a vacuum-chuck means 12 by the lower surface (FIG. 10(b));
(b) a step, in which the upper surface of the fixed wafer SW is surface-ground (FIG. 10(c));
(c) a step, in which the wafer, the upper surface of which has been surface-ground, is released from the vacuum-chuck means 12 (the waviness and bow of a wafer HW1, the upper surface of which has been surface-ground, remains uncorrected as they were) (FIG. 10(d));
(d) a step, in which the wafer HW1, the upper surface of which has been surface-ground, is turned upside down (FIG. 10(e));
(e) a step, in which the turned wafer HW1 is fixed by chucking to the vacuum-chuck means 12 by the upper surface (FIG. 10(f));
(f) a step, in which the lower surface of the fixed wafer HW1 is surface-ground (FIG. 10(g));
(g) a step, in which the wafer HW2, both surfaces of which have been surface-ground, is released from the vacuum-chuck 12 (the waviness and bow of the wafer HW2, both surfaces of which have been surface-ground, remains uncorrected as they were.) (FIG. 10(h)).
In FIG. 10(a) to FIG. 10(i), HW1 denotes a wafer, one of the surfaces of which is surface-ground and HW2 denotes a wafer, both surfaces of which are surface-ground.
Thereafter, the wafer, both surfaces of which have been surface-ground, is polished, but the waviness and bow remain on this polished wafer PW, as shown in a view (FIG. 10(i)).
In this manner, if the conventional surface-grinding technique is simply introduced, waviness and bow of a wafer or each of wafers remain even after polishing and the quality of the wafer or wafers is greatly deteriorated.
Therefore, the method shown in FIG. 7 and FIG. 10(a) to FIG. 10(i) was not put to practical use.
A wafer processing method as shown in FIG. 8 has been proposed in addition to that of FIG. 7 and FIG. 10(a) to FIG. 10(i), as a processing method including a surface-grinding technique, as described above.
The processing method of FIG. 8 is a modification of the conventional method of FIG. 6, which includes additionally a surface-grinding step H and a second chamfering step B2 after the etching step D.
The case in which a conventional surface-grinding technique is applied to the processing method of FIG. 8 is shown in FIG. 11(a) to FIG. 11(g).
In FIG. 11(a) to FIG. 11(g), the same marks as those in FIG. 10(a) to FIG. 10(i) are denoted the same members as those in FIG. 10(a) to FIG. 10(i).
The method shown in these FIG. 8 and FIG. 11(a) to FIG. 11(g) had an advantage that waviness was eliminated from a wafer, but had disadvantages that the number of the steps increased and thereby manufacturing cost was raised.
Therefore, the current surface-processing step is usually conducted by a lapping treatment and a surface-grinding technique using a surface-grinding machine and has difficulty in being introduced into an actual wafer manufacturing process, despite of the advantage of being able to process a wafer or wafers each with less dispersion of thickness.
On the other hand, by means of the lapping step used in the processing methods of FIGS. 6 and 8, waviness is improved as shown in FIG. 9(a) to FIG. 9(d) and FIG. 11(a) to FIG. 11(g), but improvement of bow is not expected very much and thus no effective elimination method of bow was available in the past.
SUMMARY OF THE INVENTION
The present invention was made in view of the above-mentioned problem.
It is an object of the present invention to provide a method and apparatus for surface-grinding of a workpiece or workpieces which makes it possible to correct and improve waviness and bow, to obtain a workpiece or workpieces without thickness dispersion, further to conduct processing of a workpiece or workpieces to higher precision than in the past, still further to simplify the processing method and to realize reduction of the processing cost.
The present invention is a surface-grinding method for a workpiece or workpieces, which is devised to solve the above-mentioned problem, wherein a first surface of the workpiece or each of the workpieces is fixedly supported by the fixedly supporting means of a surface grinding apparatus and a second surface of the workpiece or workpieces is surfaced ground, characterized in that the workpiece or workpieces are fixed by the aid of adhesive material on a base plate and the plate is fixedly supported by its own lower surface on the fixedly supporting means.
The surface-grinding method of the present invention will be described further in a more concrete manner.
It comprises:
(a) a step, in which a workpiece or workpieces are fixed at one surface thereof to the upper surface of a base plate by the aid of adhesive material;
(b) a step, in which the base plate is fixed for supporting by the lower surface of itself on a fixedly supporting means;
(c) a step, in which the other surface of each of the workpieces fixedly supported is surface-ground;
(d) a step, in which the base plate and the workpiece or workpieces, the other surface of each of which has been surface-ground, are released from the fixedly supporting means;
(e) a step, in which the workpiece or workpieces, the other surface of each of which has been surface-ground, are separated from the base plate;
(f) a step, in which the workpiece or workpieces, the other surface of each of which has been surface-ground, is turned upside down;
(g) a step, in which the workpiece or workpieces are fixedly by the other surface of each, which has been surface-ground, on the fixedly supporting means;
(h) a step, in which the one surface of each workpiece, by which it was first fixedly supported, is surface-ground; and
(i) a step, in which the workpiece or workpieces, both surfaces of each of which have been surface-ground, are released from the fixedly supporting means.
Wax, adhesive, gypsum, ice or the like can be used as the above-mentioned adhesive material.
In the state of a wafer after separation from a base plate, these adhesive materials are attached to the lower surface of the workpiece.
When they are a hindrance to surface-grinding work, it will be enough if they are removed by respective removing agents. In case of ice, all that is required is to melt the ice off by heating. In another case of an attachment like gypsum, the workpiece can be surface-ground while it is attached on the lower surface.
It is preferred to use a vacuum-chuck means as the above-mentioned fixedly supporting means for a workpiece or workpieces but a mechanical chuck means or an electro-magnetic chuck means can also be used.
On the other hand, the present inventive apparatus is a surface-grinding apparatus comprising a surface-grinding means and a fixedly supporting means. In the apparatus a workpiece or workpieces are fixed at one surface thereof to the upper surface of a base plate by the aid of adhesive material, the adhering composite of the workpiece or workpieces and the base plate is fixed by the lower surface of the plate on the fixedly supporting means and in this state the other surface of each of the workpieces is surface-ground.
In addition, surface processing of a workpiece or workpieces can be effectively conducted by application of the surface-grinding method of the present invention as the surface-grinding step in a surface processing method of a workpiece or workpieces comprising:
a slicing step, in which a raw material ingot or raw material ingots are cut into workpieces;
a surface-grinding step, in which each sliced workpiece is surface-ground;
a chamfering step, in which each surface-ground workpiece is chamfered;
a polishing step, in which each chamfered workpiece is polished.
The surface-grinding method of the present invention is well applied especially in case of the use of a wire saw, which is subject to occurrence of waviness in a slicing step. It is also applicable to the cases where any cutting means, such as a circular inner peripheral blade or a band saw, is used.
When there is the bow due to work damage in a workpiece just after a slicing step, it is preferred to conduct etching on the surface of the workpiece prior to the surface-grinding step.
A supplying means for molten adhesive material, for example, molten wax, hot-melt adhesive or the like into each gap between a base plate and a workpiece or workpieces may comprise:
a storage tank, in the interior of which molten adhesive material is stored;
a pressure means, by which a internal pressure is given to the storage tank;
a pipe means, through which the molten adhesive material is transported under pressure from the storage tank;
a pair of an upper heating means and a lower heating means, both of which face each other.
The operation is conducted as follows: The base plate is placed on the lower heating means, the workpiece or workpieces are placed on the base plate, then the workpiece or workpieces and plate all are heated by both of the heating means.
And the molten adhesive material is supplied into each gap between the base plate and each workpiece being heated, by way of the pipe means, under an internal pressure in the storage tank by the pressure means.
According to the supplying means and operation above, the base plate and each workpiece can adhere to one another without a bubble between each gap.
As a workpiece used in the present invention, a semiconductor wafer and the like are used up as examples.
The present invention realizes a fixing technique that a workpiece or workpieces, for example wafers, having waviness and bow are fixed on the working table of a surface-grinding apparatus, such as a surface-grinding machine, while the waviness and bow are kept as originally occurred, that is, uncorrected.
The fixing technique, thus, makes it possible to attain a wafer or wafers of good flatness by surface-grinding.
In concrete terms, a wafer or wafers are fixed on a thick and rigid base plate by the aid of adhesive material, such as wax, and the base plate is then chucked to a surface-grinding machine by means of a vacuum chuck means.
Since the adhesive material fills each gap between the base plate and each wafer, the wafer or wafers are supported without any deformation and can be surface-ground to the surface of good flatness.
In the next stage, if the wafer or wafers are chucked by the surface of good flatness of each on a vacuum chuck means and the other surface of each is surface-ground, the wafer or wafers without waviness, bow and thickness dispersion can be manufactured.
BRIEF DESCRIPTION OF THE DRAWINGS
Further objects and advantages of the present invention will be apparent from the following description, reference being made to the accompanying drawings wherein preferred embodiments of the present invention are clearly shown.
In the drawings:
FIG. 1(a) to FIG. 1(i) are illustrative views showing an example of a process in a surface-grinding method according to the present invention;
FIG. 2 is a schematically illustrative view showing an example of a surface-grinding apparatus according the present invention;
FIG. 3 is a schematically illustrative view showing an example of a supply apparatus for molten adhesive material according to the present invention;
FIG. 4 is a photograph showing the surface of a wafer sliced by a wire saw;
FIG. 5 is a photograph showing the surface of a wafer processed by surface-grinding according to the present invention;
FIG. 6 is a flow chart illustrating a conventional wafer processing method;
FIG. 7 is a flow chart illustrating an example of the wafer processing method in a case in which a surface-grinding step is introduced;
FIG. 8 is a flow chart illustrating another example of the wafer processing method in a case in which a surface-grinding step is introduced;
FIG. 9(a) to FIG. 9(d) are illustrative views showing changes, in sequence of steps, of the cross-sections of wafers which are processed in the process illustrated in FIG. 6;
FIG. 10(a) to FIG. 10(i) are illustrative views showing changes of the cross-sections of wafers which are processed in the process illustrated in FIG. 7, with some concrete views;
FIG. 11(a) to FIG. 11(g) are illustrative views showing changes of the cross-sections of wafers which are processed in the process illustrated in FIG. 8, with some concrete views; and
FIG. 12 is a schematically illustrative view showing a publicly known surface-grinding apparatus.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Below, an embodiment of the present invention will be explained on the basis of FIG. 1(a) to FIG. 1(i), through FIG. 5.
In FIG. 1(a) to FIG. 1(i), through FIG. 5, the same marks as those used in FIG. 6 through FIG. 12 are respectively used at the same members as or similar ones to those of FIG. 6 through FIG. 12.
In the following embodiment, the description is made about the case where a wafer is taken as a preferred example of the workpiece.
In FIG. 1(a) to FIG. 1(i), SW is a raw material wafer, which has been sliced by the use of a wire saw, not shown.
Surface irregularity drawn on both of the upper surface and lower one of the wafer SW (FIG. 1(a)) is a stressed view of waviness.
The generally curved form of the wafer SW is also a stressed view of bow.
A photograph of the raw material wafer SW, which has been sliced, is shown in FIG. 4.
The raw material wafer SW is fixed by the lower surface on the upper surface of a flat base plate 14 by the aid of adhesive material, such as wax, (Step (a), FIG. 1(b)), where the base plate 14 has to be a thick, rigid and flat plate.
As for adhesive materials other than wax suitably used in the method of the present invention are gypsum, ice and others as far as they work on a workpiece in the same way as wax does.
Then, the base plate 14, on which the wafer SW has been fixed, is fixed for supporting (by chucking) on a vacuum chuck means 12 by its own lower surface (Step (b), FIG. 1(b)).
As this vacuum chuck means 12, for example, the vacuum chuck means 12 of the surface-grinding machine 20 as shown in FIG. 2, similar to a conventional apparatus, is well used as it is.
As a fixedly supporting means for the base plate 14, the vacuum chuck means 12 is exemplified here, but it is natural that other publicly known fixedly supporting means are also applicable.
The upper surface of the wafer SW, which has been fixed on the upper surface of the base plate 14 chucked by the vacuum chuck means 12, is surface-ground (Step (c), FIG. 1(c)).
It will be enough if this surface-grinding is conducted by means of, for example, the surface-grinding means of the surface-grinding machine 20, that is, the grinding stone 22.
A wafer HW1, the upper surface of which has been surface-ground, is released from the vacuum chuck means 12 together with the base plate 14 (Step (d), FIG. 1(c)).
The wafer HW1, the upper surface of which has been surface-ground, is separated from the base plate 14 (Step (e), FIG. 1(d)).
At this time, since, on the lower surface of the wafer HW1, the adhesive material Y remains attached, this adhesive material Y is removed by a removing agent.
If ice is used, it is melted off by heating. In the case of adhesive material Y (for example gypsum), which is no hindrance against surface-grinding of the lower surface of the wafer HW1, a special removal treatment is not required, since the adhesive material Y can be removed concurrently with the surface-grinding.
The wafer HW1, the upper surface of which has been surface-ground, is turned upside down (Step (f), FIG. 1(e)).
The wafer HW1, the upper surface of which has been surface-ground, is chucked by its own upper surface on the vacuum-chuck means 12 (Step (g), FIG. 1(f)).
The lower surface of the wafer HW1, which has been fixed by chucking, is surface-ground (Step (h), FIG. 1(g)).
The wafer HW2, both surfaces of which have been surface-ground, is released from the vacuum-chuck means 12 (Step (i), FIG. 1(h)).
This wafer HW2, both surfaces of which have been surface-ground, is different from that processed by the conventional surface-grinding as shown in FIG. 10(h) and it is so well shaped that the waviness on the both surfaces is completely corrected, the thickness dispersion disappears and the bow is also corrected.
The surface photograph of the thus surface-ground wafer HW2 is shown in FIG. 5. As can be seen from the photograph, it is confirmed that the waviness and bow are completely removed.
The surface-ground wafer HW2 will be further processed by bevelling and polishing (FIG. 1(i)).
With the adoption of a surface-grinding method according to the present invention, a wafer or wafers which are free from waviness and bow, and free from thickness dispersion, can be obtained by surface-grinding.
For that reason, in a conventional wafer process, even an etching step, in some cases, as well as a lapping step, can be omitted.
In adhesion of a base plate 14 and a wafer or wafers W, it is important in order to tighten the adhesion that a bubble is not included in the adhesive material.
An example of the apparatus, which can supply adhesive material, for example molten wax, hot-melt adhesive or the like, without accompanying a bubble, is explained in reference to FIG. 3.
In FIG. 3, Mark 30 is a supply apparatus for molten adhesive material. The apparatus 30 comprises:
a storage tank 34, in the interior of which molten adhesive material, for example molten wax, hot-melt adhesive and the like, is stored;
a pressure means, for example a pressure line 36, which gives an internal pressure to the storage tank 34;
a pipe means 38, through which the molten adhesive material Y is transported under pressure from the storage tank 34;
a pair of an upper heating means, for example an upper hot plate 40, and a lower heating means, for example a lower hot plate 42, which face each other.
The upper heating means 40 is installed pivotably and in such a manner that it opens or closes freely by the help of a support member 44.
The wafer W and the base plate 14 are placed on the lower heating means 42.
When they are removed, the upper heating means 40 is opened. When the molten adhesive material Y is supplied, it is closed like the view.
Marks 46 and 46 are support legs for supporting the lower heating means 42.
Supply of adhesive material Y is conducted with this apparatus 30 in the following way:
First, the upper heating means 40 is opened, then the base plate 14 is placed on the lower heating plate 42 and after that a wafer W is placed on the base plate 14.
Then, the upper heating means 40 is closed. And the base plate 14 and the wafer W are respectively heated by the lower heating means 42 and the upper heating means 40.
In this state, adhesive material Y is supplied into the gap 48 between the base plate 14 and the wafer W, through the pipe means 38 under an internal pressure applied to the storage tank 34 by the pressure means 36.
There is no special limitation to the embodiments of the pipe means 38, since it is only required to supply the adhesive material Y to the gap 48.
In the example shown in the figure, a case is illustrated, where the pipe means 38 is penetrated through the interiors of both the lower heating means 42 and base plate 14. In this case, a through-hole 50 for a pipe has been bored in the base plate 14.
After the completion of supply operation of the adhesive material Y, the upper heating means 40 is opened and an adhering composite of the base plate 14 and the wafer W is taken out as a piece.
By the use of this supply apparatus 30 of molten adhesive material, the molten adhesive material Y can be supplied into the gap 48 without introduction of a bubble to tightly combine both of them.
In the above-mentioned embodiment, the example, in which the surface-grinding method of the present invention is applied to the surface-grinding step in a conventional processing method as is shown in FIG. 7, is explained.
The feature of the present inventive method lies, however, in that a workpiece or workpieces, such as wafers, are fixed by one surface thereof to the upper surface of a base plate by the aid of adhesive material and the other surface of each workpiece is surface-ground, while the base plate is fixedly supported by its own lower surface.
It is needless to state that any modification of the workpiece processing method, which includes this inventive feature, still falls within the technological scope of the present invention.
As described above, according to the present invention, even with a workpiece or workpieces, such as wafers, having waviness and bow, the waviness and bow can be corrected and surface-grinding technique can be applied to obtain a good workpiece having no thickness dispersion.
By these facts, the surface-grinding step can be incorporated in place of the conventional lapping step, so that workpiece processing, of higher precision than that in the past, is realized and the workpiece process can be simplified to have an advantage of realization of cost reduction. | In a surface-grinding method for a workpiece, for example a semiconductor wafer, it is possible to correct or improve waviness and bow and to obtain a semiconductor wafer having no thickness dispersion. Besides, wafer processing to higher precision than that conventionally attained is achieved and at the same time simplification of the processing method and thereby reduction of the cost are also achieved. In the present invention, while the workpiece is fixed for supporting at one surface by the fixedly supporting means of a surface-grinding apparatus, the other surface of the workpiece is surface-ground, where the workpiece adheres on the upper surface of a base plate by the aid of adhesive material and the base plate is fixedly supported by the lower surface of itself on the fixedly supporting means. | 1 |
BACKGROUND OF THE INVENTION
This invention relates to an improvement in the manufacture of powder paints, and more particularly in the manufacture of such paints wherein the raw batch ingredients comprising resinous binders and pigmentary solids are plasticized, homogenized, and formed into a coherent extrudate by mechanical extrusion ("hot extrusion process").
Powder paints are ostensibly dry ("hardened") and freeflowing at normal room temperature. They are applied to a substrate by conventional means such as electrostatic spray processes or fluidized bed processes. Because there are little or no fugitive components such as solvents or water in them, they must depend upon their own melting to coalesce, level out, and form a film. The absence in them of the fugitive components, however, is quite attractive in many industrial painting operations because atmospheric contamination from the volatile solvents, etc., is virtually, if not completely, eliminated. Powder paints are applied to hot substrates or those subsequently heated to generate the paint film.
Any single paint plant, including a powder paint plant, generally is expected to produce a wide variety of types and shades of paint in various volumes. Thus, the operators are working on a series of batch units, even though a particular batch unit or like batch units may be run in a continuous or semi-continuous manner for a restricted period of time. One of the biggest problems in making a powder paint is to obtain quite precise uniformity of color (shade) and other properties from batch unit to batch unit.
Accordingly one scheme has been to make the paint up like a traditional solvent-based paint, secure the shading, etc., then remove the solvent as by spray drying or by the process described in U.S. Pat. No. 3,737,401 (wherein the solvent is water soluble, and it is extracted by water from the rest of the paint which is then collected and dried). Thin film evaporation has also been proposed for such removal of solvent from a solvent paint preparatory to its comminution into a powder (generally passing 200 mesh U.S.S. sieve with a minimum of ultrafine material to suppress dusting).
Another process for producing powder paints is by hot extrusion of the raw batch components, which generally contain little or no volatile ingredients whatsoever. Such process is shown in U.S. Pat. No. 3,643,874. For the most part, color matching and adjustment of other critical compositional variables must be accomplished prior to such extrusion. This is especially true where thermosetting resinous vehicles are used in making such powder paints. Subjecting them to reprocessing with additional heat and/or prolonged time tends to advance their crosslinking, and this can result in prematurely hardened particles which are of little or no practical use as coatings. The thermoplastic vehicle powder paints are, of course, less susceptible to damaging from such reprocessing, but, nevertheless, it is expensive and they can become somewhat deteriorated.
A very real problem in the preparation of powder paints by the hot extrusion process is the problem of contamination between unlike batch units. Thus, even traces of acrylic resin-based particles from a previous batch appearing in an epoxy resin-based powder paint often can lead to visible specks or other imperfections which render the epoxy resin-based batch unsatisfactory. Hence, the problem of cleaning and maintaining all equipment in such extrusion process plants to a quite completely clean condition between unlike batch units is extremely critical, not only for such incompatible imperfections, but also for color matching of like batch units and color differentiation between unlike batch units.
SUMMARY OF THE INVENTION
The instant improvement is in a process for making a variety of powder paints in a series of batch units from raw batch ingredients comprising resinous binders and pigmentary solids wherein the raw batch ingredients are plasticized, homogenized, and formed into a coherent extrudate by mechanical extrusion in an extruding step while upstream of said extruding step at least a portion of said raw batch ingredients are intimately blended together as a batch blend unit in a blending step and downstream of said extruding step said extrudate is cooled, comminuted, and packaged in cooling, comminuting, and packaging steps. This improvement helps markedly to suppress interbatch contamination and enhances batch unit uniformity. It comprises:
a. as to a particular batch blend unit: transporting it to, storing it as extrusing step feed in, and feeding it to said extrusing step from a first portable batch unit transporting vessel (hopper) reserved for said particular batch blend unit and like batch blend units; and
b. as to the particular comminuted extrudate from said particular batch blend unit: collecting it from said comminuting step, and transporting it to, storing it as packaging step feed in, and feeding it to said packaging step from a second portable batch unit transporting vessel (hopper) reserved for said particular extrudate and like extrudates.
Reservation of a particular portable batch unit transporting vessel (hopper) for a particular batch blend unit or like batch blend units or extrudates therefrom can be done using a plurality of hoppers, with covering of such hoppers during the times such hoppers are being handled or stored. This is particularly effective to suppress interbatch contamination and to secure uniformity of color from like batch to like batch unit. These hopper vessels can be moved by rolling them on the floor or transported by fork lift truck and stored conveniently for use. They act as temporary storage for materials in process. While a single high volume powder paint is being made, particular hoppers can be reserved for that service. When a hopper vessel is thoroughly cleansed, it in effect becomes a "new" vessel for handling components of a new and different batch blend or extrudate. Cleansing is done conventional by air blowing, steaming, scrubbing, solvent or water washing, or the like. The fixed items (referring to the drawing) such as high intensity mixer, the top unit of the hopper-blender, feeder, extruder, chill rolls, belt, chopper, conveyors, mill and its appurtenances, and packager must be scrupulously cleaned when changes are made from one batch composition or formulation to another one unlike the immediately previous one. The skirts can be cleaned or replaced for such changes. Removal and/or disposable liners can be used in the various equipment, if desired, wherein abrasion and impact are low.
DETAILED DESCRIPTION OF THE INVENTION
The drawing is a flow diagram showing the basis of design for a powder paint production line producing about 1200 to 1500 lbs. per hour of powder paints having approximately 40 to 45 lbs. per cubic foot bulk densities. The raw batch ingredients are poured down chute 11 into hopper A (at position 12), a portable hopper of 150 cu. ft. capacity to handle a load of 4000 to 6000 lbs., usually approximately 5000 lbs., of raw batch ingredients. The raw batch ingredients are particulate resinous binder (vehicle), opacifying pigment particles such as rutile TiO 2 , tinting pigments such as carbon black or a phthalocyanine pigment, and filler and extender pigments such as clay, talc, mica, silica, and the like. The several raw batch ingredients are weighed individually, and the batch in total, by scale 13 on which hopper A rests.
Alternatively, the same ingredients can be weighed on scale 14 and fed through chute 16 into high intensity mixer 17. In such instance the ingredients of batch blend unit is subdivided into subunits, and 5 loads are intensively mixed in mixer 17, and each discharged from outlet 18 into hopper A at position 12 to make a single batch blend unit therein. The high intensity mixer cycle time is about one minute. This mixer typically is a slightly frustroconical (smaller at the top) vessel with an agitator assembly (U.S. Pat. No. 3,337,193) which scoops batch materials from the bottom of the vessel and forces them outwardly and upwardly toward the top of the vessel; the falling particles are guided downwardly through a ring on such agitator assembly, then are forced downwardly for recirculation. Typical of such mixers is the Wellex Inc., 1000 M, 26 cu. ft., 200 horsepower intensive mixer (100 Queens Drive, King of Prussia, Pennsylvania 19406).
Portable hopper A is a Gemco Brand portable hopper. It is moved then to fit under and is sealed to the top of the Gemco Brand hopper-blender unit 19, mounted on trunnions 21. Thus connected, hopper A is shown in position 12'. Near the junction of this hopper-blender top 19 with hopper A is a cantilevered internal agitator unit, not shown, in top 19. Such hopper-blender and all the other hoppers depicted in the drawing are alike and are made by the General Machine Company of New Jersey, 55 Evergreen Avenue, Newark, N.J. 07114, proprietor of the trademark "Gemco." The entire hopper-blender unit in connected, sealed condition is rotated on the trunnions 21 by drive means not shown until an extremely intimate blend of the raw batch blend unit is secured (eg., 10 to 120 minutes). The cantilever internal agitator helps to break up lumps and assist in the blending. Such hopper-blenders of the sort preferred here can be equipped to tolerate reasonable adjustments in balance, internal agitator configuration, and hopper construction to accommodate a fair amount of variation in batch loads.
At the end of the blending operation hopper A is disconnected from unit 19 and raised to position 12 inches above screw feeder 23. The hopper then is connected to such feeder by flexible skirt 22 to preclude dusting and spillage. All the portable hoppers in this design have spherical discharge valves at their conical bottoms. Often it is desirable to feed from hopper A into a conventional tramp metal detector and rejector (not shown) to remove any stray metal items such as nuts, bolts, etc. (which could damage the extruder) before they enter the feeder. These rejecters can operate on the principle of induction, magnetism, and/or physical screening.
Feeder 23 has a three cu. ft. tank, and is equipped with a 4 inch screw connected to a variable speed drive, not shown. The feeder gradually discharges the batch blend unit from hopper A, at position 12", into inlet receiver 24 of screw extruder 26.
The typical screw extruder for this operation is jacketed and the screw internally heated by an indirect heating fluid such as steam, hot water, or a synthetic oil such as Union Carbide Corporation's 50HB280X. One form of extruder that can be used is a Baker-Perkins Company 4 inch "M. P." (trademark) twin screw extruder. Another form is that shown in U.S. Pat. No. 3,643,874, a so-called "Buss-kneader" a trademark of Buss A. G. of Basel, Switzerland. Extruder temperature is regulated according to the type of paint being made, but generally is between about 90°C, and 150°C, at the heated die outlet.
In the extruder the batch blend is plasticized and homogenized, then expelled through a heated die as coherent extrudate 27.
This extrudate passes through internally water-cooled rolls 28, counter-rotating to draw the extrudate forward and flatten it into a ribbon about 1/16 inch thick. Such thin ribbon of plastic extrudate passes on to austenitic stainless steel conveyor belt 29, which is cooled with water sprays playing on the bottom of the belt below the ribbon. The plastic ribbon fully hardens as it is rapidly cooled down to about room temperature (70°-80°F). It passes into chopper 31 at the end of the belt, this breaking the cooled ribbon into small flakes. Chopper unit 31 simply is a counterclockwise rotating spined shaft with the spines passing downwardly between fixed projecting fingers that support the cooled frangible ribbon as it comes off the belt at the discharge end return bend.
The flakes are dropped into the bottom of inclined screw conveyer 32 and are conveyed thereby to portable hopper C (at position 33), of the same type as portable hopper A.
Portable hopper C is raised to position 33' and unloaded into inclined screw conveyer 34 to feed a hammer mill 36 at a rate of about 1200 to 1500 lbs. per hour. Mill 36 is fed with liquid nitrogen to remove heat of grinding and to maintain the ground product essentially isothermally at about room temperature (and above the dew point of the surrounding atmosphere). This prevents moisture from condensing on the resulting powder paint. The same temperature restriction is observed in the water cooling of the extrudate to prevent atmospheric moisture condensation on such extrudate. The powder paint product is ground so that the preponderance of it passes a 200 mesh (U.S.S.) seive. The powder passes through skirt 37 into receiver 38, then upwardly into classifier 41. This is a vertical screen unit; it is equipped with a fan on its discharge side which sucks the powder paint of appropriate fineness (-200 mesh) through such screen and passes it through discharge 43 into cyclone separator 44. Herein it falls downwardly (as shown by particles indicated as item 46) into portable hopper B (at position 47). Oversized particles rejected by the screen are returned to mill 36 for remilling through line 42. Waste gas and extremely fine particles pass out of cyclone separator 44 through line 48; the fines in such flow are collected by a bag dust collector (not shown), and the gas passes to atmosphere. While these fines can be recovered for use, they are in extremely small proportion relative to the batch blend unit, and they generally are discharged from the system as waste so as not to contaminate the products.
Hopper B is elevated to position 47' and is discharged through skirt 49 into automatic packaging unit 51 (typically a 50 lb. Bemis Packaging Service weighing sacker). Such sacker weighs out automatically 50 lb. increments of the powder paint to an accuracy of 1 oz., and the finished powder paint is discharged into cardboard boxes lined with a plastic liner such as a polyethylene liner. Such boxes are shown moving from left to right on conveyer 56 as unfilled box 53, box being filled 52, and filled box 54. The filled boxes are sealed, stacked by means not shown, and stored (preferably above the dew point and at a temperature not in excess of 75°-80°F to suppress gellation of thermosetting resinous or clumping of thermoplastic resinous powder paints).
In place of the water cooled belt and flaker, the arrangement shown in U.S. Pat. No. 3,643,874 can be used wherein the cooled flakes of paint are directly fed to the final comminuting operation. When malleable solids such as aluminum flakes are to be blended in the batch blend unit, it is often useful not to feed them into the feed end of the extruder (item 24) where they can be subjected to high shear in the entire extruder operation, but rather to fold them gently into the extrudate emerging from the hot die at the discharge end. This can be done by adding a further screw extrusion unit, not shown, to the normal discharge of primary extruder 26, which further unit has much less severe shearing action on the entire mass. Such further unit can be in-line with the discharge end of extruder 26, or can actually be a so-called "cross-head extruder" maintaining a second screw or multiple of screws perpendicular to the flow output of primary extruder 26.
The finished, ground product in hopper B can be further mixed with flow agents, metallic pigments, or other pigment additives by connecting hopper B at position 12' to the hopper-blender top unit 19 and rotatively blending as necessary or desirable to give a dry blend for the ultimate finishing. When the powder paint is made with a thermosetting resin, it is usually undesirable or impractical to recycle once-extruded extrudate or powder back through further heated or heat-generating extrusion operations. However, when the powder paint vehicle is simply a thermoplastic resin, such recycling can be practiced more freely. The use of the portable hoppers permits temporary intermediate collection and storage at various stages of the operation, and these hoppers can be covered, e.g., with rigid plastic covers, to prevent tramp contamination.
In place of using an air-cooled or water-cooled belt for chilling the extrudate and rendering it frangible, one can, of course, use other coolants such as liquid nitrogen to cool the extrudate and harden it in the manner of freezing of foods. Direct water cooling on the extrudate generally is not practiced (to preclude leaching of water solubles from the extrudate), but can be practiced with a certain water-resistant powder paint formulations. Certain powder paints such as some thermoplastic vinyl resinous powder paints advantageously are comminuted by cryogenic grinding (ground very cold by treatment with liquid nitrogen or the like to embrittle them); they should be protected from condensation of atmospheric moisture until they warm up to above the dew point.
Where the extrudate can tolerate high enough temperature, heating to render it fairly fluid (as distinguished from a putty-like mass), it is, of course, possible to subdivide such extrudate, as with a spinning disc-type atomizer or the like, then finish the cooling and hardening by dropping the particles through a chilling tower (ordinarily countercurrent to chilled dry air) for collection directly as powder paint.
Curiously, in the instance of this hot extrusion powder paint process, we have found that substantially lower proportions of pigments are used to obtain a given color or tinted finish than when the paint is compounded conventionally as corresponding solvent-based paint system.
Useful pigments include pigmentary-size opacifying agents such as rutile or anatase titania, lithopone, titanium calcium, zinc oxide and mixtures of same, extenders and fillers (herein included under the broad term "pigments") such as kaolinite clay, pigmentary silica, talc, mica, Wollastonite, calcium carbonate and barium sulfate also can be used. Many other pigmentary materials and extenders also can be used. Other pigmentary materials often are used to impart color, for example, brown, red, yellow and black iron oxides, raw sienna and burnt sienna, raw and burnt umber, chromium oxide green, phthalocyanine green (chlorinated copper phthalonitrile), the green iron salt of nitroso beta naphthol, copper phthalonitrile blue, ultramarine blue, carbon black, lamp black, toluidine red, parachlor red, para toner (red), alkali resistant red, BON red and maroon, cadmium reds and yellows, Watchung red, madder lake (red), Duratone red, carmine red, chrome yellow (lead chromate), chrome orange, and Hansa yellows (which are azo couplings of meta nitroparatoluidine and acetoacetanilide). Metal flakes, powders and pastes (preferably conventionally treated and coated) also can be used, and these preferably are handled specially in the instant extrusion process as described above. Latent curing accelerators, catalysts, and cross-linking agents also can be compounded in such powder paints.
Various classes of thermosetting resins for this compounding include: epoxy types (which are extruded at an extruder discharge head temperature, for example, of 90°-100°C--a typical powder paint being 1/3 by weight of such pigmentary solids and 2/3 by weight of such granular cross-linkable epoxy resin such as Dow Chemical Company's DER663U, a bisphenol A epoxy resin having epoxy equivalent weight of 730-840, mixed with 5% of a cross linker, of dicyandiamide or trimellitic anhydride); cross-linkable acrylic resin particles such as Farben Fabriken Bayer's L2269 acrylate-based copolymer resin having softening range of 90°-100°C, and made up similarly in pigment and resin ratio with a melamine resin cross linker such as hexamethylol melamine resin; and polyesters such as terephthalic acid/propylene glycol/glycerine polyesters having Acid No. between 6 and 10, which generally is extruded at a head temperature of approximately 127°C, using similar weight proportion of pigmentation, and a cross linking material such as 10 to 15% of a melamine resin, such as hexamethylol melamine resin, basis weight of polyester. While higher or lower temperatures can be used, it must be understood that substantially lower temperatures without special plasticizing agents tends to make it difficult to homogenize and form a coherent extrudate of the powder paint batch, and substantially higher temperatures (e.g. over 175°C) tend to engender cross linking, as do long holding times of any thermosetting resin batch material at any elevated temperatures above about 30° or 40°C.
A convenient test of thermosetting powder paints to determine their utility for application is a gel time test. In such test, a few grams of the powder paint are put on a metal dish, which is placed on a hot plate maintained at 176.67°C. The warm paint is touched with a metal spatula and strings are drawn from such paint until the stringing stops. The longer the time such paint continues to string, the less advanced the cross linking is in the powder paint and generally, the more useful it is for powder painting processes. Such gel time of 30 to 200 seconds generally is looked for in practical powder painting operations.
Various thermoplastic vinyl polymers also are useful for making powder paints, for example Union Carbide Corporation's E2000, a white, powdery vinyl chloride/modified copolymer. Typically these are extruded at about 90°-100°C, then subjected to cryogenic grinding preparatory to their packaging. | In an extrusion process for making powder paints from a series of batch blend units comprising resinous binders and pigmentary solids, interbatch contamination can be suppressed by using a same first portable (hopper) vessel for transporting, temporarily storing, and feeding extruder feed from like particular batch blend units and using a same second portable (hopper) vessel for collecting, transporting, and temporarily storing comminuted extrudates corresponding to said like particular batch blend units and feeding such comminuted extrudates into packages, especially when said first portable vessel is used for part or all of the blending operation. Like extrudates, corresponding to particular batch blend units, can be substantially completely hardened by cooling prior to their comminuting, and collected in, transported to, and temporarily stored for final comminution in a same third portable (hopper) vessel. Alternatively, such particular extrudates can be comminuted before they are substantially completely hardened, then completely hardened subsequently by cooling. | 2 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. application Ser. No. 11/077,551, filed Mar. 9, 2005, which claims priority to U.S. Provisional Application Ser. No. 60/551,419, filed Mar. 9, 2004, and U.S. Provisional Application Ser. No. 60/617,684, filed Oct. 12, 2004. The contents of all of the three prior applications are hereby incorporated by reference in their entireties.
BACKGROUND
[0002] Glucagon-like peptide-1 (GLP-1) is a gut hormone produced by intestinal endocrine L-cells in response to nutrient ingestion. GLP-1 inhibits glucagon secretion and stimulates glucose-dependent insulin release from the pancreas. It was observed that administration of GLP-1 significantly lowered blood glucose levels in Type II diabetes patients (Zander M, et al. Lancet 2002, 359: 824-830).
[0003] However, GLP-1, whether endogenously or exogenously administered, degrades rapidly. (Kieffer T. J., et al. Endocrinology 1995, 136: 3585-3596; and Mentlein R, et al. Eur. J. Biochem. 1993, 214: 829-839). The degradation is attributable to dipeptidyl peptidase IV (DPP-IV), a member of the prolyl peptidase family. Recent clinical data indicate that inhibiting DPP-IV resulte in enhanced insulin secretion, reduced plasma glucose concentrations, and improved pancreatic β-cell function (Pederson R. A., et al. Diabetes 1998, 47: 1253-1258; and Ahren B, et al. Diabetes Care 2002, 25: 869-875). Thus, inhibitors of DPP-IV are potential drug candidates for Type II diabetes.
SUMMARY
[0004] This invention is based on a surprising discovery that a group of pyrrolidine compounds inhibit DPP-IV.
[0005] One aspect of this invention relates to pyrrolidine compounds of the following general formula:
wherein R 1 is H or CN; R 2 is H, halo, nitro, cyano, amino, hydroxy, alkyl, haloalkyl, alkoxy, aryloxy, aralkyl, cyclyl, heterocyclyl, aryl, or heteroaryl;-each of R 3 , R 4 , R 5 , and R 6 , independently, is H, halo, nitro, cyano, amino, hydroxy, alkyl, haloalkyl, alkoxy, aryloxy, aralkyl, cyclyl, heterocyclyl, aryl, or heteroaryl; or R 3 and R 4 , together with the carbon atom to which they are attached, or R 5 and R 6 , together with the carbon atom to which they are attached, are a 3-8 membered ring, optionally having 1 or 2 heteroatoms and optionally substituted with halo, CN, NO 2 , —OR a , alkyl, aryl, heteroaryl, haloalkyl, —OR a , —C(O)R a , —SR a , —S(O)R a , —S(O) 2 R a , —NR a R a′ , —C(O)OR a , —C(O)NR a R a′ , —OC(O)R a , —NR a C(O)R a′ , —NR a C(O)OR a′ , or —NR a C(O)NR a′ R a″ , or optionally fused with one of cyclyl, heterocyclyl, aryl, and heteroaryl, each of R a , R a′ , and R a″ , independently, being H, alkyl, or aryl; m is 0, 1, 2, 3, 4, or 5; n is 0, 1, or 2; W is CR b R b′ , NR b , O, or S, in which each of R b and R b′ , independently, is H, halogen, alkyl, or aryl; X is O, S, or CR c (NR c′ R c″ ), in which each of R c , R c′ , and R c″ , independently, is H, alkyl, or aryl; Y is
in which R d is H, alkyl, or aryl; and Z is NR e R e′ , in which each of R e and R e′ , independently, is H, alkyl, alkoxyalkyl, haloalkyl, cyclyl, heterocyclyl, aryl, aralkyl, heteroaryl, or heteroaralkyl; or NR e R e′ , together, is a 3-8 membered ring having 1 or 2 heteroatoms, optionally substituted with halo, CN, NO 2 , —OR′, alkyl, aryl, heteroaryl, haloalkyl, —OR′, —C(O)R′, —SR′, —S(O)R′, —S(O) 2 R′, —NR′R″, —C(O)OR′, —C(O)NR′″, —OC(O)R′, —NR′C(O)R″, —NR′C(O)OR″, or —NR′C(O)NR″R′R″, or optionally fused with one of cyclyl, heterocyclyl, aryl, and heteroaryl, each of R′, R″, and R′″, independently, being H, alkyl, or aryl.
[0006] Referring to the just-described pyrrolidine compounds, a subset features that X is CHNH 2 and each of R 3 , R 4 , R 5 , and R 6 , independently, is H, halo, nitro, cyano, amino, hydroxy, alkyl, haloalkyl, alkoxy, aryloxy, aralkyl, cyclyl, heterocyclyl, aryl, or heteroaryl. In these compounds, R 3 and R 4 can be CH 3 and each of R 5 and R 6 can be H; or each of R 3 , R 4 , R 5 , and R 6 can be H; or R 3 can be CH 3 and each of R 4 , R 5 , and R 6 can be H. Another subset of the pyrrolidine compounds features R 3 and R 4 together with the carbon atom to which they attached are a cyclopropyl ring. A further subset features that Y is C(O).
[0007] Another aspect of this invention relates to pyrrolidine compounds of
wherein R 1 is H or CN; each of R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , and R 8 , independently, is H, halo, nitro, cyano, amino, hydroxy, alkyl, haloalkyl, alkoxy, aryloxy, aralkyl, cyclyl, heterocyclyl, aryl, or heteroaryl; m is 0, 1, 2, 3, 4, or 5; n is 0, 1, 2, 3, or 4; o is 0, 1, 2, or 3; W is CR a R a′ , NR a , O, or S, in which each of R a and R a′ , independently, is H, halogen, alkyl, or aryl; X is NR b , in which R b is H, alkyl, or aryl; Y is
in which R c is H, alkyl, or aryl; and Z is NR d R d′ , in which R d is a 3-8 membered monocyclic ring optionally substituted with halo, CN, NO 2 , —OR′, alkyl, aryl, heteroaryl, haloalkyl, —OR′, —C(O)R′, —SR′, —S(O)R′, —S(O) 2 R′, —NR′R″, —C(O)OR′, —C(O)NR′R″, —OC(O)R′, —NR′C(O)R″, —NR′C(O)OR″, or —R′C(O)NR″R 40 ″; and R d′ is H, alkyl, alkoxyalkyl, haloalkyl, aralkyl, or heteroaralkyl; each of R′, R″, and R′″, independently, being H, alkyl, or aryl.
[0008] Referring to the just-described pyrrolidine compounds, a subset features that n is 1 and o is 1; X is NH; W is CH 2 or CHF; R d is a cyclopropyl ring substituted with an aryl or heteroaryl group; each of R 3 , R 4 , R 7 , and R 8 is H; and each of R 5 and R 6 is CH 3 . Another subset features that Y is C(O).
[0009] Shown below are exemplary compounds of this invention:
[0010] The term “alkyl” herein refers to a straight or branched hydrocarbon, containing 1-10 carbon atoms. Examples of alkyl groups include, but are not limited to, methyl, ethyl, n-propyl, i-propyl, n-butyl, i-butyl, and t-butyl. The term “alkoxy” refers to an —O-alkyl. The term “alkoxyalkyl” refers to an alkyl group substituted with one or more alkoxy groups. The term “haloalkyl” refers to an alkyl group substituted with one or more halo groups. The term “hydroxyalkyl” refers to an alkyl group substituted with one or more hydroxy groups.
[0011] The term “aryl” refers to a 6-carbon monocyclic, 10-carbon bicyclic, 14-carbon tricyclic aromatic ring system wherein each ring may have 1 to 4 substituents. Examples of aryl groups include, but are not limited to, phenyl, naphthyl, and anthracenyl. The term “aryloxy” refers to an —O-aryl. The term “aralkyl” refers to an alkyl group substituted with an aryl group.
[0012] The term “cyclyl” refers to a saturated and partially unsaturated cyclic hydrocarbon group having 3 to 12 carbons. Examples of cyclyl groups include, but are not limited to, cyclopropyl, cyclobutyl, cyclopentyl, cyclopentenyl, cyclohexyl, cyclohexenyl, cycloheptyl, and cyclooctyl.
[0013] The term “heteroaryl” refers to an aromatic 5-8 membered monocyclic, 8-12 membered bicyclic, or 11-14 membered tricyclic ring system having one or more heteroatoms (such as O, N, or S). Examples of heteroaryl groups include pyridyl, furyl, imidazolyl, benzimidazolyl, pyrimidinyl, thienyl, quinolinyl, indolyl, and thiazolyl. The term “heteroaralkyl” refers to an alkyl group substituted with a heteroaryl group.
[0014] The term “heterocyclyl” refers to a nonaromatic 5-8 membered monocyclic, 8-12 membered bicyclic, or 11-14 membered tricyclic ring system having one or more heteroatoms (such as O, N, or S). Examples of heterocyclyl groups include, but are not limited to, piperazinyl, pyrrolidinyl, dioxanyl, morpholinyl, and tetrahydrofuranyl.
[0015] Alkyl, cyclyl, heterocyclyl, aryl, heteroaryl, aralkyl, heteroaralkyl, alkoxy, and aryloxy mentioned herein include both substituted and unsubstituted moieties. Examples of substituents include, but are not limited to, halo, hydroxyl, amino, cyano, nitro, mercapto, alkoxycarbonyl, amido, carboxy, alkanesulfonyl, alkylcarbonyl, carbamido, carbamyl, carboxyl, thioureido, thiocyanato, sulfonamido, alkyl, alkenyl, alkynyl, alkyloxy, aryl, heteroaryl, cyclyl, heterocyclyl, in which alkyl, alkenyl, alkynyl, alkyloxy, aryl, heteroaryl cyclyl, and heterocyclyl may further substituted.
[0016] The monocyclic ring mentioned herein is either substituted or unsubstituted, but cannot be fused with another aromatic or non-aromatic ring.
[0017] The pyrrolidine compounds described above include their pharmaceutically acceptable salts and prodrugs, if applicable. Such a salt can be formed between a positively charged ionic group in an pyrrolidine compound (e.g., ammonium) and a negatively charged counterion (e.g., trifluoroacetate). Likewise, a negatively charged ionic group in a pyrrolidine compound (e.g., carboxylate) can also form a salt with a positively charged counterion (e.g., sodium, potassium, calcium, or magnesium). The pyrrolidine compounds may contain a non-aromatic double bond and one or more asymmetric centers. Thus, they can occur as racemic mixtures, single enantiomers, individual diastereomers, diastereomeric mixtures, and cis- or trans-isomeric forms. All such isomeric forms are contemplated.
[0018] The pyrrolidine compounds described above can be used to inhibit DPP-IV. Accordingly, another aspect of this invention relates to a method of inhibiting DPP-IV with one or more of the pyrrolidine compounds. As inhibition of DPP-IV results in reduced blood glucose levels and enhanced insulin secretion, the compounds of this invention can be also used to treat Type II diabetes. Thus, this invention further covers a method of treating Type II diabetes by administering to a subject in need thereof an effective amount of one or more of the pyrrolidine compounds.
[0019] Also within the scope of this invention is a pharmaceutical composition containing one or more of the above-described pyrrolidine compounds and a pharmaceutically acceptable carrier, as well as use of the composition for the manufacture of a medicament for treating Type II diabetes.
[0020] The details of many embodiments of the invention are set forth in the description below. Other features, objects, and advantages of the invention will be apparent from the description and the claims.
DETAILED DESCRIPTION
[0021] The pyrrolidine compounds of this invention can be synthesized by methods well known in the art. Six exemplary synthetic routes are shown in Schemes 1-6 below.
[0022] In Scheme 1, the starting compound is amino-substituted dicarboxylic acid (1) in which an amino group and one of two carboxy groups are protected. This compound is reacted with 2-substituted pyrrolidine hydorchloride salt (2) to give monoamide intermediate (3). Note that synthesis of 2-substituted pyrrolidine hydrochloride salt (2) is well known in the art. For example, pyrrolidine-2-carbonitrile hydrochloride salt can be prepared by the procedure described in Bioorg. Med. Chem. Lett. 1996, 6: 1163. Removing the carboxy protected group of the intermediate (3) affords monoamide monoacid compound (4), which subsequently is coupled with amine to provide diamide compound (5). Deprotection of compound (5) provides desired pyrrolidine compound (6).
[0023] Scheme 2 illustrates another synthetic route for synthesizing pyrrolidine compounds. The starting compound is α-amino acid (7), in which the amino group is protected. This compound is coupled with amine (8) to give amide compound (9). Compound (9) is deprotected and subsequently reacted with 1-(2-bromo-acetyl)pyrrolidine (11) to afford desired pyrrolidine compound (12). Note that 1-(2-bromo-acetyl)pyrrolidine (11) can be prepared by methods well known in the art. See, e.g., J. Med. Chem. 2003, 46: 2774.
[0024] In Scheme 3, the starting compound is N-protected 2-amino-2-methyl-propane-sulfanoic acid (13), which is commuercially available. It is reacted with sulfuryl chloride and then with 2,3-dihydroisoindole to give sulfonyl amide (16), which is subsequently deprotected to afford amino compound (17). This amino compound is coupled with β-bromo amide (18) to form desired pyrrolidine compound (19).
[0025] In Scheme 4, thionyl chloride is reacted with 2,3-dihydroisoindole (15) and (2-amino-1,1-dimethyl-ethyl)-carbamic acid benzyl ester (20), sequentially. The product (not shown), a protected amino compound, is deprotected to afford free amino compound (21), which is subsequently coupled with β-bromo amide (18) to form desired pyrrolidine compound (22).
[0026] Similarly, two additional pyrrolidine compounds of this invention, i.e., compounds (26) and (29), can be prepared following analoguous procedures as shown in Schemes 5 and 6 below. Starting material (24) is reportedly synthesized before. See, e.g., Boehringer M. et al., WO 2003037327.
[0027] Scheme 7 below illustrates synthesis of a cyclopropyl-containing pyrrolidine compound. Starting material (30) is a N-protected β-amino acid. It reacts with cyclopropyl amine in the presence of a coupling agent (e.g., dicyclohexylcarbodiimide), followed by deprotection, to provide N-cyclopropyl amide (31), which has a free amino group. The amide is then coupled with pyrrolidine (32) to form cyclopropyl-containing pyrrolidine (33). N-protected β-amino acid (30) and pyrrolidine (32) can be prepared by known methods. See, e.g., J. Med. Chem. 2006, 49, 373; J. Med. Chem. 1988, 31, 92; and J. Med. Chem. 2002, 45, 2362.
[0028] Scheme 8 below shows synthesis of a pyrrolidine compound having a longer chain (i.e., 3 carbon atoms between carbonyl groups). Also this chain can be either substituted or unsubstituted.
[0029] The above eight schemes are provided only for illustrative purposes. A skilled person in the art, in view of them, would be able to synthesize all the pyrrolidine compounds of this invention with any necessary modifications within his or her skill. Synthetic chemistry transformations and protecting group methodologies (protection and deprotection) useful in synthesizing applicable pyrrolidine compounds are known in the art and include, for example, those described in R. Larock, Comprehensive Organic Transformations , VCH Publishers (1989); T. W. Greene and P. G. M. Wuts, Protective Groups in Organic Synthesis, 3 rd Ed., John Wiley and Sons (1999); L. Fieser and M. Fieser, Fieser and Fieser's Reagents for Organic Synthesis , John Wiley and Sons (1994); and L. Paquette, ed., Encyclopedia of Reagents for Organic Synthesis , John Wiley and Sons (1995) and subsequent editions thereof.
[0030] Pyrrolidine compounds thus obtained can be further purified by column chromatography, high performance liquid chromatography, or crystallization.
[0031] This invention covers a method for inhibiting DPP-IV by contacting it with an effective amount of one or more of the pyrrolidine compounds described above. This invention also covers a method for treating Type II diabetes by administering to a subject in need thereof an effective amount of one or more of the pyrrolidine compounds described above. The term “treating” refers to application or administration of the pyrrolidine compound to a subject, who has Type II diabetes, a symptom of Type II diabetes, or a predisposition toward Type II diabetes, with the purpose to cure, heal, alleviate, relieve, alter, remedy, ameliorate, improve, or affect the disease, the symptom, or the predisposition. “An effective amount” refers to the amount of the pyrrolidine compound which is required to confer the desired effect on the subject. Effective amounts vary, as recognized by those skilled in the art, depending on route of administration, excipient usage, and the possibility of co-usage with other therapeutic treatments such as use of other active agents.
[0032] To practice the treatment method of the present invention, a composition having one or more of the pyrrolidine compounds describe above can be administered parenterally, orally, nasally, rectally, topically, or buccally. The term “parenteral” as used herein refers to subcutaneous, intracutaneous, intravenous, intramuscular, intraarticular, intraarterial, intrasynovial, intrasternal, intrathecal, intralesional, or intracranial injection, as well as any suitable infusion technique.
[0033] A sterile injectable composition can be a solution or suspension in a non-toxic parenterally acceptable diluent or solvent, such as a solution in 1,3-butanediol. Among the acceptable vehicles and solvents that can be employed are mannitol and water. In addition, fixed oils are conventionally employed as a solvent or suspending medium (e.g., synthetic mono—or diglycerides). Fatty acids, such as oleic acid and its glyceride derivatives, are useful in the preparation of injectables, as are natural pharmaceutically acceptable oils, such as olive oil or castor oil, especially in their polyoxyethylated versions. These oil solutions or suspensions can also contain a long chain alcohol diluent or dispersant, carboxymethyl cellulose, or similar dispersing agents. Other commonly used surfactants such as Tweens or Spans or other similar emulsifying agents or bioavailability enhancers which are commonly used in the manufacture of pharmaceutically acceptable solid, liquid, or other dosage forms can also be used for the purpose of formulation.
[0034] A composition for oral administration can be any orally acceptable dosage form including capsules, tablets, emulsions and aqueous suspensions, dispersions, and solutions. In the case of tablets, commonly used carriers include lactose and corn starch. Lubricating agents, such as magnesium stearate, are also typically added. For oral administration in a capsule form, useful diluents include lactose and dried corn starch. When aqueous suspensions or emulsions are administered orally, the active ingredient can be suspended or dissolved in an oily phase combined with emulsifying or suspending agents. If desired, certain sweetening, flavoring, or coloring agents can be added.
[0035] A nasal aerosol or inhalation composition can be prepared according to techniques well known in the art of pharmaceutical formulation. For example, such a composition can be prepared as a solution in saline, employing benzyl alcohol or other suitable preservatives, absorption promoters to enhance bioavailability, fluorocarbons, and/or other solubilizing or dispersing agents known in the art. A composition having an active pyrrolidine compounds can also be administered in the form of suppositories for rectal administration.
[0036] The carrier in the pharmaceutical composition must be “acceptable” in the sense that it is compatible with the active ingredient of the composition (and preferably, capable of stabilizing the active ingredient) and not deleterious to the subject to be treated. One or more solubilizing agents can be utilized as pharmaceutical excipients for delivery of an active pyrrolidine compound. Examples of other carriers include colloidal silicon oxide, magnesium stearate, cellulose, sodium lauryl sulfate, and D&C Yellow # 10.
[0037] The pyrrolidine compounds of this invention can be preliminarily screened by an in vitro assay for one or more of their desired activities, e.g., inhibiting DPP-IV. Compounds that demonstrate high activities in the preliminary screening can further be screened for their efficacy by in vivo assays. For example, a test compound can administered to an animal (e.g., a mouse model) having type II diabetes and its therapeutic effects are then accessed. Based on the results, an appropriate dosage range and administration route can also be determined.
[0038] The specific examples below are to be construed as merely illustrative, and not limitative of the remainder of the disclosure in any way whatsoever. Without further elaboration, it is believed that one skilled in the art can, based on the description herein, utilize the present invention to its fullest extent. All of the publications, including patents, cited herein are hereby incorporated by reference in their entirety.
EXAMPLE 1
Preparation of 1-[2-amino-5-(1,3-dihydro-isoindol-2-yl)-5-oxo-pentanoyl]-4-fluoro-pyrrolidine-2-carbonitrile trifluoroacetic acid
[0039]
[0040] A solution of butoxycarbonylamino-L-glutamic acid 5-methyl ester (0.522 g, 2 mmol) and N-hydroxysuccinimide (0.23 g, 2 mmol) in 6 ml dichloromethane (DCM)/1,4-dioxane (2:1) was cooled in an ice-water bath. To this was added N,N′-dicyclohexylcarbodiimide (DCC, 0.45 g, 2.2 mmol). The mixture was stirred at room temperature for 1 hour, and then 4-fluoro-pyrrolidine-2-carboxylic acid amide (0.264 g, 2 mmol) was added. After stirred for 4 hours at room temperature, the mixture was filtered to remove DCC, and then washed with DCM. The combined organic solution was washed with 10% aqueous citric acid solution and saturated aqueous NaHCO 3 solution, dried over MgSO 4 , and concentrated in vacuo. Purification by flash column chromatography (eluted with DCM/MeOH=98/2 to 95/5) afforded 4-tert-butoxycarbonylamino-5-(2-carbamoyl-4-fluoro-pyrrolidin-1-yl)-5-oxo-pentanoic acid methyl ester (85%) as a foam.
[0041] A solution of 4-tert-butoxycarbonylamino-5-(2-carbamoyl-4-fluoro-pyrrolidin-1-yl)-5-oxo-pentanoic acid methyl ester (0.361 g, 1 mmol) in THF/H 2 O was cooled in an ice bath. To this was added LiOH (0.048 g, 2 mmol). After stirred at the low temperature for 3 hours, the reaction solution was partitioned with ethyl acetate and 10% aqueous citric acid. The organic layer was dried over MgSO 4 and concentrated in vacuo to give 4-tert-butoxycarbonylamino-5-(2-carbamoyl-4-fluoro-pyrrolidin-1-yl)-5-oxo-pentanoic acid without further purification.
[0042] A solution of the above-obtained compound and N-hydroxysuccinimide (0.361 g, 1 mmol) in 8 ml DCM/1,4-dioxane (2/1) was cooled in an ice-water bath. To this was added DCC (0.23 g, 1.1 mmol). After the mixture was stirred at room temperature for 1 hour, 2,3-dihydro-1H-isoindole (0.18 g, 1.5 mmol) was added. The reaction mixture was stirred at room temperature for 4 hours, filtered to remove DCC, and then washed by DCM. The combined organic solution was washed with 10% aqueous citric acid solution and saturated aqueous NaHCO 3 solution, dried over MgSO 4 , and concentrated in vacuo. Purification by flash column chromatography (eluted with CH 2 Cl 2 /MeOH from 98/2 to 95/5) afforded [1-(2-Carbamoyl-4-fluoro-pyrrolidine-1-carbonyl)-4-(1,3-dihydro-isoindol-2-yl)-4-oxo-butyl]-carbamic acid tert-butyl ester (83%) as a foam.
[0043] The above-obtained compound (0.462 g, 1 mmol) and imidazole (0.102 g, 1.5 mmol) were dissolved in pyridine (4 ml). The solution was cooled to −20° C. Phopsphoryl chloride (0.23 ml, 2.5 mmol) was added dropwise over a period of 2 minutes and the resulting mixture was stirred at −20° C. for 1 hour. Pyridine was removed by a high vacuum pump, the crude product was washed with 10% aqueous citric acid solution and saturated aqueous NaHCO 3 solution, dried over MgSO 4 , and concentrated in vacuo. Purification by flash column chromatography (eluted with hexane/EA=1/3) yielded N-t-BOC-[2-Amino-5-(1,3-dihydro-isoindol-2-yl)-5-oxo-pentanoyl]-4-fluoro-pyrrolidine-2-carbonitrile (93%) as a foam. This compound was ten dissolved in cool trifluoroacetic acid (2 ml) and stirred at room temperature for 10 minutes and concentrated in vacuo for over night. The title compound was obtained as a taffy.
[0044] 1 H NMR (CDCl 3 ): 8.10-7.23 (m, 4H), 5.50 (s, 0.5 H), 5.34 (s, 0.5 H), 5.01 (d, J=9.3 Hz, 1H), 4.86-4.73 (m, 4H), 4.49 (brs, 1H), 4.07-3.80 (m, 2H), 2.78 (brs, 2H), 2.63 (t, J=15.6 Hz, 1H), 2.50-2.42 (m, 1H), 2.36-2.21 (m, 2H); MS (ESI) m/z: 345.1 (M+H) + , 367.1 (M+Na) + .
EXAMPLE 2
Preparation of 1-[2-amino-5-(1,3-dihydro-isoindol-2-yl)-5-oxo-pentanoyl]-pyrrolidine-2-carbonitrile trifluoroacetic acid
[0045]
[0046] The title compound was prepared in a similar manner as described in Example 1.
[0047] 1 H NMR (CD 3 OD): 7.34-7.27 (m, 4H), 4.87-4.81 (m, overlapped singlet at 4.86, 5H), 4.40 (t, J=5.7 Hz, 1H), 3.87-3.79 (m, 1H), 3.73-3.65 (m, 1H), 2.77 (dd, J=7.2, 5.4 Hz, 2H), 2.37-2.12 (m, 6H); MS (ESI) m/z: 327.3 (M+H) + , 349.3 (M+Na) + .
EXAMPLE 3
Preparation of N-[2-(3-Chloro-phenyl)-cyclopropyl]-3-[2-(2-cyano-pyrrolidin-1-yl)-2-oxo-ethylamino]-3-methyl-butyramide
[0048]
[0049] A solution of 3-tert-butoxycarbonylamino-3-methyl-butyric acid (2.17 g, 10 mmol) and N-hydroxysuccinimide (1.15 g, 10 mmol) in 20 mL DCM/1,4-dioxane (2:1) was cooled in an ice-water bath. To this was added DCC (2.3 g, 11 mmol). The mixture was stirred at room temperature for 1 hour, and then 2-(3-chloro-phenyl)-cyclopropylamine 2.5 g, 15 mmol) was added. After stirred for 4 hours at room temperature, the mixture was filtered to remove DCC, and then washed with DCM. The combined organic solution was washed with 10% aqueous citric acid solution and saturated aqueous NaHCO 3 solution, dried over MgSO 4 , and concentrated in vacuo. Purification by flash column chromatography (eluted with Hexane/CH 2 Cl 2 /EA=4:5:1) yielded 3-N-t-butoxycarbonyl-amino-N′-((1R,2S)-2-(3-chlorophenyl)cyclopropyl)-3-methylbutanamide 2,2,2-trifluoroacetate (88%) as a foam. This compound was dissolved in cool trifluoroacetic acid (2 ml). The resulting solution was stirred at room temperature for 10 minutes and vacuumed overnight. 3-Amino-N-((1R,2S)-2-(3-chlorophenyl)cyclopropyl)-3-methylbutanamide was obtained as a taffy.
[0050] To a solution of the above-obtained compound (0.38 g, 1 mmol) in dry THF (6 ml) was added K 2 CO 3 (1.38 g, 10 mmol), and the reaction was stirred at room temperature for 1.5 hours. The resulting mixture was filtered to remove K 2 CO 3 , and the filtrate was concentrated in vacuo. After the oily residue was diluted with THF (3 ml), (S)-1-(2-bromoacetyl)pyrrolidine-2-carbonitrile was added dropwise. The resultant mixture was stirred at room temperature overnight, washed with saturated aqueous NaHCO 3 solution, dried over MgSO 4 , and concentrated in vacuo. Purification by flash column chromatography (eluted with CH 2 Cl 2 /MeOH: 96:4) yielded the title compound 3 as a light yellow oil.
[0051] 1 H NMR (CDCl 3 )(5/1 mixture of trans/cis amide isomers): 8.65 (d, J=3.3 Hz, 5/6H), 8.45 (d, J=3.3 Hz, 1/6H), 7.18-7.09 (m, 3H), 7.02-6.98 (m, 1H), 4.77-4.74 (m, 5/6H), 4.71 (d, J=2.4 Hz, 1/6H), 3.63-3.38 (m, 4H, overlapped two singlet at 3.46, 3.44), 2.93-2.89 (m, 1H), 2.35-2.15 (m, 6H, overlapped singlet at 2.32), 2.06-1.99 (m, 1H), 1.26-1.43 (m, 8H, overlapped singlet at 1.20).
EXAMPLE 4
Preparation of 3-(2-((2S,4S)-2-cyano-4-fluoropyrrolidin-1-yl)-2-oxoethylamino)-3-methyl-N-((1S,2S)-2-(5-(trifluoromethyl)-1,2,4-oxadiazol-3-yl)cyclopropyl)butanamide
[0052]
[0053] The title compound was prepared in a similar manner as described in Example 3.
[0054] 1 H NMR (CDCl 3 ) (3/1 mixture of trans/cis amide isomers): 8.81 (dd, J=11.7, 3.3 Hz, 3/4H), 8.57 (br d, J=11.7 Hz, 1/4H), 5.54 (t, J=3.3 Hz, 3/8H), 5.46 (t, J=3.3 Hz, 1/8H), 5.37 (t, J=3.3 Hz, 3/8H), 5.28 (t, J=3.3 Hz, 1/8H), 4.96 (d, J=9.0 Hz, 3/4H), 4.84 (d, J=9.0 Hz, 1/4H), 3.92 (dd, J=23.4, 23.1 Hz, 3/4H), 3.78 (d, J=3.9 Hz, 1/4H), 3.74 (d, J=3.9 Hz, 1/4H), 3.68-3.62 (m, 3/4H), 3.49-3.28 (m, 3H), 2.79 (t, J=15.6 Hz, 1/4H), 2.71 (t, J=15.6 Hz, 3/4H), 2.34-2.25 (m, 4H, overlapped singlet at 2.28), 1.58-1.46 (m, 2H), 1.17 (s, 3H), 1.16 (s, 3H).
EXAMPLE 5
Preparation of N-((1S,2R)-2-(3-chlorophenyl)cyclopropyl)-3-(2-((2S,4S)-2-cyano-4-fluoropyrrolidin-1-yl)-2-oxoethylamino)-3-methylbutanamide
[0055]
[0056] The title compound was prepared in a similar manner as described in Example 3.
[0057] 1 H NMR (CDCl 3 ) (4/1 mixture of trans/cis amide isomers): 8.41 (br d, J=3.0 Hz, 4/5H), 8.15 (br s, J=3.0 Hz. 1/5H), 7.17-6.99 (m, 4H), 5.52 (t, J=3.3 Hz, 2/5H), 5.42 (t, J=3.3 Hz, 1/10H), 5.35 (t, J=3.3 Hz, 2/5H), 5.26 (t, J=3.3 Hz, 1/10H), 4.96 (d, J=9.3 Hz, 4/5H), 4.92 (d, J=9.3 Hz, 1/5H), 3.91 (dd, J=23.4, 23.1 Hz, 4/5H), 3.77 (d, J=3.6 Hz, 1/5H), 3.73 (d, J=3.9 Hz, 1/5H), 3.65-3.61 (m, 4/5H), 3.38 (q like, J=16.5 Hz, 2H), 2.94-2.88 (m, 1H), 2.76 (t, J=15.3 Hz, 1/5H), 2.69 (t, J=15.3 Hz, 4/5H), 2.43-2.22 (m, 3H, overlapped singlet at 2.27), 2.05-1.99 (m, 1H), 1.24-1.16 (m, 8H, overlapped singlet at 1.16).
EXAMPLE 6
Preparation of 3-(2-((2S,4S)-2-cyano-4-fluoropyrrolidin-1-yl)-2-oxoethylamino)-N-((1S,2R)-2-(4-methoxyphenyl)cyclopropyl)-3-methylbutanamide
[0058]
[0059] The title compound was prepared in a similar manner as described in Example 3.
[0060] 1 H NMR (CDCl 3 ) (3/1 mixture of trans/cis amide isomers): 8.29 (br d, J=3.3 Hz, 3/4H), 8.00 (br s, J=3.3 Hz. 1/4H), 7.08 (d, J=8.4 Hz, 2H), 6.80 (d, J=8.4 Hz, 2H), 5.50 (t, J=3.0 Hz, 3/8H), 5.42 (t, J=3.0 Hz, 1/8H), 5.33 (t, J=3.0 Hz, 3/8H), 5.24 (t, J=3.0 Hz, 1/8H), 4.97 (d, J=8.8 Hz, 1/4H), 4.95 (d, J=8.8 Hz, 3/4H), 3.96-3.54 (m, 5H, overlapped singlet at 3.76), 3.40 (q like, J=16.5 Hz, 2H), 2.88-2.82 (m, 1H), 2.73 (t, J=15.6 Hz, 1/4H), 2.66 (t, J=15.6 Hz, 3/4H), 2.45-2.23 (m, 3H, overlapped singlet at 2.28), 2.0-1.97 (m, 1H), 1.19-1.09 (m, 8H, overlapped singlet at 1.18).
EXAMPLE 7
Preparation of 3-(2-((2S,4S)-2-cyano-4-fluoropyrrolidin-1-yl)-2-oxoethylamino)-N-((1S,2R)-2-(3-fluorophenyl)cyclopropyl)-3-methylbutanamide
[0061]
[0062] The title compound was prepared in a similar manner as described in Example 3.
[0063] 1 H NMR (CDCl 3 ) (3/1 mixture of trans/cis amide isomers): 8.43 (br d, J=3.3 Hz, 3/4H), 8.42 (br s, J=3.3 Hz, 1/4H), 7.20 (q like, J=7.2 Hz, 1H), 6.94-6.81 (m, 3H), 5.51 (t, J=3.3 Hz, 3/8H), 5.43 (t, J=3.3 Hz, 1/8H), 5.34 (t, J=3.3 Hz, 3/8H), 5.26 (t, J=3.3 Hz, 1/8H), 4.95 (d, J=9.3 Hz, 1H), 3.91 (dd, J=23.7, 23.4 Hz, 3/4H), 3.78 (d, J=3.6 Hz, 1/4H), 3.74 (d, J=3.9 Hz, 1/4H), 3.66-3.61 (m, 3/4H), 3.39 (q like, J=16.5 Hz, 2H), 2.95-2.88 (m, 1H), 2.74 (t, J=15.3 Hz, 1/4H), 2.67 (t, J=15.3 Hz, 3/4H), 2.45-2.22 (m, 3H, overlapped singlet at 2.27), 2.10-1.98 (m, 1H), 1.28-1.17 (m, 8H, overlapped singlet at 1.20).
EXAMPLE 8
Inhibition of DDP-IV Activities
[0064] DPP-IV was purified from human semen according to the method described in de Meester et al. (de Meester et al. (1996) J. Immun. Method 189: 99-105) with minor modifications. Briefly, the semen was diluted with 50 ml of phosphate buffered saline (PBS) and centrifuged at 900 xg for 10 minutes. The supernatant was centrifuged again at 105,000 xg for 120 minutes to separate prostasomes and seminal plasma. The prostasomes, i.e., pellets, and the seminal plasma, i.e., supernatant, were both used for further purification of DPP-IV. The pellets were washed twice with 20 mM Tris-HCl (pH 7.4), and then incubated in 20 mM Tris-HCl (pH 7.4), 1% Triton X-100 for 1 hour at 4° C. The resulting solution was centrifugated at 40,000 xg for 10 minutes to remove prostasomes debris before dialyzed against 20 mM Tris-HCl (pH 7.4), 70 mM NaCl, and 0.1% Triton X-100. The solution was then passed through a DEAE-Sepharose fast flow column (2.6×10 cM) equilibrated with 20 mM Tris-HCl (pH 7.4), 70 mM NaCl and 0.1% Triton X-100 at a flow rate of 2 ml/min. The column was subsequently eluted with 300 ml NaCl (70 to 350 mM) with a linear gradient at a flow rate of 3 ml/min. Positive fractions were pooled and adjusted to pH 8.0 by 0.5 M Tris-HCl (pH 8.0) before applied to an adenosine deaminase-Sepharose columns. The column was prepared as described in de Meester et al. After the column was washed with 10 column volumes of equilibration buffer and then with an equal amount of 50 mM Tris-HCl (pH 7.4) containing 0.5 M NaCl and 0.1% Triton X-100, DPP-IV was eluted with 2 mM Tris-HCl (pH 8.0) containing 0.1% Triton X-100. The supernatant was denatured in 20 mM Tris-HCl (pH 7.4), 1% Tris X-100 for 1 hour at 4° C. The resulting solution was handled as described above to obtain purified DPP-IV.
[0065] The kinetic constant of DPP-IV was measured as follows:
[0066] All reactions were carried out in PBS using H-Gly-Pro-pNA as a substrate in the presence of 10 nM DPP-IV. The reactions were monitored and measured at OD 405 nm. The initial rate was measured when less than 10% substrate was depleted. The steady state parameters, k cat (=V max /[E]) and K m , were determined from initial velocity measurements at 0.5-5 K m of the substrate concentrations for the first 300 seconds. Lineweaver-Burk plots were obtained using non-linear regression of the classic Michaelis-Menten equation (equation 1) to obtain K m values. The k cat was calculated from V max /[E] with the molecular weight of DPP-IV taken as 85,000.
V 0 =V max [S ]/( K m +[S ]) (equation 1)
[0067] where V 0 is the initial velocity, [S] is the substrate concentration, V max is the maximum velocity and K m is the Michaelis constant. Correlation coefficients better than 0.990 were obtained throughout.
[0068] A number of compounds of this invention were tested for their IC 50 values for inhibiting DPP-IV. The tested were carried out at 37° C. in 20 mM Tris-HCl (pH 8.0) or in PBS, with purified human semen DPP-IV. The substrate used in the tested was 500 uM H-Gly-Pro-pNA. For each compound, different concentrations were assayed to generate data points, from which the IC 50 value was calculated using the Sigma plot. All tested compounds exerted inhibitory activities against DPP-IV. Surprisingly, some of the tested compounds had the IC 50 values lower than 10 nM.
OTHER EMBODIMENTS
[0069] All of the features disclosed in this specification may be combined in any combination. Each feature disclosed in this specification may be replaced by an alternative feature serving the same, equivalent, or similar purpose. Thus, unless expressly stated otherwise, each feature disclosed is only an example of a generic series of equivalent or similar features.
[0070] From the above description, one skilled in the art can easily ascertain the essential characteristics of the present invention, and without departing from the spirit and scope thereof, can make various changes and modifications of the invention to adapt it to various usages and conditions. For example, compounds structurally analogous to pyrrolidine compounds of this invention also can be made, screened for their inhibitory activities against DPP-IV and treating Type II diabetes and used to practice this invention. Thus, other embodiments are also within the claims. | Pyrrolidine compounds described herein and methods for using them to inhibit dipeptidyl peptidase IV or treat Type II diabetes. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority of the U.S. Provisional Application No. 60/829,615 filed on Oct. 16, 2006, in the United States Patent and Trademark Office, the disclosure of which is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present general inventive concept relates to an anchor system and method for use, for example, in concrete construction, and more particularly, to an anchor system and method which includes a body having a front plate, a top plate, and a back plate and a strap inserted in body such that the body may be fixed in or to concrete or other hard building material with the strap protruding so the strap may be fixed to construction material, for example the framework of a building, steel beam, or roadway.
[0004] 2. Description of the Related Art
[0005] There are several known approaches for anchoring systems for use in the construction industry. Anchor systems are used, for example, to attach two or more concrete slabs together or to attach a concrete slab to another structure. Anchoring systems can be pre or post-installed. The anchor system is either encased in concrete when the pre-fabricated wall is poured or is attached, usually by bolting, to the concrete or other material. One common anchoring systems is for the anchor to be bolted to the building structure and then a steel beam or some framework is secured, through bolting system or soldering, to the anchor.
[0006] As structures get larger and more complex, the anchoring systems need to be more versatile allowing for variety of positioning within the building structure. Also, increasing the safety and strength capacity of anchoring systems desired. The amount of load that can be attached to the anchor system is relevant. It is therefore advantageous to have an anchoring system that has increased strength potential. An anchoring system that can be used in a variety of situations for a variety of different loads is advantageous.
SUMMARY OF THE INVENTION
[0007] The present general inventive concept relates to an adjustable anchor system and method for use in concrete construction. The present general inventive concept comprises a body with a front plate, a top plate, and a rear plate and a strap with a notch at the head for insertion in an elliptical bore in the top plate The front plate, top plate, and rear plate are all generally rectangular in shape. The front and rear plates each have at least one leg extending from the main body of the plate and at least one member extending generally perpendicular to the plate at approximately ninety degrees. The top plate has a raised lip that is reinforced and where the angled edge of the strap fits. The body can be encased in concrete, such as a wall for a building. A strap may be inserted in the elliptical bore of the body and is fixed, by welding, soldering, or bonding, to the building framework, either a steal beam or metal plate within another piece of concrete. In the bend of the at least one member, there is a punch out. The punch out serves as another means to secure the anchor system to the building material and increases the strength and the amount the anchor system can hold. The body can be made of low corrosion metal or is coated in a J-finish or other such non-corrosive finish.
[0008] The modular design concept offers improved pullout capacity of the basic anchor system. Higher capacities are achieved by the addition of component parts, for example studs in the members of the body. The present general inventive concept may be prefabricated and manufactured using an automated process that offers consistent performance levels and reliability. Because the anchor system is prefabricated and the strap is adjustable, the cost of manufacturing the anchor system is greatly reduced. The anchor system can be adjusted to fit the needs of different building structures. The anchor system is an easy, safe, accurate and economical method to locate and connect pre-cast panels to framework while decreasing building costs.
[0009] The foregoing and other objects are intended to be illustrative of the general inventive concept and are not meant in a limiting sense. Many possible embodiments of the general inventive concept may be made and will be readily evident upon a study of the following specification and accompanying drawings comprising a part thereof. Various features and subcombinations of general inventive concept may be employed without reference to other features and subcombinations. Other objects and advantages of this general inventive concept will become apparent from the following description taken in connection with the accompanying drawings, wherein is set forth by way of illustration and example, an embodiment of this general inventive concept and various features thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] A preferred embodiment of the general inventive concept, illustrative of the best mode in which the Applicant has contemplated applying the principles, is set forth in the following description and is illustrated in the drawings and is particularly and distinctly pointed out and set forth in the appended claims.
[0011] FIG. 1 is a perspective view illustrating a body of an anchor system for concrete construction of the present general inventive concept.
[0012] FIG. 2 is a top view illustrating the body of the anchor system for concrete construction of FIG. 1 .
[0013] FIG. 3 is a side view illustrating the body of the anchor system for concrete construction of FIG. 1 .
[0014] FIG. 4 is a front view illustrating the body of the anchor system for concrete construction of FIG. 1 .
[0015] FIG. 5 is a top view illustrating a strap insert for the anchor system for concrete construction of the present general inventive concept.
[0016] FIG. 6 is a side view illustrating the strap insert for the anchor system for concrete construction of FIG. 5 .
[0017] FIG. 7 is a perspective view illustrating the anchor system for concrete construction with the body engaged with the strap of the present general inventive concept.
[0018] FIG. 8 is a perspective view illustrating the anchor system for concrete construction with the body and the strap of the present general inventive concept.
[0019] FIG. 9 is a perspective view illustrating the anchor system for concrete construction in use with the strap extending from concrete.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] As required, one or more detailed embodiments of the present general inventive concept are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the principles of the general inventive concept, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present general inventive concept in virtually any appropriately detailed structure.
[0021] One embodiment of the present general inventive concept comprises a body 12 , illustrated in FIGS. 1-4 , and a strap 50 , illustrated in FIGS. 5-6 , that coordinate as an anchor system 10 , illustrated in FIGS. 7-9 . FIGS. 1-4 illustrate one embodiment of the present general inventive concept comprising body 12 with a front plate 20 , a top plate 40 , and a rear plate 30 . In one preferred embodiment the plates are generally square or rectangular in shape. Front plate 20 and rear plate 30 are parallel to each other and perpendicular to top plate 40 . Front plate 20 has at least one leg 21 a extending from the main body of front plate 20 in a direction away from top plate 40 . Leg 21 a has a bore 22 a in the approximate center of leg 21 a. Front plate 20 has at least one member 23 a extending perpendicular to front plate 20 at approximately ninety degrees and being parallel to top plate 40 . Member 23 a has a bore 24 a in the approximate center of member 23 a . A reinforced punch 25 a is located in a bend 26 a of the angle where member 23 a extends. Rear plate 30 has at least one leg 31 a extending from the main body of rear plate 30 in a direction away from top plate 40 . Leg 31 a has a bore 32 a in the approximate center of leg 31 a. Rear plate 30 has at least one member 33 a extending perpendicular to front plate 30 at approximately ninety degrees and being parallel to top plate 40 . Member 33 a has a bore 34 a in the approximate center of member 33 a . A reinforced punch 35 a is located in a bend 36 a of the angle where member 33 a extends. FIG. 2 illustrates the manner in which the members ( 23 a , 23 b , 33 a , and 33 b ) extend away from the main part of the body 12 . Top plate 40 has a large elliptical bore 41 . In one preferred embodiment elliptical bore 41 is almost as large as top plate 40 . A raised lip 42 surrounds the opening of elliptical bore 41 , and is raised and extends away from the body 12 .
[0022] In a preferred embodiment, body 12 will have 3 legs and 2 members on both the front plate 20 and the rear plate 30 for a total of 6 legs ( 21 a, 21 b, 21 c, 32 a , 32 b , and 32 c ) and 4 members ( 23 a , 23 b , 33 a , and 33 b ). FIG. 2 illustrates a top view of a preferred embodiment with members 23 a , 23 b , 33 a , and 33 b extending away from the main part of body 12 .
[0023] FIGS. 5 and 6 illustrate strap 50 . Strap 50 comprises a head 54 and a strap body 53 and an end 53 where head 54 is smaller than strap body 53 . Head 54 has a notch 51 . Strap 50 has an angled edge 55 between notch 51 and strap body 53 . Strap 50 engages with body 12 by insertion in elliptical bore 41 . Angled part 55 is sized and shaped to correspond to matingly engage with raised lip 42 . FIG. 7 illustrates one embodiment of the anchor system for concrete construction fully assembled. Strap body 53 is welded to a plate (not illustrated) embedded into a concrete slab or a steel beam of a building.
[0024] The anchor system is used in the construction industry to strengthen the framework of a building and is used as a connector of various construction pieces in a commercial building that is built with concrete and steel beams. In one preferred embodiment, the anchor system is encased in concrete when the concrete is poured for the building. Often building walls are first poured and then lifted into place for the building. When the concrete is poured, it is common to have other support materials within the walls. FIG. 9 illustrates the use of the anchor system in concrete where the body is encased in concrete and the elliptical bore can be seen with the strap sticking out of the concrete structure. The strap may then be attached, for example, by soldering to the framework of a building or structure, to a steel beam, and/or a metal plate within another piece of concrete. In one embodiment, the strap used is a flat strap as illustrated in FIGS. 5-7 . In another embodiment, illustrated in FIG. 8 , the strap used is threaded on one end and that end is coupled to the body of the anchor system 10 . FIG. 8 illustrates an embodiment where studs 61 are coupled to the bores (e.g., 34 a ) in the members (e.g., 33 a ) of the body 12 for added reinforcement when embedded in concrete.
[0025] In some structures it is advantages to run metal lines within the concrete as well and the anchor system 10 such that metal lines may be run through one or more of the bores (e.g., 22 a ) in the legs (e.g., 21 a ) and/or one or more of the bores (e.g., 34 a ) in the members (e.g., 33 a ) of the body.
[0026] In one embodiment, the anchor system 10 , including the body 12 and the strap 53 , is coated in a less corrosive finish, for example a J-finish.
[0027] In the foregoing description, certain terms have been used for brevity, clearness and understanding; but no unnecessary limitations are to be implied therefrom beyond the requirements of the prior art, because such terms are used for descriptive purposes and are intended to be broadly construed. Moreover, the description and illustration of the general inventive concept are by way of example, and the scope of the general inventive concept is not limited to the exact details illustrated or described.
[0028] Although the foregoing detailed description of the present general inventive concept has been described by reference to an exemplary embodiment, and the best mode contemplated for carrying out the present general inventive concept has been illustrated and described, it will be understood that certain changes, modification or variations may be made in embodying the above general inventive concept, and in the construction thereof, other than those specifically set forth herein, may be achieved by those skilled in the art without departing from the spirit and scope of the general inventive concept, and that such changes, modification or variations are to be considered as being within the overall scope of the present general inventive concept. Therefore, it is contemplated to cover the present general inventive concept and any and all changes, modifications, variations, or equivalents that fall within the true spirit and scope of the underlying principles disclosed and claimed herein. Consequently, the scope of the present general inventive concept is intended to be limited only by the attached claims, all matter contained in the above description and illustrated in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
[0029] Having now described the features, discoveries and principles of the general inventive concept, the manner in which the general inventive concept is constructed and used, the characteristics of the construction, and advantageous, new and useful results obtained; the new and useful structures, devices, elements, arrangements, parts and combinations, are set forth in the appended claims.
[0030] It is also to be understood that the following claims are intended to cover all of the generic and specific features of the general inventive concept herein described, and all statements of the scope of the general inventive concept which, as a matter of language, might be said to fall therebetween. | An anchor system and method to provide support in concrete construction including a concrete-embeddable body having an aperture, one or more concrete anchor legs situated on a first plane, and one or more concrete anchor members situated on a second plane that is different from the first plane, and a strap having a matable head and an elongated strap body, wherein the matable head of the strap lockingly engages the aperture of the concrete-embeddable body. | 4 |
BACKGROUND OF THE INVENTION
Growth hormone, which is secreted from the pituitary, stimulates growth of all tissues of the body that are capable of growing. In addition, growth hormone is known to have the following basic effects on the metabolic process of the body:
1. Increased rate of protein synthesis in all cells of the body;
2. Decreased rate of carbohydrate utilization in cells of the body;
3. Increased mobilization of free fatty acids and use of fatty acids for energy.
A deficiency in growth hormone secretion can result in various medical disorders, such as dwarfism.
Various ways are known to release growth hormone. For example, chemicals such as arginine, L-3,4-dihydroxyphenylalanine (L-DOPA), glucagon, vasopressin, and insulin induced hypoglycemia, as well as activities such as sleep and exercise, indirectly cause growth hormone to be released from the pituitary by acting in some fashion on the hypothalamus perhaps either to decrease somatostatin secretion or to increase the secretion of the known secretagogue growth hormone releasing factor (GRF) or an unknown endogenous growth hormone-releasing hormone or all of these.
In cases where increased levels of growth hormone were desired, the problem was generally solved by providing exogenous growth hormone or by administering an agent which stimulated growth hormone production and/or release. In either case the peptidyl nature of the compound necessitated that it be administered by injection. Initially the source of growth hormone was the extraction of the pituitary glands of cadavers. This resulted in a very expensive product and carried with it the risk that a disease associated with the source of the pituitary gland could be transmitted to the recipient of the growth hormone. Recently, recombinant growth hormone has become available which, while no longer carrying any risk of disease transmission, is still a very expensive product which must be given by injection or by a nasal spray.
Other compounds have been developed which stimulate the release of endogenous growth hormone such as analogous peptidyl compounds related to GRF or the peptides of U.S. Pat. No. 4,411,890. These peptides, while considerably smaller than growth hormones are still susceptible to various proteases. As with most peptides, their potential for oral bioavailability is low. The instant compounds are non-peptidyl agents for promoting the release of growth hormone which may be administered parenterally, nasally or by the oral route.
SUMMARY OF THE INVENTION
The instant invention covers certain benzo-fused lactam compounds which have the ability to stimulate the release of natural or endogenous growth hormone. The compounds thus have the ability to be used to treat conditions which require the stimulation of growth hormone production or secretion such as in humans with a deficiency of natural growth hormone or in animals used for food production where the stimulation of growth hormone will result in a larger, more productive animal. Thus, it is an object of the instant invention to describe the benzo-fused lactam compounds. It is a further object of this invention to describe procedures for the preparation of such compounds. A still further object is to describe the use of such compounds to increase the secretion of growth hormone in humans and animals. A still further object of this invention is to describe compositions containing the benzo-fused lactam compounds for the use of treating humans and animals so as to increase the level of growth hormone secretions. Further objects will become apparent from a reading of the following description.
DESCRIPTION OF THE INVENTION
The novel benzo-fused lactams of the instant invention are best described in the following structural formula I: ##STR1## where L is ##STR2## R 1 , R 2 , R 1a , R 2a , R 1b and R 2b are independently hydrogen, halogen, C 1 -C 7 alkyl, C 1 -C 3 perfluoroalkyl, C 1 -C 3 perfluoroalkoxy, --S(O) m R 7a , cyano, nitro, R 7b O(CH 2 ) v --, R 7b COO(CH 2 ) v --, R 7b OCO(CH 2 ) v --, R 12a R 12b N(CH 2 ) v --, R 12a R 12b NCO(CH 2 ) v --, R 12a R 12b NCOO(CH 2 ) v --, phenyl or substituted phenyl where the substituents are from 1 to 3 of halogen, C 1 -C 6 alkyl, C 1 -C 6 alkoxy, or hydroxy;
R 7a and R 7b are independently hydrogen, C 1 -C 3 perfluoroalkyl, C 1 -C 6 alkyl, substituted C 1 -C 6 alkyl, where the substituents are phenyl or substituted phenyl; phenyl or substituted phenyl where the phenyl substituents are from 1 to 3 of halogen, C 1 -C 6 alkyl, C 1 -C 6 alkoxy, or hydroxy and v is 0 to 3;
R 3a and R 3b are independently hydrogen, R 9 , C 1 -C 6 alkyl substituted with R 9 , phenyl substituted with R 9 or phenoxy substituted with R 9 with the proviso that either R 3a and R 3b must be a substitutent other than hydrogen;
R 9 is
R 4a R 12a NSO 2 (CH 2 ) v --,
R 4a R 12a NN(R 12b )SO 2 (CH 2 ) v --,
R 4a R 12a NCON(R 12b )SO 2 (CH 2 ) v --,
R 4a R 12a NCSN(R 12b )SO 2 (CH 2 ) v --,
R 4a R 12a NN(R 12b )CON(R 12b )SO 2 (CH 2 ) v --,
R 4a R 12a NN(R 12b )CSN(R 12b )SO 2 (CH 2 ) v --,
or R 13 OCON(R 12b )SO 2 (CH 2 ) v --, where v is 0 to 3;
R 12a , R 12b and R 12c are independently R 5a , OR 5a or COR 5a . R 12a and R 12b , or R 12b and R 12c , or R 13 and R 12b , or R 12a and R 4a can be taken together to form --(CH 2 ) r --B--(CH 2 ) s -- where B is CHR 1 , O, S(O) m or NR 10 , m is 0, 1 or 2, r and s are independently 0 to 3 and R 1 and R 10 are as defined;
R 13 is C 1 -C 3 perfluoroalkyl, C 1 -C 6 alkyl, substituted C 1 -C 6 alkyl, where the substitutents are hydroxy, --NR 10 R 11 , carboxy, phenyl or substituted phenyl; phenyl or substituted phenyl where the substituents on the phenyl are from 1 to 3 of halogen, C 1 -C 6 alkyl, C 1 -C 6 alkoxy or hydroxy where R 10 and R 11 are independently hydrogen, C 1 -C 6 alkyl, phenyl, phenyl C 1 -C 6 alkyl, C 1 -C 5 -alkoxycarbonyl or C 1 -C 5 alkanoyl-C 1 -C 6 alkyl;
R 4 , R 4a , R 5 and R 5a are independently hydrogen, phenyl, substituted phenyl, C 1 -C 10 alkyl, substituted C 1 -C 10 alkyl, C 3 -C 10 alkenyl, substituted C 3 -C 10 alkenyl, C 3 -C 10 alkynyl or substituted C 3 -C 10 alkynyl where the substituents on the phenyl, alkyl, alkenyl or alkynyl are from 1 to 5 of hydroxy, C 1 -C 6 alkoxy, C 3 -C 7 cycloalkyl, fluoro, R 1 , R 2 independently disubstituted phenyl, R 1 , R 2 independently disubstituted phenyl C 1 -C 3 alkoxy, C 1 -C 20 -alkanoyloxy, C 1 -C 5 alkoxycarbonyl, carboxy, formyl or --NR 10 R 11 where R 1 , R 2 , R 10 and R 11 are as defined above; or R 4 and R 5 can be taken together to form --(CH 2 ) r --B--(CH 2 ) s -- where B is CHR 1 , O, S(O) m or N--R 10 , r and s are independently 1 to 3, m is 0, 1 or 2 and R 1 and R 10 are as defined above;
R 6 is hydrogen, C 1 -C 10 alkyl, phenyl or phenyl C 1 -C 10 alkyl;
A is ##STR3## where x and y are independently 0-3; R 8 and R 8a are independently hydrogen, C 1 -C 10 alkyl, trifluoromethyl, phenyl, substituted C 1 -C 10 alkyl where the substitutents are from 1 to 3 of imidazolyl, indolyl, hydroxy, fluoro, --S(O) m R 7a , C 1 -C 6 alkoxy, C 3 -C 7 cycloalkyl, R 1 , R 2 independently disubstituted phenyl, R 1 , R 2 independently disubstituted phenyl C 1 -C 3 alkoxy, C 1 -C 5 alkanoyloxy, C 1 -C 5 alkoxycarbonyl, carboxy, formyl or --NR 10 R 11 where R 1 , R 2 , R 7a , R 10 , R 11 and m are as defined above; or R 8 and R 8a can be taken together to form --(CH 2 ) t -- where t is 2 to 6; and R 8 and R 8a can independently be joined to one or both of R 4 and R 5 to form alkylene bridges between the terminal nitrogen and the alkyl portion of the A group wherein the bridge contains from one to five carbon atoms; and pharmaceutically acceptable salts thereof.
In the above structural formula and throughout the instant specification, the following terms have the indicated meanings:
The alkyl groups specified above are intended to include those alkyl groups of the designated length in either a straight or branched configuration. Exemplary of such alkyl groups are methyl, ethyl, propyl, isopropyl, butyl, sec-butyl, tertiary butyl, pentyl, isopentyl, hexyl, isohexyl, and the like.
The alkoxy groups specified above are intended to include those alkoxy groups of the designated length in either a straight or branched configuration. Exemplary of such alkoxy groups are methoxy, ethoxy, propoxy, isopropoxy, butoxy, isobutoxy, tertiary butoxy, pentoxy, isopentoxy, hexoxy, isohexoxy and the like.
The term "halogen" is intended to include the halogen atoms fluorine, chlorine, bromine and iodine.
Certain of the above defined terms may occur more than once in the above formula and upon such occurrence each term shall be defined independently of the other.
Preferred compounds of the instant invention are realized when in the above structural formula:
n is 0 or 1;
p is 0 to 3;
q is 0 to 2;
w is0or 1;
X is O, S(O) m , ##STR4## m is 0 to 2; R 1 , R 2 , R 1a , R 2a , R 1b and R 2b are independently hydrogen, halogen, C 1 -C 7 alkyl, C 1 -C 3 perfluoroalkyl, --S(O) m R 7a , R 7b O(CH 2 ) v --, R 7b COO(CH 2 ) v --, R 7b OCO(CH 2 ) v --, phenyl or substituted phenyl where the substituents are from 1 to 3 of halogen, C 1 -C 6 alkyl, C 1 -C 6 alkoxy, or hydroxy;
R 7a and R 7b are independently hydrogen, C 1 -C 3 perfluoroalkyl, C 1 -C 6 alkyl, substituted C 1 -C 6 alkyl where the substitutents are phenyl; phenyl and v is 0 to 2;
R 3a and R 3b are independently hydrogen, R 9 , C 1 -C 6 alkyl substituted with R 9 , phenyl substituted with R 9 or phenoxy substituted with R 9 with the proviso that either R 3a and R 3b must be a substitutent other than hydrogen;
R 9 is
R 4a R 12a NSO 2 (CH 2 ) v --,
R 4a R 12a NN(R 12b )SO 2 (CH 2 ) v --,
R 4a R 12a NCON(R 12b )SO 2 (CH 2 ) v --,
R 4a R 12a NN(R 12b )CON(R 12b )SO 2 (CH 2 ) v --,
or R 13 OCON(R 12b )SO 2 (CH 2 ) v --, where v is 0 to 3;
R 12a , R 12b and R 12c are independently R 5a , OR 5a or COR 5a . R 12a and R 12b , or R 12b and R 12c , or R 13 and R 12b , or R 12a and R 4a can be taken together to form --(CH 2 ) r --B--(CH 2 ) s -- where B is CHR 1 , O, S(O) m or NR 10 , m is 0, 1 or 2, r and s are independently 0 to 3 and R 1 and R 10 are as defined;
R 13 is C 1 -C 3 perfluoroalkyl, C 1 -C 6 alkyl, substituted C 1 -C 6 alkyl, where the substitutents are hydroxy, --NR 10 R 11 , carboxy, phenyl or substituted phenyl; phenyl or substituted phenyl where the substituents on the phenyl are from 1 to 3 of halogen, C 1 -C 6 alkyl, C 1 -C 6 alkoxy or hydroxy where R 10 and R 11 are independently hydrogen, C 1 -C 6 alkyl, phenyl, phenyl C 1 -C 6 alkyl or C 1 -C 5 -alkanoyl-C 1 -C 6 alkyl;
R 4 , R 4a , R 5 and R 5a are independently hydrogen, phenyl, substituted phenyl, C 1 -C 10 alkyl, substituted C 1 -C 10 alkyl where the substituents on the alkyl or phenyl are from 1 to 5 of hydroxy, C 1 -C 6 alkoxy, C 3 -C 7 cycloalkyl, fluoro, R 1 , R 2 independently disubstituted phenyl, R 1 , R 2 independently disubstituted phenyl C 1 -C 3 alkoxy, C 1 -C 20 -alkanoyloxy, C 1 -C 5 alkoxycarbonyl, carboxy or formyl; R 4 and R 5 can be taken together to form --(CH 2 ) r --B--(CH 2 ) s -- where B is CHR 1 , O, S(O) m or N--R 10 , r and s are independently 1 to 3, m is 0, 1 or 2 and R 1 and R 10 are as defined above;
R 6 is hydrogen, C 1 -C 10 alkyl or phenyl C 1 -C 10 alkyl;
A is ##STR5## where x and y are independently 0-2; R 8 and R 8a are independently hydrogen, C 1 -C 10 alkyl, substituted C 1 -C 10 alkyl where the substitutents are from 1 to 3 of imidazolyl, indolyl, hydroxy, fluoro, --S(O) m R 7a , C 1 -C 6 alkoxy, R 1 , R 2 independently disubstituted phenyl, C 1 -C 5 alkanoyloxy, C 1 -C 5 alkoxycarbonyl, carboxy, formyl or--NR 10 R 11 where R 1 , R 2 , R 7a , R 10 , R 11 and m are as defined above; or R 8 and R 8a can be taken together to form --(CH 2 ) t -- where t is 2 to 4; and R 8 and R 8a can independently be joined to one or both of R 4 and R 5 to form alkylene bridges between the terminal nitrogen and the alkyl portion of the A group wherein the bridge contains from one to five carbon atoms;
and pharmaceutically acceptable salts thereof.
Additional preferred compounds are realized in the above structural formula when:
n is 0 or 1;
p is 0 to 2;
q is 0 to 2;
w is 0 or 1;
X is S(O) m or --CH═CH--;
m is 0 to 1;
R 1 , R 2 , R 1a , R 2a , R 1b and R 2b are independently hydrogen, halogen, C 1 -C 7 alkyl, C 1 -C 3 perfluoroalkyl, --S(O) m R 7a , R 7b O(CH 2 ) v --, R 7b COO(CH 2 ) v --, R 7b OCO(CH 2 ) v --, phenyl or substituted phenyl where the substituents are from 1 to 3 of halogen, C 1 -C 6 alkyl, C 1 -C 6 alkoxy, or hydroxy;
R 7a and R 7b are independently hydrogen, C 1 -C 6 alkyl or substituted C 1 -C 6 alkyl where the substitutents are phenyl and v is 0 to 2;
R 3a and R 3b are independently hydrogen, R 9 , C 1 -C 6 alkyl substituted with R 9 or phenoxy substituted with R 9 with the proviso that either R 3a and R 3b must be a substitutent other than hydrogen;
R 9 is
R 4a R 12a NSO 2 (CH 2 ) v --,
R 4a R 12a NN(R 12b )SO 2 (CH 2 ) v --,
R 4a R 12a NCON(R 12b )SO 2 (CH 2 ) v --,
or R 13 OCON(R 12b )SO 2 (CH 2 ) v --, where v is 0 to 2;
R 12a , R 12b and R 12c are independently R 5a or COR 5a . R 12a and R 12b , or R 12b and R 12c , or R 13 and R 12b , or R 12a and R 4a can be taken together to form --(CH 2 ) r --B--(CH 2 ) s -- where B is CHR 1 , O, S(O) m or NR 10 , m is 0, 1 or 2, r and s are independently 0 to 2 and R 1 and R 10 are as defined;
R 13 is C 1 -C 6 alkyl, substituted C 1 -C 6 alkyl, where the substitutents are phenyl or substituted phenyl; phenyl or substituted phenyl where the substituents on the phenyl are from 1 to 3 of halogen, C 1 -C 6 alkyl, C 1 -C 6 alkoxy or hydroxy;
R 4 , R 4a , R 5 and R 5a are independently hydrogen, C 1 -C 10 alkyl or substituted C 1 -C 10 alkyl where the substituents are from 1 to 5 of hydroxy, C 1 -C 6 alkoxy, fluoro, R 1 , R 2 independently disubstituted phenyl, C 1 -C 20 -alkanoyloxy, C 1 -C 5 alkoxycarbonyl or carboxy; where R 1 and R 2 are as defined above;
R 6 is hydrogen or C 1 -C 10 alkyl;
A is ##STR6## where x and y are independently 0-2; R 8 and R 8a are independently hydrogen, C 1 -C 10 alkyl, substituted C 1 -C 10 alkyl where the substitutents are from 1 to 3 of imidazolyl, indolyl, hydroxy, fluoro, --S(O) m R 7a , C 1 -C 6 alkoxy, R 1 , R 2 independently disubstituted phenyl, C 1 -C 5 alkanoyloxy, C 1 -C 5 alkoxycarbonyl or carboxy where R 1 , R 2 , R 7a and m are as defined above; or R 8 and R 8a can be taken together to form --(CH 2 ) t -- where t is 2; and R 8 and R 8a can independently be joined to one or both of R 4 and R 5 to form alkylene bridges between the terminal nitrogen and the alkyl portion of the A group wherein the bridge contains from one to five carbon atoms;
and pharmaceutically acceptable salts thereof.
Still further preferred compounds of the instant invention are realized in the above structural formula when;
n is 0 or 1;
p is 0 to 2;
q is 1;
w is 1;
X is S(O) m or --CH═CH--;
m is 0 to 1;
R 1 , R 2 , R 1a , R 2a , R 1b and R 2b are independently hydrogen, halogen, C 1 -C 7 alkyl, C 1 -C 3 perfluoroalkyl, --S(O) m R 7a , R 7b O(CH 2 ) v --, R 7b COO(CH 2 ) v --, phenyl or substituted phenyl where the substituents are from 1 to 3 of halogen, C 1 -C 6 alkyl, C 1 -C 6 alkoxy, or hydroxy; R 7a and R 7b are independently hydrogen, C 1 -C 6 alkyl or substituted C 1 -C 6 alkyl where the substitutents are phenyl and v is 0 or 1;
R 3a and R 3b are independently hydrogen, R 9 or C 1 -C 6 alkyl substituted with R 9 , with the proviso that either R 3a and R 3b must be a substitutent other than hydrogen;
R 9 is
R 4a R 12a NSO 2 (CH 2 ) v --,
R 4a R 12a NCON(R 12b )SO 2 (CH 2 ) v --,
or R 13 OCON(R 12b )SO 2 (CH 2 ) v -- where v is 0 or 1;
R 12a , R 12b and R 12c are independently R 5a or COR 5a . R 12a and R 12b , or R 12b and R 12c , or R 13 and R 12b , or R 12a and R 4a can be taken together to form --(CH 2 ) r --B--(CH 2 ) s -- where B is CHR 1 , O, S(O) m or NR 10 , m is 0, 1 or 2, r and s are independently 0 to 2 and R 1 and R 10 are as defined;
R 13 is C 1 -C 6 alkyl, substituted C 1 -C 6 alkyl, where the substitutents are phenyl or substituted phenyl; phenyl or substituted phenyl where the substituents on the phenyl are from 1 to 3 of halogen, C 1 -C 6 alkyl, C 1 -C 6 alkoxy or hydroxy;
R 4 , R 4a , R 5 and R 5a are independently hydrogen, C 1 -C 10 alkyl or substituted C 1 -C 10 alkyl where the substituents are from 1 to 3 of hydroxy, C 1 -C 3 alkoxy, fluoro, R 1 , R 2 independently disubstituted phenyl, C 1 -C 20 -alkanoyloxy, C 1 -C 5 alkoxycarbonyl or carboxy; where R 1 and R 2 are as defined above;
R 6 is hydrogen;
A is ##STR7## where x and y are independently 0 or 1; R 8 and R 8a are independently hydrogen, C 1 -C 10 alkyl, substituted C 1 -C 10 alkyl where the substitutents are from 1 to 3 of imidazolyl, indolyl, hydroxy, fluoro, --S(O) m R 7a , C 1 -C 6 alkoxy, R 1 , R 2 independently disubstituted phenyl, C 1 -C 5 alkanoyloxy, C 1 -C 5 alkoxycarbonyl or carboxy where R 1 , R 2 , R 7a and m are as defined above; or R 8 and R 8a can be taken together to form --(CH 2 ) t -- where t is 2; and R 8 and R 8a can independently be joined to one or both of R 4 and R 5 to form alkylene bridges between the terminal nitrogen and the alkyl portion of the A group wherein the bridge contains from one to five carbon atoms;
and pharmaceutically acceptable salts thereof.
Representative preferred growth hormone releasing compounds of the present invention include the following:
1. 3-Amino-3-methyl-N-[1-[[2'-(benzamido)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]butanamide;
2. 3-Amino-3-methyl-N-[1-[[2'-(benzamido)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-7-fluoro-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]butanamide;
3. 3-Amino-3-methyl-N-[1-[[2'-(benzamido)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-7-trifluoromethyl-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]butanamide;
4. 3-Amino-3-methyl-N-[1-[[2'-(benzamido)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-7-methylthio-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl ]butanamide;
5. 3-Amino-3-methyl-N-[1-[[2'-(benzamido)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-7-methoxy-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]butanamide;
6. 2-Amino-2-methyl-N-[1-[[2'-(benzamido)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]propanamide;
7. 2-Amino-2-methyl-N-[1-[[2'-(benzamido)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-7-fluoro-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]propanamide;
8. 2-Amino-2-methyl-N-[1-[[2'-(benzamido)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-7-trifluoromethyl-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]propanamide;
9. 2-Amino-2-methyl-N-[1-[[2'-(benzamido)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-7-methylthio-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]propanamide;
10. 2-Amino-2-methyl-N-[1-[[2'-(benzamido)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-7-methoxy-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]propanamide;
11. 3-[2(R)-Hydroxypropyl]amino-3-methyl-N-[1-[[2'-(benzamido)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]butanamide;
12. 3-[2(R)-Hydroxypropyl]amino-3-methyl-N-[1-[[2'-(benzamido)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-7-fluoro-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]butanamide;
13. 3-[2(R)-Hydroxypropyl]amino-3-methyl-N-[1-[[2'-(benzamido)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-7-trifluoromethyl-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]butanamide;
14. 3-[2(R)-Hydroxypropyl]amino-3-methyl-N-[1-[[2'-(benzamido)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-7-methylthio-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]butanamide;
15. 3-[2(R)-Hydroxypropyl]amino-3-methyl-N-[1-[[2'-(benzamido)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-7-methoxy-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]butanamide;
16. 3-[2(S),3-Dihydroxypropyl]amino-3-methyl-N-[1-[[2'-(benzamido)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]butanamide;
17. 3-[2(S),3-Dihydroxypropyl]amino-3-methyl-N-[1-[[2'-(benzamido)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-7-fluoro-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]butanamide;
18. 3-[2(S),3-Dihydroxypropyl]amino-3-methyl-N-[1-[[2'-(benzamido)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-7-trifluoromethyl-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]butanamide;
19. 3-[2(S),3-Dihydroxypropyl]amino-3-methyl-N-[1-[[2'-(benzamido)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-7-methylthio-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]butanamide;
20. 3-[2(S),3-Dihydroxypropyl]amino-3-methyl-N-[1-[[2'-(benzamido)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-7-methoxy-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]butanamide;
21. 3-Amino-3-methyl-N-[1-[[2'-(ethylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]butanamide;
22. 3-Amino-3-methyl-N-[1-[[2'-(ethylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-7-fluoro-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]butanamide;
23. 3-Amino-3-methyl-N-[1-[[2'-(ethylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-7-trifluoromethyl-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]butanamide;
24. 3-Amino-3-methyl-N-[l-[[2'-(ethylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-7-methylthio-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]butanamide;
25. 3-Amino-3-methyl-N-[1-[[2'-(ethylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-7-methoxy-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]butanamide;
26. 2-Amino-2-methyl-N-[1-[[2'-(ethylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]propanamide;
27. 2-Amino-2-methyl-N-[1-[[2'-(ethylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-7-fluoro-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]propanamide;
28. 2-Amino-2-methyl-N-[1-[[2'-(ethylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-7-trifluoromethyl-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]propanamide;
29. 2-Amino-2-methyl-N-[1-[[2'-(ethylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-7-methylthio-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]propanamide;
30. 2-Amino-2-methyl-N-[1-[[2'-(ethylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-7-methoxy-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]propanamide;
31. 3-[2(R)-Hydroxypropyl]amino-3-methyl-N-[1-[[2'-(ethylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]butanamide;
32. 3-[2(R)-Hydroxypropyl]amino-3-methyl-N-[1-[[2'-(ethylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-7-fluoro-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]butanamide;
33. 3-[2(R)-Hydroxypropyl]amino-3-methyl-N-[1-[[2'-(ethylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-7-trifluoromethyl-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]butanamide;
34. 3-[2(R)-Hydroxypropyl]amino-3-methyl-N-[1-[[2'-(ethylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-7-methylthio-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]butanamide;
35. 3-[2(R)-Hydroxypropyl]amino-3-methyl-N-[1-[[2'-(ethylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-7-methoxy-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]butanamide;
36. 3-[2(S),3-Dihydroxypropyl]amino-3-methyl-N-[1-[[2'-(ethylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-2,3,4,5-tetrahydro-2oxo-1H-1-benzazepin-3(R)-yl]butanamide;
37. 3-[2(S),3-Dihydroxypropyl]amino-3-methyl-N-[1-[[2'-(ethylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-7-fluoro-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]butanamide;
38. 3-[2(S),3-Dihydroxypropyl]amino-3-methyl-N-[1-[[2'-(ethylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-7-trifluoromethyl-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]butanamide;
39. 3-[2(S),3-Dihydroxypropyl]amino-3-methyl-N-[1-[[2'-(ethylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-7-methylthio-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]butanamide;
40. 3-[2(S),3-Dihydroxypropyl]amino-3-methyl-N-[1-[[2'-(ethylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-7-methoxy-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]butanamide;
41. 3-Amino-3-methyl-N-[1-[[2'-(aminosulfonyl)[1,1'-biphenyl]-4-yl]methyl]-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]butanamide;
42. 3-Amino-3-methyl-N-[1-[[2'-(aminosulfonyl)[1,1'-biphenyl]-4-yl]methyl]-7-fluoro-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]butanamide;
43. 3-Amino-3-methyl-N-[1-[[2'-(aminosulfonyl)[1,1'-biphenyl]-4-yl]methyl]-7-trifluoromethyl-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]butanamide;
44. 3-Amino-3-methyl-N-[1-[[2'-(aminosulfonyl)[1,1'-biphenyl]-4-yl]methyl]-7-methylthio-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]butanamide;
45. 3-Amino-3-methyl-N-[1-[[2'-(aminosulfonyl)[1,1'-biphenyl]-4-yl]methyl]-7-methoxy-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]butanamide;
46. 2-Amino-2-methyl-N-[1-[[2'-(aminosulfonyl)[1,1'-biphenyl]-4-yl]methyl]-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]propanamide;
47. 2-Amino-2-methyl-N-[1-[[2'-(aminosulfonyl)[1,1'-biphenyl]-4-yl]methyl]-7-fluoro-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]propanamide;
48. 2-Amino-2-methyl-N-[1-[[2'-(aminosulfonyl)[1,1'-biphenyl]-4-yl]methyl]-7-trifluoromethyl-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]propanamide;
49. 2-Amino-2-methyl-N-[1-[[2'-(aminosulfonyl)[1,1'-biphenyl]-4-yl]methyl]-7-methylthio-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]propanamide;
50. 2-Amino-2-methyl-N-[1-[[2'-(aminosulfonyl)[1,1'-biphenyl]-4-yl]methyl]-7-methoxy-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]propanamide;
51. 3-[2(R)-Hydroxypropyl]amino-3-methyl-N-[1-[[2'-(aminosulfonyl)[1,1'-biphenyl]-4-yl]methyl]-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]butanamide;
52. 3-[2(R)-Hydroxypropyl]amino-3-methyl-N-[1-[[2'-(aminosulfonyl)[1,1'-biphenyl]-4-yl]methyl]-7-fluoro-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]butanamide;
53. 3-[2(R)-Hydroxypropyl]amino-3-methyl-N-[1-[[2'-(aminosulfonyl)[1,1'-biphenyl]-4-yl]methyl]-7-trifluoromethyl-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]butanamide;
54. 3-[2(R)-Hydroxypropyl]amino-3-methyl-N-[1-[[2'-(aminosulfonyl)[1,1'-biphenyl]-4-yl]methyl]-7-methylthio-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]butanamide;
55. 3-[2(R)-Hydroxypropyl]amino-3-methyl-N-[1-[[2'-(aminosulfonyl)[1,1'-biphenyl]-4-yl]methyl]-7-methoxy-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]butanamide;
56. 3-[2(S),3-Dihydroxypropyl]amino-3-methyl-N-[1-[[2'-(aminosulfonyl)[1,1'-biphenyl]-4-yl]methyl]-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]butanamide;
57. 3-[2(S),3-Dihydroxypropyl]amino-3-methyl-N-[1-[[2'-(aminosulfonyl)[1,1'-biphenyl]-4-yl]methyl]-7-fluoro-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]butanamide;
58. 3-[2(S),3-Dihydroxypropyl]amino-3-methyl-N-[1-[[2'-(aminosulfonyl)[1,1'-biphenyl]-4-yl]methyl]-7-trifluoromethyl-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]butanamide;
59. 3-[2(S),3-Dihydroxypropyl]amino-3-methyl-N-[1-[[2'-(aminosulfonyl)[1,1'-biphenyl]-4-yl]methyl]-7-methylthio-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]butanamide;
60. 3-[2(S),3-Dihydroxypropyl]amino-3-methyl-N-[1-[[2'-(aminosulfonyl)[1,1'-biphenyl]-4-yl]methyl]-7-methoxy-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]butanamide;
61. 3-Amino-3-methyl-N-[1-[[2'-(t-butylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]butanamide;
62. 3-Amino-3-methyl-N-[1-[[2'-(t-butylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-7-fluoro-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]butanamide;
63. 3-Amino-3-methyl-N-[1-[[2'-(t-butylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-7-trifluoromethyl-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]butanamide;
64. 3-Amino-3-methyl-N-[1-[[2'-(t-butylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-7-methylthio-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]butanamide;
65. 3-Amino-3-methyl-N-[1-[[2'-(t-butylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-7-methoxy-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]butanamide;
66. 2-Amino-2-methyl-N-[1-[[2'-(t-butylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]propanamide;
67. 2-Amino-2-methyl-N-[1-[[2'-(t-butylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-7-fluoro-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]propanamide;
68. 2-Amino-2-methyl-N-[1-[[2'-(t-butylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-7-trifluoromethyl-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]propanamide;
69. 2-Amino-2-methyl-N-[1-[[2'-(t-butylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-7-methylthio-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]propanamide;
70. 2-Amino-2-methyl-N-[1-[[2'-(t-butylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-7-methoxy-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]propanamide;
71. 3-[2(R)-Hydroxypropyl]amino-3-methyl-N-[1-[[2'-(t-butylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]butanamide;
72. 3-[2(R)-Hydroxypropyl]amino-3-methyl-N-[1-[[2'-(t-butylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-7-fluoro-2,3,4,5-tetrahydro-2oxo-1H-1-benzazepin-3(R)-yl]butanamide;
73. 3-[2(R)-Hydroxypropyl]amino-3-methyl-N-[1-[[2'-(t-butylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-7-trifluoromethyl-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]butanamide;
74. 3-[2(R)-Hydroxypropyl]amino-3-methyl-N-[1-[[2'-(t-butylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-7-methylthio-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]butanamide;
75. 3-[2(R)-Hydroxypropyl]amino-3-methyl-N-[1-[[2'-(t-butylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-7-methoxy-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]butanamide;
76. 3-[2(S),3-Dihydroxypropyl]amino-3-methyl-N-[1-[[2'-(t-butylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]butanamide;
77. 3-[2(S),3-Dihydroxypropyl]amino-3-methyl-N-[1-[[2'-(t-butylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-7-fluoro-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]butanamide;
78. 3-[2(S),3-Dihydroxypropyl]amino-3-methyl-N-[1-[[2'-(t-butylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-7-trifluoromethyl-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]butanamide;
79. 3-[2(S),3-Dihydroxypropyl]amino-3-methyl-N-[1-[[2'-(t-butylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-7-methylthio-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]butanamide;
80. 3-[2(S),3-Dihydroxypropyl]amino-3-methyl-N-[1-[[2'-(t-butylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-7-methoxy-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]butanamide;
81. 3-Amino-3-methyl-N-[5-[[2'-(benzamido)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]butanamide;
82. 3-Amino-3-methyl-N-[5-[[2'-(benzamido)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-8-fluoro-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]butanamide;
83. 3-Amino-3-methyl-N-[5-[[2'-(benzamido)sulfonyl[1,1'-biphenyl]-4-yl]methyl-8-trifluoromethyl-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]butanamide;
84. 3-Amino-3-methyl-N-[5-[[2'-(benzamido)sulfonyl[1,1'-biphenyl]-4-yl]methyl-8-methylthio-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]butanamide;
85. 3-Amino-3-methyl-N-[5-[[2'-(benzamido)sulfonyl[1,1'-biphenyl]-4-yl]methyl-8-methoxy-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]butanamide;
86. 2-Amino-2-methyl-N-[5-[[2'-(benzamido)sulfonyl[1,1'-biphenyl]-4-yl]methyl-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]propanamide;
87. 2-Amino-2-methyl-N-[5-[[2'-(benzamido)sulfonyl[1,1'-biphenyl]-4-yl]methyl-8-fluoro-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]propanamide;
88. 2-Amino-2-methyl-N-[5-[[2'-(benzamido)sulfonyl[1,1'-biphenyl]-4-yl]methyl-8-trifluoromethyl-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]propanamide;
89. 2-Amino-2-methyl-N-[5-[[2'-(benzamido)sulfonyl[1,1'-biphenyl]-4-yl]methyl-8-methylthio-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]propanamide;
90. 2-Amino-2-methyl-N-[5-[[2'-(benzamido)sulfonyl[1,1'-biphenyl]-4-yl]methyl-8-methoxy-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]propanamide;
91. 3-[2(R)-Hydroxypropyl]amino-3-methyl-N-[5-[[2'-(benzamido)sulfonyl[1,1'-biphenyl]-4-yl]methyl-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]butanamide;
92. 3-[2(R)-Hydroxypropyl]amino-3-methyl-N-[5-[[2'-(benzamido)sulfonyl[1,1'-biphenyl]-4-yl]methyl-8-fluoro-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]butanamide;
93. 3-[2(R)-Hydroxypropyl]amino-3-methyl-N-[5-[[2'-(benzamido)sulfonyl[1,1'-biphenyl]-4-yl]methyl-8-trifluoromethyl-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]butanamide;
94. 3-[2(R)-Hydroxypropyl]amino-3-methyl-N-[5-[[2'-(benzamido)sulfonyl[1,1'-biphenyl]-4-yl]methyl-8-methylthio-2,3,4,5-tetrahydro-4-oxo -1,5-benzothiazepin-3(S)-yl]butanamide;
95. 3-[2(R)-Hydroxypropyl]amino-3-methyl-N-[5-[[2'-(benzamido)sulfonyl[1,1'-biphenyl]-4-yl]methyl-8-methoxy-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]butanamide;
96. 3-[2(S),3-Dihydroxypropyl]amino-3-methyl-N-[5-[[2'-(benzamido)sulfonyl[1,1'-biphenyl]-4-yl]methyl-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]butanamide;
97. 3-[2(S),3-Dihydroxypropyl]amino-3-methyl-N-[5-[[2'-(benzamido)sulfonyl[1,1'-biphenyl]-4-yl]methyl-8-fluoro-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]butanamide;
98. 3-[2(S),3-Dihydroxypropyl]amino-3-methyl-N-[5-[[2'-(benzamido)sulfonyl[1,1'-biphenyl]-4-yl]methyl-8-trifluoromethyl-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]butanamide;
99. 3-[2(S),3-Dihydroxypropyl]amino-3-methyl-N-[5-[[2'-(benzamido)sulfonyl[1,1'-biphenyl]-4-yl]methyl-8-methylthio-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]butanamide;
100. 3-[2(S),3-Dihydroxypropyl]amino-3-methyl-N-[5-[[2'-(benzamido)sulfonyl[1,1'-biphenyl]-4-yl]methyl-8-methoxy-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]butanamide;
101. 3-Amino-3-methyl-N-[5-[[2'-(ethylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]butanamide;
102. 3-Amino-3-methyl-N-[5-[[2'-(ethylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl-8-fluoro-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]butanamide;
103. 3-Amino-3-methyl-N-[5-[[2'-(ethylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl-8-trifluoromethyl-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]butanamide;
104. 3-Amino-3-methyl-N-[5-[[2'-(ethylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl-8-methylthio-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]butanamide;
105. 3-Amino-3-methyl-N-[5-[[2'-(ethylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl-8-methoxy-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]butanamide;
106. 2-Amino-2-methyl-N-[5-[[2'-(ethylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]propanamide;
107. 2-Amino-2-methyl-N-[5-[[2'-(ethylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl-8-fluoro-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]propanamide;
108. 2-Amino-2-methyl-N-[5-[[2'-(ethylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl-8-trifluoromethyl-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]propanamide;
109. 2-Amino-2-methyl-N-[5-[[2'-(ethylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl-8-methylthio-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]propanamide;
110. 2-Amino-2-methyl-N-[5-[[2'-(ethylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl-8-methoxy-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]propanamide;
111. 3-[2(R)-Hydroxypropyl]amino-3-methyl-N-[5-[[2'-(ethylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]butanamide;
112. 3-[2(R)-Hydroxypropyl]amino-3-methyl-N-[5-[[2'-(ethylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl-8-fluoro-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]butanamide;
113. 3-[2(R)-Hydroxypropyl]amino-3-methyl-N-[5-[[2'-(ethylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl-8-trifluoromethyl-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]butanamide;
114. 3-[2(R)-Hydroxypropyl]amino-3-methyl-N-[5-[[2'-(ethylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl-8-methylthio-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]butanamide;
115. 3-[2(R)-Hydroxypropyl]amino-3-methyl-N-[5-[[2'-(ethylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl-8-methoxy-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]butanamide;
116. 3-[2(S),3-Dihydroxypropyl]amino-3-methyl-N-[5-[[2'-(ethylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]butanamide;
117. 3-[2(S),3-Dihydroxypropyl]amino-3-methyl-N-[5-[[2'-(ethylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl-8-fluoro-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]butanamide;
118. 3-[2(S),3-Dihydroxypropyl]amino-3-methyl-N-[5-[[2'-(ethylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl-8-trifluoromethyl-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]butanamide;
119. 3-[2(S),3-Dihydroxypropyl]amino-3-methyl-N-[5-[[2'-(ethylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl-8-methylthio-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]butanamide;
120. 3-[2(S),3-Dihydroxypropyl]amino-3-methyl-N-[5-[[2'-(ethylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl-8-methoxy-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]butanamide;
121. 3-Amino-3-methyl-N-[5-[[2'-(aminosulfonyl)[1,1'-biphenyl]-4-yl]methyl-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]butanamide;
122. 3-Amino-3-methyl-N-[5-[[2'-(aminosulfonyl)[1,1'-biphenyl]-4-yl]methyl-8-fluoro-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]butanamide;
123. 3-Amino-3-methyl-N-[5-[[2'-(aminosulfonyl)[1,1'-biphenyl]-4-yl]methyl-8-trifluoromethyl-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]butanamide;
124. 3-Amino-3-methyl-N-[5-[[2'-(aminosulfonyl)[1,1'-biphenyl]-4-yl]methyl-8-methylthio-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]butanamide;
125. 3-Amino-3-methyl-N-[5-[[2'-(aminosulfonyl)[1,1'-biphenyl]-4-yl]methyl-8-methoxy-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]butanamide;
126. 2-Amino-2-methyl-N-[5-[[2'-(aminosulfonyl)[1,1'-biphenyl]-4-yl]methyl-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]propanamide;
127. 2-Amino-2-methyl-N-[5-[[2'-(aminosulfonyl)[1,1'-biphenyl]-4-yl]methyl-8-fluoro-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]propanamide;
128. 2-Amino-2-methyl-N-[5-[[2'-(aminosulfonyl)[1,1'-biphenyl]-4-yl]methyl-8-trifluoromethyl-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]propanamide;
129. 2-Amino-2-methyl-N-[5-[[2'-(aminosulfonyl)[1,1'-biphenyl]-4-yl]methyl-8-methylthio-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]propanamide;
130. 2-Amino-2-methyl-N-[5-[[2'-(aminosulfonyl)[1,1'-biphenyl]-4-yl]methyl-8-methoxy-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]propanamide;
131. 3-[2(R)-Hydroxypropyl]amino-3-methyl-N-[5-[[2'-(aminosulfonyl)[1,1'-biphenyl]-4-yl]methyl-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]butanamide;
132. 3-[2(R)-Hydroxypropyl]amino-3-methyl-N-[5-[[2'-(aminosulfonyl)[1,1'-biphenyl]-4-yl]methyl-8-fluoro-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]butanamide;
133. 3-[2(R)-Hydroxypropyl]amino-3-methyl-N-[5-[[2'-(aminosulfonyl)[1,1'-biphenyl]-4-yl]methyl-8-trifluoromethyl-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]butanamide;
134. 3-[2(R)-Hydroxypropyl]amino-3-methyl-N-[5-[[2'-(aminosulfonyl)[1,1'-biphenyl]-4-yl]methyl-8-methylthio-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]butanamide;
135. 3-[2(R)-Hydroxypropyl]amino-3-methyl-N-[5-[[2'-(aminosulfonyl)[1,1'-biphenyl]-4-yl]methyl-8-methoxy-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]butanamide;
136. 3-[2(S),3-Dihydroxypropyl]amino-3-methyl-N-[5-[[2'-(aminosulfonyl)[1,1'-biphenyl]-4-yl]methyl-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]butanamide;
137. 3-[2(S),3-Dihydroxypropyl]amino-3-methyl-N-[5-[[2'-(aminosulfonyl)[1,1'-biphenyl]-4-yl]methyl-8-fluoro-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]butanamide;
138. 3-[2(S),3-Dihydroxypropyl]amino-3-methyl-N-[5-[[2'-(aminosulfonyl)[1,1'-biphenyl]-4-yl]methyl-8-trifluoromethyl-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]butanamide;
139. 3-[2(S),3-Dihydroxypropyl]amino-3-methyl-N-[5-[[2'-(aminosulfonyl)[1,1'-biphenyl]-4-yl]methyl-8-methylthio-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]butanamide;
140. 3-[2(S),3-Dihydroxypropyl]amino-3-methyl-N-[5-[[2'-(aminosulfonyl)[1,1'-biphenyl]-4-yl]methyl-8-methoxy-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]butanamide;
141. 3-Amino-3-methyl-N-[5-[[2'-(t-butylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]butanamide;
142. 3-Amino-3-methyl-N-[5-[[2'-(t-butylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl-8-fluoro-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]butanamide;
143. 3-Amino-3-methyl-N-[5-[[2'-(t-butylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl-8-trifluoromethyl-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]butanamide;
144. 3-Amino-3-methyl-N-[5-[[2'-(t-butylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl-8-methylthio-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]butanamide;
145. 3-Amino-3-methyl-N-[5-[[2'-(t-butylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl-8-methoxy-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]butanamide;
146. 2-Amino-2-methyl-N-[5-[[2'-(t-butylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]propanamide;
147. 2-Amino-2-methyl-N-[5-[[2'-(t-butylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl-8-fluoro-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]propanamide;
148. 2-Amino-2-methyl-N-[5-[[2'-(t-butylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl-8-trifluoromethyl-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]propanamide;
149. 2-Amino-2-methyl-N-[5-[[2'-(t-butylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl-8-methylthio-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-y 1]propanamide;
150. 2-Amino-2-methyl-N-[5-[[2'-(t-butylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl-8-methoxy-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]propanamide;
151. 3-[2(R)-Hydroxypropyl]amino-3-methyl-N-[5-[[2'-(t-butylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]butanamide;
152. 3-[2(R)-Hydroxypropyl]amino-3-methyl-N-[5-[[2'-(t-butylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl-8-fluoro-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]butanamide;
153. 3-[2(R)-Hydroxypropyl]amino-3-methyl-N-[5-[[2'-(t-butylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl-8-trifluoromethyl-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]butanamide;
154. 3-[2(R)-Hydroxypropyl]amino-3-methyl-N-[5-[[2'-(t-butylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl-8-methylthio-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]butanamide;
155. 3-[2(R)-Hydroxypropyl]amino-3-methyl-N-[5-[[2'-(t-butylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl-8-methoxy-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]butanamide;
156. 3-[2(S),3-Dihydroxypropyl]amino-3-methyl-N-[5-[[2'-(t-butylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]butanamide;
157. 3-[2(S),3-Dihydroxypropyl]amino-3-methyl-N-[5-[[2'-(t-butylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl-8-fluoro-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]butanamide;
158. 3-[2(S),3-Dihydroxypropyl]amino-3-methyl-N-[5-[[2'-(t-butylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl-8-trifluoromethyl-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]butanamide;
159. 3-[2(S),3-Dihydroxypropyl]amino-3-methyl-N-[5-[[2'-(t-butylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl-8-methylthio-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]butanamide; and
160. 3-[2(S),3-Dihydroxypropyl]amino-3-methyl-N-[5-[[2'-(t-butylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl-8-methoxy-2,3,4,5-tetrahydro-4-oxo-1,5-benzothiazepin-3(S)-yl]butanamide.
Representative examples of the nomenclature employed are given below:
3-Amino-3-methyl-N-[1-[[2'-[[(methylaminocarbonyl)amino]sulfonyl][1,1'-biphenyl]-4-yl]methyl]-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]butanamide ##STR8##2-Amino-2-methyl-N-[1-[[2'-(benzamido)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-7-methyl-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]propanamide ##STR9## 3-[2(R)-Hydroxypropyl]amino-3-methyl-N-[1-[[2'-[(pyrrolidin-1-yl )sulfonyl][1,1'-biphenyl]-4-yl]methyl]-2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]butanamide ##STR10## 3-[2(S),3-Dihydroxypropyl]amino-3-methyl-N-[2,3,4,5-tetrahydro-5-[[2'-[2-[[[4-morpholinocarbonyl]amino]sulfonyl]methyl][1,1'-biphenyl]-4-yl]methyl]-7-methyl-4-oxo-1,5-benzothiazepin-3(S)-yl]butanamide ##STR11##
The compounds of the instant invention all have at least one asymmetric center as noted by the asterisk in the structural Formula I above. Additional asymmetric centers may be present on the molecule depending upon the nature of the various substituents on the molecule. Each such asymmetric center will produce two optical isomers and it is intended that all such optical isomers, as separated, pure or partially purified optical isomers or racemic mixtures thereof, be included within the ambit of the instant invention. In the case of the asymmetric center represented by the asterisk in Formula I, it has been found that the compound in which the 3-amino substituent is above the plane of the structure, as seen in Formula Ia, is more active and thus more preferred over the compound in which the 3-amino substituent is below the plane of the structure. In the substituent (X) n , when n=0, the asymmetric center is designated as the R-isomer. When n=1, this center will be designated according to the R/S rules as either R or S depending upon the value of X. ##STR12##
The instant compounds are generally isolated in the form of their pharmaceutically acceptable acid addition salts, such as the salts derived from using inorganic and organic acids. Examples of such acids are hydrochloric, nitric, sulfuric, phosphoric, formic, acetic, trifluoroacetic, propionic, maleic, succinic, malonic and the like. In addition, certain compounds containing an acidic function such as a carboxy can be isolated in the form of their inorganic salt in which the counterion can be selected from sodium, potassium, lithium, calcium, magnesium and the like, as well as from organic bases.
The compounds (I) of the present invention are prepared from intermediates such as those of formula H. The preparation of these intermediates is described in the following reaction Schemes. ##STR13##
Compounds of formula H are prepared by alkylation of intermediates of formula III as shown in Scheme 1. The preparation of compounds of formula III has been previously described by Fisher, et al, U.S. Pat. No. 5,206,235 and references cited therein. Alkylation of intermediates of formula III is conveniently carried out in anhydrous dimethyl formamide (DMF) in the presence of bases such as sodium hydride or potassium t-butoxide for a period of 0.5 to 24 hours at temperatures of 20°-100° C., with an alkylating agent IV, wherein Y is a good leaving group such as Cl, Br, I, O-methanesulfonyl or O-(p-toluenesulfonyl). Separation of unwanted side products, and purification of products is achieved by chromatography on silica gel, employing flash chromatography (W. C. Still, M. Kahn and A. Mitra, J. Org. Chem., 43, 2923(1978)) or by medium pressure liquid chromatography. Substituents on the alkylating agent IV may need to be protected during alkylation. A description of such protecting groups may be found in: Protective Groups in Organic Synthesis, T. W. Greene, John Wiley and Sons, New York, 1981. ##STR14##
Compounds of formula II wherein R 3a is taken as --SO 2 NR 4a R 12a are prepared from the sulfonyl chloride 1 as shown in Scheme 2. Reaction of 1 with the secondary amine R 4a R 12a NH in an inert solvent such as methylene chloride in the presence of a base, such as triethylamine or 4-dimethylaminopyridine, gives the sulfonamide product 2. Reaction of 2 with compounds of formula III is carried out using the conditions described in Scheme 1. ##STR15##
As shown in Scheme 3, an analogous series of transformations is employed to assemble compounds of formula II wherein R 3a is defined as --SO 2 N(R 12b )NR 4a R 12a (5). ##STR16##
Reaction of sulfonyl chloride 1 with the secondary amine t-BuN(R 12b )H and subsequent alkylation with III by the aforementioned procedures, leads to intermediate 7 (Scheme 4). ##STR17##
A useful synthesis of intermediate 12 is outlined in Scheme 5. Reaction of o-bromobenzenesulfonyl chloride 8 with t-butylamine in methylene chloride gives the t-butyl sulfonamide 9 in high yield. Reaction of 9 with 4-methylphenyltrimethylstannane 10 in the presence of bis(triphenylphosphine)palladium(II) chloride in dimethylformamide at elevated temperature gives the coupled product 11 in good yield. Conversion to bromide 12 is achieved by free radical bromination with N-bromosuccinimide in carbon tetrachloride in the presence of the radical initiator, azobisisobutyronitrile (AIBN). Reaction of 12 with compounds of formula III is carried out using the conditions described in Scheme 1. ##STR18##
Intermediate 7 may be converted to a new intermediate 13 by removal of the t-butyl group. As shown in Scheme 6, treatment of 7 with a strong acid, such as hydrochloric acid in methanol or trifluoroacetic acid in methylene chloride, results in loss of the t-butyl group to give the product. It may be appreciated by one skilled in the art that the protecting group G in 7 must therefore be compatible with the strongly acidic conditions employed; hence G is taken as benzyloxycarbonyl. ##STR19##
Acylsulfonamide compounds of-formula II (14) are prepared from intermediate 13 as indicated in Scheme 7. Acylation of 13 is carried out by treatment with reaction with the activated acyl imidazolide intermediate derived from R 5a COOH and N,N'-carbonyldiimidazole.
Alternatively, the acylsulfonamide product 14 is obtained by reaction of 13 with the acid chloride, R 5a COCl. ##STR20##
Intermediate 13 is also converted into N-carbamoyl and N-alkoxycarbonyl sulfonamides. Reaction of 13 with substituted carbamoyl chloride reagent 15 in an inert solvent such as methylene chloride in the presence of a triethylamine or 4-dimethylaminopyridine affords the N-carbamoyl sulfonamide product 16 as shown in Scheme 8. ##STR21##
An analogous sequence is employed in the synthesis of N-thiocarbamoyl sulfonamide 18 using the thiocarbamoyl reagent 17 as outlined in Scheme 9. ##STR22##
As illustrated in Scheme 10, reaction of 13 with an isocyanate reagent 19 also gives an N-carbamoyl sulfonamide product 20 wherein R 4a is hydrogen. The corresponding N-thiocarbamoyl sulfonamide analog of 20 can also be obtained by reaction of 13 with an appropriate isothiocyanate. ##STR23##
N-Alkoxycarbonyl sulfonamides 22 are also prepared from 13 by reaction with a chloroformate (or equivalent) reagent 21 as shown in Scheme 11. ##STR24##
Substituted hydrazide compounds of formula II (23) are prepared from intermediate 13 by a two-step sequence consisting of treatment of the hydrazine compound R 4a R 12a NN(R 12b )H with N,N'-carbonyldiimidazole, followed by reaction of the active species thus formed with intermediate 13 (Scheme 12). ##STR25##
The corresponding thio analog of 23 can be obtained from 13 by the aforementioned procedure by substituting N,N'-thiocarbonyldiimidazole for N,N'-carbonyldiimidazole.
Conversion to the final products of formula I wherein R 4 is hydrogen, is carried out by simultaneous or sequential removal of all protecting groups from intermediate II as illustrated in Scheme 13. ##STR26##
Removal of benzyloxycarbonyl (CBz) groups can be achieved by a number of methods known in the art; for example, catalytic hydrogenation with hydrogen in the presence of a platinum or palladium catalyst in a protic solvent such as methanol. In cases where catalytic hydrogenation is contraindicated by the presence of other potentially reactive functionality, removal of benzyloxycarbonyl groups can also be achieved by treatment with a solution of hydrogen bromide in acetic acid. Removal of t-butoxycarbonyl (BOC) protecting groups is carried out by treatment of a solution in a solvent such as methylene chloride or methanol, with a strong acid, such as hydrochloric acid or trifluoroacetic acid. Conditions required to remove other protecting groups which may be present can be found in Protective Groups in Organic Synthesis T. W. Greene, John Wiley and Sons, N.Y. 1981.
As shown in Scheme 14, compounds of formula I wherein R 4 and R 5 are each hydrogen can be further elaborated to new compounds which are substituted on the amino group. Reductive alkylation with an aldehyde is carried out under conditions known in the art; for example, by catalytic hydrogenation with hydrogen in the presence of platinum, palladium or nickel catalysts or with chemical reducing agents such as sodium cyanoborohydride in an inert solvent such as methanol or ethanol. Substitution on the amine can also be achieved by reaction with various epoxides. The products, obtained as hydrochloride or trifluoroacetate salts, are conveniently purified by reverse phase high performance liquid chromatography (HPLC) or by recrystallization. ##STR27##
It is noted that the order of carrying out the foregoing reaction schemes is not significant and it is within the skill of one skilled in the art to vary the order of reactions to facilitate the reaction or to avoid unwanted reaction products.
The growth hormone releasing compounds of Formula I are useful in vitro as unique tools for understanding how growth hormone secretion is regulated at the pituitary level. This includes use in the evaluation of many factors thought or known to influence growth hormone secretion such as age, sex, nutritional factors, glucose, amino acids, fatty acids, as well as fasting and non-fasting states. In addition, the compounds of this invention can be used in the evaluation of how other hormones modify growth hormone releasing activity. For example, it has already been established that somatostatin inhibits growth hormone release. Other hormones that are important and in need of study as to their effect on growth hormone release include the gonadal hormones, e.g., testosterone, estradiol, and progesterone; the adrenal hormones, e.g., cortisol and other corticoids, epinephrine and norepinephrine; the pancreatic and gastrointestinal hormones, e.g., insulin, glucagon, gastrin, secretin; the vasoactive intestinal peptides, e.g., bombesin; and the thyroid hormones, e.g., thyroxine and triiodothyronine. The compounds of Formula I can also be employed to investigate the possible negative or positive feedback effects of some of the pituitary hormones, e.g., growth hormone and endorphin peptides, on the pituitary to modify growth hormone release. Of particular scientific importance is the use of these compounds to elucidate the subcellular mechanisms mediating the release of growth hormone.
The compounds of Formula I can be administered to animals, including man, to release growth hormone in vivo. For example, the compounds can be administered to commercially important animals such as swine, cattle, sheep and the like to accelerate and increase their rate and extent of growth, and to increase milk production in such animals. In addition, these compounds can be administered to humans in vivo as a diagnostic tool to directly determine whether the pituitary is capable of releasing growth hormone. For example, the compounds of Formula I can be administered in vivo to children. Serum samples taken before and after such administration can be assayed for growth hormone. Comparison of the amounts of growth hormone in each of these samples would be a means for directly determining the ability of the patient's pituitary to release growth hormone.
Accordingly, the present invention includes within its scope pharmaceutical compositions comprising, as an active ingredient, at least one of the compounds of Formula I in association with a pharmaceutical carrier or diluent. Optionally, the active ingredient of the pharmaceutical compositions can comprise a growth promoting agent in addition to at least one of the compounds of Formula I or another composition which exhibits a different activity, e.g., an antibiotic or other pharmaceutically active material.
Growth promoting agents include, but are not limited to, TRH, diethylstilbesterol, theophylline, enkephalins, E series prostaglandins, compounds disclosed in U.S. Pat. No. 3,239,345, e.g., zeranol, and compounds disclosed in U.S. Pat. No. 4,036,979, e.g., sulbenox or peptides disclosed in U.S. Pat. No. 4,411,890.
A still further use of the disclosed novel benzo-fused lactam growth hormone secretagogues is in combination with other growth hormone secretagogues such as GHRP-6, GHRP-1 or GHRP-2 as described in U.S. Pat. Nos. 4,411,890; and publications WO 89/07110, WO 89/07111 and WO 93/04081 or B-HT 920 or in combination with growth hormone releasing factor and its analogs or growth hormone and its analogs. A still further use of the disclosed novel benzo-fused lactam growth hormone secretagogues is in combination with α 2 adrenergic agonists or β 3 adrenergic agonists in the treatment of obesity or in combination with parathyroid hormone or bisphosphonates, such as MK-217 (alendronate), in the treatment of osteoporosis. A still further use of the disclosed novel benzo-fused lactam growth hormone secretagogues is in combination with IGF-1 to reverse the catabolic effects of nitrogen wasting as described by Kupfer, et al, J. Clin. Invest., 91, 391 (1993).
As is well known to those skilled in the art, the known and potential uses of growth hormone are varied and multitudinous. Thus, the administration of the compounds of this invention for purposes of stimulating the release of endogenous growth hormone can have the same effects or uses as growth hormone itself. These varied uses of growth hormone may be summarized as follows: stimulating growth hormone release in elderly humans; prevention of catabolic side effects of glucocorticoids; treatment of osteoporosis; stimulation of the immune system; treatment of retardation; acceleration of wound healing; accelerating bone fracture repair; treatment of growth retardation, treating renal failure or insufficiency resulting in growth retardation; treatment of physiological short stature, including growth hormone deficient children; treating short stature associated with chronic illness; treatment of obesity and growth retardation associated with obesity; treating growth retardation associated with Prader-Willi syndrome and Turner's syndrome; accelerating the recovery and reducing hospitalization of burn patients; treatment of intrauterine growth retardation, skeletal dysplasia, hypercortisolism and Cushings syndrome; induction of pulsatile growth hormone release; replacement of growth hormone in stressed patients; treatment of osteochondrodysplasias, Noonans syndrome, schizophrenia, depression, Alzheimer's disease, delayed wound healing, and psychosocial deprivation; treatment of pulmonary dysfunction and ventilator dependency; attenuation of protein catabolic response after a major operation; reducing cachexia and protein loss due to chronic illness such as cancer or AIDS. Treatment of hyperinsulinemia including nesidioblastosis; adjuvant treatment for ovulation induction; to stimulate thymic development and prevent the age-related decline of thymic function; treatment of immunosuppressed patients; improvement in muscle strength, mobility, maintenance of skin thickness, metabolic homeostasis, renal hemeostasis in the frail elderly; stimulation of osteoblasts, bone remodelling, and cartilage growth; stimulation of the immune system in companion animals and treatment of disorders of aging in companion animals; growth promotant in livestock and stimulation of wool growth in sheep.
The compounds of this invention can be administered by oral, parenteral (e.g., intramuscular, intraperitoneal, intravenous or subcutaneous injection or implant), nasal, vaginal, rectal, sublingual, or topical routes of administration and can be formulated in dosage forms appropriate for each route of administration.
Solid dosage forms for oral administration include capsules, tablets, pills, powders and granules. In such solid dosage forms, the active compound is admixed with at least one inert pharmaceutically acceptable carrier such as sucrose, lactose, or starch. Such dosage forms can also comprise, as is normal practice, additional substances other than inert diluents, e.g., lubricating agents such as magnesium stearate. In the case of capsules, tablets and pills, the dosage forms may also comprise buffering agents. Tablets and pills can additionally be prepared with enteric coatings.
Liquid dosage forms for oral administration include pharmaceutically acceptable emulsions, solutions, suspensions, syrups, the elixirs containing inert diluents commonly used in the art, such as water. Besides such inert diluents, compositions can also include adjuvants, such as wetting agents, emulsifying and suspending agents, and sweetening, flavoring and perfuming agents.
Preparations according to this invention for parenteral administration include sterile aqueous or non-aqueous solutions, suspensions, or emulsions. Examples of non-aqueous solvents or vehicles are propylene glycol, polyethylene glycol, vegetable oils, such as olive oil and corn oil, gelatin, and injectable organic esters such as ethyl oleate. Such dosage forms may also contain adjuvants such as preserving, wetting, emulsifying, and dispersing agents. They may be sterilized by, for example, filtration through a bacteria-retaining filter, by incorporating sterilizing agents into the compositions, by irradiating the compositions, or by heating the compositions. They can also be manufactured in the form of sterile solid compositions which can be dissolved in sterile water, or some other sterile injectable medium immediately before use.
Compositions for rectal or vaginal administration are preferably suppositories which may contain, in addition to the active substance, excipients such as cocoa butter or a suppository wax.
Compositions for nasal or sublingual administration are also prepared with standard excipients well known in the art.
The dosage of active ingredient in the compositions of this invention may be varied; however, it is necessary that the amount of the active ingredient be such that a suitable dosage form is obtained. The selected dosage depends upon the desired therapeutic effect, on the route of administration, and on the duration of the treatment. Generally, dosage levels of between 0.0001 to 100 mg/Kg of body weight daily are administered to patients and animals, e.g., mammals, to obtain effective release of growth hormone.
The following examples are provided for the purpose of further illustration only and are not intended to be limitations on the disclosed invention.
EXAMPLE 1
3-Amino-3-methyl-N-[2,3,4,5-tetrahydro-2-oxo-1-[[2'-(benzamido)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-1H-1-benzazepin-3(R)-yl]butanamide, trifluoroacetate
Step A: 1-Bromo-2-t-butylbenzenesulfonamide
To a solution of 51.4 g (0.201 mol, 1.0 eq.) of o-bromobenzenesulfonyl chloride in 1 L of chloroform was added 53 mL of t-butylamine (36.8 g, 0.504 mol, 2.5 eq) dropwise with stirring at room temperature under nitrogen. The solution was stirred overnight at room temperature, then concentrated to dryness under vacuum to give 75.93 g of crude material. Thin layer chromatography on a silica plate eluting with 50% ethyl acetate in hexane showed one spot. The crude product was suspended in methylene chloride and the insoluble t-butylamine hydrochloride removed by filtration. The solution was concentrated to dryness under vacuum to give 57.85 g (0.198 mol, 98%) of the product. 1 H NMR (CDCl 3 , 200 MHz): δ 1.29 (s, 9H), 5.18 (br s, 1H), 7.4-7.6 (m, 2H), 7.78 (dd; 2, 8 Hz; 1H), 8.14 (dd; 2, 8 Hz; 1H). FAB-MS (Li + spike): calculated for C 10 H 14 BrNO 2 S 291,293; found 298, 300 (M+Li, 30%).
Step B: 4-Methylphenyltrimethylstannane
41.4 L of 1.0M p-tolylmagnesium bromide in diethyl ether (41.4 mol) was added dropwise, maintaining the temperature below -5° C., over 4 hours to a solution of 546 g (2.79 mol) of trimethyltin chloride in tetrahydrofuran (4 L) under nitrogen at -10° C. The suspension was allowed to warm slowly to room temperature over 12 hours then saturated ammonium chloride solution (1 L) was added followed by sufficient water (approximately 1 L) to dissolve the precipitate. The solution was extracted with ether-hexane (1:1 ) (1×4 L, 3×2 L). The combined organic phases were washed with brine, dried over magnesium sulfate and the solvents removed under vacuum. Purification by flash chromatography on silica gel eluting with hexane/ethyl acetate (95:5) gave a pale yellow oil containing white crystals of 4,4'-dimethylbiphenyl which were removed by filtration to leave 711.3 g (100%) of product. 1 H NMR (300 MHz, CDCl 3 ): δ 0.30 (s, 9H), 2.34 (s, 3H), 7.19 (d, 7.7 Hz, 2H), 7.40 (d, 7.7 Hz, 2H).
Step C: 4-Methyl-2'-(t-butylaminosulfonyl)-1,1'-biphenyl
1-Bromo-2-t-butylbenzenesulfonamide (22.4 g, 77 mmol) (Step A) and 4-methylphenyltrimethylstannane (39.35 g, 154 mmol 2eq.) were dissolved in 221 mL of dry dimethylformamide and the resulting solution treated with 2.71 g (38.6 mmol, 0.5eq) of bis(triphenylphosphine)palladium(II) chloride. The mixture was heated at 90° C. for 6 hours. The mixture was filtered through Celite and the filter cake was washed with ether. The combined organics were washed twice with water. The aqueous washings were combined and extracted with ether. The combined organics were washed with saturated aqueous sodium chloride then dried over magnesium sulfate, filtered and concentrated to dryness to yield the product which solidified on standing. Purification by preparative HPLC on silica, eluting with 10% ethyl acetate/hexane, gave 13.63 g (44.98 mmol, 58%) of the product as a yellow powder. 1 H NMR (200 MHz, CDCl 3 ): δ 1.09 (s, 9H), 2.50 (s, 3H), 3.64 (br s, 1H), 7.3-7.7 (m,7H), 8.13 (dd; 2, 8 Hz; 1H). FAB-MS: calculated for C 17 H 21 NO 2 S 303; found 304 (M+H, 3%).
Step D: 4-Bromomethyl-2'-(t-butylamino)sulfonyl-1,1'-biphenyl
To a solution of 5.0 g (16.5 mmol) of 4-methyl-2'-(t-butylaminosulfonyl)-1,1'-biphenyl in 400 mL of carbon tetrachloride was added 2.35 g (13.2 mmol, 0.8eq) of recrystallized N-bromosuccinimide and 27.5 mg of azobisisobutyronitrile (AIBN). The mixture was refluxed under a nitrogen amosphere for 4 hours at which time an additional 1.17 g (6.57 mmol, 0.40 eq) of N-bromosuccinimide and a trace of AIBN were added and refluxing continued for another 2 hours. The mixture was cooled to room temperature, filtered and the filtrate concentrated to dryness to give 7.11 g of crude product which was used without further purification. 1 H NMR (200 MHz, CDCl 3 ): δ 1.07 (s, 9H), 3.63 (br s, 1H), 4.60 (s, 2H), 7.3-7.7 (m,7H), 8.11 (dd; 2, 8 Hz; 1H). FAB-MS: calculated for C 17 H 20 BrNO 2 S 381; found 382 (M+H, 2.5%).
Step E: 3-Benzyloxycarbonylamino-3-methyl-N-[2,3,4,5-tetrahydro-2-oxo-1-[[2'-(t-butylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-1H-1-benzazepin-3(R)-yl]butanamide
A solution of 250 mg (0.610 mmol) of 3-benzyloxyxcarbonylamino-3-methyl-N-[2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]butanamide (prepared by the method of Fisher, et al; U.S. Pat. No. 5,206,235) in 1.5 mL of dimethylformamide at room temperature was treated with 32 mg of 60% sodium hydride oil dispersion (19 mg NaH, 0.79 mmol, 1.3eq). The mixture was stirred under nitrogen at room temperature for 20 minutes then treated with a solution of 303 mg (0.79 mmol, 1.3eq) of 4-bromomethyl-2'-(t-butylamino)sulfonyl-1,1'-biphenyl in 1 mL of dimethylformamide. The solution was stirred at room temperature for 12 hours then diluted with ethyl acetate and washed with pH 7 phosphate buffer solution (3×) and saturated aqueous sodium chloride. The washings were extracted once with ethyl acetate and the combined ethyl acetate solutions were dried over magnesium sulfate, filtered and concentrated to dryness to give the crude product which solidified upon standing. Purification by preparative HPLC on silica, eluting with ethyl acetate/hexane (2/1), gave 200 mg (0.28 mmol, 46%) of the product. 1 H NMR (200 MHz, CDCl 3 ): δ 1.00 (s, 9H), 1.45 (s, 3H), 1.47 (s, 3H), 1.85 (m, 1H), 2.4-2.7 (m, 5H), 3.42 (s, 1H), 4.59 (m, 1H), 4.79 (s, 1H), 4.92 (d, 15 Hz, 1H), 5.15 (s, 2H), 5.18 (d, 15 Hz, 1H), 5.66 (br s, 1H), 6.72.(d, 8 Hz, 1H), 7.15-7.65 (m, 16H), 8.18 (dd; 2, 8 Hz; 1H). FAB-MS: calculated for C 40 H 46 N 4 O 6 S 710; found 711 (M+H, 15%).
Step F: 3-Benzyloxycarbonylamino-3-methyl-N-[2,3,4,5-tetrahydro-2-oxo-1-[[2'-aminosulfonyl[1,1'-biphenyl]-4-yl]methyl-1H-1-benzazepin-3(R)-yl]butanamide
A solution of 200 mg (0.282 mmol) of the intermediate obtained in Step E in 3 mL of trifluoroacetic acid was treated with three drops of anisole. The resulting solution was stirred at room temperature under nitrogen for 14 hours. All volatiles were removed under vacuum and the residue was purified by medium pressure liquid chromatography on silica, eluting with 0.5% ammonium hydroxide in ethyl acetate to afford 100 mg (0.152 mmol, 54%) of the product. 1 H NMR (300 MHz, CD 3 OD): δ 1.40 (s, 6H), 2.00 (m, 1H), 2.32 (m, 1H), 2.5-2.7 (m, 4H), 4.42 (dd; 7, 11 Hz; 1H), 5.05 (m, 3H), 5.32 (d, 15 Hz, 1H), 7.25-7.45 (m, 13H), 7.5-7.7 (m, 3H), 8.13 (m, 1H). FAB-MS: calculated for C 36 H 38 N 4 O 6 S 654; found 677 (M+Na, 85%).
Step G: 3-Benzyloxycarbonylamino-3-methyl-N-[2,3,4,5-tetrahydro-2-oxo-1-[[2'-(benzamido)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-1H-1-benzazepin-3(R)-yl]butanamide
To a solution of 50.6 mg of benzoic acid (0.415 mmol, 3.0 eq) in 1 mL of tetrahydrofuran was added 617 mg of N,N'-carbonyldiimidazole (0.415, 3.0 eq) and the mixture was stirred at reflux under nitrogen for one hour. To this mixture was added a solution of 90 mg (0.14 mmol, 1.0 eq) of the intermediate prepared in Step E and 62.2 mg (0.403 mmol, 2.9 eq) of 1,8-diazabicyclo[5.4.0]lundece-7-ene (DBU) in 2 mL of tetrahydrofuran. The mixture was stirred at reflux for 24 hours then cooled and diluted with ethyl acetate, then washed with 5% aqueous citric acid. The organic layer was removed, dried over magnesium sulfate, filtered and solvents removed under vacuum. The residue was purified by reverse phase medium pressure liquid chromatography on C8, eluting with methanol/0.1% aqueous trifluoroacetic acid (75/25) to afford 60 mg (0.079 mmol, 57%) of the product. 1 H NMR (300 MHz, CD 3 OD): δ 1.39 (s, 6H), 2.02 (m, 1H), 2.34 (m, 1H), 2.50-2.75 (m, 4H), 4.43 (dd; 7, 12 Hz; 1H), 5.0-5.2 (m, 4H), 7.20-7.75 (m, 21H), 8.32 (d, 8 Hz, 1H). FAB-MS: calculated for C 43 H 42 N 4 O 7 S 758; found 782 (M+Na, 20%).
Step H: 3-Amino-3-methyl-N-[2,3,4,5-tetrahydro-2-oxo-l-[[2'-(benzamido)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-1H-1-benzazepin-3(R)-yl]butanamide, trifluoroacetate
Hydrobromic acid (0.5 mL of a 30% solution in acetic acid) was added to 30 mg (0.040 mmol) of the intermediate obtained in Step G and the mixture was stirred at room temperature for one hour. All volatiles were removed under vacuum and the residue redissolved in methanol and concentrated to dryness again. The residue was purified by reverse phase medium pressure liquid chromatography on C8, eluting with methanol/0.1% aqueous trifluoroacetic acid (70/30) to afford 29 mg (0.039 mmol, 99%) of the title compound. 1 H NMR (300 MHz, CD 3 OD): δ 1.38 (s, 3H), 1.42 (s, 3H), 2.20 (m, 1H), 2.40 (m, 1H), 2.56 (m, 2H), 2.6-2.8 (m, 2H), 4.48 (dd; 8, 11 Hz; 1H), 5.15 (m, 2H), 7.20-7.75 (m, 16H), 8.30 (d, 8 Hz, 1H). FAB-MS: calculated for C 35 H 36 N 4 O 5 S 624; found 625 (M+H, 100%).
EXAMPLE 2
3-Amino-3-methyl-N-[2,3,4,5-tetrahydro-2-oxo-1-[[2'-(ethylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-1H-1-benzazepin-3(R)-yl]butanamide, trifluoroacetate
Step A: 1-Bromo-2-ethylbenzenesulfonamide
Prepared from o-bromobenzenesulfonyl chloride, ethyl amine hydrochloride and triethylamine by the procedure described in Example 1, Step A. 1 H NMR (CDCl 3 , 200 MHz): δ 1.10.(t, 7 Hz, 3H), 2.98 (m, 2H), 5.07 (br s, 1H), 7.43 (m, 2H), 7.74 (dd; 2, 8 Hz; 1H), 8.15 (dd; 2, 8 Hz; 1H). FAB-MS: calculated for C 8 H 10 BrNO 2 S 263, 265; found 264, 266 (M+H, 100% ).
Step B: 4-Methyl-2'-(ethylamino)sulfonyl-1,1'-biphenyl
Prepared from 1-bromo-2-ethylbenzenesulfonamide and 4-methylphenyltrimethylstannane by the procedure described in Example 1, Step C. 1 H NMR (200 MHz, CDCl 3 ): δ 0.86 (t, 7Hz, 3H), 2.43 (s, 3H), 2.66 (m, 2H), 3.35 (br t, 1H), 7.20-7.65 (m,7H), 8.15 (dd; 2, 8 Hz; 1H).
Step C: 4-Bromomethyl-2'-(ethylamino)sulfonyl-1,1'-biphenyl
Prepared from 4-methyl-2'-(ethylamino)sulfonyl-1,1'-biphenyl by the procedure described in Example 1, Step D. 1 H NMR (200 MHz, CDCl 3 ): δ 0.88 (t, 7Hz, 3H), 2.58 (m, 2H), 3.35 (br t, 1H), 4.55 (s, 2H), 7.25-7.65 (m,7H), 8.16 (dd; 2, 8 Hz; 1H).
Step D: 3-Benzyloxycarbonylamino-3-methyl-N-[2,3,4,5-tetrahydro-2-oxo-1-[[2'-(ethylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-1H-1-benzazepin-3(R)-yl]butanamide
Prepared from 3-t-butoxycarbonylamino-3-methyl-N-[2,3,4,5-tetrahydro-2-oxo-1H-1-benzazepin-3(R)-yl]butanamide (prepared by the method of Fisher, et al; U.S. Pat. No. 5,206,235) and 4-bromomethyl-2'-(ethylaminosulfonyl)-1,1'-biphenyl by the procedure described in Example 1, Step E. 1 H NMR (400 MHz, CDCl 3 ): δ 0.77 (t, 7Hz, 3H), 1.33 (s, 6H), 1.40 (s, 9H), 1.47 (s, 3H), 1.87 (m, 1H), 2.35-2.6 (m, 7H), 3.12 (t, 7Hz, 1H), 4.52 (m, 1H), 4.83 (d, 15 Hz, 1H), 5.17 (br s, 1H), 5.38 (d, 15 Hz, 1H), 6.66 (d, 7Hz, 1H), 7.1-7.3 (m, 7H), 7.35 (d, 8 Hz, 2H), 7.46 (m, 1H), 7.55 (m, 1H), 8.10 (d, 8 Hz, 1H). FAB-MS: calculated for C 35 H 44 N 4 O 6 S 648; found 649 (M+H, 42%).
Step E: 3-Amino-3-methyl-N-[2,3,4,5-tetrahydro-2-oxo-l-[[2'-(ethylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-1H-1-benzazepin-3(R)-yl]butanamide, trifluoroacetate
A solution of 33 mg (0.051 mmol) of the intermediate obtained in Step D in 3 mL of trifluoroacetic acid was treated with three drops of anisole. The resulting solution was stirred at room temperature under nitrogen for 4 hours. All volatiles were removed under vacuum and the residue was purified by reverse phase medium pressure liquid chromatography on C8, eluting with methanol/0.1% aqueous trifluoroacetic acid (70/30) to give the title compound. 1 H NMR (400 MHz, CDCl 3 ): δ 0.89 (t, 7Hz, 3H), 1.34 (s, sH), 1.38 (s, 3H), 2.14 (m, 1H), 2.34 (m, 1H), 2.52 (m, 2H), 2.65 (m, 4H), 4.42 (dd; 7, 11 Hz; 1H), 5.04 (d, 15 Hz, 1H), 5.25 (d, 15 Hz, 1H), 7.20-7.40 (m, 9H), 7.53 (dt; 2,8 Hz; 1H), 7.62 (dt; 2, 8 Hz; 1H), 8.02 (d, 8 Hz, 1H). FAB-MS: calculated for C 30 H 36 N 4 O 4 S 548; found 549 (M+H, 100%).
EXAMPLE 3
3-Amino-3-methyl-N-[2,3,4,5-tetrahydro-2-oxo-1-[[2'-(aminosulfonyl)[1,1'-biphenyl]-4-yl]methyl]-1H-1-benzazepin-3(R)-yl]butanamide, trifluoroacetate
The title compound is prepared from 3-benzyloxycarbonylamino-3-methyl-N-[2,3,4,5-tetrahydro-2-oxo-1-[[2'-(t-butylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-1H-1-benzazepin-3(R)-yl]butanamide (Example 1, Step E) by the procedure described in Example 1, Step H
EXAMPLE 4
3-Amino-3-methyl-N-[2,3,4,5-tetrahydro-2-oxo-1-[[2'-(t-butylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-1H-1-benzazepin-3(R)-yl]butanamide, trifluoroacetate
3-Benzyloxycarbonylamino-3-methyl-N-[2,3,4,5-tetrahydro-2-oxo-1-[[2'-(t-butylamino)sulfonyl[1,1'-biphenyl]-4-yl]methyl]-1H-1-benzazepin-3(R)-yl]butanamide (Example 1, Step E) is hydrogenated in methanol in the presence of 20 weight percent palladium hydroxide on carbon catalyst at ambient temperature and one atmosphere of hydrogen for 6 hours. The reaction mixture is filtered through Celite, and concentrated under vacuum. The residue is purified by reverse phase medium pressure liquid chromatography on C8, eluting with methanol/0.1% aqueous trifluoroacetic acid to give the title compound.
EXAMPLE 5
Utilizing the procedures described in Examples 1 to 4 and general methods of organic synthesis described in the chemical literature and familiar to one skilled in the art, the following compounds of Formula 1 can be prepared from the appropriately substituted starting materials and reagents.
__________________________________________________________________________ ##STR28##R.sup.1 R.sup.9 A R.sup.4 R.sup.5__________________________________________________________________________H SO.sub.2 NHCH.sub.3 ##STR29## ##STR30## HH SO.sub.2 NHCH.sub.3 ##STR31## CH.sub.2 CH.sub.2 OH HH SO.sub.2 NHCH.sub.3 ##STR32## ##STR33## HH SO.sub.2 NHCH.sub.3 ##STR34## ##STR35## HH SO.sub.2 NHCH.sub.3 ##STR36## ##STR37## HH SO.sub.2 NHCH.sub.3 ##STR38## CH.sub.2 CH.sub.2 CH.sub.3 HH SO.sub.2 NHCH.sub.3 ##STR39## ##STR40## H6-F SO.sub.2 NHCH.sub.3 ##STR41## H H7-F SO.sub.2 NHCH.sub.3 ##STR42## H H7-CF.sub.3 SO.sub.2 NHCH.sub.3 ##STR43## H H7-OCH.sub.3 SO.sub.2 NHCH.sub.3 ##STR44## H H7-OH SO.sub.2 NHCH.sub.3 ##STR45## H H7-SCH.sub.3 SO.sub.2 NHCH.sub.3 ##STR46## H H7-S(O)CH.sub.3 SO.sub.2 NHCH.sub.3 ##STR47## H H8-OCH.sub.3 SO.sub.2 NHCH.sub.3 ##STR48## H H8-F SO.sub.2 NHCH.sub.3 ##STR49## H H8-Cl SO.sub.2 NHCH.sub.3 ##STR50## H H8-I SO.sub.2 NHCH.sub.3 ##STR51## H HH SO.sub.2 NHCH.sub.3 ##STR52## H HH SO.sub.2 NHCH.sub.3 ##STR53## H HH SO.sub.2 NHCH.sub.3 ##STR54## H HH SO.sub.2 NHCH.sub.3 ##STR55## H HH SO.sub.2 NHCH.sub.3 ##STR56## H HH SO.sub.2 NHCH.sub.3 ##STR57## CH.sub.3 HH SO.sub.2 NHCH.sub.3 ##STR58## H HH SO.sub.2 NHCH.sub.3 ##STR59## H HH SO.sub.2 NHCH.sub.3 ##STR60## ##STR61## HH SO.sub.2 NHCH.sub.3 ##STR62## ##STR63## HH SO.sub.2 NHCH.sub.3 ##STR64## H HH SO.sub.2 NHCH.sub.3 ##STR65## H HH SO.sub.2 NHCH.sub.3 ##STR66## H HH SO.sub.2 NHCH.sub.3 ##STR67## -- --H SO.sub.2 NHCH.sub.3 ##STR68## -- --H SO.sub.2 NHCH.sub.3 ##STR69## -- --__________________________________________________________________________
EXAMPLE 6
Utilizing the procedures described in Examples 1 to 4 and general methods of organic synthesis described in the chemical literature and familiar to one skilled in the art, the following compounds of Formula I can be prepared from the appropriately substituted starting materials and reagents.
__________________________________________________________________________ ##STR70##X n p R.sup.9 A R.sup.4__________________________________________________________________________-- 0 3 SO.sub.2 NHCH.sub.3 ##STR71## H-- 0 3 SO.sub.2 NHCH.sub.3 ##STR72## ##STR73##-- 0 1 SO.sub.2 NHCH.sub.3 ##STR74## H-- 0 1 SO.sub.2 NHCH.sub.3 ##STR75## ##STR76##-- 0 0 SO.sub.2 NHCH.sub.3 ##STR77## H-- 0 0 SO.sub.2 NHCH.sub.3 ##STR78## ##STR79##CO 1 1 SO.sub.2 NHCH.sub.3 ##STR80## ##STR81##CHOH 1 1 SO.sub.2 NHCH.sub.3 ##STR82## ##STR83##S 1 0 SO.sub.2 NHCH.sub.3 ##STR84## HS 1 0 SO.sub.2 NHCH.sub.3 ##STR85## HS 1 0 SO.sub.2 NHCH.sub.3 ##STR86## ##STR87##SO 1 0 SO.sub.2 NHCH.sub.3 ##STR88## HSO 1 0 SO.sub.2 NHCH.sub.3 ##STR89## HSO 1 0 SO.sub. 2 NHCH.sub.3 ##STR90## ##STR91##SO 1 0 SO.sub.2 NHCH.sub.3 ##STR92## ##STR93##S 1 2 SO.sub.2 NHCH.sub.3 ##STR94## HS 1 2 SO.sub.2 NHCH.sub.3 ##STR95## HS 1 2 SO.sub.2 NHCH.sub.3 ##STR96## ##STR97##S 1 2 SO.sub.2 NHCH.sub.3 ##STR98## ##STR99##S 1 2 SO.sub.2 NHCH.sub.3 ##STR100## HS 1 2 SO.sub.2 NHCH.sub.3 ##STR101## HS 1 2 SO.sub.2 NHCH.sub.3 ##STR102## ##STR103##S 1 2 SO.sub.2 NHCH.sub.3 ##STR104## ##STR105##O 1 1 SO.sub.2 NHCH.sub.3 ##STR106## HO 1 1 SO.sub.2 NHCH.sub.3 ##STR107## HO 1 1 SO.sub.2 NHCH.sub.3 ##STR108## ##STR109##O 1 1 SO.sub.2 NHCH.sub.3 ##STR110## ##STR111##__________________________________________________________________________
EXAMPLE 7
Utilizing the procedures described in Examples 1 to 4 and general methods of organic synthesis described in the chemical literature and familiar to one skilled in the art, the following compounds of Formula I can be prepared from the appropriately substituted starting materials and reagents.
______________________________________ ##STR112##R.sup.1 x m R.sup.9 R.sup.4______________________________________8-CF.sub.3 1 0 SO.sub.2 NH.sub.2 ##STR113##8-OCH.sub.3 1 0 SO.sub.2 NH.sub.2 ##STR114##8-F 1 0 SO.sub.2 NH.sub.2 ##STR115##H 1 0 SO.sub.2 NHCH.sub. 3 ##STR116##H 1 0 SO.sub.2 NHCH.sub.3 ##STR117##H 1 0 SO.sub.2 NHCH.sub.3 ##STR118##H 0 0 SO.sub.2 NHCH.sub.3 HH 0 0 SO.sub.2 NHCH.sub.3 ##STR119##H 1 1 SO.sub.2 NHCH.sub.3 ##STR120##H 1 1 SO.sub.2 NHCH.sub.3 ##STR121##H 1 1 SO.sub.2 NHCH.sub.3 ##STR122##H 1 1 SO.sub.2 NHCH.sub.3 ##STR123##H 1 0 SO.sub.2 NHCH.sub.3 ##STR124##8-F 1 0 SO.sub.2 NHCH.sub.3 ##STR125##8-CF.sub.3 1 0 SO.sub.2 NHCH.sub.3 ##STR126##8-OCH.sub.3 1 0 SO.sub.2 NHCH.sub.3 ##STR127##8-SCH.sub.3 1 0 SO.sub.2 NHCH.sub.3 ##STR128##9-F 1 0 SO.sub.2 NHCH.sub.3 ##STR129##8-F 1 0 SO.sub.2 NHCH.sub.3 ##STR130##8-F 1 0 SO.sub.2 NHCH.sub.3 ##STR131##H 1 0 SO.sub.2 NHCH.sub.3 HH 1 0 SO.sub.2 NH.sub.2 ##STR132##H 1 1 SO.sub.2 NHCH.sub.3 ##STR133##H 1 0 SO.sub.2 NH.sub.2 ##STR134##H 1 0 SO.sub.2 NH.sub.2 ##STR135##H 0 0 SO.sub.2 NH.sub.2 ##STR136##H 1 0 SO.sub.2 NH.sub.2 ##STR137##8-F 1 0 SO.sub.2 NH.sub.2 ##STR138##______________________________________
EXAMPLE 8
Utilizing the procedures described in Examples 1 to 4 and general methods of organic synthesis described in the chemical literature and familiar to one skilled in the art, the following compounds of Formula 1 can be prepared from the appropriately substituted starting materials and reagents.
__________________________________________________________________________ ##STR139##R.sup.1R.sup.9 A R.sup.4__________________________________________________________________________ ##STR140## ##STR141## ##STR142##H ##STR143## ##STR144## CH.sub.2 CH.sub.2 OHH ##STR145## ##STR146## ##STR147##H ##STR148## ##STR149## ##STR150##H ##STR151## ##STR152## ##STR153##H ##STR154## ##STR155## CH.sub.2 CH.sub.2 CH.sub.3H ##STR156## ##STR157## CH.sub.3H ##STR158## ##STR159## HH ##STR160## ##STR161## HH ##STR162## ##STR163## HH ##STR164## ##STR165## HH ##STR166## ##STR167## HH ##STR168## ##STR169## HH ##STR170## ##STR171## HH ##STR172## ##STR173## ##STR174##H ##STR175## ##STR176## ##STR177##H ##STR178## ##STR179## ##STR180##H ##STR181## ##STR182## ##STR183##H ##STR184## ##STR185## ##STR186##H ##STR187## ##STR188## ##STR189##H ##STR190## ##STR191## ##STR192##H ##STR193## ##STR194## ##STR195##H ##STR196## ##STR197## ##STR198##H ##STR199## ##STR200## ##STR201##H ##STR202## ##STR203## ##STR204##H ##STR205## ##STR206## ##STR207##H ##STR208## ##STR209## ##STR210##H ##STR211## ##STR212## ##STR213##6-f ##STR214## ##STR215## H6-OCH.sub.3 ##STR216## ##STR217## H7-Br ##STR218## ##STR219## H7-Cl ##STR220## ##STR221## H7-CH.sub.3 ##STR222## ##STR223## H8-Cl ##STR224## ##STR225## H8-I ##STR226## ##STR227## HH ##STR228## ##STR229## HH ##STR230## ##STR231## HH ##STR232## ##STR233## HH ##STR234## ##STR235## HH ##STR236## ##STR237## HH ##STR238## ##STR239## HH ##STR240## ##STR241## H__________________________________________________________________________
EXAMPLE 9
Utilizing the procedures described in Examples 1 to 4 and general methods of organic synthesis described in the chemical literature and familiar to one skilled in the art, the following compounds of Formula I can be prepared from the appropriately substituted starting materials and reagents.
__________________________________________________________________________ ##STR242##X n p R.sup.9 A R.sup.4__________________________________________________________________________-- 0 3 ##STR243## ##STR244## H-- 0 3 ##STR245## ##STR246## ##STR247##-- 0 3 ##STR248## ##STR249## ##STR250##-- 0 1 ##STR251## ##STR252## H-- 0 1 ##STR253## ##STR254## ##STR255##-- 0 1 ##STR256## ##STR257## ##STR258##-- 0 0 ##STR259## ##STR260## H-- 0 0 ##STR261## ##STR262## ##STR263##-- 0 0 ##STR264## ##STR265## ##STR266##CO 1 1 ##STR267## ##STR268## ##STR269##CHOH 1 1 ##STR270## ##STR271## ##STR272##S 1 0 ##STR273## ##STR274## HS 1 0 ##STR275## ##STR276## HS 1 0 ##STR277## ##STR278## ##STR279##SO 1 0 ##STR280## ##STR281## HSO 1 0 ##STR282## ##STR283## HSO 1 0 ##STR284## ##STR285## ##STR286##SO 1 0 ##STR287## ##STR288## ##STR289##S 1 2 ##STR290## ##STR291## HS 1 2 ##STR292## ##STR293## HS 1 2 ##STR294## ##STR295## ##STR296##S 1 2 ##STR297## ##STR298## ##STR299##S 1 2 ##STR300## ##STR301## HS 1 2 ##STR302## ##STR303## HS 1 2 ##STR304## ##STR305## ##STR306##S 1 2 ##STR307## ##STR308## ##STR309##O 1 1 ##STR310## ##STR311## HO 1 1 ##STR312## ##STR313## HO 1 1 ##STR314## ##STR315## ##STR316##O 1 1 ##STR317## ##STR318## ##STR319##__________________________________________________________________________ | There are disclosed certain novel compounds identified as benzo-fused lactams which promote the release of growth hormone in humans and animals. This property can be utilized to promote the growth of food animals to render the production of edible meat products more efficient, and in humans, to increase the stature of those afflicted with a lack of a normal secretion of natural growth hormone. Growth promoting compositions containing such benzo-fused lactams as the active ingredient thereof are also disclosed. | 2 |
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application is a Non-Provisional Utility application which claims benefit of co-pending U.S. Patent Application Ser. No. 60/526,638 filed Dec. 3, 2003, entitled “High Input Voltage Microcontroller Based Instant Start Ballast” which is hereby incorporated by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
REFERENCE TO SEQUENCE LISTING OR COMPUTER PROGRAM LISTING APPENDIX
[0003] Not Applicable
BACKGROUND OF THE INVENTION
[0004] One problem with prior art electronic ballasts is that the open circuit voltage of an instant-start ballast needs to be controlled when there is not a lamp coupled to the ballast. Unfortunately, prior art methods of providing this open circuit voltage control cause substantial variations in the open circuit voltage when used in conjunction with different lengths of cable, or require a high value resonant capacitor which results in a high circulating current. A high circulating current is undesirable in that it increases the conduction losses in the ballast and may result in damaging capacitive mode switching occurring during the striking transients. Therefore, an improved method and apparatus for controlling the open circuit voltage of a high input voltage electronic ballast without increasing the switching losses or creating high value circulating currents is needed.
[0005] In some prior art ballasts, the voltage on the lamp voltage sensing resistor is used to control the open circuit voltage during striking when no lamp is connected. To accomplish this, the pulse width of one switch of the half bridge is typically controlled. Controlling the pulse width controls the open circuit voltage indirectly by using inductor current to control the voltage on the capacitor. As a result, large open circuit voltage variations often result when external connections to the fixture, such as a connecting cable, add extra capacitance. In ballast implementations that can afford to use a large resonant capacitor and a small inductor, the open circuit voltage variation problem is generally not too significant. However, potentially damaging hard switching or capacitive mode switching is often observed in these high capacitance types of prior art open circuit voltage controlled ballasts. Furthermore, the use of a large resonant capacitor makes the resonant tank difficult to design. As a result, these types of ballasts suffer from more conduction losses and/or hard switching during the striking of the lamp than do typical ballasts. Conduction losses and hard switching are undesirable in that they may cause the ballast to fail. A large resonant capacitor, with a striking voltage of two lamps across it, stores a substantial amount of energy. When the striking attempt occurs when there is no load, the striking energy is transferred to the resonant inductor and can saturate the inductor. The result is undesirable hard switching occurring during the striking. Even though a MOSFET can survive the high stress transients in ballasts with a 460V bulk voltage, hard switching is undesirable and should be avoided if possible. Furthermore, for some types of ballasts, it is critically important to avoid hard switching due to their particular susceptibility to damage from transients. Thus, in many of the prior art ballasts, the resonant capacitor value is minimized and a cable compensation circuit is utilized to control the open circuit voltage such that it is constant with various lengths of connected cable attached having varying amounts of capacitance. However, these circuits are often complex and decrease the efficiency, while increasing the cost, of the ballast. Therefore, an improved method and apparatus for controlling the open circuit voltage of a ballast and compensating for any attached cables is needed.
[0006] Therefore what is needed is a new and improved electronic ballast that overcomes the above mentioned deficiencies of the prior art.
BRIEF SUMMARY OF THE INVENTION
[0007] A preferred embodiment of the present invention is directed toward an electronic ballast for producing an output voltage on a pair of output terminals for igniting and powering a gas discharge lamp connected between the output terminals. The ballast includes an inverter having a pair of transistors. A snubber circuit reduces turn off losses in the transistors. The snubber circuit includes a pair of series connected snubber capacitors connected in parallel with the pair of transistors. An extended dead time is created between gating signals of the pair of transistors to allow the snubber capacitors to discharge. The electronic ballast includes a resonant tank having a series connected tank inductor and tank capacitor and an output voltage sensing circuit that senses an output voltage of the ballast by sensing a voltage across a sampling capacitor connected in series with the tank capacitor. An open circuit voltage control circuit is also preferably included that controls a voltage across the output terminals when a gas discharge lamp is not connected between the output terminals. The open circuit voltage control circuit includes a resistor connected in series with a tank capacitor of the ballast. A cable compensation circuit is also preferably included that limits variations in the output voltage of the electronic ballast due to a cable being connected to the output terminals of the ballast. The cable compensation circuit limits variations in the output voltage by altering the gating signals provided to the transistors.
[0008] Another embodiment of the present invention is directed toward an electronic ballast for providing an output voltage on a pair of output terminals for use in powering a gas discharge lamp. The ballast includes an inverter circuit having a first transistor and a second transistor and a resonant tank having a tank capacitor and a tank inductor. A substantially lossless snubber circuit reduces turn-off losses in the first and second transistors of the inverter. The snubber circuit includes a snubber capacitor connected in parallel with each of the first transistor and the second transistor. A microcontroller provides gating signals to the transistors such that an extended dead time is created between the gating signals of the transistors to allow the snubber capacitors to discharge. An open circuit voltage control circuit controls a voltage across the output terminals of the ballast when a gas discharge lamp is not connected between the output terminals. A sampling capacitor connected in series with the tank capacitor wherein an output voltage of the ballast is sampled across the sampling capacitor.
[0009] Yet another embodiment of the present invention is directed toward an electronic ballast having a half-bridge inverter circuit that includes a pair of transistors and a pair of capacitors. Each capacitor is connected in parallel with one of the transistors. A microcontroller generates transistor switching control signals that cause the transistors to switch on and off at a rate that allows the capacitors to reduce turn off losses in the transistors. This is preferably accomplished by creating an extended dead time between the gating signals of the pair of transistors that allows the capacitors to discharge. The electronic ballast has a resonant tank having a series connected tank inductor and tank capacitor. A sampling capacitor is connected in series with the tank capacitor wherein an output voltage of the ballast is sampled across the sampling capacitor. An open circuit voltage control circuit is also included that controls a voltage across the output terminals of the ballast when a gas discharge lamp is not connected between the output terminals. The open circuit voltage control circuit has a resistor connected in series with the sampling capacitor and the voltage across the resistor is used to limit the output voltage of the electronic ballast. A cable compensation circuit is also preferably provided to limit variations in the output voltage due to cables being connected to outputs of the ballast.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0010] FIG. 1 is a schematic diagram of a lossless snubber circuit constructed in accordance with a preferred embodiment of the present invention;
[0011] FIG. 2 is a schematic diagram of a lossless lamp voltage sampling circuit having a lossless snubber circuit constructed in accordance with a preferred embodiment of the present invention;
[0012] FIG. 3 is a schematic diagram of a hybrid sampling circuit having a lossless snubber circuit constructed in accordance with the present invention; and
[0013] FIG. 4 is a schematic diagram of a cable compensation circuit having a lossless snubber circuit constructed in accordance with a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0014] A preferred embodiment of the present invention is directed toward an instant start electronic ballast for a gas discharge lamp having a substantially lossless snubber circuit for reducing the turn off loses of the transistors in the inverter of the ballast. For voltage-fed, series-resonant, half-bridge inverters, the turning-on of the FETS or transistors involves zero voltage switching, but the turning-off of the FETS and transistors involves hard switching. For most ballasts, the turning-off current is small so that losses associated with the turning-off are not significant. However, for an Instant Start—High Range Voltage ballast, the current at turn-off is near its peak and, thus, the turn-off losses are relatively high. Furthermore, due to the larger die size of the high voltage FETS, more gate charge has to be removed from the gates before they can be turned-off. This increased gate charge increases the turn-off losses for a high voltage inverter.
[0015] A simplified schematic of an electronic ballast 2 constructed in accordance with a preferred embodiment of the present invention is shown in FIG. 1 . The electronic ballast consists of a bulk DC voltage stage 4 that provides a relatively constant DC voltage to the inverting transistors 6 and 8 . In a typical fluorescent light ballast, the bulk DC voltage stage 4 includes a bridge rectifier that converts a standard AC supply voltage into a DC voltage. However, it will be readily appreciated by those skilled in the art that a variety of power sources may be utilized to provide a DC voltage.
[0016] A resonant tank comprised of an inductor 10 and capacitor 12 is used to filter the output of the inverting transistors 6 and 8 and provide the filter power signals to the lamp 14 which is represented by a resistor 14 in FIG. 1 . To reduce the turn-off losses associated with the transistors 6 and 8 , two snubber capacitors 16 and 18 are connected in parallel with the transistors 6 and 8 of a preferred ballast 2 of the present invention as shown in FIG. 1 . In the normal case, the capacitors 16 and 18 reduce the turn-off losses associated with the switches 6 and 8 . However, all of the energy stored in the capacitors 16 and 18 when the switches 6 and 8 are turned off, will be dissipated in the switches 6 and 8 at the turn-on. Thus, in a preferred embodiment such as an IHRV ballast, an extended dead time that allows the capacitors 16 and 18 to discharge is created between the gating signals of the transistors 6 and 8 to deal with this problem. Since the load current flowing through the lamp 14 is highly inductive during this extended dead time, the load 14 current will discharge the snubber capacitors 16 and 18 during the extended dead time. Thus, at the turn-on, there are no switching losses in the transistors 6 and 8 of a preferred embodiment of the present invention. Furthermore, at turn-off, the switching losses are also completely removed through the use of capacitors 16 and 18 . As a result, there are substantially no switching losses in the inverter of the ballast and the use of a 770V half bridge inverter becomes economically feasible. However, in order to use the lossless snubber capacitors 16 and 18 of FIG. 1 , the amplitude of the load 14 current should be high at the turn-off and the dead time should be large enough to allow the snubber capacitors 16 and 18 to be discharged. The length of the dead time is adjusted by controlling the gating signals provided from the microcontroller 11 to the transistors 6 and 8 . As will be appreciated by those skilled in the art, the time required for the snubber capacitors 16 and 18 to discharge will depend upon the capacitance of the particular capacitors 16 and 18 and the amount of charge stored on the capacitors 16 and 18 . Alternatively, only one capacitor can be used instead of the two capacitors 16 and 18 . However, the use of a single capacitor may be disadvantageous in that, whenever there is not enough load current to discharge the capacitor, the energy stored in the capacitor will be dissipated in the transistor or FET connected in parallel with it. Thus, if there is only one capacitor, then the dissipated energy is concentrated in only one FET or transistor. With two capacitors 16 and 18 , as shown in FIG. 1 , the voltage stress is substantially equally distributed across both switches 6 and 8 and, thus, the reliability and robustness of the ballast 2 is increased.
[0017] Referring now to FIG. 2 , an electronic ballast 30 with a series resonant tank that utilizes lossless sampling of the lamp voltage 34 in conjunction with the lossless snubber capacitors 36 and 38 of a preferred embodiment of the present invention is shown. The electronic ballast 30 includes a bulk DC voltage source 32 that provides power to the inverter circuit transistors 46 and 48 . The series resonant tank is comprised of a resonant tank inductor 40 and a resonant tank capacitor 42 . Prior art circuits use a resistor connected in series with the resonant capacitor 42 to sense the lamp voltage 32 and control the open circuit voltage. However, in the newly developed circuit of a preferred embodiment of the present invention for an IHRV ballast and/or sign ballast, the lamp voltage 34 is sensed by a sampling capacitor 44 connected in series with the resonant capacitor 42 as shown in FIG. 2 . Using the principle of voltage division with capacitors, when the sampling capacitor 44 is much bigger than the resonant capacitor 42 , the voltage drop on the sampling capacitor 44 is very small and vice versa. This is beneficial in that it is relatively easy to find a film capacitor 44 that has a small package size and is relatively inexpensive. Most preferably, the capacitor's 44 values are 330 nF 60V or 680 nF 60V. A sampling circuit comprised of capacitors 50 and 52 and resistors 54 and 56 is used to sample the voltage on capacitor 44 . The sampling circuit of FIG. 2 provides a low output impedance, a strong signal with excellent signal to noise ratio and a quick response time to an A/D converter input of an associated microcontroller. Thus, the circuit of FIG. 2 uses lossless snubber capacitors 46 and 48 and capacitor 44 based voltage division to improve the efficiency of the ballast 30 without sacrificing performance.
[0018] The sampling capacitor 44 used in the ballast of FIG. 2 can also be connected in series with a low value resistor 60 , which can be used to control the open circuit voltage 34 as shown in FIG. 3 . The hybrid sampling circuit shown in FIG. 3 samples a large amplitude version of the lamp voltage 34 across a capacitor 44 . The sampled signal is smoothed by RC filters formed by capacitors 50 and 52 and resistors 54 and 56 and then fed to the A/D converter of the microcontroller. The response of the lamp voltage is not fast in the circuit of FIG. 3 , but it is almost entirely lossless. For open circuit voltage control, the amplitude of the voltage across resistor 60 is large enough at the striking to turn on transistor 66 to trim the pulse width of the gating signal of the upper switch 46 of the half bridge. Trimming the pulse width of the gating signal of the upper switch 46 controls the open circuit voltage. However, during steady state operation, the voltage on the resistor 60 is very small, out of phase with the voltage on capacitor 44 , and still proportional to the lamp voltage 34 . Hence, the lamp voltage 34 sensing is not affected by the resistor 60 during steady state operation.
[0019] The sampling circuit described above with respect to FIG. 3 can be used independently without a cable compensation circuit. Since the voltage on resistor 60 is in phase with the current of the upper switch 46 , it is convenient to use it to control the open circuit voltage when no lamp is connected and to trim the pulse width of the upper switch 46 of the half-bridge as discussed above. However, when a long cable is connected and the capacitance of the cable is essentially in parallel with the resonant capacitor 42 , the parameters of the resonant tank circuit constructed from inductor 40 and capacitor 42 are changed. As the result, the open circuit voltage 34 decreases when a cable is connected to the output terminals of the electronic ballast. When the value of the resonant capacitor 34 is small, the decrease in the open circuit voltage 34 is significant and the ballast will not strike the lamp. The open circuit voltage can be set high to start a lamp with a long cable. However, in applications where no cable is attached, the open circuit voltage is then too high, which may cause the ballast to fail the through-lamp leakage test, or damage the film capacitor 44 . Increasing the capacitance of the resonant capacitor 42 helps to decrease the variation of the open circuit voltage but increases the conduction losses due to the circulation currents in the resonant capacitors. Furthermore, larger capacitor values lead to saturation of the resonant inductor 40 . Therefore preferred embodiments of the present invention include a cable compensation circuit.
[0020] Capacitor sampling provides a strong sample signal with low output impedance and quick response. A cable compensation circuit is created by adding zener diode 70 , resistors 72 and 76 , and capacitor 74 to the circuit of FIG. 3 as set forth in FIG. 4 . The open circuit voltage 34 as sampled by capacitor 44 rises very rapidly at node 68 . When the open circuit voltage 34 becomes too high, the zener diode 52 starts to conduct and feeds current to the base of transistor 66 such that the conductive threshold for the transistor 66 is decreased. Thus, the transistor 66 starts to turn-on earlier when the voltage on resistor 60 is lower. The pulse width of the gating signal of the upper switch 46 then becomes narrower. The true open circuit voltage is sensed in this way to change the current threshold required to turn-off the switch 46 . In an exemplary circuit constructed as described above, the open circuit voltage varies from 1.9 kV to 2.6 kV without the cable compensation circuit when 18 feet of cable is connected to or removed from the circuit. However, with the cable compensation circuit of FIG. 4 , the variation in the open circuit voltage is within approximately 100V. Thus, an electronic ballast having lossless snubber capacitors and a cable compensation circuit in accordance with the embodiment of the present invention shown in FIG. 4 represents a substantial improvement upon the prior art.
[0021] Thus, although there have been described particular embodiments of the present invention of a new and useful Lossless Snubber Capacitor Circuit, it is not intended that such references be construed as limitations upon the scope of this invention except as set forth in the following claims. | An improved high input voltage instant start electronic ballast uses a substantially lossless snubber circuit. The substantially lossless snubber circuit is incorporated into the ballast to reduce turn off losses and increase the efficiency of the ballast. The snubber circuit includes two capacitors connected in parallel with respect to the two switching transistors or FETS in the inverter of the ballast. A series-resonant lamp voltage sensing circuit is also provided that uses a voltage dividing capacitor to accomplish lossless monitoring of the open circuit voltage of the ballast. A cable compensation circuit minimizes variations in the open circuit voltage due to the connecting and disconnecting of a cable to the ballast by limiting the turn on times of the transistors during high voltage conditions. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This patent application is related to U.S. application Ser. No. ______, filed on ______ and entitled, “A CAVITATION-BASED HYDRO-FRACTURING TECHNIQUE FOR GEOTHERMAL RESERVOIR STIMULATION”, and U.S. patent application Ser. No. 12/945,252 filed on 12 Nov. 2010 and entitled, “REPETITIVE PRESSURE-PULSE APPARATUS AND METHOD FOR CAVITATION DAMAGE RESEARCH” the entire contents of which are included herein by reference as if included at length.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT
[0002] This invention was made with government support under Contract No. DE-AC05-00OR22725 awarded by the U.S. Department of Energy. The government has certain rights in the invention.
THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT
[0003] None.
BACKGROUND OF THE INVENTION
[0004] 1. Field of the Invention
[0005] The present disclosure relates to enhanced geothermal system (EGS) production and particularly to apparatuses and methods for simulating a cavitation-based hydro-fracturing technique.
[0006] 2. Description of the Related Art
[0007] Geothermal energy is an important part of the nation's renewable energy initiative. FIG. 1 illustrates a simplified schematic of a geothermal plant that generates electricity for the electrical grid. A working fluid (F) such as water is transferred with a pump 100 down into the hot rock formations through an injection well 102 , where it absorbs heat energy from the fractured rock formation. The heated working fluid (F) is then pumped to an energy conversion plant 104 through a production well 106 . Depending on the fluid's (F) temperature, it may directly be used to power a turbine or may be used to heat a secondary working fluid, which, in turn, is used to power a turbine. The turbine is coupled to a generator through a common shaft (not shown), to generate electricity for the electrical grid 108 . The cooled working fluid (F) is then injected with the pump 100 back into the hot rock geothermal reservoir through the injection well 102 to sustain the process. Geothermal energy generation is considered a green technology, because little or no greenhouse gases are emitted into the atmosphere and the energy source is renewable.
[0008] An Enhanced Geothermal System (EGS) is a man-made reservoir, created where there is sufficient underground hot rock but insufficient or little natural permeability or working fluid (F) saturation in the rock. EGS expands the geothermal energy domain into much deeper rock deposits by exploiting natural and artificial fracture systems/networks within the rock mass. Maintaining and/or creating such facture networks in complicated geological environments are critical to the successful development and long-term sustainability of the EGS. The EGS targets a huge energy source that amounts to 500 GWe in the western U.S. and 16,000 GWe in the entire U.S. Several demonstration projects are undergoing in the U.S. to validate different reservoir stimulation techniques. The ultimate reservoir will have a flow rate of 60 kg/s, a lifetime of 30 years along the drilling systems down to 10,000 meters deep at 374 Degrees Celsius.
[0009] EGS reservoir stimulation technologies currently are adapted from the oil and natural gas industry including various hydrofracking methods with or without chemical additives. A potential drawback of using hydrofracking techniques is the lack of effective control in the creation of large fractures, which could result in by-pass of targeted fracture network or even fault movement in the rock formation. The loss of hydraulic medium can reduce heat exchange efficiency and increase the cost of the development of EGS. The use of chemicals along with the unpredictable fault movement may also adversely impact the environment.
[0010] Cavitation is the process of the formation of vapors, voids, or bubbles due to pressure changes in a liquid flow as schematically illustrated in FIG. 2 . The pressure wave propagation 200 , and eventual collapse of the bubbles 202 can cause local pressure changes in the working fluid (F), which can be transmitted to a target rock surface 204 either in the form of a shock wave 206 , or by micro-jets 208 , depending on the bubble to surface distance. Pressure greater than 100,000 psi has been measured in a shock wave 206 resonating from cavitating bubbles 202 . It is generally understood that the cycle of formation and collapse of the bubbles that occurs, often at a high frequency, can generate dynamic stress on the surfaces of objects. Ultimately, the dynamic stress can contribute to the fatigue of the target surface, including micro-cracks that form and coalesce on the surface 204 , eventually leading to material removal known as cavitation damage.
[0011] The operations of geothermal, oil and natural gas wells are expensive endeavors. Well site development and production activities involve vast capital investments in land and equipment as well as the support of highly specialized personnel. Due to these large investments, opportunities for in-situ research and development efforts in the geothermal, oil and natural gas industries may not be cost prohibitive.
[0012] What are needed are apparatuses and methods for simulating a pulse-pressure cavitation technique (PPCT) in a laboratory environment.
BRIEF SUMMARY OF THE INVENTION
[0013] Disclosed are several examples of apparatuses and methods for simulating a pulse-pressure cavitation technique (PPCT) in a laboratory environment.
[0014] Described in detail below is an apparatus for generating a pulsed pressure induced cavitation technique (PPCT) from a pressurized working fluid to simulate the hydrofracturing of a specimen when a working fluid and specimen are installed. In the apparatus, a pump is fluidly coupled to, and disposed downstream of, a reservoir and fluidly coupled to, and disposed downstream of, a control valve having an open position and a closed position, the pump capable of raising the pressure of a working fluid at the control valve. Also included is a test chamber for holding a specimen when a specimen is installed in the apparatus. The test chamber is fluidly coupled to, and disposed downstream of, the control valve and receives a working fluid from the control valve when the control valve is in the open position. Also included is a pressure regulator that is fluidly coupled to, and disposed downstream of, the test chamber and fluidly coupled to, and disposed upstream of, the reservoir. When the control valve is in the open position, it causes a working fluid to flow into the test chamber as a pressure pulse, causing cavitation to occur in a working fluid adjacent to a specimen when a specimen and a working fluid are installed in the apparatus. Other features and examples will be described in greater detail.
[0015] Also described in detail below is an article or specimen for receiving a pulsed pressure induced cavitation technique (PPCT) from a pressurized working fluid as generated by a test apparatus. The specimen includes a shell body defined by a circular top surface, a circular bottom surface and a convex side surface joining the top and bottom. Also included in the shell body is an aperture defined by an opening in the top surface and an opening in the bottom surface. Also included is a core body defined by a top surface, a bottom surface and a convex side surface joining the top surface and bottom surface. The core body is disposed inside of the aperture in the shell body and the shell body and core body are made of rock materials. Other features and examples will be described in greater detail.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0016] The apparatus and method may be better understood with reference to the following non-limiting and non-exhaustive drawings and description. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating principles. In the figures, like referenced numerals may refer to like parts throughout the different figures unless otherwise specified.
[0017] FIG. 1 is a simplified sectional schematic of a geothermal energy conversion plant.
[0018] FIG. 2 is a simplified rendition of cavitation mechanics at a fluid and surface interface.
[0019] FIG. 3 is a plan view of an exemplary apparatus for simulating a cavitation-based hydro-fracturing of a specimen.
[0020] FIG. 4 is an illustration of another exemplary apparatus for simulating a cavitation-based hydro-fracturing of a specimen.
[0021] FIG. 5 is an external view of an exemplary control valve for use with the apparatuses of FIGS. 3 and 4 .
[0022] FIG. 6 is a sectional view of the control valve of FIG. 5 .
[0023] FIG. 7 is an illustration of the internal elements of the control valve of FIG. 5 .
[0024] FIG. 8 is a sectional view of a test chamber as used with the control valve of FIG. 5 .
[0025] FIG. 9 is an illustration of an exemplary test chamber with instrumentation and dual control valves installed.
[0026] FIG. 10 is an illustration of an exemplary heating device for use with the test chambers.
[0027] FIG. 11 is an illustration of an exemplary specimen.
[0028] FIG. 12 is an illustration of another exemplary specimen.
[0029] FIG. 13 is an illustration of an exemplary specimen shell.
[0030] FIG. 14 is an illustration of an exemplary specimen core for use with the shells of FIGS. 13 and 15 .
[0031] FIG. 15 is an illustration of another exemplary specimen shell.
DETAILED DESCRIPTION OF THE INVENTION
[0032] With reference now to FIG. 3 , an exemplary apparatus 300 for generating a pulsed pressure induced cavitation technique to simulate the hydrofracturing of a specimen will now be described in greater detail. A working fluid (F), such as water, hydraulic fluid, other fluid, or combination of fluids, is stored in a reservoir 302 . The reservoir 302 may be an open or closed vessel and may also include means for filtering, adding, removing, and/or monitoring the level of working fluid (F). A pump 304 draws the working fluid (F) from the upstream reservoir 302 and distributes it to one or more downstream control valves 306 at pressures less than or equal to approximately 300 psi (2068.4 kPa), greater than or equal to approximately 300 psi (2068.4 kPa), or greater than or equal to approximately 300 psi (2068.4 kPa) and less than or equal to approximately 2,000 psi (13789.5 kPa). The pump 304 may operate by compressed air or by an electric motor for example. An air operated liquid piston pump 304 from Haskel International, Inc. Burbank, Calif., 91502 is suitable for this particular application.
[0033] The control valve 306 receives the pressurized working fluid (F) from the upstream pump 304 and delivers it to a downstream test chamber 308 . High speed compressed air or electric solenoid valves may be used for the control valve 306 . A programmable controller (not shown) is used to control the timing frequency of the opening and closing of the control valve 306 to suit each particular simulation. A laptop or desktop computer using LabVIEW software by National Instruments, or a similar controller and software product, may be used. In some examples, the controller may signal the control valve 306 to open and close at a predetermined open and close frequency and/or duration schedule. Frequencies less than or equal to approximately 300 cycles per minute, greater than or equal to approximately 300 cycles per minute, or greater than or equal to approximately 300 and less than or equal to approximately 60,000 cycles per minute may be used. In other examples, the controller may signal the control valve 306 to remain in the open position for a period of time. Although a single control valve 306 is illustrated in FIGS. 3 and 4 , two or more control valves 306 may also be used as shown later in FIG. 9 .
[0034] The exemplary test chamber 308 receives the pressurized working fluid (F) from the upstream control valve 306 . In this embodiment, the test chamber 308 is a cylindrical shaped tube defining an internal cavitation chamber 310 for accepting a test specimen 312 . This example of a test chamber 308 has an upstream end cap 314 that is fluidly coupled to the upstream control valve 306 , a medial body 316 and a downstream end cap 318 . The term fluidly coupled refers to a system where the fluid is able to flow between one component and another. At least one of the end caps 314 , 318 are removable from the body 316 to allow for loading and unloading of a specimen 312 into the cavitation chamber 310 . Corresponding threads 320 on the end caps 314 , 318 , and body 316 cooperate to provide a fluid seal when assembled together (see FIG. 8 ). The end caps 314 , 318 and body 316 are machined from high-strength, corrosion-resistant material such as stainless steel for example. SAE 304 or SAE 316 stainless steel perform well in this application. Other suitable materials may also be used.
[0035] A fluid pressure regulator 322 may be fluidly coupled between the test chamber 308 and the reservoir 302 . The pressure regulator 322 may be a diaphragm type, for example, and may contain an integral pressure gauge 324 for ensuring accurate adjustments to the fluid pressure in the system. As is typical in such regulators, a clockwise turn of the adjustment knob increases system pressure and a counterclockwise turn reduces system pressure. One or more pressure gauges 324 may be installed at different locations in the system to ensure proper working fluid (F) pressure.
[0036] Referring now to FIG. 4 , another exemplary apparatus 300 for generating a pulsed pressure induced cavitation technique to simulate the hydrofracturing of a specimen will now be described in greater detail. In this example, a pressure accumulator 326 may be fluidly coupled between the pump 304 and the control valve 306 . The pressure accumulator 326 may be a gas charged type, a bellows type, or other type of pressure accumulator known in the art. The pump 304 delivers the working fluid (F) to the accumulator 326 , raising its pressure, until the control valve 306 is opened. All other components and features of this exemplary apparatus 300 are as described above.
[0037] Conduits 328 are used to fluidly couple each of the components together and direct the working fluid (F) between components. High pressure capacity conduits 328 made of stainless steel may be used. Suitable couplings such as flared end fittings, or AN style fittings may be used to join the conduits 328 to the individual components described above.
[0038] Referring now to FIGS. 5-8 , another exemplary control valve, also referred to as a rotary shutter valve 500 , will be described in greater detail. In this example, an outer housing 502 includes an upstream end 504 , an opposite downstream end 506 , and a medial portion 508 disposed between the two ends. The outer housing 502 is preferably made from two cylindrical-shaped segments that are joined together at a circumferential flange 510 to simplify assembly, cleaning, inspection, modification, and repair of the valve. The flange 510 is held together with a plurality of circumferentially spaced fasteners 512 such as rivets, clamps or threaded fasteners as shown. An O-ring type seal 514 engages a corresponding gland machined in one or both of the segments as illustrated in FIG. 6 . The outer housing 502 is machined from a high strength, high temperature and corrosion resistant material such as stainless steel. SAE 304 or SAE 316 stainless steel performs well in this application.
[0039] An inlet aperture 516 is defined by the outer housing 502 at its upstream end 504 . An integral boss 518 provides additional material for connecting a conduit 328 using fittings as described above. The inlet aperture 516 is fluidly coupled to a pressure chamber 520 , which is also defined by the outer housing 502 at its upstream end 504 . The working fluid (F) flows under pressure from the pump 304 , though the conduits 328 to the inlet aperture 516 , and into the pressure chamber 520 . The downstream end 506 of the outer housing 502 defines a pulse cavity 522 , which discharges the pressurized working fluid (F) from the rotary shutter valve 500 as a series of pressure pulses 200 into the test chamber 308 ( FIG. 8 ).
[0040] The medial portion 508 of the outer housing 502 defines a bulkhead 524 , which separates the pressure chamber 520 from the pulse cavity 522 . The bulkhead 524 is preferably made integral with the outer housing 502 , but it may also be a separate component that is joined to the outer housing 502 by threads or other mechanical means such as welding. The bulkhead 524 defines one or more bulkhead apertures 526 , which fluidly couple the pressure chamber 520 with the pulse cavity 522 . In the example shown, two, equally spaced, circular bulkhead apertures 526 are used. In other examples, more or less apertures 526 of circular or other shapes are used. Also, apertures 526 with constant (shown), converging, or diverging cross sections from their upstream to downstream ends are contemplated. The upstream surface 528 of the bulkhead 524 is planar shaped and the downstream surface 530 is concave conical shaped in the example. The concave conical shape of the downstream surface helps direct the pressure waves 200 . Other shapes (e.g., concave spherical, concave parabolic) are contemplated for the bulkhead downstream surface 530 as well.
[0041] A rotatable shutter 532 is disposed inside of the pressure chamber 520 and adjacent to the upstream surface 528 of the bulkhead 524 . The shutter 532 defines one or more windows 534 that generally conform in size, shape, and radial placement with the bulkhead apertures 526 . In the example shown, four, equally spaced, circular windows 534 are used. In other examples, more or less windows 534 of circular or other shapes and sizes are used. The shutter 532 is affixed to, or integral with, a shaft 536 that extends through the pressure chamber 520 and exits the outer housing 502 at its upstream end 504 .
[0042] Thrust bearings 538 support the shaft 536 and fit in pockets machined in the bulkhead 524 and the upstream end 504 of the outer housing. Shoulders on the shaft 536 engage with the thrust bearings 538 to prevent the shaft 536 from moving axially, thus preventing the shutter 532 from contacting the bulkhead 524 , seizing, and/or causing destructive vibrations while rotating. An O-ring type seal 540 engages a corresponding gland machined in the radially outer surface of the shutter 532 and prevents leakage of the working fluid (F) from the gap between the shutter 532 and the outer housing 502 . A material such as polyurethane, aluminum, graphite or other strong, high temperature capable material may be used for the O-ring seal 540 .
[0043] Extending outward from the upstream end 504 of the outer housing 502 is a mounting flange 542 for accepting a powering device 544 . The powering device 544 is affixed to the mounting flange 542 with one or more fasteners 546 such as rivets, bolts or screws. In the example shown, an electric motor is used as the powering device 544 , but a hydraulic motor, a pneumatic motor, or other such device would also work in this application. Electricity, air, or hydraulic fluid is supplied to the powering device 544 by wires or hoses respectively (not shown).
[0044] A coupling 548 connects the powering device 544 to the shaft 536 . The coupling 548 may include threads, set screws, shear pins, keys, collets, and/or other connecting means. In order to protect the powering device 544 from damage, the coupling 548 is designed to fail if the shutter 532 and/or shaft 536 break, seize, or become otherwise jammed in the pressure chamber 520 for some reason.
[0045] During operation of the rotary shutter valve 500 , the powering device 544 transfers rotation to the shaft 536 through the coupling 548 . The spinning shaft 536 rotates the shutter 532 , causing the windows 534 to alternately align with (unblock) and misalign with (block) the one or more bulkhead apertures 526 . The pressurized working fluid (F) in the pressure chamber 520 discontinuously flows through the apertures 526 , into the pulse cavity 522 , and out of the downstream end 506 as pressure pulses 200 . The pressure pulses cause cavitation to occur in the test chamber 308 and, in turn, introduce fractures and micro cracks in a test specimen 312 when a test specimen is installed. It is noted that the pulses 200 are controlled by the number and size of the bulkhead apertures 526 , the number and size of shutter windows 534 , the rotational speed of the shutter 532 , and the pressure of the working fluid (F). The shutter 532 can rotate at speeds less than or equal to approximately 300 revolutions per minute, greater than or equal to approximately 300 revolutions per minute, or greater than or equal to approximately 300 revolutions per minute and less than or equal to approximately 60,000 revolutions per minute (RPM).
[0046] In this example, the test chamber 308 receives the pressurized working fluid (F) directly from the pulse cavity 522 of the rotary shutter valve 500 . The test chamber 308 is a cylindrical shaped tube defining an internal cavitation chamber 310 for accepting a test specimen 312 . This example has a medial body 316 and a downstream end cap 318 . The test chamber 308 is attached to the distal end 506 with threads or other features to allow for loading and unloading of the specimen 312 . Other features of the present test chamber 308 are as described in the earlier examples.
[0047] FIG. 9 shows another example of a test chamber 308 including instruments 330 for monitoring the conditions inside the cavitation chamber 310 such as the temperature, pressure and flow rate of the working fluid (F). It is also noted that, in this particular embodiment, two control valves 306 are fluidly coupled to the test chamber 308 at the upstream end cap 314 with each valve 306 functioning as described above with respect to FIGS. 3 and 4 . In this example, the working fluid (F) pressure pulses entering the test chamber 308 are directly controlled by the frequency and/or duration schedule(s) of the control valve(s), which may be programmed to open and close according to the same schedule or according to different schedules.
[0048] Referring now to the example of FIG. 10 , the test chamber 308 may be surrounded, at least partially, by a heating element 332 to simulate the elevated temperature found in a EGS reservoir, or an oil or gas well. In the example shown, a resistance heater 332 completely surrounds the test chamber 308 , but in other examples only a portion of the chamber is surrounded by a heater. In some examples, the heater is able to raise the temperature of the test chamber 308 and specimen 312 to a temperature less than or equal to approximately 50 degrees Celsius (122 Fahrenheit), greater than or equal to approximately 50 degrees Celsius (122 Fahrenheit), or greater than or equal to approximately 50 degrees Celsius (122 Fahrenheit) and less than or equal to approximately 250 degrees Celsius (482 Fahrenheit).
[0049] Referring lastly to FIGS. 11 and 12 , exemplary specimens 312 for evaluating pressure pulse cavitation in EGS, oil or gas well rock formations are shown. The specimens 312 are generally cylindrical in shape and defined by a circular top surface 334 , a circular bottom surface 336 and a convex side surface 338 extending between the top and bottom surfaces 334 , 336 . The specimens 312 are comprised of rock or stone material from larger rock specimens of the type found in EGS reservoirs, oil or gas wells. They are machined or core drilled to shape and sized to fit within the test chamber 308 .
[0050] In the example of FIG. 11 , a blind hole 340 mimics a stimulation well. During testing, the hole 340 is filled with working fluid (F) and is subject to cavitation by controlling the opening frequency and duration of the control valve(s). In the example of FIG. 12 , a series of artificial flaws 342 are included in the side surface 338 . Here, artificial flaws 342 such as cracks or fissures are introduced into the side surface 342 with a band saw, a water jet or other cutting device to simulate an existing crack structure and/or to assist the initiation of crack stimulation.
[0051] In the examples of FIGS. 13-15 , a shell body 344 is defined by a generally circular top surface 334 , a circular bottom surface 336 and a convex side surface 338 joining the top and bottom surfaces 334 , 336 . An aperture 346 , having an interior surface 348 , is disposed through the shell body 344 and is defined by a circular opening in the top and bottom surfaces 334 , 336 . A separate, core body 350 is defined by a circular top surface 334 , a circular bottom surface 336 and a convex side surface 338 joining the top and bottom surfaces 334 , 336 . The aperture 346 of the shell 344 is sized to accept the core 350 therein. As in the previous examples, the specimens 312 are comprised of rock or stone material of the type found in EGS reservoirs, oil or gas wells. They are machined or core drilled to shape and sized to fit within the test chamber 308 .
[0052] In the present examples, artificial flaws 342 (surface flaws or through thickness flaws) may be introduced into one or both of the shell 344 and core 350 . During testing, cavitating working fluid (F) is forced to flow along the interface between the shell 344 and the core 350 . Furthermore, by incorporating a 45 degree pitch spiral notch to the side surface 338 of the core 350 and/or a spiral through thickness notch to the side surface 338 of the shell 344 , these specimens 312 can also be used to evaluate the fracture toughness degradation during the EGS reservoir operation.
[0053] Further information about a spiral-notch torsion test system (SNTT) may be found in U.S. Pat. No. 6,588,283, “Fracture Toughness Determination Using Spiral-Grooved Cylindrical Specimen and Pure Torsional Loading”, to Jy-An Wang and Kenneth C. Liu, the disclosure of which is hereby incorporated by reference. Additional information may also be found in “A New Test Method for Determining the Fracture Toughness of Concrete Materials” by J. A. Wang, K. C. Liu, D. N. in Cement and Concrete Research, Volume 40, Issue 3, March 2010, Pages 497-499, K. Scrivener editor. Such benchmark data can further provide the guideline on the stimulation pressure pulse design parameters and their effectiveness for generating crack growth.
[0054] After simulation testing, the specimens 312 are examined in order to evaluate the fracture network caused by the pressure pulse cavitation technique by the apparatus 300 . It was found that two main mechanisms occur in cavitation erosion damage: high pressure shock waves created by the collapsing vapor bubbles, which can result in material fatigue and plastic deformation; and micro-jet impingement resulting in asymmetrical collapse of the vapor bubble near the specimen 312 surface. It was also found that when the bubbles collapse due to external pressure, the working fluid (F) is accelerated toward the center of the bubble. Bubbles formed near solid surfaces have the largest potential to cause micro cracking of the specimen 312 surface.
[0055] While this disclosure describes and enables several examples of a simulator apparatuses and methods for researching geothermal reservoir stimulation, other examples and applications are contemplated. Accordingly, the invention is intended to embrace those alternatives, modifications, equivalents, and variations as fall within the broad scope of the appended claims. The technology disclosed and claimed herein may be available for licensing in specific fields of use by the assignee of record. | An apparatus 300 for simulating a pulsed pressure induced cavitation technique (PPCT) from a pressurized working fluid (F) provides laboratory research and development for enhanced geothermal systems (EGS), oil, and gas wells. A pump 304 is configured to deliver a pressurized working fluid (F) to a control valve 306, which produces a pulsed pressure wave in a test chamber 308. The pulsed pressure wave parameters are defined by the pump 304 pressure and control valve 306 cycle rate. When a working fluid (F) and a rock specimen 312 are included in the apparatus, the pulsed pressure wave causes cavitation to occur at the surface of the specimen 312, thus initiating an extensive network of fracturing surfaces and micro fissures, which are examined by researchers. | 4 |
CROSS-REFERENCE(S) TO RELATED APPLICATION(S)
[0001] This application claims a benefit of priority based on U.S. Provisional Patent Application No. 61/661,192, filed Jun. 18, 2012, the entire contents of which are hereby expressly incorporated by reference into the present application.
BACKGROUND OF THE INVENTION
[0002] The present invention relates generally to a cleaning implement, and more specifically to a cleaning implement that may be used for household dusting.
SUMMARY OF THE INVENTION
[0003] The present invention provides a novel cleaning implement that enables the user to refresh the cleaning implement multiple times without the need to dispose of or replace the cleaning implement, and further provides a method relating to use of the cleaning implement.
[0004] The cleaning implement may include a support having a longitudinal axis, a plurality of cleaning sheets each having outward facing cleaning face and an inward facing attachment face, removably attached to the support, and a plurality of folded portions extending from the cleaning sheets and generally radially from the longitudinal axis of the support. The support may be any one of a flexible sheet, a pocket, a cleaning sheet, and an intermediate attachment sheet. A series of slits in the support and the cleaning sheets may be further included that form a plurality of loops in the folded portions of the support and the cleaning sheets. Alternatively, a series of slits may be included only in each cleaning sheet that forms a plurality of loops in the folded portions of the cleaning sheets. The plurality of cleaning sheets may be attached to the support with any one of an adhesive, a stitching, a fusion bonding, and a heat sealing bond. The support may also be attached to the cleaning implement with a pocket structure formed from a separate, nonwoven sheet.
[0005] The plurality of cleaning sheets are preferably layered in a stacked configuration such that only the outwardly facing cleaning face is exposed to ambient. The cleaning sheets are also preferably configured to allow detachment of a cleaning sheet, thus exposing to the ambient an additional cleaning sheet in the stacked configuration as a cleaning sheet is removed from the stack. A cleaning solution may be impregnated into the cleaning sheets to assist in dust removal and surface cleaning or disinfecting. In order to visually identify that the cleaning sheets are running out, a final cleaning sheet in contact with the support may include an indicia visually distinguishing it from the plurality of cleaning sheets. The indicia of the final cleaning sheet may also include a color distinct from a color of the plurality of cleaning sheets. To assist a user in cleaning with the cleaning implement, a holding space may be included in the support and configured to receive a handle.
[0006] In another embodiment, the cleaning implement may include a support sheet having a first surface, a second surface, and a longitudinal axis. The cleaning implement may include a plurality of detachable cleaning sheets, each having an outwardly facing cleaning surface and an inwardly facing attachment surface supported by the support sheet in a stacked configuration. A plurality of folded portions included with the support sheet and the cleaning sheet may extend generally radially from the longitudinal axis of the cleaning implement. A means to allow detachment of the inwardly facing surface of each cleaning sheet, allows a user to expose an additional cleaning sheet in the stacked configuration to the ambient. A final cleaning sheet may be included in the stack of cleaning sheets in contact with the support sheet, and one cleaning sheet may include indicia visually distinguishing it from the plurality of cleaning sheets, for alerting a user to refill the cleaning sheets. A cleaning solution may be impregnated into the cleaning sheets to assist in dusting, cleaning, and disinfecting.
[0007] A holding space may also be included in the support sheet and configured to receive a handle. To help increase contact area with the surface to be cleaned, a series of slits may be included in the support sheet and the cleaning sheets that form a plurality of loops in the folded portions of the support and the cleaning sheets. The cleaning sheet may be attached to each other with one of an adhesive, a stitching, a fusion bonding, and a heat sealing bond to attach the plurality of cleaning sheets to each other and the support sheet.
[0008] Also disclosed is a method of cleaning. The steps may include providing a cleaning implement that has a support sheet and a plurality of additional removable sheets, wherein the sheets have a plurality of folded portions that radially extend from a longitudinal axis of the cleaning implement. The steps may also include contacting an outermost sheet with a surface to be cleaned, using the outermost sheet to trap dust or other debris that is on the surface to be cleaned, and removing the outermost sheet from the cleaning implement to expose an unused sheet until just the support sheet remains. Lastly, the steps may include attaching the cleaning implement to a handle via the support sheet.
[0009] These and other aspects and objects of the present invention will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following description, while indicating preferred embodiments of the present invention, is given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the present invention without departing from the spirit thereof, and the invention includes all such modifications.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The present invention is illustrated in the accompanying drawings in which like reference numerals represent like parts throughout.
[0011] In the drawings:
[0012] FIG. 1 is a bottom view of one embodiment of the cleaning implement of the present invention;
[0013] FIG. 2 is a top view of the cleaning implement of FIG. 1 ;
[0014] FIG. 3 is a top view of a pocket that may be a component of the cleaning implement of the present invention;
[0015] FIG. 4 is a bottom view of the pocket of FIG. 3 ;
[0016] FIG. 5 is an end view of the cleaning implement of FIG. 1 ;
[0017] FIG. 6 is another end view of the cleaning implement of FIG. 1 ;
[0018] FIG. 7 is a partial top view of a cleaning sheet that may be a component of the cleaning implement of the present invention;
[0019] FIG. 8 is a top view of the cleaning sheet of FIG. 7 ;
[0020] FIG. 9 shows another embodiment of the cleaning implement of the present invention along with a cleaning sheet that is a component of the cleaning implement;
[0021] FIG. 10 shows another embodiment of the cleaning implement of the present invention, where a cleaning sheet is being removed from the cleaning implement;
[0022] FIG. 11 shows a plurality of cleaning sheets being secured together with an attachment member; and
[0023] FIG. 12 shows a closer view of a plurality of cleaning sheets being secured together with an attachment member.
[0024] In describing the preferred embodiment of the invention which is illustrated in the drawings, specific terminology will be resorted to for the sake of clarity. However, it is not intended that the invention 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. For example, the words “connected”, “attached”, or terms similar thereto are often used. They are not limited to direct connection but include connection through other elements where such connection is recognized as being equivalent by those skilled in the art.
DETAILED DESCRIPTION
[0025] The present invention and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments described in detail in the following description.
[0026] A cleaning implement 10 is shown in FIGS. 1 , 2 , 5 , 6 , 9 , and 10 . The cleaning implement 10 includes a support 20 , e.g., a support sheet 20 , and a plurality of cleaning sheets 30 that are supported by the support 20 . The support 20 is preferably in the form of a sheet, though the support 20 could have any form suitable for supporting the cleaning sheets 30 during the dusting operation. For purposes of this application, the support 20 will be referred to as a support sheet 20 .
[0027] As shown in FIGS. 5 and 6 , the support sheet 20 and the cleaning sheets 30 are arranged about a longitudinal axis 11 of the cleaning implement 10 . In this way, the support sheet 20 and cleaning sheets 30 form the body of the cleaning implement 10 . The support sheet 20 and the cleaning sheets 30 may be rectangular in shape and have generally the same dimensions. Conversely, the support sheet 20 and cleaning sheets 30 may have different dimensions. Regardless, the support sheet 20 and cleaning sheets 30 are preferably sized so as to be effective for use as a hand-held cleaning implement. For example, in one embodiment the cleaning sheets may be about 50 cm by about 16 cm and weigh about 4 grams. In another embodiment, the cleaning sheets may be about 75 cm by about 18 cm and weigh about 7 grams.
[0028] The plurality of cleaning sheets 30 is attached to and supported by the support sheet 20 . The plurality of cleaning sheets 30 may be attached directly to the support sheet 20 , whereby the final cleaning sheet 34 , that is most radially inwardly with respect to the longitudinal axis 11 , is attached to the support sheet 20 . The outer-most cleaning sheet 35 is the sheet available for contacting a surface to be cleaned. The cleaning sheet 30 may be attached via any suitable method such as by adhesive, stitching, fusion bonding, or heat sealing. The cleaning sheets 30 include a cleaning face 31 and an attachment face 33 . The cleaning face 31 of each cleaning sheet 30 is the surface intended to contact a surface to be cleaned. The attachment face 33 , shown in FIG. 10 , contacts the cleaning face 31 of the next radially inward cleaning sheet 30 and is held to it with one of the adhesive, stitching, fusion bonding, or heat sealing. Alternatively, the plurality of cleaning sheets 30 may be attached to an intermediate attachment structure (not shown) that is in turn attached to the support sheet 20 . In such a configuration, the intermediate attachment structure would be considered to form part of the support sheet 20 .
[0029] The cleaning sheets 30 are configured so that the outermost cleaning sheet 30 is removable from the plurality of cleaning sheets 30 , as shown in FIG. 10 . Thus, during use, a user may remove the outermost cleaning sheet 35 once that cleaning sheet 30 has become soiled and has an undesirable level of efficacy with respect to dust removal. The user may simply peel away the outermost cleaning sheet 30 to expose the next, unused cleaning sheet 30 .
[0030] The ease with which the cleaning implement 10 may be refreshed is desirable to the user. In other words, the user may refresh the cleaning implement 10 numerous times without the need to completely replace the cleaning implement 10 or the need to clean the cleaning implement 10 itself, e.g., in the washing machine or the sink, or shaking the cleaning implement 10 outside. Thus, the removable cleaning sheets 30 of the cleaning implement 10 enable a user to clean for a greater period of time with minimal interruption, the minimal interruption being the removal of the outermost cleaning sheet 30 when it becomes too soiled and/or experiences reduced cleaning efficacy. Put another way, comparing a conventional cleaning implement to an embodiment of the cleaning implement 10 having ten cleaning sheets 30 , a user would have to replace the conventional cleaning implement ten times once the cleaning implement became soiled and/or experienced reduced cleaning efficacy, which is time consuming and costly, as opposed to simply removing a cleaning sheet 30 from the cleaning implement 10 , which is far more efficient and less time consuming.
[0031] The cleaning sheets 30 may be secured together using any suitable means that provides for the easy removal of the cleaning sheets 30 from the cleaning implement 10 while at the same time preventing inadvertent removal of the cleaning sheets 30 under the typical forces experienced during household dusting. For example, the cleaning sheets 30 may be attached to one another via stitching, adhesive, fusion bonding or heat sealing. In one embodiment, the sheets are attached to one another via a plurality of attachment members 24 , described in further detail below. See FIGS. 11 and 12 . Each of the cleaning sheets 30 may further include a removal member 32 , e.g., a tab, that facilitates removal of a cleaning sheet 30 from the plurality of cleaning sheets 30 .
[0032] The cleaning sheets 30 are made from a material that is flexible and that has properties enabling the cleaning sheet 30 to collect and retain dust and other debris. In one embodiment, the cleaning sheets 30 are nonwoven sheets, for example a 35-55 gsm spunlace nonwoven material. Such material may be 100% polyester, or it may be substantially polyester with microfiber of nylon. In another embodiment, the innermost cleaning sheet 30 could be made of a thicker material, such as 90-110 gsm spunlace nonwoven, to provide additional support and structure to the cleaning implement 10 and to the plurality of cleaning sheets 30 . Moreover, the cleaning sheets 30 may be impregnated with a cleaning solution to further facilitate dust removal. Additionally, the cleaning sheets 30 may include an adhesive to further improve dust removal and retention. In one embodiment, the adhesive could be applied to valleys 42 . Further, the cleaning sheets 30 and support sheet 20 may be different colors. Thus, when a user has reached the last cleaning sheet 30 , the support sheet 20 may serve as an indicator of the last cleaning sheet 30 . Alternatively, the final cleaning sheet 30 could be colored differently than the other cleaning sheets 30 or contain some other indicia notifying the user that it is the last cleaning sheet 30 .
[0033] The support sheet 20 and cleaning sheets 30 are configured about the longitudinal axis 11 of the cleaning implement 10 so as to form a plurality of folded portions 40 . As shown in FIGS. 1 and 2 , the folded portions 40 generally extend along the longitudinal axis 11 of the cleaning implement 10 . The folded portions 40 may be configured in alternative arrangements that do not extend along the longitudinal axis 11 of the cleaning implement 10 . For example, the folded portions 40 may be configured to spiral around the longitudinal axis 11 . In any event, the folded portions 40 extend radially away from the longitudinal axis 11 to facilitate dust removal and dust retention during the dusting process. For example, folded portions 40 may be used to clean hard-to-reach places that are not easily accessible using a conventional cleaning implement such as a dusting rag. In between the folded portions 40 are valleys 42 . Thus, looking at an end view of the cleaning implement 10 , the folded portions 40 and valleys 42 of the support sheet 20 and cleaning sheets 30 generally follow a wave-like pattern around the longitudinal axis 11 of the cleaning implement 10 . See FIGS. 5 and 6 .
[0034] Moreover, the folded portions 40 create a three-dimensional cleaning surface area as opposed to the generally two dimensional cleaning surface areas of conventional fiber bundle dusters. The three-dimensional surface area of the cleaning implement 10 can easily and quickly be refreshed by removing the outermost cleaning sheet 30 , whereas a conventional fiber bundle duster cannot be refreshed—it must be replaced or cleaned in some other way. Moreover, the height of the folded portions 40 corresponds to the resiliency, or “floppiness,” of the cleaning implement 10 . The greater the height of the folded portions 40 , the floppier the cleaning implement 10 will be. Conversely, the shorter the height of the folded portions 40 , the stiffer the cleaning implement 10 will be.
[0035] The support sheet 20 may be made of a flexible, resilient material that will substantially maintain its shape after exposure to typical forces of normal household dusting. In one embodiment, the support sheet 20 is made from 15-25 gsm polypropylene spunbond. Thus, the folded portions 40 of the support sheet 20 will similarly be flexible and resilient during the dusting process while maintaining its shape. The overall shape of the cleaning implement 10 will be substantially unchanged after dusting, which extends the longevity and effectiveness of the cleaning implement. The resilient nature of the cleaning implement 10 is a desirable quality to consumers as consumers do not like when a cleaning implement quickly loses its shape.
[0036] The cleaning sheets 30 , when attached to the support sheet 20 , substantially conform to the shape of the support sheet 20 . Prior to assembly into the cleaning implement 10 , the support sheet 20 may be rectangular in shape. The plurality of cleaning sheets 30 may also be rectangular in shape and attached to the support sheet 20 when the cleaning implement 10 is in an unassembled form. When assembled into the cleaning implement 10 , the support sheet 20 is configured about the longitudinal axis 11 of the cleaning implement 10 to form the folded portions 40 , a configuration that is similarly adopted by the cleaning sheets 30 . The parts of the support sheet 20 may be secured, for example to other parts of the support sheet 20 , in order to maintain the folded portions 40 . Alternatively, the support sheet 20 may be formed or processed to maintain the folded portions 40 , in other words, so that the final shape of the support sheet 20 that forms the cleaning implement 10 is the natural state of the cleaning sheet 20 .
[0037] In one embodiment, a plurality of attachment members 24 is used to maintain the shape of the cleaning implement 10 and also to secure the cleaning sheets 30 to one another. The attachment members 24 may be stitching, a heat seal, a fusion bond, a pin, or any other structure capable of holding the support sheet 20 and cleaning sheets 30 together so as to maintain the shape of the cleaning implement 10 . Alternatively, the attachment members 24 that hold the cleaning sheets 30 together may be separate from attachment members 24 that secure the cleaning sheets 30 to the support sheet 20 . There may be further attachment members 24 that hold various portions of the support sheet 20 together. In sum, there are three functions performed by attachment members 24 : (1) securing the cleaning sheets 30 to one another in a way that individual cleaning sheets 30 are removable from the stack of cleaning sheets 30 , (2) securing the plurality of cleaning sheets 30 to the support sheet 20 (3), and securing portions of the support sheet 20 to one another to form the overall shape of the cleaning implement 10 . The attachment members 24 may serve one, all, or any combination of these functions.
[0038] As shown in FIG. 11 , each valley 42 has a series of attachment members 24 , in this case three, spaced apart through the valley 42 along a line that is substantially parallel to the longitudinal axis 11 of the cleaning implement 10 . The attachment members 24 are in the form of pins or rods, and each attachment member 24 has head portions 25 on either end of the attachment member that secure the plurality of cleaning sheets 30 between the respective head portions 25 . Accordingly, when the outermost cleaning sheet 30 is peeled away, force is not exerted on the adjacent cleaning sheet 30 because adjacent cleaning sheets 30 are not directly bonded to one another. Thus, the only the outermost cleaning sheet 30 will be removed and the remaining cleaning sheets 30 will stay secured together. Alternatively, the attachment members 24 could be in the form of a string with knotted ends, which would function similarly to the pin/head configuration described above.
[0039] In the embodiment shown, for example in FIGS. 5 and 6 , the support sheet 20 is bonded to itself at various locations to maintain the shape of the cleaning implement 10 . In this embodiment, the bonds 26 are separate from the attachment members 24 described above. For example, there are a plurality of bonds 26 , with each bond 26 occurring at the neck of each folded portion 40 . The bonds 26 may be continuous and run along the length of the folded portion 40 along the longitudinal axis 11 (see FIGS. 1 , 2 ) of the cleaning implement 10 , or there may be intermittent bonds 26 , so long as the intermittent bonds 26 are capable of maintaining the shape of the cleaning implement 10 . The bonds 26 may be of any form suitable for bonding the support sheet 20 to itself, such as adhesive, heat sealing, fusion bonding, or stitching. Further, in this embodiment, the attachment members 24 also secure the cleaning sheets 30 to the support sheet 20 .
[0040] As discussed above, the support sheet 20 provides the shape and structure of the cleaning implement 10 , which includes the plurality of folded portions 40 . There may be any number of folded portions 40 , but preferably a number of folded portions 40 is such that facilitates effective dusting and ease of use. In the embodiment shown, the cleaning implement 10 has eight folded portions 40 , which has been proven to facilitate effective dusting while at the same time enabling easy removal of the cleaning sheets 30 .
[0041] As shown in FIGS. 1 , 2 , 5 , and 6 , the support sheet 20 and cleaning sheets 30 may include a plurality of cuts or slits 50 . The slits 50 may be positioned so that they correspond to the folded portions 40 . More specifically, in one embodiment the slits 50 are substantially parallel to one another and are oriented in a direction that is substantially perpendicular to the longitudinal axis 11 of the cleaning implement 10 . The slits 50 preferably do not extend into the bottom of the valleys 42 because such a configuration may compromise the ability of the attachment members 24 to hold the cleaning sheets 30 together. In other words, extending the slits 50 too far into the valleys 42 may cause the cleaning sheets 30 to separate from one another, which is undesirable.
[0042] Accordingly, each folded portion 40 is separated into a series of adjacent loops 53 that are arranged along the folded portion 40 . As with the folded portions 40 , the loops 53 extend radially outwardly from the longitudinal axis 11 , (see FIGS. 1 , 2 ) of the cleaning implement 10 . Adjacent loops 53 are therefore capable of moving independent of one another, thus increasing the dusting efficacy of the cleaning implement 10 . In the embodiment shown, the slits 50 do not extend into or through the valleys 42 of the support sheet 20 or the cleaning sheets 30 .
[0043] Put another way, when the support sheet 20 and cleaning sheets 30 are in a rectangular form, the slits 50 are arranged into slit groups 52 , with each slit group 52 organized along a line that is substantially parallel to the longitudinal axis 11 of the cleaning implement 10 . See FIGS. 7 and 8 . The slit groups 52 are spaced apart in the direction perpendicular to the longitudinal axis 11 , with the spaces between the slit groups 52 corresponding to the valleys 42 of the support sheet 20 and cleaning sheets 30 .
[0044] The pocket structure 54 , shown in FIG. 4 is configured in such a way that it forms a holding space 22 , for receiving a handle 12 , e.g., a duster handle, see FIGS. 9 , 10 . Thus, the cleaning implement 10 may be inserted onto or removed from the handle 12 . The handle 12 may have one or more support members 13 that are received by the cleaning implement 10 . The pocket structure 54 may be configured in such a way that the holding space 22 comprises multiple spaces to receive multiple support members 13 . It is also possible for the support sheet 20 to be configured to form holding spaces 22 to receive a handle 12 having two support members 13 , similar to the pocket structure 54 described above. Moreover, the support sheet 20 or pocket structure 54 may be configured to receive the support members 13 on either side, in other words, the support members 13 may be inserted into either end of the cleaning implement 10 . In an alternative embodiment, the cleaning implement 10 may include a pocket structure 54 within the holding space 22 to receive the support members 13 . For example, the pocket structure 54 may be formed from a separate nonwoven sheet (or sheets) secured together to form the pocket structure. Thus, the support sheet 20 may be formed around the pocket structure 54 .
[0045] The configuration of the cleaning implement 10 to include folded portions 40 and valleys 42 increases the cleaning surface area of the cleaning implement 10 . The cleaning surface area is defined as the surface area of the cleaning implement 10 that is used to clean. Here, the cleaning surface area is the area of one of the cleaning sheets 30 . Moreover, taking into consideration the multiple removable cleaning sheets 30 , the cleaning surface area of the cleaning implement 10 is multiplied by a factor of however many cleaning sheets 30 there are. Thus, the cleaning implement 10 has a far greater cumulative cleaning surface area than conventional dusters that must be replaced once they become soiled and/or lose cleaning efficacy, as opposed to the cleaning implement 10 that is simply and quickly refreshed by removing the outermost cleaning sheet 30 .
[0046] The present invention further includes a method of cleaning using a cleaning implement 10 as described above. The method includes providing a cleaning implement 10 as described above, and contacting the cleaning implement 10 with a surface to be cleaned. Then, the cleaning implement 10 is used to trap dust or other debris that is on the surface to be cleaned. The outermost cleaning sheet 30 is then removed from the cleaning implement 10 to expose the next, unused cleaning sheet 30 . The cleaning process may then be repeated until there are no more unused cleaning sheets 30 left.
[0047] Although the best mode contemplated by the inventors of carrying out the present invention is disclosed above, practice of the present invention is not limited thereto. It will be manifest that various additions, modifications and rearrangements of the features of the present invention may be made without deviating from the spirit and scope of the underlying inventive concept. There are virtually innumerable uses for the present invention, all of which need not be detailed here. All the disclosed embodiments can be practiced without undue experimentation.
[0048] Moreover, the individual components need not be formed in the disclosed shapes, or assembled in the disclosed configuration, but could be provided in virtually any shape, and assembled in virtually any configuration. Furthermore, all the disclosed features of each disclosed embodiment can be combined with, or substituted for, the disclosed features of every other disclosed embodiment except where such features are mutually exclusive.
[0049] Various alternatives and modifications are contemplated as being within the scope of the following claims particularly pointing out and distinctly claiming the subject matter regarded as the invention. It is intended that the appended claims cover additions, modifications and rearrangements of the invention. Expedient embodiments of the present invention are differentiated by the appended claims. | A cleaning implement is disclosed with a support sheet having a first surface, a second surface, and a longitudinal axis. A plurality of detachable cleaning sheets, each having an outwardly facing cleaning surface and an inwardly facing attachment surface, may be supported by the support sheet in a stacked configuration. A plurality of folded portions included with the support sheet and the cleaning sheet extend generally radially from the longitudinal axis of the cleaning implement. The outermost cleaning sheet may be removed from the stacked cleaning sheet to expose a new, fresh cleaning sheet. | 1 |
CROSS-REFERENCE TO RELATED APPLICATION
This is a new application having support in my prior provisional application, Ser. No. 60/029,051, entitled "Thermally Reversible Material for Forming Ceramic Molds", filed on Oct. 24, 1966.
FIELD OF THE INVENTION
This invention relates to a method for preparing an accurate ceramic mold by using a heat reversible material to make an intermediate mold of a pattern and then using the intermediate mold for casting the ceramic mold. The ceramic mold can then be used to create a more durable metal mold for casting multiple plastic parts similar to the original pattern.
BACKGROUND OF THE INVENTION
Getting new products to the market faster than one's competition is recognized as a key to gaining a large market share. One area of product development having a significant impact on overall market timing is the making of product and package prototypes for market testing. Such testing usually requires multiple look-like, feel-like, and function-like prototypes for consumers to examine or use.
Package components generally involve plastic parts made in very expensive, multiple cavity, steel molds. For example, most bottles are blow-molded and most bottle closures are injection molded. It usually takes large production quantities to justify the cost of a production mold with many cavities. For smaller markets, or for making only a few hundred test parts, single cavity molds or prototype molds are created. Prototype molds provide important learning on whether the part can be made consistently, as well as to provide a tool that can be used to make test parts.
One method of rapidly prototyping containers or parts is investment casting using patterns generated by rapid prototyping systems instead of traditional injection molded wax patterns. An example of such a pattern is a QUICKCAST™ pattern, a Trademark of 3D Systems, Inc. of Valencia, Calif. A hollow plastic pattern is coated with a thin ceramic shell usually by a dipping process. The plastic is burned out of the ceramic shell leaving minimal amounts of ash residue behind. Molten metal is then poured into the ceramic shell to cast a metal part or metal mold for a plastic part. Because the shell has only a small hole for admitting molten metal, it is difficult to inspect the critical surfaces for ash residue. Any ash residue on a critical surface will potentially ruin the metal casting. The molten metal cools and shrinks such that critical surfaces are not reproduced accurately. The larger the parts, the greater the inaccuracy.
An improved method of constructing a fully dense mold is disclosed in U.S. Pat. No. 5,507,336 issued to Tobin, April, 1996. The method comprises placing a pattern within a tube which has a melting point greater than that of the infiltration material which will be used in making the metal mold. A ceramic member is cast between the pattern surfaces and the open end of the tube to transfer the critical pattern surfaces to the ceramic member. The ceramic surfaces are inverse to the pattern surfaces. The pattern is burned out and the ceramic surfaces remains in the tube. The ceramic is then covered with metal powder and an infiltration material from the other end of the tube, and the tube is placed in a furnace to form the metal part over the ceramic surfaces. The metal part has surfaces inverse to the ceramic surfaces. A metal mold results when the ceramic piece is removed. The metal mold has the same shape as the pattern, and is useful for molding plastic parts having an inverse shape. This is an ideal process for parts having exterior critical surfaces.
Tobin's process destroys the pattern from which the ceramic mold is created. A process for quickly forming a ceramic mold pattern which does not destroy the pattern, but which is accurate, is needed. Also, it is often necessary to provide a mating metal mold for plastic part molding. In order to do this, the metal mold may require a shape which is the inverse of the pattern. Thus, the ceramic mold needs to have the same shape as the pattern, and therefore requires an intermediate mold be produced between the ceramic mold and the pattern. As with Tobin's earlier process, any ceramic mold should not be contaminated on its surface so that the resulting metal mold is accurate.
In order to avoid destroying the pattern, it is desirable to use an intermediate mold made of a material which can be discarded or reused as needed to transfer the critical pattern surfaces to the ceramic mold. Wax and silicone rubbers have been used for these purposes. Wax (which is heat reversible) has the disadvantage of being brittle and when removed from the pattern can cause small pieces to break off especially where undercuts and thin features are involved. It also can expand and crack the ceramic when heated. Silicone rubbers need to be cured, and when the ceramic releases heat as it "sets", the silicone rubber can distort and cause inaccuracies to develop in the ceramic pattern. Also, silicone rubber has to be removed from the pattern by air injection or other means which forces the silicone from the ceramic. This can cause the ceramic mold to break especially where undercuts and thin features are involved.
It is therefore an object of this invention to provide a process for making a ceramic mold having the same shape as a pattern, which produces accurate reproductions of a pattern of any size, within a tolerance of ±0.005 inches and which does not leave an ash or other residue on the ceramic mold.
It is also an object of this invention to provide a process which uses an elastic, heat reversible material to make an inverse intermediate mold of a pattern and which is not distorted during the forming of a ceramic mold therefrom, but which can be removed easily from the ceramic mold without destroying the delicate features of the ceramic mold.
These and other objects will be evident from the description herein.
SUMMARY Of THE INVENTION
In one aspect of the present invention a method of forming a ceramic mold comprises the step of placing a pattern having critical pattern surfaces in a flask having an open end. The critical pattern surfaces face upward toward the open end. Successive steps include adding a concentrated heat reversible gel solution to the flask to cover the critical pattern surfaces, and cooling the gel solution to form an elastic solid gel mold. The gel mold has critical gel mold surfaces inverse to the critical pattern surfaces. Further steps include removing the pattern from the elastic gel mold, casting a ceramic mold around the gel mold, and liquifying the gel mold via heating for removal from the ceramic mold. The ceramic mold has critical ceramic surfaces inverse to the critical gel mold surfaces, thereby accurately replicating the critical pattern surfaces. The method may further comprise the step of degassing the gel solution as it is cooled to form the gel mold.
The heat reversible gel solution preferably comprises a gel material, water, and a defoaming agent. The gel material is preferably gelatin. The gel solution may further comprises fibers or other thickeners. The defoaming agent is preferably a silicone.
In another aspect of the present invention, a method of forming a ceramic mold comprises the step of placing a pattern having critical pattern surfaces in a first flask having an open end with the critical pattern surfaces facing upward toward the open end. Other steps involve covering the critical pattern surfaces with a gelatin solution added to the first flask and cooling the gelatin solution while degassing it to form an elastic solid gelatin mold. The gelatin mold has critical gelatin mold surfaces transferred from the critical pattern surfaces which are inverse to the critical pattern surfaces. Other steps are removing the pattern and the first flask from the gelatin mold and placing the gelatin mold in a second flask with the critical gelatin mold surfaces facing upward toward an open end of the second flask. Further steps include covering the critical gelatin mold surfaces with a ceramic solution added to the second flask while degassing the ceramic solution. The ceramic solution solidifies and then exothermically binds to form a ceramic mold around the gelatin mold. The ceramic mold has critical ceramic surfaces transferred from the critical gelatin mold surfaces which are inverse to the critical gelatin mold surfaces. The ceramic critical surfaces thereby accurately replicate the critical pattern surfaces. Final steps are liquifying the gelatin mold via heating to remove the gelatin from the ceramic mold and removing the second flask from the ceramic mold. The gelatin solution preferably comprises gelatin, water, and a defoaming agent.
In still another aspect of the present invention, a method of forming a ceramic mold comprises the step of placing a pattern having critical pattern surfaces in a first flask having an open end with the critical pattern surface facing upward toward the open end. Other steps involve covering the critical pattern surfaces with a gelatin solution added to the first flask and cooling the gelatin solution while degassing the gelatin solution to form an elastic solid gelatin mold. The gelatin mold has critical gelatin mold surfaces transferred from the critical pattern surfaces which are inverse to the critical pattern surfaces. Additional steps are removing the pattern and the first flask from the gelatin mold and placing the gelatin mold in a second flask with the critical gelatin mold surfaces facing upward toward an open end of the second flask. The second flask is dimensioned to provide an annular space around the gelatin mold. Still another step is filling the annular space with a first ceramic solution added to the second flask while degassing the first ceramic solution.
The first ceramic solution solidifies without generating heat to form a first ceramic mold in order to anchor the gelatin mold in place and to form a continuous annular rim surrounding the critical gel mold surfaces. A further step includes covering the first ceramic mold and the gel mold with a second ceramic solution added to the second flask. The second ceramic solution exothermically binds to form a second ceramic mold bonded to the first ceramic mold. The second ceramic mold has critical ceramic surfaces transferred from the critical gelatin mold surfaces which are inverse to the critical gelatin mold surfaces. The critical ceramic surfaces thereby accurately replicate the critical pattern surfaces. Final steps are liquifying the gelatin mold via heating to remove the gelatin from the first ceramic mold and removing the second flask from the first and second ceramic molds.
BRIEF DESCRIPTION OF THE DRAWINGS
While the specification concludes with claims which particularly point out and distinctly claim the present invention, it is believed that the present invention will be better understood from the following description of preferred embodiments, taken in conjunction with the accompanying drawings, in which like reference numerals identify identical elements and wherein:
FIG. 1 is a sectioned front elevational view of a pattern 1, having critical pattern surfaces 13, positioned inside a first flask 3.
FIG. 2 is a sectioned front elevational view of pattern 1 inside the first flask 3 into which a concentrated gel solution 5 has been poured.
FIG. 3 is a sectioned front elevational view of a solidified gel mold 7, having critical gel mold surfaces 10 transferred from critical pattern surfaces 13, positioned inside a second flask 8 with an annular space 12 between second flask 8 and solidified gel mold 7.
FIG. 4 is a sectioned front elevational view of second flask 8 having a plaster or ceramic solution 9 poured over the solidified gel mold 7 and into annular space 12 and covering critical gel mold surfaces 10.
FIG. 5 is a sectioned front elevational view of a solidified plaster mold 11 from which has been removed second flask 8 and gel mold 7, exposing critical ceramic surfaces 14, which transferred from critical gel mold surfaces 10 and which accurately replicate critical pattern surfaces 13.
FIG. 6 is a sectioned front elevational view of an alternative embodiment to that shown in FIG. 4, wherein annular space 12 is partially filled with a non-exothermic plaster solution 15 in order to support gel mold 7 before an exothermic plaster solution (not shown) is added to second flask 8.
DETAILED DESCRIPTION OF THE INVENTION
As used herein, the term "ceramic" refers to a material such as plaster, clay, silica or other nonmetallic material which can be fired to create a hardened product.
As used herein, the term "gel" refers to a material which generally forms a colloidal gel or solid material which is elastic or rubbery, yet solid and not brittle. Gelatin is a preferred material for making a gel. It forms a tender elastic solid which does not expand or shrink with temperature changes within the range that the gel experiences while in contact with a ceramic pouring which sets into a solid shape; yet the gel melts or liquifies when the ceramic shape is heated or undergoes a further exothermic reaction.
As used herein, the term "heat reversible" refers to a material which solidifies at a temperature below about 50° C. and which melts or liquifies at temperatures above about 65° C.
FIG. 1 illustrates a pattern 1 which fits tightly against an internal surface of a flask. Pattern 1 is a representation of the exterior of a bottle closure. Pattern 1 has critical pattern surfaces, 13, which represent the detail on the outside of the bottle closure. The pattern is preferably made by a stereolithography process, well known in the prototyping art, in which an electronic file describing the pattern is rapidly fabricated by laser curing of a polymer. The pattern is placed in the flask with critical pattern surfaces facing upward toward the open end of the flask.
An elastic material is poured over the pattern. The elastic material may be an RTV silicone rubber. Making such rubber patterns is common in the art. The step of removing a rubber mold from the pattern may comprise pulling the rubber pattern directly from the pattern or air ejecting it therefrom, since it is flexible and does not adhere to the pattern. Alternatively, the elastic material may be a solid gel made from a heat reversible material, such as a hydrocolloidal gelatin solution. Gelatin easily disperses or dissolves in hot water and forms a tender elastic material when cooled.
The elastic mold is intended to be an intermediate mold which transfers the critical pattern surfaces to a ceramic mold. A ceramic solution is similarly poured over the elastic mold in an open flask and allowed to harden. However, the ceramic material typically generates heat in an exothermic binding reaction. Such heat may cause an RTV silicone rubber to expand and distort the geometry of the critical surfaces. Also, a silicone rubber mold must eventually be removed from the ceramic mold by pulling or air ejecting it from the ceramic mold. Where there are thin sections or undercuts involved, such removal steps may damage the brittle ceramic mold.
Gelatin is easily removed from a ceramic mold by melting it. The exothermic reaction of the ceramic typically melts the gelatin adjacent to it so that surface distortions do not occur as the ceramic hardens. The resulting ceramic mold can be washed with hot water, glycerin, or acetic acid to remove any residue before firing the ceramic mold to harden it.
Gelatin is a protein which is usually derived from meat and some dairy products. It forms a structure or matrix of intertwined and partially associate protein molecules in which the water is entrapped. The preferred gelatin is 250 Bloom edible porkskin gelatin available from Kind & Knox Gelatin, Sioux City, Iowa.
Other gelling systems which meet these criteria can be used. Lambda carrageenan and mixtures of xanthan gum and locust bean gum can be used. Fibers or other structural materials can be dispersed in the gel. These will add strength and can be easily removed with the melted gel from the ceramic mold.
The more concentrated the gel solution, the better. Generally, a gelatin solution is formed which contains gelatin solids, water, and a surfactant or defoaming agent. More preferably, a gelatin solution contains solid gelatin, water, and a defoaming agent. An exemplary mixture is 475 cc of water, 25 cc of defoaming agent, and 175 grams of gelatin. Similar proportions are used for other gel systems and the determination of the exact level is well within the skill of a person in this art. Other additives which can bind water or lower the water activity of the gel can be added. For example, glycerin, sugar or glycols can be added.
Typically, the gelatin is added to cold water. Then the mixture is heated. The water and gelatin or gel material is warmed to a range from about 80° C. to about 100° C. Alternatively, the gelatin or other gel material can be added to hot water. The solution is stirred until the gel is dissolved or dispersed so that the mixture appears to be homogeneous. Preferably, the solution is heated in a microwave oven to maintain the temperature of the water and enhance the dispersion. The solution can be placed under a vacuum during the dispersion to prevent foaming. Other degassing processes can also be used.
The surfactant or defoaming agent is preferably added to the water before combining the water with the gelatin. Silicones and nonionic surfactants are good defoaming agents. Dimethyl silicone can be used. A preferred defoaming agent is: polydimethylsiloxane available as Foam Drop-S from Spectrum Services of Cincinnati, Ohio.
The gel dispersion is poured over the pattern in an open ended flask. (see FIG. 2). Of some concern is moisture absorption by the pattern when the hot gelatin solution is poured onto it. Resins used in stereolithography are often moisture sensitive. It may therefore be beneficial to seal the surface of the pattern first by spraying on a thin coating of KRYLON™ paint, a product of Sherwin Williams Co., of Solon, Ohio.
Degassing is also beneficial at the gelatin pouring stage. Pouring may be done in a vacuum chamber at 30 inches of mercury vacuum, for example. The entrained air is removed to prevent air bubbles from collecting at the pattern/gel interface. Air or gas entrained within the gel may also cause the gel matrix to be unstable. The gelatin casting may be done in multiple pours, depending on the size of the part, so that degassing is more effective in removing air bubbles. The first pour of a multiple pour is preferably allowed to form a skin before the next pour so that air bubbles will not penetrate the first pour.
The flask is refrigerated until the gel has formed an elastic solid structure. Depending on the concentration of the gel, the size of the pattern, and the depth of the gel layer, from about 1 to about 15 hours are required to set the gel. Generally, from about two to eight hours in a refrigerator at 40° F. or 4° C. is sufficient. Very concentrated solutions will form an elastic solid structure within a few hours at room temperatures.
The depth of the gel solution will depend upon the pattern and the size that is desired for the ceramic mold. One skilled in the art can easily determine this without undue experimentation. Typically, a minimum gel thickness of about one inch is desired above each critical pattern surface.
The solidified intermediate gel mold is then pulled from the pattern. In a preferred embodiment, the flask is built with easily removable sides which are then pulled off the gel mold and the gel mold is then pulled off the pattern. The gel mold is structurally elastic enough to easily release the pattern piece and retain inverse replications of the the critical surfaces of the pattern without distortion, even when undercuts and thin features are involved.
It is preferred that the gel mold be stored at refrigerator temperatures, but not frozen. The protein holds the water within its matrix and prolonged exposure to warm temperatures above about 18° C. can cause the water to be released. This can affect the accuracy of gel mold critical surfaces.
FIG. 3 discloses the gel mold placed in a second flask to which a plaster or ceramic solution will be added. The gel mold is placed with the critical gel mold surfaces facing upward toward the open end of the second flask. Preferably, sufficient space is allowed between the second flask and the gel mold so that ceramic will be formed around the gel mold in that space. The ceramic mold made therefrom will have a continuous annular ceramic rim surrounding the critical ceramic surfaces so that the ceramic mold may be readily used for casting a metal infiltration mold without the need for another flask.
Plaster or other ceramic material is poured into the second flask to a depth above the gel mold. Preferably, the depth is from about 1 cm to about 5 cm above the gel mold. The poured ceramic material is preferably degassed under vacuum to remove any air which could affect the final ceramic mold formation. The plaster or ceramic material first "sets" or takes a solid shape and then completely solidifies. During the binding process, an exothermic reaction takes place in the plaster which melts the surrounding gel. The flask is preferably coated with a release agent so that the flask may be easily removed from the ceramic mold.
In a preferred embodiment, two different ceramic materials are used. The gel mold is first partially encased in a first plaster or clay material which sets up to become a rigid structure but which is not exothermic or which does not subject the gel structure to temperatures that are near its melting or liquifaction point. This non-exothermic material is typically weak. It is poured to fill or partially fill the annular space in order to anchor the gel mold, which could otherwise float upward during the casting of an entire plaster structure due to the plaster's greater density as compared to that of the gelatin. Because of the weakness of the non-exothermic ceramic, the annular wall is typically made at least one inch thick for handling purposes. The first plaster sets up in about 45-90 minutes.
After the first ceramic mold has solidified, a second plaster or clay is applied to cover the first ceramic mold and the critical gel mold surfaces. The second ceramic material does undergo an exothermic reaction to increase its strength, and it bonds readily to the first ceramic mold. The exothermnic plaster typically takes about 10 minutes to set up. Icing down the binder for the second plaster may help to slow down the reaction and provide more time for degassing the plaster. The two stage plaster casting results in a more accurate ceramic mold, whose critical ceramic surfaces accurately replicate the critical pattern surfaces of the original pattern. (See FIG. 6 which discloses the use of a first plaster 15).
The preferred non-exothermic, phosphate-bonded plaster is an 847 core mix available from Ranson & Randolph of Maumee, Ohio. C1-Core Mix, also available from Ranson & Randolph of Maumee, Ohio, is the most preferred exothermic ceramic material. It is a mixture of fused silica, zirconium silicate, ammonium phosphate, silica (cristobalitc) and magnesium oxide. Core hardner 2000, also available from Ranson & Randolph, can be used. It contains amorphous silica and dipotassium-6-hydroxy-3-oxo-9-xanthene-0-benzoate.
Preferably, the gel mold is at its refrigerated temperature when a ceramic solution is poured over it in the second flask. After the ceramic is set, the ceramic mold and remaining gelatin can be heated in an oven to completely melt the gel for easy removal. The temperature of the oven should be about 100° C. to about 275° C. to insure the melting of the gel but not so hot as to decompose the protein. Gelatin with water entrapped within the matrix melts or liquifies slowly and the center portion is well enough insulated that heat above 100° C. does not cause problems with the water boiling.
The open end of the ceramic mold, which corresponds to the bottom end of the second flask, allows easy access to pour the melted or liquid gel dispersion from the ceramic mold. Also, critical ceramic surfaces may be easily inspected from the open end to see that all gelatin and any residue is removed.
Placing the ceramic mold in a furnace and heating it to approximately 1100° F. (990° C.) for at least 3 hours fully sets the plaster for further processing. A hydrogen atmosphere can be used as there is no residue remaining on the ceramic which needs to be burned off. This lack of residue is an important distinction when compared to ceramic mold making processes using epoxies and waxes.
A metal mold may be made from the ceramic mold in accordance with the teachings of commonly assigned U.S. Pat. No. 5,507,336 issued to Tobin on Apr. 16, 1996, which is hereby incorporated herein by reference. However, the metal mold may be made without the need for an external tube because the ceramic mold of the present invention has a continuous annular rim surrounding the critical ceramic surfaces.
While particular embodiments of the present invention have been illustrated and described, it will be obvious to those skilled in the art that various changes and modifications may be made without departing from the spirit and scope of the invention, and it is intended to cover in the appended claims all such modifications that are within the scope of the invention. | A method for forming a ceramic mold comprises the step of placing a pattern having critical pattern surfaces in a flask having an open end. The critical pattern surfaces face upward toward the open end. Successive steps include adding a concentrated heat reversible gel solution to the flask to cover the critical pattern surfaces, and cooling the gel solution to form an elastic solid gel mold. The gel mold has critical gel mold surfaces inverse to the critical pattern surfaces. Further steps include removing the pattern from the elastic gel mold, casting a ceramic mold around the gel mold, and liquifying the gel mold to remove it from the ceramic mold. The ceramic mold has critical ceramic surfaces inverse to the critical gel mold surfaces, thereby accurately replicating the critical pattern surfaces. | 1 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to compositions for improving the appearance of skin, particularly to provide good coverage over imperfections such as pores and uneven skin tone, while retaining a natural skin appearance.
[0003] 2. The Related Art
[0004] A matte effect is desired for users of color cosmetics. The matte finish overcomes the shiny effect engendered by greasy skin, particularly under hot and humid conditions. Absorbent fillers such as talc, silica, kaolin and other inorganic particulates have been used to achieve the effect by their optical properties.
[0005] Imperfect skin can be hidden in two ways through manipulation of light transmission. In the first, components of the color cosmetic may simply reflect light back toward the source. An alternative approach is referred to as achieving a soft focus effect. Here the incoming light is distorted by scattering (lensing). Components of the color cosmetic in this mechanism operate as lenses to bend and twist light into a variety of directions.
[0006] While it is desirable to hide imperfect skin through a matte effect, there is also a desire to achieve a healthy skin radiance. A cosmetic covering that is too opaque hides the skin under a paint-like coating. Imperfections are hidden but there is no radiance. Where light transmission is insufficiently hindered, the opposite occurs. Here the glow may be healthy but aesthetically displeasing skin topography and color may now be apparent.
[0007] U.S. Pat. No. 5,997,890 (Sine et al.), U.S. Pat. No. 5,972,359 (Sine et al.), and U.S. Pat. No. 6,174,533 B1 (SaNogueira, Jr.) are all directed to topical compositions to provide good coverage of skin imperfections. The solution proposed by these documents is the use of a metal oxide with a refractive index of at least about 2 and a neat primary particle size of from about 100 to about 300 nm. Preferred particulates are titanium dioxide, zirconium oxide and zinc oxide.
[0008] Silicone gelling agents such as crosslinked organopolysiloxane elastomers because of their excellent skinfeel properties have been found useful in make-up compositions. For instance, U.S. Pat. No. 5,266,321 (Shukuzaki et al.) discloses an oily make-up composition comprised of a silicone gel crosslinked elastomer, titanium dioxide, mica and iron oxides. Japanese patent application 61-194009 (Harashima) describes a make-up composition comprising a cured organopolysiloxane elastomer powder and pigments which may be selected from talc, titanium dioxide, zinc oxide and iron oxides.
[0009] A challenge which has not been fully met by the known art is delivery of a composition with appropriate optics to achieve both soft focus and radiance properties in a system that still provides excellent skinfeel.
SUMMARY OF THE INVENTION
[0010] A cosmetic composition is provided which includes:
(i) a crosslinked silicone elastomer; (ii) a zinc oxide or zirconium oxide of average particle size less than 300 nm; (iii) a light reflecting inorganic material of platelet shaped particles having an average particle size of about 10,000 to about 30,000 nm; and (iv) a cosmetically acceptable carrier system.
DETAILED DESCRIPTION OF THE INVENTION
[0015] Now it has been observed that a soft focus effect with radiance can be obtained by a combination of fine particle sized zinc oxide or zirconium oxide suspended with a crosslinked silicone elastomer. The zinc or zirconium oxide must have an average particle size less than 300 nm. Absent the elastomer or the zinc or zirconium oxide, there would be insufficient soft focus effect. The oxide alone is inefficient because of excessive loss of reflectance/radiance.
Crosslinked Silicone Elastomer
[0016] A component of the present invention is a crosslinked silicone (organopolysiloxane) elastomer. No specific restriction exists as to the type of curable organopolysiloxane composition that can serve as starting material for the crosslinked silicone elastomer. Examples in this respect are addition reaction-curing organopolysiloxane compositions which cure under platinum metal catalysis by the addition reaction between SiH-containing diorganopolysiloxane and organopolysiloxane having silicon-bonded vinyl groups; condensation-curing organopolysiloxane compositions which cure in the presence of an organotin compound by a dehydrogenation reaction between hydroxyl terminated diorganopolysiloxane and SiH-containing diorganopolysiloxane; condensation-curing organopolysiloxane compositions which cure in the presence of an organotin compound or a titanate ester, by a condensation reaction between an hydroxyl terminated diorganopolysiloxane and a hydrolyzable organosilane (this condensation reaction is exemplified by dehydration, alcohol-liberating, oxime-liberating, amine-liberating, amide-liberating, carboxyl-liberating, and ketone-liberating reactions); peroxide-curing organopolysiloxane compositions which thermally cure in the presence of an organoperoxide catalyst; and organopolysiloxane compositions which are cured by high-energy radiation, such as by gamma-rays, ultraviolet radiation, or electron beams.
[0017] Addition reaction-curing organopolysiloxane compositions are preferred for their rapid curing rates and excellent uniformity of curing. A particularly preferred addition reaction-curing organopolysiloxane composition is prepared from:
(A) an organopolysiloxane having at least 2 lower alkenyl groups in each molecule; (B) an organopolysiloxane having at least 2 silicon-bonded hydrogen atoms in each molecule; and (C) a platinum-type catalyst.
[0021] The crosslinked siloxane elastomer of the present invention may either be an emulsifying or non-emulsifying crosslinked organopolysiloxane elastomer or combinations thereof. The term “non-emulsifying,” as used herein, defines crosslinked organopolysiloxane elastomer from which polyoxyalkylene units are absent. The term “emulsifying,” as used herein, means crosslinked organopolysiloxane elastomer having at least one polyoxyalkylene (e.g., polyoxyethylene or polyoxypropylene) unit.
[0022] Particularly useful emulsifying elastomers are polyoxyalkylene-modified elastomers formed from divinyl compounds, particularly siloxane polymers with at least two free vinyl groups, reacting with Si—H linkages on a polysiloxane backbone. Preferably, the elastomers are dimethyl polysiloxanes crosslinked by Si—H sites on a molecularly spherical MQ resin.
[0023] Preferred silicone elastomers are organopolysiloxane compositions available under the INCI names of dimethicone/vinyl dimethicone crosspolymer, dimethicone crosspolymer and Polysilicone-11. Ordinarily these materials are provided as a 1-30% crosslinked silicone elastomer dissolved or suspended in a dimethicone fluid (usually cyclomethicone). For purposes of definition “crosslinked silicone elastomer” refers to the elastomer alone rather than the total commercial compositions which also include a solvent (eg dimethicone) carrier.
[0024] Dimethicone/vinyl dimethicone crosspolymers and dimethicone crosspolymers are available from a variety of suppliers including Dow Corning (9040, 9041, 9045, 9506 and 9509), General Electric (SFE 839), Shin Etsu (KSG-15,16,18 [dimethicone/phenyl vinyl dimethicone crosspolymer]), and Grant Industries (Gransil™ line of materials), and lauryl dimethiconetvinyl dimethicone crosspolymers supplied by Shin Etsu (e.g, KSG-31, KSG-32, KSG-41, KSG42, KSG-43, and KSG44).
[0025] Other suitable commercially available silicone elastomer powders include vinyl dimethicone/methicone silesquioxane crosspolymers from Shin-Etsu sold as KSP-100, KSP-101, KSP-102, KSP-103, KSP-104, KSP-105, and hybrid silicone powders that contain a fluoroalkyl group or a phenyl group sold by Shin-Etsu as respectively KSP-200 and KSP-300.
[0026] The crosslinked silicone elastomers of the present invention may range in concentration from about 0.01 to about 30%, preferably from about 0.1 to about 10%, optimally from about 0.5 to about 2% by weight of the cosmetic composition. These weight values exclude any solvent such as cyclomethicone found in commercial “elastomer” silicones such as the Dow Corning products 9040 and 9045. For instance, the amount of crosslinked silicone elastomer in 9040 and 9045 is between 12 and 13% by weight.
[0027] Most preferred as the silicone elastomer is 9045 which has a D5 cyclomethicone swelled elastomer particle size (based on volume and calculated as spherical particles) which averages about 38 micron, and may range from about 25 to about 55 micron.
Micronized Zinc or Zirconium Oxide
[0028] A second important component of the present invention is that of a micronized zinc oxide or zirconium oxide having average (number) particle sizes less than 300 nm, preferably less than 200 nm, more preferably less than 100 nm and optimally less than 85 nm. Generally the particle sizes can range from about 0.01 to about 280 nm, more preferably from about 1 to about 200 nm, even more preferably from 10 to 95 nm, and optimally from 25 to 75 nm.
[0029] Average particle size of the oxide assumes a spherical shape and is defined as the diameter of the particle averaged over many particles. The average value is a number average. For spherical particles such as the zinc oxide, laser light scattering is utilized to determine the individual sizes of the particles and generate a particle size distribution plot. Based upon the distribution plot, the average particle size can be determined. In more mathematical terms, the average particle size is a diameter converted from the meso-pore specific surface area determined by the t-plot method (particle size converted excluding the specific surface area of micro pores of less than 20 Angstrom). In detail, the average particle size D, assuming the particle as spherical form, can be obtained by the following equation: D=6/pS, where S (m 2 /g) represents a meso-pore specific surface area and p(g/cm 3 ) is the density.
[0030] The amount of zinc oxide or zirconium oxide may range from about 0.1 to about 20%, preferably from about 0.5 to about 10%, optimally from about 1 to about 5% by weight of the cosmetic composition.
[0031] Since zinc or zirconium oxide particles are applied to skin, it is desirable that they be free of toxic trace metal contaminants. A particularly preferred zinc oxide has trace concentrations of lead (less than 20 ppm), arsenic (less than 3 ppm), cadmium (less than 15 ppm) and mercury (less than 1 ppm). This material is commercially available from BASF Corporation under the trademark of Z-Cote HP1. These particles are best delivered to the formula as a pre-mix of 5-80% weight by weight suspended in an organic ester base.
[0032] Zinc oxide or zirconium oxide particles of the present invention advantageously but not necessarily are substantially spherical in shape. The refractive index of these particles may preferably range from about 1.8 to about 2.3. Measurement of refractive index can be performed according to a method described in J. A. Dean, Ed., Lange's Handbook of Chemistry, 14 th Ed., McGraw Hill, New York 1992, Section 9, Refractometry, incorporated herein by reference.
Light Reflecting Platelet Particles
[0033] A third important component of compositions according to the present invention is that of light reflecting platelet shaped particles. These particles will have an average particle size D 50 ranging from about 10,000 to about 30,000 nm. For plate-like materials the average particle size is a number average value. The platelets are assumed to have a circular shape with the diameter of the circular surface averaged over many particles. The thickness of the plate-like particles is considered to be a separate parameter. For instance, the platelets can have an average particle size of 35,000 nm and an average thickness of 400 nm. For purposes herein, thickness is considered to range from about 100 to about 600 nm. Laser light scattering can be utilized for measurement except that light scattered data has to be mathematically corrected from the spherical to the non-spherical shape. Optical and electron microscopy may be used to determine average particle size. Thickness is normally only determined via optical or electron microscopy.
[0034] The refractive index of these particles is preferred to be at least about 1.8, generally from about 1.9 to about 4, more preferably from about 2 to about 3, optimally between about 2.5 and 2.8.
[0035] Illustrative but not limiting examples of light reflecting particles are bismuth oxychloride (single crystal platelets) and titanium dioxide coated mica. Suitable bismuth oxychloride crystals are available from EM Industries, Inc. under the trademarks Biron® NLY-L-2X CO and Biron® Silver CO (wherein the platelets are dispersed in castor oil); Biron® Liquid Silver (wherein the particles are dispersed in a stearate ester); and Nailsyn® IGO, Nailsyn® II C2X and Nailsyn® II Platinum 25 (wherein the platelets are dispersed in nitrocellulose). Most preferred is a system where bismuth oxychloride is dispersed in a C 2 -C 40 alkyl ester such as in Biron® Liquid Silver.
[0036] Among the suitable titanium dioxide coated mica platelets are materials available from EM Industries, Inc. These include Timiron® MP-10 (particle size range 10,000-30,000 nm), Timiron® MP-14 (particle size range 5,000-30,000 nm), Timiron® MP-30 (particle size range 2,000-20,000 nm), Timiron® MP-101 (particle size range 5,000-45,000 nm), Timiron® MP-111 (particle size range 5,000-40,000 nm), Timiron® MP-1001 (particle size range 5,000-20,000 nm), Timiron® MP-155 (particle size range 10,000-40,000 nm), Timiron® MP-175 (particle size range 10,000-40,000), Timiron® MP-115 (particle size range 10,000-40,000 nm), and Timiron® MP-127 (particle size range 10,000-40,000 nm). Most preferred is Timiron® MP-111. The weight ratio of titanium dioxide coating to the mica platelet may range from about 1:10 to about 5:1, preferably from about 1:1 to about 1:6, more preferably from about 1:3 to about 1:4 by weight. Advantageously the preferred compositions will generally be substantially free of titanium dioxide outside of that required for coating mica.
[0037] Suitable coatings for mica other than titanium dioxide may also achieve the appropriate optical properties required for the present invention. These types of coated micas must also meet the refractive index of at least about 1.8. Other coatings include silica on the mica platelets.
[0038] The amount of the light reflecting platelet shaped particles may range from about 0.1 to about 5%, preferably from about 0.5 to about 3%, more preferably from about 0.8 to about 2%, optimally from about 1 to about 1.5% by weight of the composition.
[0039] Advantageously the weight ratio of zinc oxide and zirconium oxide to light reflecting platelet shaped particles may range from about 4:1 to about 1:1, preferably from about 3:1 to about 1.5:1, optimally about 2:1 by weight. In a preferred but not limiting example, the amount of silicone elastomer and oxide particles relative to the light reflective platelet shaped particles may be present in a ratio from about 10:1 to about 1:1, preferably from about 6:1 to about 1:1, more preferably from about 5:1 to about 3:1, optimally about 4:1 by weight.
[0040] Advantageously compositions of the present invention will have a Reflectance Intensity as measured at a 30° angle ranging from 140 to 170 thousand Watt-nm/cm 2 . Light Transmission Intensity advantageously ranges from 4 to 7 million Watt-nm/cm 2 at an angle of 0°; a Transmission Intensity ranging from 1 to 2 million Watt-nm/cm 2 at a 10° angle; a Transmission Intensity ranging from 120 to 140 thousand Watt-nm/cm 2 at a 30° angle; a Transmission Intensity ranging from 60 to 80 thousand Watt-nm/cm 2 at a 40° angle; and a Transmission Intensity ranging from 40 to 60 thousand Watt-nm/cm 2 at a 50° angle.
Optional Particles
[0041] Advantageously compositions of the present invention may include a non-coated mica. These mica particles can also be platelets but of thinner and smaller particle size than the coated micas mentioned above. Particularly preferred is Satin Mica, available from Merck-Rona. These are useful to remove any excessive glitter imparted by the light scattering platelets. Advantageously the particle size of the non-coated mica is no higher than 15,000 nm and an average (volume) particle size ranging from 1,000 to 10,000 nm, preferably from 5,000 to 8,000 nm.
[0042] The amount of the non-coated mica may range from about 0.05 to about 2%, preferably from about 0.1 to about 1.5%, optimally from about 0.4 to about 0.8% by weight of the composition.
[0043] Advantageously present may also be water-insoluble organic material in the form of polymeric porous spherical particles. By the term “porous” is meant an open or closed cell structure. Preferably the particles are not hollow beads. Average particle size may range from about 0.1 to about 100, preferably from about 1 to about 50, more preferably greater than 5 and especially from 5 to about 15, optimally from about 6 to about 10 μm. Organic polymers or copolymers are the preferred materials and can be formed from monomers including the acid, salt or ester forms of acrylic acid and methacrylic acid, methylacrylate, ethylacrylate, ethylene, propylene, vinylidene chloride, acrylonitrile, maleic acid, vinyl pyrrolidone, styrene, butadiene and mixtures thereof. The polymers are especially useful in cross-linked form. Cells of the porous articles may be filled by a gas which can be air, nitrogen or a hydrocarbon. Oil Absorbance (castor oil) is a measure of porosity and in the preferred but not limiting embodiment may range from about 90 to about 500, preferably from about 100 to about 200, optimally from about 120 to about 180 ml/100 grams. Density of the particles in the preferred but not limiting embodiment may range from about 0.08 to 0.55, preferably from about 0.15 to 0.48 g/cm 3 .
[0044] Illustrative porous polymers include polymethylmethacrylate and cross-linked polystyrene. Most preferred is polymethyl methacrylate available as Ganzpearl® GMP 820 available from Presperse, Inc., Piscataway, N.J., known also by its INCI name of Methyl Methacrylate Crosspolymer.
[0045] Amounts of the water-insoluble polymeric porous particles may range from about 0.01 to about 10%, preferably from about 0.1 to about 5%, optimally from about 0.3 to about 2% by weight of the composition.
Carrier System and Optional Components
[0046] Advantageously present will be an associative polymer. Representative polymers which may be suitable for the present invention are listed in the Table below.
Supplier Name INCI Name Akzo Nobel Elfacos T 212 PPG-14 Palmeth-60 Hexyl Dicarbamate Ciba Salcare SC96 Polyquaternium 37 and Propylene Glycol Dicaprate Dicaprylate and PPG-1 Trideceth-6 Clariant Aristoflex AVC Ammonium Acryloyldimethyltaurate/VP Copolymer Clariant Aristoflex HMB Ammonium Acryloyldimethyltaurate/Beheneth-25 Methacrylate Crosspolymer Clariant Aristoflex PEA Polypropylene Terephthalate Clariant Hostacerin AMP5 Ammonium Polyacryloyldimethyl Taurate Hercules Natrosol Plus CS Cetyl Hydroxyethylcellulose Hercules PolySurf Cetyl Hydroxyethylcellulose National Starch Structure 2001 Acrylates/Steareth-20 Itaconate Copolymer National Starch Structure 3001 Acrylates/Ceteth-20 Itaconate Copolymer Noveon Pemulen (various) Acrylates/C10-30 Alkyl Acrylate Crosspolymer RITA Viscolam SMC 20 Sodium Acrylate/Sodium Acryloyldimethyl Taurate Copolymer and C13-C14 Isoparaffin and Laureth-8 SEPPIC Sepigel 305 Polyacrylamide and C13-14 Isoparaffin and Laureth-7 SEPPIC Sepigel 501 C13-14 Isoparaffin; Mineral Oil; Sodium Polyacrylate; Polyacrylamide; Polysorbate 85 SEPPIC Sepigel 502 C13-14 Isoparaffin; Isostearyl Isostearate; Sodium Polyacrylate; Polyacrylamide; Polysorbate 60 SEPPIC Simulgel 600 Acrylamide/Sodium Acryloyldimethyltaurate Copolymer; Isohexadecane; Polysorbate 80 SEPPIC Simulgel 800 Sodium Polyacryloyldimethyl Taurate; Isohexadecane; Sorbitan Oleate SEPPIC Simulgel A Ammonium Polyacrylate and Isohexadecane and PEG-50 Castor Oil SEPPIC Simulgel EG Sodium Acrylate/Acryloyldimethyl Taurate Copolymer and Isohexadecane and Polysorbate 80 SEPPIC Simulgel EPG Sodium Acrylate/Acryloyldimethyl Taurate Copolymer and Polyisobutene and Caprylyl/Capryl Glucoside SEPPIC Simulgel NS Hydroxyethyl Acrylate/Sodium Acryloyldimethyl Taurate Copolymer and Squalane and Polysorbate 60 Sud-Chemie Pure-Thix M PEG-180/Laureth-50/TMMG copolymer
[0047] Particularly preferred are taurate homopolymers and copolymers. The copolymers are especially useful wherein the taurate repeating monomer unit is acryloyl dimethyl taurate (in either free acid or salt form). Monomers forming the copolymer with taurate may include: styrene, acrylic acid, methacrylic acid, vinyl chloride, vinyl acetate, vinyl pyrrolidone, isoprene, vinyl alcohol, vinyl methylether, chloro-styrene, dialkylamino-styrene, maleic acid, acrylamide, methacrylamide and mixtures thereof. Where the term “acid” appears, the term means not only the free acid but also C 1 -C 30 alkyl esters, anhydrides and salts thereof. Preferably but not exclusively the salts may be ammonium, alkanolammonium, alkali metal and alkaline earth metal salts. Most preferred are the ammonium and alkanolammonium salts.
[0048] Most preferred as the copolymer is Acryloyl Dimethyltaurate/Vinyl Pyrrolidone Copolymer, which is the INCI nomenclature, for a material supplied by Clariant Corporation under the trademark Aristoflex® AVC, having the following general formula:
wherein n and m are integers which may independently vary from 1 to 10,000.
[0049] Number average molecular weight of copolymers according to the invention may range from about 1,000 to about 3,000,000, preferably from about 3,000 to about 100,000, optimally from about 10,000 to about 80,000.
[0050] Amounts of the associative polymer may range from about 0.001 to about 10%, preferably from about 0.01 to about 8%, more preferably from about 0.1 to about 5%, optimally from about 0.2 to about 1% by weight of the composition.
[0051] A crystalline structurant advantageously may be present in compositions according to the present invention. The structurant may include both a surfactant and a co-surfactant. The nature of the surfactant and co-surfactant will depend upon whether the crystalline structurant is anionic or nonionic. For structurants that are anionic, the preferred surfactants are C 10 -C 22 fatty acids and salts (i.e. soap) thereof and particularly combinations of these materials. Typical counterions forming the fatty acid salt are those of ammonium, sodium, potassium, lithium, trialkanolammonium (e.g. triethanolammonium) and combinations thereof. Amounts of the fatty acid to the fatty acid salt when both present may range from about 100:1 to about 1:100, preferably from about 50:1 to about 1:50, and optimally from about 3:1 to about 1:3 by weight. Illustrative fatty acids include behenic acid, stearic acid, isostearic acid, myristic acid, lauric acid, linoleic acid, oleic acid, hydroxystearic acid and combinations thereof. Most preferred is stearic acid. Among the fatty acid salts the most preferred is sodium stearate.
[0052] The co-surfactant for an anionic crystalline structurant typically is a C 10 -C 22 fatty alcohol, a C 1 -C 200 ester of a C 10 -C 22 fatty acid and particularly combinations of these materials. Relative amounts of the ester to the alcohol when both present may range from about 100:1 to about 1:100, preferably from about 50:1 to about 1:50, and optimally from about 3:1 to about 1:3 by weight. Typical fatty alcohols include behenyl alcohol, stearyl alcohol, cetyl alcohol, myristyl alcohol, lauryl alcohol, oleyl alcohol and combinations thereof. Esters of the fatty acid preferably are polyol esters such as C 2 -C 3 alkoxylated alcohol esters. Among these are the polyethoxy, polypropoxy and block polyethyoxy/polypropoxy alcohol esters. Particularly preferred are such esters as PEG-100 stearate, PEG-20 stearate, PEG-80 laurate, PEG-20 laurate, PEG-100 palmitate, PEG-20 palmitate and combinations thereof.
[0053] The relative amount of surfactant and co-surfactant for the anionic structurant may range from about 50:1 to about 1:50, preferably from about 10:1 to about 1:10, and optimally from about 3:1 to about 1:3 by weight.
[0054] Nonionic type crystalline structurant will have a surfactant and a co-surfactant different than that for the anionic systems. Preferred nonionic structurant surfactants are C 1 -C 200 esters of C 10 -C 22 fatty acid. Esters of the fatty acid preferably are polyol esters such as C 2 -C 3 alkoxylated alcohol or sorbitol esters. Among these are the polyethoxy, polypropoxy and block polyethoxy/polypropoxy alcohol esters. Particularly preferred are such esters as Polysorbate 40, Polysorbate 60, PEG-100 stearate, PEG-20 stearate, PEG-80 laurate, PEG-20 laurate, PEG-100 palmitate, PEG-20 palmitate and combinations thereof.
[0055] The co-surfactant of a nonionic structurant typically may be a combination of a C 10 -C 22 fatty alcohol, glyceryl esters of a C 10 -C 22 fatty acid, and a C 10 -C 22 unesterified fatty acid. Relative amounts of the ester to the alcohol may range from about 100:1 to about 1:100, preferably from about 50:1 to about 1:50, and optimally from about 3:1 to about 1:3 by weight. Relative amounts of the combination of glyceryl ester and fatty alcohol to unesterified fatty acid may range from about 100:1 to about 1:100, preferably from about 50:1 to about 1:50, and optimally from about 3:1 to about 1:3 by weight. Typical fatty alcohols include behenyl alcohol, stearyl alcohol, cetyl alcohol, myristyl alcohol, lauryl alcohol, oleyl alcohol and combinations thereof.
[0056] The relative amount of surfactant and co-surfactant in a nonionic structurant may range from about 50:1 to about 1:50, preferably from about 10:1 to about 1:10, and optimally from about 3:1 to about 1:3 by weight.
[0057] A crystalline structurant is formed by the surfactant and co-surfactant. Indeed, the surfactant and co-surfactant combination in their relative ratio and type of material is defined by an enthalpy which may range from about 2 to about 15, preferably from about 2.5 to about 12, and optimally from about 3.5 to about 8 Joules per gram, as measured by Differential Scanning Calorimetry. Furthermore, the crystalline structurant system advantageously may have a melting point ranging from about 30 to about 70° C., preferably from about 45 to about 65° C., and optimally from about 50 to about 60° C.
[0058] Normal forces which are positive numbers reflect a silky smooth skin feel of the formulation. Negative values have been identified with a draggy feel which many consumers dislike. Normal force is measured in the following manner. A rheometer that has a shear rate mode capability and a normal force transducer is utilized to measure the high shear normal force. These devices are available from Rheometric Scientific ARES, TA Instruments AR2000, and Paar Physica MCR. Samples are compressed between concentric parallel plates of diameter 25 mm and gap (vertical distance between the two plates) of 100 microns. The measurements are made in a continuous logarithmic shear sweep mode with a shear rate range of 1 to 10,000 s −1 . Each sweep takes 5 minutes and is conducted at ambient condition (20-25° C.). The normal force is calculated by subtracting the baseline (defined as the normal force value at or near 100 s −1 ) from the highest normal force value measured between 1000 and 10,000 s −1 . A positive normal force of 5 grams and especially 10 grams or greater is correlated to products/materials with silky sensations during rubbing in application.
[0059] The higher the positive value of the normal force the better is the soft focus effect. Ordinarily, soft focus is enhanced when the normal force ranges from about +5 to about +100 grams. Particularly desirable is a positive normal force in the range from about +10 to about +60, optimally from about +25 to about +40 grams.
[0060] A variety of other components may be present in the compositions of the present invention. Foremost is that of water which serves as a carrier in the carrier system. Amounts of water may range from about 1 to about 90%, preferably from about 30 to about 80%, optimally from about 50 to about 80% by weight of the composition.
[0061] Emollient materials may be included as carriers in compositions of this invention. These may be in the form of silicone oils, synthetic esters and hydrocarbons. Amounts of the emollients may range anywhere from about 0.1 to about 95%, preferably between about 1 and about 50% by weight of the composition.
[0062] Silicone oils may be divided into the volatile and nonvolatile variety. The term “volatile” as used herein refers to those materials which have a measurable vapor pressure at ambient temperature (20-25° C.). Volatile silicone oils are preferably chosen from cyclic (cyclomethicone) or linear polydimethylsiloxanes containing from 3 to 9, preferably from 4 to 5, silicon atoms.
[0063] Nonvolatile silicone oils useful as an emollient material include polyalkyl siloxanes, polyalkylaryl siloxanes and polyether siloxane copolymers. The essentially nonvolatile polyalkyl siloxanes useful herein include, for example, polydimethyl siloxanes with viscosities of from about 5×10 −6 to 0.1 m 2 /s at 25° C. Among the preferred nonvolatile emollients useful in the present compositions are the polydimethyl siloxanes having viscosities from about 1×10 −5 to about 4×10 −4 m 2 /s at 25° C.
[0064] Among the ester emollients are:
[0065] Alkenyl or alkyl esters of fatty acids having 10 to 20 carbon atoms. Examples thereof include isoarachidyl neopentanoate, isononyl isonanonoate, oleyl myristate, oleyl stearate, and oleyl oleate.
[0066] Ether-esters such as fatty acid esters of ethoxylated fatty alcohols.
[0067] Polyhydric alcohol esters. Ethylene glycol mono and di-fatty acid esters, diethylene glycol mono- and di-fatty acid esters, polyethylene glycol (200-6000) mono- and di-fatty acid esters, propylene glycol mono- and di-fatty acid esters, polypropylene glycol 2000 monooleate, polypropylene glycol 2000 monostearate, ethoxylated propylene glycol monostearate, glyceryl mono- and di-fatty acid esters, polyglycerol poly-fatty esters, ethoxylated glyceryl mono-stearate, 1,3-butylene glycol monostearate, 1,3-butylene glycol distearate, polyoxyethylene polyol fatty acid ester, sorbitan fatty acid esters, and polyoxyethylene sorbitan fatty acid esters are satisfactory polyhydric alcohol esters. Particularly useful are pentaerythritol, trimethylolpropane and neopentyl glycol esters of C 1 -C 30 alcohols.
[0068] Wax esters such as beeswax, spermaceti wax and tribehenin wax.
[0069] Sterols esters, of which cholesterol fatty acid esters are examples thereof.
[0070] Sugar ester of fatty acids such as sucrose polybehenate and sucrose polycottonseedate.
[0071] Hydrocarbons which are suitable cosmetically acceptable carriers include petrolatum, mineral oil, C 11 -C 13 isoparaffins, polyalphaolefins, and especially isohexadecane, available commercially as Permethyl 101A from Presperse Inc.
[0072] Humectants of the polyhydric alcohol-type can be employed as cosmetically acceptable carriers. Typical polyhydric alcohols include polyalkylene glycols and more preferably alkylene polyols and their derivatives, including propylene glycol, dipropylene glycol, polypropylene glycol, polyethylene glycol and derivatives thereof, sorbitol, hydroxypropyl sorbitol, hexylene glycol, 1,3-butylene glycol, isoprene glycol, 1,2,6-hexanetriol, ethoxylated glycerol, propoxylated glycerol and mixtures thereof. The amount of humectant may range anywhere from 0.5 to 50%, preferably between 1 and 15% by weight of the composition. Most preferred is glycerol (also known as glycerin). Amounts of glycerin may range from about 10% to about 50%, preferably from 12 to 35%, optimally from 15 to 30% by weight of the composition.
[0073] Sunscreen actives may also be included in compositions of the present invention. These will be organic compounds having at least one chromophoric group absorbing within the ultraviolet ranging from 290 to 400 nm. Chromophoric organic sunscreen agents may be divided into the following categories (with specific examples) including: p-Aminobenzoic acid, its salts and its derivatives (ethyl, isobutyl, glyceryl esters; p-dimethylaminobenzoic acid); Anthranilates (o-aminobenzoates; methyl, menthyl, phenyl, benzyl, phenylethyl, linalyl, terpinyl, and cyclohexenyl esters); Salicylates (octyl, amyl, phenyl, benzyl, menthyl, glyceryl, and dipropyleneglycol esters); Cinnamic acid derivatives (menthyl and benzyl esters, alpha-phenyl cinnamonitrile; butyl cinnamoyl pyruvate); Dihydroxycinnamic acid derivatives (umbelliferone, methylumbelliferone, methylaceto-umbelliferone); Trihydroxycinnamic acid derivatives (esculetin, methylesculetin, daphnetin, and the glucosides, esculin and daphnin); Hydrocarbons (diphenylbutadiene, stilbene); Dibenzalacetone and benzalacetophenone; Naphtholsulfonates (sodium salts of 2-naphthol-3,6-disulfonic and of 2-naphthol-6,8-disulfonic acids); Dihydroxynaphthoic acid and its salts; o- and p-Hydroxybiphenyidisulfonates; Coumarin derivatives (7-hydroxy, 7-methyl, 3-phenyl); Diazoles (2-acetyl-3-bromoindazole, phenyl benzoxazole, methyl naphthoxazole, various aryl benzothiazoles); Quinine salts (bisulfate, sulfate, chloride, oleate, and tannate); Quinoline derivatives (8-hydroxyquinoline salts, 2-phenylquinoline); Hydroxy- or methoxy-substituted benzophenones; Uric and vilouric acids; Tannic acid and its derivatives (e.g., hexaethylether); (Butyl carbityl) (6-propyl piperonyl) ether; Hydroquinone; Benzophenones (Oxybenzone, Sulisobenzone, Dioxybenzone, Benzoresorcinol, 2,2′,4,4′-Tetrahydroxybenzophenone, 2,2′-Dihydroxy4,4′-dimethoxybenzophenone, Octabenzone; 4-Isopropyldibenzoylmethane; Butylmethoxydibenzoylmethane; Etocrylene; and 4-isopropyl-dibenzoylmethane). Particularly useful are: 2-ethylhexyl p-methoxycinnamate, 4,4′-t-butyl methoxydibenzoylmethane, 2-hydroxy4-methoxybenzophenone, octyidimethyl p-aminobenzoic acid, digalloyltrioleate, 2,2-dihydroxy4-methoxybenzophenone, ethyl 4-[bis(hydroxypropyl)]aminobenzoate, 2-ethylhexyl-2-cyano-3,3-diphenylacrylate, 2-ethylhexylsalicylate, glyceryl p-aminobenzoate, 3,3,5-trimethylcyclohexylsalicylate, methylanthranilate, p-dimethylaminobenzoic acid or aminobenzoate, 2-ethylhexyl p-dimethylaminobenzoate, 2-phenylbenzimidazole-5-sulfonic acid, 2-(p-dimethylaminophenyl)-5-sulfoniobenzoxazoic acid and mixtures thereof.
[0074] Particularly preferred are such materials as ethylhexyl p-methoxycinnamate, available as Parsol MCX®, Avobenzene, available as Parsol 1789®, and Dermablock OS® (octylsalicylate).
[0075] Amounts of the organic sunscreen agent will range from about 0.1 to about 15%, preferably from about 0.5% to about 10%, optimally from about 1% to about 8% by weight of the composition.
[0076] Preservatives can desirably be incorporated into the cosmetic compositions of this invention to protect against the growth of potentially harmful microorganisms. Suitable traditional preservatives for compositions of this invention are alkyl esters of para-hydroxybenzoic acid. Other preservatives which have more recently come into use include hydantoin derivatives, propionate salts, and a variety of quaternary ammonium compounds. Cosmetic chemists are familiar with appropriate preservatives and routinely choose them to satisfy the preservative challenge test and to provide product stability. Particularly preferred preservatives are phenoxyethanol, methyl paraben, propyl paraben, imidazolidinyl urea, sodium dehydroacetate and benzyl alcohol. The preservatives should be selected having regard for the use of the composition and possible incompatibilities between the preservatives and other ingredients in the emulsion. Preservatives are preferably employed in amounts ranging from 0.01% to 2% by weight of the composition.
[0077] Compositions of the present invention may also contain vitamins. Illustrative water-soluble vitamins are Niacinamide, Vitamin B 2 , Vitamin B 6 , Vitamin C and Biotin. Among the useful water-insoluble vitamins are Vitamin A (retinol), Vitamin A Palmitate, ascorbyl tetraisopalmitate, Vitamin E (tocopherol), Vitamin E Acetate and DL-panthenol. Total amount of vitamins when present in compositions according to the present invention may range from 0.001 to 10%, preferably from 0.01% to 1%, optimally from 0.1 to 0.5% by weight of the composition.
[0078] Desquamation agents are further optional components. Illustrative are the alpha-hydroxycarboxylic acids and beta-hydroxycarboxylic acids and salts of these acids. Among the former are salts of glycolic acid, lactic acid and malic acid. Salicylic acid is representative of the beta-hydroxycarboxylic acids. Amounts of these materials when present may range from about 0.1 to about 15% by weight of the composition.
[0079] A variety of herbal extracts may optionally be included in compositions of this invention. Illustrative are pomegranate, white birch ( Betula Alba ), green tea, chamomile, licorice and extract combinations thereof. The extracts may either be water soluble or water-insoluble carried in a solvent which respectively is hydrophilic or hydrophobic. Water and ethanol are the preferred extract solvents.
[0080] Except in the operating and comparative examples, or where otherwise explicitly indicated, all numbers in this description indicating amounts of material ought to be understood as modified by the word “about”.
[0081] The term “comprising” is meant not to be limiting to any subsequently stated elements but rather to encompass non-specified elements of major or minor functional importance. In other words the listed steps, elements or options need not be exhaustive. Whenever the words “including” or “having” are used, these terms are meant to be equivalent to “comprising” as defined above.
[0082] All documents referred to herein, including all patents, patent applications, and printed publications, are hereby incorporated by reference in their entirety in this disclosure.
[0083] The following examples will more fully illustrate the embodiments of this invention. All parts, percentages and proportions referred to herein and in the appended claims are by weight unless otherwise illustrated.
EXAMPLE 1
[0084] A series of formulas were investigated for their optical properties. These are recorded in Table I below.
TABLE I Sample No. (Weight %) Component INCI/Chemical Name 1 2 3 4 5 6 7 8 Surfactant Gel Tween ® 40 Polysorbate 40 1.62 1.62 1.62 1.62 1.62 1.62 1.62 1.62 Lanette ® 16 Cetyl Alcohol 1.55 1.55 1.55 1.55 1.55 1.55 1.55 1.55 Cutina ® GMS Glycerin Monostearate 0.78 0.78 0.78 0.78 0.78 0.78 0.78 0.78 Emersol ® 315 Linoleic Acid 0.10 0.10 0.10 0.10 0.10 0.10 0.10 0.10 Pristerene ® 9559 Stearic Acid 0.25 0.25 0.25 0.25 0.25 0.25 0.25 0.25 Cholesterol NF Cholesterol 0.20 0.20 0.20 0.20 0.20 0.20 0.20 0.20 Humectant/emollient Glycerin 9.00 9.00 9.00 9.00 9.00 9.00 9.00 9.00 Sunscreen Dermablock ® OS Ethylhexyl Salicylate 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 Parsol ® MCX Ethylhexyl Methoxycinnamate 4.00 4.00 4.00 4.00 4.00 4.00 4.00 4.00 Oil Phase Dow Corning 200 Dimethicone 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 (50 cSt) Dow Corning 245 Cyclopentasiloxane 20.00 Dow Corning 5225C Formulation Aid 0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50 Dow Corning 9045 Silicone Elastomer 20.00 20.00 20.00 20.00 20.00 20.00 20.00 Polymer Aristoflex ® AVC Taurate Copolymer 0.80 0.80 0.80 0.80 0.80 0.80 0.40 0.60 Particulates Z-Cote ® HP1 as Zinc Oxide 3.08 3.08 3.08 3.08 3.08 3.08 3.08 Dispersion (65% ZnO) Ganzpearl ® GMP-0820 Polymethylmethacrylate 0.50 0.50 0.50 0.50 0.50 0.50 0.50 Satin Mica Mica 0.50 0.50 0.50 0.50 0.50 0.50 0.50 Timiron ® MP 111 TiO 2 Coated Mica 1.00 1.00 1.00 1.00 1.00 1.00 1.00 Water 53.12 53.12 56.20 53.62 53.62 54.12 53.52 53.32
Optical Measurements
[0085] Opacity is the measure of intensity attenuation of a transmitted light beam shone perpendicular to a medium or film. The higher the direct beam attenuation, the greater will be the opacity. The source of the light beam attenuation is two fold: A) Some of the original light is reflected back from the film/medium. This gives the film/medium a true white/opaque appearance with great hiding power. Using pigment-grade TiO 2 in a formulation will give the effect. B) Some of the light is deflected from the straight beam path but still transmitted through the film/medium. In effect, the film/medium goes from being transparent to translucent, creating a “blurred” image. Another term for this is soft focus.
[0086] Procedure: Apply (or draw down) a 3 mil (76.2 μm) film of a formulation using a draw down bar on to a plastic overhead transparency sheet. Let the film dry for 2 hours at room temperature. Take the coated overhead transparency and place it in an Instrument Systems goniospectrophotometer. Set the light source and detector arrayed in a straight line perpendicular to the coated transparency. The light source (set at 209 million Watt-nm/cm 2 , which serves as a reference for all Transmission Intensity values reported herein) is turned on and the measurement of the transmitted light intensity is made. Further measurements are made by moving the detector 10, 30, 40, 50 degrees away from the direct transmission normal. These values indicate the extent of soft focus light scattering. The Reflectance or “radiance” of a product is determined in the same way as opacity/soft focus light scattering, except for the positions of the light source and detector. The detector is 30 degrees on one side of the normal/perpendicular, while the light source is 20 degrees on the other side. To determine the extent of the intensity attenuation, compare the intensity value to that of an uncoated overhead transparency. The difference between these two values is the extent of the attenuation or opacity.
[0087] Results: The effect of certain components on the optical properties of the compositions was evaluated by testing formulations with those components removed. Results are reported in Table II.
TABLE II Sample No. (W-nm/cm 2 ) Acceptability Transmission Intensity 1 2 3 4 5 6 7 8 (Watt-nm/cm 2 ) Transmission Angle in degrees 0 5.5M 10M 10M 5.1M 7.9M 11M 10M 7.2M 4 to 7 million 10 1.1M 1.0M 1.6M 1.1M 1.2M 1.3M 1.1M 1.1M 1 to 2 million 30 128K 98K 104K 143K 131K 116K 110K 116K 120 to 140 thousand 40 73K 56K 46K 80K 71K 64K 63K 61K 60 to 80 thousand 50 48K 37K 25K 52K 45K 41K 41K 45K 40 to 60 thousand Reflection Angle in degrees 30 154K 160K 195K 160K 131K 109K 160K 155K 140 to 170 thousand Note: Bold values are outside the Acceptability range.
[0088] Sample 1 is a preferred embodiment of the present invention. Transmission Intensity (Opacity) at all angles and Reflection Intensity for this formula fell within the parameters necessary to achieve both soft focus and radiance. Replacement of the silicone elastomer (Dow Corning 9045) with cyclopentasiloxane (Dow Corning 245) in Sample 2 resulted in a Transmission Intensity at four angles outside the acceptability ranges. In Sample 3 the zinc oxide was omitted. Here the Transmission Intensity was also outside four of the acceptable ranges indicating the necessity of zinc oxide to achieve soft focus. Removal of Ganzpearl® GMP-0820, which consists of polymethylmethacrylate beads, in Sample 4 had only a small affect on the opacity. Sample 5 wherein Satin Mica was removed as expected demonstrated greater light transmission, but the Reflection Intensity and the 0° angle Transmission Intensity were outside the acceptable range. Removal of Timiron® MP 111 (titanium dioxide coated mica) in Sample 6 demonstrated that this component was a very significant contributor to the soft focus/radiance effect. In Samples 7 and 8 the amount of Aristoflex AVC® (taurate copolymer) was reduced. The 0° angle and 30° angle Transmission Intensity values were the only ones outside the acceptable range indicating that this copolymer had an influence and contributed to the soft focus effect.
EXAMPLE 2
[0089] In this Example we investigated the effect of zinc oxide in contrast to titanium dioxide of essentially similar average particle sizes. Results are reported in Table IV.
TABLE III Sample No. (Weight %) Formulation # INCI/Chemical Name 9 10 11 12 Surfactant Gel Tween ® 40 Polysorbate 40 1.62 1.62 1.62 1.62 Lanette ® 16 Cetyl Alcohol 1.55 1.55 1.55 1.55 Cutina ® GMS Glycerin Monostearate 0.78 0.78 0.78 0.78 Emersol ® 315 Linoleic Acid 0.10 0.1 0.1 0.1 Pristerene ® 9559 Stearic Acid 0.25 0.25 0.25 0.25 Cholesterol NF Cholesterol 0.20 0.20 0.20 0.20 Humectant/Emollient Glycerin 9.00 9.00 9.00 9.00 Sunscreen Dermablock ® OS Ethylhexyl Salicylate 2.00 2.00 2.00 2.00 Parsol ® MCX Ethylhexyl Methoxycinnamate 4.00 4.00 4.00 4.00 Oil Phase Dow Corning 200 (50 cSt) Dimethicone 1.00 1.00 1.00 1.00 Dow Corning 245 Cyclopentasiloxane Dow Corning 5225C Formulation Aid 0.50 0.50 0.50 0.50 Dow Corning 9040 Silicone Elastomer 20.00 Dow Corning 9045 Silicone Elastomer 20.00 20.00 20.00 Polymer Aristoflex ® AVC Taurate Copolymer 0.80 0.80 0.80 0.80 Particulates Z-Cote ® HP1 as Dispersion (65% ZnO) Zinc Oxide 3.08 TiO 2 (UV-grade) Titanium Dioxide 3.08 1.5 0.4 Ganzpearl ® GMP-0820 Polymethylmethacrylate 0.50 0.5 0.5 0.5 Satin Mica Mica 0.50 0.50 0.50 0.50 Timiron ® MP 111 Titanium Dioxide Coated Mica 1.00 1.00 1.00 1.00 Water 53.12 53.12 54.7 55.80
[0090]
TABLE IV
Transmission Intensity (million
W-nm/cm 2 ) at
Sample No.
0 degree angle
9
5.1
10
2.3
11
3.5
12
9.0
[0091] On an equivalent weight basis Sample 9 provided a Transmission Intensity which was within the acceptability range. By contrast, the titanium dioxide Sample Nos. 10, 11 and 12 were outside the acceptable range. | A cosmetic composition is provided which includes a crosslinked silicone elastomer, a zinc oxide or zirconium oxide of average particle size less than 300 nm and a light reflecting inorganic material of platelet shaped particles having an average particle size of about 10,000 to about 30,000 nm, in a cosmetically acceptable carrier system. The composition achieves soft focus and radiance properties which improve the appearance of skin. Good coverage over imperfections such as pores and uneven skin tone is achieved while retaining a natural skin appearance. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is the national stage entry of International Patent Application No. PCT/EP2010/007647, filed on Dec. 15, 2010, and claims priority to Application No. DE 10 2009 058 681.4, filed in the Federal Republic of Germany on Dec. 16, 2009.
FIELD OF INVENTION
[0002] The present invention relates to a balancing unit. It further relates to an external medical functional unit, and a treatment apparatus as well as methods.
BACKGROUND INFORMATION
[0003] European Patent No. EP 0 867 195 B1 describes balancing units for balancing mass and/or volume flows of medical fluids, such as blood or fluids used during the blood treatment.
SUMMARY
[0004] One object of the present invention is to propose a further balancing unit.
[0005] This object may be solved by a balancing unit for balancing medical fluids, in particular for balancing dialysate.
[0006] The balancing unit according to the present invention may comprise at least one balancing chamber and at least one conveying unit for filling the balancing chamber.
[0007] According to the present invention, the conveying unit may be a pressure controlled conveying unit or pressure limited conveying unit.
[0008] In all of the following embodiments, the use of the term “can be” or “can have” or “can comprise,” respectively, etc. is to be understood as a synonym for “preferably is” or “preferably has” or “preferably comprises,” respectively, etc.
[0009] The term “balancing” or “balancing process,” respectively, as used herein is, in one embodiment, to be understood as a comparison of masses and/or volumes of medical fluids supplied to or drawn from a patient or a treatment apparatus for treating the patient.
[0010] The term “patient” as used herein refers to a human or an animal, independently from being ill or healthy.
[0011] In the sense of the present invention, a “balancing chamber” refers to a unit or device, respectively, provided or intended to receive the medical fluids—or portions thereof—intended for balancing in an interior or inner volume, respectively.
[0012] In one embodiment according to the present invention, the balancing chamber is a chamber that is separated in at least two balancing chamber compartments or sections by means of at least one separating plate or membrane that can be designed displaceable or flexible. At least one of the balancing chamber compartments or sections can be provided or intended to receive supplied or fresh, respectively, medical fluids. At least one further balancing chamber compartment or one further balancing chamber section can be provided or intended to receive discharged or used, respectively, medical fluids.
[0013] The balancing unit can comprise more than one balancing chamber, i.e., e.g., two, three, four or more balancing chambers.
[0014] Several, e.g., two, balancing chambers can, for example, advantageously be used for ensuring a continuous flow of the medical fluids during the balancing process.
[0015] The balancing chambers can be in fluid communication or not. The balancing chambers can be fillable and/or dischargeable in common or separately.
[0016] Each balancing chamber can comprise (one or more) supply lines for supplied or fresh medical fluids and (one or more) drain lines connected with an outlet for discharged or used medical fluids. Shut-off valves may be arranged in the supply and/or drain lines.
[0017] Examples of such shut-off valves include actuators that can be retracted from and/or pushed into a part of a machine, such as a treatment apparatus. By means of these actuators, it can be possible to prevent or release a fluid flow within a fluid system of the medical fluids. Such actuators include actuators referred to as “phantom valves” as described in Application No. DE 10 2009 024 468.9, filed by the applicant of the present application in the Federal Republic of Germany on Jun. 10, 2009 and having the title “ Externe Funktionseinrichtung, Blutbehandlungsvorrichtung zum Aufnehmen einer erfindungsgemäβen externen Funktionseinrichtung, sowie Verfahren, ” which is expressly incorporated herein in its entirety by reference thereto.
[0018] Examples of balancing chambers according to one embodiment of the balancing unit of the present invention as well as their respective function are disclosed in the afore-mentioned European Patent No. EP 0 867 195 B1, filed by the applicant of the present invention and which is expressly incorporated herein in its entirety by reference thereto.
[0019] The conveying unit can be part of a fluid system in which the medical fluid is present or contained, respectively. The conveying unit can be built-in or switched into, respectively, the fluid system, e.g., for conveying the medical fluid. In or during its use, the conveying unit can be flowed through by the medical fluid to be balanced.
[0020] The fluid system can comprise lines, tubings, tubing systems, channels, chambers, indentations, units or devices, respectively, or spaces or areas for storing or retaining fluids as well as controlling devices for controlling or regulating a through-flow of the fluids, and the like.
[0021] In certain embodiments, the fluid system is provided for a dialyzing liquid.
[0022] In certain embodiments, the fluid system is provided for blood in an extracorporeal blood circuit or other fluids. Such other fluids comprise a citrate and/or calcium solution, water or a hydraulic liquid.
[0023] The pressure present in the balancing chamber upon filling is in the following referred to as filling pressure. It can be changeable. It can be increasing. It can have different values at different points of time.
[0024] In one embodiment, a maximum filling pressure of the balancing unit according to the present invention can be set by means of an adjusted rotation speed of the conveying unit. The maximum filling pressure can be predetermined by means of the characteristic curve of the conveying unit, e.g., a characteristic curve of a pump.
[0025] In one embodiment, the flow and/or the conveying pressure of the conveying unit is measured by using appropriate measuring units. Corresponding measuring units may be configured and provided therefor.
[0026] The maximum filling pressure for filling the balancing chamber of the balancing unit can be predetermined. In one embodiment according to the present invention, the maximum filling pressure can be set or is set, respectively, by changing the operating parameters of the conveying unit (e.g., by influencing the rotation speed of a pump).
[0027] In a further embodiment according to the present invention, the operating parameters of the conveying unit can be set or are set, respectively, (e.g., by influencing the rotation speed of a pump) by changing a magnetic field.
[0028] In one embodiment, the maximum filling pressure—after having been reached—can be maintained constant by the conveying unit for a certain time or can, in another embodiment, drop. This can happen depending on the preload.
[0029] The maximum filling pressure can, for example, be reached when the balancing chamber is substantially or completely filled by the one or more medical fluids to be balanced.
[0030] The maximum filling pressure can also be reached when a balancing chamber compartment or a balancing chamber section has been substantially or completely filled by operating the conveying unit.
[0031] In one embodiment of the balancing unit according to the present invention, the “pressure controlled conveying unit” or the “pressure limited conveying unit,” respectively, is a conveying unit that does not build up any higher pressure within the balancing chamber after having reached a maximum pressure or filling pressure.
[0032] In another embodiment of the balancing unit according to the present invention, the “pressure controlled conveying unit” or the “pressure limited conveying unit” is a pump, the impeller of which is overflowed by the fluid conveyed upon reaching the maximum filling pressure.
[0033] In a further embodiment of the balancing unit according to the present invention, the “pressure controlled conveying unit” is a conveying unit which can, in at least one operating state, be operated as a constant-pressure source or as a pressure source having a constant or approximately constant pressure.
[0034] In a further embodiment of the balancing unit according to the present invention, the “pressure controlled conveying unit” is a conveying unit comprising or consisting of at least one pump, wherein the pump does not comprise or is not functionally connected with any overflow valves and/or bypass lines.
[0035] In a further embodiment of the balancing unit according to the present invention, the “pressure controlled conveying unit” is a conveying unit which is not connected with a control unit for the purpose of controlling or limiting, respectively, the pressure of the conveying unit depending on the filling pressure present in a balancing chamber during filling the said balancing chamber and/or which does not comprise a control unit that is provided or intended for this purpose and configured correspondingly.
[0036] In a further embodiment of the balancing unit according to the present invention, the “pressure controlled conveying unit” is a pump that—due to its design or construction, respectively,—does not build up a pressure above a predetermined pressure—here the filling pressure. In at least one embodiment of the balancing unit according to the present invention, it is herein not—directly or indirectly, respectively,—assisted or supported, respectively, by any further elements or components, in particular no control unit, no switching mechanism, no valves, no bypass gauge pressure valves, no pressure measuring units, and the like.
[0037] If the balancing chamber filled by the conveying unit can be assumed to be a volume-fixed chamber after having reached a maximum pressure or filling pressure set by means of the machine, the conveying unit is called a “pressure controlled conveying unit” as is the case in one embodiment according to the present invention.
[0038] In one embodiment according to the present invention, the balancing unit comprises several conveying units.
[0039] In one embodiment according to the present invention, the balancing unit does not comprise any overflow valves, bypass lines, control units, switching mechanisms, valves, bypass gauge pressure valves, pressure measuring units, and the like, that are suited and provided or intended or configured for limiting the conveying pressure of the conveying unit.
[0040] In one embodiment according to the present invention, the balancing unit does not comprise a roller pump or a gear pump comprising a bypass valve and/or a pressure regulation.
[0041] If the balancing unit according to the present invention comprises several conveying units, the said conveying units could, in one embodiment, be designed in the same manner or differently.
[0042] In one embodiment according to the present invention of the balancing unit, the said balancing unit comprises several conveying units connected in series. In this way, it can advantageously be possible to disburden or unload, respectively, the balancing chamber in a controlled manner.
[0043] In one embodiment according to the present invention of the balancing unit, the single conveying units are arranged for running or being operated, respectively, in the same direction of conveyance or for conveying in the same direction, respectively.
[0044] In one embodiment according to the present invention, the conveying units run in different directions or convey in opposite directions, respectively. Hereby, it can advantageously be possible to build up pressure in a targeted manner and/or to limit the volume flow of the medical fluids. This can advantageously contribute to further reducing the forces acting on the balancing chamber. In particular, it can advantageously be possible to reduce or to even minimize the forces acting on the balancing chamber and the walls thereof.
[0045] In one embodiment according to the present invention, at least two conveying units run or convey, respectively, in the same direction. Hereby, it can advantageously be possible to reduce pressure in a targeted manner. This may also advantageously contribute to further reducing the forces acting on the balancing chamber (unloading the chamber). In particular, it can advantageously be possible to reduce or to even minimize the forces acting on the balancing chamber and the walls thereof.
[0046] In a further embodiment of the balancing unit according to the present invention, the “pressure controlled conveying unit” is a centrifugal pump, a pressure source, a membrane pump or a rotary pump.
[0047] In one embodiment, a “centrifugal pump” or a rotary pump can advantageously provide a high volume flow at low pressures and/or a low volume flow at high pressures.
[0048] In one embodiment according to the present invention, the centrifugal pump is an axial pump having the advantages known to a person skilled in the art in connection with axial pumps.
[0049] In a further embodiment according to the present invention, the centrifugal pump is a radial pump or a diagonal pump having the advantages known to a person skilled in the art in connection with radial pumps or diagonal pumps, respectively.
[0050] The maximum pressure of the centrifugal pump—and thus the maximum filling pressure—can be set by the rotation speed, e.g., by means of rotation speed control, such that the maximum pressure load on the entire system can advantageously be defined (highly) exactly.
[0051] The centrifugal pump can have the characteristic that an overflow of the impeller or of the rotational section, respectively, occurs above a certain fluid pressure, e.g., when the balancing chamber is completely filled. This overflow can result in a pressure control in the fluid conveyed such that the centrifugal pump operates in a pressure controlled manner in the sense of the present invention.
[0052] For achieving the pressure control the centrifugal pump does, in one embodiment, advantageously not require any assistance by further components, such as a control unit, a regulation unit, valves, etc.
[0053] According to the present invention, a pressure source is understood to be any fluid conveying apparatus the initial fluid pressure of which is constant or substantially constant.
[0054] By means of the incompressible pumped liquid or a corresponding fluid, the membrane pump generates exactly the pressure in the liquid or the fluid with which the membrane is operated or actuated, respectively (e.g., mechanically, electromagnetically, pneumatically or hydraulically). Thus, in a further embodiment of the present invention, a membrane pump is to be considered as a pressure source, in particular as a pressure controlled conveying unit.
[0055] In a further preferred embodiment, the conveying unit comprises at least one rotating section or rotational section, respectively. In one embodiment according to the present invention, the latter is supported by a mechanical bearing; in another embodiment, it is supported by a magnetic bearing.
[0056] The rotational section can exclusively or additionally be supported magnetically.
[0057] The rotational section can be arranged in an interior of the conveying unit.
[0058] In or during its use, the rotational section can be completely flushed by the medical fluids flowing through the conveying unit.
[0059] In one embodiment, the rotational section is an impeller or a rotor.
[0060] In a further embodiment, the conveying unit comprises at least one rotational section intended and designed for being actuated or operated magnetically by means of an external actuation or by means of an electrical field.
[0061] In a further embodiment, the external actuation of the rotational section is designed to be operated mechanically, e.g., by means of releasable fluid-tight couplings.
[0062] The term “external actuation” as used herein refers to an actuation for the rotational section that can be but does not have to be part of the balancing unit.
[0063] The external actuation can be arranged at an apparatus interacting with a balancing unit according to the present invention, such as a treatment apparatus. The external actuation can be part of the apparatus.
[0064] The magnetic driving or propelling, respectively, force or effect can by achieved by using one or more magnets. It can be achieved by using current-carrying conductors or live conductors, respectively. For example, live coils can be used.
[0065] In one embodiment according to the present invention of the balancing unit, the conveying unit is a magnetically supported centrifugal pump such as, for example, that described in European Patent Application No. EP 0 900 572 A1.
[0066] Such a magnetically supported centrifugal pump can—like every other magnetically supported conveying unit in the sense of the present invention—offer the advantage that a mechanical and/or electrical interface to the machine is not required and/or fluids do not have to be transferred from the machine or the treatment apparatus, respectively, to the pump.
[0067] In a further preferred embodiment, the medical fluid is selected from dialyzing liquid, blood, substituate liquid, drugs, drug preparations as well as mixtures or combinations thereof.
[0068] In one embodiment according to the present invention, in particular, balancing on the dialysate side during a dialysis is envisaged.
[0069] In one embodiment according to the present invention, balancing on the blood side during a dialysis is envisaged.
[0070] Further fluids that may be of interest and/or required for a balancing process in connection with a blood treatment of a patient include solutions or metabolites of the patient present in a solved form, such as, for example, substances obligatory excreted by urine, and the like.
[0071] In a further preferred embodiment, at least one first conveying unit is provided for conveying in a first direction. Further, there is provided at least one second conveying unit for conveying in a second direction opposite to the first direction.
[0072] The object of the present invention is further solved by an external medical functional unit. All advantages achievable by means of the balancing unit according to the present invention can in certain embodiments undiminishedly also be obtained by means of the external medical functional unit according to the present invention that comprises at least one balancing unit according to the present invention.
[0073] In one embodiment of the present invention, the external medical functional unit is embodied or designed as an external liquid circuit having a dialysate and an extracorporeal blood circuit or as a blood or dialysate cassette, respectively, or as a combined blood/dialysate cassette. The external medical functional unit may, e.g., be a blood or dialysate cassette, respectively, or a combined blood/dialysate cassette for dialysis.
[0074] In one embodiment according to the present invention, the external medical functional unit is a disposable unit, a single use article or a one-use product.
[0075] In one embodiment according to the present invention, the external medical functional unit is a disposable cassette.
[0076] The disposable cassette can be a solid or hard part. It can be made from a plastic material. The disposable cassette can be manufactured by using an injection molding method.
[0077] The object of the present invention is further solved by means of a treatment apparatus. All advantages achievable by means of the balancing unit according to the present invention can in certain embodiments undiminishedly also be obtained by means of the treatment apparatus according to the present invention.
[0078] The treatment apparatus according to the present invention is suited for treating medical fluids. It is designed to operate at least one balancing unit according to the present invention.
[0079] At least for this purpose, the treatment apparatus can comprise a control unit. The control unit can be or comprise a microprocessor.
[0080] In one preferred embodiment of the treatment apparatus according to the present invention, the treatment apparatus comprises a unit or device, respectively, provided or intended and configured for actuating the conveying unit of the balancing unit via a magnetic actuation interface.
[0081] The device or unit can, for example, be or comprise a magnet or a magnetic system and/or a live conductor such as, for example, one or more live coils.
[0082] The treatment apparatus can be connected functionally with a balancing unit according to the present invention and/or with an external medical functional unit according to the present invention.
[0083] In one embodiment according to the present invention, the treatment apparatus according to the present invention comprises at least one balancing unit according to the present invention.
[0084] In one embodiment according to the present invention, the treatment apparatus according to the present invention is firmly connected with the balancing unit according to the present invention.
[0085] In one embodiment according to the present invention, a repeated use of the firmly connected balancing unit according to the present invention is envisaged.
[0086] In one embodiment according to the present invention, the treatment apparatus according to the present invention is a hemodialysis device.
[0087] In certain embodiments, the treatment apparatus furthermore comprises further devices or units or is intended to be coupled therewith. Among those are, for example, an extracorporeal blood circuit, control devices for controlling the performance of a medical treatment, devices for monitoring and/or displaying a balancing process of the medical fluids used and/or circulated during a medical treatment, devices for displaying or representing states and/or parameters of the medical treatment or of the balancing process, such as screens, and the like, devices for operating or actuating, respectively, or controlling one or more components of the treatment apparatus, such as keypads, and the like, in order to, e.g., prompt the performance of a medical treatment, and the like.
[0088] In one embodiment according to the present invention, the treatment apparatus is a blood treatment apparatus.
[0089] Examples of blood treatment methods include dialysis methods such as a hemodialysis, in particular by using ultrafiltration, a hemodiafiltration, a peritoneal dialysis, an automatic peritoneal dialysis, and the like. For performing those methods, the blood treatment device can be designed or embodied correspondingly.
[0090] Finally, the balancing unit according to the present invention can be advantageously used in a peritoneal dialysis for determining the volume of the dialysis liquid that is directed into the peritoneal space of the patient and/or conveyed out of the patient therefrom. Thereby, for example, both balancing chamber compartments of a divided or bifid balancing chamber of the balancing unit can mutually be filled with fresh dialysis liquid (upon entrance of the dialysis liquid into the patient's abdomen) and/or with used dialysis liquid (upon removal of the dialysis liquid out of the patient's abdomen). The volumes and/or masses of the medical fluids, e.g., of the dialysis liquid, that are of interest during a balancing process can thereby, for example, be determined by the number of fillings of the balancing chamber.
[0091] The object of the present invention is further solved by a method. All advantages achievable by means of the balancing unit according to the present invention can undiminishedly also be obtained by the methods according to the present invention.
[0092] A method according to the present invention comprises balancing at least one medical fluid by using at least one balancing unit according to the present invention or at least one external medical functional unit according to the present invention or at least one treatment apparatus according to the present invention.
[0093] A method according to the present invention comprises filling a balancing chamber by means of at least one conveying unit and operating the conveying unit in at least one operating state as a constant-pressure source.
[0094] In order to operate the conveying unit in the desired operating state as a constant-pressure source, a certain rotation speed of the conveying unit can be set at which a fixed or definite, respectively, or predetermined pressure difference can be set in the conveying unit.
[0095] The present invention proposes a balancing unit in which the conveying unit can be operated as a constant-pressure source after filling the balancing chamber(s).
[0096] The constant-pressure source can advantageously contribute to ensuring a maximum filling pressure within the balancing chamber. The constructional requirements for the balancing chamber can thus be low.
[0097] Generally, the accuracy of a balancing process can primarily depend on the pressure variations between two filling procedures. This may result from the fact that the switching process for terminating a filling process is subject to minor variations and that the filling pressure or the pressure inside the chamber significantly increases at the end of the filling process.
[0098] Furthermore, it is known that a balancing chamber is usually not stable towards pressure. For this reason, its filling volume can change.
[0099] As the medical fluids introduced into the balancing chamber by means of the conveying unit can displace the fluids present in the balancing chamber to the same degree or with the same speed or rate, respectively, it can advantageously be possible to reach a constant or uniform mass and/or volume flow of the fluids to be balanced.
[0100] As a pressure difference for operating the balancing chamber can be set in an advantageously simple manner by means of the rotation speed and/or the maximum conveying pressure of the conveying unit, the pressure controlled conveying unit can set an advantageously precisely adjustable (also dynamically adjustable) balancing chamber pressure while balancing the medical fluids.
[0101] An adverse pressure increase and/or pressure variations of the balancing chamber can thus advantageously be prevented. An undesired volume expansion or change of the balancing chamber can thus advantageously be prevented.
[0102] In this way, it can advantageously be possible to improve a mass and/or volume accuracy of a balancing process.
[0103] This can, for example, also advantageously contribute to exactly determining the fluid volume that is drawn from a patient during a treatment, e.g., ultrafiltration during a dialysis treatment, via the dialysis filter membrane, and/or to set the said fluid volume onto the rate desired by the attending physician. The safety and optionally also the tolerance of a blood treatment can thus advantageously be further improved.
[0104] Thus, it can advantageously be possible to prevent an incorrect balancing wherein an incorrect balancing can add up, e.g., in the course of a blood treatment session. If the balancing influences the treatment performed, the balancing accuracy improved by means of the balancing unit according to the present invention in at least one embodiment can advantageously result in an improved and/or safer treatment, e.g., by setting the ultrafiltration rate in a more adequate manner.
[0105] The balancing chamber of the balancing unit according to the present invention can advantageously be used as a pressure controlled volumetric balancing chamber having sufficient stability.
[0106] Technically complex constructions such as strut members or reinforced plastic materials or the like, with which a sufficient stability has to be ensured in the state of the art, can advantageously be omitted when using the balancing unit according to the present invention. The construction of the balancing unit according to the present invention can thus advantageously be simplified due to the pressure control provided by means of the conveying unit.
[0107] Supporting walls of the balancing chamber at fixed structures of the treatment apparatus is not required. The usability of the balancing unit has thus become broader without losing its functional accuracy.
[0108] Additionally, the conveying unit in the balancing unit according to the present invention can advantageously do without using sensors and/or overflow valves and/or bypass gauge pressure valves, in particular for the purpose of limiting the pressure in an interior of the balancing chamber, and the like. Thus, it can further advantageously be possible to simplify operating the balancing unit. The conveying unit may be designed more simply.
[0109] In this way, the dimensions of the balancing unit or the required space for the balancing unit, respectively, can advantageously be kept small.
[0110] Due to the magnetic support of the conveying unit, the construction of the conveying unit can advantageously be simplified. Thus, it can advantageously be possible to omit mechanical components such as bearings and the like and to thus advantageously ensure little wear of the components and/or little abrasive wear. This advantageously allows avoiding or reducing a heating of the conveying unit or of the balancing unit.
[0111] Moreover, the conveying unit of the balancing unit according to the present invention can advantageously comprise little disposition for cavitation.
[0112] Another advantage can be only little noise development upon using the balancing unit according to the present invention.
[0113] Because the pressure of the conveying unit does not increase even with an ongoing volume flow after terminating the filling of the balancing chamber, it can advantageously be avoided having to shut down the conveying unit in case of a full, i.e. substantially or completely filled, balancing chamber. Thus, a fluid, e.g., flowing through the centrifugal pump, can overflow a rotational section of the centrifugal pump. In this way, a good rinseability (and flushability) of the conveying unit can be ensured with a directed flow within the space of the centrifugal pump in which fluid flows.
[0114] The magnetic actuation interface for operating the conveying unit or a rotational section thereof, respectively, can advantageously provide a contactless and/or seal-free actuation of the conveying unit. In this way, it can advantageously be possible to omit open interfaces between the balancing unit and the treatment apparatus.
[0115] It can thus advantageously be possible to ensure a particular safe operation of the balancing unit. An—albeit only extremely small—contamination risk of the medical fluids can thus advantageously be reduced and even completely excluded.
[0116] The balancing unit according to the present invention can advantageously be used as a disposable unit, i.e. as a one-way article for single use. As the conveying unit can be provided as an integral component of the disposable unit, it can be discarded together with the disposable unit such that the safety and the hygiene of a medical treatment can advantageously be further improved.
[0117] The use of centrifugal pumps has in certain embodiments the advantage of an inherent pressure control in case of an occlusion downstream the pump as compared to pressure-regulated peristaltic hose pumps, toothed gear pumps or peristaltic pumps. The pressure built up there can be adjusted by the rotation speed in a simple manner. A pressure-regulated peristaltic hose pump requires at least one pressure sensor comprising a control circuit; a peristaltic hose pump comprising a gauge pressure bypass valve has to be exactly calibrated to the allowed pressure. Thus, by using centrifugal pumps, the balancing unit according to the present invention is in certain embodiments less complex.
[0118] Exemplary embodiments of the present invention will be described with respect to the accompanying drawings. In the drawings, the same reference numerals denote same or identical elements or components, respectively.
BRIEF DESCRIPTION OF THE DRAWINGS
[0119] FIG. 1 shows an exemplary balancing unit according to the present invention during a first cycle in a schematically simplified manner.
[0120] FIG. 2 shows an exemplary pressure curve plotted against the time during filling a balancing chamber.
[0121] FIG. 3 shows an exemplary pressure difference between the pump outlet and the pump inlet of a centrifugal pump plotted against the volume flow.
[0122] FIG. 4 shows the exemplary balancing unit according to the present invention of FIG. 1 during a second cycle in a schematically simplified manner.
[0123] FIG. 5 shows the exemplary balancing unit according to the present invention of FIG. 1 , comprising two further centrifugal pumps downstream the balancing chamber in a schematically simplified manner.
[0124] FIG. 6 shows the exemplary balancing unit according to the present invention comprising the balancing chamber, valves, and centrifugal pumps in a schematically simplified manner, wherein one of the centrifugal pumps arranged downstream rotates in another direction.
[0125] FIG. 7 shows an exemplary centrifugal pump comprising a magnetic support and a magnetic actuation in a schematically simplified manner.
[0126] FIG. 8 shows an exemplary treatment apparatus according to the present invention comprising a balancing unit and an external medical functional unit in a schematically simplified manner.
[0127] FIG. 9 shows an exemplary balancing unit according to the present invention in a further embodiment during a first cycle in a schematically simplified manner.
DETAILED DESCRIPTION
[0128] In the following, the balancing unit is exemplarily described as a part of a blood treatment apparatus for dialysis. It is intended to balance the dialysis liquid supplied to and drawn from a patient. However, it can in principle also be envisaged to balance the patient's blood.
[0129] FIG. 1 shows an exemplary balancing unit 100 according to the present invention comprising a balancing chamber 1 .
[0130] As shown in FIG. 1 , the balancing chamber 1 is separated or divided into a first balancing chamber compartment 3 a and into a second balancing chamber compartment 3 b. However, the balancing chamber does in principle not have to be divided in two balancing chamber compartments having substantially or completely the same size.
[0131] The first balancing chamber compartment 3 a is separated from the second balancing chamber compartment 3 b by means of a fluid-tight membrane 5 .
[0132] The first balancing chamber compartment 3 a is filled with a flow 7 a of a dialysis liquid via a tubing 9 a. A valve 11 a is thereby present in an opened position by means of a controlling unit 13 a.
[0133] The conveying unit can be a centrifugal pump. As shown in FIG. 1 , the first chamber compartment 3 a is filled by means of a centrifugal pump 15 a.
[0134] The valve 11 a can be designed as a tubing clamp (or generally as a squeezing mechanism). Such a tubing clamp can be opened and closed by means of an electrically controlled actuation. This has the advantage that the medical fluid substantially only contacts the tubing 9 a, but, however, does not contact parts of the valve 11 a or of the controlling unit 13 a. This can advantageously contribute to reducing a contamination risk of the medical fluids.
[0135] A second flow 7 b of the dialysis liquid is discharged out of the second balancing chamber compartment 3 b via a tubing 9 b. A valve 11 b is thereby also present in an opened position, mediated by means of a controlling unit 13 b.
[0136] The second balancing chamber compartment 3 b can be emptied. Discharging or draining dialysis liquid out of the second balancing chamber compartment 3 b can be effected at the same time as supplying or introducing dialysis liquid into the first balancing chamber compartment 3 a.
[0137] As shown in FIG. 1 , valves 11 c and 11 d are each closed by means of the corresponding controlling units 13 c and 13 d. There is no fluid conveyed in tubings 9 c and 9 d.
[0138] FIG. 2 shows a diagram representing an exemplary pressure curve or course 17 during filling a balancing chamber plotted against the time.
[0139] An initial pressure at t=0 corresponds to a pressure with which in FIG. 1 —which is in the following also referred to—the flow 7 a of the dialysis liquid is introduced into the first balancing chamber compartment 3 a via the tubing 9 a after opening the valve 11 a. In order to allow discharging flow 7 b of the dialysis liquid via tubing 9 b out of the second balancing chamber compartment 3 b, valve 11 b should be opened.
[0140] While the first balancing chamber compartment 3 a is filled and the second balancing chamber compartment 3 b is emptied, the pressure in the balancing chamber drops at first.
[0141] When the first balancing chamber compartment 3 a has been filled, the pressure rises. A final pressure 18 corresponding to the end point of the pressure course 17 during filling of the balancing chamber and thus corresponding to the maximum filling pressure can depend on the pressure applied by the centrifugal pump 15 a. This pressure can in turn depend on several parameters of the centrifugal pump, for example, on the construction principle of the centrifugal pump (radial pump, axial pump, diagonal pump, impeller shape, impeller diameter, etc.) and/or the set rotation speed of the centrifugal pump 15 a and thus the set operating point. Moreover, the final pressure can depend on the preload of the centrifugal pump 15 a, i.e., the pressure present at a dialysate inlet of the centrifugal pump 15 a.
[0142] FIG. 3 shows a diagram comprising an exemplary pressure difference ΔP between the pump outlet and the pump inlet of a centrifugal pump 15 a (ordinate) plotted against the volume flow Q of the medical fluids (abscissa).
[0143] At a characteristic curve 19 of an ideal pressure source which is indicated for comparison, the pressure difference ΔP is independent from the volume flow Q. The amount or extent, respectively, of the pressure difference ΔP depends, inter alia, on the set rotation speed of a centrifugal pump.
[0144] The actual pressure courses (ΔP, Q) usually divert from the ideal characteristic curve. A possible pressure course of a characteristic curve for a pressure controlled conveying unit such as the centrifugal pump 15 a of the balancing unit 100 according the present invention of FIG. 1 is shown by characteristic curve 21 of a centrifugal pump. It can be recognized that a good approximation of the pressure course to the ideal characteristic curve can be obtained by means of the centrifugal pump 15 a. FIG. 3 also shows that the centrifugal pump 15 a can be understood as a pressure controlled conveying unit in the sense of the present invention: Despite an increase of a volume flow, the pump outlet pressure does not increase anymore after having reached a certain pressure level.
[0145] FIG. 4 shows the exemplary balancing unit 100 of FIG. 1 during a second cycle. The second cycle can follow the first cycle according to FIG. 1 .
[0146] In the second cycle of a centrifugal pump 15 c, a flow 7 c of dialysis liquid is conveyed into the second chamber compartment 3 b via the tubing 9 c. At the same time, a flow 7 d of dialysis liquid is removed from the first chamber compartment 3 a.
[0147] FIG. 5 shows the exemplary balancing unit 100 of FIG. 1 comprising two additional centrifugal pumps 15 b and 15 d downstream the balancing chamber 1 .
[0148] All centrifugal pumps 15 a - d arranged in the balancing unit 100 according to the present invention of FIG. 5 convey in the same direction of conveyance as indicated by the arrow of the pump heads pointing to the left (related to the representation of FIG. 5 ).
[0149] By means of the centrifugal pumps 15 b and 15 d arranged downstream, emptying the two chamber compartments 3 a and 3 b can be supported. This can be advantageous in order to, for example, reduce or keep low a maximum pressure (see end point 18 of the curve of the pressure course in FIG. 2 ) in the balancing chamber 1 . Low pressures in the balancing chamber 1 can in turn advantageously contribute to simplifying the construction (such as, e.g., a lower stiffness, lower material thicknesses, etc.) of the balancing unit 100 as stated above. The latter could in particular be advantageous if the balancing unit 100 is embodied as a part of a disposable unit.
[0150] FIG. 6 shows the exemplary balancing unit 100 comprising the balancing chamber 1 similarly to FIG. 5 , however, with the difference that the centrifugal pump 15 b is provided or intended and configured for also running in another direction or conveying in the opposite direction, respectively, as indicated by means of the arrow of the pump head pointing to the left (related to the representation of FIG. 6 ).
[0151] When running in the opposite direction of rotation, the centrifugal pump 15 b operates as a pressure reducer, in particular as an adjustable pressure reducer.
[0152] In the embodiment of FIG. 6 , inlet and outlet of the centrifugal pump 15 b can be interchanged.
[0153] “Interchanging” inlet and outlet can be effected in different ways. Examples hereof are reversely inserting the centrifugal pump, providing valves correspondingly arranged and controlled, and the like.
[0154] Valves correspondingly arranged and controlled can be preferably operated by means of actuators of a dialysis machine across a flexible membrane, e.g., by squeezing and/or releasing the relevant fluid paths.
[0155] A reversion of the direction can be intended additionally or alternatively. The conveying units contemplated can be provided or intended and configured to be operated in one direction or in two directions opposite to each other.
[0156] FIG. 7 shows an exemplary centrifugal pump 15 a comprising an impeller 25 as a rotational section, a rotor 27 , coils 29 and a stator 31 . The centrifugal pump 15 a comprises a housing 32 having an inlet and an outlet (recognizable in FIG. 1 by means of arrows).
[0157] The centrifugal pump 15 a is flowed through in the flow direction shown. The actuation of the impeller 25 is performed by means of a circumferential electromagnetic field generated by controlling the coils 29 of the stator 31 .
[0158] Impeller magnets or at least ferromagnetic materials can be integrated into the impeller 25 .
[0159] The support of the impeller 25 can then, on the one hand, be carried out by means of the impeller magnets and, on the other hand, by means of magnets provided outside the centrifugal pump. The magnets can be arranged circumferentially in the same movement of rotation as the impeller 25 . Instead of the circumferential magnets or in addition hereto, also a circumferential electromagnetic field in a coil arrangement can support impeller 25 or fixate the said impeller 25 in a stable circumferential position, respectively. Though not shown in the figures, this embodiment is encompassed by the present invention as well.
[0160] FIG. 8 shows a balancing unit 100 according to the present invention and an exemplary treatment apparatus 300 according to the present invention comprising a dialyzer 33 comprising a blood inlet 33 a and a blood outlet 33 b as well as further elements or components, respectively, in a schematically simplified manner.
[0161] On the basis of FIG. 1 , FIG. 9 shows an exemplary balancing unit according to the present invention of a further embodiment during a first cycle in a schematically simplified manner. It can be recognized that the centrifugal pump 15 b conveys in a direction opposite to the direction of conveyance of the centrifugal pump 15 a. By means of the conveying units pumping in directions opposite to each other of this embodiment, a too high initial pressure can advantageously be prevented or reduced. This can be the case when the dialysate is produced from RO water (reverse osmosis water) and concentrates. In doing so, the RO water supply can have such a high line pressure that the balancing unit could be damaged thereby. | A balancing unit for medical fluids includes at least one balancing chamber and at least one conveying unit for filling the balancing chamber, in which the conveying unit is a pressure controlled conveying unit and/or is designed and provided for being operated in at least one operating state as a constant-pressure source. An external medical functional unit, a treatment apparatus and methods are also described. | 0 |
RELATED PATENT APPLICATIONS
This application is a Continuation-In-Part of prior U.S. patent application Ser. No. 10/868,745, filed Jun. 9, 2004, now U.S. Pat. No. 7,150,320 which was a Continuation-In-Part of prior U.S. patent application Ser. No. 10/307,250, filed Nov. 30, 2002, now U.S. Pat. No. 7,077,201 which was a Continuation-In-Part of prior U.S. patent application Ser. No. 09/566,622, filed May 8, 2000, now U.S. Pat. No. 6,733,636B1 issued May 11, 2004, entitled WATER TREATMENT METHOD FOR HEAVY OIL PRODUCTION, which claimed priority from prior U.S. Provisional Patent Application Ser. No. 60/133,172, filed on May 7, 1999. Also, this application claims priority from U.S. Provisional Patent Application Ser. No. 60/578,810, filed Jun. 9, 2004. The disclosures of each of the above identified patents or patent applications are incorporated herein in their entirety by this reference, including the specification, drawing, and claims of each patent or application.
COPYRIGHT RIGHTS IN THE DRAWING
A portion of the disclosure of this patent document contains material that is subject to copyright protection. The applicant no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever.
TECHNICAL FIELD
The invention disclosed and claimed herein relates to treatment of water to be used for steam generation in operations which utilize steam to recover oil from geological formations. More specifically, this invention relates to novel, improved techniques for efficiently and reliably generating from oil field produced waters, in high pressure steam generators, the necessary steam for down-hole use in heavy oil recovery operations.
BACKGROUND
Steam generation is necessary in heavy oil recovery operations. This is because in order to recover heavy oil from certain geologic formations, steam is required to increase the mobility of the sought after oil within the formation. In prior art systems, oil producers have often utilized once-through type steam generators (“OTSG's). As generally utilized in the industry, once through steam generators—OTSG's—usually have high blowdown rates, often in the range of from about 20% to about 30% or thereabouts. Such a blowdown rate leads to significant thermal and chemical treatment inefficiencies. Also, once through steam generators are most commonly provided in a configuration and with process parameters so that steam is generated from a feedwater in a single-pass operation through boiler tubes that are heated by gas or oil burners. Typically, such once through steam generators operate at from about 1000 pounds per square inch gauge (psig) to about 1600 psig or so. In some cases, once through steam generators are operated at up to as much as about 1800 psig. Such OTSG's often operate with a feedwater that has from about 2000 mg/L to about 8000 mg/L of total dissolved solids. As noted in FIG. 1 , which depicts the process flow sheet of a typical prior art water treatment system 10 , such a once through steam generator 12 provides a low quality or wet steam, wherein about eighty percent (80%) quality steam is produced. In other words, the 80% quality steam 14 is about 80% vapor, and about 20% liquid, by weight percent. The steam portion, or high pressure steam produced in the steam generators is injected via steam injection wells 16 to fluidize as indicated by reference arrows 18 , along or in combination with other injectants, the heavy oil formation 20 , such as oils in tar sands formations. The injected steam 14 eventually condenses and an oil/water mixture 22 results, and which mixture migrates through the formation 20 as indicated by reference arrows 24 . The oil/water mixture 22 is gathered as indicated by reference arrows 26 by oil/water gathering wells 30 , through which the oil/water mixture is pumped to the surface. Then, the sought-after oil is sent to an oil/water separator 32 in which the oil product 34 separated from the water 35 and recovered for sale. The produced water stream 36 , after separation from the oil, is further de-oiled in a de-oiling process step 40 , normally by addition of a de-oiling polymer 42 or by other appropriate processes. Such a de-oiling process usually results in generation of an undesirable waste oil/solids sludge 44 . However, the de-oiled produced water stream 46 is then further treated for reuse.
The design and operation of the water treatment plant which treats the de-oiled produced water stream 46 , i.e., downstream of the de-oiling unit 40 and upstream of injection well 16 inlet 48 , is the key to the improvement(s) described herein.
Most commonly in prior art plants such as plant 10 , the water is sent to the “once-through” steam generators 12 for creation of more steam 14 for oil recovery operations. The treated produced water stream 12 F which is the feed stream for the once through steam generator, at time of feed to the steam generator 12 , is typically required to have less than about 8000 parts per million (“PPM”) of total dissolved solids (“TDS”). Less frequently, the treated produced water stream 12 F may have up to about 12000 parts per million (as CaCO3 equivalent) of total dissolved solids, as noted in FIG. 8 . Further, it is often necessary to meet other specific water treatment parameters before the water can be reused in such once-through steam generators 12 for the generation of high pressure steam.
In most prior art water treatment schemes, the de-oiled recovered water 46 must be treated in a costly water treatment plant sub-system 10 before it can be sent to the steam generators 12 . Treatment of water before feed to the once-through steam generators 12 is often initially accomplished by using a warm lime softener 50 , which removes hardness, and which also removes some silica from the de-oiled produced water feedstream 46 . Various softening chemicals 52 are usually necessary, such as lime, flocculating polymer, and perhaps soda ash. Underflow 56 produces a waste sludge 58 which must be further handled and disposed. Then, an “after-filter” 60 is often utilized on the clarate stream 59 to prevent carry-over of any precipitate or other suspended solids, which substances are thus accumulated in a filtrate waste stream 62 . For polishing, an ion exchange step 64 , normally including a hardness removal step such as a weak acid cation (WAC) ion-exchange system that can be utilized to simultaneously remove hardness and the alkalinity associated with the hardness, is utilized. The ion exchange systems 64 require regeneration chemicals 66 as is well understood by those of ordinary skill in the art and to which this disclosure is directed. As an example, however, a WAC ion exchange system is usually regenerated with hydrochloric acid and caustic, resulting in the creation of a regeneration waste stream 68 . Overall, such prior art water treatment plants are relatively simple, but, result in a multitude of liquid waste streams or solid waste sludges that must be further handled, with significant additional expense.
In one relatively new heavy oil recovery process, known as the steam assisted gravity drainage heavy oil recovery process (the “SAGD” process), it is preferred that one hundred percent (100%) quality steam be provided for injection into wells (i.e., no liquid water is to be provided with the steam to be injected into the formation). Such a typical prior art system 11 is depicted in FIG. 2 . However, given conventional prior art water treatment techniques as just discussed in connection with FIG. 1 , the 100% steam quality requirement presents a problem for the use of once through steam generators 12 in such a process. That is because in order to produce 100% quality steam 70 using a once-through type steam generator 12 , a vapor-liquid separator 72 is required to separate the liquid water from the steam. Then, the liquid blowdown 73 recovered from the separator is typically flashed several times in a series of flash tanks F 1 , F 2 , etc. through F N (where N is a positive integer equal to the number of flash tanks) to successively recover as series of lower pressure steam flows S 1 , S 2 , etc. which may sometimes be utilized for other plant heating purposes. After the last flashing stage F N , a residual hot water final blowdown stream 74 must then be handled, by recycle and/or disposal. The 100% quality steam is then sent down the injection well 16 and injected into the desired formation 20 . Fundamentally, though, conventional treatment processes for produced water used to generate steam in a once-through steam generator produces a boiler blowdown which is roughly twenty percent (20%) of the feedwater volume. This results in a waste brine stream that is about fivefold the concentration of the steam generator feedwater. Such waste brine stream must be disposed of by deep well injection, or if there is limited or no deep well capacity, by further concentrating the waste brine in a crystallizer or similar system which produces a dry solid for disposal.
As depicted in FIG. 3 , another method which has been proposed for generating the required 100% quality steam for use in the steam assisted gravity drainage process involves the use of boilers 80 , which may be packaged, factory built boilers of various types or field assembled boilers with mud and steam drums and water wall piping. Various methods can be used for producing water of a sufficient quality to be utilized as feedwater 80 F to a boiler 80 . One method which has been developed for use in heavy oil recovery operations involves de-oiling 40 of the produced water 36 , followed by a series of physical-chemical treatment steps. Such treatment steps normally include a series of unit operations as warm lime softening 54 , followed by filtration 60 for removal of residual particulates, then an organic trap 84 (normally non-ionic ion exchange resin) for removal of residual organics. The organic trap 84 may require a regenerant chemical supply 85 , and, in any case, produces a waste 86 , such as a regenerant waste. Then, a pre-coat filter 88 can be used, which has a precoat filtrate waste 89 . In one alternate embodiment, an ultrafiltration (“UF”) unit 90 can be utilized, which unit produces a reject waste stream 91 . Then, effluent from the UF unit 90 or precoat filter 88 can be sent to a reverse osmosis (“RO”) system 92 , which in addition to the desired permeate 94 , produces a reject liquid stream 96 that must be appropriately handled. Permeate 94 from the RO system 92 , can be sent to an ion exchange unit 100 , typically but not necessarily a mixed bed demineralization unit, which of course requires regeneration chemicals 102 and which consequently produces a regeneration waste 104 . And finally, the boiler 80 produces a blowdown 110 which must be accommodated for reuse or disposal.
The prior art process designs, such as depicted in FIG. 3 , for utilizing packaged boilers in heavy oil recovery operations, have a high initial capital cost. Also, such a series of unit process steps involves significant ongoing chemical costs. Moreover, there are many waste streams to discharge, involving a high and ongoing sludge disposal cost. Further, where membrane systems such as ultrafiltration 90 or reverse osmosis 92 are utilized, relatively frequent replacement of membranes 106 or 108 , respectively, may be expected, with accompanying on-going periodic replacement costs. Also, such a process scheme can be labor intensive to operate and to maintain.
In summary, the currently known and utilized methods for treating heavy oil field produced waters in order to generate high quality steam for down-hole use are not entirely satisfactory because:
such physical-chemical treatment process schemes are usually quite extensive, are relatively difficult to maintain, and require significant operator attention; such physical-chemical treatment processes require many chemical additives which must be obtained at considerable expense, and many of which require special attention for safe handling; such physical-chemical treatment processes produce substantial quantities of undesirable sludges and other waste streams, the disposal of which is increasingly difficult, due to stringent environmental and regulatory requirements.
It is clear that the development of a simpler, more cost effective approach to produced water treatment would be desirable in the process of producing steam in heavy oil production operations. Thus, it can be appreciated that it would be advantageous to provide a new produced water treatment process which minimizes the production of undesirable waste streams, while minimizing the overall costs of owning and operating a heavy oil recovery plant.
SOME OBJECTS, ADVANTAGES, AND NOVEL FEATURES
The new water treatment process(es) disclosed herein, and various embodiments thereof, can be applied to heavy oil production operations. Such embodiments are particularly advantageous in they minimize the generation of waste products, and are otherwise superior to water treatment processes heretofore used or proposed in the recovery of bitumen from tar sands or other heavy oil recovery operations.
From the foregoing, it will be apparent to the reader that one of the important and primary objectives resides in the provision of a novel process, including several variations thereof, for the treatment of produced waters, so that such waters can be re-used in producing steam for use in heavy oil recovery operations.
Another important objective is to simplify process plant flow sheets, i.e., minimize the number of unit processes required in a water treatment train, which importantly simplifies operations and improves quality control in the manufacture of high purity water for down-hole applications.
Other important but more specific objectives reside in the provision of various embodiments for an improved water treatment process for production of high purity water for down-hole use in heavy oil recovery, which embodiments may:
in one embodiment, eliminate the requirement for flash separation of the high pressure steam to be utilized downhole from residual hot pressurized liquids; eliminate the generation of softener sludges; minimize the production of undesirable liquid or solid waste streams; minimize operation and maintenance labor requirements; minimize maintenance materiel requirements; minimize chemical additives and associated handling requirements; increase reliability of the OTSG's, when used in the process; decouple the de-oiling operations from steam production operations; and reduce the initial capital cost of water treatment equipment.
Other important objectives, features, and additional advantages of the various embodiments of the novel process disclosed herein will become apparent to the reader from the foregoing and from the appended claims and the ensuing detailed description, as the discussion below proceeds in conjunction with examination of the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
In order to enable the reader to attain a more complete appreciation of the novel water treatment process disclosed and claimed herein, and the various embodiments thereof, and of the novel features and the advantages thereof over prior art processes, attention is directed to the following detailed description when considered in connection with the accompanying figures of the drawing, wherein:
FIG. 1 shows one typical prior art process, namely a generalized process flow diagram for a physical-chemical water treatment process configured for use in heavy oil recovery operations.
FIG. 2 shows another prior art process, namely a generalized process flow diagram for a physical-chemical water treatment process as used in a steam assisted gravity drainage (SAGD) type heavy oil operation.
FIG. 3 shows yet another prior art physical-chemical treatment process scheme, also as it might be applied for use in steam assisted gravity drainage (SAGD) type heavy oil recovery operations.
FIG. 4 shows one embodiment of an evaporation based water treatment process, illustrating the use of the evaporation based process in combination with the use of packaged boilers for steam production, as applied to heavy oil recovery operations.
FIG. 5 shows another embodiment for an evaporation based water treatment process for heavy oil production, illustrating the use of the process in combination with the use of once-through steam generators for steam production, as applied to heavy oil recovery operations, which process is characterized by feed of evaporator distillate to once-through steam generators without the necessity of further pretreatment.
FIG. 6 shows a common variation for the orientation of injection and gathering wells as utilized in heavy oil recovery, specifically showing the use of horizontal steam injection wells and of horizontal oil/water gathering wells, as often employed in a steam assisted gravity drainage heavy oil gathering project.
FIG. 7 shows the typical feedwater quality requirements for steam generators which produce steam in the 1000 pounds per square inch gauge range, or thereabouts, for conventional steam boiler installations.
FIG. 8 shows the typical feedwater quality requirements for steam generators which produce steam in the 1000 pounds per square inch gauge range, or thereabouts, for once-through type steam generator installations.
FIG. 9 provides a simplified view of a vertical tube falling film evaporator operating a high pH in the treatment of produced water from heavy oil operations, for production of distillate for reuse in once through steam generators or in conventional steam boilers.
FIG. 10 shows further details of the use of evaporators at high pH, illustrated by use of falling film evaporators, and indicates selected injection points for caustic injection to raise the pH of the concentrated brine to maintain solubility of silica in the concentrated brine.
FIG. 11 illustrates the solubility of silica in water as a function of pH at 25° C. when such silica species are in equilibrium with amorphous silica, as well as the nature of such soluble silica species (molecule or ion) at various concentration and pH ranges.
FIG. 12 diagrammatically illustrates functional internal details of the operation of a falling film evaporator, which evaporator type would be useful in the evaporation of produced waters from heavy oil production; details illustrated include the production of steam from a falling brine film, by a heat exchange relationship from condensation of steam on a heat exchange tube, and the downward flow of such steam condensate (distillate) by gravity for the collection of such condensate (distillate) above the bottom tube sheet of the evaporator.
The foregoing figures, being merely exemplary, contain various elements that may be present or omitted from actual process implementations depending upon the circumstances. An attempt has been made to draw the figures in a way that illustrates at least those elements that are significant for an understanding of the various embodiments and aspects of the invention. However, various other elements of the unique process methods, and the combination of apparatus for carrying out the methods, are also shown and briefly described to enable the reader to understand how various features, including optional or alternate features, may be utilized in order to provide an efficient, low cost process design which can be implemented in a desired throughput size and physical configuration for providing optimum water treatment plant design and operation.
DESCRIPTION
Many steam assisted heavy oil recovery schemes, such as a steam assisted gravity drainage (SAGD) heavy oil recovery process injection and recovery well arrangements of the type depicted in FIG. 6 , most efficiently utilize a 100% quality steam supply 70 . It would therefore be desirable to produce such a steam supply by an efficient process scheme such as I have found may be provided by evaporation based heavy oil produced water treatment method(s). Various embodiments and details of such evaporation based produced water treatment method(s) are depicted in FIGS. 4 , 5 , 6 , 9 , 10 and 12 .
As depicted in FIG. 6 , in a SAGD process, horizontal injection wells 16 ′ and horizontal oil/water gathering wells 30 ′ are advantageously utilized spaced apart within an oil bearing formation 20 . As particularly illustrated in FIGS. 4 and 5 , a process for the use of an evaporation based water treatment system 120 has been developed to treat produced water, in order to produce high quality steam for use in further heavy oil recovery. Conceptually, such an evaporative water treatment process may, in one embodiment, be situated process wise—that is, water flow wise—between the point of receipt of a de-oiled produced water stream 46 and the point of steam injection at well head 48 of injection well 16 . The process, in combination with the steam injection well 16 , oil recovery well 30 , and related oil water separation equipment 32 and de-oiling equipment 40 , and boilers 80 as shown in FIG. 4 , or alternately, once through steam generators 12 as shown in FIG. 5 , can substantially reduce capital costs and can minimize ongoing operation and maintenance costs of heavy oil recovery installations. Boilers 80 may be packaged, factory built boilers of various types or field assembled boilers with mud and steam drums and water wall piping, or more generally, conventional steam boilers. In some locales, such as northern Canada, the possibility of elimination of the need for handling of waste sludges and other waste streams made possible by the evaporation based, water treatment system 120 may be especially important, since it may be difficult to work with such waste materials during the extremely cold winter months.
It has been observed that it may be desirable in some instances to use a packaged boiler 80 to produce the required steam 70 , rather than to utilize a traditional once-through type steam generator 12 to produce 80% quality steam 14 and then utilize separator(s) 130 to separate steam 132 from liquid 134 . It is noteworthy in such an economic process evaluation that packaged boilers 80 are often less expensive on a capital cost basis and on an operating cost basis than once-through type oil-field steam generators 12 . Also, package boilers can be utilized to produce pure steam 70 , and thus produce only a minimal liquid blowdown stream 110 . Also, as shown in FIGS. 4 and 5 , boiler blowdown stream can be either sent to the evaporator feed tank 210 , or injected into the sump reservoir 152 of evaporator 140 , such as via line 111 , or into the recirculating brine via line 111 ′. One type of packaged boiler suitable for use in the process described herein is a water tube boiler having a lower mud drum and an upper steam drum and water cooled sidewalls substantially extending therebetween in a manner which encloses a combustion chamber. However, most such packaged boilers require a much higher quality feed water 80 F than is the case with requirements for feedwater 12 F for a once-through type steam generator. As a result, in one embodiment, the process disclosed herein includes an evaporation unit 140 based approach to packaged boiler 80 feedwater 80 F pretreatment. In other words, the de-oiled produced water 46 generated can be advantageously treated by an evaporative process operating at elevated pH, and provides a significantly improved method for produced water treatment in heavy oil production.
An oil/water mixture 22 is pumped up through oil gathering wells 30 . The oil water mixture 22 is sent to a series of oil/water separators 32 . An oil product 34 is gathered for further conditioning, transport, and sale. The produced water 36 which has been separated from the oil/water mixture 22 is then sent to a produced water de-oiling step 40 , which may be accomplished in dissolved air flotation units with the assistance of the addition of a de-oiling polymer 42 , or by other appropriate unit processes.
In the water treatment method disclosed herein, the de-oiled produced water 46 is treated and conditioned for feed to one or more mechanical vapor recompression evaporator units 140 (normally, multiple redundant units) to concentrate the incoming produced water stream 46 . The necessary treatment and conditioning prior to the evaporator unit 140 can be efficiently accomplished, but may vary somewhat based on feedwater chemistry—i.e. the identity and distribution of various dissolved and suspended solids—and on the degree of concentration selected for accomplishment in evaporator units 140 .
In the usual case, it may be necessary or appropriate to add a selected base such as caustic 232 via line 146 to the evaporator feed tank 210 , or by line 147 to a point upstream of the feedwater heat exchanger 148 , such as before the suction of pump 149 as seen in FIG. 10 , in order to avoid silica scaling in the feedwater deaerator 150 and the feed heat exchanger 148 . Moreover, feed of a selected base such as caustic 232 to the evaporator feed tank 210 via line 146 or to another point upstream of the feedwater heat exchanger 148 via line l 47 can be utilized to raise the pH of the concentrated brine recirculating in the evaporator 140 . Also, raising the pH of the concentrated brine recirculating in the evaporator can be accomplished by direct injection of a selected base such as caustic 232 into the sump 141 , as indicated by line 157 , or by feed of a selected base such as caustic 232 into the suction of recirculation pump 153 , as indicated by line 159 . Moreover, in one embodiment, it may be advantageous to use addition of a selected base such as caustic 232 to the feed tank 210 such as by line 146 as the primary method for raising the pH of the recirculating brine in the sump of the evaporator 140 to a desired pH level, and to use addition of a selected base such as caustic 232 to the evaporator sump 141 , such as by line 157 or line 159 , as a pH trim control to fine tune the pH of the brine 152 in sump 140 and thus of recirculating brine 162 . Also, the selected base such as caustic 232 can be added at an appropriate point upstream of the feed tank 210 when desired such as via line 146 ′.
At feedwater heat exchanger, the feedwater pump 149 is used to provide sufficient pressure to send feedwater from the evaporator feed tank 210 through the feedwater heat exchanger 148 , prior to the deaerator 150 . In the opposite direction, the distillate pump 143 moves distillate 180 through the feedwater heat exchanger 148 , so that the hot distillate is used to heat the feedwater stream directed toward the deaerator 150 .
The conditioned feedwater 151 is sent as feedwater to evaporator 140 . The conditioned feedwater 151 may be directed to the inlet of recirculation pump 153 , or alternately, directed to the sump 141 of evaporator 140 as indicated by broken line 151 ′ in FIG. 10 . Concentrated brine 152 in the evaporator 140 is recirculated via pump 153 , so only a small portion of the recirculating concentrated brine is removed on any one pass through the evaporator 140 . In the evaporator 140 , the solutes in the feedwater 46 are concentrated via removal of water from the feedwater 46 . As depicted in FIGS. 10 and 12 , an evaporator 140 is in one embodiment provided in a falling film configuration wherein a thin brine film 154 is provided by distributors 155 and then falls inside of a heat transfer element, e.g. tube 156 . A small portion of the water in the thin brine film 154 is extracted in the form of steam 160 , via heat given up from heated, compressed steam 162 which is condensing on the outside of heat transfer tubes 156 . Thus, the water is removed in the form of steam 160 , and that steam is compressed through the compressor 164 , and the compressed steam 162 is condensed at a heat exchange tube 156 in order to produce yet more steam 160 to continue the evaporation process. The condensing steam on the outer wall 168 of heat transfer tubes 156 , which those of ordinary skill in the evaporation arts and to which this disclosure is directed may variously refer to as either condensate or distillate 180 , is in relatively pure form, low in total dissolved solids. In one embodiment, such distillate contains less than 10 parts per million of total dissolved solids of non-volatile components. Since, as depicted in the embodiments shown in FIGS. 4 , 5 , 9 , and 10 , a single stage of evaporation is provided, such distillate 180 may be considered to have been boiled, or distilled, once, and thus condensed but once.
It is to be understood that the falling film evaporator 140 design is provided only for purposes of illustration and thus enabling the reader to understand the water treatment process(es) taught herein, and is not intended to limit the process to the use of such evaporator design, as those in the art will recognize that other designs, such as, for example, a forced circulation evaporator, or a rising film evaporator, may be alternately utilized with the accompanying benefits and/or drawbacks as inherent in such alternative evaporator designs.
In any event, in a falling film evaporator embodiment, the distillate 180 descends by gravity along tubes 156 and accumulates above bottom tube sheet 172 , from where it is collected via condensate line 174 . A small portion of steam in equilibrium with distillate 180 may be sent via line 173 to the earlier discussed deaerator 150 for use in mass transfer, i.e, heating and steam stripping descending liquids in a packed tower to remove non-condensable gases 148 such as carbon dioxide. However, the bulk of the distillate 180 is removed as a liquid via line 180 ′, and may optionally be sent for further treatment in a distillate treatment plant, for example such as depicted in detail in FIG. 4 , or as merely depicted in functional form as plant 181 in FIG. 5 , to ultimately produce a suitable feedwater, such as feedwater 80 F′ in the case where packaged boilers 80 are utilized as depicted in FIG. 4 . As shown in the embodiment set forth in FIG. 5 , the distillate treatment plant 181 is optional, especially in the case of the use of once through steam generators, and in such instance the distillate 180 may often be sent directly to once-through steam generators as feedwater 12 F′(as distinguished from the higher quality from feedwater 12 F discussed hereinabove with respect to prior art processes) for generation of 80% quality steam 14 . Also, as shown in FIG. 4 , a distillate treatment plant 181 may also be optional in some cases, depending on feedwater chemistry, and in such cases, distillate 180 may be fed directly to boiler 80 as indicated by broken line 81 .
In an embodiment where boilers 80 are used rather than once through steam generators 12 , however, it may be necessary or desirable to remove the residual organics and other residual dissolved solids from the distillate 180 before feed of distillate 180 to the boilers 80 . For example, as illustrated in FIG. 4 , in some cases, it may be necessary to remove residual ions from the relatively pure distillate 180 produced by the evaporator 140 . In most cases the residual dissolved solids in the distillate involve salts other than hardness. In one embodiment, removal of residual dissolved solids can be accomplished by passing the evaporator distillate 180 , after heat exchanger 200 , through an ion exchange system 202 . Such ion-exchange systems may be of mixed bed type or include an organic trap, and directed to remove the salts and/or organics of concern in a particular water being treated. In any event, regenerant chemicals 204 will ultimately be required, which regeneration results in a regeneration waste 206 that must be further treated. Fortunately, in the process scheme described herein, the regeneration waste 206 can be sent back to the evaporator feed tank 210 for a further cycle of treatment through the evaporator 140 .
In another embodiment, removal of residual dissolved solids can be accomplished by passing the evaporator distillate 180 through a heat exchanger 200 ′ and then through electrodeionization (EDI) system 220 . The EDI reject 222 is also capable of being recycled to evaporator feed tank 210 for a further cycle of treatment through the evaporator 140 .
The just described novel combination of process treatment steps produces feedwater of sufficient quality, and in economic quantity, for use in packaged boilers 80 in heavy oil recovery operations. Advantageously, when provided as depicted in FIG. 4 a single liquid waste stream is generated, namely evaporator blowdown 230 , which contains the concentrated solutes originally present in feedwater 46 , along with additional contaminants from chemical additives (such as sodium hydroxide or caustic 232 , when utilized to elevate the pH of recirculating brine 152 , or regeneration chemicals 204 ). Also, in many cases, even the evaporator blowdown 230 can be disposed in an environmentally acceptable manner, which, depending upon locale, might involve injection in deep wells 240 . Alternately, evaporation to complete dryness in a zero discharge system 242 , such as a crystallizer or drum dryer, to produce dry solids 244 for disposal, may be advantageous in certain locales.
Various embodiments for new process method(s), as set forth in FIGS. 4 and 5 for example, are useful in heavy oil production since they generally offer one or more of the following advantages: (1) eliminate many physical-chemical treatment steps commonly utilized previously in handing produced water (for example, lime softening, filtrating, ion exchange systems, and certain de-oiling steps are eliminated); (2) result in lower capital equipment costs, since the evaporative approach to produced water treatment results in a zero liquid discharge system footprint size that is about 80% smaller than that required if a prior art physical-chemical treatment scheme is utilized, as well as eliminating vapor/liquid separators and reducing the size of the boiler feed system by roughly 20%; (3) result in lower operating costs for steam generation; (4) eliminate the production of softener sludge, thus eliminating the need for the disposal of the same; (5) eliminate other waste streams, thus minimizing the number of waste streams requiring disposal; (6) minimize the materiel and labor required for maintenance; (7) reduce the size of water de-oiling equipment in most operations; and (8) decouple the de-oiling operations from the steam generation operations.
One of the significant economic advantages of using a vertical tube, falling film evaporator such as of the type described herein is that the on-line reliability and redundancy available when multiple evaporators are utilized in the treatment of produced water. An evaporative based produced water treatment system can result in an increase of from about 2% to about 3% or more in overall heavy oil recovery plant availability, as compared to a produced water treatment system utilizing a conventional prior art lime and clarifier treatment process approach. Such an increase in on-line availability relates directly to increased oil production and thus provides a large economic advantage over the life of the heavy oil recovery plant.
In the process disclosed herein, the evaporator 140 is designed to produce high quality distillate (typically 2-5 ppm non-volatile TDS) which, after temperature adjustment to acceptable levels in heat exchangers 200 or 200 ′(typically by cooling to about 45° C., or lower) can be fed directly into polishing equipment (EDI system 220 , ion exchange system 202 , or reverse osmosis system 224 ) for final removal of dissolved solids. The water product produced by the polish equipment just mentioned is most advantageously used as feedwater for the packaged boiler 80 . That is because in the typical once-though steam generator 12 used in oil field operations, it is normally unnecessary to incur the additional expense of final polishing by removal of residual total dissolved solids from the evaporator distillate stream 180 . In some applications, final polishing is not necessary when using conventional boilers 80 . This can be further understood by reference to FIG. 6 , where a typical boiler feed water chemistry specification is presented for (a) packaged boilers, and (b) once-through steam generators. It may be appropriate in some embodiments from a heat balance standpoint that the de-oiled produced waters 46 fed to the evaporator for treatment be heated by heat exchange with the distillate stream 180 . However, if the distillate stream is sent directly to once-through steam generators 12 , then no cooling of the distillate stream 180 may be appropriate. Also, in the case of once-through steam generators 12 , it may be necessary or appropriate to utilize a plurality of flash tanks, F 1 etc., in the manner described above with reference to FIG. 2 .
Also, as briefly noted above, but significantly bears repeating, in those cases where the EDI system 220 is utilized for polishing, the membrane reject stream includes an EDI reject stream 222 that is recycled to be mixed with the de-oiled produced water 46 in the evaporator feed tank 210 system, for reprocessing through the evaporator 140 . Similarly, when reverse osmosis is utilized the a membrane reject stream includes the RO reject stream which is recycled to be mixed with the de-oiled produced water 46 in the evaporator feed tank 210 system, for reprocessing through the evaporator 140 . Likewise, when ion-exchange system 202 is utilized, the regenerant waste stream 206 is recycled to be mixed with the de-oiled produced water 46 in the evaporator feed tank system, for reprocessing through the evaporator 140 .
Again, it should be emphasized that the blowdown 230 from the evaporator 140 is often suitable for disposal by deep well 240 injection. Alternately, the blowdown stream can be further concentrated and/or crystallized using a crystallizing evaporator, or a crystallizer, in order to provide a zero liquid discharge 242 type operation. This is an important advantage, since zero liquid discharge operations may be required if the geological formation is too tight to allow water disposal by deep well injection, or if regulatory requirements do not permit deep well injection.
Since many produced waters encountered in heavy oil production are high in silica, with typical values ranging up to about 200 mg/l as SiO 2 , or higher. In order to minimize the capital cost of an evaporator, and particularly, a mechanical vapor recompression (MVR) evaporation system 140 , and while simultaneously providing a process design which prevents the scaling of the inner surfaces 260 of the heat transfer tubes 156 with the ever-present silica, operation of the evaporator 140 at high pH, i.e., in preferably excess of about 10.5 is undertaken. More preferably, operation in the range from about 11 to about 12, or even a higher pH in appropriate cases, can be used to keep the silica in aqueous solution. This is important, since silica solubility must be accounted for in the design and operation of the evaporator 140 , in order to prevent silica scaling of the heat transfer surfaces 260 . The solubility characteristics of silica are shown in FIG. 11 . Since the high pH operation assures increased silica solubility, a concentration factor (i.e, ratio of rate of feed 151 to rate of blowdown 230 ) for the evaporator 140 can be selected so that silica solubility is not exceeded. Operation at high pH also allows the use of low cost heat transfer tubes 156 and other brine wetted surfaces such as sump walls 270 of sump 141 , thus minimizing the capital cost of the system.
Since the calcium hardness and sulfate concentrations of many produced waters is low (typically 20-50 ppm Ca as CaCO3), it is possible in many cases to operate the evaporators 140 with economically efficient concentration factors, while remaining below the solubility limit of calcium sulfate, assuming proper attention to feedwater quality and to pre-treatment processes.
It is to be appreciated that the water treatment process described herein for preparing boiler feedwater in heavy oil recovery operations is an appreciable improvement in the state of the art of water treatment for oil recovery operations. The process eliminates numerous of the heretofore encountered waste streams, while processing water in reliable mechanical evaporators, and in one embodiment, in mechanical vapor recompression (“MVR”) evaporators. Polishing, if necessary, can be accomplished in ion exchange, electrodeionization, or reverse osmosis equipment. The process thus improves on currently used treatment methods by eliminating most treatment or regeneration chemicals, eliminating many waste streams, eliminating some types of equipment. Thus, the complexity associated with a high number of treatment steps involving different unit operations is avoided.
In the improved water treatment method, the control over waste streams is focused on a the evaporator blowdown, which can be conveniently treated by deep well 240 injection, or in a zero discharge system 242 such as a crystallizer and/or spray dryer, to reduce all remaining liquids to dryness and producing a dry solid 244 . This contrasts sharply with the prior art processes, in which sludge from a lime softener is generated, and in which waste solids are gathered at a filter unit, and in which liquid wastes are generated at an ion exchange system and in the steam generators. Moreover, this waste water treatment process also reduces the chemical handling requirements associated with water treatment operations.
It should also be noted that the process described herein can be utilized with once through steam generators, since due to the relatively high quality feedwater—treated produced water—provided to such once through steam generators, the overall blowdown rate of as low as about 5% or less may be achievable in the once through steam generator. Alternately, as shown in FIG. 5 , at least a portion of the liquid blowdown 134 from the once through steam generator 12 can be recycled to the steam generator 12 , such as indicated by broken line 135 to feed stream 12 F′.
In yet another embodiment, to further save capital and operating expense, industrial boilers of conventional design may be utilized since the distillate—treated produced water—may be of sufficiently good quality to be an acceptable feedwater to the boiler, even if it requires some polishing. It is important to observe that use of such boilers reduces the boiler feed system and evaporative produced water treatment system size by twenty percent (20%), eliminates vapor/liquid separation equipment as noted above, and reduces the boiler blowdown flow rate by about ninety percent (90%).
In short, evaporative treatment of produced waters using a falling film, vertical tube evaporator is technically and economically superior to prior art water treatment processes for heavy oil production. It is possible to recover ninety five percent (95%) or more, and even up to ninety eight percent (98%) or more, of the produced water as high quality distillate 180 for use as high quality boiler feedwater (resulting in only a 2% boiler blowdown stream which can be recycled to the feed for evaporator 140 ). Such a high quality distillate stream may be utilized in SAGD and non-SAGD heavy oil recovery operations. Such a high quality distillate stream may have less than 10 mg/L of non-volatile inorganic TDS and is useful for feed either to OTSGs or to conventional boilers.
The overall life cycle costs for the novel treatment process described herein are significantly less than for a traditional lime softening and ion exchange treatment system approach. And, an increase of about 2% to 3% in overall heavy oil recovery plant availability is achieved utilizing the treatment process described herein, which directly results in increased oil production from the facility. Since boiler blowdown is significantly reduced, by as much as 90% or more, the boiler feed system may be reduced in size by as much as fifteen percent (15%) or more. Finally, the reduced blowdown size results in a reduced crystallizer size when zero liquid discharge is achieved by treating blowdown streams to dryness.
Although only several exemplary embodiments of this invention have been described in detail, it will be readily apparent to those skilled in the art that the novel produced waste treatment process, and the apparatus for implementing the process, may be modified from the exact embodiments provided herein, without materially departing from the novel teachings and advantages provided by this invention, and may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. Therefore, the disclosures presented herein are to be considered in all respects as illustrative and not restrictive. It will thus be seen that the objects set forth above, including those made apparent from the preceding description, are efficiently attained. Many other embodiments are also feasible to attain advantageous results utilizing the principles disclosed herein. Therefore, it will be understood that the foregoing description of representative embodiments of the invention have been presented only for purposes of illustration and for providing an understanding of the invention, and it is not intended to be exhaustive or restrictive, or to limit the invention only to the precise forms disclosed.
All of the features disclosed in this specification (including any accompanying claims, and the drawing) may be combined in any combination, except combinations where at least some of the features are mutually exclusive. Alternative features serving the same or similar purpose may replace each feature disclosed in this specification (including any accompanying claims, and the drawing), unless expressly stated otherwise. Thus, each feature disclosed is only one example of a generic series of equivalent or similar features. Further, while certain process steps are described for the purpose of enabling the reader to make and use certain water treatment processes shown, such suggestions shall not serve in any way to limit the claims to the exact variation disclosed, and it is to be understood that other variations, including various treatment additives or alkalinity removal techniques, may be utilized in the practice of my method.
The intention is to cover all modifications, equivalents, and alternatives falling within the scope and spirit of the invention, as expressed herein above and in any appended claims. The scope of the invention, as described herein and as indicated by any appended claims, is thus intended to include variations from the embodiments provided which are nevertheless described by the broad meaning and range properly afforded to the language of the claims, as explained by and in light of the terms included herein, or the legal equivalents thereof. | A process for treating produced water to generate high pressure steam. Produced water from heavy oil recovery operations is treated by first removing oil and grease. Pretreated produced water is then fed to an evaporator. Up to 95% or more of the pretreated produced water stream is evaporated to produce (1) a distillate having a trace amount of residual solutes therein, and (2) evaporator blowdown containing substantially all solutes from the produced water feed. The distillate may be directly used, or polished to remove the trace residual solutes before being fed to a steam generator. Steam generation in a packaged boiler, such as a water tube boiler having a steam drum and a mud drum with water cooled combustion chamber walls, produces 100% quality high pressure steam for down-hole use. | 2 |
PRIORITY
[0001] This application claims priority to U.S. provisional patent application No. 62/064,550, filed on Oct. 16, 2014, the entire content of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to shade devices and more particular to a shade device or floating umbrella in a body of water, such as a pool.
[0004] 2. Description of the Related Art
[0005] Various floating umbrella type designs are known in the prior art. For example, U.S. Pat. No. 5,505,645 (Engler) describes a floating assembly for swimming pools having a pole with a float connected to the middle, a hinged anchor weight at the bottom end, and various structures such as an umbrella, a net basket for games, and a tetherball game attached to the upper end. The umbrella embodiment has a tray attached above the float. One problem with Engler is that all the embodiments attach to a central shaft. This is an issue because the buoy may become imbalanced and lose stability in the water. Further, Engler hinges the ballast weight, which creates an issue for manufacturing and durability for the device. Engler's drink tray connects to the shaft via a pivotal connection. This may increase the overall stability of the device but undermines the functionality of the drink tray as it will be susceptible to wave action in the pool. As another example, U.S. Patent Publication No. US20140110413 (Kelly et al.) describes a floating valet that can be used to hold personal items while in the water. Kelly shows a floating plate or disc with multiple receptacles for drinks and other personal items along with a water proof bag for protecting items that may be damaged by water. One problem with Kelly is that the device must be anchored in a body of water to a single location. The valet floats but must be anchored in order to support an umbrella. This anchoring prohibits movement of the shaded area around the body of water and also requires a body of water with a bed that allows for a drilled anchor to be installed (e.g., not a plastered swimming pool).
[0006] A need exists for an improved method and system for weighting and supporting umbrellas and other shade providing structures in a water setting that allows for shading of an area in a body of water.
[0007] The embodiments provided in this disclosure solve various problems existing in the prior art, including separating the umbrella and canopy structure and allowing the buoy to independently float while weighted in the body of water without having to be anchored.
SUMMARY
[0008] In one embodiment of the disclosed application is a commercially available umbrella that floats on a weighted buoy device and provides shade to an area within a recreational swimming pool or other body of water where persons may gather. In some embodiments, the device may be used to prevent or reduce evaporation from the surface of a swimming pool. An additional embodiment of the device holds drinks on the float portion of the weighted buoy. Finally, a plurality of floats may be coupled together to provide sufficient floating structure for a larger canopy or a plurality of canopies.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The following drawings form part of the present specification and are included to further demonstrate certain aspects of the present invention. The invention may be better understood by reference to one or more of these drawings in combination with the detailed description of specific embodiments presented herein.
[0010] FIG. 1 illustrates one embodiment of a floating canopy device with a commercially available umbrella.
[0011] FIG. 2 illustrates another embodiment of a floating device without a commercially available umbrella.
[0012] FIG. 3 illustrates an exploded diagram of the floating device of FIG. 2 according to one embodiment.
[0013] FIG. 4 illustrates a side view of the floating device of FIG. 2 according to one embodiment.
DETAILED DESCRIPTION
[0014] Various features and advantageous details are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well-known starting materials, processing techniques, components, and equipment are omitted so as not to unnecessarily obscure the invention in detail. It should be understood, however, that the detailed description and the specific examples, while indicating embodiments of the invention, are given by way of illustration only, and not by way of limitation. Various substitutions, modifications, additions, and/or rearrangements within the spirit and/or scope of the underlying inventive concept will become apparent to those skilled in the art from this disclosure. The following detailed description does not limit the invention.
[0015] Reference throughout the specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with an embodiment is included in at least one embodiment of the subject matter disclosed. Thus, the appearance of the phrases “in one embodiment” or “in an embodiment” in various places throughout the specification is not necessarily referring to the same embodiment. Further, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.
[0016] The disclosed embodiments provide significant advantages over the prior art because of the simplicity of design and the ability to float and remain upright in water.
[0017] FIG. 1 illustrates one embodiment of a floating canopy device 100 . Device 100 includes weighted buoy 9 with canopy structure 8 to provide a shaded area. In one embodiment, the canopy is a commercially available umbrella. Weighted buoy 9 is attached to canopy 8 via shaft 7 , which in one embodiment is a commercially available umbrella shaft. In one embodiment, weighted buoy 9 comprises underwater ballast 4 connected to float 10 by rod 1 . Underwater ballast 4 serves as a counterweight to the floating canopy for better stability. The ballast can be made of various materials, including coated grey cast iron or aggregate filled high-density polyethylene. Ballast 4 is generally cylindrical in shape, approximately 6 inches in diameter by 3 inches deep. Float 10 is preferably made in a circular or disc shaped structure and in some embodiments may be considered a floating ring, but can comprise various other structures depending on the intended uses of the float. In one embodiment, float 10 and ballast 4 are connected by rod 1 . Rod 1 serves as a moment arm for float 10 that balances the canopy device 100 in an upright position and keeps the device from tipping over. In one embodiment, the length of rod 1 is adjustable or extendable based on the size, shape, and/or weight of canopy 8 . In operation, once weighted buoy 9 is fully assembled, umbrella shaft 7 is inserted into float 10 . In some embodiments, shaft 7 may also be inserted into rod 1 . In all positions, shaft 7 is rigidly coupled to rod 1 in a substantially straight position such that they do not bend or hinge in relation to each other. When canopy or umbrella 8 is at least partially opened, it provides shade in a swimming pool, lake, or other body of water at the location of the user's choice. In one embodiment, device 100 is configured to hold beverages or drinks in cup holders integrated into float 10 .
[0018] FIG. 2 is an enlarged illustration of weighted buoy 9 from FIG. 1 , without an umbrella coupled to the buoy. In one embodiment, float 10 is comprised of lower shell piece 10 b and upper shell piece 10 a that may be glued or otherwise fastened together. The two shell pieces fit around specially designed foam insert 5 , shown in FIGS. 3-4 . In one embodiment, each shell piece is made of an injection molded plastic. In one embodiment, upper shell 10 a comprises a plurality of cup holders 6 for holding drinks above water when the device is floating in a body of water. In other embodiments, upper shell 10 a may include a plurality of flat sections or other attachments (not shown) to hold food, drinks, or other items.
[0019] FIG. 3 illustrates an exploded diagram of the components of weighted buoy 9 from FIG. 2 . The exploded view shows foam insert 5 as it would appear between upper shell piece/section 10 a and lower shell piece/section 10 b . Foam insert 5 has the necessary size, shape, and material density to allow the weighted buoy and umbrella to float. In one embodiment, foam insert 5 is approximately 18 inches in diameter and 3 inches deep and provides the necessary buoyancy to keep device 100 floating in the water. In one embodiment, upper section 10 a is approximately the same size as lower section 10 b . In this embodiment, optional drain holes 12 b are shown on lower shell 10 b , which allow any water in float 10 to exit. In one embodiment, drain holes 12 b may be coupled to drain holes 12 a (see FIG. 4 ) at the bottom of each cup holder 6 , which allows water to exit the cup holders. One embodiment may include a locking device to tighten and/or secure the umbrella shaft 7 to weighted buoy 9 . For example, locking device may comprise ferrule 2 and nut 3 such that when tightened, umbrella shaft 7 is locked into place with float 10 and rigidly coupled to rod 1 . In this embodiment, ballast 4 includes built in male threads 4 a for securing ballast 4 to rod 1 , which may include corresponding female threads 1 b on the inside diameter of rod 1 . The opposite end of rod 1 terminates with male threads 1 a , which may be secured into corresponding female threads on upper float portion 10 a . Likewise, upper shell piece/section 10 a is coupled to an upper portion of rod 1 via a threaded engagement. Nut 3 may be attached to ferrule 2 by a threaded engagement, such that ferrule 2 extends through an inner conduit or hole of float 10 . In some embodiments, different lengths of rod 1 may be utilized for different weights and sizes of canopy 8 . Such rods are easily removable and replaceable by a user of device 100 .
[0020] FIG. 4 illustrates a cross section drawing of weighted buoy 9 from FIG. 2 . In one embodiment, ballast 4 may be hollow and be filled with aggregate or cement to achieve a desired weight. Once filled, ballast 4 can then be plugged with cap 4 b to prevent the weighted compound from escaping. Upper shell 10 a may connect to lower shell 10 b with an interrupted annular snap latch 14 . Upper shell 10 a may contain a series of drains 12 a in cup holders 6 which allow water to flow out of cup holders 6 . In between upper shell 10 a and lower shell 10 b is foam insert 5 that creates the buoyancy for weighted buoy 9 and/or device 100 . Foam insert 5 has a cut out in the center 5 a for the center connections of upper shell 10 a and lower shell 10 b . In addition, foam insert 5 contains a plurality of cutouts 5 b matching cup holders 6 and cup holder drains 12 a and 12 b . In one embodiment, ferrule 2 fits securely inside float 10 and may contain a swage feature on its lower end that holds the ferrule securely in place. Ferrule 2 extends through the top of the upper float portion 10 b to connect with nut 3 . Ferrule 2 contains male threads to securely connect to nut 3 . Nut 3 tightens down on ferrule 2 with a series of female threads. When securely tightened, the combination of the lower ferrule and the nut create a friction fit to secure canopy shaft 7 in place.
[0021] In one embodiment, a plurality of weighted buoys may be coupled together to provide sufficient floating structure for a larger canopy. In one embodiment, a larger canopy comprises a plurality of supporting poles or shafts, each one configured to insert into a weighted buoy. One or more of these buoys may include a plurality of cup holders. In one embodiment the weighted buoy includes a built in audio speaker. In one embodiment the umbrella may include a system to pump and atomize water to create a water vapor mist. In one embodiment the canopy may be replaced with a light pole. In one embodiment the canopy may be replaced with a signal flag on a pole. In one embodiment a tool receptacle may be attached to the weighted buoy for additional storage of items. In one embodiment the canopy may include a series of Light Emitting Diode (LED) lights. In another embodiment the canopy may be replaced with a camouflaged canopy to provide cover for hunters. In still another embodiment small motors may be mounted to the bottom of the float so the buoy could be remotely positioned or retrieved by an end user.
[0022] Many other variations in the configurations of the rod, float, ballast, canopy, and umbrella are within the scope of the invention. For example, the canopy may be comprised of many different materials or structures. As another example, the rod could be replaced with a flexible device that connects the weight to the float. It is emphasized that the foregoing embodiments are only examples of the very many different structural and material configurations that are possible within the scope of the present invention.
[0023] Although the invention(s) is/are described herein with reference to specific embodiments, various modifications and changes can be made without departing from the scope of the present invention(s), as presently set forth in the claims below. Accordingly, the specification and figures are to be regarded in an illustrative rather than a restrictive sense, and all such modifications are intended to be included within the scope of the present invention(s). Any benefits, advantages, or solutions to problems that are described herein with regard to specific embodiments are not intended to be construed as a critical, required, or essential feature or element of any or all the claims.
[0024] 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. The terms “coupled” or “operably coupled” are defined as connected, although not necessarily directly, and not necessarily mechanically. The terms “a” and “an” are defined as one or more unless stated otherwise. The terms “comprise” (and any form of comprise, such as “comprises” and “comprising”), “have” (and any form of have, such as “has” and “having”), “include” (and any form of include, such as “includes” and “including”) and “contain” (and any form of contain, such as “contains” and “containing”) are open-ended linking verbs. As a result, a system, device, or apparatus that “comprises,” “has,” “includes” or “contains” one or more elements possesses those one or more elements but is not limited to possessing only those one or more elements. Similarly, a method or process that “comprises,” “has,” “includes” or “contains” one or more operations possesses those one or more operations but is not limited to possessing only those one or more operations. | A floating canopy or shading device designed to provide shaded areas to swimming pools, lakes, and other bodies of water traditionally lacking in shade. In one embodiment, the canopy is an umbrella attached to a weighted buoy that floats on a body of water. In one embodiment, the weighted buoy may include a float connected to a ballast via one or more rods that serves as a counterweight. | 0 |
BACKGROUND OF THE INVENTION
The present invention relates to a method for setting a shoe position in an extended-nip press and an extended-nip press.
Generally an extended-nip press comprises a press roll cooperating with a backing roll. Typically, the press roll comprises a rotating endless-loop blanket of a flexible, liquid-impervious material, a rigid and advantageously stationary roll support beam that extends axially through the interior of the endless blanket and has a stub shaft mounted at its both ends, at least one press shoe resting on the roll support beam and having a concave top face, loading means for pressing the concave top face against the flexible endless blanket so as to form a press nip zone in cooperation with the backing roll, two blanket-clamping roll heads axially movable on their respective stub shafts, clamp elements for engaging the lateral rims of the blanket to the respective roll heads and at least one element for tightening and/or moving the flexible endless blanket in the axial direction of the respective stub shaft.
The shape of the nip pressure profile generated by the press nip zone and imposed on the web passing therethrough is determined by the shape of the concave face of the press shoe and its position relative to the backing roll and the means loading the shoe. Hence, the shape of the nip pressure profile can be adjusted either by controlling the concave shape of the shoe top face or by moving the position of the shoe relative to the backing roll and/or the shoe loading means.
Among other factors, an advantageous shape of the nip pressure profile is dependent on the paper grade being manufactured. For instance, lightweight paper grades are problematic by undergoing rewetting in an extended-nip press, whereby the most advantageous nip pressure profile for these grades is adjusted such that the peak pressure in the machine direction is close to the outgoing side of the press nip zone. Thicker paper grades, thick paperboards in particular, are problematic by undergoing collapse of the web internal structure if the machine direction nip pressure profile rises excessively steeply and the maximum nip pressure is too high. Hence, thick paper grades are generally most advantageously run using a relatively smooth nip pressure profile having the peak pressure adjusted in the machine direction close to the middle of the press nip zone. Typically, a papermaking machine is used for making more than a single paper grade. Accordingly, it is desirable that the pressure profile of an extended-nip press be adjustable as required by the paper grade being manufactured.
For Instance, patent publication FI 65103 teaches the adjustment of the nip pressure profile to take place by way of providing the support means of the press shoe with transfer means adapted to shift the center of the shoe loading force relative to the shoe. In accordance with the teaching of the publication, the center of shoe loading force can be implemented in two different ways: either by using a movable support assembly adapted mechanically movable relative to the shoe or by using a stationary support assembly by means of which the magnitude of the loading force imposed on the shoe can be hydraulically varied between the leading and trailing edges of the shoe, whereby the center of the loading force is changed relative to the shoe. The arrangements disclosed in the publication are hampered by the complexity of their construction and, hence, high manufacturing costs.
Patent publication U.S. Pat. No. 4,973,384 discloses another prior-art technique of adjusting the nip pressure profile. The embodiment described in the publication has a plurality of grooves made in the cross-machine direction to the underside of the shoe. The upper end of the cylinder loading the shoe has respectively mounted thereon a cross-machine pivot pin aligned in parallel with the grooves of the shoe, whereby the pin can act as a pivotal point for the shoe. Then, the shape of the machine-direction nip pressure profile can be varied by moving the shoe position on the pivot pin of the loading cylinder from one groove to another. A disadvantage of the embodiment disclosed in the publication is that due to the substantially high forces imposed at the pivot point between the shoe of the extended-nip press and its loading cylinder, the spacing between the grooves on the shoe underside must be made relatively wide such that a sufficient portion of shoe material remains on the ridges between the grooves to bear the loading forces imposed thereon. As a result, the control of the nip loading profile takes place in rather coarse steps. Furthermore, the cylinders located underneath the shoe are subject to wear thus needing frequent maintenance.
SUMMARY AND OBJECTS OF THE INVENTION
It is an object of the method and extended-nip press according to the invention to eliminate or at least reduce the above-described problems related to the prior art.
It is a further object of the present invention to provide a method for setting the shoe position in an extended-nip press and, further, an extended-nip press, wherein the shoe position, particularly the tilt angle thereof, can be set and changed at a sufficiently high precision in order to control the nip pressure profile of the extended-nip press. It Is still a further object of the invention to provide an extended-nip press having a simple and reliable function and construction.
It is further another object of the invention to provide an extended-nip press, wherein the shoe and the element loading the same cooperate so that this combination of elements compensates for thermal expansion occurring in an extended-nip press.
To achieve the above-mentioned objects and others, the method for setting the shoe position in an extended-nip press and the extended-nip press according to the invention are principally characterized by what is stated in the characterizing parts of the appended base claims.
The method according to the present invention is characterized in that the shoe element is connected to the loading element by means of a detachable saddle element adapted between the shoe element and the loading element and that the position of the shoe element relative to the loading element is set by adjusting the relative position between the saddle element and the shoe element. In the context of the present text, saddle element refers to a preferredly planar part adapted between the loading element and the shoe element so as to connect the loading element to the shoe element in a functional manner. Loading element in the present context refers to a cylinder or an assembly acting as a loading cylinder such that the shoe element can be pressed at a desired force against a backing roll. The shoe element may comprise a single part or be assembled from a plurality of parts. To set, or change, the position, that is, the angle or alignment of the shoe element in a desired direction, the center of the force imposed by the loading element on the shoe element is changed, whereby also the shape of the nip pressure profile is altered.
In a preferred embodiment of the present invention, the surface of the saddle element facing the loading element and, respectively, the surface of the loading element facing the saddle element are shaped so that these two mating faces form a ball joint. These shaped faces may be implemented so that, e.g., the loading element face is made spherically convex while the saddle element face is made spherically concave or vice versa.
Advantageously, the saddle element and the shoe element are connected to each other by at least one dismountable keyed keyway joint. Key in the present context refers to a key part having a wedged, curved or prismatic shape that connects the saddle element to the shoe element. The key may be a separate element or, alternatively, a structural and integral part of the saddle element or the shoe element. Keyway refers to a wedged, curved or straight-walled slot suited to accommodate the insertion of the key therein for connecting the saddle element to the shoe element. In this context, keyed keyway joint refers to a joint accomplished by inserting the connecting key in the keyway made to the element to be jointed.
Particularly advantageously the surface of the saddle element facing the shoe element and/or the surface of the shoe element facing the saddle element is provided with plural keyways that are located at different distances from the center of the saddle element and of which keyways at least one is utilized for connecting the saddle element to the shoe element. Then, the position of the shoe element relative to the saddle element can be varied by using a different keyway for connecting the elements to each other.
In a preferred embodiment of the method according to the present invention, both the saddle element and the shoe element have on their mating surfaces a keyway, whereby the shoe element can be connected to the saddle element by a detachable key inserted in the keyways provided in the saddle element and the shoe element. Particularly advantageously, the key used for the connection has an asymmetrical shape, whereby the rotation of the key gives a means for changing the mutual disposition of the saddle element and the shoe element that are connected to each other by the key. Eccentricity of the key in this context refers to an asymmetrical cross section of the key relative to its center axis such that the mutual disposition of the saddle element and the shoe element connected to each other by the key can be varied depending on the position of the key.
The extended-nip press according to the present invention is characterized in that the shoe element is connected to its loading element by a detachable saddle element adapted between the shoe element and the loading element.
One of greatest benefits of the method according to the invention is that the position and, as a result, the tilt angle of the shoe can be changed in a rapid and uncomplicated fashion.
The greatest benefit of the extended-nip press according to the invention is its uncomplicated, yet extremely functional construction that can be implemented at a reasonable manufacturing cost, whereby also its maintenance and servicing becomes easy and quick. Furthermore, the construction of the extended-nip press according to the present invention is very durable in use.
An additional benefit of a preferred embodiment of the invention, wherein the saddle element and the loading element form a ball joint, is its good tolerance to thermal expansion by virtue of the joint construction that permits unidirectional tilting of the shoe element. As a result, the entire shoe element can be made from aluminum which is cost-efficient material but has a high thermal expansion coefficient. Due to the good thermal conductivity of aluminum, heat is efficiently transferred to the different parts of the shoe.
A still another benefit of the arrangement according to the invention is that the construction used therein does not need a separate support member for receiving the forces imposed on the shoe. Yet, the present construction may be complemented with limiting member as a safety precaution in malfunction situations in order to prevent the shoe element from slipping away from its normal position. During normal operation of the press, between the shoe and the limiting member remains a gap to prevent the shoe from contacting the limiting member.
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.
DETAILED DESCRIPTION OF THE DRAWINGS
The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings, which are given by way of illustration only, and thus are not limitative of the present invention, and wherein:
FIG. 1 is a diagrammatic cross-sectional view of an extended-nip press as seen from the end of the press;
FIG. 2 is a diagrammatic cross-sectional view of an alternative embodiment of an extended-nip press as seen from the end of the press;
FIG. 3 is an enlarged view illustrating the connection between the saddle element and the shoe element;
FIG. 4 is a cross-sectional view illustrating the extended-nip press of FIG. 2 adjusted to another operating position; and
FIG. 5 is a diagrammatic top view of the saddle element.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIGS. 1 and 2 is diagrammatically shown an exemplary embodiment of the construction of an extended-nip press as seen from the end of the press, that is, in a view in the cross-machine direction of the press. The extended-nip press shown therein comprises an upper backing roll 1 and a lower press roll 2 that define therebetween a press zone, later called a press nip N. The backing roll 1 may be a heated roll or an unheated roll. The press roll 2 comprises an endless-loop blanket 3 made from a flexible and liquid-impervious material with a rigid, stationary roll support beam 4 extending axially through the interior of the endless-loop blanket. Furthermore, the press roll 2 comprises loading means 5 that urge the blanket 3 toward the backing roll for forming the above-mentioned nip N in order to remove water from a web passed through the nip. Herein, web refers to a paper or paperboard web. The travel direction of the web passed into the nip is denoted by an arrow in the diagram.
Loading means 5 comprise a loading element 6 connected to a roll support beam 4 and shoe element 8 that is connected to the loading element via a saddle element 7 and is aligned parallel to the center axis of the press roll. The shoe element 8 is connected to the saddle element by a key 9 inserted into both a keyway 10 made on the surface of the shoe element facing the saddle element and a keyway 11 a made on the surface of the saddle element facing the shoe element. The structure connecting the saddle element to the shoe element is described in more detail later in the text. As drawn in the diagram, the center line A of shoe element 8 which is connected by saddle element 7 to loading element 6 is situated at the center line of backing roll 1 , while the center line B of loading element 6 is offset from both of these lines so as to be located to the left from the center line of the backing roll, that is, on the outgoing side of the press zone. As a result, the peak pressure in the nip pressure profile in the basic situation shown in the diagram is located closer to the trailing edge of the press zone.
The loading element 6 is a cylinder which is actuated by a pressurized medium and, in the exemplary embodiment of FIG. 1, comprises a cylinder block with a piston adapted in sealed manner to move in the bore of the cylinder block. The end 12 of the cylinder facing the saddle element is made spherical. Advantageously, the extended-nip press includes a plurality of these loading elements that are placed in a row extending over the entire width of the extended-nip press.
The saddle element 7 is a planar component with its underside, that is, the surface facing the loading element, machined to incorporate a concave recess that after the saddle element is connected to the loading element allows the spherical end surface of the loading element and this concave recess of the saddle element to form a ball joint allowing the shoe element connected to the saddle element to rotate relative to the loading element. The top surface of the saddle element, that is, the surface facing the shoe element is provided with keyways of which in the diagram are shown two denoted by reference numerals 11 a and 11 b. The saddle element keyways and their location are discussed in more detail later in the text.
The shoe element 8 shown in FIG. 1 is made from a suitable metal such as aluminum. The top surface of the shoe element opposed to the backing roll has a concave cross section forming a pressure pocket 13 . As shown in the diagram, the pressure pocket is generally of the hydrodynamic type. Alternatively, a hydrostatic pressure pocket may be used, whereby the shoe element would additionally comprise at least one line connection for feeding cooling/lubricating oil into the pressure pocket. When the shoe element is pressed against the backing roll, the endless-loop blanket assumes a shape that is determined by the concave face of the shoe element and the curvature of the backing roll adapted to cooperate with the press roll, whereby the blanket together with the backing roll defines a press zone through which the paper or paperboard web is passed to remove water from the web.
FIG. 2 shows an alternative embodiment of an extended-nip press. The construction shown in the diagram is otherwise identical to that of FIG. 1 with the exception that shoe element 8 herein comprises two parts: a topmost shoe plate 14 adapted to face the blanket and a pressure plate 15 connected to the saddle element. The shoe plate and the pressure plate can be made from the same material, e.g., from aluminum. The plates may also be of different materials, e.g., so that the shoe element is of aluminum while the pressure plate is of steel. The shoe plate and the pressure plate are joined to each other by an interface 16 comprising a recess 17 on the underside of the shoe plate and a projection 18 at the ingoing side of the press.
In addition to those described above, an extended-nip press includes other parts and elements omitted from the diagrams for greater clarity. These means are, e.g., means for feeding coolant and lubricant onto the top surface of the shoe, means for feeding pressurized medium into the cylinder acting as the loading element, etc. Furthermore, an extended-nip press may be implemented in an inverted fashion, whereby the press roll is located above the backing roll.
FIG. 3 shows a partially sectional enlarged view of the components of FIG. 2 as to the connection of the shoe formed by the shoe plate 14 and the pressure plate 15 to the saddle element 8 by means of a key 9 fitted into keyways 10 and 11 of the mated components. As drawn in FIG. 3, the key may have an eccentric shape by being asymmetrical about the vertical center axis of its cross section such that the key is wider by its portion insertable into the keyway 11 of the saddle element than by its portion insertable in the keyway 10 of the shoe element, whereby the key has a substantially L-shaped cross section. As a result, 180° rotation of the key allows the mutual disposition between the shoe element and the saddle element to be changed by a given distance which is equal to the difference of widths across the above-mentioned top and underside surfaces of the key. For instance, if the top surface of the key is made 1 mm narrower than the underside of the key, rotation of the key upside down makes a 1 mm change in position of the shoe element relative to the saddle element. Now, inasmuch the position of the saddle element relative to the loading element has remained unchanged, the shoe element has been moved by the above-mentioned distance relative to the loading element. By these actions, the center point of the force imposed by the loading element on the shoe element is moved to another point of the shoe element thus tending to rotate the shoe element that subsequently rotates supported by the ball joint formed between the shoe element and the saddle element. As a consequence, the location of the press zone and/or the nip pressure profile thereof is modified by the rotation of the shoe element.
FIG. 4 shows the extended-nip press of FIG. 2 now illustrating the effect of the rotation of the above-described key element on the position of the shoe element 8 relative to the saddle element 7 and the loading element 6 . As compared with the operating position illustrated in FIG. 2, the shoe element is herein shifted in the direction of the ingoing side of the press zone, that is, to the right as is evident, e.g., by examining the position of the left-side edge of the shoe element pressure plate 15 that has been shifted from the position of FIG. 2 to a new position flush with the left-side edge of saddle element 7 . Due to the shift in the shoe element position, center point A of the shoe element has moved farther away from center point B of the loading element, whereby the center point of the force imposed by loading element on the shoe element has respectively shifted closer to the outgoing side of the press zone resulting in a change of the nip pressure profile in the press zone such that pressure peak is located closer to the outgoing side of the press.
FIG. 5 shows the saddle element 7 in a top view, that is, from the side facing the shoe element. To the top surface of the saddle element are machined keyways 11 a, 11 b, 11 c and 11 d. The keyways are located at different distances from the center point of the saddle element. Otherwise the saddle element is symmetrical about the vertical center axis of its cross section. By placing the keyways at different distances from the center point of the saddle element, the position of the shoe element connected by the key to the saddle element can be changed relative to the center point of the saddle element and, thus, relative to the loading element. Resultingly, rotation of the saddle element gives four alternative positions for the shoe element.
In the exemplary embodiments shown in the diagrams, the shoe element is in its basic position in FIG. 1 . Herein, the locations of the keyways made on the saddle element are shifted by 2 mm relative to each other, and the asymmetry of the key expressed as the width difference between its top surface and underside surface is 8 mm. With these design parameter values, the position of the shoe element can be changed from its basic position so that the press shoe may be moved from its basic position maximally 2 mm to the left, that is, toward the outgoing side of the press zone and maximally 12 mm toward the incoming side. Having the key in its basic position, rotation of the saddle element gives the shoe element four different positions: normal position, −2 mm, +2 mm and +4 mm. If the key is rotated upside down, the shoe element is moved 8 mm toward the incoming side, whereby rotation of the saddle element gives the shoe element respectively the following four positions: +8 mm, +6 mm, +10 mm and +12 mm.
It must be understood that the invention is not limited by the exemplary embodiment described above, but rather may be varied within the inventive spirit and scope of the appended claims. For instance, the location of the keyways may be shifted differently in varying applications. Furthermore, the location of the keyways may be modified, e.g., so that the keyways are located successively on the saddle element or, alternatively, the selectable keyways may be made on the shoe element. Moreover, the connection of the loading element to the saddle element could be implemented without using a detachable and asymmetric key, whereby key must be made into an integral portion of either one of the elements to be connected to each other.
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. | A method for setting a position of a shoe in an extended-nip press having a press roll and a backing roll, said press roll including a rotating endless-loop blanket of a flexible, liquid-impervious material, a rigid stationary roll support beam extending through an interior of endless blanket, a shoe element with a concave top face mounted above the roll support beam, and a loading element for loading the shoe element by pressing the top face thereof against the endless-loop blanket to make the blanket form a press nip zone in cooperation with the backing roll. The shoe element connects to the loading element by a detachable saddle element mountable between the shoe element and the loading element and by setting the position of the shoe element relative to the loading element through changing a mutual disposition of the saddle element and the shoe element. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to engine analyzers and, in particular, to engine analyzers having digital oscilloscope displays.
2. Description of the Prior Art
Digital storage oscilloscopes are well known and typically have two modes of operation, viz., live and freeze. In the live mode, one or more selected input signals are repeatedly sampled by a data acquisition system and the resulting digitized waveform data is displayed on the screen of the oscilloscope and saved in memory. It is known in prior digital engine analyzers to store input waveform data in a memory which is divided up into sections. When the freeze mode is activated, data acquisition is suspended and the most recently-displayed section of waveform data remains "frozen" on the screen. At this point the operator can review previously acquired waveform data that has been saved in memory by recalling it from memory and displaying it on the screen.
It is known to provide digital oscilloscopes with multiple display traces (e.g., two), so that a number of waveforms can be simultaneously displayed. A dual-trace scope can typically be operated in either single-trace mode or dual-trace mode.
It is also known to provide engine analyzers with screen displays which essentially constitute digital oscilloscopes. In the case of a multi-cylinder internal combustion engine, two of the engine waveforms which are commonly displayed on an engine analyzer scope are the primary and secondary ignition voltages which appear, respectively, across the primary and secondary windings of the ignition coil. The primary and secondary waveforms are typically acquired from the engine by means of separate primary and secondary pickup leads. The analyzer also typically has a no. 1 cylinder lead to detect the firing of the no. 1 cylinder so that the analyzer can identify the cylinders once the firing order of the engine is known. Other leads may be utilized to acquire other types of waveforms generated by the engine.
The horizontal scale (also called sweep) of an oscilloscope screen represents time. Broadly speaking, in a digital engine analyzer scope there are two types of sweeps: engine sweeps and fixed-time sweeps. Engine sweeps display a waveform for either a single cylinder ignition or for a complete engine cycle (the time between consecutive firings of the same cylinder), and are typically used to display waveforms related to cylinder ignition events. For engine sweeps, the analyzer includes means for identifying the cylinder firings in the stored waveform data. Engine sweeps may be of any of three different types: cylinder, parade and raster. In a cylinder sweep, only a single cylinder waveform is displayed. In parade and raster sweeps, all of the cylinders for a complete engine cycle are displayed simultaneously on the screen, the cylinders being displayed in horizontal progression across the width of the screen in a parade sweep and being stacked vertically one atop the other in a raster sweep. Since engine sweeps begin and end with the firing of a cylinder, the time represented by an engine sweep varies with engine speed. Fixed-time sweeps (e.g., 10 ms, 100 ms, etc.) display a fixed period of time across the width of the screen display, and are typically used to display waveforms other than primary and secondary waveforms.
An oscilloscope screen essentially displays snapshots of discrete portions of the waveform representing an electrical signal. The mechanism which determines the starting point for each snapshot is referred to as triggering. Prior digital analyzer scopes have supported three types of triggering, viz., auto, signal and cylinder triggering. Auto triggering occurs randomly on a periodic basis, the repeat rate being determined by the selected horizontal time scale. Signal triggering occurs when the displayed signal crosses a threshold level with either a rising or a falling slope. The threshold level and the slope can typically be set by the user. Cylinder triggering occurs when a selected cylinder of the engine under test is fired. This latter trigger mode is used to examine signals from the electrical system of the engine while synchronizing with a selected cylinder. Cylinder triggering normally requires that the no. 1 pickup and either a primary or secondary signal pickup be connected to the engine.
It is known in prior digital engine analyzers to operate the analyzer in either ignition scope mode or a standard lab scope mode. The ignition scope mode is normally used for analyzing primary and secondary waveforms. The lab scope mode is typically used for analyzing waveforms other than primary and secondary waveforms, the display of which other waveforms utilizes a fixed-time sweep. Accordingly, such prior analyzers must use either auto or signal triggering when operating in the lab scope mode and, similarly, are typically constrained to use cylinder triggering when operating in the cylinder or ignition scope mode. Thus, prior engine analyzers do not permit cylinder triggering when viewing a waveform with a fixed-time sweep.
SUMMARY OF THE INVENTION
It is a general object of the invention to provide an improved method and apparatus for analyzing waveforms of multi-cylinder internal combustion engines, which avoid the disadvantages of prior apparatus and methods while affording additional structural and operating advantages.
An important feature of the invention is the provision of a method for utilizing cylinder triggering of a waveform display with a fixed-time sweep.
In connection with the foregoing feature, another feature of the invention is the provision of a method of the type set forth, which affords user selection of the trigger cylinder from a control panel.
A further feature of the invention is the provision of an apparatus for performing the method of the type set forth.
Certain ones of these and other features of the invention are attained by providing a system for analyzing the operation of a multi-cylinder internal combustion engine in which the cylinders are fired in a predetermined firing ordering beginning with a no. 1 cylinder, the system comprising: sensing means adapted to be coupled to an associated engine for generating a cylinder clock signal indicative of the firing of each cylinder and a sync signal indicative of the firing of the no. 1 cylinder, waveform acquisition means adapted to be coupled to the associated engine for receiving analog input waveforms therefrom and generating digitized waveform data representative of such analog waveforms, memory means for storing the digitized waveform data, means responsive to the cylinder clock signal and the sync signal for identifying cylinder firings, a display device having a screen display with a fixed-time sweep for displaying stored waveform data, processing means coupled to the memory means and to the display device and operating under stored program control for controlling storage and display of the waveform data, the processing means including trigger means for controlling the triggering of the display device at a trigger point which corresponds to the firing of a preselected trigger cylinder so that the displayed waveform data includes data for a period of time beginning with the firing of the trigger cylinder, and switch means operable for selecting the trigger cylinder for triggering the display device.
The invention consists of certain novel features and a combination of parts hereinafter fully described, illustrated in the accompanying drawings, and particularly pointed out in the appended claims, it being understood that various changes in the details may be made without departing from the spirit, or sacrificing any of the advantages of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
For the purpose of facilitating an understanding of the invention, there is illustrated in the accompanying drawings a preferred embodiment thereof, from an inspection of which, when considered in connection with the following description, the invention, its construction and operation, and many of its advantages should be readily understood and appreciated.
FIG. 1 is a functional block diagram of an engine analyzer system incorporating a digital oscilloscope display in accordance with the present invention;
FIG. 2 is a screen display obtainable with the engine analyzer system of FIG. 1; and
FIG. 3 is a flow chart diagram of a software program of the engine analyzer of FIG. 1 for controlling the triggering of the waveform display.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, there is illustrated an engine analyzer, generally designated by the numeral 10, in accordance with the present invention. The engine analyzer 10 is adapted for analyzing the operation of an associated multi-cylinder internal combustion engine 11 by, inter alia, monitoring analog waveform signals generated by the engine 11. In this regard, the analyzer 10 is provided with a plurality of signal pickup leads 12 adapted for connection to selected points in the engine 11 for acquiring input signals therefrom. While three such leads have been shown in FIG. 1, this is simply for purposes of illustration, and it will be appreciated that a larger number of leads may be provided. The signal pickup leads 12 preferably include a no. 1 cylinder probe for coupling to the no. 1 cylinder and primary and secondary leads for, respectively, acquiring the voltages on the primary and secondary windings of the ignition coil, all in a known manner. Other auxiliary leads may be provided for acquiring other signals, including non-ignition related signals, which auxiliary leads may include general-purpose voltage pickup probes, which will hereinafter be referred to as "pinpoint" leads.
The signal pickup leads 12 are coupled to a signal conditioning and trigger detection module 13, which performs pre-conditioning operations on the input waveform signals and passes the waveform signals to a data acquisition system 15. The signal conditioning and trigger detection module 13 also generates two digital signals, a cylinder clock signal indicating the firing of each cylinder, and an engine sync signal indicative of the firing of the no. 1 cylinder, which latter signals are also supplied to the data acquisition system 15, which digitizes the analog input waveform signals to produce digitized waveform data. The digitized waveform data is passed to a direct memory access (DMA) controller 16, which controls its storage in a memory 17.
The analyzer 10 also includes a central processing unit (CPU) 18 which includes a trigger control function 19 and is coupled to each of the data acquisition system 15, the DNA controller 16 and the memory 17, as well as to a display module 20. The CPU 18, under program control, controls the operation of the data acquisition system 15 and the DMA controller 16 and also receives interrupts from the data acquisition system 15, which interrupts may be responsive, inter alia, to the cylinder clock signals. The CPU 18 also controls transfer of stored waveform data from the memory 17 to the display module 20 for display, and also controls the various operational modes of the display module 20. In this regard, the display module 20 is preferably a color oscilloscope display and is operable in live and freeze modes, in single-trace and dual-trace modes, with various sweeps and with various types of triggering, the latter being controlled by the trigger control function 19. User selection of these and other parameters is effected through an appropriate user interface, which may include a keyboard 21 and/or a mouse 22 which are coupled to the CPU 18.
The display module 20 is provided with a plurality of different fixed-time sweeps and the usual cylinder, parade and raster engine sweeps, as described above in connection with prior engine analyzers. In addition, the display module 20 is preferably provided with 5 ms engine sweeps, which are similar to the standard engine sweeps discussed above, except that only the first 5 ms of each cylinder is plotted. There are 5 ms engine sweeps corresponding to each of the standard engine sweeps, viz., cylinder 5 ms, parade 5 ms and raster 5 ms.
When the display module 20 is operating in dual-trace mode, a number of restrictions apply to the combinations of sweeps allowed on the two traces. If the first trace is a fixed-time sweep, the sweep for the second trace is forced to have the same sweep as the first trace. If the first trace is an engine sweep, the second trace must also be an engine sweep, although it can be a different engine sweep. For example, the first trace can be a cylinder sweep and the second trace can be a parade sweep. If the first trace is a 5 ms engine sweep, the second trace must also be a 5 ms engine sweep. For example, the first trace can be a cylinder 5 ms sweep and the second trace can be a parade 5 ms sweep. Thus, the sweeps for the two traces must be of the same type. It will be appreciated that these rules are enforced by the operating software of the central processing unit 18 in a manner which precludes invalid combinations.
The digital waveform data in the analyzer 10 is managed and stored in the memory 17 by frames, wherein a frame is the waveform data for the time period across the width of the screen display in the case of a fixed-time sweep. The cylinder clock and engine sync signals permit the analyzer 10 to keep track of the cylinders in a known manner.
The engine analyzer 10 supports all of the three standard types of triggering for digital display scopes in engine analyzers, viz., cylinder triggering, automatic triggering and signal triggering. Engine sweeps and 5 ms engine sweeps use cylinder triggering. Fixed-time sweeps use either automatic or signal triggering, as is standard in prior art digital scopes and engine analyzers. However, it is a significant aspect of the present invention that the analyzer 10 also supports the use of cylinder triggering with fixed-time sweeps.
Referring now to FIG. 2, there is illustrated a screen display 30 which is one of a number of screen displays available with the engine analyzer 10, which will be useful for explaining the significant aspects of the invention. The screen display 30 is set up in a single-trace display mode, so that it has a single rectangular waveform plot area 31 for displaying a waveform along a horizontal axis or trace. Displayed below the waveform plot area 31 is a control panel area 32, including a number of icons and indicators in the nature of rectangular boxes in which text or other indicia may be displayed, the boxes being arranged in horizontal rows. In the lowermost row is a scope mode indicator 33, which indicates the selected scope mode. In this case the indicated mode is "Lab Scope", which is typically used for displaying signals other than primary and secondary signals. In Lab Scope mode, the display module 20 always uses a fixed-time sweep. Another common mode (not shown) is Ignition Scope, which is used for displaying primary and secondary ignition waveforms. An engine sweep is always used in the Ignition Scope mode.
The control panel area 32 also includes a Signal icon 34, which includes boxes 34a and 34b for respectively indicating the signals displayed in the two traces of the dual-trace display scope. In each of these boxes, the user can select from among a plurality of different signal options, with different options respectively corresponding to different ones of the signal pickup leads 12. In this case, the signal displayed on the first trace is the signal appearing on the "pinpoint 1" lead. For the box 34b, one of the available options is "OFF". When this option is selected, as in FIG. 2, the second trace is OFF so that the scope is operating in single-trace mode.
There is also a Pattern/Sweep icon 35 which indicates the selected sweep, in this case a 100 ms fixed-time sweep. As was indicated above, since a Lab Scope display mode has been selected, only fixed-time sweeps can be used. Time indicia 36 indicating the sweep time scale are displayed across the bottom of the waveform plot area 31 in 20 ms increments.
There is also provided a Scale icon 37 which indicates the scale of the plot area 31 along the vertical axis. In this case a 25-volt scale has been selected. Accordingly, scale indicia 38 are arranged in 5-volt increments along the left-hand side of the waveform plot area 31. In this case, it will be noted that the zero level of the scale is set so that the scale goes from -5 volts to +20 volts. The location of this zero level can be selectively changed by the use of control arrows 39.
The control panel area 32 also includes a Trigger icon 40, which includes a box 40a for indicating which one of the three types of triggering has been selected. In accordance with the present invention, the user can select from among not only auto and signal triggering, as in the prior art, but also cylinder triggering, as in FIG. 2. When cylinder triggering is selected, the icon 40 also includes a box 40b which indicates the particular cylinder which is being used as the trigger. The icon 40 also includes a box 40c which indicates the particular one of signal pickup leads 12 from which the trigger signal is being acquired, in this case the secondary lead.
It will be appreciated that, normally, each of the icons 35, 37 and 40 includes vertically arranged boxes respectively corresponding to the two traces of the scope. However, in this case, since a single-trace mode has been selected, the boxes corresponding to the second trace are eliminated.
The screen display 30 also includes a memory buffer icon 41 in the nature of a narrow vertical box arranged along the right-hand side of the waveform plot area 31 which, in the live display mode illustrated in FIG. 2, illustrates by the darkened area the portion of the memory storage buffers which are filled. It will also be noted that the waveform plot area 31 is provided with horizontal and vertical dotted grid lines 42, respectively aligned with the vertical and horizontal scale indica. If desired, these grid lines can be selectively turned off by the user. There are also displayed in the waveform plot area 31 cylinder indicia 43 which indicate the cylinder numbers and the points at which the respective cylinders are fired. These indicia may also optionally be turned off. An RPM indicator 44 is also provided in the upper right-hand corner of the screen indicating the current speed of the engine under test.
As can be seen in FIG. 2, the screen display 30 includes other icons, indicators and other types of indicia which are not pertinent to the present invention and, therefore, are not discussed herein.
A waveform 45 is plotted in the waveform plot area 31, a starter crank signal being shown for purposes of illustration. By default, the trigger point 46 of the of the waveform display is positioned at the left-hand edge of the waveform plot area 31. This trigger point is indicated by a trigger cursor 47, which is a triangular icon, only half of which is illustrated in FIG. 2, since the apex of the triangle signifies the trigger point. Note that the cylinder indicium 43 for cylinder 3, the selected trigger cylinder in this case, also appears in vertical alignment with the trigger cursor 47. The position of the trigger point on the screen can be selectively shifted to coincide with any of the time indicia 36, in a manner described below.
In general, each of the several icons in the control panel area 32 represents a switch, which can be operated by the user by means of either the keyboard 21 or the mouse 22. For the icons above the bottom row, i.e., icons 34, 35, 37 and 40, the icon box with respect to which a selection is to be made is first activated, activation being indicated on the screen by emphasizing the icon. Emphasis is indicated by a thickened or brightened border around the box. Thus, in FIG. 2 box 34b is emphasized. With the keyboard 21, the arrow keys are used to shift the activation and emphasis to the appropriate box and then the "+" and "-" keys are used to increment or decrement the selections within the emphasized box. With the mouse 22, the mouse is clicked once on the box to be activated to emphasize it. Then each subsequent click of the mouse button on the emphasized icon will index the switch one option forward. Alternatively, the mouse button can be held down, locking the cursor within the emphasized box, and the mouse is then moved up and down to scroll the available options through the emphasized box. The option within the emphasized box is selected as soon as it appears in the box. In this manner, the user can selectively change the trigger mode by use of the icon box 40a. When trigger cylinder is selected, the default trigger cylinder is the no. 1 cylinder, which the user can change by use of the icon box 40b.
Adjustment of the trigger offset, i.e., the position of the trigger point 46 on the screen, is by a slightly different technique. With the keyboard 21, the user activates the Pattern/Sweep box and then uses the "page up" and "page down" keys to shift the trigger cursor 47 to the right or to the left, with each operation of the key shifting the cursor one time-scale division, in this case 20 ms. By use of the mouse 22, the user places the mouse cursor on the appropriate one of the arrow icons 48 and then clicks the mouse button, with each click jumping the trigger cursor 47 one scale division (20 ms in this case) either right or left, depending upon which arrow is selected.
While the above-described switch selection techniques are used in the preferred embodiment, it will be appreciated that the engine analyzer 10 could be programmed so that switch selections could be made with other combinations of operations of the keyboard 21 and/or the mouse 22.
Referring now to FIG. 3, there is illustrated a flow diagram 50 indicating the triggering selection routine when the display module 20 is operating in the Lab Scope or fixed-time sweep mode. When the lab scope mode is entered at 51, the program first at 52 initializes the hardware and starts data acquisition by the data acquisition system 15 for a fixed-time sweep and enables data storage in the memory 17 via the DMA controller 16. Then, at 53 the program checks to see if the EXIT key has been pressed. If so, the routine is exited at 54. If not, the program next asks at 55 if a control panel switch has been activated. If so, the program checks at 56 to see if it is the cylinder selection switch of icon 40a. If so, it modifies the trigger cylinder selection accordingly at 57 and then returns to block 52. If it was not the cylinder selection switch, the program processes the other switches at 59 before returning to block 52.
If, at 55, a switch was not activated, the program checks at 59 to see if cylinder triggering has been selected. If not, the program processes auto and signal triggering at 60 and then returns to decision 53. If cylinder triggering has been selected, the program checks at 61 to see if the firing of the selected trigger cylinder has been detected. If it has, the program then, at 62, records the location of the cylinder firing with reference to the waveform data, and then at 63 waits one sweep time for waveform data to accumulate. Then, at 64, the program plots the waveform data starting at the trigger cylinder firing as previously recorded, or if there is a trigger offset, starting the trigger offset time prior to the firing of the trigger cylinder, and returns to decision 53. If, at 61, the firing of the trigger cylinder has not been detected, the program returns immediately to decision 53.
From the foregoing, it can be seen that there has been provided an improved engine analyzer which permits the use of cylinder triggering with a fixed-time sweep on an oscilloscope display, while also permitting user-selection of the trigger cylinder.
While particular embodiments of the present 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. The matter set forth in the foregoing description and accompanying drawings is offered by way of illustration only and not as a limitation. The actual scope of the invention is intended to be defined in the following claims when viewed in their proper perspective based on the prior art. | An engine analyzer has an oscilloscope screen display operable with a fixed-time sweep. The analyzer includes a data acquisition system for digitizing analog input waveforms and a memory for storing the digitized waveform data, the analyzer including sensors for detecting each cylinder firing and the firing of the no. 1 cylinder for identification of the cylinders. A processor includes trigger means for controlling the triggering of the oscilloscope display at a trigger point which corresponds to the firing of a trigger cylinder which is selectable by the user, so that the displayed waveform data begins with the stored data for the selected trigger cylinder. The user can also selectively vary the location of the trigger point on the screen display. | 5 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to currently pending, previously filed, U.S. Provisional Patent Application Ser. No. 60/605,729, filed Aug. 30, 2004, for “Architectural Cornice, Parapet and Column-Capping Module”. The entire disclosure content of this prior-filed provisional application is hereby incorporated herein by reference.
BACKGROUND AND SUMMARY OF THE INVENTION
[0002] In the architecture and outwardly visible design of many plural-story buildings, decorative (and otherwise functional) roof-rimming parapet, or cornice/parapet, structure is often employed. Such structure is normally made to be intentionally ornamental, and may also function as structure which additionally visually obscures, from ground(or other)-level lateral view, building equipment infrastructure, such as heating and airconditioning, etc. equipment, mounted on the roof top surface, or plane, of a building. Such parapet structure, which is also referred to herein as a parapet roof rim, may also serve conveniently and importantly as a personnel guard wall along a roof's edge/perimeter.
[0003] The present invention generally concerns such parapet structure, or parapet roof-rim structure, and more specifically, parapet structure which is designed into the form of modular parapet units which can be pre-designed to have various different decorative profiles and appearances (configurations), and which can quickly, conveniently, easily and changeably, be “hung” and stabilized by gravity adjacent the rim of a building's roof structure to provide all of the parapet functions mentioned above, and more.
[0004] In general terms, the modular parapet units which are proposed by the present invention “fit” categorically into elongate, modular configurations which can be characterized as (a) being straight and linear, (b) possessing an inside corner (typically about 90 degrees) configuration, and (c) possessing an outside corner (typically about 270-degrees) configuration. The modular parapet structure of this invention is, of course, and with respect to angular configurations, not confined to the two specific corner configurations just generally mentioned.
[0005] As will be seen, in addition to the various conventional parapet functions which are furnished by the modular structure of this invention, also furnished very conveniently by the invention is the opportunity for ready modular pre-design of parapet units of virtually any appropriate outside appearance, which units can be prepared for installation in a building construction. Additionally offered by the present invention is an opportunity for selective changing from time to time of the effective appearance of a building, simply through the easily implemented practice of changing the specific gravity-hung parapet structure per se.
[0006] The units of this modular invention, while very appropriately hung and stabilized by gravity, preferably in such a fashion that inwardly and downwardly directed vectors which produce angular moments tend to hold the hung units against the supporting building structure with which they dock, can also be positively locked against inadvertent removal in any one of a number of different, preferably reversible/undoable manners.
[0007] As will be seen, one interesting feature of one characteristic embodiment of the invention is that certain interconnecting components of the proposed parapet structure can function to lock between them sheets of moisture-barriering flashing structure to provide excellent weather sealing around and along a building's roof-rim perimeter.
[0008] The various features and advantages which are offered and attained by the present invention will now become more fully apparent as the description which follows below is read in conjunction with the accompanying drawings.
DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a fragmentary, simplified, isometric view of a corner region in a plural-story building illustrating both inside and outside corner structure features, with respect to which modular parapet structure made in accordance with the present invention is shown to be in place. Several parapet units, both linear and angular, are shown in this figure.
[0010] FIG. 2 is a somewhat enlarged, simplified, schematic and fragmentary view, taken generally as if along line 2 - 2 in FIG. 1 , illustrating, in very general terms, how a representative parapet unit made in accordance with practice of the present invention may be gravity hung and stabilized, and if desired releasably locked in place, on what is referred to herein as docking structure which is provided adjacent the edge-defining perimeter, or rim, of the plane of the roof structure provided by the frame of the building structure shown in FIG. 1 . FIG. 2 also illustrates how implementation and installation of the parapet structure of this invention can function to obscure, beyond certain angular lines of lateral view relative to the horizontal, direct viewing of building equipment structure mounted on the roof of the building illustrated in FIGS. 1 and 2 .
[0011] FIG. 3 provides a somewhat more detailed view, like that presented by a portion of FIG. 2 , illustrating one representative set of forms of gravity-docking reception structure and gravity-docking structure employed in accordance with the modular parapet structure of the present invention, illustrated in essentially the same settings pictured in FIGS. 1 and 2 . FIG. 3 is presented on a slightly larger scale than that employed in FIG. 2 .
[0012] FIGS. 4 and 5 are similar to FIG. 3 , except that, on a slightly larger scale, they illustrate two, different, outwardly appearing ornamental, roof-rimming configurations for the body of a modular parapet unit made in accordance with practice of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0013] Turning now to the drawings, and referring first of all to FIGS. 1 and 2 , indicated generally at 10 is a plural-story building including an internal frame, or frame structure, 12 on the outside of which is mounted a suitable surfacing structure 14 . Specifically shown in FIG. 1 is what can be thought of as being an outside corner portion, or region, of building 12 , including a pair of outside corners 10 a , 10 b which are defined by angles of about 270-degrees, and an inside corner 10 c which is defined by angle of about 90-degrees.
[0014] While frame 12 and surfacing structure 14 can, as will become apparent, take a number of different forms, the specifics of which forms constitute no part of the present invention, for the purpose of description and illustration herein, building frame 12 has been built in accordance with the teachings of U.S. Pat. No. 6,837,016 B2 which illustrates and describes a plural-story, moment-frame structure, and surfacing structure 14 takes the form of the surfacing structure described in currently pending U.S. patent application Ser. No. 10/818,014, filed Apr. 5, 2004 for “Matrix Frame/Panel Skin Building Structure”.
[0015] Defined by the upper portion of frame structure 12 is roof structure 16 which, in building 10 , is defined by what is referred to herein as a perimeter-rimmed, or edge-rimmed, upper surface, or plane, 16 a . Illustrated at 18 in FIGS. 1 and 2 is a fragmentary portion of roof-mounted building equipment structure, such as air conditioning structure, which is disposed inwardly from the perimeter of roof structure 16 .
[0016] In accordance with practice of the present invention, the elongate edges, or perimeter stretches, of roof structure 16 are provided with changeable and selectively reconfigurable, modular, parapet roof-rim structure, or roof-rim parapet structure, 20 , constructed in accordance with the present invention. Parapet structure 20 herein includes plural modular units, such as straight and linear units 20 a , outside corner units, such as units 20 b , and inside corner units (where required) such as single inside corner unit 20 c.
[0017] Adding reference now to FIG. 3 along with FIGS. 1 and 2 , the units in parapet structure 20 have been designed with predetermined cross-sectional configurations, such as the configuration generally shown in FIGS. 1, 2 and 3 —a configuration which has been purposely designed to provide building 10 with a roof-rimming parapet structure of having a selected, pleasing ornamental design. As will become apparent, an interesting and important feature of the invention is that the structure and practice of this invention allow for essentially any appropriate, selectable cross-sectional ornamental configuration, and thus permit a building's roof rim structure to be decorated with a variety of different designable looks. Moreover, and as will also become apparent, the fact of constructing a building, such as building 10 , with a given design for a parapet structure constructed in accordance with the invention, does not prevent this look from being changed at a later date if so desired simply by removing the removably mounted parapet units of one design and replacing them with appropriate modular units of another design.
[0018] Included in parapet structure 20 is what is referred to herein as a gravity-lock engageable, gravity-docking reception structure, riser structure, or vertically protruding lip 22 which is suitably joined to building frame 12 as a structure effectively distributed along the rim of roof structure 16 . Structure 22 rises by a selectable, appropriate elevation H 1 above plane 16 a . In the specific embodiment of the invention which is now being described, the upper end of this riser structure has, as can be seen, a somewhat inverted, U-shaped, cross-sectional configuration which is intended, as will be explained, dockably to receive complementary, external gravity-docking structure (also referred to as complementary structure) which is provided on the inner sides of parapet units, or components, 20 a , 20 b , 20 c . Those skilled in the art will recognize that gravity-docking reception structure 22 can be shaped in various different ways, can be placed at different selected elevations effectively above the plane of a roof top, such as plane 16 a , and may be suitably integrated with a building surfacing structure, or with the framework for such a surfacing structure, such as surfacing structure 14 . In the illustration provided in FIGS. 2 and 3 , integration with surfacing structure 14 is what is specifically shown.
[0019] The earlier-mentioned docking structure which, of course, is external to structure 22 , and which is also referred to herein as gravity-docking structure, and as hook structure, has the illustrated, generally inverted U-shaped hooklike configuration which enables it to be lowered and gravity caught and locked, so-to-speak, on structure 22 . This hook structure is shown generally at 24 in FIGS. 2 and 3 .
[0020] It will be evident that the specific structural configurations for riser structure 22 and hook structure 24 may take on a host of different configurations depending upon designer choice. What is important is that the riser structure and the hook structure be configured so that the parapet units of the invention can be gravity-impelled lowered, as illustrated by arrow 26 in FIG. 2 , to cause the hook structure to “dock” with the upper end of the riser structure at the appropriate lateral location along the building roof rim, whereby the different parapet units become, automatically, properly seated and gravity locked, so-to-speak, in a condition (vertical arrangement/fit) with the relevant hook structures appropriately docked with the riser structure. Preferably, the riser structure and the hook structure of this invention are configured in such a fashion that when docking occurs, there a tendency for the relevant parapet unit to experience inwardly and downwardly directed vectors which produce an angular moment as illustrated by arrow 28 in FIG. 2 . This moment causes the associated parapet unit to seat in an appropriate disposition relative to the associated building structure. This characteristic of the parapet structure of this invention is referred to herein as a self-locating interaction characteristic.
[0021] Preferably, once a parapet unit has been appropriately docked in place, so-to-speak, it is then anchored against inadvertent movement by an appropriate removable locking structure, such as a bolting structure like that shown generally at 30 in FIG. 3 .
[0022] As can be seen, the parapet structure so far described is one which offers basically all of the features and advantages that are considered (as expressed earlier herein) to be interesting and important in a building parapet structure. This parapet structure may take on a number of different shapes and forms to provide a selected, decorative outside rimming appearance for the roof rim structure in a building. The proposed modular parapet structure can easily and quickly, and without complexity, be lowered, self-positioned, and gravity-seat stabilized and locked in position, as determined by the dockingly interengaged gravity-docking reception structure and the gravity-docking structure. The specific sizes with are employed in a particular building construction are clearly a matter of designer choice. Preferably, the interactive reception and gravity-docking structures are designed whereby, with the parapet roof-rim structure in place, it rises sufficiently above the roof elevation (see H 2 in FIG. 3 ), not only to provide a personnel protective barrier (a rim wall), around the perimeter of a roof structure, but also to furnish visual occlusion below a certain, shallow angle below the horizontal, such as angle a pictured in FIG. 2 , of rooftop building equipment structure, such as structure 18 . Dash-double-dot line 32 in FIG. 2 illustrates this occluding capability of the structure of this invention relative to a finally positioned parapet unit 20 a which is shown seated in a finally established position in dashed lines in FIG. 2 .
[0023] As has been mentioned herein, the parapet structure of this invention offers the opportunity for wide ranging designing and installation use of different, ornamental parapet configurations, and two, additional such configurations are shown at 34 , 36 in FIGS. 4 and 5 , respectively, in drawings to illustrate this import characteristic of the invention.
[0024] Another selectively useable feature of the invention, employable in certain modifications thereof, involves using the basic interconnecting components of the parapet roof-rim structure of the invention to lock between them expanses of sheet-like moisture-barriering flashing structure. Heavy, darkened lines 38 in FIGS. 2-5 , inclusive, show such a flashing structure.
[0025] In FIGS. 2 and 3 , flashing structure 38 includes outer and inner expanses 38 a , 38 b which lie adjacent the outer and inner sides (the left and right sides, respectively, in these figures) of gravity-docking reception structure 22 , and a connector expanse 38 c which joins expanses 38 a , 38 b where it extends laterally over the top of structure 22 .
[0026] In FIGS. 4 and 5 , flashing structure 38 does not include connector expanse 38 c.
[0027] In all four of these figures, inner flashing-structure expanse 38 b extends downwardly along the inner side of structure 22 , and as a continuum laterally inwardly in an expanse 38 d which substantially directly overlies the plane of building roof structure 16 .
[0028] Obviously, the materials employed in the implementation of this invention are a matter of designer choice, as are the sizes of parapet units, the configurations of such units, and the specific configurations of the hook and riser structures which interact to promote gravity seating and locking of a parapet unit in place. Also, it will be clear that the proposed parapet roof-rim structure of this invention readily lends itself to various kinds of cooperative incorporation in a wide variety of building roof rim structures.
[0029] Accordingly, while a preferred embodiment, and certain variations thereof, have been described herein for the parapet structure of this invention, other variations and modifications, some of which have been generally suggested, are clearly possible, and are considered to come within the scope of the claims and spirit of this invention. | Modular, selectively employable building parapet roof-rim structure including (a) gravity-docking reception structure deployed along and adjacent at least a portion of the perimeter of a building roof structure which is adjacent the top of a building frame, and (b) a dockable, modular parapet unit including gravity-docking structure removably and replaceably dockable, under the influence of gravity, with the reception structure to dispose the parapet unit as at least a part of an outwardly visible parapet roof-rim structure associated with the building roof structure. The parapet structure may be associated with moisture-barriering flashing structure which becomes locked into place along the rim of a building roof between inter-engaging components in the parapet structure. | 4 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims benefit United States provisional patent application Ser. No. 60/275,740, filed Mar. 14, 2001, hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of Invention
[0003] This invention relates to a game; and more particularly to a board game for children, as well as adults.
[0004] 2. Related Art
[0005] Many different types of board games are known in the art, including U.S. Pat. No. 4,934,708 that describes a family quiz board game. However, the inventor is not aware of a board game having a picnic motif featuring ant movements and ant related structures for children, as well as adults, especially which reinforces each player's knowledge of mathematical relationships, such as odd numbers, even numbers and greater than and less than relationships.
SUMMARY OF THE INVENTION
[0006] In its broadest sense, the invention provides a method for playing a game involving family members, wherein each player's knowledge of mathematical relationships. The mathematical relationships may include a greater than relationship, a less than relationship, an odd number relationship, an even number relationship, or a combination thereof. The method includes the following steps:
[0007] Each player is provided with a token.
[0008] A game board is provided having
[0009] a start space,
[0010] an end space,
[0011] a plurality of sequentially disposed game spaces arranged between the start space and the end space,
[0012] an ant cave arranged in relation to one of the sequentially disposed game spaces,
[0013] an ant tunnel arranged between and connecting a first one of the sequentially disposed game spaces and a second non-adjacent one of the sequentially disposed game spaces so that a player whose token lands on the first one of the sequentially disposed game spaces may move across the ant tunnel to a given one of the sequentially disposed game spaces located on the other side of the ant tunnel, and
[0014] a move-to-ant-cave indicator on selected ones of said sequentially disposed game spaces indicating that a player whose token lands thereon is to go to the ant cave on the game board. The ant cave is typically located less than five game board spaces from the start space to effectively send the player almost back to the start space.
[0015] A mathematical relationship indicator is provided for indicating one or more mathematical relationships. The mathematical relationship indicator would typically include playing cards having the one or more mathematical relations printed thereon. However, the mathematical relationship indicator may also be any other device for providing a mathematical relationship in relation to a request from a player, e.g a computerized mathematical relationship indicator where a player presses a button and a mathematical relationship is displayed.
[0016] A random number generator is provided operable for providing a random number signifying a number of the sequentially disposed game board spaces to which each player advances the player's token. The random number generator would typically be a die having two or more numbers printed thereon. The die would be a cube having the numbers 1-6 printed thereon. However, the random number generator may also be any other device for providing a random number in relation to a request from a player, e.g a computerized random number generator.
[0017] Each player sequentially determines the number of sequentially disposed game board spaces to advance the player's token by operating the random number generator on each player's turn.
[0018] When the player's token lands on the first one of the sequentially disposed game spaces on a player's turn, then on a player's next turn a player's token may be advanced across the ant tunnel.
[0019] When the player lands on the selected ones of the sequentially disposed game board spaces having the move-to-ant-cave indicator, the player's token is moved to the ant cave.
[0020] The player's token is moved from the ant cave to one of the sequentially disposed game board spaces determined the number provided by the random number generator on the player's next turn after:
[0021] the player determines a mathematical relationship provided by the mathematical relationship indicator, which is typically done by picking a playing card,
[0022] the player determines the random number provided by the random number generator signifying the number of the sequentially disposed game board spaces to which the player may advance the player's token, which is typically done by rolling the die, and
[0023] the player moves the player's token from the ant cave only when to the random number satisfies the mathematical relation provided by the mathematical relationship indicator.
[0024] A game winner is determined as a first player that moves the player's token from the start space to the end space.
DESCRIPTION OF THE DRAWING
[0025] The drawing includes FIGS. 1 - 2 as follows:
[0026] [0026]FIG. 1 shows a game board for a game that is the subject matter of the present invention.
[0027] [0027]FIG. 2, including FIGS. 2 ( a ) to ( l ), shows game cards for use with the game board shown in FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
[0028] Game Parts Lists
[0029] The game includes the following parts:
[0030] 1. A game board 10 shown in FIG. 1;
[0031] 2. Game or playing cards shown in FIG. 2;
[0032] 3. Ant game pieces for two or more players;
[0033] 4. A game die having six sides; and
[0034] 5. An instruction sheet.
[0035] [0035]FIG. 1: Game Board
[0036] [0036]FIG. 1 shows a game board generally indicated as 10 having a start space or box 12 , an end space or box 14 , a series of game spaces or locations 16 , 18 , 20 , . . . , 120 in between, an ant cave 130 , an ant tunnel 140 and a location 150 for placing the game cards (FIG. 2). As shown, the ant cave 130 is positioned next to a space 22 , and the ant tunnel 140 is position between spaces 44 and 86 .
[0037] The start space or box 12 is the location where the ant game pieces or tokens of two or more players are placed to start the game.
[0038] The object of the game is to be the first player to land on the end space 14 and win the game.
[0039] The series of game spaces 16 , 18 , . . . , 120 are arranged between the start space 12 and the end space 14 where the players land after rolling the game die and moving their game piece or token. As shown, the series of game spaces 20 16 , 18 , . . . , 120 include shaded spaces 22 , 32 , 46 , 50 , 68 , 72 , 84 , 92 , 106 and 116 and non-shaded spaces 16 - 20 , 24 - 30 , 34 - 44 , 48 , 52 - 66 , 70 , 74 - 82 , 86 - 90 , 94 - 104 , and 108 - 114 and 118 - 120 .
[0040] [0040]FIG. 2: Game Playing Cards
[0041] [0041]FIG. 2 shows the game playing cards include cards 200 , 202 , 204 , . . . , 218 having the following conditions:
[0042] 1. Card 200 —Greater than 1 (FIG. 2 ( a ));
[0043] 2. Card 202 —Greater than 2 (FIG. 2 ( b ));
[0044] 3. Card 204 —Greater than 3 (FIG. 2 ( c ));
[0045] 4. Card 206 —Greater than 4 (FIG. 2 ( d ));
[0046] 5. Card 208 —Greater than 5 (FIG. 2 ( e ));
[0047] 6. Card 210 —Less than 2 (FIG. 2 ( f ));
[0048] 7. Card 212 —Less than 3 (FIG. 2 ( g ));
[0049] 8. Card 214 —Less than 4 (FIG. 2 ( h ));
[0050] 9. Card 216 —Less than 5 (FIG. 2 ( i )); and
[0051] 10. Card 218 —Less than 6 (FIG. 2 ( j )).
[0052] 11. Card 220 —Odd (FIG. 2 ( k ))
[0053] 12. Card 222 —Even (FIG. 2 ( l ))
[0054] Ant Game Pieces or Tokens
[0055] The game pieces or tokens may include two or more different objects, for example, shaped like ants and having different colors for the different players to move around the game board 10 .
[0056] Game Die
[0057] The game die may be a standard die shaped like a cube and having six sides numbered “1”, “2”, “3”, “4”, “5” and “6”. The scope of the invention is also intended to include other types of random number generating means, including, but not limited to, a spinning wheel with numbers 1-6, or a computer random number generator.
[0058] The Instruction Sheet and Rules of the Game
[0059] This patent application in whole or in part may be used as the instruction sheet and include the following rules of play:
[0060] (1) To start the game, each player picks a different ant game piece or token and places it in the start space.
[0061] (2) The players must then determine which player goes first, second, third, etc.
[0062] (3) In order of play, each player takes a turn by rolling the game die and moving their ant game piece the number on the game die around the game board advancing in the direction from the start space 12 to the end space 14 .
[0063] (4) When a player lands on a non-shaded space their turn ends, and the next player goes.
[0064] (5) When a player lands on a shaded space their ant game piece automatically moves into the ant cave 130 , and the next player goes.
[0065] The Ant Cave 130
[0066] (6) In order for a player to get out of the ant cave 130 , on their next turn the player picks a card and rolls the game die. If the number on the game die meets the mathematical condition or relationship on the game card, then the player moves their ant game piece the number on the game die with space 22 counted as their first move. For example, if the player picks a card saying “greater than 2” and rolls a “3” (or higher) on the game die, then the player moves their ant game piece out of the ant cave 130 the number on the game die (i.e. “3”) to the space 26 . If the player rolls a “2” (or less), then the player remains in the ant cave 130 , and the next player goes. Alternatively, if the player picks a card saying “less than 5” and rolls a “4” (or less) on the game die, then the player moves their ant game piece out of the ant cave 130 the number on the game die (i.e. “4”) to the space 28 . In this case, if the player rolls a “5”, then the player remains in the ant cave 130 , and the next player goes. Moreover, as shown, if the player picks a card, rolls a “1” or “6” and meets the condition on the game card, then the player still remains in the ant cave 130 since the spaces 22 and 32 are shaded spaces. (Note that the way the game board 10 is presently configured the card 208 —Greater than 5 (FIG. 2 ( e )) and the card 210 —Less than 2 (FIG. 2 ( f ) would effectively not be needed since if the player rolls a “1” or “6” they remain in the ant cave 130 since the spaces 22 and 32 are shaded spaces.) Alternatively, if the player picks a card saying “odd” and rolls a “1”, “3” or “5” on the game die, then the player moves their ant game piece out of the ant cave 130 the number on the game die (e.g. if the player rolls a “3”, then the player moves to the space 26 ). In this case, if the player rolls a “2”, “4” or “6”, then the player remains in the ant cave 130 , and the next player goes. Alternatively, if the player picks a card saying “even” and rolls a “2”, “4” or “6” on the game die, then the player moves their ant game piece out of the ant cave 130 the number on the game die (e.g. if the player rolls a “4”, then the player moves to the space 28 ) In this case, if the player rolls a “1”, “3” or “5”, then the player remains in the ant cave 130 , and the next player goes.
[0067] The Ant Tunnel 140
[0068] (7) If a player lands on the space 44 , then on their next turn they may take the ant tunnel 140 or not at their discretion. (The player must land on the space 44 to take advantage of this option.) For example, if the player is on the space 44 and rolls a “1”, then the player may move their ant game piece either to the shaded space 46 (go to ant cave 130 ) or the space 86 . (Strategically, the player is likely to cross the ant tunnel and move their ant game piece to space 86 to advance more quickly to the end space 14 .) Alternatively, if the player is on the space 44 and rolls a “4”, then the player may move their ant game piece to either the space 52 or the space 92 . (Strategically, the player is likely to move their ant game piece to space 52 and is not likely to cross the ant tunnel 140 to avoid going to the ant cave 130 after landing on the shaded space 92 .) As described herein, the ant tunnel 140 itself is not considered a space to be counted when a player moves their ant game piece.
The Scope of the Invention
[0069] The scope of the invention is not intended to be limited to the number of shaded or non-shaded spaces, the color of the shaded or non-shaded spaces, the arrangement thereof between the start space 12 and the end space 14 , the shaded spaces being permanently printed on the game board 10 , or the color of the spaces. The scope of the invention is intended to include the game having separated shaded pieces (not shown) for arrangement by the players at the start of the game at different spaces along the path from the start space 12 to the end space 14 . In this game, the game board could come without the shaded space being printed thereon and the players would arrange the separated shaded pieces (not shown) on different non-shaded spaces to make them into shaded spaces. The game is shown and described with one series of game spaces 16 , 18 , . . . , 120 arranged between the start space 12 and the end space 14 . However, the scope of the invention is also intended to include two or more series of game spaces such as 16 , 18 , . . . , 120 arranged between the start space 12 and the end space 14 so players may take different paths to get from the start space 12 to the end space 14 . The two or more series of game spaces may be interconnected so players may move from one series of game spaces to another series of game spaces to get from the start space 12 to the end space 14 . Moreover still, the scope of the invention is also intended to include the non-shaded spaces being colored one color, for example, blue and the shaded spaces being colored a different color, for example, red.
[0070] The scope of the invention is not intended to be limited to the number of ant caves, the placement thereof between the start space 12 and the end space 14 , or the ant cave(s) being permanently printed on the game board 10 . For example, the game may have more than one ant cave, and different shaded spaces may send a player back to different ant caves. The scope of the invention is also intended to include the game having one or more separated ant cave pieces (not shown) for arrangement by the players at the start of the game at different spaces along the path from the start space 12 to the end space 14 . In this game, the game board 10 could come without the ant cave 130 being printed on the game board 10 , and the players would arrange the ant cave(s) at different spaces along the path from the start space 12 to the end space 14 .
[0071] The scope of the invention is not intended to be limited to the position of the shaded space in relation to the ant cave 130 . For example, the shaded space may be arranged “2”, “3”, “4” and “5” or more spaces away from the ant cave 130 , instead of at the shaded spaces 22 and 32 as shown in FIG. 1 where rolls of “1” and “6” send the player back to the ant cave 130 .
[0072] The scope of the invention is not intended to be limited to the number of ant tunnels, the placement thereof between the start space 12 and the end space 14 , or the ant tunnel(s) being permanently arranged on the game board 10 . For example, the game may have more than one ant tunnel, and different ant tunnels may advance a player to different spaces on the game board. The scope of the invention is also intended to include the game having one or more separated ant tunnel pieces (not shown) for arrangement by the players at the start of the game between different spaces along the path from the start space 12 to the end space 14 . In this game, the game board 10 could come without the ant tunnel 140 being printed on the game board 10 , and the players would arrange the ant tunnel(s) between different spaces.
[0073] The scope of the invention is not intended to be limited to the position of the shaded space in relation to the ant tunnel 140 . For example, the shaded space may be arranged “1”, “2”, “3”, “5”, “6” or more spaces away from the ant tunnel 140 , instead of at the shaded space 92 as shown in FIG. 1 where a roll of “4” sends the player back to the ant cave 130 .
[0074] The scope of the invention is also intended to include the game having an erasable game board for receiving erasable magic marker(s). In this case, the game may come with permanently printed start and end spaces and non-shaded spaces therebetween, the players could color or mark the shaded spaces, ant cave(s) and ant tunnel(s) on the game board at the start of the game. After the game, the players may erase the shaded spaces, the ant cave(s) and the ant tunnel(s) from the game board, and color in new shaded spaces, ant cave(s) and ant tunnel(s) at different spaces at the start of the next game. The game may include different colored magic markers for coloring the shaded spaces, ant cave(s) and ant tunnel(s) in different colors.
[0075] The scope of the invention is not intended to be limited to the number of game cards or the conditions on the game cards. For example, the cards may also include one or more of the aforementioned game cards, and include game cards having the conditions “1”, “2”, “3”, “4”, “5” and “6”, as well as a card saying “lose a turn”, a card saying “you may send another player to the ant cave”, or a card saying “exchange your ant game piece on the game board with an ant game piece of another player”.
[0076] The scope of the invention is not intended to be limited to players moving only forward. The scope of the invention is intended to include the movement of ant game pieces in the forward and/or backward directions at their discretion.
[0077] The scope of the invention is intended to cover game play where one player may land on another player and either player or both players move back to the start space 12 or some other space on the game board.
[0078] The scope of the invention is not intended to be limited to how long a player remains in the ant cave 130 . For example, a player may lose a turn after going to the ant cave 130 , or a player may automatically get out of the ant cave 130 after picking three game cards and making three unsuccessful rolls of the game die.
[0079] The scope of the invention is not limited to how the order of play is determined. For example, each player may roll the game die and the player with the highest roll of the die goes first, and players follow in order of play in a clockwise manner in relation to their space around the game board.
[0080] The scope of the invention is not intended to be limited to the game die, or the number of sides on the game die. For example, the game may be played with a game die having other than six sides or two game dice.
[0081] It is also to be understood that the attached claims cover all of the generic and specific features of the invention herein described and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween. | Ant game is provided for playing with family members, where player's knowledge of mathematical relationships are applied, including greater than, less than, odd number or even number relationship, or a combination thereof. The game board has start and end spaces, sequentially disposed game spaces arranged therebetween, an ant cave arranged next to one sequentially disposed game space, an ant tunnel connecting one sequentially disposed game space and another non-adjacent sequentially disposed game space so that a player whose token lands on the first sequentially disposed game space may move across the ant tunnel to a given sequentially disposed game space located on the other side of the ant tunnel, and a move-to-ant-cave indicator on some sequentially disposed game spaces indicating that a player whose token lands thereon is to go to the ant cave. | 0 |
FIELD OF THE INVENTION
The presently disclosed technology relates to a safety guard for a pallet truck. More particularly, the presently disclosed technology provides a safety guard for the rear steer wheel assembly of a pallet truck.
BACKGROUND OF THE INVENTION
Pallet trucks are used to lift, pull, push, and move loaded pallets. A pallet truck typically includes a frame with two forks extending forwardly of the frame. Extending behind the frame is an operator handle, by which the pallet truck may be maneuvered by a worker. At least one steer wheel is provided behind the frame, and is turnable by movement of the operator handle; two steer wheels are often provided. The steer wheel(s), located behind the frame, is close to the feet of a worker using the pallet truck.
So configured, the pallet truck is pulled and pushed by a worker with the operator handle, the steer wheel(s) allowing for turning of the pallet truck by side-to-side orientation of the operator handle relative to the pallet truck frame.
In operation, the forks of a pallet truck may first be positioned beneath a loaded pallet. By thereafter pivoting the operator handle downwardly, a lifting mechanism of the pallet truck causes the frame and forks to raise, thereby lifting the loaded pallet from the surface upon which it had rested. Various lifting mechanisms have been provided in the art, which cause the forks and frame to lift the weight of the loaded pallet so that the pallet may thereafter be transported upon the pallet truck. Part of the weight of the loaded pallet truck is borne by the steer wheel(s) at the rear of the pallet truck. So loaded, the pallet truck may be pulled and pushed to a second location, and the load thereafter lowered and removed from the forks 24 , 25 .
Various embodiments of pallet trucks are known, as disclosed in part in the following references, the entire disclosure of each of which is incorporated by reference herein in its entirety for all purposes:
U.S. Pat. No. 2,309,138 U.S. Pat. No. 2,488,521 U.S. Pat. No. 2,940,767 U.S. Pat. No. 2,462,007 U.S. Pat. No. 2,993,703 U.S. Pat. No. 3,026,089 U.S. Pat. No. 3,119,627 U.S. Pat. No. 3,188,107 U.S. Pat. No. 3,261,617 U.S. Pat. No. 3,286,985 U.S. Pat. No. 3,462,167 U.S. Pat. No. 3,567,240 U.S. Pat. No. 3,608,922 U.S. Pat. No. 3,701,211 U.S. Pat. No. 3,843,147 U.S. Pat. No. 3,940,338 U.S. Pat. No. 3,982,767 U.S. Pat. No. 4,223,901 U.S. Pat. No. 4,589,669 U.S. Pat. No. 5,253,972 U.S. Pat. No. D401,716 U.S. Pat. No. D419,741
In all such embodiments, at least one steer wheel is included at the rear of the pallet truck, near the location at which the operator of such a pallet truck is positioned during use of the pallet truck.
Use of a pallet truck with a rear steel wheel (or wheels) subjects the operator to the risk of running over his/her foot with the rear steer wheel as the operator pulls the pallet truck toward himself or herself, a maneuver required in the use of such a pallet truck. Particularly with loaded pallet trucks, that risk may cause great physical injury to the foot. An operator's foot may slip to the wheel(s) while trying to pull the pallet truck toward the operator, or an operator may allow his/her foot to remain too long in the path of a steer wheel of a pallet truck rolling backwards. Furthermore, the feet of nearby co-workers are also at risk of injury from the rolling of such rear steer wheels.
In view of the wide use of pallet trucks and the risks of injury to operators thereof of running over one's own foot or the foot of a co-worker with a rear steer wheel, it would be desirable to provide a pallet truck steer wheel safety guard.
SUMMARY OF THE INVENTION
A pallet truck steer wheel safety guard is disclosed. In accordance with certain aspects of certain embodiments of the present subject matter, a combination is provided of a pallet truck that includes a steering assembly and a steer wheel safety guard. The steering assembly includes at least one rear steer wheel, the rear steer wheel defining an axis of rotation residing in a horizontal plane. The axis of rotation may be turnable in the horizontal plane relative to the orientation of the pallet truck. The steer wheel safety guard is carried by the steering assembly and is turnable with the steering assembly relative to the orientation of the pallet truck. The safety guard is disposed behind the rear steer wheel, and defines a length parallel to the axis of rotation of the steer wheel. Further, the safety guard defines a height perpendicular to the length, the height extending below the plane of the axis of rotation of the steer wheel.
In accordance with additional aspects of other embodiments of the present subject matter, the steer wheel safety guard may further include a strut, the strut attached to the safety guard and extending to and attached to the steering assembly. In accordance with yet additional aspects of other embodiments of the present subject matter, the steering assembly may include a steering column, the strut being attached to the steering column.
In accordance with still further aspects of other embodiments of the present subject matter, an axle may be provided, wherein the rear steer wheel rotates upon the axle, and an axle strut may be provided extending from the safety guard to the axle and carried by the axle.
In accordance with other aspects of other embodiments of the present subject matter, a combination is provided that includes a pallet truck with a steering assembly turnable relative to the pallet truck. The steering assembly includes a rear steer wheel defining a width and rotating upon an axle. The axle may reside in a horizontal plane. The combination may further provide a steer wheel safety guard that includes a bumper disposed behind the rear steer wheel and a strut attached to the bumper and carried by the steering assembly. The safety guard may define a length parallel to the axle, the length approximating the width of the rear steer wheel. The safety guard may further define a height perpendicular to the length, the height extending below the plane in which the axle resides.
In accordance with additional aspects of other embodiments of the present subject matter, the rear steer wheel may be adapted to roll upon a surface below the axle, with the safety guard extending downwardly proximate to that surface.
In accordance with still further aspects of the present subject matter, the bumper may include flanges extending forward and adjacent to the rear steer wheel(s). Still further, an axle strut may be provided, extending from the bumper to the axle. The axle strut may define an aperture therethrough, with the axle disposed through the aperture. The axle strut may be disposed upon the axle inboard of the rear steer wheel(s), or outboard of the rear steer wheel(s). Further, the aperture may include a mounting slot adapted for passage of the axle therethrough.
In accordance with aspects of other embodiments of the present subject matter, a combination is provided of a pallet truck and a steer wheel safety guard. The pallet truck has a steering assembly including steer wheels and a steering column. The steer wheels reside on an axis of rotation. The steer wheels together define a side-to-side width along the axis of rotation, and further define a radius of rotation. The steering column may be in communication with the steer wheels to turn the axis of rotation relative to the pallet truck. The safety guard may include a bumper, the bumper being disposed behind the steer wheels. The bumper may define a length parallel to the axis rotation upon which the steer wheels reside, that length at least as great as the side-to-side width of the steer wheels. The bumper may further define a height perpendicular to the length, the height extending at least half of the radius of the steer wheels below the axle. The safety guard may further include a steering column strut, the strut having opposed ends. One end of such steering columns strut may be attached to the bumper and the other end may be attached to the steering column.
In accordance with additional aspects of other embodiments of the present subject matter, the steer wheels may be adapted to roll upon a surface below the axle and the safety guard may extend proximate to that surface. In accordance with yet additional aspects of other embodiments of the present subject matter, the bumper may further include flanges extending forward adjacent to the rear steer wheels.
In accordance with still further aspects of other embodiments of the present subject matter, an axle may be provided along the axis rotation of the steer wheels, and a axle strut may be provided extending from the bumper to the axle. The axle strut may define an aperture therethrough with the axle disposed through the aperture. The axle strut may be disposed upon the axle inboard of the rear steering wheels, or outboard of the rear steering wheels. In other embodiments, the aperture in the axle strut may include a mounting slot adapted for passage therethrough of the axle.
Additional aspects and features of the present subject matter are set forth in the appended drawings and in the detailed description below, or will be apparent to those of ordinary skill in this technology. It should be further appreciated that modifications and variations to specific features and elements may be practiced in various embodiments, and uses of the inventions, without departing from the spirit and scope of the subject matter. Variations might include, but are not limited to, substitution of equivalent means, features, or aspects for those that are illustrated, referenced, or discussed herein, as well as the functional, operational, or positional reverse of various parts, features, aspects, or the like. It is to be understood that different embodiments, as well as presently preferred embodiments of the present subject matter, may include various combinations or configurations of the presently disclosed features, elements, or aspects, or their equivalents. Such embodiments may include combinations of features, parts, or aspects, or configurations thereof that are not expressly shown in the figures or stated in the detailed description. Additional embodiments of the present subject matter, not necessarily expressed in the summarized section, may include or incorporate various combinations of aspects of features, components, or aspects referenced in the summarized subjects above, and/or other features, components, or aspects as otherwise discussed in this disclosure. Those of ordinary skill in the art will better appreciate the features and aspects of such embodiments and others upon review of the remainder of this specification.
BRIEF DESCRIPTION OF THE DRAWINGS
A full and enabling disclosure of the present invention, including the best mode thereof, directed toward one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures. It should be noted that the appended drawings are not necessarily to scale in all instances.
FIG. 1 is a perspective view of an exemplary pallet truck;
FIG. 2 is a first perspective view of a steering assembly of an exemplary pallet truck;
FIG. 3 is a second perspective view of a steering assembly of an exemplary pallet truck;
FIG. 4 is a perspective view of a pallet truck steer wheel safety guard in accordance with certain aspects of the present invention;
FIG. 5 is a perspective view of a pallet truck steer wheel safety guard in accordance with certain aspects of the present invention;
FIG. 6 is a perspective view of a pallet truck steer wheel safety guard in accordance with certain aspects of the present invention, attached to a steering assembly of a pallet truck;
FIG. 7 is a perspective view of a pallet truck steer wheel safety guard in accordance with certain aspects of the present invention;
FIG. 8 is a perspective view of a pallet truck steer wheel safety guard in accordance with certain aspects of the present invention;
FIG. 9 is a perspective view of a pallet truck steer wheel safety guard in accordance with certain aspects of the present invention.
DETAILED DESCRIPTION
Reference will now be made in detail to presently preferred embodiments of the present subject matter, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, and is not meant as a limitation of the invention. Features illustrated or described as part of one embodiment may be used on another embodiment to yield a further embodiment. It is intended that the present application includes such modifications and variations as come within the scope and spirit of the invention. Selected combinations or aspects of the disclosed subject matter correspond to a plurality of different embodiments of the present invention. Certain features may be interchanged with certain devices or features not expressly mentioned, which perform the same or similar function.
The present subject matter may be more fully appreciated with reference to an exemplary pallet truck, an embodiment of which is depicted in FIG. 1 . The pallet truck, generally 20 , is used to move a load 22 (depicted in phantom). The pallet truck 20 includes a frame 42 and forks 24 , 25 extending forwardly from such frame. Forks 24 , 25 may be rolled beneath load 22 , then the operator handle 38 pivoted up and down about handle pivot pin 40 , causing frame 42 and forks 24 , 25 to raise, thereby also raising load 22 .
As shown in FIG. 1 , a pallet truck includes at least one steer wheel 30 at the rear of the pallet truck. By moving operator handle 38 side to side, steer wheel 30 is caused to turn, thereby allowing for steering of pallet truck 20 . Operation of pallet truck 20 requires that an operator, generally A, lift, steer, push, and pull upon operator handle 38 . To do so, operator A is positioned near a steer wheel 30 .
Pallet truck 20 includes steering assembly 28 . An exemplary embodiment of a steering assembly 28 is depicted in greater detail in FIG. 2 and FIG. 3 . Operator handle 38 is attached to pallet truck 20 about handle pivot pin 40 . Pivoting operator handle 38 up and down about handle pivot pin 40 actuates the lifting mechanism of pallet truck 20 , raising and lowering frame 42 and forks 24 , 25 . Swinging operator handle 38 side to side causes steering column 32 to turn steer wheels 30 . As can be seen particularly in FIG. 3 , steering column 32 depends downwardly from frame 42 . Steer wheels 30 are mounted upon wheel axle 31 , which is disposed through steering column 32 . Wheel axle 31 is secured in steering column 32 with axle bolt 34 .
FIG. 4 depicts an embodiment of a pallet truck steer wheel safety guard in accordance with the present invention. The safety guard, generally 60 , includes a bumper 62 and a steering column strut 65 . Bumper 62 may be a rigid member, configured for placement behind the steer wheel of a pallet truck. More particularly, bumper 62 may be disposed proximate to the plane upon which the wheel of the pallet truck is to be operated, to thereby prevent accidental contact of the pallet truck steer wheels with the operator's foot. Safety guard 60 may also include flanges 72 , flanges 72 disposed to extend forward of bumper 62 and adjacent the rear steer wheel or steer wheels of the pallet truck. Steering column strut 65 is an elongated, rigid member. Steering column strut 65 includes strut end 66 which is attached to bumper 62 . Opposite strut end 66 may be included a tab 67 . Tab 67 may be used to mount safety guard 60 upon the steering assembly of a pallet truck. For example, tab 67 may be affixed to a steering column, such as steering column 32 in FIG. 2 and FIG. 3 . Such attachment may be made by bolting tab 67 to a steering column 32 through steering column strut hole 68 . Alternatively, tab 67 may be affixed to a steering column 32 by spot welding. Still alternatively, tab 67 may be affixed to a steering column 32 with use of a circumferential clamp, such as a hose clamp. Alternative methods of attachment of tab 67 , so as to result in a fixed structural assembly, may also be employed. Furthermore, tab 67 may alternatively be fixed upon other structures of a pallet truck steering assembly that turn with the steer wheel in other embodiments of pallet trucks. The embodiment of the safety guard depicted in FIG. 4 includes lateral flanges 72 , but such flanges need not be provided in all instances.
FIG. 6 illustrates an embodiment of a pallet truck steer wheel safety guard, of a configuration similar to that shown in FIG. 4 , attached to a steering assembly of a pallet truck. As illustrated in FIG. 6 , safety guard 60 has been attached to steering column 32 with axle bolt 34 , axle bolt 34 having been disposed through tab 67 and through steering column 32 .
FIG. 5 illustrates another embodiment of a safety guard 60 . The embodiment of the safety guard 60 shown in FIG. 5 includes a bumper 62 , a steering column strut 65 , a tab 67 , and flanges 72 . The embodiment illustrated in FIG. 5 , however, also includes two axle struts 64 a,b . While two axle struts 64 a,b are illustrated in FIG. 5 , other embodiments may include only a single such axle strut 64 a or 64 b . Axle struts 64 a,b are elongated, rigid members, extending from bumper 62 for placement about a wheel axle 31 (such as shown in FIG. 3 ) of a pallet truck. Axle struts 64 a,b may include an axle hole 76 a,b , as illustrated for example in FIG. 7 . Axle hole 76 a,b may be defined within an axle strut 64 a,b opposite the attachment of axle strut 64 a,b to a bumper 62 . Axle hole 76 a,b may be configured for the passage of a wheel axle 31 (see FIG. 3 ) therethrough. As illustrated in FIG. 7 , an axle strut 64 a,b may be configured upon a safety guard 60 such that the axle strut 64 is carried by wheel axle 31 inboard of a wheel 30 , between a wheel 30 and steering column 32 ; such a configuration is depicted in FIG. 7 . Alternatively, the axle strut 64 a,b may be configured upon the safety guard 60 such that, when mounted to a pallet truck, the axle struts 64 a,b are disposed outboard of the steer wheel 30 , as illustrated in FIG. 8 , opposite wheel 30 from steering column 32 . With reference to FIG. 8 for illustration, in one embodiment safety guard 60 may include two axle struts 64 a,b that are biased toward each other and that define axle holes 76 a,b opposite bumper 62 . So configured, such a safety guard 60 may provide for snap-fit engagement of axle struts 64 a,b over axle ends 36 of the steering assembly of a pallet truck.
Returning to FIG. 5 , safety guard 60 with at least one axle strut 64 a or b may also include an axle slot 74 a,b leading to the aperture 76 a,b . Aperture slot 74 a,b may be configured to allow passage into axle hole 76 a,b of a wheel axle 31 , such that safety guard 60 may be installed upon a pallet truck without removal of a steer wheel 30 from the pallet truck steering assembly. For example, axle struts 64 a,b may be inserted inboard of steer wheels 30 , on either side of steering column 32 , and interfitted on to wheel axle 31 by passing wheel axle 31 through axle slots 74 a,b , disposing wheel axle 31 in axle holes 76 a,b ; steering column strut 65 may then be affixed to steering column 32 , resulting in an assembled, installed, and functional pallet truck steer wheel safety guard.
A further embodiment of a pallet truck steer wheel safety guard in accordance with the present invention is illustrated in FIG. 9 . As shown in FIG. 9 , bumper 62 may be configured as a curvilinear shell. Although not illustrated in FIG. 9 , such an embodiment of safety guard 60 may be attached to the steering assembly of a pallet truck as described above with reference to other embodiments of safety guard 60 .
As disclosed herein, the present invention provides a safety guard for a pallet truck steer wheel that protects the feet of operators of such a pallet truck from injury by such a steer wheel. While preferred embodiments of the invention have been shown and described, modifications and variations may be made thereto by those skilled in the art without departing from the spirit and scope of the present invention. Thus, it should be understood that aspects of various embodiments may be interchanged, both in whole or in part. Furthermore, those of ordinary skill in the art will appreciate that the foregoing description is by way of example only, and is not intended to be a limitation of the invention as further described in the appended claims. | A pallet truck steer wheel safety guard is provided. In combination with a steering assembly of a pallet truck, a steer wheel safety guard is disposed behind the steer wheel and defines a length parallel to the axis of rotation of the steer wheel. The safety guard defines a height perpendicular to such length, the height extending below the axis of rotation of the steer wheel. The safety guard includes a bumper, and may also include at least one strut extending from the bumper for attachment to the pallet truck. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
A safety ladder assembly and a safety extension used in combination with a ladder suitable to permit safe and easy access to a landing area, working platform or scaffold. Particularly, a portable and stowable safety ladder assembly which provides safe and convenient access to working platforms and includes a pair of safety extension members having horizontal handgrips or grab bars that enable a user to safely walk up or down the ladder.
2. Description of the Related Art
Occupational injuries resulting from ladder falls are a known hazard, especially for vehicles having flatbeds such as dock-height and drop-deck flatbed trailers and railcars, especially (but not limited to) those with head racks. Such falls result as the operator and/or driver is attempting to ascend or descend the flatbed, therein resulting in a disabling injury or even death. The Bureau of Labor Statistics (BLS) records for falls from non-moving vehicles show upwards of approximately 15,000 fall injuries per year. Moreover, access to the working surface of the flatbed poses significant risk of falling to the ground without a firmly installed flatbed ladder. Also, falls from ladders is one of the top three causes of occupational fatalities according to BLS statistics. Previously, access by ICC rail, a wheel rim or from cab to trailer transfer to access a flatbed having a height of approximately five feet or alternatively using a step ladder which can easily tip over and is unstable.
One prior art attempt for reducing ladder falls in a trucking application is providing a plurality of steps welded to the frame of a transport vehicle. This method, however, still places the driver and/or operator at risk when ascending up or descending down the ladder (again, especially when the trailer has a head rack that must be climbed around).
Furthermore, since tractors and trailers are sometimes interchangeable, operators will not always have the aforementioned steps available to them (even owner-operators who may be forced to use a rental tractor at times). Consequently, many drivers carry a portable step ladder strapped to the rear of the sleeper portion of the tractor. Often times, however, such portable step ladders are not utilized due to the inconvenience of deploying them when needed. Moreover, the base or feet of such prior art ladders are unstable, in particular, they are prone to inadvertent displacement or shifting from the support area on the ground surface when a user is ascending up or descending down the ladder. The base is also susceptible to slipping in hazardous surface conditions such as rain, snow, ice, etc., and thus, causes the ladder to move and/or topple over.
Another manner of ascending up or descending down the ladder to access a working platform of a flatbed trailer is by climbing up the rim and/or tire of the trailer (or the tractor, whose wheels are under the trailer). This manner, however, is extremely dangerous, especially when hazardous weather conditions such as rain, snow, ice, etc., are present.
Some prior art ladders include attachments permitting a user to access a landing area of a roof or other structure. Such attachments are secured at a distal end opposite the base of the ladder and include a pair of parallel vertical side rails or bars used as handrails for grasping by the user when access to the landing area is required.
The aforementioned design, however, has serious ergonomic drawbacks that lack adequate safety protocols to the user. For instance, such ladders lack any stability control that securely anchors the ladder against a vertically surface such as a wall to and prevent forward and/or lateral displacement of the ladder away from a support area on the ground.
Moreover, the use of vertical handgrips does not permit the user to adequately use a power gripping orientation of the hands required to maintain balance without slipping when falling backwards away from the front face of the ladder. Even still, if a power grip is used, it is nonetheless ineffective in the occurrence of a fall from the ladder since a slide of the user's hands will precede out of control, thus causing the user to fall to the ground as a result of the impact load from body's weight.
The configuration and size of the vertical grab bars also make it impossible for a user to encircle them by hand. As a result the hand cannot form adequate gripping power necessary to withstand an impact load of the body if the user slips or loses balance. Accordingly, a “pinch grip” must be used which makes fall safety virtually impossible to achieve. Moreover, the spatial distance between the upper gripping area of the vertical handgrips and the walk through area is ergonomically problematic insofar as it requires the user to assume an unnatural, unsafe and uncomfortable bending position when ascending to the landing area from the ladder or transitioning from the landing area to the ladder. Such bending may actually result in the user falling from the ladder and/or the working platform.
Lastly, the prior art ladders lack the ability to have a user safely ascend/descend from the ladder using 3-point control, i.e., with two feet on the ladder or the ground and one hand one the ladder, or with two feet on the handgrips handles and one foot on the ladder. Any such attempt at three point control will result in the ladder tipping over and/or the user losing balance on the ladder and falling therefrom.
Accordingly, there is a very pressing need to mitigate or otherwise reduce the number of deaths and injuries resulting from falls from a ladder.
SUMMARY OF THE INVENTION
In view of the foregoing, it is an object of the present invention to provide a portable safety ladder assembly and a safety extension which permits a user to safely and quickly enter and leave a working platform/landing area of a structure or vehicle such as the flatbed of a transport vehicle or railcar.
It is another object of the invention to provide a portable safety ladder assembly ergonomically designed to mitigate or otherwise reduce various occupational injuries and/or deaths by acting as a fall arrest system capable of supporting an impact load from the body of the user in the occurrence of a user falling therefrom.
It is yet another object of the invention to provide a stowable portable safety ladder assembly sized for compact and convenient stowing.
It is a further object of the invention to provide a portable safety ladder assembly having removable safety extensions that are quickly and easily moveable between operative/inoperative positions on the side frames of the ladder and a storage position on the front and rear ends of the ladder.
It is still another object of the invention to provide a portable safety ladder assembly that may be securely anchored to a surface of a structure, vehicle and the like to prevent forward and/or lateral shifting or displacement (i.e., movement in directions parallel and/or perpendicular to the outer peripheral surface) of the ladder when placed in an operable position.
It is yet another object of the invention to provide a safety ladder extension having a plurality of horizontally oriented handgrips permitting a user to safely ascend/descend from a working platform or surface of a structure or vehicle, even under hazardous surface conditions such as rain, ice, snow, etc.
Another object of the invention is to provide a portable safety ladder assembly having safety extension members that are vertically and rotationally moveable relative to the ladder between operative and inoperative positions.
Still another object of the invention is to provide a portable safety ladder assembly having safety extension members that lie at the same angle and also in the same plane as the ladder when the assembly is leaned against an intended structure or vehicle.
Yet another object of the invention is to provide a safety ladder extension having horizontally extending handgrips and vertical poles forming a unique configurative array permitting a user to maintain a continuum of grips when ascending/descending from a ladder, even under hazardous surface conditions such as rain, ice, snow, etc.
Still an additional object of the invention is to provide a portable safety ladder assembly having safety extension members that when placed in an operative position is elevated above the working surface to a height permitting a user to stand at a substantially erect position (i.e., not a bending position) when transitioning from the ladder's walk-through section.
Yet and still another object of the invention is to provide a portable safety ladder assembly that permits three-point control by the user, i.e., the ability to safely ascend/descend from the ladder with two feet on the ladder/on the ground and one hand on the ladder, or two feet on the handles and one foot on the ladder.
Yet an additional object of the invention is to provide a safety extension a safety ladder extension having horizontally extending handgrips and vertical poles forming a unique configurative array permitting a user to use either a power- or hook-type handgrip that withstands impact loads from the user's body during the occurrence of a fall backwards by the user.
These, as well as other objects and characteristics of the present invention may be achieved in accordance with an aspect of the invention which includes a portable safety ladder assembly including a main ladder section or frame having a distal end including a walk-through area, a base end opposite the distal end which engages a base surface to provide an area of support for the assembly when the assembly is placed in an operable position against the outer peripheral frame, a pair of parallel side rails connected by a plurality of horizontal rungs, a front section from which a user engages the rungs when traversing up and down the assembly, and a rear section opposite the front section that is positioned proximate the outer peripheral frame, a first safety extension member provided on a respective one side rail and a second safety extension member provided on a respective other side rail, each of the safety extension members having first, second, third and fourth parallel horizontal handgrips, the handgrips being connected in an array such that the first and second horizontal handgrips are connected by a first outer vertical side pole, the second and third horizontal handgrips are connected by a second inner vertical side pole and the third and fourth horizontal handgrips are connected by a third outer vertical side pole, wherein the first horizontal handgrip is spaced above and proximate the walk-through section and the fourth horizontal handgrip is spaced above the walk-through a distance permitting the user to stand substantially erect when accessing the working platform.
Yet other objects and characteristics of the present invention may be achieved in accordance with another aspect of the invention which includes a portable safety ladder assembly having the main ladder section and safety extension set forth hereinabove, and also a stabilizing mechanism for secureably anchoring the main ladder section to a surface and preventing at least one of forward and lateral displacement of the main ladder section away from a support area.
Still other objects and characteristics of the present invention may also be achieved in accordance with a further aspect of the invention which includes a portable safety ladder assembly having the main ladder section and safety extension set forth hereinabove, and also a coupling mechanism mounted on the side ends for removeably receiving a respective the leg portion in a manner such that the safety extension members and the main ladder lie in substantially the same plane when the assembly is placed in the operable position.
Yet and still other objects and characteristics of the present invention may also be achieved in accordance with an additional aspect of the invention which includes a portable safety ladder assembly having the main ladder section and safety extension set forth hereinabove and a storage mechanism mounted on the front and rear ends for removeably storing the safety extension members on the main ladder when the assembly is in an inoperable position.
Yet further objects and characteristics of the present invention may also be achieved in accordance with an aspect of the invention which includes a portable safety ladder assembly having the main ladder section, safety extension, stabilizing mechanism and coupling mechanism set forth hereinabove.
Still further objects and characteristics of the present invention may also be achieved in accordance with an aspect of the invention which includes a portable safety ladder assembly having the main ladder section, safety extension, coupling mechanism and storage mechanism set forth hereinabove.
Yet and still further objects and characteristics of the present invention may also be achieved in accordance with an aspect of the invention which includes a portable safety ladder assembly having the main ladder section, safety extension coupling mechanism, storage mechanism and stabilizing mechanism set forth hereinabove.
Yet additional objects and characteristics of the present invention may be achieved in accordance with an additional aspect of the invention which includes a safety extension in combination with a ladder having a pair of side rails connected by a plurality of spaced rungs, the safety extension having a pair of safety extension members each provided on a respective side rail, each of the safety extension members having, a leg portion adapted for connection to a respective side rail in a manner such that the safety extension members and the ladder lie in substantially the same plane when the assembly is placed in a position accessible by a user, and first, second, third and fourth parallel horizontal handgrips, the handgrips being connected in an array such that the first and second horizontal handgrips are connected by a first outer vertical side pole, the second and third horizontal handgrips are connected by a second inner vertical side pole and the third and fourth horizontal handgrips are connected by a third outer vertical side pole, the first horizontal handgrip being spaced above and proximate the walk-through section while the fourth horizontal handgrip being spaced above the walk-through a distance permitting the user to stand substantially erect when traversing through the walk-through section.
Still additional objects and characteristics of the present invention may be achieved in accordance with an additional aspect of the invention which includes a method of accessing a landing area which includes the steps of providing a ladder having at a distal end thereof a walk-through area, providing a pair of safety extension members coupled to the ladder such that each safety extension member and the ladder lie in substantially the same plane, such safety extension members having a plurality of parallel horizontal handgrips connected by inner and outer vertical side poles, wherein the upper most horizontal handgrip is spaced above the walk-through section a distance permitting a user to stand substantially erect when accessing the landing area, positioning the ladder to an operable position against a surface area, traversing up the ladder and engaging the horizontal handgrips once the walk through area is reached to access the landing area.
Accordingly, the safety ladder assembly set forth herein extends numerous advantages in its portability and adaptability to facilitate quick and easy transfer of the user to a working surface (landing) while mitigating or otherwise greatly reducing the threat of occupational hazards that have heretofore have caused death or serious physical harm. Further advantages extending from practice of the invention may be achieved by a safety ladder that is easily stowable and quickly and efficiently assembled/disassembled on site. Also advantageous is a safety ladder extension having horizontally extending handgrips and vertical poles forming a unique configurative array permitting a user to maintain a continuum of grips when ascending up or descending down the ladder, even under hazardous surface conditions such as rain, ice, snow, etc. Such an array is also ergonomically efficient in permitting the user to employ either a power- or hook-type handgrip that withstands impact loads from the user's body during the occurrence of a fall backwards by the user. The array also permits the user to access the working platform from the walk-through area of the ladder in a natural exiting position, particularly, in a substantially erect position (i.e., not bend downwardly), when ascending/descending from the ladder.
Advantages of the invention may also be derived from a safety ladder assembly having a pair of safety extensions that are rotationally and releaseably connectable to the main ladder section to provide ease in assembly, storage and transfer. Further advantageous of the invention may also be derived from a safety ladder assembly having a mechanism for securely stabilizing the assembly against the outer periphery of a surface, thereby preventing falls resulting from inadvertent forward and/or lateral shifting or displacement of the ladder from a support area. Such a stabilizing feature also maintains the assembly at the support area even in hazardous ground conditions such as rain, snow, ice and the like.
These and other objects, features and advantages of the invention will become more apparent from the following description when taken in conjunction with the detailed drawings that show, for purposes of illustration only, the preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The advantages of the invention will become more apparent to those skilled in the art in conjunction with the detailed description of the preferred embodiments, in which:
FIG. 1 is a perspective view of a user utilizing the portable safety ladder assembly towards the landing area of a flatbed trailer vehicle;
FIG. 2 is a frontal view of a portable safety ladder assembly in an operable or user-ready position;
FIG. 3 is a frontal view of a safety extension member;
FIG. 4 is a side view of the coupling mechanism and the stabilizing mechanism;
FIG. 5 is a frontal view of a portable safety ladder;
FIG. 6A is a frontal view of a portable safety ladder assembly with a safety extension member in a storage position on the front end of the ladder frame; and
FIG. 6B is a frontal view of a portable safety ladder assembly with a safety extension member in a storage position on the rear end of the ladder frame.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As illustrated in the drawing figures, provided herein is a portable safety ladder assembly 10 including a ladder 20 and a safety extension 30 for permitting a user to have safe access to a working platform of an intended structure such as a flatbed trailer, rail car and the like. The safety ladder assembly 10 or the safety extension 30 are not limited to use soley with flatbed trailers or railcars, and may be used for non-trailer purposes and various applications requiring access to any landing area, working platform, scaffold and the like.
As shown in FIG. 1 , the ladder 20 includes a walk-through section 21 at a distal, uppermost end, a base end 22 which contacts and engages a base surface, e.g., the ground, to provide an area of support for the assembly 10 when placed in an operable position. The ladder 20 also includes a pair of parallel side rails 23 connected by a plurality, i.e., more than two, of horizontal rungs 24 , a front section 25 directly facing wherein which a user may access and engage the rungs 24 , and a rear section 26 lying proximate the outermost peripheral surface of the frame of the intended structure or vehicle when the assembly 10 is placed in a user ready position. Preferably, the width of each rung 24 is about sixteen inches, the space between each rung 24 is preferably about twelve inches and the width of the walk-through section 21 is preferably about eighteen inches. The width of each rung and the spacing between rungs, however, is not limited to any particular size and thus, may be of any size or range of sizes permitting access to a working platform or landing area.
FIGS. 2 and 3 illustrate a safety extension 30 which includes a pair of safety extension members 31 removeably attached to the ladder 20 by collars 27 , 28 . Each safety extension member 31 includes a lower section which attaches to the side rails 23 of ladder 20 which permits a user to safely access a working platform. Each safety extension member 31 has a lower section including a support pole or leg 32 and an upper section including a plurality of spaced, parallel horizontal handgrips 33 connected by vertical poles 34 in a unique configurative array permitting the user to maintain a continuum of grips when moving up or down the ladder 20 . The space between each handgrip 33 preferably coincides with the spacing between rungs, i.e., about twelve inches. The uppermost handgrip 33 is preferably spaced a distance of about three and one-half feet above the walk-through section 21 to enable the user to stand substantially erect, i.e., not bend over, when either ascending up or descending down the ladder. The spacing of the handgrips is not limited to any particular size, and thus, may vary. Moreover, while a plurality of horizontal handgrips 33 are shown herein, the invention is not limited to a plurality, and thus, may include one or two handgrips, preferably spaced a distance from the walk-through area that permits safe use of the assembly 10 in a similar manner as having a plurality of handgrips.
As shown in FIG. 4 , a stabilizing mechanism 40 is provided to anchor or otherwise stably secure the ladder 20 to a substantially vertically extending surface of a structure or vehicle at a specific contact or engagement area. In essence, the stabilizing mechanism 40 serves to stabilize the ladder 20 as it leans against a vertically extending surface of an intended structure or vehicle while preventing forward and/or lateral shifting or displacement of the ladder 20 away from a support area on the ground surface, even in hazardous surface conditions such as snow, rain, ice, etc. Such a mechanism includes a C-shaped clamp or bracket 41 attached by bolts or comparable means to the rear section 26 of the ladder 20 for engaging, abutting or otherwise contacting at least the upper surface and outer peripheral contact areas of the frame of the intended structure or vehicle. The bracket 41 includes a base 42 connecting a pair of parallel arms extending from the base 42 in a direction substantially parallel to the ground surface including an upper arm 43 and a lower arm 44 to form a modular unit sized to receive and engage both the front, upper and lower surfaces of the intended contact surface. It should be noted that the size of the brackets 41 is not limited to any particular size, and thus, may vary depending on the application. Moreover, while a single bracket 41 is shown, practice of the invention is not limited to use of a single bracket, and thus may, encompass a stabilizing mechanism 40 having two or a plurality of brackets 41 . It should be further noted that the stabilizing mechanism 40 may be retrofitted to existing ladders and/or provided on ladders without safety extensions.
For those applications requiring use of the assembly 10 to access the working platform 110 of the flatbed of a trailer, as illustrated in FIG. 1 the bracket 41 is also adapted to engage, abut or otherwise contact the tie down rail 120 on the frame of the flat bed. An alternative embodiment for flatbed trailer applications is a stabilizing mechanism 40 encompassing a pair of C-shaped clamps or brackets 41 a positioned on the outer peripheral edge of the flatbed frame. Each bracket 41 a includes a base 42 a connecting a pair of parallel arms extending from the base 42 a substantially parallel to the ground surface including a left arm 43 a and a right arm 44 a forming a modular unit sized to receive and engage both the front, inner and outer surface areas of the of a respective side rail 23 . The brackets 41 a are preferably moveable between a first position within an annular space or compartment within the frame 120 and a second position in which the brackets 41 a extend or otherwise protrude from the frame 120 when the assembly 10 is placed in an operable position. The brackets 41 a may be retractable or spring-loaded to enable movement from an inoperable, storage position to an operable position. While a stabilizing mechanism 40 a having two brackets 41 a is illustrated herein, practice of the invention is not limited to any particular number of brackets 41 a , and thus, may include a single bracket sized to receive to both front and outermost surface areas of each side rail 23 .
As illustrated in FIG. 5 , attached by bolt or comparable means to the outermost peripheral surface of each side rail 23 is a pair of cylindrical-shaped mounting collars 50 including an upper collar 51 and lower collar 52 which permit removable coupling of the safety extension 30 to the ladder 20 . The upper collar 51 is located proximate the walk-through area 21 while the lower collar 52 is spaced therebelow towards the base end 22 of the ladder 20 . The collars 51 , 52 each have an annular channel 53 therein sized to receive the lower support leg 32 of the safety extension members 31 while the lower collar 52 further includes a stop member 54 at a lowermost portion thereof which abuts, contacts or otherwise engages the bottommost portion of the support leg 32 once inserted therein.
As shown in FIG. 2 , each support leg 32 is insertable into the collars 51 , 52 in such a manner that the safety extension members 31 lie at substantially the same inclined angle as the ladder 20 when the assembly 10 is laid against the intended structure or vehicle, i.e., is placed in the operable position. In essence, both the ladder 20 and the safety extension 30 lie in substantially the same plane when the assembly 10 is placed in the operable position against the intended structure or vehicle.
The support legs 32 may each be provided with one or a plurality of apertures, openings or holes 35 which correspond to a hole 55 in the upper collar 51 . These holes 35 , 55 are sized to receive one or more locking pins 56 configured to selectively retain or otherwise restrict the support legs 32 within the channel 53 . The use of a plurality of holes 35 permits appropriate indexing of the safety extension member 31 to a selected height above the walk-through section 21 . The adjustable nature of the safety extension members 31 makes the assembly 10 accommodating to users of varying heights. Each locking pin 56 may be permanently or removeably affixed to each side rail 23 via a chain or comparable means.
Removal of the locking pin 56 from the corresponding holes 35 , 55 permits selective rotational and/or longitudinal movement of the safety extension members 31 about a vertical axis at the channel 53 . Such movement permits the safety extension members 31 to be moved between operable and inoperable positions and permits selective height adjustments to the safety extension members 31 . For example, in the operable position, the safety extension members 31 are flared outwardly relative to the side rails 23 , thus making the handgrips 33 accessible for grasping by the user. In the inoperable position, the handgrips 33 are flared inwardly so that a first safety extension member 31 contacts, abuts or otherwise engages the other safety extension member 31 . The size of the collars 51 , 52 are not limited to any one particular size, and thus, may vary depending on the application.
As shown in FIGS. 6A and 6B , a mechanism 60 for stowing away the safety extension members 31 is attached by bolt or comparable means to the front section 25 and rear section 26 of the frame of the ladder 20 . A pair of cylindrical-shaped mounting collars including an upper collar 61 and a lower collar 62 which permit removable coupling of the safety extension members 31 to the ladder 20 . The upper collar 51 is located proximate the walk-through area 21 while the lower collar 52 is spaced therebelow towards the base end 22 of the ladder 20 . The collars 51 , 52 have an annular channel 53 therein sized to receive the lower leg portion of each safety extension member 31 while the lower collar 52 further includes a stop member 54 at a lowermost portion thereof which abuts, contacts or otherwise engages the bottommost portion of the safety extension member 31 once received therein. The size of the collars 51 , 52 are not limited to any one particular size, and thus, may vary depending on the application.
In order to safely stow the disassembled assembly 10 in a storage area or compartment of a vehicle or structure, a portable rectangular-shaped box, bin or container having an interior spaced sized to receive the assembly 10 may be used. The container may have a hinged or removable opening moveable between an open position allowing the assembly 10 to be fully inserted into the interior space and a closed position sealing the assembly 10 within the space. For those applications requiring use of a transport vehicle such as a truck, trailer and the like, the portable storage container may be fitted and secured underneath the trailer flatbed, permitting easy access thereto when needed.
The components for the ladder 20 and the safety extension 30 are preferably constructed of durable and robust materials such as fiberglass, aluminum, composites, or comparable materials known in the art. While components such as the safety extension 30 , stabilizing mechanism(s) 40 and storage assembly 50 are shown herein as a unitary assembly, they are adaptable for retrofitting to existing ladders structures and architectures.
It is apparent that innumerable variations of the preferred embodiments described hereinbefore may be utilized. However, all such variations within the spirit and scope of the invention are deemed to be covered by the following claims. | A safety ladder assembly and a safety extension used in combination with a ladder suitable to permit safe and easy access to the landing areas, working platforms, scaffolds, etc. The assembly includes safety extension members having a plurality of horizontal handgrips ergonomically designed to prevent falls from the ladder when a user is ascending upward or descending downward. | 4 |
FIELD OF THE INVENTION
Enhanced centrifugal separation and extraction of gas from a liquid utilizing centrifugal force as the driving means.
BACKGROUND OF THE INVENTION
Centrifugal separation of substances having different specific gravities is historical. Cyclone separators for removing sawdust from airstreams are an example of removal of solids from gases. Separation of solids from liquids is shown in Ford U.S. Pat. No. 5,811,006. In this patent the objective is to remove the “heavier” solids from a “lighter” liquid by centrifuging the solids-laden stream against the inner wall of a circular chamber, along which the heavier solid material flows to the bottom, while the liquid rises to and out of the top at the center of the swirling mass.
This concept has been extended to the separation of gases, both free and dissolved, from liquids. In this case, the heavier material is the liquid, and the lighter material is the gas. Examples are shown in Mazzei et at U.S. Pat. Nos. 5,338,341 and 5,622,545, and in Mazzei U.S. Pat. Nos. 5,674,312 and 6,193,893. It is this latter group of patents with which this invention is concerned. This invention is not concerned with elimination of solids from a liquid stream, but instead is concerned with removal of gases from a liquid stream.
The separation (extraction) of gases from liquids is a matter of great importance in many fields. It is particularly important when the gases to be separated are undesirable for several possible reasons. Such reasons might include their use and recovery as “sweeping” gases to carry with them some other existing gas of greater risk, or gases which involve their own problems such as corrosion or pollution.
Another, and rather surprising application is the separation of gases from liquid stream whose flow is to be measured. Water used in oil extraction systems is somewhat oily and frequently includes methane. The presence of the gas or gases frustrates the accurate measurement of the water flow. It is a useful function of this invention to remove the gases prior to measurement, thereby enabling accurate measurement. It is possible to return extracted gases to the liquid stream after measurement, which in some circumstances may be desirable.
While this invention will find its greatest employment separating gases from water with little or no saline content, it can be use to de-gas any liquid. Waters with considerable salinity, especially seawater are readily treated. The recovery of gases from such waters is otherwise usually quite difficult. therefore there is no limitation on the type of liquid. It merely must be amenable to rapid flow through the device.
In whatever event, the objective is to reduce as much as possible the presence of the gas in a liquid stream. The principal driving means is derived from the difference in the specific gravities of liquids and gases. The specific gravity of any liquid is far greater than that of any gas, so that centrifugal forces can separate gases from a liquid when in the free state.
There is another class of forces which are derived from pressure in the liquid. These are defined by Henry's Law, which relies on the difference between pressures perceived by the gas in the liquid and the gas phase contiguous to it. The lower pressures in the liquid caused by the rapid movement of the fluid through a reducing cross-section considerably reduce the solubility of the gases. This effect is of much less importance compared with the centrifugal forces, but is worth pursuing in some applications.
With special attention to U.S. Pat. Nos. 5,338,342 and 5,622,545, gases therein are separated through a central horizontally-slotted cylindrical tube located co-axially in a cylinder. One objective in patents is to contain in a quieter central region a quantity of water and gas, from which the gas rises and exits the system. This is a classical mass-separation technique, which only incidentally reduces the angular momentum of the liquid stream and does not optimally affect the pressure and velocity in the vortex chamber.
Such a usual centrifugal arrangement characterized by the above patents still involve a lively and undisciplined environment. If the objective is to rid the system of gas, a lively central region is not to be preferred. Instead, this invention proposes to combine an enhanced very forceful and lively centrifugal region of a liquid stream containing the gas, with an internal quiescent region where the separated gas can quietly rise from the system.
It is interesting to observe in a separator without a central tube, the conditions of the incoming stream, the whirling mix of liquid and gas as they begin to separate, and the lively vortex at the center, whose alignment, shape and length vary and move around, and is always rapidly rotating. Especially there is a rotation of the interface between water and the separating gases, this being the boundary of the vortex. It can readily be appreciated that the vortex itself and the gases in it are in vigorous motion.
In said U.S. Pat. Nos. 5,338,341 and 5,622,545 one of the inventors therein, and the sole inventor herein, attempted to stabilize the vortex by providing horizontal slots through the wall of a vertical cylinder located inside of a vertical, coaxial cylinder. The objective there was to limit the vortex to a defined region, and to a significant extent it did and does improve the separation of the gases from the water. However, it has not proved as effective as the instant invention, particularly in the removal of certain gases that are difficult to remove, for example radon. Also, its performance on seawater was less than optimal. The device of this function works well removing gases from seawater, which has always been regarded as a difficult task.
In this invention, the slots in the internal tube will not lie in planes normal to the axis of the tube, but rather at an angle to it, and thereby will provide a wall or walls that will be impinged upon by the fluids.
In addition, the forgoing earlier separator tended to require a considerable “foot print” in the sense of occupied real estate for its installation. The present device requires only a significantly smaller footprint, and is surprisingly small for the work that it does. In fact, one of its very useful embodiments is only about 15 inches tall and about 4.6 inches outer diameter and routinely treats a flow volume between about 5 and about 50 gallons per minute depending on the inlet and outlet pressures that are used.
While only purely cylindrical elements are shown in said patents, and they can be utilized in this invention, significant improvements have been obtained with the use of at least one tapered element (preferably both) which reduces the lateral dimension of the whirling stream as it flows to a lower outlet. This results in a faster linear speed, a greater centrifugal force, and a larger gradient for gas separation.
BRIEF DESCRIPTION OF THE INVENTION
A separator according to this invention includes a housing with an injection port and a water exit port, said housing including an interior centrifuge wall with a linear central axis and a circular lateral cross-section that forms the outer boundary of a centrifuge section, said ports being axially spaced apart from one another.
A hollow extractor is disposed inside of the centrifuge wall with an outer wall which is laterally spaced from said centrifuge wall. The extractor has a substantial lateral wall thickness and a plurality of slots through its wall which are not in planes normal to the central axis, but which instead lie in imaginary planes that are parallel to it, or which form a substantial angle with said axis, and which have a substantial axial length. The inner wall of the extractor forms a gas chamber that extends axially toward an upper gas exit port.
According to a preferred but optional feature of the invention, either the centrifuge wall or the extractor wall (or both) is or are tapered so as to reduce the lateral dimension of the centrifuge chamber as it approaches the water exit port.
According to yet another preferred but optional feature of the invention, each slot is bounded in part by a sidewall which faces toward the whirling water so as to be impacted by gas or whatever else strikes it, thereby to reduce its angular momentum and quiets the lateral flow of fluid into the gas chamber.
According to yet another preferred but optional feature of the invention, the extractor is provided as unitary insert fitted into the centrifuge chamber.
The above and other features of this invention will be fully understood from the following detailed description and the accompanying drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an external side view of the presently preferred embodiment of a separator according to the invention;
FIG. 2 is an axial cross-section of the body of the separator of FIG. 1 , with its cap removed;
FIG. 3 is a top view of FIG. 2 ;
FIG. 4 is a side view of an extractor for use with the body of FIG. 1 ;
FIG. 5 is an axial cross-section of FIG. 4 ;
FIG. 6 is a top view of FIG. 4 ;
FIG. 7 is an axial cross-section showing the extractor of FIG. 4 installed in the body of FIG. 2 ;
FIGS. 8-10 schematically show different useful angular relationships between the centrifuge wall and the extractor wall;
FIGS. 11-13 show different slot patterns; and
FIG. 14 is a detail of a useful diverter adjacent to a slot.
DETAILED DESCRIPTION OF THE INVENTION
The presently-preferred embodiment of a separator 20 according to this invention is shown in FIGS. 1-7 . FIG. 1 , shows its outer body 21 , cap 22 closing its upper end, injection fitting 23 near its upper end, water outlet fitting 24 near its lower end, gas outlet fitting 26 at its upper end, and a drain fitting 27 at its bottom end. Injection port 28 enters through fitting 23 . Water exit port 29 exits through fitting 24 .
A surface 30 of revolution, herein called the “centrifuge wall” is centered on a central axis 31 which extends from the top end 32 to the bottom end 33 of the separator. In the preferred embodiment, this is a frusto-conical surface tapering narrowly toward the bottom end of the housing.
It includes a diametrically enlarged injection chamber 35 into which an injection port 28 (which is preferably a nozzle) projects water to be de-gassed tangentially into the separator. Region 35 is somewhat enlarged. The spinning (whirling) movement of the gas-containing liquid starts in this region, and the stream flows downwardly.
Centrifugal wall 30 tapers inwardly and gradually toward its lower end, from which water exit port 29 discharges water from which gas has been extracted.
Extractor 50 ( FIG. 4 ) is fitted in the body of this device, as shown in FIG. 7 . The extractor has a top flange 51 which when installed fits against upper shoulder 52 on the body, and is held in place by cap 22 . This flange closes the upper end of injection chamber 35 .
Below the flange, the depending portion 53 of the extractor is frusto-conical. Conveniently it will be a hollow molded plastic material with a constant wall thickness, having an external wall surface 54 and an internal wall surface 55 . Surfaces 54 and 55 will preferably be identically tapered, although the taper angles can differ. As best shown in FIG. 7 , extractor 50 will fit in the body, leaving between its external wall surface and the centrifuge wall 30 of the body, a centrifuge chamber 56 that directly communicates with injection chamber 35 .
The conical angles of wall 30 and surface 54 will conveniently be equal, perhaps about 4 degrees included angle. Because of their narrowing taper, the net lateral cross-section area of the centrifuge region decreases. Because the same amount of liquid must pass, the velocity will increase and the pressure will decrease. The gas will have an increased force gradient for it to migrate to the center. The gas will have a lesser solubility which although it may be rather small, still it can be an advantage.
Three sets 60 , 61 , 62 of four slots each extend axially along and through the extractor. The slots are evenly spaced apart around the extractor, while the sets of slots are spaced from each other. Slot 63 , which is typical of all of the slots, lies in a respective imaginary plane which includes the central axis. Each slot has a width 65 , a depth 66 equal to the thickness of the extractor wall, and a length 67 .
At the lower end of the extractor, a foot 68 fits against a shoulder 69 around the drain port, so that any solids which may have accumulated in the extractor can be drained away without removing the extractor from the body.
The simplest slot arrangement is shown in FIGS. 1-7 . When whirling fluid enters a slot, it encounters sidewall 70 of the slot, which decelerates it and deflects it into the central quiescent region 71 .
However, it will sometimes be desirable to provide means which will have an even greater decelerating effect. Such a means is shown in FIG. 14 , where a deflector 75 adjacent to the inner edge 76 of slot 77 is shown which will further direct the flow of fluid either radially inward, or even with some reversal of motion. The effect, with or without the additional deflector is to create a quiescent region inside the extractor, without significant turbulence, and with minimal rotation. At the top this region will contain mostly gas. Toward the bottom it may be flooded with water.
FIGS. 1-7 , and in particular FIGS. 4-6 , show a conveniently manufactured extractor, readily prepared with injection molding techniques, with or without secondary-operations such as mechanical machining of the slots. If preferred for economy of tooling, the slots could be machined. The objective is to provide an extractor with passages which receive fluids in such a way that the quiescent region inside the extractor is separated from the rapid violent motion in the separation chamber. Locating the slots near where the gas vortex boundary will be located is a first consideration.
The second consideration is to use the wall thickness of the slots as a means to isolate the quiescent region by changing the direction of flow from tangential to radial, by stopping the tangential flow with the wall of the slot. Then the gas can quietly flow into the quiescent region, and out through the gas exit port. The gas exit port will be connected to a pressure-sensitive relief valve which maintains a proper pressure in the separator.
The embodiment illustrated in FIGS. 1-7 is at once the most effective and the most readily manufactured embodiment. However, different slot patterns and different angular relationships between the centrifuge wall and the extractor are within the scope of this invention.
FIG. 8 shows an external centrifuge wall 85 which is cylindrical, and an internal extractor which is tapered, but whose external wall 86 is reversely tapered compared to the extractor of FIG. 4 . It increases in diameter toward the bottom. Notice that the centrifuge region 87 between them reduces in lateral dimension as it extends toward the bottom.
FIG. 9 shows an external centrifuge wall 90 and an internal extractor 91 , both of which are cylinders. Here the lateral dimension (lateral thickness) of the centrifuge region is constant, but slots according to this invention are used. The advantages of the slots are employed, but not the reduction of thickness of the centrifuge region. Therefore only some of the advantages of this invention are attained.
FIG. 10 shows an external centrifuge wall 95 which tapers narrowly toward its bottom end and an internal extractor 96 which is cylindrical. All of the advantages of the embodiment of FIGS. 1-7 are attained.
In all of the arrangements of FIGS. 8-10 , slots (not shown) of any configuration according to this invention can be formed in the wall of the extractor. Sets of straight longitudinal slots are preferred for their simplicity and demonstrated effectiveness. However, at least some of the benefits of this invention can be attained with the use of other types of slots and slot patterns.
For example, FIG. 11 shows the use of series of spaced apart rectangular, shorter slots 100 , 101 , 102 in the wall of an extractor 103 . These short slots are spaced apart by imperforate regions 104 , 105 , for example. Their width is similar to that of the slots in FIG. 4 . In fact, the entire surface of the extractor can be studded with these, the sidewall facing toward the stream action as before. These may be thought of as “interrupted” long slots.
FIG. 12 shows slots 106 , 107 , 108 in a staggered array, rather than in an aligned group.
FIG. 13 shows slots 110 , 111 which are slanted at a substantial angle 112 relative to the vertical. Such slots are not preferred because of the component of downward flow along their sidewall, but still can be employed to some advantage.
All of the slot embodiments of FIGS. 11-13 can be formed in any of the extractor arrangements. Their slot widths and depths will be about the same as those of FIG. 4 .
A suitable separator according to FIGS. 1-7 can be made with the following dimensions, which will accommodate flow rates between about 5 and about 50 gallons per minute.
Injection chamber diameter 3.6 inches Injection chamber height 2.12 inches Centrifuge chamber height to water outlet center—12.94 inches Centrifuge wall lower diameter—2.6 inches Centrifuge wall lower diameter—2.0 inches Centrifuge wall taper—about 4 degrees included angle Extractor length flange to tip—15.88 inches Slot length—about 3.8 inches Slot width—about 0.80 inches Extractor taper angle—about 4 degrees included angle
The bottom ends of the housing and of the extractor will have dimensions to fit the assembly as shown. The various sizes and capacities can be scaled from the above or determined by experiment, using the criteria discussed above. The taper angles need not be uniform over the entire length. They may be changed along the length as desired.
While the examples given relate to water streams, it is to understood that they relate also to other liquids as well, as discussed above.
The term “quiescent” as used herein relates to fluid movement in which much of the rotational velocity has been removed while moving through the slots. It does not require total stillness.
This invention is not to be limited by the embodiments shown in the drawings and described in the description, which are given by way of example and not of limitation, but only in accordance with the scope of the appended claims. | Separation and extraction of gas from a liquid, utilizing centrifugal forces. The area of the lateral spacing between an inner circular centrifugal surface and the outer wall of an internal extractor diminishes toward an outlet. The wall of the extractor is pierced by slots whose walls calm the inward flow of gas into the interior of the extractor. | 1 |
This application is a divisional of application Ser. No. 10/345,278, filed Jan. 16, 2003, now abandoned the contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an adhesive sheet for affixation of a wafer and a method for processing using the same. More particularly, the present invention relates to an adhesive sheet for affixation of a wafer used in dicing of a semiconductor wafer into chips and to a method for dicing a semiconductor wafer by using the same.
2. Description of the Related Art
In general, semiconductor wafers made of silicon, gallium arsenide, etc., are manufactured in the condition of having a large diameter. This wafer is cut and separated (diced) into element chips and, thereafter, the resulting chips are subjected to a mounting step. Conventionally, the semiconductor wafer is subjected to each step of dicing, cleaning, drying, expanding, picking up and mounting in the condition of being affixed to an adhesive sheet in advance. As the adhesive sheet for affixation of a wafer used in dicing, sheets described in, for example, Japanese Patent Laid-Open No. 7-86212, are known. The adhesive sheet for affixation of a wafer described in Japanese Patent Laid-Open No. 7-86212 is composed of a radiation-setting adhesive layer arranged on a substrate. This sheet can be peeled away from a semiconductor wafer with ease by being irradiated with radioactive rays after dicing.
However, there is the following problem in the method for processing using the aforementioned conventional adhesive sheet for affixation of a wafer. That is, when there is another step between the steps of picking up and mounting, foreign matter, etc., may adhere to even a chip having been already cleaned and dried. In particular, since the back of the chip becomes a mounting surface, when adhesion of foreign matter, etc., occurs, problems of reduction in mounting precision, etc., are brought about.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a reliable adhesive sheet for affixation of a wafer capable of overcoming the aforementioned problems in the conventional technology and reducing adhesion of foreign matter, etc., before mounting of the chip.
The aforementioned object of the present invention can be achieved by an adhesive sheet for affixation of a wafer, the adhesive sheet including a first substrate, a first adhesive layer arranged on the first substrate, a second substrate arranged on the first adhesive layer, and a second adhesive layer arranged on the second substrate, wherein a chemical reaction which causes reduction in the adhesion of the first adhesive layer and a chemical reaction which causes reduction in the adhesion of the second adhesive layer are different.
Regarding the aforementioned adhesive sheet for affixation of a wafer, for example, the first adhesive layer can be formed from a radiation-setting adhesive, and the second substrate can be formed from a heat-shrinkable plastic film. Furthermore, the first substrate may be formed from a heat-shrinkable plastic film and the second adhesive layer may be formed from a radiation-setting adhesive.
A method for processing using the aforementioned adhesive sheet for affixation of a wafer includes the step of affixing the sheet to a wafer, the step of dicing the wafer with the sheet affixed thereto, the step of peeling the first substrate and the first adhesive layer away from the diced wafer by reducing the adhesion of the first adhesive layer of the sheet and, thereby, dividing the wafer into a plurality of chips, and the step of peeling the second substrate and the second adhesive layer away from each of the chips by reducing the adhesion of the second adhesive layer of the sheet.
Regarding the aforementioned method for processing, when the first adhesive layer is composed of a radiation-setting adhesive, and the second substrate is composed of a heat-shrinkable plastic film, the first substrate is peeled away from the wafer by irradiating the first adhesive layer with radioactive rays, and the second substrate is peeled away from each of the chips by being allowed to heat-shrink.
On the other hand, regarding the aforementioned method for processing, when the first substrate is composed of a heat-shrinkable plastic film, and the second adhesive layer is composed of a radiation-setting adhesive, the first substrate is peeled away from the wafer by being allowed to heat-shrink, and the second substrate is peeled away from each of the chips by irradiating the second adhesive layer with radioactive rays so as to cure the second adhesive layer.
Further objects, features and advantages of the present invention will become apparent from the following description of the preferred embodiments with reference to the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic sectional view showing an adhesive sheet for affixation of a wafer according to a first embodiment of the present invention.
FIG. 2A to FIG. 2D are schematic sectional views for illustrating a method for processing a wafer by using the adhesive sheet for affixation of a wafer according to the first embodiment.
FIG. 3 is a schematic sectional view showing an adhesive sheet for affixation of a wafer according to a second embodiment of the present invention.
FIG. 4A to FIG. 4D are schematic sectional views for illustrating a method for processing a wafer by using the adhesive sheet for affixation of a wafer according to the second embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The embodiments of the present invention will be described below in detail with reference to the drawings.
(First Embodiment)
FIG. 1 is a schematic sectional view showing an adhesive sheet for affixation of a wafer according to a first embodiment of the present invention. As shown in FIG. 1 , an adhesive sheet 101 for affixation of a wafer is composed of a first substrate 102 , a first adhesive layer 103 , a second substrate 104 , and a second adhesive layer 105 . In order to protect the second adhesive layer 105 before being subjected to use, preferably, a strippable sheet 106 is temporarily adhered on the second adhesive layer 105 .
As the first substrate 102 , preferably, a synthetic resin film having extensibility in the length direction and width direction is used. Specific examples of such films include polyethylene films, polypropylene films, polybutene films, poly(vinyl chloride) films, poly(ethylene terephthalate) films, poly(butylene terephthalate) films, polybutadiene films, polyurethane films, polymethylpentene films, ethylene-vinyl acetate films, ionomers, ethylene-methacrylic acid copolymer films, etc., and cross-linked films thereof. The first substrate 102 may be composed of a laminate of these films. In general, the film thickness of the first substrate 102 is 10 to 300 μm, and preferably, is 50 to 200 μm.
The first adhesive layer 103 is composed of a radiation-setting adhesive, and a system primarily containing the adhesive and a system primarily containing a radiation-polymerized synthetic oligomer are uniformly dispersed. The adhesion of this radiation-setting adhesive is significantly reduced by irradiation of radioactive rays.
The second substrate 104 is composed of a heat-shrinkable plastic film. Examples of such films suitably used include transparent films having been subjected to adequate extension processing and being made of, for example, polyolefins, e.g., polyethylene, polypropylene, and polymethylpentene, poly(vinyl chloride), polyester, and polystyrene. In particular, a film having a film thickness of 10 to 300 μm is preferable. The heat shrinkage factor (%) of this heat-shrinkable plastic film is preferably 5% or more in any one of the vertical direction and the horizontal direction of the film, more preferably, is 10% or more, and especially preferably, 20% or more.
The second adhesive layer 105 is composed of a material containing at least a partially cross-linked material of a carboxyl group—containing hydrophilic polymer in which a part of the carboxyl groups are partially neutralized and a surfactant. This surfactant is composed of at least one surfactant selected from the group consisting of anionic surfactants and cationic surfactants, and is in a liquid state at room temperature.
In order to peel the second substrate 104 and the second adhesive layer 105 away from the wafer affixed thereto, the second substrate 104 is heated so as to bring about heat-shrinkage. The heating is performed in a furnace or in a hot water bath. The heating temperature is determined depending on the material of the heat-shrinkable plastic film of the second substrate 104 , and it is essential that the heating temperature is equivalent to or more than the temperature at which this heat-shrinkable plastic film brings about heat-shrinkage. However, the heating must be performed within the range in which circuits arranged on the wafer surface are not adversely-affected. Specifically, regarding the furnace, the heating is desirably performed at 60° C. to 200° C., and preferably, at 80° C. to 100° C. Desirably, the heating time is 20 seconds to 5 minutes, and preferably, is 40 seconds to 2 minutes. Regarding the hot water bath, desirably, the heating temperature is 60° C. to 100° C., and preferably, at 70° C. to 100° C., while the heating time is 20 seconds to 5 minutes, and preferably, is 40 seconds to 2 minutes. According to such a heating, the heat-shrinkable plastic film as the second substrate 104 is allowed to heat-shrink into the shape of a roll or cluster, and accompanying this, the adhesion of the second adhesive layer 105 is reduced.
Next, a method for processing a wafer by using the adhesive sheet for affixation of a wafer according to the first embodiment will be described with reference to schematic sectional views shown in FIG. 2A to FIG. 2D . In FIG. 2A to FIG. 2D , the same members are indicated by the same reference numerals.
FIG. 2A shows the condition that the adhesive sheet 101 for affixation of a wafer according to the first embodiment is affixed to a silicon wafer 110 . Reference numerals 102 , 103 , 104 , and 105 denote the first substrate, first adhesive layer, second substrate, and second adhesive layer, respectively, similarly to those in FIG. 1 .
The silicon wafer 110 provided with the adhesive sheet 101 for affixation of a wafer by affixation is diced into the condition shown in FIG. 2B . Although the wafer 110 is cut into a plurality of silicon chips 110 a, these are joined to each other by the sheet 101 . Subsequently, radioactive rays are applied from the first substrate 102 side and, therefore, the adhesive of the first adhesive layer 103 is cured. According to this, the adhesion of the first adhesive layer 103 is significantly reduced and, therefore, the first substrate 102 and the first adhesive layer 103 can be peeled away from the wafer 110 .
FIG. 2C shows the condition that the first substrate 102 and the first adhesive layer 103 have been peeled off. Individual silicon chips 110 a are in the condition of being separated from each other, and under this condition, it is also possible to electrically connect by tape automated bonding (TAB) and inner lead bonding (ILB).
The separated individual silicon chips 110 a are heated from the second substrate 104 side and, therefore, the second substrate 104 is allowed to heat-shrink. Accompanying this, the adhesion of the second adhesive layer 105 is reduced. Consequently, the second substrate 104 and the second adhesive layer 105 can be peeled away from the silicon chip 110 a . As shown in FIG. 2D , the chip 110 a after these are peeled away therefrom is mounted on a mount member 120 immediately after the peeling.
As described above, according to the present embodiment, since the silicon chip 110 a is covered with the second substrate 104 as the back between the instant when the silicon wafer 110 is cut and the instant when the silicon chip 110 a is mounted, adhesion of foreign materials, etc., can be prevented. Consequently, reduction in mounting precision due to adhesion of foreign materials, etc., can be avoided during mounting and, therefore, a semiconductor chip having high reliability can be provided.
(Second Embodiment)
FIG. 3 is a schematic sectional view showing an adhesive sheet for affixation of a wafer according to a second embodiment of the present invention. As shown in FIG. 3 , an adhesive sheet 201 for affixation of a wafer is composed of a first substrate 202 , a first adhesive layer 203 , a second substrate 204 , and a second adhesive layer 205 . In order to protect the second adhesive layer 205 before being subjected to use, preferably, a strippable sheet 206 is temporarily adhered on the second adhesive layer 205 .
The first substrate 202 is composed of a heat-shrinkable plastic film. The material, thickness, and heat shrinkage factor suitably adopted for this film are similar to those for the second substrate 104 in the first embodiment. As the first adhesive layer 203 , one similar to the second adhesive layer 105 in the first embodiment is used suitably.
The peeling of the first substrate 202 and the first adhesive layer 203 is performed by heating the second substrate 104 so as to bring about heat-shrinkage. The heating is performed in a furnace or in a hot water bath. Regarding the heating temperature and the heating time, suitable conditions are similar to those in the peeling of the second substrate 104 and the second adhesive layer 105 in the first embodiment.
As the second substrate 204 , preferably, a synthetic resin film having extensibility in the length direction and width direction is used. The specific material and suitable thickness of such a film can be similar to those of the first substrate 102 in the first embodiment. As the second adhesive layer 205 , a radiation-setting adhesive similar to the first adhesive layer 103 in the first embodiment can be used suitably.
Next, a method for processing a wafer by using the adhesive sheet for affixation of a wafer according to the second embodiment will be described with reference to schematic sectional views shown in FIG. 4A to FIG. 4D . In FIG. 4A to FIG. 4D , the same members are indicated by the same reference numerals.
FIG. 4A shows the condition that the adhesive sheet 201 for affixation of a wafer according to the second embodiment is affixed to a silicon wafer 210 . Reference numerals 202 , 203 , 204 , and 205 denote the first substrate, first adhesive layer, second substrate, and second adhesive layer, respectively, similarly to those in FIG. 3 . The silicon wafer 210 in the present embodiment has openings arranged by anisotropic etching from the back of the silicon wafer. Since openings are arranged, it is possible to use the chips for an ink feed path in an ink-jet head.
The silicon wafer 210 provided with the adhesive sheet 201 for affixation of a wafer by affixation is diced into the condition shown in FIG. 4B . Although the wafer 210 is cut into a plurality of silicon chips 210 a , these are joined to each other by the sheet 201 . Subsequently, heating is performed from the first substrate 202 side and, therefore, the first substrate 202 is allowed to shrink. As a result, the adhesion of the first adhesive layer 203 is significantly reduced and, therefore, the first substrate 202 and the first adhesive layer 203 can be peeled away from the wafer 210 .
FIG. 4C shows the condition that the first substrate 202 and the first adhesive layer 203 have been peeled off. Individual silicon chips 210 a are in the condition of being separated from each other, and under this condition, it is also possible to electrically connect by TAB and ILB.
The separated individual silicon chips 210 a are irradiated with radioactive rays from the second substrate 204 side and, therefore, the second adhesive layer 205 is cured so that the adhesive thereof is significantly reduced. Consequently, the second substrate 204 and the second adhesive layer 205 can be peeled away from the silicon chip 210 a . As shown in FIG. 4D , the chip 210 a , after these are peeled away therefrom, is mounted on a mount member 220 immediately after the peeling. As described above, according to the present embodiment, since the silicon chip 210 a is covered with the second substrate 204 as the back between the instant when the silicon wafer 210 is cut and the instant when the silicon chip 210 a is mounted, adhesion of foreign materials, etc., can be prevented. Consequently, reduction in mounting precision due to adhesion of foreign materials, etc., can be avoided during mounting and, therefore, a semiconductor chip having high reliability can be provided. When the silicon chip having an opening for an ink feed path in an ink-jet head is used, intrusion of foreign materials into the opening causes non-ejection during ejection of ink. However, when the adhesive sheet for affixation of a wafer according to the present embodiment is used, intrusion of foreign materials into the opening can be reduced and, therefore, significant improvement of the reliability in manufacture of the ink-jet head is achieved.
While the present invention has been described with reference to what are presently considered to be the preferred embodiments, it is to be understood that the invention is not limited to the disclosed embodiments. On the contrary, the invention is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims. The scope of the following claims is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures and functions. | An adhesive sheet for affixation of a wafer includes a first substrate, first adhesive layer arranged on the first substrate, second substrate arranged on the first adhesive layer, and second adhesive layer arranged on the second substrate. A chemical reaction which causes reduction in the adhesion of the first adhesive layer and a chemical reaction which causes reduction in the adhesion of the second adhesive layer are different. A method for processing using this sheet includes the steps of affixing the sheet to a wafer, dicing the wafer with the sheet affixed thereto, peeling the first substrate and first adhesive layer away from the diced wafer by reducing the adhesion of the first adhesive layer and, thereby, dividing the wafer into a plurality of chips, and peeling the second substrate and second adhesive layer away from each of the chips by reducing the adhesion of the second adhesive layer. | 8 |
FIELD OF THE INVENTION
This invention relates to the field of high pressure water cleaning devices for highways, runways, parking decks, and other hard surfaces.
PRIOR ART BACKGROUND
The use of paint stripes on road surfaces is the accepted method to indicate vehicle lanes, crossing lanes, parking areas and numerous other indicators. Various pavement marking techniques are known, including the use of traffic paint, thermoplastic, epoxy paint and preformed tapes. Common pavement surfaces are asphalt and concrete. Most pavement marking systems are intended to be as durable and permanent as possible, and resistant to weathering and wear from traffic. The removal of such striping is typically required when the road is to be resurfaced or if the indication is to be changed. The removal of such stripes is typically performed by use of abrasive wheels, grinding teeth, or the blasting of abrasive particles against the material to be removed. The use of these carbide teeth and grinding wheels results in an undesirable trench or groove in the road.
For example, paint, when used for roadway marking, penetrates into the pavement, perhaps ⅛-⅜ inch, so that mere surface removal of the paint is not sufficient to remove the marking. For example, a pavement marking removal technique that uses abrasive wheels or teeth can create excessive heat which may be suitable for removing painted markings but can melt thermoplastic materials causing equipment to gum up, by reconstituting the thermoplastic.
Current pavement marking removal machines typically employ various forms of cutting devices to remove the marking material, as well as a portion of the underlying layer of pavement material, for example, ⅛-⅜ inch, in order to effectively remove painted lines, including paint which has penetrated the porous pavement. A common type of machine employed for removing pavement marking is known as a “Road Pro” grinder manufactured by Dickson Industries, Inc., in Dickson U.S. Pat. No. 5,236,278. This type of machine employs parallel passive shafts that extend between circular rotating end plates. Hardened steel star wheels are carried on the parallel passive shafts, and these star wheels strike and abrade the pavement surface.
Another approach to pavement marking removal is the use of diamond saw blades arranged to make a dado cut. Still other types of machines use grinders or shot blast as described in Patent Registrations U.S. Pat. Nos. 4,753,052; 4,376,358; 3,900,969; 4,336,671; 3,977,128 and 4,377,924.
NLB Corporation markets a high pressure water jet system for removing paint from pavement under the name “StarJet”. The water jet system includes a blast head frame mounted on an attachment to the front bumper of a prime-mover truck. Casters support the frame for movement over the pavement and the path of the blast head is controlled by the driver steering the truck. Because of the position of the driver and the cab body of the prime-mover, it is difficult to see the blast head's position with regard to the stripes on the pavement. Any vision at all requires the driver to lean out of the driver's side window resulting in fatigue and other non ergonomically efficient factors. Positioning the head to the passenger side is performed manually with some difficulty and greatly complicating the driver's ability to view the blast path. The driver must now position himself in an almost upright standing position. Further, due to the length of the extension holding the blast head, the angular off-set, and the swivel of the casters, the movement of the wheel of the truck is not directly related to the path of the blast head.
NLB Corporation also has another system marketed under the mark “StripeJet”, that is a self propelled tractor with a blast head on the front of the tractor. The blast head has a shroud and high pressure inlet with a vacuum recovery.
Another stripe removal system is marketed by the Blasters Corporation which is mounted on a truck similar to the “StarJet” device. Another model appears to be a self-powered four wheeled tractor, similar to a grass mower, which supports a driver and is connected to the prime-mover by high pressure lines for delivery of high pressure water to a blast head. The blast head is on the front of the tractor.
The problem with the prior art is the inability to place an operator close to the material removal site by use of a device that has over-all dimensions that allow for easy transfer sideways on a truck or trailer having a width less than 8′6″.
SUMMARY OF THE PRESENT INVENTION
Briefly, disclosed is a cleaning system for removing coatings from a hard surface by high pressure liquid. The system employs a liquid reservoir connected to a high pressure pump for directing ultra high pressure water through a blast head mounted on a self-propelled mobile frame. The mobile frame is a self-propelled tractor wherein the blast head and tractor are of a size for removably docking transversely on a bed of said truck. The cleaning system is mounted on the truck or pulled behind the truck on a trailer. The truck is then tethered to the tractor during operation. The truck bed includes a ramp sized to support the tractor for docking and transport.
It is an object of this invention to provide a vacuum recovery truck mounted stripe removal system having a compact unit for safe, fast over-the-road travel to job sites.
It is another object of this invention to provide a unit that is quickly deployed, with hoses not having to be disconnected, and in operation at the job site.
It is a further object of this invention to provide a tractor mounted blast head that is hydraulically articulated from left to right and at the same time when moved all the way to the right this also brings the blast head closer to the wheels of the tractor thereby reducing its overall dimension to under 8′6″ when in its upright and locked position to reduce the over-all dimensions of the blast head for over-the-road transportation.
It is still another object of this invention to provide a blast head that is articulated to swing horizontally independently of the tractor path for more flexibility in coverage.
It is a further object of this invention to provide a high pressure water jet for removal of paint or other coverings and a vacuum recovery system for the water and debris being generated.
It is yet another object of this invention to provide a collection/filter receptacle for the removed materials for ease of disposal and the release of filtered wastewater. This allows an operator to easily regain all of the available capacity not occupied by paint chips or road debris of the vacuum chamber by simply releasing the dump valve. All of the remaining debris is retained until such time as the vacuum chamber is completely full of actual debris. The amount of capacity able to be regained will be continually diminished as the vacuum tank fills with debris and will eventually reach a point of inefficiency at which point it must be dumped. When the material is dumped, it is dumping semi dried, dewatered debris in which the wastewater is not mixed with the debris.
Other objectives and advantages of this invention will become apparent from the following description taken in conjunction with the accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention. The drawings constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
While the novel features of the invention are set forth with particularity in the appended claims, the invention, both as to organization and content, will be better understood and appreciated from the following detailed description, taken in conjunction with the drawings, in which:
FIG. 1 is a side view of the stripe removal system;
FIG. 2 is a perspective of the stripe removal system with blast head deployed;
FIG. 3 is a front view of the blast head and tractor;
FIG. 4 is perspective of the blast head link;
FIG. 5 is a side view of the tractor with blast head stowed;
FIG. 6 is a side view of the liquid reservoir and sump; and
FIG. 7 is a perspective of the sump and waste removal system.
DETAILED DESCRIPTION OF THE INVENTION
The paint removal system 10 , shown in FIG. 1 , includes a prime-mover truck 11 and a trailer 17 . The truck has a forward cab-over 18 for the driving controls and operator. Mounted on the bed 12 of the truck is the water reservoir 13 and the sump 14 or vacuum chamber. The reservoir and sump are interconnected by a strategically positioned duct for continuous dumping of filtered wastewater when operating from a fixed position where liquid is supplied to the high pressure pump by a means other than the reservoir 13 .
The sump 14 is positioned on the rear end of the bed 12 . The rear portion 91 of the bed is pivotally mounted on the truck frame and hydraulicly powered to move in the vertical plane permitting dumping of the contents of the sump 14 . The sump 14 is connected to the vacuum pump 15 by hose 16 . The intake of a high power vacuum pump capable of approximately 1100 CFM (cubic feet per minute) is connected to the vacuum tank. The vacuum tank and pump are also mounted on the bed of the prime-mover 11 .
A ramp 19 is hinged to the edge of the bed 12 between the vacuum pump 15 and the cab 18 . The ramp can be lowered to provide a pathway for the self propelled tractor 20 . As shown, the ramp 19 is in the stowed or traveling position for highway transport. When the ramp is unfolded it is approximately 9 feet in length.
The trailer 17 is removably attached to the prime-mover through a conventional trailer hitch. Mounted on the bed 22 of the trailer is a high pressure fluid pump greater than 25,000-40,000 psi and from 2-15 gallons per minute. A high pressure hose connects the pump with the blast head during operations.
In FIG. 2 the mobile tractor 20 is illustrated in the normal operations position. The tractor is similar to a riding mower with a small engine self propelling the tractor. The blast head 23 has at least one and up to sixteen high pressure nozzles 69 delivering high pressure fluid to the surface to be cleaned. The high pressure nozzle is carried on a chassis 24 mounted on casters 25 . A shroud 27 descends from the chassis and surrounds the high pressure nozzle. The blast head is connected to the high pressure hose by line 26 and the shroud 27 is connected to the sump by waste removal hose 28 . The high pressure hose 26 and the vacuum hose 28 is supported by a swinging boom 29 which is mounted on the prime mower 11 shown in FIG. 1 to provide freedom of movement for the tractor and to prevent tangling or running over of the hoses by the prime mover.
As shown in FIGS. 3-5 , the blast head 23 is connected to the tractor 20 by an articulated link 31 which is capable of horizontal movement, as shown in FIGS. 3 and 4 , and vertical movement, as shown in FIG. 5 . A bar 32 is attached to the tractor frame by rods 33 and 34 . The bar 32 is located between the front wheels of the tractor. The horizontal swinging movement of the link results in a widened path of the high pressure nozzle to adjust for different widths or patterns of striping of the surface being cleaned and deviations in direction of the tractor. The horizontal movement is powered by the hydraulic cylinder 35 connected to bar 32 which may be controlled by the operator moving a joy stick on the tractor. As the hydraulic piston 36 , connected to the trailing arm 37 , arm 37 and 38 move, with the trailing arms rotating about pins 39 and 40 attached by brackets 41 and 42 on bar 32 .
The forward end of the articulated link 31 has a plate 43 connected to the forward ends of trailing arms 37 and 38 . The arms 37 and 38 are rotatably connected to the plate by brackets 41 ′ holding pins 39 ′ respectively. The forward arms 44 and 45 are rotatably connected to the plate 43 to rotate vertically. Pins 46 and 47 extend horizontally through brackets 48 and 49 . Another hydraulic cylinder 50 is connected to the plate 43 and the piston 51 is connected to the forward end of the arm 44 . As the piston 51 moves, the distance between the to be cleaned and the blast head 23 changes. The vertical movement permits elevation changes to accommodate the contours of the surface. Further, the blast head 23 may be raised to the vertical position and then manually flipped up and back reducing the overall length to permit the tractor 20 and blast head 23 to be stowed on a truck bed sideways consuming a space less than 8′6″ for highway travel, shown in FIG. 5 . The forward ends of the arm 44 and 45 are attached by pins 52 and 53 to brackets 54 and 55 to prevent binding as the arms are manipulated. The brackets are mounted on blast head attachment plate 56 .
A blast head attachment plate 56 is removably connected to the chassis 24 of the blast head 23 to provide support and control of the blast head from the tractor through the link 31 .
The liquid reservoir 13 and the sump 14 are shown in FIG. 6 . As illustrated, the liquid reservoir and vacuum chamber have a common enclosure with an internal partition dividing them. The sump 14 has a inlet 57 for connection by hose 28 to the vacuum shroud 27 . An outlet 58 is connected to the vacuum pump hose 66 . The liquid reservoir has a hatch 60 for inspecting and cleaning the reservoir with approximately 600-1500 gallons of liquid. An outlet 61 is connected to a low pressure pump by a low pressure suction hose 62 . The low pressure 12 volt pump is used to pump water out of the reservoir 13 back to the water blasting pump 67 about 40 Psi and 20 g.p.m.
A recycling valve 63 is mounted in a connector pipe 68 having one end opening into the reservoir 13 and the other end opening into the sump 14 . The connector is located near the top of the sump and reservoir to allow for some settling of debris in the sump. The valve 63 opens or closes the connection.
In FIG. 7 , the sump 14 is shown with the rear door 65 open for unloading the porous enclosure 64 . The door has a seal (not shown) to maintain the negative pressure therein during operation. The porous enclosure may be a wire screen or mesh box sized to fit within the sump 14 . An additional filter bag 68 having between 5-200 micron porosity may be inserted into the enclosure. The dimensions of the enclosure 64 are somewhat less than the interior of the sump which provides a marginal area 80 between the enclosure and the interior walls and floor of the sump which provides an exit path for filtered water through valve 70 . The inlet 57 empties into the enclosure 64 thereby preventing coatings from being entrained in the vacuum system. One side of the enclosure is hinged and latched to permit entry into the enclosure or removal of the filtered bags. By opening the sump door and raising the dump bed of the truck, the waste material can be easily and quickly removed without prolonged interruption of the operations. The filtered bag is the disposal container, and is dumped with the material. A permanent filter material can also be utilized which requires cleaning after each use but does not waste a filter bag each time it is dumped.
In operation, the process for using the disclosed equipment in a mobile operation for stripe removal:
1. Connection valve remains closed. Water side is used only as a fresh water supply and is not placed under vacuum at any time.
2. Filter material position in the vacuum tank at a distance off the walls and floor of the tank. A filter tank “bag” may also be hung by hooks from the ceiling to produce even cleaner waste water.
3. The vacuum tank is placed under vacuum by starting the diesel powered vacuum pump which is connected by an air outlet hose to the vacuum tank.
4. As strip material is removed creating a slurry of water and debris, the mixture is drawn through the inlet hose into the vacuum tank being trapped in the filter.
5. When the vacuum tank reaches its full capacity, a shutoff ball is forced upwards towards the air outlet hose and makes contact with a ball seal causing loss of tank vacuum.
6. The drain valve is then opened on the vacuum tank, and into the open cavity between the walls and floor allowing an exit from the drain.
7. The shutoff valve is closed allowing for a capacity equal to the capacity previously occupied by dirty water, only the debris slurry remains inside the tank.
8. Steps 1-7 are repeated until the strip is removed.
9. Upon opening of a door to the vacuum container, allows for a removal of all debris captured in the filter.
The instant invention may also be used in a non-mobile setting in continuous operation as follows.
1. The connection valve remains open except when it is necessary to dump the water side. Water side is used as an overflow vacuum tank and is under vacuum much of the time.
2. Filter material positioned in the vacuum tank at a distance off the walls and floor of the tank. A filter “bag” may also be hung by hooks from the ceiling to produce even cleaner waste water.
3. Vacuum tank is placed under vacuum by starting the diesel powered vacuum pump which is connected by the air outlet hose to the vacuum tank. Water side is under vacuum as well by way of connection valve.
4. As strip material is removed creating a slurry of water and debris, the mixture is drawn through the inlet hose into the vacuum tank being trapped in the filter.
5. As the debris and water level rise to the level of the connection valve, the water will begin flowing through the connection valve into the water side. The water in the water side tank will be filtered water as the water has had to first flow through the filter material to reach the connection valve.
6. When the waste water has reached the level of the connection valve it will be visible to the operator through a strategically positioned sight glass. At that point, without shutting down the vacuum or the operation, the operator closes the connection valve which releases the water side tank from vacuum.
7. Next, the operator must open the drain valve on the water side to release the waste water being held there.
8. After the water tank has drained completely, the water side drain valve must be closed.
9. The connection valve is reopened allowing wastewater to flow freely into the water side box.
10. Repeating of steps 1-9 while never shutting down or affecting the blasting operation whatsoever. This may be continued until the vacuum tank is full of debris.
11. It is now necessary to shut off the vacuum power unit and open the drain valve on the vacuum tank. This allows the water to drain through the filter material, into the open cavity between the walls and floor, and exit the drain. This allows the debris to dewater.
12. Opening of the vacuum door allows for a release of all material to repeat the process.
A number of embodiments of the present invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the invention is not to be limited by the specific illustrated embodiment but only by the scope of the appended claims. | A system for removing paint and other coatings from hard surfaces is mounted on a truck for over-the-road travel. The truck bed carries a high power vacuum pump, a self propelled tractor with an attached blast head, a liquid reservoir, a sump or vacuum tank, and a ramp for loading the tractor. The reservoir is connected to a low pressure pump that transfers water to the high pressure pump. The high pressure pump is connected to the blast head by a high pressure hose. A vacuum hose is connected to the sump which has an internal enclosure for separating the waste materials from the liquid for easy dumping of semi dried materials. | 4 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims the benefit of the following provisional application: U.S. Serial No. 60/026,565, filed Sep. 23, 1996, under 35 USC 119(e)(i).
FIELD OF THE INVENTION
The present invention relates to a portable cold pack for medicinal vials and, more particularly, to a cold pack for use by emergency medical technicians and ambulatory services.
BACKGROUND OF THE INVENTION
Certain medicines are temperature sensitive and must be refrigerated to a lower than room temperature such as insulin. These refrigerated medicines cause particular storage difficulties for emergency medical personnel. Ambulances are equipped with heaters, but they are not commonly equipped with refrigeration units. Medicines requiring refrigeration have heretofore been held in cooling packages and even sometimes placed in conventional coolers (see U.S. Pat. Nos. 5,390,797, 5,390,791, 4,250,998, 4,429,793, 4,368,819, 5,405,012 and 276,590). The energy needed to chill the medicine in the cooling packages and cooler is supplied by a medium such as water, ice, dry ice or a chilled gel. Refrigerating medicines in conventional cooling packages and coolers has many drawbacks, particularly when used with ambulatory services. In general, conventional cooling packages and coolers are bulky and difficult to manipulate. Thus, quick and efficient access to the medicine in the cooling packages and coolers is restricted by the cooling packages and cooler per se. Additionally, the chilling medium may spill.
Ambulances are sometimes too active to return to their base to replenish the supply of refrigerated medicines and/or ice, if and when the medicines approach their upper limit of safe storage temperature. Therefore, the manner in which medicines requiring refrigeration are stored may not chill the medicine for the entire shift of the ambulance operators.
It is therefore an object of the present invention to provide a portable cold pack for refrigerating medicines to hold the medicine below the temperature at which the medicine degrades. Further, it is an object to hold the medicine below the critical temperature for a substantial period of time.
It is further an object of the invention to provide such a cold pack that is easily used in an emergency medical situation, namely, the medicinal vials must be quickly and easily accessible to the medical personnel. The device must also be easily and quickly closed and sealed because time is not only of an essence when accessing the medicine for the patient, but also when it comes time to clean up the treatment site and transport the patient for further medical attention.
It is a further object of the invention to provide such a cold pack which adequately seals itself to preserve the chilled atmosphere within the cold pack for cooling medicines and is easily openable.
SUMMARY OF THE INVENTION
The objects and purposes of the invention, including those set forth above, are met by providing a cold pack for medicinal vials which includes: an outer housing attached to a base, wherein the base has a supporting depression therein for receiving a tray of medicinal vials. The outer housing has a hollow interior for receiving the tray therein. The tray is enclosed by a closure means keeping the tray in a chilled state inside the housing.
To further the cooling ability of the cold pack for medicinal vials, the cold pack may be placed within a reclosable insulated bag. This will further the cooling ability of the cold pack. The insulated bag can be attached to or placed in the drug case used by medical personnel to transport medicines to the patient's location.
BRIEF DESCRIPTION OF THE DRAWINGS
A preferred embodiment of the present invention is described in detail hereinafter with reference to the accompanying drawings, in which:
FIG. 1 is an exploded isometric view of the cold pack in an open state;
FIG. 2 is a sectional view taken along line 2--2 in FIG. 1 and showing the cold pack in an open state;
FIG. 3 is a view similar to FIG. 2 and showing with the cold pack in a closed state;
FIG. 4 is an enlarged view of the top area of FIG. 3;
FIG. 5 is an exploded view similar to FIG. 1; and
FIG. 6 is an enlarged partial view of the cold pack transitioning between a closed position to an open position or vice versa.
DETAILED DESCRIPTION
Certain terminology will be used in the following description for convenience in reference only and will not be limiting. The words "up", "down", "right" and "left" will designate directions in the drawings to which reference is made. The words "in" and "out" will refer to directions toward and away from, respectively, the geometric center of the device and designated parts thereof. Such terminology will include derivatives and words of similar import.
FIG. 1 shows a cold pack 10 which includes a base 11, a hollow, thin-walled housing 12, and a medicinal vial holder 13. All components of the cold pack 10 are made of a uniformly thick thermoplastic material and shaped during a vacuum forming process. The base 11 has a pair of upstanding and upwardly converging side walls 14 and a pair of upstanding and upwardly converging side end walls 15, all contained in respective planes inclined to the vertical. Upper ends of each of the walls 14, 15 terminate in a common plane and are connected by a top wall 16. The top wall 16 has a socket-like depression 17 formed therein which is adapted to removably receive the vial holder 13. A hinge 20 is integrally formed to and extends laterally along a bottom edge of each of the side walls 14.
More specifically, the socket-like depression 17 has opposing side walls 21, 22 and opposing end walls 23 extending between the side walls 21, 22. While the socket-like depression 17 may be of any geometric shape, in the preferred embodiment, the side walls 21 and 22 are generally parallel to each other. Further, one of the side walls 21 is shorter in height than the other side wall 22 so that a bottom wall 24 of the socket-like depression 17 connected to the bottom edge of the side walls 21, 22 is inclined therebetween. The end walls 23 are generally convergingly inclined from the sidewall 22 toward the side wall 21.
The base 11 additionally has a facing member 25 formed on and protrudes outwardly from each of the end walls 15. Each of the facing members 25 has plural facing surfaces 26 thereon angularly related to each other. In this particular embodiment, two angularly related surfaces 26 are provided to form an inverted V-shape in cross section.
The housing 12, in the preferred embodiment, includes two cover members 30, 31 which are integrally formed with each of the hinges 20, and are each pivotal about the respective hinges between first and second positions. The first position is shown in FIGS. 1 and 2, whereas the second position is shown in FIG. 3. The cover member 30 has a hollow thin walled section 32 defined by a base sheet 33 formed into a generally rectangularly shaped receptacle 34 having upstanding and opposing end walls 36 and 37, as well as upstanding and opposing side walls 38 and 39 connecting the end walls. A bottom wall 40 connects bottom edges of each of the side and end walls 36-39 through correspondingly radiussed corner sections. The hinge 20 interconnects the end wall 36 to the base 11 to facilitate the aforesaid pivotal movement. A skirt 45 projects outwardly from an upper edge of the side and end walls 37-39 and downwardly along an outside facing surface of the side walls 38, 39 and the end wall 37 remote from the hinge 20. A lower outer edge of the skirt 45 forms an outwardly extending flange 46. The upper edge of the side walls 38, 39 and the end wall 37 remote from the hinge 20 are coplanar and terminate a distance above the level of the hinge 20 as shown in FIG. 2. End portions 47 of the side walls 38 and 39 adjacent to and facing the base 11 each define a facing surface 48. Each facing surface 48 is conformed to the respective facing surface 26 on the facing member 25 of the base 11 so that as the cover member 30 pivots about the hinge 20, the opposing facing surfaces 26 and 48 will be in a close juxtaposition to form a loose seal, especially when the cover member 30 is pivoted 90° from the open or first position shown in FIG. 2 to the closed or second position shown in FIG. 3. The angularly related facing surfaces 26 and 48 additionally allow the cover 23 to pivot through the 90° movement without interfering with the structure of the hinge 20.
The juncture between the upper edges of the side walls 38, 39 and the end wall 37 remote from the hinge 20 and the skirt 45 defines a bead or tongue 50 having an uppermost flat surface segment 51 extending parallel to the bottom wall 40 and an acute angle stepped segment 52 forming the upper edge of the skirt 45. A first wall surface 53 of the stepped segment 52 is oriented generally parallel to the flat surface segment 51 and is contiguous with the skirt 45 whereas a second wall surface 54 is inclined to the vertical. The edge joining the inclined wall surface 54 to the flat surface segment 51 defines a lip 55. The region of the cover member 30 generally adjacent and above the level of the hinge 20 is open so that the end portion 47 of the side walls 38, 39 adjacent the hinge 20 straddle about half the left to right dimension of the base 11 illustrated in FIG. 2 when the cover member is moved to the closed position.
The uppermost flat surface 51 terminates shortly before the end portion 47 of the side walls 38, 39 to allow the stepped segment 52 to extend between the flat surface 51 and the end portion 47. The inclined wall surface 54 of the stepped segment 52 has a portion 57 inclined with respect to the vertical extending from a portion 56 of the wall surface 53 to the uppermost flat surface segment 51.
The interior of the rectangularly shapped receptacle 34 includes on the interior walls thereof at about a mid-height level, here on the end walls 36 and 37 and the immediately adjacent area of the contiguous side walls 38 and 39, structure defining spaced lower and upper ledges 58 and 59. Each respective ledge 58 and 59 includes a lower stepped configuration 60 and an upper stepped configuration 61, respectively.
A wall section 62 is received on the ledges 58 and 59 and is cemented in place. The wall section 62 includes a sheet of uniformly thick thermoplastic material having a perimeter thereof formed into a U-shaped flange 63, one leg 64 of the U-shaped flange being contiguous with the sheet. The other leg 65 of the U-shaped flange terminates at an upper edge thereof in an outwardly extending flange 66 adapted to rest on an upper surface area 67 of the upper ledge 59.
The wall section 62 inside the aforesaid perimeter includes a pair of convergingly inclined sections 68 and 69 extending upwardly from opposite ends thereof adjacent the end walls 36 and 37. The wall section 62 also includes a pair of convergingly inclined sections 70 and 71 extending upwardly from opposite sides adjacent the side walls 38 and 39. The pair of convergingly inclined sections 70, 71 generally mirror each other about a center line of the wall section 62. The upper edges 72, 73, 74 and 75 of the four inclined sections 68, 69, 70 and 71, respectively, are coplanar and are contiguous with a wall segment 76 forming generally a centrally disposed depression or pocket 77. The wall segment 76 is in the general form of a segment of a sphere or like surface area. Further, the wall segment 76 is yieldable to forces applied to a bulbous side 78 thereof. In this embodiment, the bulbous side 78 faces and opposes the bottom wall 40 of the rectangularly shaped receptacle 34 in the cover member 30.
A space or cavity 80 is defined between the bulbous side 78 and the bottom wall 40 of the receptacle 34. A bag 81 of refreezable liquid is placed into the cavity 80 and occupies a majority of the space therein. Such bags 81 of refreezable liquid are marketed by Mid-Lands Chemical Company, Inc. of Omaha, Nebr. under the trademark POLAR PACK.
The cover member 31 has a hollow thin walled section 82 defined by the base sheet 33 formed into a generally rectangularly shaped receptacle 84 having upstanding and opposing end walls 86 and 87, as well as upstanding and opposing side walls 88 and 89 connecting the end walls 86, 87. A bottom wall 90 connects the bottom edges of each of the side and end walls 86-89 through correspondingly radiussed corner sections. The hinge 20 interconnects the end wall 86 to the base 11 to facilitate the aforesaid pivotal movement. A skirt 95 projects outwardly from an upper edge of the side and end walls 87-89 and downwardly along an outside facing surface of the side walls 88, 89 and the end wall 87 remote from the hinge 20. The lower outer edge of the skirt 95 forms an outwardly extending flange 96. The upper edge of the side walls 88, 89 and the end wall 87 remote from the hinge 20 are coplanar and terminate a distance above the level of the hinge 20 as shown in FIG. 2. End portions 97 of the side walls 88 and 89 are adjacent to and face the base 11 each defining a facing surface 98.
Each facing surface 98 is conformed to the respective facing surface 26 on the facing member 25 so that as the cover member 31 pivots about hinge 20, the opposing facing surfaces 26 and 98 will be in close juxtaposition to form a loose seal, especially when the cover member 31 is pivoted 90° from the open or first position shown in FIG. 2 to the closed or second position shown in FIG. 3. The seal between the opposed facing surfaces 26 and 98 need not be air tight. It is important, however, that the angularly related surfaces 26 and 98 allow the cover 31 to pivot through the 90° movement without interfering with the structure of the hinge 20.
The juncture between the upper edges of the side walls 88, 89 and the end wall 87 remote from the hinge 20 and the skirt 95 defines a bead or tongue 100 having an uppermost flat surface segment 101 extending parallel to the bottom wall 90 integrally connected to the skirt 95 and an acute angle stepped segment 102 forming the upper portion of side walls 88, 89 and end wall 87. One wall surface 103 of the stepped segment 102 is oriented generally parallel to the flat surface segment 101 and is contiguous with the side walls 88, 89 and end wall 87, whereas the other wall surface 104 is inclined to the vertical. The edge joining the other wall surface 104 to the uppermost flat surface segment 101 defines a lip 105. The region of the cover member 31 generally adjacent to and above the level of the hinge 20 is open so that an end portion 97 of the side walls 88, 89 adjacent the hinge 20 straddle the width of the base 11 when the cover member 31 is moved to the closed position.
The uppermost surface 101 and the stepped segment 102 on both side walls 88 and 89 form a right angle corner as at 106 adjacent the hinge 20. The facing surface 98 extends on those right angle segments between the uppermost flat surface 101 and the hinge 20 as shown in FIG. 1. A portion 107 of the inclined wall surface 104 of the stepped segment 102 extends from the uppermost flat surface 101 to the wall surface 103 and faces the interior of cover member 31.
The interior of the rectangularly shaped receptacle 84 of the cover member 31 is identically shaped to interior of the first described cover member 30. Thus, the same reference numerals have been used to denote the identically formed individual structural features in conjunction with the receptacle 84. Further description of these identically formed features is deemed to be superfluous.
The medicinal vial holder 13 includes a sheet of uniformly thick thermoplastic material formed into a rectangular shaped tray segment 109 having a compartmented depression region 110 thereon. Each compartment 110A, 110B, 110C and 110D of the compartmented region 110 on the tray segment 109 are identical and includes a generally cylindrical bottom wall 111 terminating adjacent the upper edges thereof in integrally formed locking lugs 112 which protrude into the region normally occupied by a medicine containing vial so as to be adapted to yieldingly hold a vial in the compartment. In this embodiment, each lug 112 is smaller in length than a length of the bottom wall 111. End walls 113 are formed at the respective ends of the bottom walls 111. The upper edge of each of the bottom walls 111 and end walls 113 are all coplanar and transition from an uppermost flat surface 118 into a peripherally outwardly extending skirt 114 around the entirety of the holder 13. The skirt 114 includes an inclined wall segment 115 on each of the four sides of the rectangle and which are joined together at each of the four corners. The lower edge of the skirt 114 is formed into an outwardly extending stiffening flange 116. The structure of the skirts 114 on each of the long sides and narrow sides is elastically yieldable.
Either of the narrow ends of the tray segment 109 is designatable as a holder segment 117 conforming in shape to the shape of the socket-like depression 17 on the base 11. That is, the outward inclination of the wall segment 115 at the narrow end is generally similarly inclined to the bottom wall 24 of the socket-like depression 17. Further, the spacing between the coplanar surface 118 extending between the upper edges of the skirts 114 and the upper edges of the bottom walls 111 and an opposite facing surface 119 on a side of the flange 116 remote from the surface 118 is nearly equal to the spacing between the side walls 21 and 22 of the socket-like depression 17. Further, the wall segments 115 of the skirt 114 on opposite sides of the long sides of the tray segment 109 are inclined at an angle that is generally parallel to the end walls 23 of the socket-like depression 17 when a longitudinal axis of the holder 13 is oriented perpendicular to the top wall 16 of the base member 11. As a result, a narrow end of the tray segment 109, namely, the holder segment 117 thereof is receivable in the socket-like depression 17 as shown in the drawings. The fit between the holder segment 117 and the walls 21-24 of the socket-like depression 17 is snug.
In use the holder 13 is received by the socket-like depression 17. The flange 116 on the long side side wall portions of the wall segment 115 of the holder 13 is slightly wider than the spacing between the end walls 23 of the socket-like depression 17. Thus a slight application of force is applied to the holder 13 to deform the elastically yieldable wall segments 115 of the long side skirts 114 due to the long side flanges 116 contacting the end walls 23 of the socket-like depression 17. Once the holder 13 is in the depression 17, the elastically yieldable wall segments 115 continue to press outwardly onto the end walls 23 to maintain the contact between the flanges 116 at the end thereof against the end walls 23 to thereby enhance the snug fit of the holder 13 in the depression 17 in the base 11.
When the holder 13 is to be removed from the depression 17, it may be pulled upwardly out of the depression 17. Alternatively, and if the holder 13 is held quite firmly in the depression 17, it may be necessary for a person (user) to pivot the holder 13 by gripping the holder above the holder segment 117 positioned in the depression 17 urging the exposed tray segment 109 of the holder 13 clockwise as shown in FIG. 2 about a pivot axis defined by the juncture between the surface 119 of the flange 116 and the upper edge segment of the side wall 22 of the depression 17 so as to easily overcome the snug fit and, facilitate removal of the holder 13 from the depression 17.
As shown in FIGS. 3 and 4, the lips 55 and 105 and associated stepped segments 52 and 102 are nested with one another to form a clasp 122 holding the cover members 30 and 31 in the closed position. The surfaces 51 and 101 face one another when the cover 30 and 31 are in the closed position.
The differing depths of the side walls 21, 22 of depression 17 allows the easy removal of the holder 13 from the depression 17 by pivoting the holder clockwise toward the cover member 31. The shorter depth of the side wall 21 allows the coplanar surface 118 of the holder segment 117 to be easily removed from the depression 17 during the clockwise movement. On the other hand, the side wall 22 has a depth into the depression greater than side wall 21 which prevents the holder 13 from pivoting counterclockwise toward the cover member 30. Thus, when an emergency medical technician removes the holder 13 from the depression 17, the holder 13 is pivoted clockwise so that the medicine containing vials will face upwardly toward the emergency medical technician and to provide ready access to the vials.
When transitioning the cold pack 10 from the closed position to the open position, the user can grasp the flanges 46, 96 and/or the skirts 45, 95 to apply opposing separating forces to each cover member 30, 31. The flexibility of the thermoplastic construction allows the lips 55, 105 to thereby be forced past each other and the open position is attained by rotating the cover members 90° in respective directions away from the holder 13. The cold pack 10 may also be opened by placing the cold pack on the bottom wall 40 of the cover member 30, then rotating cover member 31 through 180° so as to lie in the same plane as the cover member 31. The holder 13 in the depression 17 will resist falling out of the depression 17 due to the aforesaid snug fit in the depression.
As mentioned above, to transition the cold pack 10 from its open or first position to its closed or second position, the cover members 30, 31 are rotated 90° about the hinges 20 toward the holder 13. Just prior to attaining the second or closed position (FIG. 6), the portions 57 of the inclined wall surface 54 slidingly engage the portions 107 of inclined wall segment 104 of each of the right angle corner segments 106. The sliding engagement of the portion 57 and the wall segment 107 effects an alignment of the lips 55 and 105 to facilitate them snapping past each other locking the cold pack 10 into the closed or second position. When the cold pack 10 is in the closed position, the portion 56 of the surface 53 faces and opposes the right angled portion of the flat surface segment 101.
When the cold pack 10 is in the closed position, a storage space 120 is defined by and between the interior surfaces of the side walls 38, 39, 88, 89 above (FIG. 2) the wall sections 62 and the interior surfaces of the end walls 37, 87 for cold storing the holder 13 positioned in the socket-like depression 17. The storage space 120 is essentially insulated from the outside environment and stores the temperature sensitive medicine below its critical temperature for a substantial period of time.
The cold pack 10 can be reused by placing the entire cold pack 10 in a freezer and refreezing the liquid in the bags 81 positioned therein. The use of the ice packs or bags 81 to provide the coolant has a serious drawback, namely, the ice bags expand when frozen. The depression or pocket 77 formed by the wall segment 76 will yield to the expanding ice bag during the freezing thereof. The wall segment 76 will expand to the broken line showing at 121 in FIG. 3 and to a close juxtaposition to the medicine containing vials on one side of the holder 13 and the surface 119 on the other side of the holder 13.
The medicinal vials V are of a commonly used shape having a cylindrical liquid containing main body B with a reduced diameter neck N extending from one end of the body. A cap C is positioned on an end of the neck remote from the body for sealing the liquid medicine within the vial.
Although a particular preferred embodiment of the invention has been disclosed in detail for illustrative purposes, it will be recognized that variations or modifications of the disclosed apparatus, including the rearrangement of parts or altering the number and size of compartments in the holder, lie within the scope of the present invention. | A portable cold pack for cold storage and transporting of medicinal vials placed on a holder. The cold pack has a hollow, thin-walled housing and a base having a socket depression therein for receiving the holder. The housing and the base define an interior storage space around the holder. The hollow walls of the housing contain therein refreezable liquid for providing cooling energy. The socket depression orients the holder in the storage space in a close relationship to the interior surface of the hollow, thin-walled housing so as to efficiently cool the medicine within the vials. A closure assembly allows repeated access to the holder within the storage space. | 5 |
FIELD OF THE INVENTION
The present invention relates to an apparatus for supplying inert gas to a welding location, and more particularly, to an apparatus for concentrating an inert gas at a localized region along a pipe joint to be welded.
BACKGROUND OF THE INVENTION
In TIG (tungsten inert gas) welding and some other welding methods, it is desirable to establish an inert atmosphere in the region of a desired weld joint, such as between two pipe butt ends. To weld such a joint, typically the pipe ends are beveled to a weld angle of about 35° and cleaned. Thereafter, a purge dam apparatus can be installed, as more fully discussed below. The pipe sections are then fit-up to establish proper root-gap tolerances between two pipe sections. Generally, the root gap should be approximately 3/32" or at least 1/32" larger than the diameter of welding filler wire to be used.
Next, the pipe interiors adjacent the pipe ends are purged. Conventionally, such purging is done in a two-stage operation. During the first stage, prior to welding, an inert purge gas is used to displace the air in the pipe until the gas inside the pipe reaches an acceptably low oxygen level. Without an inert atmosphere in the pipes, the interior surface of the welded joint is subject to oxidation, inclusion of impurities and incomplete fusion of the pipe edges, particularly with stainless steel pipes. Once the required oxygen level inside the pipe has been achieved, normally 1% or less, a welding operation can be initiated. During the second stage, the purge gas flow rate is reduced for welding to prevent excessive root concavity and to keep the root weld puddle from "blowing out" from too great a back pressure. However, a purge gas flow rate is maintained sufficient so that the purge maintains a slight positive pressure on the inside of the pipe while the root pass is welded to eliminate air re-entry into the pipe, minimize oxidation of the root surface and produce a smooth bead profile. In addition, during welding the arc zone is filled with a shielding inert gas to surround the arc and thereby protect the electrode and molten metal from oxidation.
Currently, two methods are utilized to back-purge a pipe root pass weld zone. In one method, the entire volume of a long pipe run is subject to purge gas flow. However, this requires a large amount of purging gas, typically argon, particularly with pipe work of large diameter.
Rather than losing the time and gas volume filling the entire piping system with argon, operators commonly fit gas-retaining dams on each side of the weld zone inside the pipe system to create a small gas chamber which isolates the inside diameter a few inches on each side of the joint. Various types of closure dams are known including soluble dams, inflatable bladder dams, collapsible disk dams and thermally disposable dams. Although such systems are successful in reducing gas consumption over the first described method, there is still a significant time requirement to purge the zone between the dam using a two-stage operation, particularly with respect to that required for the pre-welding operation first stage purge. Necessarily, the time required for the first stage of purging depends on the maximum oxygen level permitted by the welding procedure, the volume of the system being purged, and the purge gas flow rate. However, the relationships between the purge gas flow rates and time are not linear; i.e., a system that can be purged in one hour at a flow rate of 50 c.f.h. generally will not be purged to the same degree in one-half hour if the flow rate is increased to 100 c.f.h. An increase in the purge flow rate increases the turbulence within the system, which results in an increase in the mixing of air and the inert purge gas. This will require additional volume changes of gas within the pipe to achieve the desired level of purity, generally at least four to five volume changes for high purge gas flow rates. At lower flow rates, less mixing occurs, and the heavier purge gas forces the air upward and out of the pipe system. The lower purge gas flow rates require correspondingly lower volume of purge gas used since as few as two or three volume changes can be made to yield a sufficiently oxygen-free atmosphere for welding. On the other hand, such lower gas flow rates correspondingly increase the time required to achieve such an oxygen-free atmosphere.
To make the weld, the weld joint should be sealed around the circumference of the pipe with masking tape to prevent the escape of purge gas. Typically, the pipe sections are fitted in a device that allows an operator to rotate the pipe sections as welding progresses by a remote control, such as by a foot control pedal. During the welding of the root pass, the welder should peel the tape off the joint in increments just prior to welding that increment. Initially, at least three to four tack welds should be made circumferentially spaced around the pipe to ensure that the two pipe sections do not move during subsequent closure welding. Tack welding is not usually performed until pre-weld or first stage purging has been completed and should be done with care because the tack welds normally become part of the final weld. Generally, the weld joint is kept sealed except in the area where welding is being conducted. The tack welds are then ground to a feather edge to ensure that the closure welds will fuse into the tack welds. Finally, closure welding is performed much like the tack welding. Again, the joint is kept sealed except in the area where welding is being performed. Again, to do this, as a welder approaches the tape, the welder peels it back, an inch or so at a time, until the weld is completed. As such, a welder has a limited view of the internal weld bead during a welding operation so that it is fairly difficult for the welder to correct any deficiencies in the bead during the welding operation.
Thus, there is a need for an apparatus which allows for a more economic purging of pipes such as by reducing the time required for purging with the abovedescribed processes while maintaining gas consumption at a reasonable level and which allows the welder an unimpeded view of the weld bead as it is created during a welding operation.
SUMMARY OF THE INVENTION
In accordance with the present invention, an apparatus and method for providing inert gas to a desired location for a welding operation is provided which overcomes the aforementioned problems of the prior art.
In one form, the apparatus includes a gas feed line and structure for mounting the feed line to extend in a first direction in a pipe. A gas locator tube communicates with the gas feed line to direct inert gas from the gas feed line in a second direction different from the first direction towards a pipe joint to be welded. The locator tube is capable of continually directing inert gas in the second direction as the pipe is rotated during a welding operation. Preferably, the first and second directions are substantially perpendicular to each other. The first direction can be in an axial direction and the second direction can be in a radial direction relative to the pipe.
In one form, the gas locator tube is an elongate tube having spaced ends with one end including a gas outlet port and the other end including an enlarged weighted counterbalance. The gas outlet port is adjacent the pipe joint to be welded. The elongate tube can include a trailing shield at the one end so that the gas ejected from the outlet port is localized along the joint to be welded.
The mounting structure can include an elongate hub shaft and locating member with the hub shaft having the gas feed line extending therethrough and being rotatable about the gas feed line. The locating member can be mounted to the hub shaft and sized to snugly fit within the pipe whereby the hub shaft and locating member rotate with the pipe about the feed line as the pipe is rotated during a welding operation.
In one form, the apparatus is in combination with the pipe.
In another form of the invention, an apparatus for concentrating an inert gas at a localized region along a pipe joint to be welded is provided. The apparatus includes a gas feed line directing an inert gas axially along the length of a pipe and a locating member including a central aperture therethrough mounted in the pipe axially spaced from a joint to be welded. A shaft and bearing assembly extends through the locating member's central aperture with the gas feed line extending through the assembly. The pendulum structure is attached to the gas feed line for directing inert gas from the feed line in a predetermined radial direction at the butt end of the pipe towards the joint to be welded as the pipe is welded during a welding operation.
The pendulum structure can include an elongate member having a hollow tube portion connected to the gas feed line extending perpendicular thereto and an enlarged weighted counterbalance portion at the bottom of the elongate member to maintain the member in substantially an upright position as the pipe is rotated during a welding operation.
The locating member can include expansible air ram means for securely engaging an inner wall surface of the pipe to position the gas feed line substantially along a central longitudinal axis of the pipe during a welding operation.
The locating member can be mounted on the shaft and bearing assembly with the shaft and bearing assembly and locating member rotating about the feed line as the pipe is rotated during a welding operation.
In yet another form of the invention, an inert gas feed assembly is provided including an inert gas feed means for directing inert gas from an inert gas source into a pipe and adjacent a pipe joint to be welded and positioning structure for securely mounting the inert gas feed means in a predetermined position in the pipe. A trailing shield is attached to the inert gas feed means and defines a localized zone for inert gas adjacent the pipe joint to be welded. The pendulum structure cooperates with the inert gas feed means to direct inert gas to the trailing shield adjacent the pipe joint to be welded such that during a welding operation the trailing shield moves between (1) a first position relative to the pipe joint to be welded, (2) a second position angularly displaced from the first position relative to the pipe joint to be welded with the angular displacement substantially corresponding to the angular displacement of the pipe during rotation thereof as a joint is being welded.
The pendulum structure can include an elongate member having a hollow tube portion connected to the gas feed structure and an enlarged counterbalance portion at the bottom of the elongate member to maintain the member in a substantially upright position as the pipe is rotated during a welding operation.
The invention further contemplates a method of supplying inert gas to a localized zone adjacent a pipe joint to be welded. The method includes the steps of directing inert gas through an inert gas feed tube having a delivery end along the length of a pipe to the butt end thereof toward a joint to be welded, causing the inert gas to accumulate in a localized region at the joint to be welded to substantially purge the region of other gases before a welding operation begins, and maintaining the delivery end at a predetermined substantially fixed location which remains adjacent the top of the pipe interior after the welding operation begins and as the pipe is rotated during the welding operation.
The method can further include the step of redirecting the inert gas after it has reached the butt end of the pipe radially toward the joint to be welded.
In one form, the step of directing inert gas includes the step of providing an elongate member having a hollow tube portion and inert gas is caused to accumulate in the joint region by extending the hollow tube portion towards the joint region.
In one form, the step of maintaining the region at a predetermined substantially fixed location in the pipe includes the step of counterbalancing the elongate member to maintain the hollow tube portion in an upright position extending towards the joint region as the pipe is rotated during a welding operation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an end view of a pipe section to be welded including an apparatus for supplying inert gas to a welding location, according to the invention;
FIG. 2 is a cross-sectional view taken along line 2--2 of FIG. 1;
FIG. 3 is a perspective view of the apparatus illustrated in FIGS. 1 and 2;
FIG. 4 is an end view of a pipe section to be welded and showing an alternative embodiment of an apparatus for supplying inert gas to a welding location according to the invention; and
FIG. 5 is a cross-sectional view taken along 5--5 of FIG. 4.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1-3 illustrate an apparatus 10 for back-purging a localized region 12 on the underside of a pipe joint 14 formed between two butt ends 16 and 18 of corresponding pipe sections 20 and 22 to be welded. In the purging apparatus 10, a gas feed line 24 is connected at one end 26 to a source of inert gas, such as argon, as by a hose quick disconnect mechanism as at 27, and at its other end 28 to an elongate member 30. The gas feed line 24 can be of typical construction, such as stainless steel tubing and the like, with the gas feed line 24 being modified at its end 28 by attaching the elongate member 30 thereto as by welding or the like. The elongate member 30 is attached to the gas feed line 24 such that it extends at right angles thereto. The member 30 has spaced ends 32 and 34 and includes a hollow tube portion 36 which redirects inert gas from the gas feed line 24 towards the pipe joint 14 to be welded.
At the end 32 of the member 30, the tube portion 36 has a gas outlet port 38 with a trough-shaped trailing shield 40 formed thereat so that inert gas ejected from the outlet port 38 is substantially confined in the localized region 12 along the pipe joint 14 to be welded. The trailing shield trough 40 has parallel sidewalls 41A and 41B which extend towards the pipe joint 14 and are spaced approximately 1/4" therefrom. The sidewalls 41A and 41B are also provided with a radius of curvature at their upper surfaces to substantially match that of the pipe to more effectively maintain purge gas in the region 12. In this manner, an entire section of the interior of the pipe sections 20 and 22 need not be isolated as by dams and the like utilized in the prior art and then purged in the previously described two-step back purging operation as the trailing shield 40 more specifically locates inert gas at the precise region being welded to allow for an instant purge in region 12 and, therefore, the weld area.
As described earlier, the pipe sections 20 and 22 generally will be fit-up in an apparatus (not shown) which allows a welder to rotate the pipes during a welding operation by means of a foot pedal so that the welder need not move the welding torch and filler metal around the circumference of the pipe sections 20 and 22 to complete the weld of the pipe joint 14. Generally, it is desirable for welding to be performed in the flat, 12 o'clock, position. To maintain the localized region 12 of inert gas in the upright, 12 o'clock, position, the elongate member 30 includes an enlarged, weighted counterbalance 42 formed at its other end 34. Although illustrated and described as being in an upright, 12 o'clock position, it will be appreciated that the counterbalance 42 can be formed and weighted to cant the elongate member 30 to one side or the other of the vertical, if so desired.
Thus, with the purging apparatus 10, as described herein, the localized region of inert gas 12 will continually be maintained at the precise location where welding is to take place in the relatively small, confined area defined by the trailing shield 40. In this manner, the two-stage operation required with the dam-based apparatuses previously described is no longer necessary as the area 12 defined by the trailing shield 40 can be purged in a matter of seconds.
To accurately position the purging apparatus 10 for back-purging the previously described localized region 12, a hub shaft and bearing assembly 44 and a locating member 46 are provided. The locating member 46 can be sized to snugly fit within a pipe with the assembly 44 extending through the center of the locating member so that with the locating member installed in the pipe section 22, the assembly 44 extends along the central, longitudinal axis 48 of the pipe section 22, which should substantially correspond with the axis 50 of the pipe section 20 with the pipe sections 20 and 22 fitted up for a welding operation.
More specifically, the hub shaft and bearing assembly 44 includes an elongate, cylindrical hub portion 52 which extends substantially through the middle of the locating member 46. Although the assembly 44 is described and illustrated as extending along the central axes of the pipes, it will be appreciated that the assembly 44 can be positioned differently relative to the pipe central axis 48 with the apparatus 10 still providing inert gas to the localized region 12.
The locating member 46 can be sized to snugly fit within a pipe, such as pipe section 22, so that the locating member securely engages the inner wall surface 54 of the pipe section 22 so as to preferably position the gas feed line 24 along the central axis 48 of the pipe section 22. In one form, the locating member can have a central portion 56 made from a rubber or other resiliently flexible material. Preferably, the locating member 46 has a circular shape and a diameter at least 1/4" larger than the diameter of the inner wall surface 54 of the pipe section 22. On either side of the circular rubber portion 56, a pair of circular steel plates 58 can be adhered thereto with both the rubber portion 56 and the circular plates 58 and 60 having central apertures to form a ring shape so that the cylindrical portion 52 of the shaft and bearing assembly 44 can be fit therethrough and be removably attached to the locating member 46 as by a bayonet connection or the like.
The cylindrical portion 52 includes roller bearings 64 and 66 at either end thereof with the gas feed line 24 extending through the bearings 64 and 66 so as to be journalled for rotation in the cylindrical portion 52.
Thus, with the purging apparatus 10 installed in pipe section 22, and with the pipe sections 20 and 22 fitted up for a welding operation such that their respective axes 50 and 48 are substantially aligned with one another, the circular rubber portion 56 will frictionally engage the pipe inner wall surface 54 to substantially fix the locating member 46 and the shaft and bearing assembly 44 in the pipe section 22 with the cylindrical portion 52 extending axially in the pipe section 22 along the axis 48. The apparatus 10 can be slid into position wherein the elongate member 30 is at the butt ends 16 and 18 of the pipe sections 20 and 22 so that it extends towards the joint 14 to be welded. With the purging apparatus 10 so installed, as the welder rotates the pipe sections 20 and 22 during a welding operation, the shaft and bearing assembly 44 and the locating member 46 rotate along with the pipe sections. On the other hand, as the gas feed line 24 is journalled for rotation in the cylindrical portion 52, the counterbalance 42 will act under the influence of gravity as a pendulum to minimize the angular movement of the elongate member 30 and maintain the elongate member 30 extending in a substantially upright, radial direction at the butt end 18 of the pipe section 22 with the locating member 46 and attached cylindrical portion 52 rotating about the gas feed line 24 as the pipe sections are rotated during a welding operation.
With the purging apparatus 10 as described herein, the two-stage purging system utilized with dam-based apparatuses is eliminated as the localized region 12 of inert gas is much smaller in comparison to the region formed between dams on opposite sides of a joint to be welded and correspondingly requires significantly less time to be purged. Moreover, the required use of tape for maintaining purge gas within the zone between the dams in the piping system is eliminated, providing a more open view of the welded joint during formation, more readily permitting visual inspection of a root pass weld minutes after completion, thereby allowing for immediate rectification of any problems, if required.
For comparison purposes, test welding operations were performed utilizing the two-stage purging process with purge dams and the purging apparatus 10 described herein. Performing a typical welding operation for stainless steel pipes having an 18-inch O.D. with purge dams set back approximately 3 inches on either side of the joint, the initial purge was conducted at 30 c.f.h. for approximately five minutes. During the reduced purge gas flow second stage for welding, the flow rate was reduced to 5 c.f.h. for approximately 15 minutes before the actual welding process was initiated. Welding was then completed in 15 minutes while continuing the low flow rate second stage purge. In total, approximately 5.0 cubic feet of purge gas was used with the total welding operation taking approximately 35 minutes. Utilizing the purge apparatus 10 described herein for welding another 18" O.D. joint, the purge gas flow was set at 60 c.f.h. with welding beginning approximately the same time the purge gas flow begins. With the actual welding process taking approximately 15 minutes, the total gas volume used was approximately 15 cubic feet which increases gas consumption over the previously described method utilizing dams set back on either side of the joint. However, the time savings using the apparatus 10 of the present invention are significant: assuming labor and overhead to be approximately $45 per hour, the purging apparatus saves approximately 20 minutes or $15 per pipe joint welded as the dam system required 35 minutes for completion of a root pass while the purging apparatus 10 only requires 15 minutes. In addition, with the cost of purge gas at approximately $0.18 per cubic foot, the addition of 10 cubic feet only costs approximately $1.80 extra, thus still yielding a savings of approximately $13 per joint despite increased gas consumption.
It is also desirable that the purging apparatus 10 described herein be usable with a wide variety of pipe I.D.s without having to tailor the diameter of the locating member 46 for the various pipe sizes. To this end, a purging apparatus 70 is provided having a modified locating member 72, as illustrated in FIGS. 4 and 5. The locating member 72 can have a wide variety of shapes and is illustrated as being a hexagonal plate, preferably made from 0.75 inch thick aluminum. Mounted to the plate 74 are three expansible air rams 76 with each being of identical construction. The air rams 76 each include an air cylinder 78 having a piston 80 attached to a piston rod 81 mounted for sliding reciprocating movement therein. The air rams 76 can each be supplied with pressurized air from an air supply line 82 connected to a shop air source (not shown). The piston rods 81 can each include pipe engaging pads 83 at the end of the rods 81 distal from the piston 80 outside of the air cylinders 78. Thus, with the cylinders 78 pressurized, the shafts 81 will slide outwardly until their pads 83 securely engage the pipe inner wall surface 54. A split distribution box 84 may be provided to ensure that each cylinder 78 is equally pressurized with shop air so as to accurately center the locating member 72 and accordingly the gas feed line 24 within the pipe section 22. With the use of a locating member 72 having air rams 76 mounted thereon, the purging apparatus 70 can be used with a wide range of different diameter pipes. To provide for further flexibility, the air rams 76 can be slidably mounted on the locating member 72 so that they can be adjusted outwardly from the center of the locating member 72 for larger diameter pipes. After a welding operation is completed, the cylinders 78 are evacuated to cause the rods 81 to retract and allow for easy removal of the purging apparatus 10 from the welded pipes. In all other respects, the purging apparatus 70 is constructed and operates the same as the purging apparatus 10 with the gas feed line 24 attached to the elongate member 30 having counterbalance 42 and journalled for rotation in the shaft and bearing assembly 44.
While the invention has been described with respect to its preferred embodiments, which constitute the best modes known to the inventor, it should be understood that various changes and modifications may be made without departing from the scope and spirit of the invention which is intended to be set forth in the claims appended hereto. | An apparatus for providing inert gas to a desired location for a welding operation is provided. The apparatus includes a gas feed line and structure for mounting the feed line to extend in a first direction in a pipe. A gas locator tube communicates with the gas feed line to direct inert gas from the gas feed line in a second direction, different from the first direction, towards a pipe joint to be welded. The locator tube is capable of continually directing inert gas in the second direction as the pipe is rotated during a welding operation. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a filing under 35 U.S.C. §371, which claims priority to PCT Application PCT/EP2007/009195, filed Oct. 23, 2007, and U.S. Provisional Patent Application No. 60/863,037, filed Oct. 26, 2006, which are each hereby incorporated by reference in their entirety.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to the conditioning of Intermediate and Low Level Radioactive Waste materials, and more particularly to apparatus, methods and systems for encapsulation of waste materials for long term storage.
[0003] It is well known that certain waste by products of industrial processes, especially radioactive waste materials generated by nuclear processing plants, and other hazardous waste material, need to be safely and securely disposed of, typically by encapsulation techniques within containers, in a way that is suited to long term storage (e.g. in a robust containment, until the radioactivity has decayed to non-hazardous levels).
[0004] More recently, an example of such storage involves mixing the radioactive hazardous waste—typically in the form of wet sludge with dry encapsulation powders, such as cement—in a container such as a metal drum having an integral mixing paddle. The mixture is allowed to cure in the drum. The purpose of this is to encapsulate the (radioactive) waste in an (eventually) solid material within the drum; the drums can then be disposed in a suitable storage location, such as an underground storage site.
[0005] A problem with known systems is that an internal paddle is used within the drum for mixing. In the case where the paddle is re-used, cleaning of the paddle is required, which is a time consuming process and generates radioactive secondary waste. In the case where the paddle is left in the drum and disposed of therewith, extra parts (paddles) are required for each drum.
[0006] A further problem is that through the use of moving paddles within the drum, the preloading of the drum with additional solid articles of waste (e.g., metal items and fuel element debris, etc.), prior to adding the sludge waste and the dry grout powders, is prevented, as the solids would block/hinder the paddles' movement and hence prevents the incorporation of solid waste in the same drum thus reducing the overall amount of waste stored in the drum, per unit volume.
[0007] A further problem is that, with the use of such drums, the amount of stored volume of waste is not optimized in relation to the volume utilisation in the store.
BRIEF DESCRIPTION OF THE INVENTION
[0008] Various embodiments of the present invention seek to address the aforementioned and other issues, and provide improved techniques for the encapsulation of waste for long term storage by a process that is insensitive to the geometry of the long term storage container.
[0009] According to one aspect of the present invention there is provided apparatus for encapsulating waste material in a container for long term storage, comprising: a first storage vessel, for holding waste material; a second storage vessel, for holding encapsulation medium; a static vane in-line mixer, coupled for receiving waste material, and coupled to the second storage vessel, and producing, in use, a mixture of the waste material and encapsulation medium; wherein the in-line mixer is arranged for filling the container and wherein the in-line mixer comprises a disposable component located inside the container mounted on an internal surface of the container.
[0010] The apparatus may further include a dewatering unit ( 108 ), coupled for receiving waste material from the first vessel ( 106 ) and outputting dewatered waste material; wherein the inline mixer ( 112 ) is coupled to the dewatering unit and to the second storage vessel ( 114 ), for receiving material therefrom and producing a mixture of the dewatered waste material and encapsulation medium. Preferably, the dewatering unit includes a dewatering vessel and a pump for providing a degree of vacuum in the dewatering vessel. Preferably, the dewatering unit is operable for concentrating the waste material such that the dewatered waste material output is at about 40% v/v.
[0011] In one embodiment, the container comprises a main body and a separate lid member; the lid member being adapted for fixed attachment to the main body of the container, and inline mixer is provided in or on a lid member; such that when the lid member is fixedly attached to the main body of the container, the inline mixer is enclosed within the container.
[0012] In another embodiment, the container comprises unitary component with a main body and an integrally formed or fixedly attached lid member.
[0013] The inline mixer may comprise a static inline mixer, for example provided with fixed internal vanes.
[0014] The apparatus further may include a first pump disposed between the first vessel and the dewatering unit and/or a second pump disposed between the second vessel and the inline mixer. The apparatus further may include a valve upstream of each of two inlet ports of the inline mixer.
[0015] The waste material may comprise sludge, liquid or semi solid material.
[0016] In one embodiment, the waste material comprises radioactive sludge from nuclear processing plant, and the encapsulation medium comprises grout. Preferably, the encapsulation medium is a cement-based grout, for example comprising a mixture of BFS and OPC or PFA and OPC.
[0017] In another embodiment, the waste material comprises VOC5, and the encapsulation medium comprises polymer compound.
[0018] According to another aspect of the present invention there is provided a system for encapsulating waste material for long term storage, comprising: the apparatus of any of claims 1 to 14 of the appended claims; and a container, the container comprising (i) a main body and separate lid member, or (ii) a unitary component with a main body and an integrally formed or fixedly attached lid member. The container may contain solid hazardous waste,
[0019] According to another aspect of the present invention there is provided a container for use in conjunction with the apparatus of any of claims 1 to 14 of the appended claims, or in the system of claim 15 or 16 of the appended claims; the container comprising: (i) a main body and separate lid member, or (ii) a unitary component with a main body and an integrally formed or fixedly attached lid member; wherein the inline mixer is disposed inside the container or on mounted an internal surface of the container, for example on an inner surface of the lid member.
[0020] According to another aspect of the present invention there is provided a method of encapsulating waste material in a container for long term storage, comprising: (a) providing a first storage vessel, for holding waste material; (b) providing a second storage vessel, for holding encapsulation medium; (c) providing a static vane inline mixer, coupled for receiving waste material, and coupled to the second storage vessel, (f) mixing the waste material and encapsulation medium in the inline mixer; (g) filling the container with the mixture output from the inline mixer, wherein (c) includes providing a container, wherein the inline mixer comprises a disposable component disposed inside the container or on mounted an internal surface of the container.
[0021] The method may further include: (d) providing a dewatering unit, coupled to the first vessel, and (e) dewatering the waste material received from the first vessel and outputting dewatered waste material; wherein the inline mixer is coupled to the dewatering unit and to the second storage vessel, (f) comprises producing a mixture of the dewatered waste material and encapsulation medium. Preferably, the dewatering unit includes a dewatering vessel and (e) includes using a pump to provide a degree of vacuum in the dewatering vessel. Preferably, (e) includes concentrating the waste material such that the dewatered waste material output is at about 40% v/v.
[0022] In one embodiment, the container comprises a main body and a separate lid member; and (c) includes fixedly attaching the lid member to the main body of the container, and wherein inline mixer is provided in or on a lid member; such that when the lid member is fixedly attached to the main body of the container, the inline mixer is enclosed within the container.
[0023] In another embodiment, the container comprises unitary component with a main body and an integrally formed or fixedly attached lid member. Preferably, the inline mixer comprises a static inline mixer, for example provided with internal vanes.
[0024] The method may further include: (h) pumping with a first pump the material output from the first vessel to the dewatering unit; and/or (i) pumping with a second pump the material output from the second vessel to the inline mixer.
[0025] The method may further include: (j) controlling the flow of material to the inline mixer using a valve upstream of each of two inlet ports of the inline mixer.
[0026] The waste material may comprise sludge, liquid or semi solid material.
[0027] In one embodiment, the waste material comprises radioactive sludge from nuclear processing plant, and the encapsulation medium comprises grout. Preferably, the encapsulation medium is a cement-based grout, for example comprising a mixture of BFS and OPC or PEA and OPC.
[0028] In another embodiment, the waste material comprises VOCs, and the encapsulation medium comprises polymer compound.
[0029] The method may further include preloading the container with solid hazardous waste.
[0030] A versatile encapsulation plant is provided for use in the encapsulation of waste, particularly that arising in the Nuclear Industry. The design allows within a single process plant the capacity to condition both solid waste materials and sludge wastes (individually or in combination) into an encapsulated product form suitable for safe, long-term storage.
[0031] The process provides the equipment necessary to receive sludge wastes streams; dewater the sludge to remove excess water and concentrate the sludge; receive a pre-mixed wet encapsulation medium, or grout: transfer the dewatered sludge and grout into a static in-line mixer; depositing the ‘mixed’ sludge/grout stream into a waste container, drum or box suitable for long term storage.
[0032] The storage container, drum or box could also have been previously ‘loaded’ with solid wastes, thus allowing the encapsulation of these solid wastes using the sludge/grout mixed material.
[0033] Once the mixed sludge/encapsulation medium has been transferred into the storage container, drum or box, it is left undisturbed for a number of hours to allow ‘curing’. This results in a container, drum or box containing a single solid mass of encapsulated waste suitable for storage.
[0034] The system may employ a standard cuboid storage box, giving
[0035] (i) a 25% volume utilisation increase for sludge waste compared to a ‘large drum’ lost paddle in-drum mixing system occupying the same floor area, and
[0036] (ii) a 60% increase compared with a drum stillage containing 4 in-drum mixed drums occupying the same floor area.
[0037] The design is capable of filling drums and boxes in a range of sizes.
[0038] It has been found that circa 25% w/w sludge solids incorporation can be achieved for sludge type waste streams, compared with c. 15% w/w typical with in-drum mixing technology. These two aspects result in a dramatic reduction (greater than 50%) in the number of boxes containing conditioned sludge waste required to be stored, with the consequent large savings in lifetime costs.
BRIEF DESCRIPTION OF THE DRAWINGS
[0039] Embodiments of the invention will now be described in detail, by way of example, with reference to the accompanying drawings, in which:
[0040] FIG. 1 shows schematically a hazardous waste encapsulation system according to an embodiment of the invention:
[0041] FIG. 2 shows in more detail (a) the main body of the container, and (b) the underside of the lid or of the topside of the container, in the encapsulation system of FIG. 1 ; and
[0042] FIG. 3 depicts part of the encapsulation system of FIG. 1 in more detail, showing the connection of the dewatering system.
[0043] In the description and drawings, like numerals are used to designate like elements. Unless indicated otherwise, any individual design features and components may be used in combination with any other design features and components disclosed herein.
DETAILED DESCRIPTION OF THE INVENTION
[0044] FIG. 1 shows schematically a hazardous waste encapsulation system according to an embodiment of the invention.
[0045] For solid waste streams, the encapsulation medium, or grout, is prepared in an adjacent mixing plant and pumped directly to the encapsulation container or box 104 .
[0046] For sludge waste streams (as in the embodiment of FIG. 1 ), the encapsulation apparatus 102 according to the invention, in preferred embodiments, makes use of a dewatering unit 108 for conditioning the sludge waste feed, and an in-line static mixer 112 to mix the sludge with a pre-mixed encapsulation medium or ‘grout’. The dewatering unit 108 removes excess water from the sludge and is provided to allow the flexibility to receive a wide range of sludge type streams.
[0047] The sludge is transferred from a transit storage vessel 106 into the dewatering unit 108 via sludge waste feed 110 . The dewatering unit suitably includes a pump 109 , for providing a degree of vacuum within the container vessel of the dewatering unit 108 .
[0048] Returning again to FIG. 1 , a wet encapsulation medium prepared in an adjacent mixing plant 114 is then fed into the other input of the static in-line mixer 112 . Whilst the most frequent medium to be employed is cement based grout, using combinations of Blast Furnace Slag (BFS) and Ordinary Portland Cement (OPC), the various embodiments of the invention may also be used to encapsulate using other encapsulation media such as polymer compounds. The latter allows the potential to encapsulate sludges containing organics, i.e. VOCs etc.
[0049] Both the conditioned sludge feed 110 and encapsulation medium feed 118 are fed simultaneously into the static in-line mixer 112 . Flow control systems are employed to ensure strict matching of the two flow rates to maintain the correct sludge to encapsulation medium ratio.
[0050] The process allows the maximum utilisation of a cuboid box volume (25% greater than the large in-drum mixing container and 60% greater than a drum stillage containing 4 in-drum mixed drums configuration) and an increased incorporation rate (−25 wt %) of the sludge solids in grout.
[0051] As there are no moving parts within the box 104 , the sludge bearing encapsulation medium can be used to encapsulate solid waste pre-loaded into the box 104 .
[0052] FIG. 2 shows in more detail (a) the main body of the container 104 , and (b) the underside of the lid or of the topside of the container, in the encapsulation system of FIG. 1 .
[0053] The in-line mixer 112 may be located, as in the example shown here, inside the lid 116 of a NIREX 3 m 3 Box 104 . As seen in FIG. 2( a ), a valve arrangement, generally designated 120 , receives the feeds 110 and 118 (see FIG. 1 ; with one valve being provided for each feed line) and couples to an input port 122 of the inline mixer 112 .
[0054] The main body 124 of the box 104 is generally cuboid with and upper edge 126 on which are provided guide/retention members 128 at each corner. The guide/retention members 128 assist in receiving and retaining the lid 116 . It will be appreciated by persons skilled in the art that while the box 104 may be fabricated, delivered and/or used in the form of separate main body 124 and lid 116 , it is also possible that the box 104 is fabricated/provided as an integral container, with the inline mixer mounted on the underside of the topside of the box.
[0055] Referring in particular to FIG. 2( b ), a static in-line mixer 112 is used to mix the sludge and encapsulation medium upon transfer to the box 104 . The in-line mixer 112 is for example a Chemineer Kenics Static KMS In-line mixer.
[0056] The in-line mixer 112 consists of a tube 130 and has no moving parts or components. The in-line mixer 112 is fed from two pipes, one ( 110 ) feeding the sludge, and one ( 118 ) feeding the wet encapsulation medium.
[0057] As the sludge and encapsulation medium pass through the tube 130 of the mixer, fixed elements or plates (not shown) inside the in-line mixer 112 cause the two streams to mix together, forming a homogenous stream of combined sludge and encapsulation medium. The resultant homogenous material then falls into the box 104 . The box is filled to a predetermined level and left for a set period of time for curing. The combined sludge/encapsulation medium then hardens to form a solid mass within the box 104 .
[0058] As will be appreciated by persons skilled in the art, the diameter, length and number of elements within the in-line mixer can all be changed to give the process the versatility to encapsulate differing waste streams. These parameters may be controlled and set following initial ‘proving trials’.
[0059] FIG. 3 depicts part of the encapsulation system of FIG. 1 in more detail, showing the connection of the dewatering unit 108 . The dewatering unit 108 removes excess water from the sludge, employing for example ‘HydroTrans’ technology (see UK patent applications Nos GB2389094A and GB2406293A), using fluid to mobilise and transport solids, thus removing supernate from the sludge and concentrating the sludge up to approx. 40% v/v, depending on the properties of the sludge. Next, the conditioned slurry/sludge is fed into one input of a static in-line mixer 112 .
[0060] Referring to the dewatering unit 108 , as stated previously, this system allows the removal of excess water from the sludge, thereby concentrating the sludge. The process is referred to as the AtmoTrans system. A separate filter system (i.e. ‘Dynasep’ system), and vortex arrangements can also be employed as necessary to provide filtration of finer slow settling particles (see the abovementioned UK patent applications).
[0061] For the dewatering unit 108 , the selection and sizing of the equipment, vessels, pipework and valves is dependant on the characteristics of the sludge being recovered for encapsulation. The overall process is able to handle waste streams with a wide range of characteristics, concentrations, particle size and make-up. As the dewatering principles are determined and known, this means that for a specific application the system will be tailored to match the sludge feed stream.
[0062] The various embodiments minimize the equipment within the cell (box), thus reducing radioactive/contamination area maintenance requirements and increasing availability and reliability. A key feature of the use of dewatering technology is, again, that minimal equipment is located within the cell.
[0063] Additionally, large elements of the plant(s) may be fabricated off site, minimizing the site installation activities, with the consequential reduction in worker radiation dose uptake during construction.
[0064] The plant and process may be configured to allow for a variety of different sludge waste streams. Both the dewatering plant and the in-line mixers parameters can be changed to allow this high degree of versatility. The dewatering technology uses techniques that re-uses water to transfer sludges, and hence minimizes the consumption and potential contamination of clean water.
[0065] The various embodiments also allow the use of a ‘disposable’ in-line mixer (i.e. the mixer is built into the box and remains in the box, encapsulated) that simplifies the cleaning requirements for the process and eliminates the generation of secondary contaminated wash water waste
[0066] The various embodiment also may fill a ‘square’ box, as opposed to the existing in-drum mixing technologies; this allows much greater storage volumes to be achieved—a 25% volume utilization increase compared to a ‘large drum’ lost paddle in-drum mixing system and a 60% increase compared with a drum stillage containing 4 in-drum mixed drums. Also, in addition a wide range of boxes, waste drums, smaller containers and larger containers can also be used and benefit from this technology.
[0067] The process can be integrated with the encapsulation of solid materials. The solid waste would be located in the box prior to encapsulation, the mixed sludge/encapsulation matrix is then added using the in-line mixing technology, thus encapsulating the solids in a sludge matrix compound. This ultimately reduces the number of boxes requiring long-term storage significantly, and cannot be provided by current in-drum mixing technologies.
[0068] It should be noted that the various embodiments are not limited to a particular form of encapsulation medium.
[0069] It is to be understood that the above description is intended to be illustrative, and not restrictive. For example, the above-described embodiments (and/or aspects thereof) may be used in combination with each other. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from its scope. While the dimensions and types of materials described herein are intended to define the parameters of the invention, they are by no means limiting and are exemplary embodiments. Many other embodiments will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. In the appended claims, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Moreover, in the following claims, the terms “first,” “second,” and “third,” etc. are used merely as labels, and are not intended to impose numerical requirements on their objects. Further, the limitations of the following claims are not written in means-plus-function format and are not intended to be interpreted based on 35 U.S.C. §112, sixth paragraph, unless and until such claim limitations expressly use the phrase “means for” followed by a statement of function void of further structure.
[0070] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims. | An apparatus for encapsulating waste material (e.g radioactive sludge from nuclear processing plant) in a container (e.g Nirex box) for long term storage, comprising: a first storage vessel, for holding sludge; a second storage vessel, for holding encapsulation medium (e.g. cement based grout); an inline mixer (e.g. a static inline mixer), coupled for receiving sludge, and coupled to the second storage vessel, and producing, in use, a mixture of the sludge and grout; wherein the inline mixer is arranged for filling the container. Preferably, a dewatering unit (e.g. HydroTrans based), coupled for receiving sludge and outputting dewatered sludge to be mixed by the inline mixer. An encapsulation system comprising the encapsulation apparatus, and corresponding encapsulation methods, are also disclosed. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of International Application No. PCT/FR2014/051650, filed on Jun. 27, 2014, which claims the benefit of FR 13/56304, filed on Jun. 28, 2013. The disclosures of the above applications are incorporated herein by reference.
FIELD
[0002] The present disclosure relates to an aircraft turbojet engine nacelles and more particularly concerns the de-icing of turbojet engine nacelles.
BACKGROUND
[0003] The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.
[0004] An aircraft is powered by one or more propulsive assembly each comprising a turbojet engine housed in a tubular nacelle. Each propulsive assembly is fastened to the aircraft by a pylon generally located under or on an airfoil or at the fuselage.
[0005] “Upstream” means what comes before a considered point or element, in the direction of the air flow in a turbojet engine, and “downstream” means what comes after the considered point or element, in the direction of the air flow in the turbojet engine.
[0006] A nacelle generally has a structure comprising an air intake upstream of the turbojet engine, a mid-section intended to surround a fan or the compressors of the turbojet engine and its casing, a downstream section able to house thrust reversal means and intended to surround the gas generator of the turbojet engine, and is generally ended by an ejection nozzle whose outlet is located downstream of the turbojet engine.
[0007] Conventionally, the space comprised between the nacelle and the turbojet engine is called secondary flow path.
[0008] Generally, the turbojet engine comprises a set of blades (compressor and optionally a fan or non-streamlined propeller) rotationally driven by a gas generator through a set of transmission means.
[0009] A lubricant distribution system is provided to provide a good lubrication of the transmission means and of any other accessories such as electrical generators, and to cool them.
[0010] During the flight, depending on the temperature and humidity conditions, ice may be formed on the nacelle, particularly at the external surface of the air intake lip equipping the air intake section.
[0011] The presence of ice or rime changes the aerodynamic properties of the air intake and disturbs the air conveying towards the fan. In addition, the rime formation on the air intake of the nacelle and the ice ingestion by the engine in case of detachment of ice blocks can damage the engine or the airfoil, and present a risk to the safety of the flight.
[0012] A solution to de-ice the external surface of the nacelle consists in preventing the formation of ice on this external surface while keeping the concerned surface at a sufficient temperature.
[0013] Thus, the lubricant heat can be used to heat the external surfaces of the nacelle, the lubricant being thereby cooled and able to be reused in the lubrication circuit.
[0014] Documents U.S. Pat. No. 4,782,658 and EP 1479889 particularly, describe the implementation of such de-icing systems using the engine lubricant heat.
[0015] More particularly, Document U.S. Pat. No. 4,782,658 describes a de-icing system using outside air bled by a scoop and heated through an air/oil exchanger to serve the de-icing. Such system allows a better control of exchanged heat energy, but the presence of scoops in the external surface of the nacelle results in a loss of aerodynamic performances.
[0016] Document EP1479889 describes, meanwhile a system for de-icing an air intake structure of a turbojet engine nacelle using an air/oil exchanger in a closed circuit, the heated inside air of the air intake structure being put into forced circulation by a fan.
[0017] It should be noted that the air intake structure is hollow and forms a closed chamber for the circulation of de-icing air heated by the exchanger disposed within this chamber.
[0018] Thus, the heat energy available for the de-icing depends on the lubricant temperature.
[0019] In addition, the exchange surface of the air intake structure is stationary and limited and the actually dissipated energy depends mainly on the heat required for the de-icing and then on the outer conditions.
[0020] It follows that the cooling of the lubricant, as well as the temperature at which the air intake is kept, are difficult to control.
[0021] There is another solution in which are associated a heat exchanger and conduits for the circulation of a fluid to be heated so as to form a plurality of loops for the recirculation of the fluid to be heated through the exchanger, and such that a circulation area of the fluid to be heated is in contact with an external wall so as to enable a heat exchange by conduction with the outside air in the nacelle. The circulation of the fluid to be heated is performed by forced circulation.
[0022] There are solutions to de-ice the turbojet engine nacelles by means of hot air bleeding. These solutions conventionally rely on a hot air bleeding in the compressor of the turbojet engine. This bled hot air is under high pressure and high temperature, for one hand it is fed directly into an air intake lip of a nacelle to be de-iced, for the other hand it is led to an air/air exchanger (i.e., precooler) where it is cooled by the outside air to be used for the cabin air conditioning and the de-icing of the aircraft airfoil.
[0023] It has been noticed that systems as previously presented for de-icing the air intake lip by cooling of the lubricant cause friction losses in the secondary flow path due to the presence of the exchanger, and engine thrust losses when an air bleeding is performed in the secondary flow path where these losses have a significant impact on consumption (they represent about 0.5% of the total consumption), but also that such systems have a poor efficiency when the turbojet engine runs at idle and/or at low power (for example during the taxiing phase of the aircraft or when the aircraft is descending) in the case where the cooling of the engine oil involves a bleeding of the air coming from outside of the nacelle.
[0024] Solutions consisting of de-icing the air intake lip by bleeding the hot air in the compressor have drawbacks particularly in that the high temperature of the bleed air in the compressor of the turbojet engine leads to the use of costly materials for the front bulkhead of the air intake to be de-iced and for the inlet piping with commonly more than a wall to reduce the risks of bursting, and that they implement a specific air bleeding on the high-pressure compressor which reduces the power or the available thrust of the turbojet engine. Indeed, the solutions for de-icing by hot air bleeding in the compressor of the turbojet engine presented hereinabove implement conventionally three air bleedings in the compressor including one dedicated for the de-icing of the air intake lip of the nacelle.
SUMMARY
[0025] The present disclosure provides a de-icing device for an air intake lip of an aircraft nacelle, said device comprising a pre-exchanger, a fan bleeding means able to bleed low-pressure air downstream of the fan, two means for bleeding high-pressure air downstream of different stages of the compressor as well as controlled valves and check valves installed in an air circulation network wherein the pre-exchanger comprises a low-pressure air outlet able to open into the air intake lip of the aircraft nacelle via a piping of the air circulation network.
[0026] According to other features of the present disclosure, the de-icing device includes one or more of the following features considered alone or according to all possible combinations:
the de-icing device comprises a discharge valve of a high-pressure air circulating through the pre-exchanger; the de-icing device comprises a mixing valve of at least a part of the high-pressure air for the cabin conditioning and the airfoil de-icing with the low-pressure air for the air intake lip de-icing; the de-icing device comprises a detector of the air intake lip temperature;
[0030] The present disclosure also concerns a nacelle having a de-icing device according to the present disclosure and a forced opening means for each controlled valve implemented in the de-icing device according to the present disclosure.
[0031] The present disclosure also concerns an aircraft having a nacelle according to the present disclosure.
[0032] This solution enables removing the air bleeding from the compressor dedicated to the de-icing of the air intake lip of the aircraft nacelle and directly connected to the lip, but also reducing the temperature of the air intake lip de-icing air such that less costly or lighter materials may be used to manufacture the front bulkhead of the lip, such as for example aluminum or some composite materials instead of titanium often up to then used.
[0033] Furthermore, this solution may have no influence neither on the provision of the aircraft nor on the reliability of the latter, the same number of valves being present particularly, and may have no air bleeding valve downstream of the dedicated compressor unlike a conventional nacelle design.
[0034] Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
DRAWINGS
[0035] In order that the disclosure may be well understood, there will now be described various forms thereof, given by way of example, reference being made to the accompanying drawings, in which:
[0036] FIG. 1 is a schematic view of a first air circulation network according to a first form of the present disclosure;
[0037] FIG. 2 is a schematic view of the a second air circulation network according to a second form of the present disclosure; and
[0038] FIG. 3 is a schematic view of a third air circulation network according to a third form of the present disclosure.
[0039] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.
DETAILED DESCRIPTION
[0040] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.
[0041] In all the forms described hereinafter, and in the interest of simplification, the pipings connecting the different elements of the air circulation network are each called <<piping 3 >>.
[0042] In all the forms described hereinafter, the term <<passing through the network>> means passing through all or part of a network, the term <<controlled valve>> means a valve acting as a valve cock, an actuator or not.
[0043] Referring to FIG. 1 , it is described the first air circulation network 1 according to the first form of the present disclosure.
[0044] The first network 1 is comprised in an aircraft nacelle 100 .
[0045] The nacelle 100 comprises an external aerodynamic wall 110 comprising an upstream air intake lip 111 , an internal aerodynamic wall 120 , the air intake lip 111 connecting upstream both the external 110 and the internal 120 aerodynamic walls.
[0046] The first air circulation network 1 for the high-pressure air cooling comprises a heat pre-exchanger.
[0047] The first network 1 comprises check valves allowing the air flow only in one direction (respectively 4 , 5 ), controlled valves (respectively 6 , 7 , 8 , 9 ), and the pipings 3 . The valves 4 , 5 , 6 , 7 , 8 , 9 are used to control the air circulation in the first network 1 .
[0048] The first network 1 comprises two different orifices for high-pressure air bleeding in two different stages of the compressor 10 and 11 intended to supply high-pressure hot air to the first network 1 , as well as an orifice 12 for the low-pressure air bleeding downstream of the fan intended to supply the low-pressure cold air to the first network 1 .
[0049] In operation of the first network 1 , the high-pressure hot air enters through the high-pressure air bleeding orifices downstream of the compressor stages 10 and 11 , and the low-pressure cold air enters through the low-pressure air bleeding orifice 12 downstream of the fan.
[0050] The intake flow rates of the high-pressure hot air and of the low-pressure cold air in the first network 1 are set by means of the controlled valves 6 , 7 , 8 depending on the requirement.
[0051] The high-pressure hot air thus enters the first network 1 via the two air bleeding orifices 10 , 11 downstream of the compressor. The pipings 3 connecting the orifices 10 , 11 meet upstream of the pre-exchanger 2 .
[0052] The high-pressure hot air enters through the orifice 11 of the high-pressure air bleeding downstream of the stage where the bleeding of the compressor occurs in the piping 3 of the first network 1 . This air then passes through the check valve 5 of the first network 1 , the piping 3 , the controlled valve 7 and then the pre-exchanger 2 .
[0053] Simultaneously, the high-pressure hot air also enters through the air bleeding orifice 10 downstream of another stage further downstream of the compressor in the piping 3 of the first network 1 . This air then passes through the controlled valve 6 of the first network 1 , the piping 3 , then through the controlled valve 7 and finally through the pre-exchanger 2 .
[0054] Depending on the required pressure for the cabin air conditioning, the valve 6 may be open or closed.
[0055] When the valve 6 is closed, the air circulates from the orifice 11 towards the pre-exchanger 2 via check valve 5 .
[0056] When the valve 6 is open, the bled air pressure via the orifice 10 being higher than the bled air pressure via the orifice 11 the check valve 5 is closed and the air thus circulates from the orifice 10 towards the pre-exchanger 2 .
[0057] Simultaneously, the low-pressure cold air enters through the low-pressure air bleeding orifice 12 downstream of the fan in the piping 3 of the first network 1 . This low-pressure air then passes through the controlled valve 8 of the first network 1 , the piping 3 , and then enters the pre-exchanger 2 . The opening of the controlled valve 8 of the fan bleeding is driven in order to keep a suitable temperature of the conditioning air.
[0058] The pre-exchanger 2 is a pre-exchanger chosen from all those known to those skilled in the art and it is, of course, adapted to its accurate use in the nacelle of a turbojet engine and its operation is known.
[0059] The pre-exchanger 2 has at least two outlets, one of the high-pressure air 18 and the other of the low-pressure air 19 to which are connected outlet pipings 3 .
[0060] Once the air entered the pre-exchanger 2 , it exits therefrom through the outlet piping 3 .
[0061] The low-pressure 19 outlet piping 3 of the pre-exchanger 2 allows conveying the low-pressure air circulating therein directly towards the air intake lip 111 in order to the de-ice it if necessary.
[0062] The air intake lip 111 may also comprise an over-temperature detector 15 which can be used to block supplying the high-pressure air from the compressor of the aircraft turbojet engine in case of failure of a regulation member such as the fan bleeding controlled valve 8 .
[0063] The high-pressure 18 outlet piping 3 then splits so as one of the resulting pipings 3 allows a part of the high-pressure air to circulate towards the nacelle outlet to be then ejected after passing through the controlled valve 9 , also called discharge valve 9 , allowing to regulate the discharge flow rate of the high-pressure air coming from the pre-exchanger 2 , this controlled valve 9 being used only during the phases when the de-icing of the air intake lip 111 is active; the other of the resulting pipings 3 allows the other part of the high-pressure air to circulate towards a conditioning unit (not shown) of the air of a cabin of the aircraft comprising the nacelle 100 and a de-icing unit of an aircraft airfoil after passing through the check valve 4 , used to prevent air from circulating from the air-conditioning circuit towards the engine in case of failure thereof. A conventional firewall-type valve controlled from the cockpit of an aircraft can also be used (it will be controlled in the closed position in case of failure or an engine fire).
[0064] When the de-icing is not active, the discharge valve 9 is kept closed, the pressure in the air conditioning circuit is regulated by the valves 6 and 7 , and the temperature is regulated by varying the low-pressure air flow rate in the pre-exchanger 2 via the valve 8 . The temperature and the air flow rate sent in the lip are a consequence of the setting of the preceding valves.
[0065] When the de-icing is necessary, the regulation mode of the valves changes. The de-icing air flow rate is regulated by the low-pressure valve 8 . The de-icing air temperature is regulated by the high-pressure air flow rate in the pre-exchanger by the valves 6 and 7 . The pressure in the air conditioning circuit is set by the discharge valve 9 .
[0066] With reference to FIG. 2 , it is described the second air circulation network 13 according to the second form of the present disclosure.
[0067] This second network 13 is similar to the first network 1 for all that concerns the air circulation network upstream of the pre-exchanger 2 .
[0068] The pre-exchanger 2 may also include a high-pressure outlet 18 and a low-pressure outlet 19 to which two outlet pipings 3 are connected.
[0069] However, none of these outlet pipings 3 splits, thus it may only remain the outlet piping 3 allowing directly conveying the low-pressure air from the pre-exchanger 2 towards the air intake lip 111 for its possible de-icing, and the high-pressure outlet piping 3 allows conveying the air from the pre-exchanger 2 to the conditioning and de-icing unit of the aircraft airfoil by passing through the check valve 4 .
[0070] The second network 13 also may have a controlled valve 14 installed in a piping 3 connecting the high-pressure 18 outlet piping 3 of the check valve 4 and the low-pressure 19 outlet piping 3 of the pre-exchanger 2 . This controlled valve 14 is a mixing valve allowing mixing the air circulating through the two outlet pipings 3 from the pre-exchanger 2 . This controlled mixing valve 14 allows eliminating the splitting of the outlet piping 3 which had split in the first network 1 as well as the high-pressure air ejection outside of the nacelle 100 .
[0071] The mixing controlled valve 14 is driven so as to keep the desired temperature in the de-icing system.
[0072] In the same manner as shown in FIG. 1 , the air intake lip 111 may comprise an over-temperature detector 15 whose operation is similar to that explained in the description of FIG. 1 .
[0073] The operation of the second network 13 upstream of the pre-exchanger 2 is similar to that of the first network 1 illustrated in FIG. 1 .
[0074] The third network 13 shown in FIG. 3 is similar to the first, with the difference that the discharge valve 9 and the valve 8 are removed. The low-pressure air at the low-pressure outlet 19 of the pre-exchanger 2 is diverted towards a valve 17 allowing its ejection outwards of the nacelle 100 and towards the lip 111 by means of a controlled valve 16 when the de-icing is active.
[0075] The valve 16 controls the de-icing low-pressure air flow rate. The air temperature towards the aircraft air conditioning circuit is set by adjusting the flow rate through the valve 17 .
[0076] When the de-icing is not active, the outlet valve 17 regulates the low-pressure air flow rate as in the first network and the valve 16 is closed.
[0077] In case of failures, the device according to the present disclosure allows, in some cases, to overcome some undesirable consequences.
[0078] For example when the controlled valve 7 , present on the network and which allows regulating the high-pressure hot air bleeding in the turbojet engine, fails and remains blocked in the open position or is forced in the open position, then the controlled discharge valve 9 allows regulating the pressure in the first air circulation network 1 .
[0079] When it is the controlled valve 9 which fails so that it remains blocked in the open position or it is forced in the open position, the de-icing of the nacelle cannot be enabled only for some flight cases, it is the controlled valve 7 of hot bleeding air regulation which is then used to regulate the temperature of de-icing of the nacelle while the air conditioning for the cabin of the aircraft and the airfoil de-icing are made with another engine.
[0080] When it is the controlled valve 8 of the fan bleeding which is blocked in the open position or forced in the open position, the regulation of the nacelle de-icing temperature is achieved with the controlled discharge valve 9 to avoid losing the air conditioning and the ability of de-icing the nacelle.
[0081] While the present disclosure has been described with particular forms, it is obvious that it is by no means limited and that it comprises all technical equivalents of described means as well as their combinations if the latter fall in the scope of the present disclosure. | The present disclosure provides a device for de-icing an air inlet lip of an aircraft nacelle. The device includes a pre-exchanger, an intake orifice of taking in low-pressure air downstream from a fan, and two high-pressure air intake orifices downstream from a compressor in addition to controlled valves and check valves installed in an air flow network. In particular, the pre-exchanger includes a low-pressure air outlet capable of opening into the air inlet lip of the aircraft nacelle via a pipe of the air flow network. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of Korean Patent Application No. 2003-4131, filed Jan. 21, 2003, in the Korean Intellectual Property Office, the disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates, in general, to a door control device for refrigerators, and a refrigerator with such a device. More particularly, the present invention relates to a door control device for refrigerators which controls the open angle of a refrigerator door as a user desires, maintains the selected open angle of the door, and dampens a door closing action to retard the energy generated from the door closure. The present invention also relates to a refrigerator having such a door control device.
[0004] 2. Description of the Related Art
[0005] As is well known to those skilled in the art, refrigerators are domestic appliances which keep food and drink cool, for a desired lengthy period of time, while maintaining the freshness of the food and drink. A refrigerator typically comprises a freezer compartment and a refrigerator compartment, with a door provided on each compartment to close the compartment.
[0006] Refrigerators are typically arranged side by side with other kitchen furniture or appliances, such as a kitchen sink or a microwave oven. A large-sized refrigerator may be installed in a specified recess formed in a kitchen wall. Due to such an arrangement of the refrigerators, there sometimes occurs interference between the doors of a refrigerator and neighboring furniture, appliances, or the kitchen wall. As a result, the refrigerator doors are easily damaged and are inconvenient for users while opening or closing the doors.
[0007] In an effort to solve such problems, the inventors of the present invention proposed a door control device for allowing a user to control the maximum open angles of refrigerator doors, as disclosed in Korean Patent Application No. 2002-53288. However, the conventional door control device is problematic in that a user is forced to loosen and tighten bolts to adjust the maximum open angles of refrigerator doors, making the device inconvenient for the users. In addition, the device only allows a user to adjust the maximum open angles of refrigerator doors, so it is difficult to control the open angles of the refrigerator doors as users desire, or to maintain the selected open angles of the refrigerator doors.
SUMMARY OF THE INVENTION
[0008] Accordingly, it is an aspect of the present invention to provide a door control device for refrigerators, which controls the open angle of a refrigerator door as a user desires, maintains the selected open angle of the door, and dampens a door closing action to retard the energy generated from the door closure. It is another aspect of the present invention to provide a refrigerator having the door control device.
[0009] Additional aspects and advantages of the invention will be set forth in part in the description which follows and, in part, will be obvious from the description, or may be learned by practice of the invention.
[0010] The foregoing and/or other aspects of the present invention are achieved by providing a door control device for a refrigerator having a refrigerator door, including a movable body coupled to the refrigerator door, wherein the movable body is arranged to move in opposite directions in accordance with opening and closing actions of the refrigerator door, and a control unit controlling an opposite directional movement of the movable body in a multi-stage manner.
[0011] Also, a guide element contains the movable body, in order to guide the opposite directional movement of the movable body.
[0012] Also, a link bar is hinged at a first end thereof to an end of the movable body, and is connected at a second end thereof to the refrigerator door.
[0013] Also, the link bar is hinged to the refrigerator door.
[0014] Also, the movable body is provided with a plurality of grooves formed along a longitudinal side surface thereof.
[0015] The foregoing and/or other aspects of the present invention are also achieved by providing a door control device for a refrigerator having a refrigerator door, including a movable body coupled to the refrigerator door, wherein the movable body is arranged to move in opposite directions in accordance with opening and closing actions of the refrigerator door, and a dampening unit dampening a rearward movement of the movable body during a door closing action, thus retarding energy generated from door closure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] These and/or other aspects and advantages of the invention will become apparent and more readily appreciated from the following description of preferred embodiments, taken in conjunction with the accompanying drawings of which:
[0017] FIG. 1 is an exploded perspective view of a part of a refrigerator having a door control device, according to an embodiment of the present invention;
[0018] FIG. 2 is a top view of the part of the refrigerator having the door control device of the present invention; and
[0019] FIG. 3 is a top view of the part of the refrigerator having the door control device of the present invention, and showing the operation of the door control device of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] Reference will now be made in detail to the present preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to the like elements throughout. The embodiments are described below in order to explain the present invention by referring to the figures.
[0021] FIG. 1 is an exploded perspective view of a part of a refrigerator having a door control device according to an embodiment of the present invention. FIG. 2 is a top view of the part of the refrigerator having the door control device. FIG. 3 is a top view of the part of the refrigerator having the door control device, showing the operation of the door control device of the present invention.
[0022] As shown in FIGS. 1 and 2 , the door control device according to the present invention is used with a refrigerator 100 . The refrigerator 100 having the door control device is configured as follows.
[0023] The refrigerator 100 comprises a cabinet 101 with storage compartments, typically a freezer compartment and a refrigerator compartment, with doors 102 hinged to the cabinet 101 to close the respective storage compartments. For ease of description, only one door 102 is shown in the drawings. The refrigerator 100 also has a door control device according to the present invention. The door control device includes a leg casing 103 which is installed in a lower portion of the cabinet 101 . A longitudinal movable bar 104 is axially arranged in the leg casing 103 such that the bar 104 is axially moved under the guide of a channeled rail 105 in opposite directions. A longitudinal side surface of the movable bar 104 is uneven, with four grooves 10 a, 10 b, 10 c and 10 d formed along the uneven surface of the bar 104 at regular intervals. The channeled guide rail 105 is axially installed in the leg casing 103 to hold the movable bar 104 and to guide any axial movement of the bar 104 . A hinge bracket 106 is mounted to the door 102 . A curved link bar 107 is hinged at a first end thereof to an end of the movable bar 104 , and at a second end thereof to the hinge bracket 106 at a position spaced apart from a rotating axis of the door 102 by a predetermined distance in a radial direction from the rotating axis. A control chamber 108 is perpendicularly defined at a sidewall of the leg casing 103 , and a control unit 200 is installed in the control chamber 108 so as to control the axial movement of the bar 104 in a multi-stage manner. A dampening unit 300 is installed in the leg casing 103 at a position behind the rear end of the movable bar 104 , so that the dampening unit 300 dampens a rearward moving action of the movable bar 104 during the door closure. The dampening unit 300 thus dampens the door closing action, and retards the energy generated from the door closure.
[0024] The control unit 200 comprises a retractable locking unit and a first spring 21 . The first spring 21 is axially arranged in the control chamber 108 , and the retractable locking unit comprises a roller 22 and a roller bracket 23 . The roller bracket 23 is elastically supported at a first end thereof by the first spring 21 , and rotatably holds the roller 22 at a second end thereof. The roller 22 is thus perpendicularly placed relative to the movable bar 104 , and is elastically retractable, so that the roller 22 is sequentially seated into the four grooves 10 a, 10 b, 10 c and 10 d while rolling on the uneven surface of the movable bar during an axial movement of the movable bar 104 in the leg casing 103 .
[0025] The uneven surface of the movable bar 104 , having the four grooves 10 a, 10 b, 10 c and 10 d, is smoothly curved to form a waved configuration, so that the roller 22 rolls on the uneven surface of the bar 104 while being sequentially seated into the four grooves 10 a, 10 b, 10 c and 10 d in response to an axial movement of the movable bar 104 .
[0026] The dampening unit 300 is an elastic support unit which elastically supports the rear end of the movable bar 104 . That is, the dampening unit 300 includes a support member designed as an end plate 31 , and an elastic member comprised of two second springs 32 . The end plate 31 is mounted to the rear end of the movable bar 104 , and the second springs 32 are connected to the end plate 31 at two positions while being arranged in parallel, so that the second springs 32 are brought into contact with a rear end wall of the leg casing 103 during a door closing action.
[0027] The operational effect of the refrigerator having the door control device of the present invention will be described herein below, with reference to FIG. 3 .
[0028] When a user (not shown) rotates the door 102 in a direction as shown by the arrow of FIG. 3 to open the door 102 to a desired open angle, the link bar 107 , hinged to the hinge bracket 106 of the door 102 , is pulled toward the front of the refrigerator 100 , so that the movable bar 104 , hinged at a front end thereof to the rear end of the link bar 107 , is axially moved toward the front of the refrigerator 100 . During the forward movement of the movable bar 104 , the roller 22 rolls on the uneven surface of the bar 104 . In such a case, the uneven surface of the movable bar 104 has the four curved grooves 10 a, 10 b, 10 c and 10 d, so that the roller 22 , held by the roller bracket 23 and elastically biased by the first spring 21 , perpendicularly advances and retracts repeatedly, relative to the uneven surface of the movable bar 104 , during the forward movement of the bar 104 .
[0029] When the user opens the door 102 to a desired open angle, for example, 90° as shown in FIG. 3 , the roller 22 rolls on the uneven surface of the forward moving bar 104 , while repeatedly advancing and retracting relative to the uneven surface of the bar 104 , until the roller 22 is seated into the third groove 10 c, which corresponds to the desired open angle of 90°. When the door 102 is opened to reach the desired open angle of 90°, the user releases his/her handling force from the door 102 , so that the roller 22 of the roller bracket 23 , biased by the first spring 21 , is somewhat strongly pushed into the third groove 10 c corresponding to the open angle of 90°. The roller 22 is thus maintained at the position thereof inside the third groove 10 c, and the door 102 is maintained at the open position of the open angle of 90°. That is, the control unit 200 , including the roller 22 , stops the axial movement of the movable bar 104 , and allows the door 102 to be maintained at its open state of the open angle of 90°. Even though external force, such as weight of the door 102 , is applied to the door 102 on which the user does not impose his/her physical force, the control unit 200 prevents an undesired axial movement of the movable bar 104 . The open angle of the door 102 is thus not changed, but the open door 102 is maintained at its open state at the desired open angle.
[0030] FIG. 3 shows the door 102 , which is maintained at its open state, at an open angle of about 90°. However, it should be understood that the open angle of the door 102 may be controlled by the variable position of the roller 22 relative to the four grooves 10 a, 10 b, 10 c and 10 d of the movable bar 104 , and the door 102 is maintained at a desired open angle determined by the roller seated in either of the four grooves 10 a, 10 b, 10 c and 10 d.
[0031] When the user closes the open door 102 , the second springs 32 are brought into contact with the rear end wall 103 a of the leg casing 103 , and elastically support the movable bar 104 moving backward in the leg casing 103 during the door closing action. Therefore, the second springs 32 dampen the door closing action, thus reducing the door closing speed and retarding the energy generated from the door closure. The door 102 is thus smoothly and gently closed without applying impact energy to the refrigerator.
[0032] In an embodiment of the present invention, the movable bar has four grooves to change the open angle of the door between four angles. However, it should be understood that the number of grooves formed on the movable bar may be changed to five or more grooves, or three or less grooves, in order to change the number of open angles of the door which may be selected by a user, as desired. In addition, the grooves for seating the roller of the control unit may be formed on a separate member mounted to a side surface of the movable bar.
[0033] The control chamber which receives the first spring of the control unit may be integrally formed on the sidewall of the leg casing by outwardly depressing the sidewall, as shown in the drawings. Alternatively, the control chamber may be defined in a separate member which is provided at a predetermined position around the sidewall of the leg casing.
[0034] In addition, the end plate and the second springs may be provided on the inner surface of the rear end wall of the leg casing, in place of the rear end of the movable bar. Alternatively, the end plate and the second springs may not be mounted to the inner surface of the rear end wall of the leg casing or the rear end of the movable bar, but arranged between the rear end wall of the leg casing and the rear end of the movable bar.
[0035] As is apparent from the above description, the present invention provides a door control device for refrigerators, which allows a user to easily control the open angle of a refrigerator door as desired without forcing the user to perform additional work to control the open angle of the door. The door control device also maintains a selected open angle of the door, and dampens a door closing action to retard the energy generated from the door closure. The door control device thus prevents interference between the refrigerator doors and neighboring furniture, appliances or kitchen wall, and is convenient for users of refrigerators. The door control device also prevents rapid door closure.
[0036] Although a few embodiments of the present invention have been shown and described, it would 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 claims and their equivalents. | A door control device for refrigerators and a refrigerator with the device. The door control device for a refrigerator having a refrigerator door includes a movable body coupled to the refrigerator door, wherein the movable body is arranged to move in opposite directions in accordance with opening and closing actions of the refrigerator door, and a control unit controlling an opposite directional movement of the movable body in a multi-stage manner. | 4 |
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] The present application claims the benefit of U.S. Provisional Patent Application No. 60/908,367 (Attorney Docket No. 026451-000300US), filed Mar. 27, 2007, the entire contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates generally to medical apparatus and methods, more specifically to instrument immobilizers and even more specifically, but not by way of limitation to an apparatus and methods for anchoring an intracranial probe or lead to the cranium.
[0004] Implanting medical devices within the cranium is an increasingly important approach for treatment of disorders such as Parkinson's Disease, essential tremor and dystonia. This approach may also be used to treat a wide array of neuropsychiatric problems, such as depression, epilepsy, obsessive compulsive disorder, obesity and chronic pain. Most of these devices interact with the brain by delivering current through an implanted probe to modulate brain activity. In addition, infusion of drugs through a permanently implanted probe has been proposed as a primary treatment, or as an adjunctive treatment to electrical stimulation, for Alzheimer's and Parkinson's Diseases, among others.
[0005] As part of the implant procedure, the probe must be stabilized in the brain. Ideally, any prosthetic device is attached directly to the tissue on which it operates, in this case, the brain. Direct attachment of electrical and chemical probes to brain tissue is impractical. A more easily implementable solution is a system of flexible probes that bend and float with the brain as the brain moves within the cranial cavity. Such probes are secured to the cranium. In this manner, mechanical forces from outside the cranium are prevented from acting on the brain-to-probe interface.
[0006] There are a number of current techniques for securing a probe to the cranium. For example, in one approach, a permanently implanted probe is fixed by a sliding door which closes to form a slot just wide enough to slightly compress and grip the body of the probe. A common feature of such devices is that they grip the probe somewhere within the craniotomy opening, and that the slot has a fixed orientation relative to the cranium.
[0007] In another approach, the probe passes through a narrow aperture at the center of a craniotomy opening. The probe is held in place by a surgeon as it is bent over into a slot leading to the exit from the device. Hinged arms swing into place to narrow the slot and anchor the probe within the slot.
[0008] Current anchoring devices are typically positioned over the craniotomy opening, and they are attached to the cranium with several peripheral screws. An implantable lead is placed through the cranial opening and the lead is gripped by two opposing thin bars. In some cases, it is possible to damage the lead by crushing it between the thin bars. It would therefore be desirable to grip the lead with wider bars to more evenly distribute the gripping force over a greater axial length of the implantable lead. It would also be desirable to provide a more stable mounting for the skull-mounted portion of the anchoring device. Additionally, current devices often have a small opening for receiving the lead and thus it would be desirable to provide an anchoring device having a wider opening for the lead, to permit adjustment of lead position for optimal placement, especially when using a large multi-channel probe array, a feature shared by only a few currently available anchoring systems.
[0009] 2. Description of the Background Art
[0010] Prior patents and publications describing anchors for cranial probes include: U.S. Pat. Nos. 4,328,813; 5,464,446; 6,044,304; 2004/0267284; 2005/0192594; and WO 2004/026161.
BRIEF SUMMARY OF THE INVENTION
[0011] The invention generally provides an anchor for securing an implantable lead within tissues in a patient. The terms “lead” and “probe” will be used interchangeably with one another in this disclosure, as will the terms “anchor base” and “cylinder.” Often the lead may comprise an electrode or a catheter, and the lead is often implanted into brain tissue through a craniotomy in the patient's skull. A current and/or therapeutic agent may be delivered through the lead to the tissue and the anchor is usually composed of materials that are compatible with magnetic resonance imaging. The anchor may be fabricated from metals that do not interfere with MRI and/or polymers such as polyphenylene sulfide, polyetheretherketone (PEEK), polyetherimide, polyimide, polysulfone and the like.
[0012] In a first aspect of the present invention an apparatus for securing an implantable lead within tissue of a patient comprises a base that is adapted to be secured to a patient's skull adjacent a craniotomy. The base has an upper surface, a lower surface and a central passage therebetween which is adapted to receive the implantable lead. The apparatus also includes a cover that can be releasably coupled to the base so as to substantially cover the central passage and also to capture the lead therebetween. A first rotating member or door, is coupled with the base and is rotationally movable so as to meet and engage the lead at a plurality of positions within the central passage. Rotating the door also adjusts the position of an opening within the central passage in which the lead may pass through and also closes or reduces the size of the central passage while still allowing the lead to pass therethrough.
[0013] Often, the first rotating member comprises a removable insert that is adapted to releasably grip the lead and that may be received in a recessed region of the rotating member. The removable insert is usually adapted to be removably coupled to the first rotating member with a rotationally actuated tool that may be coupled to the first rotating member. The first rotating member may have a surface defining a wedge shaped or indented region that is adapted to receive and align the tool.
[0014] The apparatus may have a pin or rivet engaged with the first rotating member that secures the first rotating member to the base while allowing rotation of the first rotating member relative to the base. The first rotating member may also have a surface that defines a receptacle that is adapted to receive a tool for turning the first rotating member into a desired position so as to engage the lead and fix the lead into a position. The first rotating member may further comprise a resilient end that is adapted to releasably grip the lead. The resilient end may lie in the same plane as the first rotating member and may be composed of an elastomer. The resilient end often is constructed with a substantially solid core while sometimes it may be porous. Often the resilient end comprises surface features that are adapted to capture the lead. The surface features may include a plurality of convex or concave regions adjacent to one another or the surface features may be scallops. Sometimes the surface features may comprise a plurality of resilient fingers that extend outward from the resilient end. The surface features may also comprise combinations thereof.
[0015] The apparatus may further comprise a ratchet mechanism that is adapted to restrict the first rotating member to motion in one direction. Often the apparatus also comprises a fixing element such as a set screw that is adapted to immobilize the first rotating member. The apparatus also often comprises a second rotating member that is coupled with the base and a spacer may be used to separate the first and second rotating members from one another. The second rotating member is rotationally movable so as to meet and engage the lead at a plurality of positions within the central passage. Rotating the second door also adjusts the position of an opening within the central passage in which the lead may pass through and also closes or reduces the size of the central passage while still allowing the lead to pass therethrough. Usually, the first and second rotating members are movable independently of one another and they may be retained in the base with a retaining member such as a ring. Also, the first and second rotating members may lie in the base adjacent to one another. Sometimes the second rotating member comprises a removable insert that is adapted to releasably grip the lead. The insert on the second rotating member may take the same form as the insert on the first rotating member. Often the resilient end on the first rotating member lies in a plane between the first and second rotating members.
[0016] The apparatus may further comprise a locking mechanism coupled with the first and second rotating members. The locking mechanism locks the first and second members together thereby preventing relative motion therebetween. The locking mechanism may be a detent and comprise a protuberance on either the first or second rotating member and a receptacle for receiving the protuberance on the other rotating member. These features allow the rotating members to snap into position with one another thereby ensuring the lead is gripped therebetween.
[0017] Often, the apparatus further comprises one or more tabs that extend radially outward from the base. The tabs are adapted to be secured to the skull adjacent the craniotomy. The tabs often define apertures that can receive a fastener such as a screw, thereby securing the base adjacent the craniotomy.
[0018] Sometimes the base is cylindrical and may be sized to fit at least partially within the craniotomy, and at least a portion of the base may be securely press fit into the craniotomy. The base may comprise a discrete upper and a discrete lower portion that are fastened together, or the base may be of unitary construction. The base may be recessed at least partially into the craniotomy, or the lower surface of the base may sit substantially flush with the top of the skull. The base may also have one or more receptacles that are adapted to releasably receive at least a portion of the cover. Often, the upper surface of the base defines one or more channels that are sized and shaped to accept the lead after the lead has been disposed therein. The base may also be adapted to receive and retain other surgical instruments such as instrument positioning guides or other reference devices often used during neurosurgery. These other surgical instruments may releasably lock with a flange in the base, a retaining member in the base or any other portion of the base or components therein.
[0019] Often the cover is adapted to be removably coupled to the base. Sometimes the cover comprises one or more legs that are adapted to releasably snap fit into engagement with the base. Alternatively, the legs may be disposed on the base or on a retaining member that fits in the base. The cover may have a surface that defines one or more channels that are sized and shaped to accept the lead after it has been disposed therein. One or more plugs may be placed into the channels or a gasket may be disposed between the cover and the base in order to seal any gaps therebetween.
[0020] In another aspect of the present invention, a system for securing an implantable lead within tissue of a patient comprises an apparatus for securing the implantable lead within tissue. The apparatus comprises a base adapted to be secured to a patient's skull adjacent a craniotomy, the base having an upper and lower surface and a central passage therebetween. The implantable lead is often disposed in the central passage. The apparatus also comprises a first rotating member coupled with the base and having a removable insert adapted to engage the lead. A retaining pin may couple the insert with the first rotating member. The first rotating member is rotationally movable so as to meet and engage the lead at a plurality of positions within the central passage. Rotating the door also adjusts the position of an opening within the central passage in which the lead may pass through and also closes or reduces the size of the central passage while still allowing the lead to pass therethrough. The system also includes a tool having a proximal end, a distal end and a handle, the tool being adapted to introduce and remove the removable insert to or from the first rotating member.
[0021] Often the tool also comprises a pin disposed near the distal end that is adapted to retain the insert when the insert is decoupled from the first rotating member. The tool is usually adapted to be rotated so as to simultaneously engage the insert and withdraw the retaining pin from the insert. The tool may have an angled surface that facilitates seating of the tool against the first rotating member.
[0022] The system may also include a cover that can be coupled to the base so as to substantially cover the central passage and also to capture the lead therebetween. The system may also comprise a potting material that is used to fill gaps between the base and the craniotomy in order to reduce or eliminate leakage of body fluids, such as cerebral spinal fluid (CSF), from around the base.
[0023] In another aspect of the present invention, a method of securing an implantable lead into tissue of a patient comprises positioning a base having an upper surface, a lower surface and a central passage therethrough, adjacent a craniotomy in a skull of a patient. The base may be secured adjacent the craniotomy and to the skull and an implantable lead is inserted through the central passage into the tissue. Rotating a first rotating member that is coupled to the base moves the rotating member so that it meets and engages the implantable lead at a plurality of positions within the central passage.
[0024] The method may also comprise the step of rotating a second rotating member that is also coupled to the base so as to meet and engage the lead at a plurality of positions within the central passage thereby securing the lead in the tissue. Rotating the second door also adjusts the position of an opening within the central passage in which the lead may pass through and also closes or reduces the size of the central passage while still allowing the lead to pass therethrough. The method may also include rotationally adjusting the first and second rotating members in order to capture the lead therebetween or to release the lead therefrom. Often the method includes attaching and/or removing an insert that is adapted to engage the lead and that is coupled to the first or second rotating members.
[0025] The method may also comprise inserting one or both of the two rotating members into a secure base ring intraoperatively. In early stages of the lead implantation procedure, a wide lumen is available. After the lead is placed, an opening in such rotating members allows them to pass around the lead and rest in the base, and grip the lead. The method may further comprise retaining the two rotating members within the base by interlocking a retaining member placed over the rotating members and within the base, thereby restricting axial movement of the rotating members relative to the base.
[0026] Sometimes securing the base comprises press fitting at least a portion of the base into the craniotomy and often securing the base comprises coupling the base to the skull adjacent the craniotomy with a fastener such as a screw. Sometimes securing the base comprises recessing at least a portion of the base in the craniotomy, or the base may be coupled adjacent the craniotomy such that a bottom surface of the base is substantially flush with the craniotomy.
[0027] Usually, a cover is engaged with the base so as to substantially cover the central passage and capture the implantable lead therebetween. The cover and/or base may have channels which can accept the lead after being positioned therein. Often the first and second rotating members are locked and this may be accomplished by threadably engaging the rotating members with a set screw or by using detents in order to prevent relative motion therebetween. Sometimes, the lead may be bent into a channel that is defined by a top surface of the base and a potting material may be applied in order to fill gaps between the base and the craniotomy, thereby reducing or eliminating leakage of body fluids such as CSF from around the base.
[0028] These and other embodiments are described in further details in the following description related to the appended drawing figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] FIGS. 1A-1D illustrate cross-sections of several anchor assembly embodiments having fixation tabs that allow the anchor to be placed within a craniotomy at varying depths.
[0030] FIG. 1E shows an anchor attached to a patient's cranium.
[0031] FIGS. 2A-2G show top and cross section views of rotating doors.
[0032] FIGS. 3A-3F show alternative embodiments of the grip bars.
[0033] FIGS. 4A-4F show alternative embodiments of the rotating doors.
[0034] FIG. 5A shows a top view of the cylinder without the rotating doors.
[0035] FIG. 5B shows a side view of an exemplary embodiment of a cover.
[0036] FIG. 5C shows a bottom view of an exemplary embodiment of a cover.
[0037] FIG. 6A shows a cross section view of an assembled anchor with rotating doors.
[0038] FIGS. 6B-6K show the components of the anchor depicted in FIG. 6A .
[0039] FIG. 7A shows an alternative embodiment of a mechanism for retaining the moving members within the cylinder.
[0040] FIG. 7B shows a bottom view of the anchor assembly in FIG. 7A .
[0041] FIGS. 8A-8C show an anchor base of unitary construction.
[0042] FIGS. 8D-8M show various components in various stages of assembly with the anchor base of FIGS. 8A-8C .
[0043] FIGS. 9A-9C illustrate the use of set screws to lock the rotating doors in position.
[0044] FIGS. 10A-10J show the use of a tool for placement and removal of inserts into the rotating doors.
[0045] FIGS. 11A-11D show side views of a tool as it us used to insert, place, attach and detach inserts into the anchor.
[0046] FIGS. 12A-12C show an alternative embodiment of rotating doors that are adapted to pass around a placed lead intraoperatively and snap together.
[0047] FIGS. 13A-13C show an alternative embodiment of the anchor base which may be used with the doors of FIGS. 12A-12C .
[0048] FIGS. 14A-14E illustrate exemplary embodiments of retaining members which hold the rotating doors in the anchor base.
[0049] FIGS. 15A-15D illustrate an exemplary embodiment of a retaining member which retains the rotating doors and the cap.
[0050] FIG. 16 illustrates an exemplary embodiment of an anchor base with rotating doors that are held in place with a retaining member.
DETAILED DESCRIPTION OF THE INVENTION
[0051] In the drawings like numerals describe substantially similar components. Now turning to FIG. 1A is a cross section exploded view of the anchor assembly, showing the probe 5 , cap 200 , and cylinder body 10 , also referred to as an anchor base in this application, assembled with parts that grip the probe. In this embodiment, the radial tabs 20 are elevated relative to the bottom surface of base 10 so that the cylinder body 10 may be recessed into a craniotomy. The cylinder 10 is fixed to the cranium by screws which pass through openings 25 in tabs 20 and secure the tabs to the cranium. In an alternative embodiment, the cylinder may have ridges, protrusions or other surface features (not shown) which generate a friction fit with the wall of the craniotomy, in conjunction with or in lieu of the radial tabs. Rotating doors 110 and 120 are shown rotated to a position such that the grip bars 70 are positioned to grip the probe 5 . In the section shown in FIG. 1A , the grip bars 70 are positioned by removable inserts 140 and 150 , which in turn are captured in the doors 110 and 120 by rotating rivets 130 . An upper rivet plate 134 and a lower rivet plate 136 coupled to rivet 130 help lock the inserts into position. A ring-like spacer 16 separates doors 110 and 120 . The cap 200 has legs or pins 220 with catches 225 which snap into receiving sockets 40 within the cylinder 10 . The receiving sockets 40 not only provide fixation for a cap, but also provide a site and mechanism for attaching other instruments to the device. Examples of other devices that could be attached thereto include positioning guides or other reference instruments commonly used during neurosurgery.
[0052] The grip bars 70 may be made of a soft material, for example an elastomer, such as silicone rubber, polyurethane, or Santoprene™, or they may be made of the same material as the doors. Grip bars 70 may be porous or have holes running through them to make them compressible. Pores could be produced by many methods, including gas bubbles forming during the curing process, dissolving filler materials, or by withdrawing filaments introduced at the time the bars are formed or molded. During implantation, the probe 5 is placed intracranially, and the rotating doors 110 and 120 are rotated to place the grip bars 70 against the probe 5 . The probe 5 is bent to course along a groove 30 on the superior surface of the cylinder 10 , and onto the surface of the cranium. The cap 200 is then lowered so that pins of the cap 220 are inserted into sockets of the cylinder 40 , and the cap presses against the probe 5 . In some embodiments, a groove in the cap 210 wraps around the probe 5 . As the cap is lowered, pins 220 and protrusions from the pins 225 are displaced towards the center of the cylinder by catches 45 , until the protrusions snap outward under the catches, retaining the cap. In other embodiments, the cap may have an elastomeric gasket shaped so as to seal the space between the cap and the base, except for allowing passage for the probe through one set of grooves 30 and 210 . In other embodiments, the elastomeric gasket shall leave all sets of grooves open, and the unused probe passages are filled with separate plugs with radial dimension similar to the probe.
[0053] FIG. 1B shows the embodiment of FIG. 1A with the probe 5 positioned intracranially, and the cap 200 snapped into the closed position. In this embodiment, the tabs 20 are elevated so that cylinder 10 may be recessed in the craniotomy allowing the top of the cylinder to be substantially level with the cranium. Such an embodiment has the advantage that the top of the cap extends minimally above the cranium.
[0054] FIG. 1C shows an alternative embodiment of the assembly shown in FIGS. 1A-B , in which the cylinder 10 is partially recessed into the cranium. FIG. 1D shows an alternative embodiment of the assembly shown in FIGS. 1A-1C , in which the tabs 20 are positioned so that the lower surface of the cylinder 10 is at the level of the outer surface of the cranium. Such an embodiment has the advantage that the craniotomy opening need only be as large as the inner lumen of the cylinder 10 . The rotating door grip mechanism provides the particular advantage that if the probe 5 is inserted through the center of the device as shown in FIG. 1B , the doors may be rotated together, thereby rotating the probe while still retaining vertical fixation.
[0055] FIG. 1E illustrates the anchor base or cylinder 10 attached to a patient's cranium C. In FIG. 1E , anchor 10 is positioned over a craniotomy so that a portion of the anchor fits within the craniotomy opening in order to reduce the portion of anchor 10 protruding out of the patient's cranium C. Fixtures F such as screws removably couple the anchor 10 to the cranium and a lead 5 is place through the central opening of the anchor 10 into the patient's brain B. A cover 200 may then be snap fit into engagement with the anchor 10 , thereby capturing the lead 5 in a desired position.
[0056] FIG. 2A shows the lower rotating door 120 , apart from the rest of the anchor. The door is a disk with a large cutout 122 within its interior. Along one edge of the cutout is a bar 70 which can grip the probe placed in an intracranial position. Near the bar is a ledge depressed into the door 80 into which a gripping insert can be placed. The insert is retained from movement towards the open portion of the disk by terminating the depression at two stops 85 . FIG. 2B shows both rotating doors overlayed, with the both rivets 130 in the open position and both inserts removed. In this configuration a relatively large opening in the center of the anchor is available for the probe or any related test or accessory instrumentation.
[0057] FIG. 2C shows the upper rotating door 110 with the rivet 130 in the closed position, and gripping insert 140 in place. The upper door also has a cutout 112 , a gripping bar 70 and a place for seating the insert. The insert 140 rests on the depressed ledge 80 . Motion of the insert towards the open part of the door 140 is prevented by the stops 85 , as in the lower door. Motion of the insert up out of the ledge, or rotation of the insert out of the ledge is prevented by the rivet 130 . The upper plate of the rivet 134 is a partial disk. When it is in the closed position, as shown in FIG. 2C , the upper plate covers the edge of the insert, so that it is locked into place on the depressed seating ledge 80 . When it is open, the insert may be removed. The upper plate has three sockets 132 which may accept prongs from an insertion and removal tool, in order to rotate the rivet. A lower plate of the rivet 136 is similar to the upper plate 134 and also helps hold the insert. Lower plate 136 may be seen in FIG. 1A .
[0058] FIG. 2D shows a side view of the two rotating doors 110 , 120 , with the inserts 140 , 150 in place, and the rivets in the closed position. When the rotating doors 110 , 120 are rotated, the inserts are pushed toward each other by their corresponding doors. FIG. 2E shows the two rotating doors 110 , 120 overlayed, with the inserts locked in place by the rivets 130 . FIG. 2F also shows the two rotating doors overlayed, with the inserts removed and the doors opened to their maximum aperture. FIG. 2G shows both top and side views of the two inserts 140 and 150 . The head or top portion 164 of insert 150 along with the head or top portion 162 of insert 140 is seen in the side view of FIG. 2G . The divots in the inserts 165 , 166 accommodate the rivets. When the rivets are rotated into the closed position, the tails of the inserts 160 fit between the head of the rivet 134 and the seating depression in the rotating door 80 . When the inserts are in place, their grip bars 70 are continuous with the grip bars of the rotating doors. The tails of the inserts 160 sit in recessed ledges 80 in the rotating doors.
[0059] FIGS. 3A-3F show alternative embodiments of the grip bars 70 , with greater contact between the grip bars and the probe compared to the embodiment shown in previous Figures. Only views from above are shown. In FIG. 3A , the grip bars are scalloped to conform to the shape of the probe, and the spacing between scallops is less than the diameter of the probe, allowing many prospective positions where the probe could be placed. In FIG. 3B , the grip bars are also scalloped, but with a shape complementary to the shape in FIG. 3A . This shape generates as many prospective positions as the shape in FIG. 3A , but instead of apposing the probe with conforming surfaces, this shape contacts the probe at 4 points, compared to two points in the embodiment shown in the other Figures. In FIG. 3C , the grip bars completely surround the probe, generating fewer prospective fixation positions compared to the embodiments of FIGS. 3A-3B . In FIG. 3D , thin flanges or resilient fingers protrude from the grip bars, such that the flanges from one grip bar are out of phase or alternate with the flanges from the other grip bar. FIGS. 3E-3F are similar to the embodiment of FIG. 3D , except that the flanges on opposite grip bars are in phase with one another so that they oppose each other, rather than the out of phase or alternating pattern seen in FIG. 3D . FIG. 3E has longer flanges, while FIG. 3F has shorter flanges. These different embodiments illustrate examples of how the contact area of the grip bar with the probe may be increased compared to the embodiments shown in the other Figures.
[0060] FIGS. 4A-4F show alternative embodiments of the grip bars 70 , with one or both grip bars attached directly to the rotating door 110 , 120 , without an insert or the possibility of removing a portion of the grip bar 70 . In FIGS. 4A-4D , the grip bars are centered on a plane between the rotating doors, as in FIG. 2D , while in FIGS. 4E and 4F , the grip bars 70 are centered in the planes of their respective rotating doors. When the grip bars are centered on a plane between the rotating doors, they do not transmit a bending moment to a probe inserted parallel to the axis of the cylindrical anchor body, while the embodiment in FIGS. 4E-4F the grip bars could potentially transmit a bending moment to such a probe.
[0061] FIGS. 4A-4B show an embodiment with an upper rotating door 110 similar to the embodiments shown in FIGS. 2A-2G , while the lower rotating door has no insert, and its grip bar is one continuous member. FIG. 4A shows the rotating doors in position to grip the probe, while FIG. 4B shows the rotating doors opened to their maximum aperture. The maximum aperture of this embodiment is nearly the same as the maximum aperture illustrated in FIG. 2F , except near the center of the cylinder.
[0062] FIGS. 4C-4D , show an embodiment in which neither rotating door has an insert, and both grip bars are single, continuous members. FIG. 4C shows the rotating doors in position to grip the probe, while FIG. 4D shows the rotating doors opened to their maximum aperture. In this embodiment, the maximum aperture is smaller than in the embodiments of FIGS. 2A-2G and FIGS. 4A-4B .
[0063] FIGS. 4E-4F show an embodiment in which neither rotating door has an insert, and both grip bars 70 are single, continuous members, as in FIGS. 4C-4D . FIG. 4E is a cross section view, which shows that in this embodiment the grip bars 70 are centered in the plane of their respective rotating doors. FIG. 4F shows that the maximum aperture of this embodiment is wider than any of the other illustrated embodiments, except near the center.
[0064] In other embodiments, the grip bars could be attached directly to the rotating doors for their full length, without any inserts or rivets. It will be obvious to those skilled in the art that many other specific forms are possible.
[0065] FIG. 5A shows a top view of the cylinder or anchor base 10 , without the rotating doors. The anchor is fixed to the cranium by screws through screw-holes 25 in radial tabs 20 . A relatively short set screw 50 inserts into a threaded hole 56 to impinge upon the upper rotating door 110 , (not shown) and lock it into place. A relatively long set screw 52 having a flat point 51 inserts into a threaded hole 56 to impinge upon the lower rotating door 120 , (not shown) and lock it into place. Another relatively long set screw 54 having a cone point 55 inserts into a threaded hole 56 to impinge upon both rotating doors 110 and 120 (not shown) and lock them into place. In the illustrated embodiment, screws 50 and 52 have a flat tip, and impinge upon the outer upper corner of the rotating doors, while the screw 54 has an angled tip, and impinges upon the flat edge of both rotating doors. Receiving sockets 40 having catches 45 are adapted to receive the cap thereby snap fitting the two components together. Additionally, grooves or channels 30 radially extend outward from anchor 10 and provide a channel for holding the lead when the lead is captured between the anchor 10 and the cap.
[0066] Alternatively, one of the rotating doors could be held in place by a one-way ratcheting mechanism. In such an embodiment, a no-back pawl is a beam integrated with the anchor cylinder, in the plane of one of the rotating doors. The outer edge of the corresponding rotating door has the gear teeth. The pawl permits the gear teeth to pass freely in the direction which moves the grip bar 70 towards the probe, closing the door, but prevents the rotating door from opening. Such an embodiment makes fixing the doors faster, as only one set screw must be tightened, yet still permits the opening between the doors to be adjusted to any angular position, multiple times if necessary.
[0067] FIG. 5B shows a cross section view of the cap 200 . It is dome shaped. Three pins 220 protrude downward, one of which is visible in this view. FIG. 5C shows a bottom view of the cap. The shape is a dome, truncated adjacent to pins 220 which protrude downward to snap into sockets 40 in the cylinder 10 . The dome-shaped disk is truncated adjacent to the pins so that a tool may be inserted into the socket 40 , alongside a pin 220 to facilitate removing the cap 200 when necessary. In the preferred embodiment, grooves 210 in the cap 200 increase the area of the cap 200 contacting the probe, compared to grooveless embodiments. FIG. 5C shows a bottom view of cap 200 highlighting grooves 210 and pins 220 .
[0068] Initially the probe is gripped by the rotating doors and fixed into position. The probe is then bent to lay in grooves 30 on the upper surface of the cylinder. The cap is lowered, with pins 220 sliding into sockets 40 and protrusions 225 from the pins snapping into place under catches 45 . When the cap is snapped in place, it presses upon the probe. In the preferred embodiment, grooves in the cap 210 increase the surface area of the cap in contact with the probe, increasing stability and decreasing point pressure on the probe.
[0069] FIG. 6A shows an exemplary embodiment of an anchor base assembled with all of its components. FIGS. 6B-6K show the various components of the assembly in FIG. 6A . In FIG. 6A , the anchor base is composed of upper 12 and lower 14 portions. In the illustrated embodiment, radial tabs 20 are attached to the upper portion 12 of the cylinder 10 , so that the cylinder may be recessed into the craniotomy opening. In other embodiments the tabs may be attached to the lower portion 14 of the cylinder 10 . A shelf 26 , which retains the moving members within the cylinder, is integrated into the lower portion of the cylinder 14 . The upper portion 12 of the cylinder is the more massive, because it must contain the threaded holes 56 for the set screws (seen in FIG. 6B ). Within the cylinder the upper 110 and lower 120 rotating doors are separated by a spacer ring 16 . The upper 12 and lower 14 portions of the cylinder are attached by an adhesive. In alternative embodiments, the base could be attached by welding or other mechanism of plastic deformation, by screws or other mechanisms which will be obvious to those skilled in the art. FIG. 6B shows the upper 12 portion of the anchor assembly while FIG. 6C shows a cross-section take along line 6 C- 6 C and FIG. 6D shows a cross section taken along line 6 D- 6 D. FIG. 6E shows the upper door 110 with insert 140 and rivet 130 that is positioned in the upper 12 portion of the anchor assembly. A spacer ring 6 F is then positioned next in the anchor assembly and a cross section of ring 16 taken along line 6 G- 6 G is shown in FIG. 6G . Next lower door 120 with rivet 130 and insert 150 is loaded into the anchor assembly. The lower 14 portion of the anchor base is seen in FIG. 6I . When the lower portion 14 is fastened to the upper 12 portion, the upper and lower doors 110 , 120 and spacer 16 are captured therebetween. FIG. 6J shows a cross section of lower portion 14 taken along line 6 J- 6 J and FIG. 6K shows a cross section of lower portion 14 taken along line 6 K- 6 K.
[0070] FIGS. 7A-7B show an alternative embodiment of assembling the anchor employing a plurality of pins 17 penetrating the anchor cylinder wall, and extending beneath the lower rotating door 120 . The pins course through narrow channels 18 in the cylinder wall. Together, the pins provide a support that retain the moving members within the cylinder. FIG. 7A shows a cross section of the anchor assembled with all of its components and FIG. 7B shows a bottom view of the anchor base with channels 18 . It is clear to those skilled in the art that this embodiment may be combined with the embodiments shown in FIGS. 6A-6I and FIGS. 8A-8M . In embodiment of FIGS. 6A-6I , the pins would provide the additional advantage of helping to retain the base of the cylinder. In the embodiment of FIG. 5 , the pins provide further support for the moving members around the cutout that facilitates insertion of the rotating doors 28 .
[0071] FIGS. 8A-8M show an alternative embodiment of an anchor assembly employing a different assembly method. In this embodiment, the body of the cylinder is monolithic. The bottom of the cylinder has a shelf 26 which retains the moving members. One side of the shelf is cut away 27 so that the rotating doors may be inserted from below during assembly. Such an embodiment is most compatible with a cylinder body which recesses into the craniotomy, because in such embodiments the slot is not impeded by the radial attachment tabs 20 . To assemble this embodiment, the upper rotating door 110 is slid into the central chamber of the cylinder. Next, the spacer 16 is inserted below the upper rotating door. Finally, the lower rotating door 130 is inserted. One side of the bottom of the cylinder is cutout 28 to facilitate sliding the rotating doors and the spacer parts into the center of the cylinder. The rivets 130 may be attached to the rotating doors in sequence after each is inserted into the central chamber, or after both rotating doors have been inserted. The rotating doors may be prevented from exiting the central chamber by tilting the slot slightly, so that the final door is strained as it is inserted and then snaps into place, or by placing one or more pins in the slot opening so as to constrain the motion of the lower door to rotational motion only. Alternatively, in both of these embodiments, an extended shelf may be fixed in the entry slot. FIG. 8A shows the anchor base that holds the upper 110 and lower 120 rotating doors. FIG. 8B shows a cross section of the anchor base of FIG. 8A taken along line 8 B- 8 B and FIG. 8C shows a cross section of the anchor base taken along line 8 C- 8 C. FIG. 8D shows the bottom of the anchor base and FIG. 8E shows the anchor base after upper door 110 has been inserted into the base. FIG. 8F shows the anchor base after both upper 110 and lower 120 doors and spacer 16 have been loaded into the anchor base. FIGS. 8G-8L illustrate the sequence of loading components into the anchor base during assembly and FIG. 8M shows the assembled anchor.
[0072] FIGS. 9A-9C show cross section views, illustrating how set screws can be positioned in three different positions, so as to impinge on the upper rotating door 110 alone, lower rotating door 120 alone, or on both rotating doors 110 , 120 simultaneously. Exemplary embodiments are shown, illustrating how the rotating doors may be fixed with standard set screws. Small diameter screws, such as 0-80, are appropriate for this application, because the cylinder body 10 is thin. A thin body 10 is desired so that it does not protrude much above the surface of the cranium.
[0073] FIG. 9A shows a set screw 50 positioned to fix the upper rotating door 110 . In this embodiment, a flat set screw is used. The tip of such a screw typically has a wide flat surface orthogonal to the screw's axis of symmetry, bounded by a narrow conical ring 51 . When the screw is deployed with its long axis tilted at approximately 30 degrees from horizontal, one edge of the conical ring is nearly parallel to the outer edge of the upper rotating door 110 . As the screw is tightened, the conical ring 51 impinges upon the outer edge of the upper rotating door, but away from the lower rotating door 120 .
[0074] FIG. 9B shows a similar set screw 52 positioned to fix the lower rotating door 120 . This screw is similar to the upper door fixation screw 50 , except that it is longer. FIG. 9C shows a set screw 54 positioned so as to impinge upon both rotating doors 110 and 120 simultaneously. In this embodiment a cone-point set screw is illustrated. Such a set screw has a wide conical ring 55 terminating at the tip of the screw, with a tip angle of approximately 118 degrees. When the screw 54 is deployed with its long axis tilted approximately 60 degrees from horizontal, it fixes both rotating doors.
[0075] FIGS. 10A-10J show an insertion tool 300 with handle 350 for placement and removal of inserts 140 and 150 into the rotating doors 110 and 120 . FIGS. 10A-10F show portions of the tool 300 from several views. A side view of the tool is seen in FIGS. 10A-10C and the tool is seen from a top view in FIGS. 10D-10F . FIGS. 10A and 10D show only the lowest portion, which interfaces directly with the insert, rotating door, and upper plate of the rivet. An orienting edge 320 at the bottom of the tool is complementary to the shape of the upper plate of the rivet 134 . Tabs 310 at the bottom of the tool fit precisely into matching sockets 132 in the upper portion of the rivets. In an alternative embodiment of the tool and the top of the rotating rivet, the tabs 310 are slightly larger at their lower most position, and/or the sockets 132 are narrower at their upper most position, to facilitate a snap fit of the tool with the rivet rotor.
[0076] FIGS. 10B and 10E show a platform 340 at the base of the insertion/removal tool. The platform forms a bridge between the small features and tight tolerances of the components shown in FIGS. 10A-10B , and the grip or handle 350 through which the surgeon applies torque, is shown in FIGS. 10C and 10F . In the embodiment illustrated, the grip 350 is a hexagonal post with an angled handle, which my be turned digitally or with a wrench. In other embodiments, the grip may take another form, for example, a cap screw. In another embodiment, it could be a cylindrical post, with one or a plurality of radial holes into which a lever arm can be inserted.
[0077] FIGS. 10G-10J show how the tool mates to the upper plate of the rivet 134 and couples with an insert 150 on lower rotating door 120 . The lower portion of the tool has an angled shape 320 complementary to the edge of the upper plate of the rivet 134 , to facilitate alignment of the tool with the rivet, and to apply torque to the rivet as the tool is rotated. For fine positioning and additional torque, the tool has tabs 310 which insert into matching divots in the upper plate of the rivet 132 . A curved pin 335 holds an insert 140 or 150 in position next to the tool 300 while the insert is placed into or removed from a rotating door 110 or 120 . A bulge 330 is provided for mounting the pin 335 . This mounting bulge 330 is positioned so that it does not impinge upon the upper portion of the insert 140 as the tool is rotated.
[0078] FIGS. 11A-11D show the tool and insert through the cycle of positioning, attachment and detachment. In FIG. 11A , two insertion tools are above the anchor, and the inserts are seated in the rotating doors, retained by the rivets. In FIG. 11B , the tools are lowered to a position adjacent to the upper portion of the rivets 134 and the inserts 140 and 150 . The inserts are seated in the rotating doors, retained by the rivets. In FIG. 11C , the tools have been rotated as indicated by the double headed arrows, so that the holding pins retain the inserts to the bottom of the insertion tools. The rivets no longer retain inserts. In FIG. 11D , the inserts 140 and 150 are retained against the insertion tools by the holding pins 335 and lifted away from the rotating doors. The lower surface of the insertion tool fits into divots 165 and 166 , (not shown) in the inserts, so that the insert has a definite position relative to the insertion tool. The rotating doors and rivets lie below the tool as the tool is lifted away.
[0079] FIG. 12A-12C show an exemplary embodiment of the rotating doors adapted for intraoperative assembly. In FIG. 12A the rotating doors 110 and 120 have gaps 71 positioned so that they can be passed around an indwelling medical lead and placed in a receiving anchor base. The gaps 71 may be positioned as in FIG. 12B , so that the doors may be passed around the lead in a single movement. Intraoperative handling is facilitated by holes 74 in the doors. Once inserted into the receiving base, the doors can be rotated as in FIG. 12C in order to grip the medical lead. A snap mechanism can operate whereby a protrusion or detent from one door 73 lodges into a cavity 72 on the other, so as to maintain the doors in apposition against the lead.
[0080] FIGS. 13A-13C show exemplary embodiments of the anchor base 10 and cap 200 adapted for intraoperative assembly with doors such as shown in FIGS. 12A-12C . In the exemplary embodiment of FIG. 13C , base 10 has two tabs 20 for attachment to the cranium, but the number of tabs may be modified as required. The doors pass around the lead, and they are placed so that the lower door rests upon a shelf 26 , and the upper door rests upon the lower door. A retaining member, such as those illustrated in FIGS. 14A-14E may optionally be inserted interfacing with an annular groove 41 in such a way as to partially occlude the lumen of the base 10 and prevent removal of the rotating doors. Two embodiments of the cap 200 are shown in FIGS. 13A and 13B , with pins 220 placed so that the cap 200 can be attached to the base 10 by protrusions 225 from the pins 220 into the annular groove 41 . In the embodiment of FIG. 13B , cavities 226 are placed in the cap 200 , so as to extend the effective length of the pins 220 and control the strain of the pin and mating forces, as will be familiar to those skilled in the art. The annular groove 41 can also be a point of attachment for additional instruments used intraoperatively such as a positioning guide or other reference instruments often used during neurosurgery. The retaining member may similarly be modified to permit attachment of other instruments used intraoperatively. The base 10 and cap 200 could optionally have features to force a particular alignment of the cap and base. For example, a pin may extend from the cap and seat in a groove on the base.
[0081] FIGS. 14A-14E show several exemplary embodiments of a retaining member which may be placed intraoperatively, so as to hold or retain the doors within the base. All of these embodiments include a hole feature to facilitate manipulation of the member. One embodiment 400 is a conventional retaining ring, as will be well familiar to those skilled in the art and this is seen in FIG. 14A . In FIG. 14B , retaining member 410 includes a member 415 to increase the security of placement of the retention member. Additional security may be desirable if mounting features for a cap or intraoperative instruments are added to the retention feature. In FIG. 14C , the retaining member 420 occupies half, more or less, of the annular groove, so as to generate less interference with a medical lead placed in the lumen of the base. In FIGS. 14D and 14 E the ends of retaining members 430 and 440 interface with a groove, such as 41 of FIG. 13C , but the body of these retaining members cross through the lumen of the base. Such disposition of the body of the retaining member keeps the groove free to accept other attachments. Retaining member 430 passes straight across, while retaining member 440 curves away from the center, so that it is clear of the center during placement. The depictions of retaining members 430 and 440 also include material 450 above the plane of the annular groove. Such material may be arranged so as to strengthen or stiffen the retaining member, or to interface with other parts.
[0082] FIGS. 15A-15D show an embodiment where retaining member 460 has pins 220 extending in such a way that they could snap into the cap 200 and thereby attach it to the base 10 . FIG. 15A is a perspective view of the anchor base 10 with retaining member 460 and cap 200 assembled together. FIG. 15B shows cap 200 and FIG. 15C shows the retaining member 460 . Anchor base 10 is seen in FIG. 15D . FIG. 16 is a perspective view of anchor base 10 with the doors 110 and 120 and retaining member 440 assembled together. The retaining member 440 seats into an annular groove 41 , but its body is within the center of the base, leaving much of the groove 41 clear.
[0083] While the exemplary embodiments have been described in some detail for clarity of understanding and by way of example, a variety of additional modifications, adaptations and changes may be clear to those of skill in the art. Hence, the scope of the present invention is limited solely by the appended claims. | An apparatus for securing an implantable lead within tissue of a patient includes a base adapted to be secured to a patient's skull adjacent a craniotomy. The base has an upper surface and a lower surface with a central passage therebetween. The central passage is adapted to receive the implantable lead therethrough. The apparatus also has a cover that is releasably coupled to the base so as to substantially cover the central passage and capture the implantable lead therebetween. A first rotating member is also coupled with the base and the first member is rotationally movable so as to meet and engage the implantable lead at a plurality of positions within the central passage. | 0 |
CROSS RELATED APPLICATIONS
This application claims priority to U.S. Prov. Appl. 62/004,829, which was filed May 29, 2014.
FIELD OF THE INVENTION
The field relates to machines for automatic rolling, folding and forming of confections.
BACKGROUND
Devices for folding confections are known in the art. However, machines that are capable of rolling, folding and forming a confection are not known. In particular, a machine that uses cylindrical extensions that open and close to engage a confection blank and then roll and fold the confection are not known.
Hand rolling and forming is used for many processes due to the complexity of building machines to do this type of work, but hand rolling and forming is time consuming and can lead to repetitive stress disorders.
SUMMARY
A machine for automatically folding, rolling and forming a product from a flat blank to a rolled and formed product, comprises a first stage comprised of a pair of extension devices, each of the extension devices having a gripping member and an elongated extension, the gripping member and the extension being arranged such that a portion of the blank is gripped between the gripping member and the extension, and a distal end of one of the pair of extensions opposes a distal end of the other of the pair of extensions, such that the pair of extensions grip opposite portions of the blank; and a drive, the drive comprising a mechanism for opening and closing the gripping member in relation to the extension and a belt or chain, the pair of extension devices being coupled to the belt or chain, such that the extension device cycles from a starting position to a finishing position and returns again to the starting position, wherein the drive includes at least one guide arranged to retract at least a portion of the extension from the rolled and formed product, releasing the rolled and formed product for further processing, and the drive includes a rotary drive, the rotary drive engaging the pair of extensions during a portion of the cycle, such that the pair of extensions roll up the blank. In one example, the second stage comprises a crimping device that engages the rolled and formed product and crimps a portion of the product, the crimped portion being secured while the product is fed into a cooker, the cooker supplying heat to at least partially cook the product before exiting the cooker, such that the product substantially retains its shape and is crimped. For example, the second stage may further comprise a cutter, the cutter being arranged such that the product is divided into two products after crimping, such as along the crimped portion. A rotating shaft may drive the crimper and the cutter. The second stage may further comprise an ejector, wherein the ejector pushes the two products from the second stage to a subsequent stage for further processing or packaging. The drive may comprise a rotating shaft that drives gears, and the gears may be coupled with a chain. The extension device may be attached to the chain, such that the chain carries the extension device through the cycle. Each of the pair of extension devices may comprise a flange coupled to the respective extension, such that the guide engages a respective one of a pair of flange. Then, the flanges retract the pair of extensions from the product. An undulating plate opposes the chain on an opposite side of the crimped portion of the product, such that the product lowers and rises in an undulating way through the pan, such as a frying pan with hot frying oil. The mechanism for opening and closing the gripping member in relation to the extension may comprise a push rod and a lever arm, wherein the gripping member is fixedly coupled to the lever arm, such that when the push rod pushes a portion of the lever arm, the lever arm pivots about a pivot point, opening the gripping member in relation to the extension. In one example, the push rod extends through the flange and extends beyond the flange, and the at least one guide engages each of the respective push rods of the pair of extension devices, such that the respective gripping member opens in relation to the respective extension, before the gripping member grips the blank and before the pair of extensions retract from the rolled product.
A method of folding, rolling and forming a product from a flat blank to a rolled and formed product may use the one of the machines, previously described by opening the gripping member of each of the pair of extension devices; disposing the pair of extension devices on opposite sides of the blank; gripping opposite sides of the blank by closing the gripping member; folding at least a portion of the blank over onto itself; rotating the extension and rolling the blank, and forming a rolled product. For example, a step of crimping along a center portion between the pair of extensions may be used to crimp the product. The method may comprise dipping the crimped blank in a pan of hot oil, at least partially cooking the blank, and may include raising and lowering the crimped blank in an undulating pattern of highs and lows, while remaining submersed in the oil. Optionally, a step of cutting the crimped blank where the crimped blank is crimped may be added, dividing the crimped blank into two products.
A machine for rolling, folding and forming of a product comprises a first stage including gears coupled to one or more rotating shafts and cams or guides that operate at least one pair of opposing extensions, such as sticks, rods or cylindrical extensions. A shaped blank is placed on a plate, by hand or automatically, as is known in the art, then the extensions engage, fold, roll and deliver a formed product to an optional second stage. The second stage may be activated by a rotating shaft, which may be the same rotating shaft that drives the first stage or a different rotating shaft, for example.
For example, a flat confection blank may be placed on the plate. Cylindrical extensions are coupled with gearing, such that clips open and engage a portion of the blank between the cylindrical extensions and a respective clip, folding the blank, rolling the blank and delivering the blank to be crimped, fried, cut into two halfs and delivered by the second stage to a subsequent stage for processing and packaging. For example, processing may include seasoning, additional cooking, cooling, inspection, distribution to packages, package sealing, boxing, crating and distribution of completed packages to storage or delivery to wholesale or retail.
In one example, a first stage or a second stage will include cylindrical extensions having pins that move away from each other, allowing the blank to be placed on the plate, with the two cylindrical extensions being on opposite sides of the plate. Then, the pins move toward each other, while a gripping device, such as a clip, opens. The plate may have cut-outs on opposite sides of the plate or a slot to accommodate the engagement of the gripping devices of the cylindrical extensions on a portion of the blanks. As the pins move toward each other, opposite sides of the blank are inserted between respective gripping device and cylindrical extension, and the gripping device gently closes on the blank. After the two cylindrical extensions reach their nearest point, a gear attached to the cylindrical extension engages roll bars on a roll bar assembly, while the cylindrical extensions are moved forward above the plate. The gears of the two cylindrical extensions contact the roll bars and rotate the two cylindrical extensions as the cylindrical extensions are moved forward by gearing of the machine. By moving forward and rotating at the same time, the cylindrical extensions may roll up the blank. As the cylindrical extensions form the blank and deliver the blank to the second stage, cam or guide following structures may cause the gripping devices to open and the cylindrical extensions to withdraw from the rolled up blanks, while feeding the blanks into the second stage.
In one example, the first stage is operated by an electric motor rotating a shaft. Alternatively, the rotating shaft may be operated by a hand crank. In one example, the second stage is operated by a second shaft, driven by a second motor. The second motor and the first motor may be synchronized by sensors monitoring the progress of blanks proceeding through the first stage. Alternatively, the first stage and the second stage may be operated by a common rotating shaft.
In one example, the blank is rolled up and is fed into a crimping device, such that a rolled up confection is folded and formed. The confection may be fed into a tray for hot liquid for blanching, such that the confection retains its form after exiting from the machine. Then, the confection may exit the machine and may be further processed, such as by deep frying or baking, as is known in the art.
In one example, the confection is transferred from the cylindrical extensions to a crimping device by extracting the cylindrical extension outwardly after the confection is brought to the crimping device. Then, rotating fingers, coupled to the machines gearing, engage the confection and move it through the crimping device. In one example, two different sets of fingers are used to move the confection through the crimping device and a curing step. During the curing step, for example, the confection may be dipped in a hot liquid, such as boiling water or oil.
In one example, a machine comprises a pair of cylindrical extensions coupled to a first set of gears driven by a rotating shaft for opening the extensions for insertion of a flat blank and closing the cylindrical extensions onto the flat blank. A second set of gears, operated by the same rotating shaft, starts to moved the extensions forward, only after the extensions close onto the blank. A third set of gearing comprising elongated roller bars rotate the extensions, rolling up the blank and folding it onto itself. In one example, another set of gears rotate fingers that engage the rolled up blank and feed it through a forming device, such as device for crimping the blank.
In another example, a plurality of pairs of cylindrical extensions increase the productivity of the machine, such as 12 pairs of cylindrical extensions, in one example.
For example a folding and rolling device may be comprised of a housing that is mounted to a belt or chain drive, the belt or chain drive being driven by a gear engaging a belt or chain or a plurality of belts and chains. For example, the housing may be mounted directly to a chain or a plurality of chains. The cylindrical extension may extend through the housing, a distal end of the cylindrical extension extending from the housing and having a mechanism that engages a blank for folding and rolling the blank. In one example, a gripping mechanism is pivotally attached to a surface of the distal end, such that the gripping mechanism may be opened and closed during operation of the device. Opposite of the distal end, an opposite end may extend from an opposite side of the housing, such that, when the opposite end of the cylindrical extension engages a guide disposed at a position in the machine, the opposite end pushes a lever that pivots the pivotally attached gripping mechanism, opening the gripping mechanism. A biasing mechanism may be included within the cylindrical extension, such that when the opposite end is not pushed, then the spring returns the gripping mechanism to a closed position. For example, a gripping mechanism may be a clip or an elongated member that captures and retains a portion of the blank between a cylindrical shell and the clip or elongated member.
In one example, the opposite end has a shaped flange, and the push rod extends through the shaped flange, such that a first end of the push rod engages the a portion of the guide or guides for opening of the gripping mechanism. The shaped flange may be engaged by another portion of the guide, such that the shaped flange is pulled through a channel formed in the guide. The shaped flange may be attached to the cylindrical shell, which extends through the housing, forming an exterior surface of the cylindrical extension. Thus, when the shaped flange is pulled into the channel formed in the guide, the cylindrical extension may be retracted, outwardly from the blank, releasing the blank from the grip of the device. Alternatively, a linear actuator may be used to retract the cylindrical extension from the blank, either during engagement with the blank or after the blank is formed and before the blank is fully crimped and fed through a second stage of the machine.
In one example, a rocker arm assembly is spring actuated and includes a guide follower, such that a rocker arm guide may engage the guide follower to fix the alignment of the gripping member with the blank, along a portion of a cyclical path of the cylindrical member. During another portion of the cyclical path, a gear may be attached to the cylindrical extension, and the gear may be operatively engaged such the gear rotates the cylindrical extension about its longitudinal cylindrical axis of rotation. Rotation of the cylindrical extension may roll up the blank, for example. In this way, the orientation of the gripping member may be aligned for operatively engaging and disengaging the blank.
BRIEF DESCRIPTION OF THE DRAWINGS
The following drawings are illustrative examples and do not further limit any claims that may eventually issue.
FIG. 1 illustrates an example of a machine for rolling, folding and forming of a confection.
FIG. 2 illustrates a perspective view of gearing of the machine of FIG. 1 , some of the structural features, such as the bottom, sides and plate being hidden from view for better observation of the gearing.
FIG. 3 illustrates another perspective view of the gearing of the machine of FIG. 1 .
FIG. 4 illustrates a detail view of one set of the gearing of the machine of FIG. 1 with a solid line representing the chain connecting the set of gearing.
FIG. 5 illustrates a top plan view of the gearing and roller bars of the machine of FIG. 1 .
FIG. 6 illustrates a confection as folded and formed by the machine of FIG. 1 .
FIG. 7 illustrates a top view of a confection blank.
FIG. 8 illustrates one end view of an example of a machine having a plurality of pairs of cylindrical extensions for increased productivity.
FIG. 9 illustrates an opposite end of the machine of FIG. 8 .
FIG. 10 illustrates a side view of the machine of FIGS. 8 and 9 .
FIG. 11 illustrates the opposite side view off the machine in FIG. 10 .
FIG. 12 illustrates the side view of FIG. 11 with some obscuring support structures hidden for clarity.
FIG. 13 illustrates a bottom view with the pan containing hot oil remove.
FIG. 14 illustrates a top view of the example shown in FIGS. 8-13 .
FIG. 15 illustrates a detail view of a portion of the second stage of the example in FIGS. 8-14 .
FIG. 16 illustrates a detail view of the machine with hidden surfaces removed, showing more detail about the drive mechanisms of this example.
FIG. 17 illustrates a bottom, perspective view of a detail of the second stage of a machine.
FIG. 18 illustrates a top view of a machine with some hidden structures removed to show another view of the drive mechanisms.
FIG. 19 illustrates the same view as FIG. 18 without a cover on a chain tensioning mechanism.
FIG. 20 illustrates a detail view of the chain tightening mechanism of FIG. 19 .
FIG. 21 illustrates a detail view of the attachment of cylindrical extension devices to chain drives of the first stage of a machine.
FIG. 22 illustrates a detail view of the second stage of a machine.
FIG. 23 illustrates a partial detail view of a cylindrical extension device.
FIG. 24 illustrates a side plan view of a first stage of a machine having 12 pairs of cylindrical extension devices.
FIG. 25 illustrates a detail view showing attachment of one of cylindrical extension devices.
FIG. 26 illustrates a detail view of one-half of the first stage showing guides engaging cylindrical extension devices.
FIG. 27 illustrates another detail view of all 12 pairs of the cylindrical extension devices.
FIGS. 28-35 illustrate various views with various structures hidden for explaining the operation of one example of a cylindrical extension device.
When the same reference characters are used, these labels refer to similar parts in the examples illustrated in the drawings.
DETAILED DESCRIPTION
A new type of confection may be rolled, folded and formed by a machine comprising gearing capable of engaging opposite sides of a flat confection blank 1 , as illustrated in FIG. 7 , for example. The flat confection blank 1 may be rolled up, folded over on itself and formed into two finished confections, such as the chip in FIG. 6 , for example.
As illustrated in FIG. 1 , for example, a hand crank 11 , 12 , 14 has a handle 12 . The handle 12 may rotate a shaft 101 that rotatingly engages gearing of the machine 10 , as illustrated in FIG. 2 , for example. Alternatively, the hand crank may be replaced with an electric motor that rotates the shaft 101 . The machine in FIG. 1 comprises structural elements, such as a front plate 16 , a bar 18 coupling the front plate 16 to an intermediate support 50 , 51 , the intermediate support 51 and the from plate 16 supporting a pair of roller assemblies 166 on opposite sides of the machine 10 . Each roller assembly has a plurality of rollers 167 capable of engaging a gear 23 , 24 attached to cylindrical extensions 20 , 21 , such that when the cylindrical extensions 20 , 21 are displaced, the gears 23 , 24 engage the rollers 167 , rotating the cylindrical extensions 20 , 21 .
In the example of FIG. 1 , each cylindrical extension 20 , 21 has a gripping device 22 . The gripping device may be biased closed, such as by a spring, such that a gentle gripping force is applied to a confection blank 1 placed on the plate 18 of the machine 10 .
As the handle 12 is rotated, the gearing first causes the cylindrical extensions 20 , 21 to separate, without moving the cylindrical extensions 20 , 21 forward or back. This is achieved using a plurality of gear sets, each of the gears in a gear set being coupled, one to the other, by a chain, belt or other flexible connecting device, each such chain represented by a solid black line 201 in the drawings of FIGS. 1-5 , for example.
For example, the machine 10 of FIGS. 1-5 has a plurality of gear sets, one set 170 , 7 , 8 , 103 , 170 ′ for moving the cylindrical extensions forward and back (SET FB), another set, 164 , 193 , 190 , 198 , 193 , 199 , 197 , 191 , as illustrated in FIG. 4 , for retracting the cylindrical extensions and returning the cylindrical extensions back toward a centerline of the plate 18 (SET RR), another set 102 , 9 , 146 , 148 , 110 , 140 , 142 for rotating pairs of fingers 31 , 32 , 39 that feed the confection through a forming device 130 , 131 (SET RF) and another set 23 , 24 , 166 for rotating the cylindrical extensions 20 , 21 (SET RCE). In this example, each of these sets of gears are actuated by rotation of the handle 12 attached to the shaft 101 . Thus, rotation of a single shaft 101 drives all of the processes for rolling, folding and forming a confection blank 1 .
In FIG. 1 , gear support members 41 , 43 and 45 are spaced apart by spacer bars 42 , 44 . Two of the support members 41 , 45 engage respective supports extending upwardly from an upper portion 130 of the crimping device. Pairs of fingers 31 , 32 extend from a hub 34 on either side of one of the supports extending from the upper portion 130 of the crimping device. A shaft engages the hub 34 , rotating the hub 34 and the fingers 31 , 32 , when gear SET RF is engaged by rotating the shaft 101 . In this example, a second pair of fingers 39 extends from a second hub 37 , which engages the second support of the upper portion 130 . A first pair of fingers 39 engages the rolled and folded confection, first, moving the confection through a first portion of the forming device 36 , and then another pair of fingers 31 , 32 engages the rolled, folded and formed confection to move the confection downwardly and forward through a tray, which may be filled with a hot liquid, such as hot water or oil, for example. As shown in FIG. 1 , the pairs of fingers rotate in direction A, for example.
FIG. 2 is a similar view to FIG. 1 , except some of the structural member are hidden to better show the gearing of the machine. For example, connector 160 is slidingly engaged with intermediate support 51 , but is only partially visible in FIG. 1 . The connector 160 is pivotally engaged to an arm 162 , which is rotatingly engaged on disk 163 , which is attached to a gear 164 by a shaft. The gear 164 is coupled, such as by a chain, represented by a solid line in the drawing, to gear SET RR.
FIG. 3 illustrates a different view than FIG. 2 , but hides the same structural features for a better view of gear SET FB. In this view, an arm 173 is attached by joint 174 to a cylindrical extension support 175 . Two cylindrical extension supports 175 , both labeled 175 , support each of the cylindrical extension 20 , 21 and house a pair of gears 23 , 24 attached to respective ones of the cylindrical extensions 20 , 21 . These gears 23 , 24 engage rollers 167 of a pair of roller bars 166 positioned on opposite sides of the machine 10 , as illustrated in FIG. 5 , for example. The roller bars comprise a plurality of elongated rollers 167 that are capable of engaging the roller gears 23 . 24 of the cylindrical extensions 20 , 21 whether the cylindrical extensions are retracted from the centerline of the plate 18 or extending toward the centerline of the plate 18 .
In operation, a blank 1 is placed on the plate 18 , with one end, opposite of the direction of movement B, laying over slots formed in the plate 18 . The cylindrical extensions 20 , 21 are coupled with gearing SET RR. Then, the handle 12 is rotated, such that the cylindrical extensions 20 , 21 move toward each other, while an open gripping device 22 on each cylindrical extension is positioned on an opposite side of the blank 1 from the cylindrical extension 20 , for example. Cut-outs on opposite sides of the plate 18 accommodate the positioning of the gripping device 22 . The gripping device 22 may be biased by a spring such that it gently grips the blank 1 during the remainder of the processing. When the gear SET FB has rotated armature gears 170 , 170 ′ a specific rotational amount, the pair of arms 173 begin to engage the pair of extension supports 175 moving the cylindrical extensions forward. The roller gears 23 , 24 then engage the rollers 167 of the roller bars 166 , rolling up the blank 1 , as the cylindrical extensions 20 , 21 rotate. The machine moves the extensions 20 , 21 forward and rotates the extensions, at the same time, rolling up the blank 1 and folding it over on itself. After the blank 1 is rolled up and folded onto itself, it is fed into a crimping device by a first pair of fingers 39 . The confection may be fed into a tray for hot liquid for blanching, by a second pair of fingers 31 , 32 .
FIGS. 8-11 illustrate various plan views of a machine comprising a plurality of pairs of cylindrical extension members. For example, 12 pairs of cylindrical extension devices are arranged in a circuit, which increases productivity compared to a single pair of cylindrical extensions. The machine has a frame 320 that supports the machine 300 . A pan 310 may be used for boiling water or oil to boil or fry a confection, at least partially. The machine shown has two stages, a first stage 301 and a second stage 302 . The first stage has guides 331 , 341 and following cams 332 that can permit or prevent rotation of the cylindrical extensions of the cylindrical extension devices. A lower portion 322 of the second stage 302 directs products through the pan 310 , which may be filled with boiling water or oil for at least partially frying or boiling the products.
Some hidden structures are removed in FIGS. 12-14 to provide alternative views of the machine. In these views, the location of two drive motors 303 , 304 is shown, and the location of a plate 324 is identified. FIGS. 15-17 illustrate some details of the second stage 302 and its relationship with the first stage 301 . A circular cutting blade 306 is shown in relation to a pair of disks 308 for moving finished or semi-finished products to a subsequent stage for additional preparation or packaging, for example.
In the drawings of FIGS. 18-20 , a top view of the chain drive system is shown. A chain tightening system 333 is illustrated and is detailed in FIG. 20 . FIG. 20 shows a locking mechanism 337 for locking the adjustable length of the tightening mechanism using a locking nut. A slot in a bearing assembly 336 engages a track of a structural support 335 . The bearing assembly 336 is shown engaging a axle of a rotatable axle in FIG. 19 .
FIG. 21 illustrates a detailed view of the second stage 302 . The sinusoidal/undulating path of the lower portion 322 of the second stage is designed to keep the product in the pan 310 for a longer duration than would be provided by a straighter path through the pan.
FIG. 22 illustrates a detailed view of a cylindrical extension device 350 having a shaped flange 352 coupled to the cylindrical extension and a pair of attachment points 351 that attach the device 350 to the chain drives of the first stage 301 of the machine 300 . FIG. 23 illustrated a detail of a bottom view of the device 350 and shows the tip 353 of a push rod that opens the gripping member 359 . The attachment points 351 are shown to include elongated pins that extend through the chain links and cotter pins that retain the elongated pins onto the attachment points 351 , for example. FIGS. 24 and 25 illustrate detailed views of the cylindrical extension devices 350 mounted at attachment points 351 to the drive chains. FIG. 24 illustrates how a portion of the devices 350 engage with guides 331 , 341 during a portion of the transit, such that the rotation of the cylindrical extensions is controlled. During a portion when the devices 350 do not engage the guides 331 , 341 , a row of pins engages with a gear in the devices 350 , causing the blank to be rolled by the cylindrical extensions.
FIGS. 26 and 27 illustrate a how guides 362 , 363 engage with the pin 353 and disk-shaped flange 352 to open the grabbing member 359 and retract the cylindrical extensions from the products after rolling of the products. FIGS. 28 and 29 show the guide followers 357 that follow guides 331 , 341 , retaining rocker arms and keeper 354 in a position that prevents rolling of the cylindrical extensions during a portion of the cycle. During another portion of the cycle, gear 358 engages pins 359 . Gears 358 are fixed to the cylindrical extensions 355 causing the extensions 355 to rotated when engaged with the pins 359 . Spring biased keepers 354 do not prevent rotation of the gears 358 during this portion of travel, and blanks are rolled up by the cylindrical extensions. FIGS. 30-35 step through several views removing certain structures in each view, such that the action of guides 362 , 363 on the rod 353 and flange 352 is explained. The rod 353 is a spring 374 biased push rod that opens and closes gripping member 359 . When it engages the guides, the rod 353 tip pushes a lever arm attached to the member 359 opening the member. The biasing mechanism 374 forces the gripping member 359 closed, otherwise, engaging anything, such as a blank, that is disposed between the gripping member 359 and the cylindrical extension 355 . A sensor 367 (or alternatively a linear actuator) may be used to determine when the product is released by the extension 355 . Another guide surface 364 engages the flange 352 , which is fixedly coupled to the extension 355 . Thus, the extension 355 is retracted from the rolled up blank when the flange 352 engages the guide 362 surface 364 . An extension may be used to gradually return the extension 355 back to its neutral location, before completing the circuit and engaging another blank. The detailed view of FIG. 32 shows a housing 371 that may engage the pivot point of the rocker arm of the gripping member 359 . A spring retainer 377 and end cap 373 retain a spring 374 , as one example of a biasing mechanism. FIGS. 33-35 illustrate the mechanism that occurs when guide 363 engages the tip of the push rod 353 , which opens the gripping member 359 to allow for engagement of the blank at the start of the extension devices 350 cycle.
This detailed description provides examples including features and elements of the claims for the purpose of enabling a person having ordinary skill in the art to make and use the inventions recited in the claims. However, these examples are not intended to limit the scope of the claims, directly. Instead, the examples provide features and elements of the claims that, having been disclosed in these descriptions, claims and drawings, may be altered and combined in ways that are known in the art. | A machine comprises at lease one pair of cylindrical extensions coupled to gears driven by a rotating shaft for opening the extensions for insertion of a flat blank and closing the cylindrical extensions onto the flat blank. The flat blank is folded and rolled. A second set of gears, operated by a rotating shaft, crimps, at least partially fries, cuts and directs finished products to the next step in processing and packaging. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a brake cylinder device with a built-in automatic shoe clearance adjustment mechanism.
2. Summary of the Related Art
FIG. 12 shows a conventional brake cylinder device with a built-in automatic shoe clearance adjustment mechanism. This conventional hydraulically actuating cylinder, positioned between adjacent facing ends of brake shoes, functions to automatically adjust clearances between a brake drum and the brake shoes in addition to its function to separate the brake shoes apart and to restrict the returning positions of the brake shoes.
This brake cylinder device is designed to be bilaterally symmetrical except for some parts such as a locator 380 in the central portion; therefore, an arrangement of the device at the right half is mainly explained here. A cylinder body 100 has a large diameter bore 110 with a bottom, a partition 130 having a small diameter bore 120 which is coaxial to the large diameter bore 110 , formed to be a fluid flow passage between opposed large diameter bores 110 , 110 of the brake cylinder device via the small diameter bore 120 . An adjustment gear 210 is formed at the periphery on the right end of a piston 200 stroking out from the large diameter bore 110 , on which a piston head 220 is concentrically fit with a capacity to make a relative rotation. A notched groove 221 is formed at the right part of the piston head 220 to receive a shoe web of the brake shoe, not shown in FIG. 12 .
An adjustment bolt 300 is engaged in non-reversible screw threaded connection with an internal thread of a coaxial blind-end hole of the piston 200 . Here, “non-reversible screw threaded connection” means a screw threaded connection that does not cause relative rotation between the two members if a thrust force in the axial direction is transmitted on either one of the piston 200 or the adjustment bolt 300 . A first clutch face 310 in a conical shape formed at the left end of the adjustment bolt 300 makes a clutch engagement with a corresponding clutch face formed at the halfway of the small diameter bore 120 in the partition 130 .
A drive ring 320 , the outer peripheral surface of which is beveled to provide a clutch face into engagement with a corresponding internal clutch face formed on a projection of the partition 130 at the entrance of the small diameter bore 120 . Clutch engagements among the adjustment bolt 300 , the drive ring 320 , and the corresponding clutch faces of the cylinder body 100 are to be in conical shape in order to obtain a more stable rotational resistance than that of the clutch engagements with flat surfaces. The internal circumference of the drive ring 320 is provided with a fast thread, which is in mesh with a corresponding external thread 330 at the left side of the adjustment bolt 300 in a manner of reversible screw threaded connection with a slight gap (backlash hereinafter). Here, “reversible screw threaded connection” means a screw threaded connection that does cause relative rotation between the two members when a thrust force in the axial direction is applied on either one of the piston 200 or the adjustment bolt 300 . An adjustment spring 340 provided between the adjustment bolt 300 and the drive ring 320 constantly urges the drive ring 320 in the direction to be into clutch engagement with the corresponding internal clutch face of the cylinder body 100 by its spring force.
A through hole 350 with a shaped large diameter bore 360 is formed inside the adjustment bolt 300 extending in its axial direction. The large diameter bore 360 is formed at the left part of the through hole 350 via a stepped surface 351 , and there is a locator spring 370 positioned between facing two large diameter bores 360 , 360 of the adjustment bolts 300 , 300 . This locator spring 370 is to prevent free movement due to vibration caused while in braking operation by acting an urging force to the adjustment bolts 300 , 300 . Moreover, the locator 380 and a spacer 390 are positioned between the right end of the locator spring 370 and the stepped surface 351 , so that a torsion force of the locator spring 370 does not affect on both adjustment bolts 300 , 300 . Further, only the spacer 390 is positioned between the left end of the locator spring 370 and the stepped surface 351 . The reference number 400 is a piston cup defining a hydraulic chamber 140 , 410 is a backup ring, 420 is a dust boot sealing the large diameter bore 110 , and 430 is an O-ring supporting the end of the adjustment bolt 300 in the side of the clutch face.
While in braking operation, upon pressurizing the hydraulic chamber 140 located at the bottom of the small diameter bore 120 ; the piston 200 moves the brake shoe outwardly into lining contact with the brake drum ultimately causing a braking effect. (It is noted that the shoe, lining, and drum are not shown in FIG. 12 . These components are known to those of ordinary skill in the art and no further explanation is warranted.)
The operation of the automatic shoe clearance adjustment mechanism is explained hereunder. While in braking operation, the adjustment bolt 300 moves together with the piston 200 outwardly. Now, if the lining wears out and an amount of outward movement of the adjustment bolt 300 takes up and exceeds the backlash between the drive ring 320 and the adjustment bolt 300 , the drive ring 320 is urged out of engagement with the corresponding clutch face and smoothly rotates.
When the brake is released and the adjacent brake shoe is retracted by the shoe return spring, (not shown in FIG. 12 ), the piston 200 and the adjustment bolt 300 return to the amount of the backlush, the drive ring 320 is urged once again strongly into clutching engagement disabling the rotation thereof, and the adjustment bolt 300 is thereafter caused to be rotated until the clutch face 310 at the left end of the adjustment bolt 300 comes into the clutch engagement and screwed out from the piston 200 . Accordingly, the retracted position of the piston 200 may be set in response to the amount of the lining wear.
As is evident from the above-described operation of the automatic shoe clearance adjustment, the locator spring 370 positioned between the facing large diameter bores 360 , 360 of the pair of adjustment bolts 300 , 300 is constantly urging the adjustment bolts 300 , 300 in the axial direction in order to prevent the free movement due to vibration caused while in braking operation. However, because the torsion force of the locator spring 370 acting on the adjustment bolt 300 may result in unstable automatic shoe clearance adjustment operation, a conventional device provides the locator 380 and the spacer 390 between one end of the locator spring 370 and the stepped surface 351 . Here, the conventional device has the following points to be improved.
In order to act the force of the locator spring 370 to the axis center of the adjustment bolt 300 , the spacer 390 with a concave portion guiding the top of the locator 380 into the axis of the adjustment bolt 300 is used. However, this concave portion is provided only at one surface of the spacer 390 , there is a possibility of misassembling the spacer 390 into the large diameter bore 360 of the adjustment bolt 300 .
The piston cup 400 , the dust boot 420 , and the O-ring 430 used in the cylinder device are rubber or elastomeric members and need to be replaced periodically. Accordingly, there is a possibility of loosing the members or omitting a particular member during assembly and reassembly in addition to the above-described misassembly of the spacer 390 during reassembly.
This invention is made to improve the above-described points and is to provide a brake cylinder device with a built-in automatic shoe clearance adjustment mechanism enable to eliminate the possibility of loosing the members, omitting the particular member, and misassembling.
BRIEF SUMMARY OF THE INVENTION
The present invention is directed to a brake cylinder device with a built-in automatic shoe clearance adjustment mechanism. The device includes a pair of opposing pistons slidably fit in a cylinder bore of a cylinder body and a pair of adjustment bolts having a coaxial through hole. One end of each adjustment bolt is screwed into the piston with a non-reversible screw thread connection. The other end of each adjustment bolt is urged into clutching engagement with the cylinder body. A pair of drive rings, internally threadingly engage the other side of the adjustment bolt in a reversible screw thread connection with a backlash in the axial direction. The peripheral surface of the drive ring is urged by an adjustment spring into clutching engagement with a partition of the cylinder body. The pistons, adjustment bolts, adjustment springs, and drive rings are provided oppositely and symmetrically in the cylinder bore. A locator spring is positioned between two facing adjustment bolts. A locator is placed in the vicinity of the end of the locator spring. A spacer is placed between the top end of the locator and one of the adjustment bolts, having a supporting portion which engages with and supports the top end of the locator along the axis of the adjustment bolt. A fluid flow passage penetrates through the spacer, wherein the supporting portions formed on the axial center of the spacer are identically shaped both on the front and back surfaces thereof.
The top end of the locator has a conical shaped portion (convex shape) and the supporting portion of the spacer has a tapered concave portion. The spacer supports the top end of the locator and the conical shaped portion is disposed within and engages the tapered concave portion of the space. An angle of the tapered concave portion is designed to be larger than an angle of the conical shape top end of the locator to define a point contact between the conical shaped top end and the tapered concave portion.
The locators are preferably positioned one each adjacent side of the locator spring and the spacers are disposed between the top end of both locators and an associated adjustment bolt. The spacer is preferably symmetrically formed to have front and back surfaces of the same shape. The spacer is integrally pressed in the through hole of the adjustment bolt and is substantially integrated therewith. The outer circumferential diameter on the back and front surfaces of the spacer is preferably designed to be smaller than an inner diameter of the through hole of adjustment bolt. The locator is urged by the locator spring such that the top end of the locator and the supporting portion of the spacer are aligned with the axis of the adjustment bolt.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
FIG. 1 is a sectional view of the brake cylinder device according to the present invention;
FIG. 2 is a sectional view of the adjustment bolt assembly;
FIG. 3 is a partial sectional view of the locator spring integrated with the locator at one end of the locator spring;
FIG. 4 is a partial sectional view of the locator spring integrated with the locator at both ends of locator spring;
FIG. 5 is a plan view of the spacer;
FIG. 6 is a longitudinal sectional view of the spacer in FIG. 5 with a curved peripheral surface;
FIG. 7 is a longitudinal sectional view of the spacer in FIG. 5 with a chamfered circumference;
FIG. 8 is a partial sectional view of another locator and spacer according to an alternate embodiment of the present invention;
FIG. 9 is a plan view of the clip of the piston head;
FIG. 10 is a left side view of the clip of FIG. 9;
FIG. 11 is a top view of the clip of FIG. 9; and
FIG. 12 is a sectional view of the prior art.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
One embodiment of the invention is explained with reference to the figures. The brake cylinder device of the present invention includes many corresponding components as shown in the conventional art of FIG. 12 and are identified with the same reference numerals for the sake of brevity and avoiding redundant explanation of the common components previously described.
As shown in FIG. 1, a locator spring 500 is positioned between the facing large diameter bores 360 , 360 on the axis of both adjustment bolts 300 , 300 , which gives an urging force on the axis of the adjustment bolts 300 , 300 in order to prevent the free movement of the adjustment bolts 300 , 300 due to vibration caused during the braking operation. The locator spring 500 is of a taper-like compression coil spring. The locator spring 500 has two turns parallel the right end and the outside diameter of one turn adjacent the left end is slightly smaller than the large diameter bore 360 . Here, a substantial part of the locator spring 500 is disposed in the large diameter bores 360 , 360 of both adjustment bolts 300 , 300 , which minimize the entire length of the cylinder device.
As shown in FIGS. 1 and 3, the locator spring 500 has a locator 600 at one end. The parallel turns at one end of the locator spring 500 are pressed to be installed between a large diameter flange 610 and a small diameter flange 620 , both projecting from the locator 600 . In addition, the locator spring 500 and the locator 600 are desirably integrated for convenient handling. Further, the top end of the locator 600 has a projected conical shaped abutment (convex portion) 630 .
Referring to FIGS. 1 and 2, the spacer 700 positioned between the stepped surface 351 of the adjustment bolt 300 and the locator 600 may be provided only in one large diameter bore 360 considering the automatic shoe clearance function. However, the spacer 700 should be provided in both large diameter bores 360 , 360 of the facing adjustment bolts 300 , 300 in terms of avoiding the possibility of misassembly.
As shown in FIGS. 5-7, the spacer 700 has conical supporting portions (tapered concave portions) 710 , 710 at its center of the front and back surfaces thereof, where the top end of the abutment (convex portion) 630 of the locator 600 is supported on the axis of the adjustment bolt 300 , and has a plurality of fluid flow passages 720 around an outer periphery thereof to permit the fluid passing through. Accordingly, if the supporting portions, i.e., the concave portions 710 , 710 , are provided at the center on the front and back surfaces of the spacer 700 , there is no need to be concerned about the side of the spacer 700 during assembly. In addition, the passage 720 is at least, but not limited to, a shape capable of fluid flow between the hydraulic chamber 140 and the through hole 350 passing through the adjustment bolt 300 for the improvement of air bleeding.
Providing the locator 600 and the spacer 700 in the above described manner, the spring force of the locator spring 500 acts on the axial center of the adjustment bolt 300 . Thus, no biased load is generated on the adjustment bolt 300 , and the torsion force by the locator spring 500 affecting the adjustment bolt 300 is prevented, thereby enabling a stable automatic shoe clearance adjustment operation.
Furthermore, during assembly, the spring force of the locator spring 500 causes the top end of the abutment (convex portion) 630 to slide along the supporting portion (concave portion) 710 of the spacer 700 to automatically adjust its position on the axis of the adjustment bolt 300 so that the top end of the abutment (convex portion) 630 of the locator 600 does not deviate from the axis of the adjustment bolt 300 . To that end, the outside diameter of the locator spring 500 relative to the inside diameter of the large diameter bore 360 of the adjustment bolt 300 , the outside diameter of the large diameter flange 610 of the locator 600 , or the size and shape, of the supporting portion (concave portion) 710 of the spacer 700 may be appropriately selected.
In addition, FIG. 1 shows a case when the spacers 700 , 700 are positioned on the right and left side of the device while the locator 600 is positioned only at one end of the locator spring 500 . However, the positions of the locator 600 and the locator spring 500 as appear in FIG. 1 may be reversed without detracting from their respective functions. Here, these members are bilaterally non-symmetrical, which increases a possibility for the operator to misassemble the members. However, if the spacers 700 , 700 are provided at both sides, the locators 600 , 600 may also be provided at both sides of the locator spring 500 to maintain bilateral symmetry as shown in FIG. 4 . Such an arrangement completely eliminates a possibility for misassembly. In such case, the locator spring 500 is in the form of a barrel shape.
The top end of the abutment (convex portion) 630 of the locator 600 is angled to be smaller than the angle of the concave portion 710 of the spacer 700 so that a convex-concave engagement between the two members creates a point contact. This eliminates the necessity of using a low friction material or coating the locator 600 and the spacer 700 , which reduces the manufacturing cost.
In addition, as is evident from the above explanation, the spacer 700 functions to act the force by the locator spring 500 on the axis of the adjustment bolt 300 and to permit the fluid flow between the hydraulic chamber 140 and the through hole 350 . Therefore, although it is not necessary for the front and back surfaces of the spacer 700 to have the same size and shape as shown in FIGS. 5-7, having the same size and shape enables a common design thus facilitating manufacture and reducing the cost. The spacer 700 may be integrally processed by sintered alloy steel, aluminum die-cast, or heat resistant thermoplastic resin, thereby further facilitating the manufacture and reducing costs.
Also, as a means to position the spacer 700 , the peripheral surface of the spacer 700 may be pressed in the inner circumferential surface of the large diameter bore 360 in the adjustment bolt 300 so as to facilitate the handling of the members and eliminate a problem of omitting the particular member. In this case, however, the diameter of circumference of the spacer 700 is designed (specified) to be smaller than the inside diameter of the large diameter bore 360 of the adjustment bolt 300 to avoid causing a scratch at the circumference of the front and back surfaces thereof when the spacer 700 is pressed in. For example as shown in FIG. 6, the intermediate portion of the peripheral surface of the spacer 700 may be projected to form a curved portion 730 which is pressed to engage the inner circumferential surface of the large diameter bore 360 , where the circumferences of the front and back surfaces do not contact the large diameter bore 360 . In addition, as shown in FIG. 7, chamfers 740 may be employed instead of the above described curved structure.
Here, the above-described embodiment of this invention explains about an example where the locator 600 has the conical shaped abutment (convex portion) 630 and the spacer 700 has the concave portion 710 . However, as shown in FIG. 8, the concave portion 630 A may be formed at the top end of the locator 600 , and the conical shaped abutment (convex portion) 710 A may be formed at the supporting portion of the spacer 700 to obtain the same effective result.
A piston clip 800 , as shown in FIG. 1 and FIGS. 9-11, comprises an attachment section 810 clamping the peripheral surface of a piston head 220 for its installment and an engagement section 820 engaging with the adjustment gear 210 at the front end of the piston 200 . The attachment section 810 , has a notched end to give an elastic force, and the engagement section 820 is folded from one side surface to form a reverse-U shape having a protuberance inside an adjacent end end.
The piston clip 800 increases the rotational resistance of the piston 200 in order to securely prevent the rotation of the piston 200 due to vibration and make the piston 200 substantially integrated with the piston head 220 . Further, when the adjustment gear 210 of the piston 200 is rotated to be adjusted by a tool from outside of the brake. The piston clip 800 has a function to allow for manual adjustment by considering if the U-shaped piston clip 800 is twisted to give a feeling of rotating over the pitch or to give a hammering (impact) noise due to the springing force.
The above-structure of this invention provides the following advantages.
Designing the front and back surfaces of the spacer to have the same shape enables to give common members, thereby facilitating the manufacture and preventing the misassembly.
The spacer may be integrally processed which also facilitates the manufacture.
The spacer may be pressed in the bore of the adjustment bolt to be substantially integrated with the adjustment bolt, which facilitates the handling of the members and eliminates a possibility of omitting the particular member when performing maintenance work.
The outside diameter of the circumferences at the front and back surfaces of the spacer is designed (specified) to be smaller than the inside diameter of the large diameter bore at the part of the through hole of the adjustment bolt to avoid causing a scratch at the circumference of the front and back surfaces when the spacer 700 is pressed in. This arrangement eliminates a chance of contamination by dust due to scratches and prevents biting in the piston cup or the O-ring.
Providing a spacer in a large diameter bore of both adjustment bolts eliminates a chance of misassembling the members. In addition, the spacer and the locator may be positioned at both sides of the locator spring, which also eliminates a chance of misassembly and gives a more stable automatic shoe clearance adjustment operation compared to the case when the locator is positioned only in one of the large diameter holes.
The angle of the concave portion is designed to be larger than that of the conical shaped abutment (convex portion) so that a convex-concave engagement of the locator and the spacer becomes a point contact. This reduces the manufacturing cost and facilitates a stable automatic shoe clearance adjustment operation without having an effect of torsion force by the locator spring on the adjustment bolt.
Integrating the locator spring with the locator positioned in the bore of the adjustment bolt facilitates handling and eliminates the chance of omitting the members when conducting maintenance.
While in assembling, the spring force of the locator spring causes the top end of the locator to slides along the supporting portion of the spacer to automatically align its position on the axial center of the adjustment bolt so that the top end of the locator does not deviate from the axis of the adjustment bolt. Therefore, even an unskilled person may give a urging force of the locator spring on the axis of the adjustment bolt, thereby giving a stable automatic shoe clearance adjustment operation.
While the foregoing invention has been shown and described with reference to a preferred embodiment, it will be understood by those possessing skill in the art that various changes and modifications may be made without departing from the spirit and scope of the invention. | A brake cylinder device with a built-in automatic shoe clearance adjustment device which prevents a chance of misassembly, loosing, or omitting the spacer. The brake cylinder device includes an adjustment bolt screwed into a pair of pistons symmetrically slidably positioned inside a cylinder body. A locator spring is positioned between both adjustment bolts. A locator is positioned at the end of the locator spring, and a spacer engages the top end of the locator and has a supporting portion to support the top end on the axis of the adjustment bolt. The supporting portion of the spacer has the front and back surfaces of the same shape. | 5 |
BACKGROUND OF THE INVENTION
The present invention relates to a memory reclamation method, in particular one in which conflicting deletion attempts for a stored data object may be made.
Garbage collection is the automated reclamation of system memory space after its last use by a programme. A number of examples of garbage collecting techniques are discussed in “Garbage Collection- Algorithms for Automatic Dynamic Memory Management” by R. Jones et al, pub. John Wiley & Sons 1996, ISBN 0-471-94148-4, at pages 1 to 18, and “Uniprocessor Garbage Collection Techniques” by P. R. Wilson, Proceedings of the 1992 International Workshop on Memory Management, St. Malo, France, September 1992. Whilst the storage requirements of many computer programs are simple and predictable, with memory allocation and recovery being handled by the programmer or a compiler, there is a trend toward functional languages having more complex patterns of execution such that the lifetimes of particular data structures can no longer be determined prior to run-time and hence automated reclamation of this storage, as the program runs, is essential.
A common feature of a number of garbage collection reclamation techniques, as described in the above-mentioned Wilson reference, is incrementally traversing the data structure formed by referencing pointers carried by separately stored data objects. The technique involves first marking all stored objects that are still reachable by other stored objects or from external locations by tracing a path or paths through the pointers linking data objects.
This may be followed by sweeping or compacting the memory—that is to say examining every object stored in the memory to determine the unmarked objects whose space may then be reclaimed.
Normally, the garbage collection and reclamation process runs on the computer in parallel to a program process, the garbage collection and reclamation process operating on the heap (memory area) occupied by data objects of the program process, so that garbage from the program process can be detected as soon as possible and the appropriate resources reclaimed. A result of the two processes running in parallel to each other and operating the same memory area is that they could both be operating on the same data objects at the same time. In the event of only a single processing thread being available to the two processes, steps from the garbage collection and reclamation process are interleaved with steps of the program process. A single step of the garbage collection and reclamation process may not necessarily completely process a data object and those data objects that it has pointers referenced to.
Many computer programming languages offer functions for manual reclamation of memory used by data objects. As opposed to automatic garbage collection, to manually reclaim memory used by a data object a programmer must explicitly execute an appropriate function from within the program that created the data object. Indeed, a popular feature of Object-Oriented programming languages such as C++ is the ability to define a destructor method for an object class. A destructor method is a function written by a programmer specifically for an object class. The default operation performed by a destructor method is to delete the object it is associated with from the heap. The programmer can include calls to other functions from within a destructor method so that when the destructor method is executed for a data object created from the object class, resources held by the data object can be reclaimed, such as file handles and other objects referenced by pointers from the object, before the data object is automatically deleted from the computer's memory heap. This method is particularly popular for reclamation of linked list and tree data structures where destructors for each object in the linked list can be recursively called until the end of the list is reached, thereby reclaiming the whole linked list from a single destructor method call. In this manner, a programmer, knowing that a program has finished with a data object, could execute the destructor method from the program so that the object and its resources can be reclaimed in an orderly fashion as soon as the object is finished with.
It will be apparent, however, that such manual memory reclamation methods conflict with the garbage collection and reclamation methods described above. If a garbage collection and reclamation process is part way through processing a series of linked data objects, when the program process manually reclaims the resources held by the data objects, the next time the garbage collection and reclamation process resumes, it will attempt to process a data object that no longer exists resulting in an error state being generated and potentially a system failure.
In Java (® Sun Microsystems Inc.) virtual machines there is no provision for manual memory reclamation methods. All memory reclamation must be performed by an automatic garbage collector. However, as Java (® Sun Microsystems Inc.) supports multiple processing and different garbage collection mechanisms have different strengths and weaknesses (for example reference counting can quickly identify 0-referenced data objects as garbage but cannot identify cyclic data structures as garbage, whilst the mark-sweep algorithm can identify most types of garbage but takes much longer to identify it), it is desirable that a number of automatic garbage collectors operate concurrently on the heap occupied by data objects. In order for garbage collectors to operate concurrently they must have some conflict resolution mechanism in the event that one garbage collector tries to reclaim a data object that another garbage collector is currently processing.
Before arriving at the solution of the present invention, a number of other possible solutions were explored. Data objects that are currently being processed by the garbage collection and reclamation process can be marked such that before a manual reclamation operation, or the data object being processed by another garbage collection and reclamation process, a mark is checked for and the operation can be aborted if the data object is found to be marked. However, by aborting the operation, reclamation of the resources held by the data object becomes reliant on the garbage collection and reclamation process recognising them as garbage and reclaiming them in the future—this reclamation may be at some indefinite time in the future or, if the program process is permanently running and keeps a valid pointer referencing the data object, the data object may never be recognised as garbage and would therefore never be reclaimed.
Alternatively the garbage collection and reclamation process could place a mutual exclusion lock (by a method such as semaphores) on the data object(s) it is processing. Such a lock, however, prevents the program process from accessing and manipulating the data objects and would at least halt the execution of the program process at the point it requires access to the data object(s) until the lock(s) are released and could cause the program process to fail.
SUMMARY OF THE INVENTION
According to the present invention, there is provided a method of reclaiming memory space allocated to a data structure comprising data objects linked by identifying pointers, in which the memory allocated to data objects is reclaimed using two systems:
a first system, by which a selected part of the data structure is traversed by following the pointers, one of at least two identifiers being allocated to the data objects, a first identifier which indicates that the data object has been traversed so that the data objects referenced by the pointers of that data object have been identified, and a second identifier which indicates that the data object is referenced by a pointer, but the data object has not yet been traversed; and
a second system, by which an individual data object is selected for deletion to enable the associated memory space to be reclaimed,
wherein the second system reads the first system identifier for the individual data object, and if the first identifier is present deletes the data object thereby reclaiming the associated memory space, and if the second identifier is present, allocates a third identifier, and wherein the first system operates to reclaim the memory space allocated to data objects having the third identifier.
An advantage of the present invention is that the second system does not delete the data object if the first system has not finished traversing it, but adds a marker so that deletion will only take place when the first system is ready.
Preferably, the first system comprises an automatic garbage collection system. The invention thus eliminates the conflict between automatic garbage collection and manual memory reclamation. Preferably, the first system also operates to reclaim the memory space allocated to data objects having no identifier. The second system may be the manual deletion of data objects. This may be in the form of the deletion of data objects by a creating program of the objects when the objects are no longer needed. Alternatively and preferably, the second system comprises an automatic garbage collection system. The invention thus eliminates the conflict between the two automatic garbage collection systems. Preferably, the second system also reclaims memory space allocated to data objects referenced by pointers from the data object having the third identifier.
The invention also provides a data processing apparatus for implementing the method of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described by way of example only, with reference to the accompanying drawings, in which:
FIG. 1 is a block diagram of a data processing system suitable to embody the present invention;
FIGS. 2 to 4 represent a group of partially linked data objects as tracing proceeds, using a tricolour marking scheme;
FIG. 5 represents the group of partially linked data objects of FIG. 3 including a data object for which a deletion attempt conflicting with a garbage collection process has been made;
FIGS. 6 and 7 represents a data object for which a deletion is processed by a method of reclaiming memory space embodying the present invention;
FIG. 8 is a flow chart describing features of a method of reclaiming memory space embodying the present invention; and
FIG. 9 represents a group of partially linked data objects processed by a program, a first garbage collection process and a second garbage collection process embodying the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 represents a data processing system, such as a personal computer, which acts as host for a number of software utilities which may, for example, configure the system as a browser for data defining a virtual environment. The system comprises a central processing unit (CPU) 10 coupled via an address and data bus 12 to random-access (RAM) and read-only (ROM) memories 14 , 16 . These memories may be comprised of one or several integrated circuit devices and may be augmented by a system hard-disk as well as means to read from additional (removable) memory devices, such as a CD-ROM. The present invention is particularly embodied in memory management for a working area of the RAM 14 under control of the CPU 10 ; a controlling program for this may initially be held in ROM 16 and loaded up with the operating system on power-up. Also coupled to the CPU 10 via bus 12 are first and second user input devices 18 , 20 which may suitably comprise a keyboard and a cursor control and selection device such as a mouse or trackball. Audio output from the system is via one or more speakers 22 driven by an audio processing stage 24 . Video output from the system is presented on display screen 26 driven by display driver stage 28 under control of the CPU 10 . A further source of data for the system is via online link to remote sites, for example via the Internet, to which end the system is provided with a network interface 30 coupled to the bus 12 .
FIGS. 2 to 4 schematically illustrate the basic principles of tracing in incremental garbage collecting using a tricolour marking scheme, the terminology of which will be used in the following examples. A particular feature of incremental collectors is that the procedure is not carried out contiguously but in discrete steps interspersed with periods of program execution to avoid introducing lengthy breaks to the execution. The tricolour scheme is a convenient method to describe the process of marking as it spreads through the “network” formed by memory objects linked by pointers. In the scheme, objects which have been reached and passed by the traversal process (i.e. the traversal has reached all linked immediate descendants) are coloured black; those objects reached by the traversal whose actual or potential descendants have not been reached are coloured grey, and all other objects are coloured white.
In the partially-linked collection of objects of FIGS. 2 to 4 , FIG. 2 shows the status after the first incremental stage of the tracing procedure starting from object 35 and spreading outwards/downwards, with object 35 marked black and the three objects 36 , 38 , 39 to which it carries pointers being marked grey. FIG. 3 represents the status after a further incremental stage with the descendant objects 40 , 41 , 42 , 44 , 45 of objects 36 , 38 , 39 having been reached by the traversal and accordingly marked grey. As all their descendants have been reached, objects 36 , 38 , 39 are marked black at this stage. FIG. 4 represents the final stage at which it has been determined that there are no remaining linked objects, and objects 40 , 41 , 42 , 44 , 45 are marked black. This concludes the mark phase and shows that there are two “unreachable” objects 37 , 43 to which there are no pointers. These objects are still marked white, indicating them to be garbage and thus available for deletion.
The tricolour marking scheme is discussed in greater detail in the previously cited Wilson reference including various techniques for handling the incremental nature of the procedure, where the layout of the data structure may change during traversal, with the interspersed segments of program execution shifting the arrangement of placed pointers. One particular point to note is that the hierarchical layout of objects in FIGS. 2 to 4 is purely for the purposes of illustration: in actuality, the objects may be spread throughout the available memory with the hierarchy only determined by the arrangement of linking pointers.
The problem of conflicting deletion attempts is explained with reference to FIG. 5 which represents the group of partially linked data objects of FIG. 3 . The incremental garbage collector has processed data objects 35 , 36 , 38 and 39 and has references to data objects 40 , 41 , 42 , 44 and 45 which are due to be processed when the garbage collector next resumes. However, between the garbage collector processing data object 38 and data object 42 , a process external to the garbage collector executes a destructor operation for data object 38 , which in turn executes a destructor operation for data object 42 . When the garbage collector subsequently resumes and follows its reference to what it expects to be a data object it may find no data object at all in which case an error condition is generated, alternatively the process external to the garbage collector may have created another data object in the memory area previously occupied by data object 42 , in which case the garbage collector will incorrectly believe that the new data object is linked to data object 38 and in turn to data object 35 .
The method of reclaiming memory space embodying the present invention is explained with reference to FIG. 6. A program has created in the heap data object 50 linked to descendent data object 52 which is in turn linked to descendent data object 54 which is linked to data object 56 . The program uses the data objects 50 - 56 to store its data and subsequently manipulates the objects and stored data during its execution. In this example the garbage collector has processed data objects 50 and 52 and is due to process data object 54 when it next resumes. During its period of execution, the program determines that data object 52 and its descendants are no longer needed and executes the destructor method for data object 52 which has been written to recursively call the destructor for each of its descendants. To the extent described above this is conventional in the art.
The present invention effectively modifies known manual memory reclamation operations, such as destructor methods, to make them compatible with automatic garbage collection. The modified destructor method determines the marking status of data object 52 from a data field of the object. On finding the status to be black, the destructor recursively calls the destructor for each descendant data object, in this case data object 54 . The destructor for data object 54 determines its marking status to be grey, indicating a conflict between the destructor and the garbage collector. The destructor for data object 54 therefore, instead of deleting the data object 54 , changes the marking status of the data object 54 to red, indicating a request to delete the object. The destructor for data object 54 then recursively calls the destructor for data object 56 which, determining the marking status of data object 56 to be white, deletes the data object 56 and returns to the destructor for data object 54 . This destructor in turn ends its execution returning to the destructor for data object 52 which ends by deleting data object 52 from the heap. If all the data objects had a black or white marking status, there would have been no conflict and the data objects could have all been recursively deleted. Instead, data object 54 remains, with a red marking status.
The garbage collector resumes its marking of the data objects shown in FIG. 7 . When processing each referenced data object, its respective marking status is checked. Upon processing data object 54 , the garbage collector finds its status to be red. In the same way as the status of data objects marked grey are changed to black when their descendent data objects are processed, data objects marked red are changed to white. This is performed as an atomic test-and-set operation (if (state=red) then state=white). The data object is then reclaimed with other garbage during the reclamation phase of the garbage collection.
In a preferred embodiment of the present invention, any red status objects processed by the garbage collector during the marking phase are immediately deleted by the garbage collector without waiting for the reclamation phase.
The operation of destructors or other manual reclamation functions embodying features of the present invention will depend on the structures of data objects they are written for reclaiming. For example, if a data object is the descendant of two parent data objects (such as where the data objects are linked in a cyclic structure), only one of which is deleted, or requested to be deleted, it may be desired that the data object is not deleted in which case the manual reclamation function for the parent data objects would be written without code recursively calling for the manual reclamation of the descendant data object. Indeed, it may be preferable that only the highest level data object is deleted or marked red, indicating a request for deletion, so that the automatic garbage collector recognises the orphaned descendants as garbage on its next mark phase through the memory heap.
In a further example of manual reclamation embodying features of the present invention, when a data object is marked red indicating a deletion request conflicting with garbage collection, the red mark is propagated down the tree or list to any other descendants of the red marked data object.
FIG. 8 is a flowchart describing features of the method of the present invention. In step 800 , a program that has created a number of data objects in the form of data structures on the heap, some of which it no longer uses, is interrogated to obtain a reference to each top level (root) data object for data structures it is currently using. These references are stored in a pool. As will be understood from the following description, the pool is used to store data objects being processed by the garbage collector—references are added to and removed from the pool as the garbage collector traverses the data structures. During the processing according to the method of the present invention, references to descendant data objects will be added to the pool and, as each data object is completely processed its respective reference is removed from the pool. The marking status of all data objects in the heap is made white in step 810 . For each data object referenced in the pool, if its marking status is found to be white, it is changed to grey in step 820 and a reference to each, if any, descendent data object is added to the pool in step 830 . The reference to the data object is kept in the pool so that it is subsequently processed again. If the marking status of a data object is found to be grey, it is changed to black in step 840 and the reference to that data object is removed from the pool in step 850 . If the marking status of a data object is found to be red, it is changed to white in step 860 and the reference to the data object is removed from the pool in step 870 . As discussed previously with reference to FIGS. 6 and 7, an object can only be assigned a red marking status by a manual deletion operation conflicting with a grey marking status. The change of marking status from grey to red is performed during the manual deletion operation.
In this manner, once all references to data objects in the pool are exhausted, all data objects in the heap will have a marking status of black, if they are linked to a root data object held by the program and have not been requested to be deleted, or white otherwise. The subsequent reclamation phase of the garbage collection may then reclaim memory held by data objects having a white marking status by a method such as sweeping, compaction etc.
It will be apparent to the skilled person that the deletion request mechanism of the present invention may be implemented in a number of ways dependent on the programming language and compiler used.
For those Object-Oriented languages permitting the use of destructor methods, the deletion of a data object is automatic once its destructor method has been called. In order to implement the present invention in this case, the compiler could be modified so that destructor methods could be aborted if a red marking of an object is found. Alternatively, it may be permitted to include a finaliser method within destructors able to resurrect data objects in which case the finaliser can resurrect the data object if a red marking of that data object is found.
For less sophisticated languages, allowing delete or de-allocation functions to be used on data objects, the programmer could write an appropriate function which checks the marking status of a data object before deleting or de-allocating it.
Other operations performed by deletion functions or destructor methods, such as recursive deletion of lists or trees would be dependent on the programmer calling the appropriate operations from the respective function.
FIG. 9 represents a group of partially linked data objects processed by a program, a first garbage collection process and a second garbage collection process embodying the present invention. A Java (® Sun Microsystems Inc.) virtual machine has a program process 900 running in a first thread. The program process 900 has created a number of data objects 910 - 960 on the heap 905 . Some of the data objects are linked together by pointers to form tree 915 - 935 and list 950 - 960 data structures. The program process accesses the data objects via root data objects 910 , 915 and 970 . Those data objects not reachable from the root data objects, such as objects 940 and 950 - 960 are no longer accessible to the program process and are therefore garbage. A first garbage collection process 980 , running in a second thread, is operating on the heap. The garbage collection process 980 uses a reference-count algorithm to detect and delete unreferenced data objects. A second garbage collection process 990 , running in a third thread, is also operating on the heap. The garbage collection process 990 uses a mark-sweep algorithm, as has been previously described with reference to FIG. 8 to detect and reclaim garbage. On processing the heap, the first garbage collection process 980 detects and attempts to delete unreferenced data object 940 . However, the second garbage collection process 990 is currently processing this object (and has therefore marked it grey). The first garbage collection process detects the grey marking of the data object and, instead of deleting it, changes the marking status to red. The second garbage collection process 990 then continues, as has been described with reference to FIG. 8 whilst the first garbage collection process 980 would delete the red marked data object when it resumes, as has been previously described.
Although defined principally in terms of a software implementation, the skilled reader will be well aware that the above-described functional features could equally well be implemented in hardware, or in a combination of software and hardware.
From reading the present disclosure, other modifications will be apparent to persons skilled in the art. Such modifications may involve other features which are already known in the design, manufacture and use of data processing and storage apparatus and devices and component parts thereof and which may be used instead of or in addition to features already described herein. | A method of reclaiming memory space allocated to a data structure comprising data objects ( 910-960 ) linked by identifying pointers, in which the memory allocated to data objects is reclaimed using two systems: a first system ( 980 ), by which a selected part of the data structure is traversed by following the pointers, one of at least two identifiers being allocated to the data objects, a first identifier which indicates that the data object has been traversed so that the data objects referenced by the pointers of that data object have been identified, and a second identifier which indicates that the data object is referenced by a pointer, but the data object has not yet been traversed; and a second system ( 990 ), by which an individual data object is selected for deletion to enable the associated memory space to be reclaimed. The second system ( 990 ) reads the first system identifier for the individual data object, and if the first identifier is present deletes the data object thereby reclaiming the associated memory space. If the second identifier is present, it allocates a third identifier, where the first system ( 980 ) operates to reclaim the memory space allocated to data objects having the third identifier. | 8 |
PRIORITY CLAIM
[0001] This application claims priority benefit of U.S. Provisional Patent Application No. 61/620,176, filed Apr. 4, 2012, and U.S. Provisional Application No. 61/622,265, filed Apr. 10, 2012, the disclosures of which are incorporated in their entireties herein.
STATEMENT OF GOVERNMENT INTEREST
[0002] This invention was made with government support under Grant Number R01 CA070375. Awarded by the National Institutes of Health (NIH). The government has certain rights in the invention.
INCORPORATION BY REFERENCE
[0003] This application contains, as a separate part of disclosure, a Sequence Listing in computer-readable form (filename: 46904PCT_SeqListing.txt; created Mar. 27, 2013; 446,686 bytes—ASCII text file) which is incorporated herein by reference in its entirety.
BACKGROUND
[0004] Natural products continue to be a rich source of clinical drugs for treatment of human and animal diseases. 1,2 With respect to drug development, advanced understanding of their biosynthesis is significant for rational strain improvement efforts. This includes genetic manipulation (e.g. gene knock-out, knock-in, and whole gene cluster amplification) of the key biosynthetic and regulatory genes in order to increase the yield of pharmaceuticals to a desired level. 3-6 Knowledge on biosynthesis is also valuable for guiding generation of novel natural product analogs as new drug candidates by metabolic engineering, mutasynthesis and allied approaches. 7-11 In addition, biochemical characterization of diverse biosynthetic enzymes continues to reveal new catalytic mechanisms that inspire inventions of novel chemical and biological catalysts in organic chemistry for production of fine-chemical and medicinal agents. 12,13
[0005] Elucidation of the biosynthetic pathway of a particular natural product or a family of natural products first requires identification of the gene cluster encoding its production. 14-16 Next, the combined genetic (in vivo) and biochemical characterization (in vitro) of each individual biosynthetic enzyme provides important information, including enzyme substrate specificity, co-factor requirements, and the precise order of multiple biosynthetic steps. 17,18 With this information available, it becomes possible to reconstitute the entire biosynthetic pathway in a heterologous host 19-21 or in a multi-component in vitro reaction. 22,23
[0006] Across all microbes, plants and animals that generate natural products, it is particularly challenging to elucidate a biosynthetic pathway completely when unprecedented steps are involved, or precedent knowledge of biosynthetic origin is limited or non-existent. Conventionally, the hunting for such enzymes catalyzing these unusual biotransformations via unexplored mechanisms depends on implementing reasonable biosynthetic principles, and the scanning of the activity of all possible candidate enzymes against all hypothetical substrates. 18,24,25 Thus, the entire process can require prolonged and intensive efforts, especially for those complex natural products assembled by a large number of biosynthetic enzymes.
[0007] Due to the discovery of natural products from different microorganisms bearing the same unique structural core, but varying from one another in their tailoring groups, opportunities for facile identification of unique enzymes arise. In this scenario comparative bioinformatic analysis suggests that homologous genes can be linked to formation of a common structural core, whereas cluster-specific genes provide the basis for structural differences. 26-29 Recent advances in whole genome sequencing technology have made this approach rapid and cost-effective. 30-34 Thus, identification of biosynthetic gene clusters for structurally related natural products from different microorganisms has become practical for comparative analysis of these systems. Deep annotation provides adequate information to develop hypotheses regarding key gene(s) and their protein products. This in turn guides experimental strategies to explore unusual biotransformation(s) of interest using genetic and/or biochemical approaches. Although considerable information can be gleaned from biosynthetic pathway mining and annotation, putative biochemical function can only be verified by analysis of the gene product in vitro using natural or suitable model substrates.
DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 (A) Structures of (±)-notoamide A ((±)-1), paraherquamide A (2), and malbrancheamide (3). The unique structural features in 2 and 3 compared to 1 are highlighted in dashed boxes; (B) Proposed formation of the antipodal bicyclo[2.2.2]diazaoctane ring systems.
[0009] FIG. 2 —The (−)-notoamide A (not), (+)-notoamide A (not′), paraherquamide (phq), and malbrancheamide (mal) biosynthetic gene clusters identified from genome sequencing and bioinformatic mining of Aspergillus sp. MF297-2, Aspergillus versicolor NRRL35600 , P. fellutanum ATCC20841, and M. aurantiaca RRC1813, respectively. Homology of open reading frames across gene clusters is shown by same colored arrows. The not and not′ genes in the red box are unlikely involved in notoamide biosynthesis.
[0010] FIG. 3 —Proposed biosynthetic pathway for antipodal notoamide metabolites.
[0011] FIG. 4 —Proposed biosynthetic pathway for paraherquamide A.
[0012] FIG. 5 —Proposed biosynthetic pathway for malbrancheamide natural products.
[0013] FIG. 6 —Summary of divergent NRPS strategies that culminate in the formation of structurally related bicyclo[2.2.2]diazaoctane ring systems in distinct oxidation states.
[0014] FIGS. 7 A- 7 C—Sequence Table showing correlation between sequence identification numbers and specific open reading frames.
SUMMARY OF THE INVENTION
[0015] The disclosure provides a host cell that produces a prenylated indole alkaloid.
[0016] The disclosure provides a host cell transformed with one or more polynucleotides selected from the group consisting of: a polynucleotide encoding SEQ ID NO: 3 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 3 having MalA activity; a polynucleotide encoding SEQ ID NO: 5 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 5 having MalB activity; a polynucleotide encoding SEQ ID NO: 7 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 7 having MalC activity; a polynucleotide encoding SEQ ID NO: 9 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 9 having MalD activity; a polynucleotide encoding SEQ ID NO: 11 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 11 having MalE activity; a polynucleotide encoding SEQ ID NO: 13 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 13 having MalF activity, and a polynucleotide encoding SEQ ID NO: 15 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 15 having MalG activity.
[0017] The disclosure further provides a host cell transformed with one or more polynucleotides selected from the group consisting of: a polynucleotide encoding SEQ ID NO: 18 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 18 having NotA activity; a polynucleotide encoding SEQ ID NO: 20 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 20 having NotB activity; a polynucleotide encoding SEQ ID NO: 22 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 22 having NotC activity; a polynucleotide encoding SEQ ID NO: 24 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 24 having NotD activity; a polynucleotide encoding SEQ ID NO: 26 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 26 having NotE activity; a polynucleotide encoding SEQ ID NO: 28 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 28 having NotF activity; a polynucleotide encoding SEQ ID NO: 30 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 30 having NotG activity; a polynucleotide encoding SEQ ID NO: 32 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 32 having NotH activity; a polynucleotide encoding SEQ ID NO: 34 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 34 having NotI activity; a polynucleotide encoding SEQ ID NO: 36 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 36 having NotJ activity; a polynucleotide encoding SEQ ID NO: 38 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 38 having NotK activity; a polynucleotide encoding SEQ ID NO: 40 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 40 having NotL activity; a polynucleotide encoding SEQ ID NO: 42 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 42 having NotM activity; a polynucleotide encoding SEQ ID NO: 44 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 44 having NotN activity; a polynucleotide encoding SEQ ID NO: 46 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 46 having NotO activity; a polynucleotide encoding SEQ ID NO: 48 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 48 having NotP activity; a polynucleotide encoding SEQ ID NO: 50 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 50 having NotQ activity, and a polynucleotide encoding SEQ ID NO: 52 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 52 having NotR activity.
[0018] The disclosure further provides a host cell transformed with one or more polynucleotides selected from the group consisting of: a polynucleotide encoding SEQ ID NO: 55 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 55 having phqA activity; a polynucleotide encoding SEQ ID NO: 57 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 57 having phqB activity; a polynucleotide encoding SEQ ID NO: 59 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 59 having phqC activity; a polynucleotide encoding SEQ ID NO: 61 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 61 having phqD activity; a polynucleotide encoding SEQ ID NO: 63 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 63 having phqE activity; a polynucleotide encoding SEQ ID NO: 65 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 65 having phqF activity; a polynucleotide encoding SEQ ID NO: 67 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 67 having phqG activity; a polynucleotide encoding SEQ ID NO: 69 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 69 having phD2 activity; a polynucleotide encoding SEQ ID NO: 71 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 71 having phqI activity; a polynucleotide encoding SEQ ID NO: 73 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 73 having phqJ activity; a polynucleotide encoding SEQ ID NO: 75 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 75 having phqK activity; a polynucleotide encoding SEQ ID NO: 77 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 77 having phqL activity; a polynucleotide encoding SEQ ID NO: 79 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 79 having phqM activity; a polynucleotide encoding SEQ ID NO: 81 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 81 having phqN activity, and a polynucleotide encoding SEQ ID NO: 83 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 83 having phqO activity.
[0019] The disclosure also provides a host cell transformed with one or more polynucleotides selected from the group consisting of: a polynucleotide encoding SEQ ID NO: 3 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 3 having MalA activity, a polynucleotide encoding SEQ ID NO: 5 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 5 having MalB activity; a polynucleotide encoding SEQ ID NO: 7 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 7 having MalC activity; a polynucleotide encoding SEQ ID NO: 9 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ D NO: 9 having MalD activity; a polynucleotide encoding SEQ ID NO: 11 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 11 having MalE activity; a polynucleotide encoding SEQ ID NO: 13 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 13 having MalF activity; a polynucleotide encoding SEQ ID NO: 15 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 15 having MalG activity; a polynucleotide encoding SEQ ID NO: 18 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 18 having NotA activity; a polynucleotide encoding SEQ ID NO: 20 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 20 having NotB activity; a polynucleotide encoding SEQ ID NO: 22 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 22 having NotC activity; a polynucleotide encoding SEQ ID NO: 24 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 24 having NotD activity; a polynucleotide encoding SEQ ID NO: 26 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 26 having NotE activity; a polynucleotide encoding SEQ ID NO: 28 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 28 having NotF activity; a polynucleotide encoding SEQ ID NO: 30 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 30 having NotG activity; a polynucleotide encoding SEQ ID NO: 32 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 32 having NotH activity; a polynucleotide encoding SEQ ID NO: 34 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 34 having NotI activity; a polynucleotide encoding SEQ ID NO: 36 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 36 having NotJ activity; a polynucleotide encoding SEQ ID NO: 38 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 38 having NotK activity; a polynucleotide encoding SEQ ID NO: 40 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 40 having NotL activity; a polynucleotide encoding SEQ ID NO: 42 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 42 having NotM activity; a polynucleotide encoding SEQ ID NO: 44 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 44 having NotN activity; a polynucleotide encoding SEQ ID NO: 46 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 46 having NotO activity; a polynucleotide encoding SEQ ID NO: 48 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 48 having NotP activity; a polynucleotide encoding SEQ ID NO: 50 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 50 having NotQ activity; a polynucleotide encoding SEQ ID NO: 52 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 52 having NotR activity; a polynucleotide encoding SEQ ID NO: 55 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 55 having phqA activity; a polynucleotide encoding SEQ ID NO: 57 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 57 having phqB activity; a polynucleotide encoding SEQ ID NO: 59 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 59 having phqC activity; a polynucleotide encoding SEQ ID NO: 61 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 61 having phqD activity; a polynucleotide encoding SEQ ID NO: 63 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 63 having phqE activity; a polynucleotide encoding SEQ ID NO: 65 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 65 having phqF activity; a polynucleotide encoding SEQ ID NO: 67 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 67 having phqG activity; a polynucleotide encoding SEQ ID NO: 69 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 69 having phD2 activity; a polynucleotide encoding SEQ ID NO: 71 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 71 having phqI activity; a polynucleotide encoding SEQ ID NO: 73 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 73 having phqJ activity; a polynucleotide encoding SEQ ID NO: 75 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 75 having phqK activity; a polynucleotide encoding SEQ ID NO: 77 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 77 having phqL activity; a polynucleotide encoding SEQ ID NO: 79 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 79 having phqM activity; a polynucleotide encoding SEQ ID NO: 81 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 81 having phqN activity, and a polynucleotide encoding SEQ ID NO: 83 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 83 having phqO activity.
[0020] The disclosure also provides a MalA protein having the amino acid sequence set out in SEQ ID NO: 3 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 3 having MalA activity.
[0021] The disclosure also provides a MalB protein having the amino acid sequence set out in SEQ ID NO: 5 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 5 having EtuA2 activity.
[0022] The disclosure also provides a MalC protein having the amino acid sequence set out in SEQ ID NO: 7 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 7 having MalC activity.
[0023] The disclosure also provides a MalD protein having the amino acid sequence set out in SEQ ID NO: 9 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 9 having MalD activity.
[0024] The disclosure also provides a MalE protein having the amino acid sequence set out in SEQ ID NO: 11 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 11 having MalE activity.
[0025] The disclosure also provides a MalF protein having the amino acid sequence set out in SEQ ID NO: 13 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 13 having MalF activity.
[0026] The disclosure also provides a MalG protein having the amino acid sequence set out in SEQ ID NO: 15 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 15 having MalG activity.
[0027] The disclosure also provides a NoA protein having the amino acid sequence set out in SEQ ID NO: 18 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 18 having NotA activity.
[0028] The disclosure also provides a NotB protein having the amino acid sequence set out in SEQ ID NO: 20 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 20 having NotB activity.
[0029] The disclosure also provides a NotC protein having the amino acid sequence set out in SEQ ID NO: 22 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 22 having NotC activity.
[0030] The disclosure also provides a NotD protein having the amino acid sequence set out in SEQ ID NO: 24 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 24 having NotD activity.
[0031] The disclosure also provides a NotE protein having the amino acid sequence set out in SEQ ID NO: 26 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 26 having NotE activity.
[0032] The disclosure also provides a NotF protein having the amino acid sequence set out in SEQ ID NO: 28 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 28 having NotF activity.
[0033] The disclosure also provides a NotG protein having the amino acid sequence set out in SEQ ID NO: 30 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 30 having NotG activity.
[0034] The disclosure also provides a NotH protein having the amino acid sequence set out in SEQ ID NO: 32 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 32 having NotH activity.
[0035] The disclosure also provides a NotI protein having the amino acid sequence set out in SEQ ID NO: 34 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 34 having NotI activity.
[0036] The disclosure also provides a NotJ protein having the amino acid sequence set out in SEQ ID NO: 36 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 36 having NotJ activity
[0037] The disclosure also provides a NotK protein having the amino acid sequence set out in SEQ ID NO: 38 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 38 having NotK activity
[0038] The disclosure also provides a NotL protein having the amino acid sequence set out in SEQ ID NO: 40 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 40 having NotL activity.
[0039] The disclosure also provides a NotM protein having the amino acid sequence set out in SEQ ID NO: 42 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 42 having NotM activity.
[0040] The disclosure also provides a NotN protein having the amino acid sequence set out in SEQ ID NO: 44 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 44 having NotN activity.
[0041] The disclosure also provides a NotO protein having the amino acid sequence set out in SEQ ID NO: 46 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 46 having EtuT activity.
[0042] The disclosure also provides a NotP protein having the amino acid sequence set out in SEQ ID NO: 48 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 48 having NotP activity.
[0043] The disclosure also provides a NotQ protein having the amino acid sequence set out in SEQ ID NO: 50 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 50 having NotQ activity.
[0044] The disclosure also provides a NotR protein having the amino acid sequence set out in SEQ ID NO: 52 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 52 having NotR activity.
[0045] The disclosure also provides a phqA protein having the amino acid sequence set out in SEQ ID NO: 55 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 24 having phqA activity.
[0046] The disclosure also provides a phqB protein having the amino acid sequence set out in SEQ ID NO: 57 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more dentical to SEQ ID NO: 57 having phqB activity.
[0047] The disclosure also provides a phqC protein having the amino acid sequence set out in SEQ ID NO: 59 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 59 having phqC activity.
[0048] The disclosure also provides a phqD protein having the amino acid sequence set out in SEQ ID NO: 61 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 61 having phqD activity.
[0049] The disclosure also provides a phqE protein having the amino acid sequence set out in SEQ ID NO: 63 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 63 having phqE activity.
[0050] The disclosure also provides a phqF protein having the amino acid sequence set out in SEQ ID NO: 65 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 65 having phqF activity.
[0051] The disclosure also provides a phqG protein having the amino acid sequence set out in SEQ ID NO: 67 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 67 having phqH activity
[0052] The disclosure also provides a phqH protein having the amino acid sequence set out in SEQ ID NO: 69 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 69 having phqH activity
[0053] The disclosure also provides a phqI protein having the amino acid sequence set out in SEQ ID NO: 71 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 71 having phqI activity.
[0054] The disclosure also provides a phqJ protein having the amino acid sequence set out in SEQ ID NO: 73 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 73 having phqJ activity.
[0055] The disclosure also provides a phqK protein having the amino acid sequence set out in SEQ ID NO: 75 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 75 having phqK activity.
[0056] The disclosure also provides a phqL protein having the amino acid sequence set out in SEQ ID NO: 77 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 77 having phqL activity.
[0057] The disclosure also provides a phqM protein having the amino acid sequence set out in SEQ ID NO: 79 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 79 having phqM activity.
[0058] The disclosure also provides a phqN protein having the amino acid sequence set out in SEQ ID NO: 81 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 81 having phqN activity.
[0059] The disclosure also provides a phqO protein having the amino acid sequence set out in SEQ ID NO: 83 or a protein 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more identical to SEQ ID NO: 83 having phqO activity.
[0060] The disclosure also provides a polynucleotide set out in SEQ ID NO: 2 or a polynucleotide 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more homologous thereto.
[0061] The disclosure also provides a polynucleotide set out in SEQ ID NO: 4 or a polynucleotide 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more homologous thereto.
[0062] The disclosure also provides a polynucleotide set out in SEQ ID NO: 6 or a polynucleotide 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more homologous thereto.
[0063] The disclosure also provides a polynucleotide set out in SEQ ID NO: 8 or a polynucleotide 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more homologous thereto.
[0064] The disclosure also provides a polynucleotide set out in SEQ ID NO: 10 or a polynucleotide 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more homologous thereto.
[0065] The disclosure also provides a polynucleotide set out in SEQ ID NO: 12 or a polynucleotide 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more homologous thereto.
[0066] The disclosure also provides a polynucleotide set out in SEQ ID NO: 14 or a polynucleotide 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more homologous thereto.
[0067] The disclosure also provides a polynucleotide set out in SEQ ID NO: 17 or a polynucleotide 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more homologous thereto.
[0068] The disclosure also provides a polynucleotide set out in SEQ ID NO: 19 or a polynucleotide 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more homologous thereto.
[0069] The disclosure also provides a polynucleotide set out in SEQ ID NO: 21 or a polynucleotide 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more homologous thereto.
[0070] The disclosure also provides a polynucleotide set out in SEQ ID NO: 23 or a polynucleotide 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more homologous thereto.
[0071] The disclosure also provides a polynucleotide set out in SEQ ID NO: 25 or a polynucleotide 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more homologous thereto.
[0072] The disclosure also provides a polynucleotide set out in SEQ ID NO: 27 or a polynucleotide 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more homologous thereto.
[0073] The disclosure also provides a polynucleotide set out in SEQ ID NO: 29 or a polynucleotide 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more homologous thereto.
[0074] The disclosure also provides a polynucleotide set out in SEQ ID NO: 31 or a polynucleotide 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more homologous thereto.
[0075] The disclosure also provides a polynucleotide set out in SEQ ID NO:33 or a polynucleotide 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more homologous thereto.
[0076] The disclosure also provides a polynucleotide set out in SEQ ID NO:35 or a polynucleotide 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more homologous thereto.
[0077] The disclosure also provides a polynucleotide set out in SEQ ID NO:37 or a polynucleotide 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more homologous thereto.
[0078] The disclosure also provides a polynucleotide set out in SEQ ID NO: 39 or a polynucleotide 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more homologous thereto.
[0079] The disclosure also provides a polynucleotide set out in SEQ ID NO: 41 or a polynucleotide 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more homologous thereto.
[0080] The disclosure also provides a polynucleotide set out in SEQ ID NO: 43 or a polynucleotide 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more homologous thereto.
[0081] The disclosure also provides a polynucleotide set out in SEQ ID NO: 45 or a polynucleotide 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more homologous thereto.
[0082] The disclosure also provides a polynucleotide set out in SEQ ID NO: 47 or a polynucleotide 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more homologous thereto.
[0083] The disclosure also provides a polynucleotide set out in SEQ ID NO: 49 or a polynucleotide 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more homologous thereto.
[0084] The disclosure also provides a polynucleotide set out in SEQ ID NO: 51 or a polynucleotide 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more homologous thereto.
[0085] The disclosure also provides a polynucleotide set out in SEQ ID NO: 54 or a polynucleotide 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more homologous thereto.
[0086] The disclosure also provides a polynucleotide set out in SEQ ID NO: 56 or a polynucleotide 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more homologous thereto.
[0087] The disclosure also provides a polynucleotide set out in SEQ ID NO: 58 or a polynucleotide 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more homologous thereto.
[0088] The disclosure also provides a polynucleotide set out in SEQ ID NO: 60 or a polynucleotide 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more homologous thereto.
[0089] The disclosure also provides a polynucleotide set out in SEQ ID NO: 62 or a polynucleotide 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more homologous thereto.
[0090] The disclosure also provides a polynucleotide set out in SEQ ID NO: 64 or a polynucleotide 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more homologous thereto.
[0091] The disclosure also provides a polynucleotide set out in SEQ ID NO: 66 or a polynucleotide 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more homologous thereto.
[0092] The disclosure also provides a polynucleotide set out in SEQ ID NO:68 or a polynucleotide 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more homologous thereto.
[0093] The disclosure also provides a polynucleotide set out in SEQ ID NO: 70 or a polynucleotide 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more homologous thereto.
[0094] The disclosure also provides a polynucleotide set out in SEQ ID NO: 72 or a polynucleotide 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more homologous thereto.
[0095] The disclosure also provides a polynucleotide set out in SEQ ID NO: 74 or a polynucleotide 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more homologous thereto.
[0096] The disclosure also provides a polynucleotide set out in SEQ ID NO: 76 or a polynucleotide 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more homologous thereto.
[0097] The disclosure also provides a polynucleotide set out in SEQ ID NO: 78 or a polynucleotide 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more homologous thereto.
[0098] The disclosure also provides a polynucleotide set out in SEQ ID NO: 80 or a polynucleotide 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more homologous thereto.
[0099] The disclosure also provides a polynucleotide set out in SEQ ID NO: 82 or a polynucleotide 98% or more, 97% or more, 96% or more, 95% or more, 90% or more, 85% or more, 80% or more, or 75% or more homologous thereto.
[0100] The disclosure also provides a polynucleotide encoding a protein of any one of the polynucleotides of the disclosure.
[0101] The disclosure also provides an expression vector comprising a polynucleotide of the disclosure.
[0102] The disclosure also provides a host cell transformed with an expression vector of the disclosure or a polynucleotide of the disclosure.
[0103] The disclosure also provides a method for producing prenylated indole alkaloid or a metabolic intermediate for producing a prenylated indole alkaloid comprising the step of growing a host cell of the disclosure under conditions to express the protein encoded by the transformed polynucleotide and producing a prenylated indole alkaloid or the metabolic intermediate for producing a prenylated indole alkaloid. In various aspects, the method further comprises the step of isolating the prenylated indole alkaloid or the metabolic intermediate of the prenylated indole alkaloid. In various aspects, the host cell is a prokaryote. In various aspects, the host cell is selected from the group consisting of E. coli, Streptomyces lavendulae, Myxococcus xanthus , and Pseudomonas fluorescens.
DESCRIPTION OF THE INVENTION
[0104] “Sequence identity” means that two amino acid or polynucleotide sequences are identical over a region of comparison, such as a region of at least about 250 residues or bases. Optionally, the region of identity spans at least about 100-500 residues or bases, and spans the active domain of the polypeptide. Several methods of conducting sequence alignment are known in the art and include, for example, the homology alignment algorithm (Needleman & Wunsch, J. Mol. Biol., 48, 443 (1970)); the local homology algorithm (Smith & Waterman, Adv. Appl. Math., 2, 482 (1981)); and the search for similarity method (Pearson & Lipman, Proc. Natl. Acad. Sci. USA, 85, 2444 (1988)). Preferably, the algorithm used to determine percent sequence identity and sequence similarity is the BLAST algorithm (Altschul et al., J. Mol. Biol., 215, 403-410 (1990); Henikoff & Henikoff. Proc. Natl. Acad. Sci. USA, 89, 10915 (1989); Karlin & Altschul, Proc. Natl. Acad. Sci. USA, 90, 5873-5787 (1993)). Software for performing BLAST analyses is publicly available through the National Center for Biotechnology Information. Other examples of alignment software, including GAP, BESTFIT, FASTA, PILEUP, and TFASTA provided by Wisconsin Genetics Software Package (Genetics Computer Group, 575 Science Dr., Madison, Wis.), and CLUSTALW (Thompson et al., Nuc. Acids Res., 22, 4673-4680 (1994); http://www.ebi.ac.uk/Tools/clustalw2/index.html), are known in the art. The degree of homology (percent identity) between a native and a mutant sequence may be determined, for example, by comparing the two sequences using computer programs commonly employed for this purpose. Briefly, the GAP program defines identity as the number of aligned symbols (i.e., nucleotides or amino acids) which are identical, divided by the total number of symbols in the shorter of the two sequences. The default parameters for the GAP program include: (1) a unary comparison matrix (containing a value of 1 for identities and 0 for non-identities) for nucleotides, and the weighted comparison matrix of Gribskov and Burgess, Nucl. Acids Res. 14:6745, 1986, as described by Schwartz and Dayhoff, eds., Atlas of Protein Sequence and Structure, National Biomedical Research Foundation, pp. 353-358, 1979; (2) a penalty of 3.0 for each gap and an additional 0.10 penalty for each symbol in each gap; and (3) no penalty for end gaps.
[0105] Alterations of the native amino acid sequence may be accomplished by any of a number of known techniques. Mutations can be introduced at particular loci by synthesizing oligonucleotides containing a mutant sequence, flanked by restriction sites enabling ligation to fragments of the native sequence. Following ligation, the resulting reconstructed sequence encodes an analog having the desired amino acid insertion, substitution, or deletion.
[0106] Alternatively, oligonucleotide-directed site-specific mutagenesis procedures can be employed to provide an altered gene having particular codons altered according to the substitution, deletion, or insertion required. Techniques for making such alterations include those disclosed by Walder et al. (Gene 42:133, 1986); Bauer et al. (Gene 37:73, 1985); Craik (BioTechniques, January 1985, 12-19); Smith et al. (Genetic Engineering: Principles and Methods, Plenum Press, 1981); and U.S. Pat. Nos. 4,518,584 and 4,737,462, which are incorporated by reference herein.
[0107] The disclosure provides an example of the comparative analysis of biosynthetic gene clusters (mined from the whole genome) and pathways for structurally related fungal indole alkaloids bearing the unusual bicyclo[2.2.2]diazaoctane core, including the anticancer agents (−)-notoamide A ((−)-1) and (+)-notoamide A ((+)-1), 35,36 the anthelmintic paraherquamide A (2), 37-39 and the calmodulin-inhibitor malbrancheamide 40-42 (3) ( FIG. 1A ) produced by Aspergillus sp. MF297-2, 43 Aspergillus versicolor NRRL35600, Penicillium fellutanum ATCC20841, and Malbranchea aurantiaca RRC1813, respectively. These fungal natural products are assembled from an L-tryptophan, a second cyclic amino acid residue, and one or two isoprene units through biosynthetic pathways that are proposed to feature an intriguing intramolecular Diels Alderase (IMDAse), and a number of unique enantiomerically selective enzymes. 44-49 The diverse bioactivities of this natural product family suggests that elucidation of their biosynthesis could direct future structural diversification via biosynthetic engineering, thereby leading to enhanced biological activities.
[0108] This comparative analysis provides significant insights into a number of intriguing biosynthetic questions: (1) which enzyme in each pathway is likely responsible for the formation of the bicyclo[2.2.2]diazaoctane core via the proposed intramolecular [4+2] Diels-Alder (IMDA) cyclization; (2) which enzyme in the pathway of 1 and 2 installs the spiro-oxindole functionality via a putative epoxide-initiated Pinacol-type rearrangement; and (3) what genetic difference controls formation of the dioxopiperazine in 1 versus the monooxopiperazine in 2 and 3.
[0109] The most significant structural similarity between 1-3 is the bicyclo[2.2.2]diazaoctane core ( FIG. 1A ). Biosynthetically, this unique structural moiety was proposed to arise from a [4+2] IMDA reaction (FIG. 1 B). 44,46 This presumed cycloaddition reaction is also believed to catalyze the first enantiodivergent step in an otherwise common biosynthetic pathway from Aspergillus sp. MF297-2 and A. versicolor NRRL35600, leading to formation of (−)-1 and (+)-1, respectively, together with several other enantiomeric metabolites (FIG. 3 ). 47 Currently, it remains unknown whether a specific IMDAse indeed exists in these biosynthetic pathways. However, if it does exist, one would expect its encoding gene should be present in all four gene clusters. Second, the spiro-oxindole is absent in 3, suggesting the responsible enzyme is likely absent from the pathway for 3, and present in those for 1 and 2. Third, a specific reductase responsible for reducing the tryptophan carbonyl group would be expected in the gene cluster of 2 and 3, but not 1. This genetic difference would account for the lack of the second amide carbonyl group in the piperazine ring of 2 and 3. Finally, the different hydroxylation status of the indole amide, distinct aromatic decoration among 1-3, together with other unique structural features including the tailoring of the proline moiety and N-methylation in 2, are also expected to be reflected at the genetic level.
[0110] The following examples are provided to illustrate particular embodiments of the present invention, and are not to be construed as limiting the scope of the invention.
Example 1
[0111] The genomes of A. versicolor NRRL35600 , P. fellutanum ATCC20841, and M. aurantiaca RRC1813A harboring not′, phq, and mal gene clusters, respectively were sequenced to approximately 99, 84, and 181 times coverage of their estimated genome size (35 Mb), using the Illumina Solexa technology (Genome Analyzer IIx).
[0112] First, the key biosynthetic gene notE′ (Table 1) encoding a non-ribosomal peptide synthetase (NRPS) was mined from the genome sequences using the notE DNA sequence from the reported not gene cluster 43 as a probe for homologous genes. NotE′, which shows 79% identity and 86% similarity to NotE at the amino acid (AA) level, was predicted to be a bimodular NRPS with the A-T-C-A-T-C (A: adenylation, T: thiolation, C: condensation) domain organization using the PKS/NRPS Analyzer (http://nrps.igs.umaryland.edu/nrps/). Genome walking from notE′ toward 5′ and 3′ ends identified another nine genes (notA′-J′, Table 1 and FIG. 2 ) that display high AA sequence similarity (>70%) with corresponding gene products of the not gene cluster. Notably, the overall nucleotide identity between notA′-J′ (25,440 bp) and notA-J (26,210 bp) is 71%, which is not surprising since both metabolic pathways are responsible for assembling “identical”, yet antipodal compounds. In addition to the high sequence similarity, the genetic architecture (i.e. order and direction of genes) within this region is identical in the two clusters ( FIG. 2 ). The pattern of the exon/intron arrangement in the corresponding genes is also highly similar to each other (see Supplementary Information). In contrast, the sequence similarity is reduced drastically and the gene architecture differs after notK′/notK (Table 1, FIG. 2 ), strongly suggesting the previously assigned not gene cluster (notA-R) probably ends at notJ.
[0113] At the genetic level, it is not possible to glean the key differences that account for production of antipodal notoamide metabolites, suggesting that subtle active site sequence variation in those enantiomerically selective enzymes play a critical role in the control of absolute chirality. This requires direct biochemical analysis of the key notoamide biosynthetic enzymes, including structural biology efforts, which is currently ongoing in our laboratories.
[0114] Second, the paraherquamide (phq) gene cluster (47,884 bp) was identified from the partially assembled P. fellutanum genome by using a select group of not genes including the NRPS gene notE, the prenyltransferase genes notC and notF, and the P450 monooxygenase gene notG as in silico probes. 43 Fifteen genes were identified that are likely involved in paraherquamide biosynthesis. The largest number of biosynthetic genes among the four studied metabolic pathways is consistent with 2 as the most complex structure compared to 1 and 3. Comparative bioinformatic analysis demonstrates that nine (phqA, B, F, G, H, J, K, L, and M) out of fifteen total phq genes are homologous to corresponding not genes (Table 1), although their homology is significantly lower than that between not and not′ genes. Notably, the bimodular phqB NRPS gene is different from notE in that a reductase (R) domain is located at its carboxy terminus instead of a condensation (C) domain, which is found in notE and notE′. This difference is significant because the reductase (vs condensation) domain is presumed to account for the presence of the monooxopiperazine in 2 (vs dioxopiperazine in 1) (see below). 50 Among the remaining six cluster-specific genes, phqC shows high sequence similarity to 2-oxoglutarate (2OG) and Fe(II) dependent oxygenases. 51,52 The phqD and phqE genes, which putatively encoding a pyrroline-5-carboxylate reductase and a short chain dehydrogenase, respectively, might be involved in the formation of the β-methyl-proline starter unit. The phqI gene that encodes the third prenyltransferase in phq is unique as it is free of introns, and therefore, distinct from the single intron-containing prenyltransferase genes phqA/notC and phqJ/notF. It is worth noting that the presence of three prenyltransferase genes is inconsistent with the two isoprene groups incorporated into the structure of 2. Thus, it is of special interest to examine whether the third prenyltransferase gene is redundant or plays an alternative, and as yet unknown function in the biosynthesis of 2. Furthermore, phqN is predicted to function as a methyltransferase, likely responsible for the N-methylation in 2. Finally, the phqO P450 gene with a unique exon/intron organization pattern is hypothesized to catalyze the C14 hydroxylation of the β-methyl-proline moiety.
[0115] Third, the seven-gene containing mal gene cluster (20179 bp) was mined from the genome of Malbranchea aurantiaca RRC1813A using phqB as an in silico probe to identify the metabolic system for 3. It has the smallest size among gene clusters of 1-3, which is consistent with the simplest structure and corresponding biosynthetic pathway. The genes malB, malD, malE, malF, and malG are common to the four gene clusters. Thus, except for the regulatory gene of malD (homologous to notA, notA′ and phqG), the remaining four biosynthetic genes (and their homologues in not, not′ and phq) are possibly responsible for installing the shared structural features of 1-3. This strongly suggests that the hypothetical Diels Alderase (if extant) should be represented by one of these four gene products (see below). Interestingly, the mal genes show greater sequence similarity to phq genes than not (or not′) genes, perhaps indicating their closer evolutionary relationship. Similar to PhqB, the NRPS MalG harbors a reductase domain at its carboxy terminus, which is consistent with the monooxopiperazine moiety in 3. Again, the apparent redundancy of the second prenyltransferase (3 only contains one isoprene group) is difficult to rationalize, but genetic disruption or RNA silencing (malB or malE) efforts are likely to shed light on the individual role of these enzymes. Finally, it is evident that the flavin-dependent halogenase MalA is likely involved in the introduction of one or both chlorine atoms in the biosynthesis of 3.
Example 2
[0116] Since the discovery of the biosynthetic gene cluster of (−)-1 from marine Aspergillus sp. MF297-2, in vitro biochemical characterization of the reverse prenyltransferase NotF using the NRPS (NotE) product brevianamide F 53 (4) as substrate and the normal prenyltransferase NotC using 6-hydroxy-deoxybrevianamide E (6) as substrate has partially established the early steps of the notoamide pathway leading to notoamide S (7) (FIG. 3 ). 43 The P450 monooxygenase NotG is likely catalyzing the C6 indole hydroxylation since its close homologue FtmC (59%/72% identity/similarity) in fumitremorgin biosynthesis had been characterized to hydroxylate the analogous aromatic C—H bond in the indole ring of tryprostatin B, 54,55 which is structurally similar to deoxybrevianamide E (5). 56
[0117] As the proposed pivotal branching point in notoamide biosynthesis, 47,57,58 7 can be diverted to notoamide E (8) through an oxidative pyran ring closure putatively catalyzed by either NotH P450 monooxygenase (based on precedented examples of pyran ring formation from the epoxide intermediate generated by P450 enzymes 59 ), or the NotD oxidoreductase. This step would be followed by an indole 2,3-epoxidation-initiated Pinacol-like rearrangement catalyzed by NotB FAD monooxygenase (FMO) leading to the formation of notoamide C (9) and notoamide D (10). 58 Notably, notB (or notB′) is only observed in the not (or not′) gene cluster, consistent with the fact that this branching pathway leading to natural products 9 and 10 is only observed in notoamide biosynthesis.
[0118] On the other hand, extensive precursor feeding and incorporation studies using stable isotopically labeled intermediates have supported 7 as the substrate for the hypothetical IMDA. 47 As a working hypothesis, a two-electron oxidation catalyzed by an oxidase would give rise to the achiral azadiene intermediate (11), which may immediately undergo a spontaneous stereoselective [4+2] IMDA cyclization in the active site of the same oxidase, yielding either (+)-notoamide T ((+)-12) in Aspergillus sp. MF297-2 or (−)-notoamide T ((−)-12) in A. versicolor . The opposing conformation (endo/exo) assumed by achiral 11 presumably determined by the scaffolding of each putative Diels-Alderase might account for the enantio-divergence at this key step. The five oxidases encoded by the not gene cluster, include FMO NotB and NotI, P450 enzymes NotG and NotH, and the FAD-dependent oxidoreductase NotD. NotB was recently identified as the notoamide E oxidase. 58 NotI is highly similar to NotB with 42% protein sequence identity and 59% similarity, and is predicted to catalyze a similar conversion from (+)-stephacidin A 60 ((+)-13) to (−)-notoamide B ((−)-14) via the 2,3-epoxidation of (+)-13 followed by a Pinacol-type rearrangement. Thus, if the putative function of NotG (see above) is correct, NotH (or NotD) is likely the bifunctional oxidase that also functions as the IMDAse responsible for generation of (+)-12. To generate antipodal (−)-12, NotH′ (or NotD′) is expected to catalyze a Diels Alder reaction leading to the opposite stereochemistry. Currently, this hypothesis is being tested in our laboratories through in vitro characterization of NotH/NotH′ (or NotD/NotD′). With comparative analysis of four gene clusters (Table 1), it appears that NotD/NotD′ is more likely to serve as the IMDAse since its homologs (PhqH and MalF) are present in all clusters. This hypothesis is based on the assumption that these four biosynthetic pathways use the same type of protein scaffolding enzyme to catayze the [4+2] cyclo addition. However, we have recently begun to challenge this assumption (see below). Presently, the possibility that NotH/NotH′ functions as the IMDAse in notoamide biosynthesis cannot be excluded. Once its identity is determined, the final oxidase NotD (or NotH) will likely be found to catalyze the oxidative pyran ring formation ( FIG. 3 ).
[0119] Another important fact of these two related notoamide pathways is that enzymes catalyzing the biosynthetic steps after formation of 12 must also be enantiomerically and diastereochemically selective. Specifically, in previous precursor incorporation studies of racemic 13 C-labeled (±)-13 with Aspergillus sp. MF297-2 and A. versicolor, 61 it was ascertained that only one enantiomer of 13 can be processed (currently presumed by NotI and NotI') to form downstream products. Understanding the subtle differences between these two enzymes will likely provide significant insights into how related enzymes have evolved to adopt opposing enantiomeric selectivity.
[0120] Finally, it remains unclear which enzyme could be responsible for the final hydroxylation steps leading to notoamide A (1) and sclerotiamide 62 (15) since all five oxidative enzymes in the not(′) gene cluster has been assigned a putative function. It is possible that 1 and 15 are opportunistically produced upon the activity of unknown oxidases whose genes reside outside of the defined notoamide gene cluster. Alternatively, the possibility that a not oxidase may possess bi-functionality cannot be excluded.
Example 3
[0121] Previous feeding studies demonstrated that L-isoleucine is the precursor to the β-methyl-β-hydroxy proline moiety in 2. 45,63 Identification of the pyrroline-5-carboxylate reductase PhqD and the short chain dehydrogenase PhqE from phq cluster suggests a reasonable pathway from L-isoleucine to β-methyl proline ( FIG. 4 ). Similar to the partially identified biosynthesis of 4-methyl proline in cyanobacterial Nostoc sp., 64 PhqE presumably oxidizes the terminally hydroxylated L-isoleucine (by an unknown enzyme) to the corresponding aldehyde. Spontaneous cyclization and dehydration would yield the 4-methyl pyrolline-5-carboxylic acid, which is then reduced by PhqD leading to the β-methyl proline precursor.
[0122] The presence of a C-terminal NAD(P)-dependent reductase domain in the bimodular paraherquamide NRPS (A-T-C-A-T-R) clearly indicates that the mechanism for dipeptide release by PhqB must be different from the final condensation domain of NotE (FIG. 3 ). 50 What likely occurs is that the PhqB R domain utilizes NADPH for hydride transfer to reduce the thioester bond of the T domain-tethered linear dipeptide to a hemithioaminal intermediate, which spontaneously cleaves the C—S bond to release the aldehyde product. Subsequently, the acid-activated aldehyde is intramolecularly trapped by the nucleophilic amine from the adjacent amino acid to form a hemiaminal intermediate, which then undergoes a spontaneous dehydration and double bond rearrangement leading to formation of the monooxopiperazine intermediate 16 (likely existing as the enol form) prior to all other biosynthetic steps. This hypothesis is in good agreement with previous observations 65,66 that the dioxopiperazine analog of preparaherquamide (17) cannot be incorporated into 2 by P. fellutanum since all substrates for downstream enzymes should bear the monooxopiperazine ring system. In this scheme ( FIG. 4 ), formation of the diene in 16 is achieved by a reductive process, as opposed to the 2e − oxidation step proposed in the notoamide biosynthetic pathway ( FIG. 3 ). If this is correct, in contrast to an oxidase (NotH/NotH′ or NotD/NotD′) proposed to be the Diels Alderase in notoamide biosynthesis, the reverse prenyltransferase (proposed to be PhqJ) might act as the scaffold for an IMDA reaction after introduction of the reverse prenyl group to 16. In this proposed route, the terminal double bond of the isoprene group would become the dienophile to react with the azadiene in the prenyltransferase active site, thus resulting in formation of the [2.2.2]diazaoctane intermediate 17.
[0123] Following formation of 17, the pyran ring formation is proposed to be installed by PhqA prenyltransferase (22% identical to NotC), PhqL (29% identical to NotG) and PhqH oxidoreductase (34% identical to NotD) (or PhqM P450 enzymes (15% identical to NotH)). The FMO PhqK (32% identical to NotI) is likely responsible for generation of the spiro-oxindole, and the N-methylation is likely mediated by the PhqN methyltransferase leading to the isolable natural product paraherquamide F 38,67 (18). However, the order of these biosynthetic steps cannot be predicted without further in vivo genetic studies and/or in vitro biochemical analysis.
[0124] In late-stage paraherquamide biosynthesis, the third P450 monooxygenase PhqO is probably responsible for the C14 hydroxylation, transforming 18 to paraherquamide G 38,67 (19), and paraherquamide E 38,67 (20) to the final product 2. However, expansion from the 6-membered ring pyran (in 18 and 19) to the 7-membered dioxepin ring (in 2 and 20) represents a poorly understood but intriguing process. Possibly, phqC that encodes a 2OG-Fe(II)-oxygenase is involved in this ring expansion, which is consistent with previous reports showing this class of enzyme functioning as an expandase. 68
[0125] Finally, the biosynthetic genes, including phqI as well as phqM (or phqH, the one uninvolved in the pyran ring formation), do not have a clearly prescribed role and appear to be redundant.
Example 4
[0126] Except for using L-proline instead of β-methyl proline as the starter unit, the biosynthetic route through premalbrancheamide (21) ( FIG. 5 ) is proposed to parallel that of paraherquamide biosynthesis through 17 ( FIG. 4 ). Mediated by NRPS MalG (A-T-C-A-T-R, 37% identical to PhqB) and prenyltransferase MalE (36%/34% identical to NotF/PhqJ), 21 is produced with its structure slightly different from 17 in lacking the C1 methyl group.
[0127] Subsequently, the halogenase MalA presumably chlorinates the C9 position (malbrancheamide numbering) first to afford the isolable natural product malbrancheamide B (22), which could be further chlorinated by MalA at C8 leading to the final product malbrancheamide (3). This putative pathway is partially supported by the previous feeding study showing that the 13 C labeled 21 can be incorporated into 22 by M. aurantiaca. 69 Lack of observed 13 C labeled 3 from the fermentation broth was interpreted to suggest that the second chlorination might be too slow to incorporate detectable levels of 13 C material from 22 to 3. Notably, the order of these two chlorinations seems unexchangeable since the C8-monochloro regioisomer of 22 (C9-monochlorinated) was not detected as a natural product despite considerable effort. 42 It is also possible that the dichloro species, malbrancheamide, arises from a pre-halogenated tryptophan-based assembly.
[0128] Blast (http://blast.ncbi.nlm.nih.gov/) sequence analysis revealed significant homology of MalA to the family of flavin-dependent tryptophan halogenases. 70-73 This result suggests two alternative malbrancheamide biosynthetic pathways. First, MalA could chlorinate tryptophan at C4 and C5 (tryptophan numbering) sequentially prior to being loaded onto the second T domain of MalG. Then, both monochlorinated and dichlorinated tryptophan could be processed by subsequent assembly enzymes, thereby respectively leading to 22 and 3 in parallel. Second, MalA might only monochlorinate the C4 position of tryptophan, resulting in 22. Then, 22 is converted into 3 by either MalA or another unidentified halogenase that resides outside mal. To test these hypotheses, it would be the best to conduct in vitro functional analysis of purified MalA against selected substrates such as L-tryptophan and 22. Alternatively, whether or not the 13 C labeled 22 can be incorporated into 3 in an in vivo precursor feeding study would also provide useful information about the timing of the two chlorination steps in malbrancheamide biosynthesis.
[0129] According to the proposed malbrancheamide biosynthetic pathway ( FIG. 5 ), only three enzymes are required to assemble the final product 3. Inactivation of these seemingly redundant genes including malB, malC, and malF (Table 1) is currently underway. Interestingly, the MalC short chain dehydrogenase related to PhqE, which is presumed to participate in preparation of β-methyl proline starter unit in paraherquamide biosynthesis (see above), is present in the mal gene cluster although apparently unnecessary for malbrancheamide biosynthesis. This implies that malC, together with other redundant genes, might be residuals from ancestral or a horizontally transferred gene cluster (e.g. one analogous to phq). The evolving biosynthetic gene cluster not only recruits new genes, but also eliminates or retains unused genes when facing a diverse living environment and selection pressure during its evolutionary history. 24
[0130] Recently, a novel malbrancheamide-type natural product named spiromalbramide (23) ( FIG. 5 ) was isolated from a marine invertebrate-derived Malbranchea graminicola fungal strain. 74 This new derivative contains the spiro-oxindole moiety that is found in notoamides and paraherquamides, but is absent from malbrancheamides. Based on the comparative analysis of not, not′, phq, and mal gene cluster, we are now capable of predicting that an FMO gene homologous to notI, notI′ or phqK should reside in the uncharacterized biosynthetic gene cluster of 23. So far, the Solexa genome sequencing of M. graminicola has been completed. This prediction will be tested in the near future as soon as the biosynthetic gene cluster is mined and annotated from genome sequences.
Example 5
[0131] In principle, the shared genes from different clusters are responsible for assembling the common structural core among similar natural products. The cluster-specific gene products are presumed to modify these structures by a series of variant tailoring steps, thereby leading to structural diversification. However, it is noteworthy that the redundant genes and multifunctional genes could complicate comparative analysis of gene clusters. Therefore, conclusions can only be unambiguously drawn after genetic and/or biochemical confirmation of enzymatic activities.
[0132] Following these simple but logical principles, we performed a comparative analysis wasperformed for four related gene clusters including not, not′, phq, and mal, based on the proposed complete biosynthetic pathways for (+)/(−)-notoamides, paraherquamides, and malbrancheamides with a biosynthetic enzyme assigned for each individual step ( FIG. 3-5 ). For example, the function of the not-specific gene notB can be readily connected to the pathway specific transformation from notoamide E (8) to notoamide C (9) and D (10). This was recently confirmed by in vitro characterization of NotB FMO enzyme. 58
[0133] Furthermore, detailed comparative analysis resulted in nomination of the oxidases NotH and NotH′ (or NotD and NotD′), and the prenyltransferases PhqJ and MalE as putative Diels-Alderases to catalyze the distinctive IMDA reactions for these pathways. Next, comparative functional analysis of these enzymes in vitro will enable us to test this long standing hypothesis regarding the existence of a Diels-Alderase in the biosynthesis of fungal indole alkaloids with the bicyclo[2.2.2]diazaoctane core. It is striking that Nature has conscripted two evolutionarily related gene cluster paradigms, to construct the novel bicyclo[2.2.2]diazaoctane ring system by vastly different mechanistic protocols ( FIG. 6 ). In one instance, for the notoamides, the net transformation from the NRPS-loaded dipeptide to the bicyclo[2.2.2]diazaoctane core, a net two-electron oxidation is required to reach the key, putative azadiene species required for the proposed IMDA construction. In the other, the paraherquamide and malbrancheamide systems, the NRPS-loaded dipeptide substrate is cleaved in a net two-electron reduction, that we speculate cyclizes and dehydrates to the related (reduced) azadiene species for the homologous IMDA construction. This insight was most readily presented to us, by the analysis of the respective gene cluster annotations, and has provided a very satisfying level of corroboration with labeled precursor incorporation experiments that at first, seemed incongruous. We expect that the tremendous insights that the bioinformatics analyses have provided in these systems, will render understanding the possible biogenesis of these and related natural products more efficient, congruent and intellectually satisfying.
[0134] The foregoing description and examples have been set forth merely to illustrate the invention and are not intended to be limiting. Since modifications of the described embodiments incorporating the spirit and substance of the invention may occur to persons skilled in the art, the invention should be construed broadly to include all variations within the scope of the appended claims and equivalents thereof.
REFERENCES
[0000]
1. J. W.-H. Li and J. C. Vederas, Science, 2009, 325, 161.
2. D. J. Newman and G. M. Cragg, J. Nat. Prod., 2007, 70, 461.
3. R. Li and C. A. Townsend, Metab. Eng., 2006, 8, 240.
4. R. H. Baltz, J. Ind. Microbiol. Biotechnol., 1998, 20, 360.
5. S. Baba, Y. Abe, T. Suzuki, C. Ono, K. Iwamoto, T. Nihira and M. Hosobuchi, Appl.
Microbiol. Biotechnol., 2009, 83, 697.
6. J.-H. Noh, S.-H. Kim, H.-N. Lee, S. Y. Lee and E.-S. Kim, Appl. Microbiol. Biotechnol., 2010, 86, 1145.
7. W. R. Strohl, Metab. Eng., 2001, 3, 4.
8. D. E. Cane, C. T. Walsh and C. Khosla, Science, 1998, 282, 63.
9. C. T. Walsh, ChemBioChem, 2002, 3, 125.
10. C. Sanchez, L. Zhu, A. F. Brana, A. P. Salas, J. Rohr, C. Mendez and J. A. Salas, Proc. Natl. Acad. Sci. U.S.A., 2005, 102, 461.
11. J. Pollier, T. Moses and A. Goossens, Nat. Prod. Rep., 2011, 28, 1897.
12. J. L. Que and W. B. Tolman, Nature, 2008, 455, 333.
13. A. L. Goff, V. Artero, B. Jousselme, P. D. Tran, N. Guillet, R. Métayé, A. Fihri, S. Palacin and M. Fontecave, Science, 2009, 326, 1384.
14. K. T. Watts, B. N. Mijts and C. Schmidt-Dannert, Adv. Synth. Catal., 2005, 347, 927.
15. Y. Xue, L. Zhao, H.-w. Liu and D. H. Sherman, Proc. Natl. Acad. Sci. U.S.A., 1998, 95, 12111.
16. J. C. Carlson, J. L. Fortman, Y. Anzai, S. Li, D. A. Burr and D. H. Sherman, ChemBioChem, 2010, 11, 564.
17. J. D. Kittendorf and D. H. Sherman, Bioorg. Med. Chem., 2009, 17, 2137.
18. J. C. Carlson, S. Li, S. S. Gunatilleke, Y. Anzai, D. A. Burr, L. M. Podust and D. H. Sherman, Nat. Chem., 2011, 3, 628.
19. H. Zhang, B. A. Boghigian, J. Armando and B. A. Pfeifer, Nat. Prod. Rep., 2011, 28, 125.
20. U. Galm and B. Shen, Expert Opin. Drug. Discov., 2006, 1, 409.
21. L. Tang, S. Shah, L. Chung, J. Carney, L. Katz, C. Khosla and B. Julien, Science, 2000, 287, 640.
22. Q. Cheng, L. Xiang, M. Izumikawa, D. Meluzzi and B. S. Moore, Nat. Chem. Biol., 2007, 3, 557.
23. C. J. Balibar, A. R. Howard-Jones and C. T. Walsh, Nat. Chem. Biol., 2007, 3, 584.
24. L. Gu, B. Wang, A. Kulkarni, T. W. Geders, R. V. Grindberg, L. Gerwick, K. Hakansson, P. Wipf, J. L. Smith, W. H. Gerwick and D. H. Sherman, Nature, 2009, 459, 731.
25. Y. Anzai, S. Li, M. R. Chaulagain, K. Kinoshita, J. Montgomery and D. H. Sherman, Chem. Biol., 2008, 15, 950.
26. U. Galm, E. Wendt-Pienkowski, L. Wang, S.-X. Huang, C. Unsin, M. Tao, J. M. Coughlin and B. Shen, J. Nat. Prod., 2011, 74, 526.
27. B. Peant, G. LaPointe, C. Gilbert, D. Atlan, P. Ward and D. Roy, Microbiology, 2005, 151, 1839.
28. K. S. Ryan, PLoS One, 2011, 6, e23694.
29. K. Buntin, H. Irschik, K. J. Weissman, E. Luxenburger, H. Blocher and R. Müller, Chem. Biol., 2010, 17, 342.
30. R. D. Hawkins, G. C. Hon and B. Ren, Nat. Rev. Genet., 2010, 11, 476.
31. M. L. Metzker, Nat. Rev. Genet., 2010, 11, 31.
32. T. J. Treangen and S. L. Salzberg, Nat. Rev. Genet., 2012, 13, 36.
33. C. Shaffer, Nat. Biotechnol., 2007, 25, 149.
34. S. C. Schuster, Nat. Methods, 2008, 5, 16.
35. H. Kato, T. Yoshida, T. Tokue, Y. Nojiri, H. Hirota, T. Ohta, R. M. Williams and S. Tsukamoto, Angew. Chem. Intl. Ed., 2007, 46, 2254.
36. T. J. Greshock, A. W. Grubbs, P. Jiao, D. T. Wicklow, J. B. Gloer and R. M. Williams, Angew. Chem. Intl. Ed., 2008, 47, 3573.
37. M. Yamazaki, E. Okuyama, M. Kobayashi and H. Inoue, Tetrahedron Lett., 1981, 22, 135.
38. J. G. Ondeyka, R. T. Goegelman, J. M. Schaeffer, L. Kelemen and L. Zitano, J. Antibiot., 1990, 43, 1375.
39. R. M. Williams, J. Gao, H. Tsujishima and R. J. Cox, J. Am. Chem. Soc., 2003, 125, 12172.
40. S. Martinez-Luis, R. Rodriguez, L. Acevedo, M. C. Gonzalez, A. Lira-Rocha and R. Mata, Tetrahedron, 2006, 62, 1817.
41. M. Figueroa, M. C. Gonzalez and R. Mata, Nat. Prod. Res., 2008, 22, 709.
42. K. A. Miller, T. R. Welch, T. J. Greshock, Y. Ding, D. H. Sherman and R. M. Williams, J. Org. Chem., 2008, 73, 3116.
43. Y. Ding, J. R. deWet, J. Cavalcoli, S. Li, T. J. Greshock, K. A. Miller, J. M. Finefield, J. D. Sunderhaus, T. J. McAfoos, S. Tsukamoto, R. M. Williams and D. H. Sherman, J. Am. Chem. Soc., 2010, 132, 12733.
44. R. M. Williams and R. J. Cox, Acc. Chem. Res., 2003, 36, 127.
45. E. M. Stocking, J. F. Sanz-Cervera, C. J. Unkefer and R. M. Williams, Tetrahedron, 2001, 57, 5303.
46. E. M. Stocking and R. M. Williams, Angew. Chem. Intl. Ed., 2003, 42, 3078.
47. J. D. Sunderhaus, D. H. Sherman and R. M. Williams, Isr. J. Chem., 2011, 51, 442.
48. A. W. Grubbs, G. D. I. Artman, S. Tsukamoto and R. M. Williams, Angew. Chem. Intl. Ed., 2007, 46, 2257.
49. T. J. Greshock, A. W. Grubbs, S. Tsukamoto and R. M. Williams, Angew. Chem. Intl. Ed., 2007, 46, 2262.
50. T. A. Keating, D. E. Ehmann, R. M. Kohli, C. G. Marshall, J. W. Trauger and C. T. Walsh, ChemBioChem, 2001, 2, 99.
51. N. Steffan, A. Grundmann, S. Afiyatullov, H. Ruan and S.-M. Li, Org. Biomol. Chem., 2009, 7, 4082.
52. R. P. Hausinger, Crit. Rev. Biochem. Mol. Biol., 2004, 39, 21.
53. A. J. Birch and J. J. Wright, J. Chem. Soc. Chem. Commun., 1969, 644.
54. S.-M. Li, J. Antibiot., 2011, 64, 45.
55. N. Kato, H. Suzuki, H. Takagi, H. Kakeya, M. Uramoto, T. Usui, S. Takahashi, Y. Sugimoto and H. Osada, ChemBioChem, 2009, 10, 920.
56. P. S. Steyn, Tetrahedron Lett., 1971, 12, 3331.
57. S. Tsukamoto, H. Kato, T. J. Greshock, H. Hirota, T. Ohta and R. M. Williams, J. Am. Chem. Soc., 2009, 131, 3834.
58. S. Li, J. M. Finefield, J. D. Sunderhaus, T. J. McAfoos, R. M. Williams and D. H. Sherman, J. Am. Chem. Soc., 2012, 134, 788.
59. M. Oliynyk, C. B. W. Stark, A. Bhatt, M. A. Jones, Z. A. Hugher-Thomas, C.
Wilkinson, Z. Oliynyk, Y. Demydchuk, J. Staunton and P. F. Leadlay, Mol. Microbiol., 2003, 49, 1179.
60. J. Qian-Cutrone, S. Huang, Y. Z. Shu, D. Vyas, C. Fairchild, A. Menendez, K. Krappitz, R. Dalterio, S. E. Klohr and Q. Gao, J. Am. Chem. Soc., 2002, 124, 14556.
61. J. M. Finefield, H. Kato, T. J. Greshock, D. H. Sherman, S. Tsukamoto and R. M. Williams, Org. Lett., 2011, 13, 3802.
62. C. Authrine and J. B. Gloer, J. Nat. Prod., 1996, 59, 1093.
63. E. M. Stocking, J. F. Sanz-Cervera and R. M. Williams, J. Am. Chem. Soc., 2000, 122, 1675.
64. H. Luesch, D. Hoffmann, J. M. Hevel, J. E. Becker, T. Golakoti and R. E. Moore, J. Org. Chem., 2002, 68, 83.
65. Y. Ding, S. Gruschow, T. J. Greshock, J. M. Finefield, D. H. Sherman and R. M. Williams, J. Nat. Prod., 2008, 71, 1574.
66. E. M. Stocking, J. F. Sanz-Cervera and R. M. Williams, Angew. Chem. Intl. Ed., 2001, 40, 1296.
67. J. M. Liesch and C. F. Wichmann, J. Antibiot., 1990, 43, 1380.
68. K. S. Hewitson, N. Granatino, R. W. D. Welford, M. A. McDonough and C. J. Schofield, Phil. Trans. R. Soc. A, 2005, 363, 807.
69. Y. Ding, T. J. Greshock, K. A. Miller, D. H. Sherman and R. M. Williams, Org. Lett., 2008, 10, 4863.
70. K. H. vanPee and E. P. Patallo, Appl. Microbiol. Biotechnol., 2006, 70, 631.
71. J. Zeng and J. Zhan, ChemBioChem, 2010, 11, 2119.
72. C. S, Neumann, C. T. Walsh and R. R. Kay, Proc. Natl. Acad. Sci. U.S.A., 2010, 107, 5798.
73. C. Dong, S. Flecks, S. Unversucht, C. Haupt, K. H. vanPee and J. H. Naismith, Science, 2005, 309, 2216.
74. K. R. Watts, S. T. Loveridge, K. Tenney, J. Media, F. A. Valeriote and P. Crews, J. Org. Chem., 2011, 76, 6201.
[0000]
TABLE 1
Comparative analysis* of gene clusters of not, not′, phq, and mal
Function
Function
Function
Not
Not′
(% identity to
Phq
(% identity to
Mal
(% identity to
proteins
proteins
corresponding
proteins
corresponding
proteins
corresponding
(AA)
Function
(AA)
Not protein)
(AA)
Not protein)
(AA)
Not/Phq protein)
NotA
Negative regulator
NotA′
Negative regulator
PhqA
Prenyltransferase
MalA
Halogenase (—/—)
(339)
(334)
(70% NotA)
(405)
(22% NotC)
(667)
NotB
FAD
NotB′
FAD
PhqB
NRPS [A-T-C-A-
MalB
Prenyltransferase
(456)
monooxygenase
(455)
monooxygenase
(2449)
T-R]
(369)
(28% NotC/34%
(88% NotB)
(26% NotE)
PhqA)
NotC
Prenyltransferase
NotC′
Prenyltransferase
PhqC
2OG-Fe(II)-
MalC
Short chain
(427)
(426)
(87% NotC)
(353)
oxygenase (—)
(264)
dehydrogenase
(—/52% PhqE)
NotD
Oxidoreductase
NotD′
Oxidoreductase
PhqD
Pyrroline-5-
MalD
Negative
(621)
(612)
(80% NotD)
(322)
carboxylate
(336)
regulator (36%
reductase (—)
NotA/55% PhqG)
NotE
NRPS [A-T-C-A-
NotE′
NRPS [A-T-C-A-
PhqE
Short chain
MalE
Prenyltransferase
(2241)
T-C]
(2225)
T-C]
(265)
dehydrogenase (—)
(438)
(36% NotF/34%
(79% NotE)
PhqJ)
NotF
Prenyltransferase
NotF′
Prenyltransferase
PhqF
Efflux pump (18%
MalF
Oxidoreductase
(453)
(435)
(79% NotF)
(411)
NotK)
(590)
(37% NotD/39%
PhqH)
NotG
P450
NotG′
P450
PhqG
Negative regulator
MalG
NRPS [A-T-C-A-
(544)
monooxygenase
(544)
monooxygenase
(338)
(34% NotA)
(2345)
T-R] (27%
(87% NotG)
NotE/37% PhqB)
NotH
P450
NotH′
P450
PhqH
Oxidoreductase
(502)
monooxygenase
(499)
monooxygenase
(602)
(34% NotD)
(84% NotH)
NotI
FAD
NotI′
FAD
PhqI
Prenyltransferase
(434)
monooxygenase
(433)
monooxygenase
(462)
(—)
(85% NotI)
NotJ
Unknown
NotJ′
Unknown (80%
PhqJ
Prenyltransferase
(371)
(362)
NotJ)
(406)
(32% NotF)
NotK
Efflux pump
NotK′
Efflux pump (14%
PhqK
FAD
(564)
(577)
NotK)
(459)
monooxygenase
(32% NotI)
NotL
Transcriptional
NotL′
Transcriptional
PhqL
P450
(484)
activator
(620)
factor (15% NotL)
(563)
monooxygenase
(29% NotG)
NotM
Unknown
NotM′
Unknown (—)
PhqM
P450
(402)
(454)
(536)
monooxygenase
(15% NotH)
NotN
Dehydrogenase
NotN′
Unknown (—)
PhqN
Methyltransferase
(340)
(416)
(326)
NotO
Short-chain
NotO′
Unknown (—)
PhqO
P450
(331)
dehydrogenase
(462)
(451)
monooxygenase (—)
NotP
Unknown
NotP′
Unknown (—)
(322)
(292)
NotQ
Unknown
NotQ′
Transcription
(152)
(506)
factor
NotR
Transcriptional
NotR′
Unknown
(461)
coactivator
(172)
*Genes were predicted using the FGENESH-M tool from http://www.softberry.com; Functions of gene products were predicted using BLAST search
—: Homology cannot be calculated due to unrelatedness | The biosynthesis of fungal bicyclo[2.2.2]diazaoctane indole alkaloids with a wide spectrum of biological activities have attracted increasing interest. Their intriguing mode of assembly has long been proposed to feature a non-ribosomal peptide synthetase, a presumed intramolecular Diels-Alderase, a variant number of prenyltransferases, and a series of oxidases responsible for the diverse tailoring modifications of their cyclodipeptide-based structural core. Until recently, the details of these biosynthetic pathways have remained largely unknown due to lack of information on the fungal derived biosynthetic gene clusters. Herein, we report a comparative analysis of four natural product metabolic systems of a select group of bicyclo[2.2.2]diazaoctane indole alkaloids including (+)/(−)-notoamide, paraherquamide and malbrancheamide, in which we propose an enzyme for each step in the biosynthetic pathway based on deep annotation and on-going biochemical studies. | 2 |
STATEMENT AS TO POSSIBLE RIGHTS UNDER FEDERALLY SPONSORED RESEARCH
This invention was made with support from the National Institute of Health under Grant No. GM47372. The United States Government may have rights in the invention.
FIELD OF THE INVENTION
The present invention relates to displacement chromatography of oligonucleotides using low molecular weight, high affinity anionic displacers.
BACKGROUND OF THE INVENTION
Oligonucleotides have generated significant interest as drug candidates for a wide variety of diseases, in particular as antisense therapeutics and as potent antibiotics. Several antisense oligonucleotide drugs are currently undergoing human clinical trials, and many others are in a preclinical phase.
Oligonucleotides are single strands of nucleic acids with DNA or RNA bases, ranging in length from two to 50 bases or nucleotides. Phosphorothioate derivatives of oligonucleotides have also been utilized because of their higher in vivo stability compared to the parent phosphodiester compounds. In the phosphorothioate derivatives, a non-bridging oxygen atom in the phosphodiester backbone is replaced with a sulfur atom. This substitution enhances nuclease resistance and thus, in vivo stability.
Solid-phase synthesis methods are now available for large-scale preparation of oligonucleotides. Solid-state synthesis of an oligonucleotide results in a crude product containing not only the desired full-length (n-length or n-mer) oligonucleotide, but also multiple, closely-related deletion or “failure sequences,” primarily of length n−1. These so-called failure sequences arise by failure to add a base at the necessary position. Such failures or deletions can arise at multiple positions along the chain. Multiple failure sequences, of length (n—1, n−2, n−x), are also present for any given length. In addition, (n+1)mers may be present. Therefore, purification methods that operate on a preparative scale are needed.
Chromatographic preparation and purification of oligonucleotides can potentially provide the necessary scale and purity, but can also present unique challenges. First, oligonucleotides exhibit an extremely high binding affinity for anion-exchange chromatographic resins as compared to molecules typically encountered in biopharmaceutical purification (for example, proteins). Second, the failure sequences present are so closely-related to the desired product that the components are difficult to separate. Finally, oligonucleotides exhibit several centers of isomerism leading to the possibility of considerable heterogeneity of the mixtures of product and failure sequences.
A chromatographic system can be operated in one of two major modes, elution (including linear gradient, step gradient, and isocratic elution) or displacement. The two modes may be distinguished both in theory and in practice. In elution chromatography, a solution of the sample to be purified is applied to a stationary phase, commonly in a column. A mobile phase is chosen such that the sample is neither irreversibly adsorbed nor totally unadsorbed, but rather binds reversibly. As the mobile phase is caused to flow over the stationary phase, an equilibrium is established between the mobile phase and the stationary phase whereby components of the sample pass along the column at speeds which reflects their affinity for the stationary phase relative to the other components that may occur in the original sample. The differential migration process is outlined schematically in FIG. 1, and a typical chromatogram is shown in FIG. 2 . Of particular note is the fact that the eluting solvent front, or zero column volume in isocratic elution, always precedes the sample off the column.
A modification and extension of isocratic elution chromatography is found in step gradient chromatography wherein a series of eluants of varying composition are passed over the stationary phase.
In ion-exchange chromatography, step changes in the mobile phase salt concentration and/or pH are employed to elute or desorb materials such as, for example, proteins.
A schematic illustrating the operation of a chromatographic system in displacement mode is shown in FIG. 3 . The column is initially equilibrated with a buffer in which most of the components to be separated have a relatively high affinity for the stationary phase. Following the equilibration step, a feed mixture containing the components to be separated is introduced into the column and is then followed by a constant infusion of the displacer solution. A displacer is selected such that it has a higher affinity for the stationary phase than any of the feed components. As a result, the displacer can effectively drive the feed components off the column ahead of its front. Under appropriate conditions, the displacer induces the feed components to develop into adjacent “squarewave” zones of highly concentrated, often pure material. The displacer emerges from the column following the zones of purified components. After the breakthrough of the displacer with the column effluent, the column is regenerated and is ready for another cycle.
An important distinction between displacement chromatography and elution chromatography is that in elution chromatography, desorbents, including salts for ion-exchange chromatography, move through the feed zones, while in displacement chromatography, the displacer front always remains behind the adjacent feed zones in the displacement train. This distinction is important because relatively large separation factors are generally required to achieve satisfactory resolution in elution chromatography, while displacement chromatography can potentially purify components from mixtures having low separation factors.
A key operational feature which distinguishes displacement chromatography from elution chromatography is the use of a displacer molecule. In elution chromatography, the eluant usually has a lower affinity for the stationary phase than any of the components in the mixture to be separated, whereas in displacement chromatography, the eluant, which is the displacer, has a higher affinity.
Displacement chromatography has some particularly advantageous characteristics for process scale chromatography of biological macromolecules such as oligonucleotides. First, displacement chromatography can concentrate components from mixtures. By comparison, isocratic elution chromatography results in product dilution during separation. Second, displacement chromatography can achieve product separation and concentration in a single step. Further, since the displacement process operates in the nonlinear region of the equilibrium isotherm, high column loadings are possible. This allows for improved column utilization compared to elution chromatography. Furthermore, displacement chromatography can purify components from mixtures having low separation factors, while relatively large separation factors are required for satisfactory resolution in desorption chromatography.
Preparative ion-exchange chromatography operated in the displacement mode is, therefore, a potentially attractive method for purifying oligonucleotides because of the high resolution and high throughput that can be obtained. However, displacement chromatography, as it is traditionally known, has a number of drawbacks compared to elution chromatography for the purification of oligonucleotides. Two of the major problems are difficulty in regeneration of the column and the presence of displacer in some of the purified fractions.
Since the displacement process uses a high affinity compound as the displacer, the time for regeneration and re-equilibration can be long compared to elution chromatography. The second problem, that of contamination by the displacer, has arisen because a common characteristic of displacers used in ion-exchange systems has been their relatively high molecular weight. Heretofore the art has taught the use of high molecular weight polyelectrolyte displacers on the assumption that it is necessary to have a large polyelectrolyte in order to ensure a higher binding coefficient than the biomolecule that is to be displaced. The rationale behind such an assumption is that the binding of a molecule to an adsorbent surface of an ion-exchange stationary phase is related only to its characteristic charge. Characteristic charge is the average number of sites of interaction of a solute with a stationary phase. High molecular weight displacers exhibit both of the disadvantages enumerated above: they bind tightly to the stationary phase and, therefore, require stringent conditions for regenerating the column, and traces of the displacer that may contaminate the product fraction are difficult to remove.
Low molecular weight displacers for protein separation that do not require extensive regeneration of the column and that can be readily removed from the product have been described by Cramer et al. (U.S. Pat. No. 5,606,033, issued Feb. 25, 1997; U.S. Pat. No. 5,478,924, issued Dec. 26, 1995). However, while the low molecular weight displacers identified so far have been successful in displacing moderately bound biomolecules such as proteins, they have been unsuccessful in displacing very highly retained compounds in ion-exchange systems, for example, oligonucleotides. Prior art disclosures relating to purification of oligonucleotides in ion-exchange systems have described only the use of relatively large polyelectrolytes (>40,000 Daltons) as displacers. For example, use of displacement chromatography with a high molecular weight polyelectrolyte displacer, a sulfonated polysaccaride, for the purification of oligonucleotides has been reported by Gerstner et al. ( J. Nucl. Acids Res. 1995, 23, 2292-2299).
Therefore, there is a need for a separation process of oligonucleotides having the advantages of displacement chromatography (high resolution and high throughput) while avoiding the disadvantages (difficult column regeneration and contamination of the product with the displacer.)
SUMMARY OF THE INVENTION
In one aspect, the present invention relates to methods for purifying an oligonucleotide, or several oligonucleotides, comprising:
(a) loading said oligonucleotide onto an anion-exchange column having a stationary phase; and
(b) displacing said oligonucleotide from said anion-exchange column by an anionic displacer having a molecular weight of less than about 10,000, said anionic displacer having a higher affinity for said stationary phase of said anion-exchange column than said oligonucleotide.
Preferably, the molecular weight of the displacer is less than about 5,000. More preferably, the molecular weight of the displacer is less than about 2,500.
A preferred composition for the displacer is a substituted or unsubstituted aromatic compound having at least one anionic substituent. Another preferred composition for the displacer is a substituted or unsubstituted aliphatic compound having at least one anionic substituent. Preferred anionic substitutents are sulfate, sulfonate, phosphate, phosphonate and carboxylate groups. More preferred anionic substitutents are sulfonate groups. A preferred aromatic compound is a substituted or unsubstituted polycyclic aromatic compound having at least one anionic substituent. Preferred polycyclic aromatic sulfonates are amaranth and calcion.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic representation of isocratic linear elution chromatography as typically practiced.
FIG. 2 is a typical HPLC elution chromatogram.
FIG. 3 is a schematic representation of displacement chromatography.
FIG. 4 is a dynamic affinity plot for three displacers, a typical 20mer phosphorothioate oligonucleotide SEQ ID NO. 2 (also identified by ISIS compound number 2105), and a protein.
FIG. 5 is a displacement chromatogram for SEQ ID NO. 1 (also identified by ISIS compound number 2302) purified using amaranth as the displacer (Example 1).
FIG. 6 a is an analytical anion-exchange chromatogram of the oligonucleotide feed shown in FIG. 5 .
FIG. 6 b is an analytical anion-exchange chromatogram of one of the purified fractions from the displacement shown in FIG. 5 .
FIG. 7 a is an analytical capillary gel electropherogram of the feed from the displacement of the oligonucleotide in FIG. 5 .
FIG. 7 b is an analytical capillary gel electropherogram of the purified pool from displacement of the oligonucleotide in FIG. 5 .
FIG. 8 shows an HPLC chromatogram illustrating the effective regeneration of the column used in FIG. 5 (Example 2).
FIG. 9 a is an analytical capillary gel electropherogram of the crude phosphodiester 20mer SEQ ID NO. 1 (also identified by ISIS compound number 2302) containing several lower retained impurities which appear as shoulders on the main product peak (Example 3).
FIG. 9 b is a displacement chromatogram for the phosphodiester illustrated in FIG. 9 a.
FIG. 9 c is an analytical capillary gel electropherogram of the purified pool from the displacement of the phosphodiester illustrated in FIG. 9 a.
FIG. 10 is a displacement chromatogram for a phosphorothioate 20mer SEQ ID NO. 2 (also identified by ISIS compound number 2105) purified using displacement chromatography (Example 4).
FIG. 11 is an anion-exchange chromatogram for the feed of the displacement chromatography shown in FIG. 10 .
FIG. 12 is an anion-exchange chromatogram of the purified pool of the displacement chromatography shown in FIG. 10 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The method of the present invention relates to separation and purification of oligonucleotides by ion-exchange chromatography operated in the displacement mode. A low molecular weight anionic displacer having higher affinity for the stationary phase than the oligonucleotides to be separated or purified is utilized. The oligonucleotide to be purified is dissolved in a solvent and loaded onto an anion-exchange column having a stationary phase. The oligonucleotide is eluted with an anionic displacer which displaces the oligonucleotide from the anion-exchange column.
In the context of the present invention, low molecular weight means a molecular weight of less than 10,000. Preferably, a displacer used in the method of the present invention has a molecular weight of less than 5,000. More preferably, the displacer has a molecular weight of less than 2,500.
Affinity of the displacer for the stationary phase of the chromatographic system relative to the oligonucleotides to be separated or purified is defined with reference to an improved mathematical model for displacement chromatography: Steric Mass Action (SMA) ion-exchange model. The SMA ion-exchange model is capable of predicting complex behavior in ion-exchange systems. This model has three solute parameters: characteristic charge ν is the number of salt counterions displaced by the solute when it binds to the stationary phase surface; steric factor σ is the number of salt counterion sites on the surface which are shielded by the adsorbed solute and hence unavailable for exchange with any other solute molecules; and equilibrium constant κ is that for the exchange reaction between the salt counterions and the solute.
According to the SMA model, the governing parameter that regulates the ability of one solute to displace another is dynamic affinity. Dynamic affinity is defined as: λ = ( K Δ ) 1 v
wherein λ is the dynamic affinity, Δ is the displacer partition ratio, and κ and ν are as defined above. Δ is equal to Q d /C d , where Q d and C d are the displacer concentrations in the stationary phase and mobile phase, respectively. The value of parameter Δ varies with the operating conditions for the displacement, which include the concentrations of displacer and salt.
Affinity of the displacer for the stationary phase of an anion-exchange system higher than that of the oligonucleotides to be separated or purified for the same stationary phase is defined with reference to the SMA model. Higher affinity means that the displacer has a greater dynamic affinity λ than that of the oligonucleotides. Dynamic affinity of the displacer and the oligonucleotides can be readily determined by constructing a plot of log κ versus ν for the displacer and oligonucleotides. This is called a dynamic affinity plot. The slope of the line is the dynamic affinity λ of the compound or mixture of compounds. Where the line for the displacer falls above or counterclockwise from the line for the oligonucleotides, the displacer has higher affinity for the stationary phase under those operating conditions than does the oligonucleotide or mixture of oligonucleotides. The plot is, therefore, used to determine the ability of a displacer to displace a given oligonucleotide under the operating conditions for the displacement.
An exemplary dynamic affinity plot is shown in FIG. 4 . The values of log κ and ν are plotted for a typical phosphorothioate antisense oligonucleotide, a typical protein and several potential displacers. Viewed in a counterclockwise direction, that is, in order of increasing slopes, starting with the line for a typical protein, this plot shows increasing affinity of the solutes under the experimental conditions. It is evident that even the highest affinity low molecular weight displacer previously identified for anion-exchange, sucrose octasulfate, did not possess enough affinity to displace this oligonucleotide. In fact, the oligonucleotide has an equilibrium constant that is several orders of magnitude higher than that of a typical anionic protein, β-lactoglobulin A, as shown in FIG. 4 .
The three SMA parameters, ν, σ, and κ, may be determined experimentally. The characteristic charge and equilibrium constant of the oligonucleotides to be purified may be determined using linear gradient elution retention data with different slopes of the linear gradient (Shukla et al., Ind. Eng. Chem. Res., 1998, 37, 4090-4098, which is herein incorporated by reference). The steric factor of the oligonucleotides may then be determined from the capacities obtained from frontal experiments at two or more displacer concentrations (Gadam et al, J. Chromatogr., 1993, 630, 37-52), which is herein incorporated by reference). The magnitude of the induced gradient obtained during these frontal experiments can provide an independent measure for the characteristic charge ν.
A slightly different procedure may also be employed to obtain the SMA parameters of the displacer. Isocratic experiments may be conducted at different mobile phase salt concentrations, and a plot of log k′ vs. log (salt concentration), where k′ is the dimensionless retention time of a solute at a specific mobile phase salt concentration, may be made. The values of the slope and intercept of the line are used to calculate the characteristic charge ν and the equilibrium constant κ, respectively (Gadam et al., J. Chromatogr., 1993, 630, 37-52). The frontal experiments described above may be used to determine the steric factor and an independent measure of ν.
The retention process in ion-exchange is not solely determined by electrostatic interactions but may be greatly enhanced by non-specific interactions. One of the dominant factors which can play a major role in governing retention on an anion-exchange resin are hydrophobic interactions. For example, aromatic compounds having multiple sulfonic acid functionalities may be effective displacers for oligonucleotides.
Therefore, an anionic displacer having higher affinity for a stationary phase of an anion-exchange system may be an aromatic, substituted aromatic aliphatic or substituted aliphatic compound containing at least one anionic substituent. Preferred anionic substituents are sulfate, sulfonate, phosphate, phosphonate and carboxylate groups. More preferred is a substituted or unsubstituted aromatic anionic displacer containing at least one sulfonate group. The anionic displacer may also be a polycyclic aromatic or substituted polycyclic aromatic compound containing at least one anionic substituent. Preferred anionic substituents are sulfate, sulfonate, phosphate, phosphonate and carboxylate groups. A preferred substituted or unsubstituted polycyclic aromatic anionic displacer contains at least one sulfonate group. Examples of polycyclic aromatic sulfonate displacers having higher affinity for a stationary phase than an oligonucleotide are amaranth (I) and calcion (II), both available from Aldrich Chemical Company. The structures of I and II are shown below.
Other exemplary aromatic sulfonates which may exhibit higher affinity for a stationary phase of an anion-exchange system than an oligonucleotide to be purified under the operating conditions of the system are New Coccine, Ponceau S, Ponceau SS, Hydroxy Naphthol Blue, Brilliant Black, Anthraquinone Disulfonic Acid, Potassium Indigotetrasulfonate, Sulfazo III, Reactive Orange 16, Acid Alizarin Violet N, Acid Black 24, Acid Blue 29, Acid Blue 80, Acid Blue 92, Acid Blue 113, Acid Blue 120, Acid Green 25, Acid Green 27, Acid Orange 8, Acid Orange 51, Acid Orange 63, Acid Orange 74, Acid Red 1, Acid Red 4, Acid Red 8, Acid Red 97, Acid Red 106, Acid Red 114, Acid Red 151, Acid Red183, Acid Violet 5, Acid Violet 7, Acid Yellow 17, Acid Yellow 25, Acid Yellow 29, Acid Yellow 34, Acid Yellow 38, Acid Yellow 40, Acid Yellow 42, Acid Yellow 65, Acid Yellow 76, and Acid Yellow 99. All of these compounds are commercially available from Aldrich Chemical Company.
The method of the present invention may be used with conventional anion-exchange systems and conventional displacement chromatography procedures. An example of a useful anion-exchange column is a Poros HQ/M column, which has a stationary phase composed of a rigid polystyrene-divinylbenzene bead covered with a hydrophilic layer. The column is available from PerSeptive Biosystems, Inc. Displacement chromatography operations are typically carried out by initially equilibrating the column with carrier solution and then sequentially perfusing with feed, displacer, and regenerant solutions. The feed and the displacer solutions are commonly prepared in the same buffer solution as the carrier.
As used herein, the term oligonucleotide includes oligomers containing two or more nucleoside subunits having phosphorus internucleoside linking moieties. Nucleoside subunits according to the invention have a ribofuranose moiety attached to a nucleobase through a glycosyl bond. Oligonucleotides according to the present invention preferably comprise from about 5 to about 50 nucleosides. It is more preferred that such compounds comprise from about 8 to about 30 nucleosides. It is most preferred that such compounds comprise from about 15 to about 25 nucleosides.
Additional objects, advantages, and novel features of the present invention will become apparent to those skilled in the art upon examination of the following examples. The following examples illustrate the invention and are not intended to limit the same. Those skilled in the art will recognize, or be able to ascertain through routine experimentation, numerous equivalents to the specific substances, compositions, and procedures described herein. Such equivalents are considered to be within the scope of the present invention.
EXAMPLES
Example 1
Displacement Chromatography of a Phosphorothioate 20mer, SEQ ID NO: 1 (ISIS-2302) GCC CAA GCT GGC ATC CGT CA (P═S)
FIG. 4 shows a Dynamic Affinity plot for preferred displacers for a typical phosphorothioate oligonucleotide, amaranth (I) and calcion (II), in comparison to a disaccaride bearing eight sulfate groups, sucrose octasulfate. The line for sucrose octasulfate falls below that of the oligonucleotide, while those for amaranth and calcion fall counterclockwise (above) to that of the oligonucleotide. Therefore, both amaranth and calcion have higher affinity for the stationary phase than the oligonucleotide.
The ability of the dynamic affinity parameter to predict real-world behavior was confirmed for amaranth in a separation of a typical phosphorothioate oligonucleotide. FIG. 5 shows a histogram of a displacement separation of SEQ ID NO: 1, a 20-mer phosphorothioate antisense oligonucleotide, using amaranth as a displacer on a Poros HQ/M column (4.6×100 mm I.D., 20 μm particles), at a flow rate of 0.2 mL/min. The carrier solution and mobile phase was a 20 mM NaOH/500 mM NaCl solution. The feed and displacer solution were prepared from the carrier solution and the feed consisted of 11.98 mg oligonucleotide. An effective displacement was demonstrated with a sharp boundary between zones containing the impurities and the desired oligonucleotide, and between zones containing the oligonucleotide and the amaranth displacer. Thus, the histogram demonstrates the resolving power of amaranth in displacement chromatography of oligonucleotides.
High temperature anion-exchange analysis of the feed and of the fraction containing the desired oligonucleotide confirmed the purity of the product oligonucleotide. Chromatograms from the displacement experiment show the oligonucleotide fraction collected (FIG. 6 a ) and the feed component from the displacement experiment (FIG. 6 b ). Even though the feed was only about 58% pure, the oligonucleotide fraction had a purity of about 99% by anion-exchange analysis. Capillary electropherograms for the feed and product pool from the example in FIG. 5 are shown in FIGS. 7 a and 7 b.
The displacement histogram depicted in FIG. 5 was prepared using the separation parameters listed above and the general procedure illustrated below. One fractions per minute was collected and analyzed by analytical anion-exchange assay to determine the concentration of the components and their purities. Standard curves for the peak area versus the oligonucleotide concentration and the peak area versus the displacer concentration were generated using the sample of pure oligonucleotide and a sample of known concentration for the displacer, respectively. The concentration of oligonucleotide and amaranth in each of the fractions was then determined by using this standard curve to calculate a value of the extinction coefficient (peak area per unit concentration). The same extinction coefficient was assumed for the mono-phosphodiester (P═O)1 component and other impurity species since these are chemically very similar. For these experiments the cumulative impurity concentration was determined by subtracting the main peak, i.e. the all phosphorothioate (P═S) parent peak, concentration from the total oligonucleotide concentration in each fraction. A histogram was generated to represent this experimental data by plotting the cumulative concentration of impurities, product oligonucleotide and amaranth for each of the fractions vs. volume of column effluent.
Example 2
Column Regeneration Following Displacement Chromatography
Following purification of the phosphorothioate oligonucleotide in Example 1 above the column was regenerated. Demonstrating effective regeneration of the stationary phase after a displacement run is important to enable the use of a compound as an efficient displacer. FIG. 8 shows an HPLC chromatogram with the breakthrough curves for nitrate ions before and after the column had been put through several successive displacement steps as illustrated in Example 1. As can be seen, the breakthrough curves overlay each other signifying an effective column regeneration using standard protocols. The 4 step regeneration protocol is shown below.
1) Elute column with 5 column volumes of 2.5 M NaCl and 20 mM NaOH.
2) Elute column with 5 column volumes water.
3) Elute column with 5 column volumes 25% v/v acetonitrile and 20 mM NaOH.
4) Elute column with 5 column volumes water.
Example 3
Displacement Chromatography of a Phosphodiester 20mer, SEQ ID NO: 1 (ISIS-2302) GCC CAA GCT GGC ATC CGT CA (P═O)
The column that was regenerated after about 3 displacement runs in Example 2 was used to purify SEQ ID NO: 1 as a Phosphodiester. The general procedure illustrated in Example 1 was followed. High temperature anion-exchange analysis of the feed mixture for this separation is shown in FIG. 9 a. The mixture contained several lower retained impurities which appear as shoulders on the main product peak. The displacement chromatogram resulting from the displacement of this oligonucleotide using amaranth is shown in FIG. 9 B. Again, an effective separation was achieved resulting in a yield of 69.7% at 99% purity by the anion-exchange assay. The analytical capillary gel electropherogram of the purified pool of the purified phosphodiester is shown in FIG. 9 c.
Example 4
Purification of a Phosphorothioate 20mer Using Displacement Chromatography, SEQ ID NO: 2 (ISIS-2105) TTG CTT CCA TCT TCC TCG TC (P═S)
SEQ ID NO: 2, a phosphorothioate 20mer, was purified by displacement chromatography using amaranth as the displacer. The chromatography was performed as per the procedure illustrated in Example 1 above. Column: 4.6×100 mm, Poros HQ/M; mobile phase: 20 mM NaOH/500 mM NaCl; loading: 10 mg phosphorothioate oligonucleotide; flow rate: 0.2 mL/min; feed purity=91.22%. FIG. 10 shows the displacement chromatogram. FIG. 11 shows the anion-exchange chromatogram and FIG. 12 shows the anion-exchange chromatogram of the purified pool.
While the invention has been particularly shown and described with reference to the preferred embodiments thereof, it will be understood by those skilled in the art that other changes in form and details may be made without departing from the spirit and scope of the invention.
2
1
20
DNA
Artificial Sequence
Novel Sequence
1
gcccaagctg gcatccgtca 20
2
20
DNA
Artificial Sequence
Novel Sequence
2
ttgcttccat cttcctcgtc 20 | A method for purifying oligonucleotides by displacement chromatography on anion-exchange media, using high affinity, low molecular weight (less than about 10000 Da) displacers, is disclosed. Several examples of high affinity, low molecular weight anionic displacers are provided, including polycyclic aromatic compounds having sulfonic acid moieties attached thereon. The efficacy of the technique for high resolution separation of oligonucleotides is demonstrated for an industrial mixture. | 2 |
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application is a continuation of application Ser. No. 10/667,105, filed Sep. 18, 2003, now U.S. Pat. No. 7,377,522, which claims the benefit of Provisional Application No. 60/412,045, filed Sep. 18, 2002, the disclosures of which are hereby incorporated by reference.
BACKGROUND
[0002] When negotiating a curve with a typical automotive-type vehicle, the resulting centrifugal forces tend to roll the vehicle body and associated chassis (hereinafter jointly referred to as “body”) about its roll center relative to the underlying suspension system, and also displace the body and suspension system laterally outwardly relative to the radial center of the curve, tending to cause the vehicle to pivot about its outer wheels. This latter tendency is commonly known in the motor vehicle art as the “jacking effect.” During braking and acceleration, the resulting longitudinal forces acting on a typical automotive-type vehicle tend to pitch the body about its pitch center relative to the underlying suspension system and also tend to displace the body and suspension system forwardly during braking and rearwardly during acceleration to cause the vehicle to pivot about its front or rear wheels, respectively. This is known as the “pitching effect.”
[0003] The locations of the roll center and pitch center are functions of the construction of the vehicle body and the configuration of the vehicle suspension system. In a conventional vehicle, the center of gravity of the vehicle is located above the roll center and pitch center. Since the centrifugal forces caused by cornering and the longitudinal forces caused by accelerating and braking act through the center of gravity of the vehicle, the magnitude of the couple tending to cause the body to roll about its roll center is a function of the magnitude of the centrifugal force and the vertical distance separating the center of gravity from the roll center, and the magnitude of the couple tending to cause the body to pitch about its pitch center is a function of the magnitude of the longitudinal force and the vertical distance separating the center of gravity from the pitch center. These vertical distances are commonly known as the “roll couple” and “pitch couple,” respectively.
[0004] In a typical vehicle, as the body rolls outwardly about its roll center, it tends to compress the outer suspension springs (relative to the radial center of the curve about which the vehicle is traveling) thus increasing the weight on the outer wheels while simultaneously unloading the inward suspension springs, thereby reducing the weight on the inside wheels. As a result, the cornering traction of the vehicle is reduced. Also, as the body pitches forwardly about its pitch center during braking, it tends to compress the forward springs, thus increasing the weight on the forward wheels while simultaneously unloading the rearward springs, thereby reducing the weight on the rearward wheels. This resulting imbalance in the weight being carried by the forward and rearward wheels decreases the maximum braking capacity of the vehicle. The foregoing loading changes on the vehicle wheels caused by cornering and braking will occur simultaneously when the vehicle's brakes are applied while cornering, thereby potentially causing even greater imbalance on the weights on the vehicle wheels than caused by cornering alone or braking alone. This imbalance may result in the loss of substantially all of the traction of one or more wheels.
[0005] The lateral force tending to cause a vehicle to pivot about its outer wheels, i.e., jacking effect, acts through the portion of the vehicle known as the roll reaction center. The longitudinal forces tending to cause a vehicle to pitch about its forward or rearward wheels acts through the pitch reaction center. In a conventional vehicle, the roll reaction center coincides with the roll center and the pitch reaction center coincides with the pitch center. As a result, the magnitude of the jacking effect is a function of the magnitude of the centrifugal force and the elevation of the roll reaction center above the ground, and the magnitude of the pitching effect is a function of the magnitude of the longitudinal braking/acceleration force and the elevation of the pitch reaction center above the ground. With respect to the effect of cornering forces on a vehicle, the height of the roll reaction center above the ground is commonly known as the jacking couple, and with respect to the effect of braking and acceleration forces on the vehicle, the height of the pitch reaction center above the ground is commonly known as the pitching couple.
[0006] In conventional vehicles, attempts have been made to design the suspension system to minimize the heights of the roll reaction center and pitch reaction center, thereby to reduce the jacking effect and pitching effect. Placement of the roll reaction center and the pitch reaction center at a low elevation, however, results in the center of gravity of the body being located at a substantial distance above the roll center and pitch center, thereby increasing the magnitude of the roll couple and pitch couple. The increase in the roll couple and pitch couple results in decreased stability of the vehicle, especially since in typical suspension systems the body roll and jacking effect and the body pitch and pitching effect are all cumulative, reducing the braking, acceleration and cornering ability of the vehicle.
[0007] Conventional vehicles also do not have any significant accommodation for absorbing the energy of a vehicle crash so as to reduce the likelihood of injury to passengers. As a consequence, all too often passengers are seriously injured, or even killed, during vehicle collisions, some of which do not occur at very high speeds.
SUMMARY
[0008] This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This summary is not intended to identify key features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.
[0009] Embodiments of the present invention seek to reduce the detrimental effects on vehicle handling caused by braking, by acceleration, by simultaneous cornering and braking, and by simultaneous cornering and acceleration. Embodiments of the present invention constitute an improvement of the vehicle suspension system disclosed in applicant's prior U.S. Pat. No. 4,550,926 which simply concerns suspension systems for counteracting cornering forces imposed on vehicles. Enhanced vehicle handling is achieved by the improved suspension systems of the present invention, in which not only do the roll couple and jacking couple oppose each other, thereby causing the body roll to counteract the jacking effect, but also the pitch couple and the pitching couple oppose each other, thereby causing the body pitch to counteract the pitching effect, thus improving the cornering traction of the vehicle, the braking traction of the vehicle, the acceleration traction of the vehicle (especially in a front-wheel-drive-vehicle), the simultaneous cornering and braking traction of the vehicle, and the simultaneous cornering and acceleration traction of the vehicle.
[0010] To this end, vehicle suspension systems of the present invention may be joined to the vehicle body to pivot about transverse and/or longitudinal axes located above the center of gravity of the vehicle body so that the cornering forces acting through the center of gravity tilt the body about the longitudinal axis inwardly into the curve and so that simultaneously the longitudinal braking or acceleration forces acting through the center of gravity tilt the body about the transverse axis toward the rear or front, respectively, of the vehicle.
DESCRIPTION OF THE DRAWINGS
[0011] The foregoing aspects and many of the attendant advantages of this invention will become more readily appreciated as the same become better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:
[0012] FIG. 1 is a side elevational view of an embodiment of the present invention;
[0013] FIG. 2 is a top view of FIG. 1 with portions broken away;
[0014] FIG. 3 is an enlarged fragmentary view of the portion of the suspension system of the embodiment of FIGS. 1 and 2 ;
[0015] FIG. 4 is a side elevational view of another embodiment of the present invention;
[0016] FIG. 5 is a top view of FIG. 4 with portions broken away;
[0017] FIG. 6 is a top view of a further embodiment of the present invention;
[0018] FIG. 7 is a side elevational view of FIG. 6 ;
[0019] FIG. 8 is a front elevational view of FIGS. 6 and 7 ;
[0020] FIG. 9 is a further front elevational view of the embodiment shown in FIGS. 6 , 7 and 8 with the body and tie structure tilted as when negotiating a curve;
[0021] FIG. 10 is a top view of a further embodiment of the present invention;
[0022] FIG. 11 is a side elevational view of FIG. 10 ;
[0023] FIG. 12 is an enlarged fragmentary view of portions of the embodiment shown in FIGS. 10 and 11 ;
[0024] FIG. 13 is a further embodiment of the present invention in side elevational view;
[0025] FIGS. 14 , 15 and 16 illustrate a further embodiment of the present invention in front elevational, side elevational and top view;
[0026] FIG. 17 is a front view of a further embodiment of the present invention;
[0027] FIG. 18 is a front view of another embodiment of the present invention;
[0028] FIG. 19 is an enlarged fragmentary view of a portion of FIG. 18 ;
[0029] FIG. 20 is a front elevational view of a further embodiment of the present invention;
[0030] FIGS. 21 and 22 are top cross-sectional views of FIG. 20 ;
[0031] FIG. 23 is an enlarged, fragmentary, elevational view of FIG. 20 ;
[0032] FIGS. 24 , 25 and 26 illustrate a further embodiment of the present inventions in front elevational view, top view and fragmentary side elevation view;
[0033] FIG. 27 is a front elevational view of a further embodiment of the present invention;
[0034] FIG. 28 is another front elevational view of a further embodiment of the present invention;
[0035] FIG. 29 is a side elevational view of a further embodiment of the present invention;
[0036] FIG. 30 is a top view of another embodiment of the present invention;
[0037] FIG. 31 is a side elevational view of FIG. 30 ;
[0038] FIG. 32 is a partial front elevational view of a further embodiment to the present invention;
[0039] FIG. 33 is a top elevational view of a portion of FIG. 32 ;
[0040] FIG. 34 is a fragmentary front elevational view of a further embodiment of the present invention;
[0041] FIG. 35 is a fragmentary front elevational view of a further embodiment of the present invention;
[0042] FIG. 36 is a side elevational view of FIG. 35 ;
[0043] FIG. 37 is a fragmentary top view showing a further embodiment of the present invention;
[0044] FIG. 38 is a further alternative of the embodiment of the present invention shown in FIG. 37 ;
[0045] FIG. 39 is a front elevational view of a further embodiment of the present invention;
[0046] FIG. 40 is a front elevational view of a further embodiment of the present invention;
[0047] FIG. 41 is a front elevational view of a further embodiment of the present invention;
[0048] FIG. 42 is a side elevational view of a further embodiment of the present invention;
[0049] FIG. 43 is an enlarged fragmentary view of FIG. 42 ;
[0050] FIG. 44 is a side elevational view of a further embodiment of the present invention;
[0051] FIG. 45 is a side elevational view of another embodiment of the present invention;
[0052] FIG. 46 is a cross-sectional view of FIG. 45 taken substantially along lines 46 - 46 thereof;
[0053] FIG. 47 is an enlarged fragmentary view of FIG. 45 ;
[0054] FIG. 48 is a side elevational view of a further embodiment of the present invention;
[0055] FIG. 49 is a side elevational view of a further embodiment of the present invention;
[0056] FIG. 50 is a front elevational view of the present invention integrated into a railway car;
[0057] FIG. 51 is a top elevational view of FIG. 50 ;
[0058] FIG. 52 is a view similar to FIG. 50 of another embodiment of the present invention;
[0059] FIG. 53 is a partial front view of a further embodiment of the present invention;
[0060] FIG. 54 is another partial front view of a further embodiment of the present invention;
[0061] FIG. 55 is a partial top view of another embodiment of the present invention;
[0062] FIG. 56 is a fragmentary top elevational view of FIG. 55 ;
[0063] FIG. 57 is a fragmentary front view of a further embodiment of the present invention; and
[0064] FIG. 58 is a fragmentary side view of FIG. 57 .
DETAILED DESCRIPTION
[0065] Referring initially to FIGS. 1 and 2 , a vehicle 50 having a body 52 is shown as mounted on the suspension system 54 of the present invention, which in turn is supported on forward wheel assemblies 56 and rearward wheel assemblies 58 . An elongated tie structure 60 is interposed between the vehicle body 52 and the wheel assemblies 56 and 58 . The tie structure 60 may extend longitudinally along the lower elevation of the vehicle 50 and is interconnected to the body 52 through a slide assembly 62 to enable the body to slide longitudinally relative to the tie structure as well as pivot about a longitudinal axis 64 which is located at an elevation above the center of gravity 66 of the vehicle 50 . The tie structure 60 is also connected to the wheels 56 and 58 by pivot arm assembles 68 .
[0066] As used in the present application, the term “body” is intended to include a relatively rigid structure that may include a chassis, frame and/or the body thereof, and any additional supports and members attached thereto for accommodating the suspension system of the present invention.
[0067] The body 52 has a forward portion 52 F and a rearward portion 52 R. The body 52 may be constructed with a conventional body shell and an underlying chassis, may be in the form of a unibody having an integral chassis, or may be constructed in other manners without departing from the spirit or scope of the present invention.
[0068] At the front of the vehicle 50 , as shown in FIG. 1 , the suspension system 54 includes load support and control devices in the form of combination spring/shock absorber assemblies 70 for supporting the vehicle body 52 . The upper ends of the spring/shock absorber assemblies 70 are coupled to a body structure member 72 utilizing a ball joint connection 74 . The lower ends of the spring/shock absorber assemblies 70 are interconnected to forward hub carriers 76 of the wheel assemblies 56 . The forward hub carriers are connected to the forward end portions of the tie structure 60 by pivot arm assemblies 68 through ball joints 78 located at the distal ends of the pivot arm assemblies. Spring/shock absorber assemblies, such as assemblies 70 , are well known in the art and are commonly referred to as MacPherson struts. MacPherson struts are widely used in conjunction with both front-wheel and rear-wheel drive vehicles.
[0069] Referring to FIG. 3 , at the forward corners the tie structure 60 is connected to the hub carriers 76 by the pivot arm assemblies 68 . Each pivot arm assembly includes a generally triangular-shaped pivot arm 68 A composed of a longitudinal member 68 B, a transverse member 68 C 1 , and a diagonal member 68 C, which cooperatively form the triangular shape. The pivot arm may be adapted to pivot relative to the forward end of tie structure 60 about a transverse axis. To this end, the end of each pivot arm longitudinal member 68 B extends beyond the transverse member 68 C 1 to be closely receivable between a pair of mounting ears 68 D extending longitudinally from the forward end of the tie structure 60 . A pivot pin 68 E extends through the center of a bushing 68 F pressed within a bore formed in the end of the longitudinal member 68 B, as well as through close-fitting through-bores formed in the mounting ears 68 D. A nut 68 G or other appropriate type of fastener may be engaged with the pin 68 E to retain the pivot arm 68 A between the two mounting ears 68 D.
[0070] A cylindrical stub shaft 68 H extends transversely from an extension 681 of the pivot arm diagonal member 68 C that extends beyond the transverse member 68 C 1 in the same manner in which the longitudinal member 68 B of the pivot arm extends beyond the transverse member 68 C 1 . The stub shaft 68 H may engage within a close-fitting bushing 68 J pressed within a bore formed in a mounting bracket 68 K, which is secured to the adjacent face of the tie structure end member. The mounting bracket 68 K, which may be composed of a standard, commercially available pillow block, is mounted on the tie structure member by any appropriate means, such as by hardware members 68 L, extending through openings formed in the flange portions of the mounting bracket and into engagement with the end of the tie structure. It will be appreciated that, by this construction, the pivot arm 68 A is adapted to freely pivot about its transverse axis.
[0071] Each pivot arm assembly 68 also includes a spring-type directional control device in the form of a torsion bar 68 M having a splined end 68 N for anti-rotational engagement with the correspondingly splined interior of a stub shaft 68 H. The opposite end of the torsion bar extends through the close-fitting bushing 68 O pressed within a mounting bracket 68 P. The mounting bracket 68 P is secured to the adjacent face of the tie structure 60 by any appropriate method, for instance, by hardware members 68 Q extending through holes formed in the flange portions of the mounting bracket 68 P to threadably engage the tie structure. As with mounting bracket 68 K, the mounting bracket 68 P may be composed of a standard, commercially available pillow block.
[0072] The torsion bar 68 M may be adjusted to impose no appreciable load when the vehicle is at rest and in a level orientation. This is accomplished by adjusting the position of a bearing plate 68 R relative to the free end of a cantilevered swing arm 68 S extending upwardly from the end of the torsion bar 68 M, which extends beyond the mounting bracket 68 P. The lower end of the swing arm 68 S is fixedly attached to the torsion bar 68 M by any appropriate method, for instance, by use of splines (not shown) or weldments (not shown). The bearing plate 68 R is carried by the lead end of a lead screw 68 T, or similar member, extending forwardly from the tie structure 60 . It will be appreciated that the location of the bearing plate is adjusted by rotation of the lead screw 68 T.
[0073] As in any motor vehicle, the forward wheels 56 of vehicle 50 are steerable. Such steering may be carried out by any number of conventional steering systems which may include typical steering arms (not shown) extending from the forward hub carriers 76 to interconnect with a transfer steering rod assembly (not shown). The steering rod assembly may extend outwardly from a rack and pinion assembly (not shown) mounted on the tie structure 60 . Typically, the interconnection between the steering rod assemblies and the rack and pinion assembly permits the steering rod to pivot in response to the up-and-down and other movement to the front wheels relative to the tie structure. Typically, this is made possible by utilizing ball joints between the steering rod assemblies and the hub carriers, as well as between the steering rod assemblies and the rack and pinion assembly.
[0074] At the rear of the vehicle 50 , the suspension system 54 includes load supporting and control devices in the form of combination spring/shock absorber assemblies 80 for supporting a rear portion 52 R of the vehicle body. The rear spring/shock absorber assemblies 80 may be similar in construction and installation to the forward spring/shock absorber assemblies 70 . In this regard, the upper ends of the rear spring/shock absorber assemblies 80 are secured to overhead portions of the body 52 at rear locations of the body structure member 72 through the use of ball joints 82 . The lower ends of the spring/shock absorber assemblies 80 are coupled to and carried by rear hub carriers 84 of the rear wheel assemblies 58 .
[0075] The rear hub carriers 84 are connected to the distal, rearward ends of pivot arm assemblies 86 by ball joints 82 . The pivot arm assemblies 86 may be similar in construction and operation to pivot arm assembly 68 , described above. The rear wheels 58 may be powered by vehicle engine 89 mounted on the tie structure. Alternatively, the engine and associated drive train may be mounted on the body instead of the tie structure. In a manner typical of conventional vehicles, a transmission 90 may be interposed between engine 88 and a rearwardly extending drive shaft 92 . The rearward end of the drive shaft is coupled to a differential 94 . Transverse axial shafts 96 extend outwardly from opposite sides of the differential 94 to drive the rear wheel assemblies 58 .
[0076] Optionally, a dampening system may be used in conjunction with the rear pivot arm assemblies 86 , as well as the front pivot arm assemblies 68 . In this regard, a dampening system 95 is shown in FIG. 1 in conjunction with rear pivot arm assembly 86 . The dampening system 95 includes a bracket 97 fixed to and extending laterally from pivot arm of the pivot arm assembly 86 to be coupled to the distal end of a dampener/shock absorber 99 , which in turn is coupled to a bracket 101 depending downwardly from tie structure longitudinal side member 98 . It will be appreciated that by this construction the pivoting movement of the pivot arm assembly is dampened to a degree desired.
[0077] As shown in FIGS. 1 and 2 , the tie structure 60 of the present invention may be generally in the form of a rectangular box type structure that extends longitudinally along the lower elevations of vehicle 50 between the hub carriers of the forward and rearward wheels 56 and 58 . In one embodiment of the present invention the tie structure may be composed of elongated top and bottom side members 98 and 100 extending along both sides of the vehicle 50 and spaced vertically apart by forward and rearward vertical members 102 and 104 , as well as by forward and rearward intermediate vertical members 106 . The forward ends of the longitudinal members 98 and 100 may be transversely connected by upper and lower crossmembers 108 and 110 . These same crossmembers may be utilized at the rear end of the tie structure 60 . A plurality of intermediate crossmembers 112 may be utilized for reinforcing purposes. Additional reinforcing members (not shown) may be added to the tie structure 60 , if needed. The tie structure 60 may be constructed from many appropriate materials, such as tubing or channel stock. Moreover, the tie structure may be constructed in other configurations without departing from the spirit or scope of the present invention.
[0078] The slide system 62 extends longitudinally between body 52 and tie structure 60 , and is supported above the tie structure by forward and rearward assemblies 114 and 116 that may be in the form of A-arms or other structure. As shown in FIGS. 1 and 2 , the arm assembly 114 includes opposed arm Sections 118 and 120 interconnected with crossarms 121 A and 121 B to form a rigid assembly structure. The forward end portion of arm Sections 118 and 120 are pivotally pinned at the lower forward ends to the corner portions of the upper section of the tie structure 60 . A cross pin 122 captures the forward lower end portion of the arm Sections 118 and 120 between parallel, spaced-apart mounting ears 124 and 126 extending upwardly from the tie structure 60 . From the connection location with the tie structure 60 , the arm Sections 118 and 120 extend upwardly and inwardly to couple with a gimbal assembly 128 mounted on the forward end of a stub shaft 130 projecting forwardly from slide 132 of the slide assembly 62 . A cross shaft 134 connects the adjacent ends of arm Sections 118 and 120 to the gimbal assembly 128 . In this manner, the slide 132 together with the body is capable of tilting about longitudinal axis 64 (defined by stub shaft 130 and gimbal 128 ) relative to arm assembly 114 . In addition, the slide 132 , together with the body, is capable of pitching movement relative to the arm assembly 114 at an axis 135 extending transversely through the gimbal assembly 128 to pitch about a pitch center PC defined by the intersection of lines 135 A and 135 B extending from arm assemblies 114 and 116 as shown in FIG. 1 .
[0079] The rear arm assemblies 116 may be constructed similarly to the forward arm assemblies 114 . Thus, the construction of the rearward arm assembly 116 will not be repeated here. Also, it is to be understood that rather than using front and rear arm assemblies, the slide system would be supported by arm assemblies that are coupled to side portions of the tie structure 60 .
[0080] The slide assembly 62 includes an elongate, rectangular, slide member 132 extending through and capable of sliding relative to an exterior longitudinal collar-type slideway 136 that may encase the entire, or at least a portion of, the slide 132 extending between the forward arm 114 and rearward arm assemblies 116 . The slideway 136 may be attached to vehicle body 52 by attachment brackets 138 or by other convenient technique.
[0081] As will be appreciated, the slide system 62 enables the body 52 to move longitudinally relative to the tie structure 60 . For example, if the body 52 impacts against another vehicle or other structure, this relative movement between the body and tie structure enables the body to move relative to the tie structure in the direction that the impact load is applied to the body, i.e., away from the impact location. This may advantageously result in reduced crash forces imposed on passengers in the vehicle (especially if the vehicle seat or seats are adapted to move relative to the body 52 , in a manner for example, disclosed below) and less damage to the vehicle since some of the energy of the impact is expended in moving the slide 132 relative to the slideway 136 .
[0082] The slideway may be nominally held in position relative to the slide 132 by a shear pin 139 . If a crash occurs, as described above, the shear pin 139 will break, allowing relative movement of the body 52 and tie structure 60 . In addition, a selected friction load may be applied between the slide 132 and the slideway 136 to help absorb the force applied to the vehicle during a crash. Moreover, such friction load can be designed to increase linearly or nonlinearly with the distance of relative travel between the slide 132 and the slideway 136 . Also, other techniques may be used to nominally position the slideway 136 relative to the slide, such as through the use of springs or other resilient members (not shown).
[0083] It is to be understood that vehicle 50 may be constructed without the slide system 62 and still provide significant advantages over conventional automobiles and other vehicles.
[0084] It will be appreciated that in the embodiment of the present invention shown in FIGS. 1 and 2 , as well as in other embodiments of the present invention, if the body moves significantly due to a crash or other large impact load, the connections between the spring/shock absorber assemblies 70 and 80 with the body and/or hub carriers are designed to break away. Such break away connection can be designed to not cause significant damage to the spring/shock absorber assemblies, so that they can be re-used.
[0085] Also, it will be appreciated that portions of the body may be constructed with crushable body panels or parts that absorb at least some of the energy during a crash. This could result in less overall damage to the vehicle and less injury to the passengers, as opposed to a conventional vehicle.
[0086] In another aspect of the present invention, when the vehicle 50 is cornering, the centrifugal force imposed on the body 52 acts at the center of gravity 66 , which is below the elevation of gimbals 128 , resulting in the outward lateral movement of the center of gravity, thereby causing the body to tilt about the longitudinal axis 64 or roll center at the gimbals 128 , rather than imposing a jacking effect on the vehicle. As a result, the body 52 is tilted inwardly about axis 64 in the direction towards the center of the curve along which the vehicle 50 is traveling. The body, as thus tilted, thereby compresses the inside springs 70 and 80 and causes extension of the outside springs. In addition, by the inward tilting of the body, a relatively larger load is retained on the inside wheel assemblies of the vehicle 50 , rather than being shifted substantially to the outside wheel assemblies of the vehicle in the manner of a conventional vehicle. This enables vehicle 50 to maintain better traction when negotiating a corner than a conventional vehicle.
[0087] In addition, when the vehicle 50 negotiates a corner, the centrifugal forces acting on the body 52 and the tie structure 60 cause the outward pivot arm assemblies 68 and 86 to pivot about the tie structure to wind up the torsion bars 68 M, thereby to allow the outward side of the tie structure to lower somewhat. Simultaneously, the centrifugal forces acting on the body 52 and the tie structure 60 tend to cause the inward pivot arm assemblies to pivot in the opposite direction about the tie structure, thereby allowing the inward side of the tie structure to raise upwardly somewhat relative to the body. This outward roll of the tie structure is significantly less than the inward roll of the body noted above.
[0088] During the rolling movement of the tie structure, the rate of force transfer through the tie structure is reduced since it acts over an extended period of time rather than substantially instantaneously. As a consequence, the jacking effect imposed on the vehicle 50 is reduced. The jacking effect is what tends to raise the inside wheels and roll the vehicle about its outside wheels during cornering. As a result, the effective roll reaction center of the vehicle is at an elevation below the elevation of the pivot axis 64 . The roll reaction center is the elevation point through which the lateral forces act to cause the jacking effect.
[0089] The combination spring/shock absorbers 70 and 80 , and optionally the torsion bars 68 M, may be sized so that the roll stiffness of the tie structure is higher than the roll stiffness of the body. Thus, the amount by which the tie structure rolls outwardly during cornering is significantly less than the amount by which the body at the same time tilts inwardly, so that the net effect is to maintain the body in an inwardly tilted orientation relative to the tie structure, even though the tie structure is rolling somewhat in the outward direction, as described above. Also, the body 52 is permitted to move relatively further than the tie structure 60 , but the body movement stops relative to the tie structure before the tie structure movement stops.
[0090] Still referring to FIGS. 1 and 2 , stop or limit members 140 may be imposed between the arms 118 and 120 and the tie structure 60 to limit the angular movement of the arms, at least in the direction toward the tie structure. Such stops 140 may be composed of resilient blocks mounted to the underside of the A-arms to press against the adjacent portion of the tie structure when the A-arm pivots about its connection to the tie structure towards the tie structure. The resilient block may be configured to impose a progressively higher rate of resistance with increased deformation of the blocks, thereby providing a rising rate of resistance materials for blocks exhibiting these characteristics, including natural or synthetic rubber. Of course, numerous other systems could be utilized to limit the tilt or movement of the A-arms toward (and also away from) the tie structure, as desired.
[0091] In addition to, or in lieu of, stops 140 between arms 118 and 120 and the tie structure 60 , stops may also be employed to limit the amount of roll or pitch of the body relative to the tie structure. In this regard, roll and/or pitch stops 142 may be mounted on the upper end of posts or similar structures 144 extending upwardly from the forward and rearward ends of the tie structure. It is believed desirable to incorporate the body stops 142 so that the roll of the body terminates before the roll of the tie structure terminates during cornering. It is desirable to allow the shifting of the tie structure to occur over a time period longer than it takes for the body roll or pitch to be completed, thereby to reduce, to the extent possible, the rate of centrifugal force transfer between the body and tie structure, since during this shifting movement the full jacking effect caused by the centrifugal force imposed on the vehicle during cornering is not brought to bear on the vehicle.
[0092] It will also be appreciated that the present invention advantageously helps keep the body relatively level when a wheel hits a hole or depression or hits a bump in the road. For example, if a front wheel 56 hits a pothole, the corresponding portion of the tie structure lowers. Since the roll center is above the center of gravity, the body will swing up about the roll center at the location that the tie structure lowers. As such, the body tends to stay relatively level, even when the wheel and associated portion of the tie structure drop due to the pothole. It will be appreciated that if the wheel assembly hits a bump, the tie structure will raise and the body will tend to lower relative to the raised portion of the tie structure, thereby tending to keep the body relatively level.
[0093] Although the interconnections between the ends of the slide system 62 and the tie structure 60 are illustrated in FIGS. 1 and 2 as accomplished through the use of forward and rearward arm assemblies 114 and 116 , the arm assemblies may be replaced with alternative structures. For example, the arms 118 and 120 may extend parallel to each other, in which case the transverse shaft 134 of the gimbal 128 may be lengthened to accommodate this different configuration of the arms.
[0094] Although the vehicle 50 has been described and illustrated as accommodating longitudinal movement between the body 52 and the tie structure 60 , the body may also be adapted to shift sideways relative to the tie structure. In this regard, the attachment brackets 138 used to attach the body to the slide assembly may be replaced with a transverse slide assembly permitting transverse movement of the body relative to the tie structure. Such transverse slide assembly can be of many constructions, including rods that slide within collars, slides that slide within a slideway, etc.
[0095] Although the vehicle 50 has been described above as employing an engine 89 that drives the rear wheels 58 , in addition, or as an alternative, electric motors may be incorporated within the wheel assemblies 56 and/or 58 to provide motive force to the vehicle. The electric motors may be of many constructions, for example as shown and described in U.S. Pat. No. 5,438,228, which is incorporated herein by reference. It is to be understood that other electric motor configurations may be utilized without departing from the spirit or scope of the present invention.
[0096] Body 52 may be detachably mounted to the tie structure 60 . In this regard, fasteners or connectors, such as threaded connectors 146 , may be used to secure body structural member 72 to the slide assembly brackets 138 . Detachably attaching the body to the tie structure results in numerous advantages. For instance, if the body is damaged, it can be easily removed and replaced. In addition, multiple body configurations could be utilized with a particular tie structure and chassis. Thus, the vehicle owner can convert the vehicle into different uses or for example as a passenger vehicle, enclosed load carrying vehicle, or an open box load carrying vehicle, perhaps similar to a pickup truck. To accommodate a detachable body, electrical connections can be incorporated between the body and the tie structure that automatically connect the electrical lines when the body is mounted on the tie structure and correspondingly automatically disconnect the electrical lines when the body is detached from the tie structure. In addition, the steering of the vehicle can be accomplished through electrical servo motors, linear actuators, etc., rather than through mechanical linkages. In this manner it will not be necessary to separately connect and disconnect steering linkages that may extend between the body and the tie structure, the vehicle frame or the hub carrier. Also, if servo motors, etc., are used, a conventional steering wheel can be replaced with a “steering stick,” perhaps similar to the control stick of aircraft.
[0097] Another embodiment of the present invention is illustrated in FIGS. 4 and 5 . In this embodiment, vehicle 150 was constructed similarly to vehicle 50 of FIGS. 1 , 2 and 3 , but with the exception of a slide system 152 . Thus, like parts in FIGS. 3 and 4 are numbered the same as in FIGS. 1 , 2 , and 3 , but with the addition of the suffix “A.”
[0098] The slide system 152 may be constructed with a cross-shaped slide collar housing 154 for receiving therein four separate slides 156 , 158 , 160 and 162 extending from the slide housing 154 in the forward, right hand, rearward and left hand directions, respectively, relative to the direction of the vehicle 150 . The outward ends of the slides 156 and 160 may be attached to brackets 164 and 166 , respectively, extending upwardly from transverse intermediate crossmembers 112 A of the tie structure 60 A. The outward ends of the lateral slides 158 and 162 may be attached to brackets 168 extending downwardly from body structural member 72 A. A compressible member 170 may be positioned between the inward ends of each of the slides 156 , 158 , 160 and 162 and a stop 171 disposed inwardly of the adjacent end of the slides. The compression member 170 may place a nominally outward load on the slides, which load can be overcome if a sufficiently high relative force is imposed between the vehicle body 52 A and the tie structure 60 A. The compressible member 170 can be composed of various structures, such as a compression spring, crushable material, etc. Perhaps one advantage of the use of a compression spring as the compressible member is that after relative movement takes place between the body 52 A and the tie structure 60 A, the body can be returned to a nominal position relative to the tie structure.
[0099] It will be appreciated that the body 52 A is capable of moving both longitudinally and laterally relative to the tie structure 60 A, thereby to accommodate loads imposed on the body in both the longitudinal and transverse directions. Moreover, with the present invention, the body is capable of tilting relative to the tie structure 604 about longitudinal axis 64 A extending concentrically relative to slides 156 and 160 . Also, the body is capable of pitching relative to the tie structure 60 A about the transverse axis 172 extending concentrically with the transverse slides 158 and 162 .
[0100] It will be appreciated that during normal operation of vehicle 150 , the slide system may be designed to not come into play. The vehicle body is able to roll about longitudinal axis 64 A, and pitch about transverse axis 172 without the body moving relative to the tie structure 60 A through the slide system 152 . In other words, the roll and pitch stiffness of the body due to springs 70 A and 80 A is less than lateral and/or longitudinal displacement stiffness of the body due to compression members 170 .
[0101] Alternatively, the slide assembly 152 may be designed to function during the normal operation of the vehicle. For example, the slide assembly 152 may be designed to shift longitudinally or laterally during the normal operation of the vehicle.
[0102] Rather than it being “passive,” the slide system 152 may be powered to actively shift the body 52 A relative to the tie structure 60 A. In this regard, compressible member 170 of the slide system 152 may be replaced by fluid, for instance, hydraulic fluid, that may be delivered to and extracted from selected locations in the housing 154 by a fluid pump 173 in fluid flow communication with the housing 154 by lines 174 A and 174 B. A fluid reservoir 175 may be utilized with the fluid pump to store extra fluid as well as the return fluid from the housing 154 . Although the fluid pump 173 is illustrated as being in fluid flow communication with the housing 154 in the fore and aft directions, the fluid pump 173 can also be used to shift the body 52 A in the lateral direction.
[0103] It will be appreciated that the slide system 152 , as well as other slide systems of the present invention, might be conveniently and advantageously incorporated into a pre-existing vehicle. Of course, some modifications to the vehicle likely would be required so that the slide system 152 can be interposed between the existing vehicle body and existing vehicle chassis/frame. Perhaps it is more likely that adaptation of a slide system 152 into an existing vehicle might be easier to accomplish if the vehicle has a body with a separate underlying frame rather than being of a unibody construction.
[0104] Portions of the body 52 A may be constructed from crushable material to absorb some of the energy from an impact force imposed on the vehicle. Such body portions may be designed to be easily removable from the vehicle to facilitate replacement thereof. It will be appreciated that by a combination of constructing the body 52 A with crushable material and utilizing the slide system 152 , described above, the vehicle can be made to better protect passengers during a crash, and also reduce the overall damage caused to the vehicle.
[0105] FIGS. 6 , 7 and 8 disclose a further embodiment of the present invention wherein a vehicle 176 is shown as having a body structure 178 positioned within the perimeter of a tie structure 180 . The vehicle is mounted on forward and rearward wheel assemblies 182 and 184 . As in the prior embodiments of the present invention, described above, the body structure 178 is capable of longitudinal and lateral movement relative to the tie structure 180 and is also capable of tilting relative to the tie structure about a longitudinal axis 186 . Also, as discussed more fully below, the body is capable of pitching about a transverse axis 278 relative to the tie structure.
[0106] The tie structure 180 shown in FIGS. 5 , 6 , and 7 may be shaped and constructed somewhat similarly to the tie structures 60 and 60 A noted above. In this regard, the tie structure may be in the form of a rectangular box-type structure that extends longitudinally along the lower elevations of the vehicle 176 . The tie structure may be composed of elongated top and bottom side beams 188 and 190 extending along both sides of the vehicle, and spaced vertically apart by forward and rearward vertical members 192 and 194 as well as intermediate vertical members (not shown). The forward ends of the side beams 188 and 190 may be transversely connected by upper and lower crossmembers 196 and 198 . The same types of crossmembers may be utilized at the rear end of the tie structure 180 . One or more intermediate crossmembers (not shown) may be utilized for reinforcing purposes. Such crossmembers may extend through the body 178 . Additional reinforcing members (also not shown) may be added to the tie structure, as needed. Such reinforcing members may also extend through the body. It is to be understood that the tie structure 180 may be constructed from many appropriate materials, such as tubing or channel stock. Moreover, the tie structure may be constructed in other configurations without departing from the spirit or scope of the present invention.
[0107] The tie structure 180 may be supported by wheel assemblies 182 and 184 through the use of torsion assemblies 200 . The inboard ends of the torsion bar assemblies 200 may be connected to the tie structure 180 in a manner similar to that illustrated and described above in relation to FIGS. 1 , 2 and 3 . The outboard ends of the torsion bar assemblies 200 may be connected to the lower portions of wheels hub assemblies 201 through the use of ball joint assemblies in a well-known manner.
[0108] The body structure 178 is illustrated in FIGS. 6-8 as being of a generally tubular or similar construction and positioned partially within the perimeter of the tie structure. The body structure may include a rectangular box-type structure composed of upper and lower side beams 204 and 206 extending along opposite sides of the body and vertically spaced apart by forward and rearward vertical members 208 and 210 . Additional vertical members (not shown) may be utilized intermediate the forward and rearward vertical members. The forward and rearward ends of the longitudinal upper and lower side beams 204 and 206 may be transversely connected by upper and lower crossmembers 212 and 214 .
[0109] The body structure 178 can be covered by a body shell (not shown) in the manner of race cars. Ideally, the body shell is easily removable from the body structure.
[0110] The body structure 178 may be connected to the tie structure 180 through the use of an intermediate slide assembly 216 that spans across an intermediate portion of the tie structure at or near the fore and aft center of the vehicle. The slide assembly 216 may include a transverse central bar member 216 A having blind bores formed in the ends thereof for slidably receiving plunger rods 216 B therein. A compression spring or other resilient device 216 C may be interposed between the blind ends of the bores formed in the bar 216 A and the adjacent, inward ends of the rods 216 B, thereby to impose a nominal outward load on the rods. A pivot pin 217 may extend outwardly from the ends of the rods 216 B to engage within close-fitting through-holes formed in slide plate assemblies 218 , which slidably engage with a slideway 220 positioned along the top of the tie structure upper side beams 188 . The slide plate block 218 may have a bottom transverse slide section that closely engages within and is slideable relative to the slideway 220 . The slide plate assemblies may also include upright plate portions that extend upwardly from transverse slide section to pass through a narrow slot or entrance formed in the upper section of the slideway 220 (at the upper portion of side beams 188 ), to an elevation corresponding to the end portion of slide assembly 216 . It will be appreciated that other alternative constructions for slide plate assemblies 218 and slideway 220 may be utilized without departing from the spirit or scope of the present invention. Also, the slide plate assembly 218 may be nominally positioned relative to the length of slideway 220 by any convenient means, such as by use of compression or extension springs or shear pins (not shown).
[0111] The body structure 178 may be coupled to the immediate slide assembly 216 by use of a bracket 224 that extends downwardly from the central upper portion of the body to be pinned to the intermediate slide assembly by a longitudinal pin 226 that is longitudinally aligned with roll axis 186 . This construction allows the body structure 178 to roll relative to the intermediate slide assembly 216 and tie structure 180 about the roll axis 186 . The body structure 178 is supported and stabilized relative to the hub assemblies 201 by strut assemblies 232 that extend upwardly from the hub assemblies for connection to upper portions of the body by use of standard connection joints, such as ball joints 236 .
[0112] Turning now to FIGS. 6-8 , there is shown one exemplary embodiment of a system for achieving relative longitudinal movement (lateral movement may also be provided) between the tie structure 180 and the body 178 upon impact loads applied to the tie structure with the distance of relative movement proportional, or otherwise related, to the magnitude of the impact load. This system includes a forward bumper assembly 240 mounted against the forward end of the tie structure 180 by mounting bracket 242 . The forward bumper assembly 240 may include a plurality of telescoping, forwardly extending tubular members 244 A, 244 B, 244 C, 244 D, etc., disposed within an outer, flexible cover structure 246 . The telescoping members 244 may be designed to contract or compress when the bumper assembly 246 impacts against another vehicle or other object in a controlled manner so as to dissipate some of the force of the impact.
[0113] The interior of the bumper 246 may be filled with a fluid that can be used to enhance the structural integrity of the bumper assembly. The fluid within the bumper assembly 240 may also be utilized to shift the body 178 relative to the tie structure 180 when the bumper assembly impacts against another vehicle or other object. To this end, an elongate manifold 248 extends at least partially along the width of the bumper, at the rearward portion thereof. The manifold 248 is in fluid flow communication with the fluid within the bumper assembly 240 . The manifold 248 may be in the form of a tubular member or of other appropriate construction.
[0114] The manifold 248 is in fluid flow communication with fluid actuators 250 which are illustrated in FIGS. 6-8 as being in the form of a fluid cylinder. The actuators 250 each includes a cylinder portion 252 in fluid flow communication with the bumper assembly 240 through a fluid pipe or a line 254 . The cylinders 252 are pinned to the upper side beams 188 of the tie structure 180 by a pair of parallel, spaced apart mounting ears 256 extending upwardly from the upper surfaces of the beams 188 to receive the adjacent ends of the cylinders 252 therebetween. Close-fitting pins 258 extend through aligned openings formed in the mounting ears 256 and in the adjacent end of the cylinder 252 to pivotally couple cylinders 252 to the mounting ears. A piston rod 260 is extendible outwardly of the opposite end of the cylinder 252 . The forward or free end of the rod 260 is pinned to the forward portion of slide plate 218 for the use of a pivot pin 262 .
[0115] The vehicle 176 also may include a rear bumper assembly 264 that may be constructed essentially identically or at least somewhat similarly to the forward bumper assembly 240 . As with the forward bumper assembly 240 , the rearward bumper assembly 264 may also function as a bladder for fluid used to shift the body structure 178 relative to the tie structure 180 during a crash or application of an input load to the tie structure. To this end, the rear bumper assembly 264 may be in fluid flow communication with rearward fluid actuators 266 , that may be constructed essentially identically or similarly to the forward fluid actuators 250 . As such, the details of the construction of the rear bumper assembly 264 and rear fluid actuators 266 will not be repeated here.
[0116] As an alternative, the fluid actuated system, described above, may be replaced with a mechanical linkage system (not shown). The mechanical linkage system can be configured so that if an impact load is applied to the front and rear bumper assembly 240 , 264 , the body can be shifted away from the location of the impact relative to the bumper.
[0117] A seat assembly 268 for the vehicle driver/occupant is located in the forward portion of the body 178 . Although the vehicle 176 is illustrated as configured for limited occupancy, for instance for racing, the vehicle may be reconfigured to carry a plurality of passengers. In this regard, the body 178 may be widened relative to the width of the tie structure so as to occupy substantially the entire width between the side beams 188 and 190 of the tie structure.
[0118] The seat assembly may be mounted on a slide system to move under impact in the manner of the seat assemblies shown in FIG. 13 . Also, the assembly 268 may be enclosed in a surrounding cockpit 269 , which in turn may be mounted on a slide assembly (not shown) to protect the driver and allow the cockpit to continue to move in the direction of travel of the vehicle despite the impact force applied to the vehicle.
[0119] A propulsion engine 270 is illustrated as disposed within the rear portion of the body 178 . The engine 270 may be coupled to a transaxle 272 to transmit the engine power to rear wheel assemblies 184 through drive axles 274 that extend transversely outwardly from each side of the transaxle to drivingly engage the rear wheel assemblies 184 in a manner well known in the art. Universal joints, constant velocity joints or other connectors may be utilized between the transaxle 272 and the drive axles 274 as well as between the drive axles and the rear wheel assemblies 182 in a manner well known in the art to accommodate relative movement between the transaxle and the rear wheel assemblies. Moreover, rather than carrying the weight of the engine 270 in the body 178 , the engine can instead be mounted on the tie structure 180 .
[0120] As a further aspect of the present invention, an air foil/ground effect structure 276 is mounted on the underportion of the body 178 . The air foil or ground effect structure ideally spans between the wheel assemblies 182 and 184 in the side-to-side direction and beyond the wheel assemblies in the fore and aft direction as illustrated in FIGS. 6-8 . The ground effect structure may be a singular structural member or composed of a plurality of members that cooperatively form the ground effect structure. Also, the ground effect structure may be oriented (tilted downwardly in the forward direction) relative to the ground to cause a partial vacuum to be created under the vehicle, thereby to impart a downward load on the vehicle when traveling at a sufficiently high speed. This downward load on the body is transferred to the tie structure and from there to the forward and rearward wheel assemblies 182 and 184 .
[0121] The ground effect structure 276 may also serve to “close off” the lower front portion of the vehicle 176 to also help create a partial vacuum beneath the vehicle. Also, during use, the pitch of the body may serve to keep the body relatively level with respect to the ground and also maintain a constant distance between the underside of the body and the ground. Also, the ground effect structure 276 may be constructed to be somewhat adjustable in orientation to alter the amount of downward load created, in a manner well known in the art.
[0122] Rather than being carried by the body 178 , the ground effect structure can be connected to the tie structure, so that the downward load created during vehicle travel is imposed on the tie structure rather than on the body. Of course this load is carried through the tie structure connections with the wheel assemblies. Alternatively, a separate air foil 277 may be mounted on the upper portions of the tie structure to impart a downward load thereon. In a known manner, the angle of attack of the air foil may be adjustable so as to vary the downward force generated by the air foil.
[0123] In use, if the vehicle 176 hits or is hit by another vehicle or object at, for instance, the front of the vehicle, the body 178 may shift rearwardly relative to the tie structure 180 , a distance in proportion to the level of impact sustained. In this regard, fluid within the forward bumper assembly 240 may flow out therefrom through lines 254 as the bumper assembly is deformed and thereby reduced in volume. The fluid flowing from the bumper assembly through lines 254 is routed to linear actuators 250 , thereby to extend the piston rods 260 thereof outwardly therefrom, which in turn pushes the slide plates 218 rearwardly relative to the tie structure, thereby shifting the body 178 also rearwardly. Flow restrictors may be used in line 254 or in cylinder 252 to control the rate of movement of the body relative to the tie structure. Also, at the same time, the fluid in the rear actuators flows out of the actuators and into the rear bumper assembly or to a separate actuator (not shown). Further, a flow controller can be incorporated into the rear actuators or rear fluid lines to control the flow of fluid between the rear actuators and the associated accumulator or rear bumper 264 .
[0124] Simultaneously, during breaking, the body may pivot about transverse axis 278 defined by pins 217 due to the braking force being applied to the body at its center of gravity 280 , which is at a level below transverse axis 278 . As such, a larger downward force is applied to the rear springs of the vehicle 176 than in a conventional vehicle (whereupon braking, the pitching of the vehicle imposes a larger downward force on the front vehicle springs and may substantially unload the rear vehicle springs), thereby providing good contact between the rear wheel assemblies 184 and the ground to improve the braking ability of the vehicle.
[0125] In addition, the vehicle 176 is capable of tilting in the inward direction when cornering to compress the inside springs, while at the same time the tie structure 180 is capable of swinging slightly outwardly when cornering, thereby preventing the longitudinal axis 186 of the vehicle from serving as a roll reaction center, i.e., the elevation or point to which the lateral forces act to cause a jacking effect that tends to raise the inside wheels and roll the vehicle about its outside wheels. As a result, as discussed above, the effective roll reaction center of the vehicle is at an elevation below the elevation of the pivot axis 186 , resulting in a lower rate of force transfer being imposed on a vehicle during cornering. Thus, the construction of the vehicle 176 can provide the same operating characteristics and advantages provided by the vehicles 50 and 150 when cornering, as discussed above.
[0126] The embodiments of the present invention, including that of FIG. 9 , provide positive dynamic camber to the vehicle. FIG. 9 shows the tie structure 180 tilted outwardly relative to the curve (right hand direction) and the body structure 180 tilted inwardly into the curve (left hand direction) to a greater extent than the outward tilt of the tie structure. As a result of such tilting of the tie structure and body, and the interconnection of the tie structure to the wheel assemblies 182 and 184 and the connection of the strut assemblies 232 to the body above the roll center 186 , the wheels are tilted inwardly into the curve, providing positive dynamic camber. As will be appreciated, this improves the traction, turning and cornering abilities of the vehicle.
[0127] The body structure 178 is also capable of pitching relative to the tie structure by rotation of the body about transverse pivot axis 278 . In this regard, the rods 216 B may rotate relative to the center bar portion 216 A. Alternatively, the pivot pins 217 extending outwardly from the rods 216 B may pivot relative to the slide blocks 218 . Since the transverse pivot axis 278 is located above the center of gravity 236 , during braking a longitudinal force is imposed on the springs of the vehicle 174 in a forwardly direction at the elevation of the center of gravity 234 . In the present invention such longitudinal force will tend to cause the body to pivot about transverse axis 278 , so that the rear end of the body tends to lower, while the front end of the body tends to rise, thereby maintaining significant load on the rearward torsion bar assemblies. It will be appreciated that during hard acceleration the opposite effect occurs, thereby maintaining significant loading on the front wheels of the vehicle.
[0128] Also, during hard braking, or perhaps during a crash or impact, the body structure 178 is capable of moving longitudinally relative to the tie structure by the sliding of the slide block plates 228 relative to the slideway 220 . Such sliding movement can reduce the effect of a crash on the body, and in particular on the occupant(s) of the vehicle. This may be very significant if the vehicle construction shown in FIG. 9 is employed in a racing vehicle.
[0129] Rather than relying solely on compression of the bumper assemblies to cause the body 178 to shift relative to the tie structure, a powered system might be employed. In this regard, one or more hydraulic pumps can be utilized to force fluid into and out of linear actuators 254 when it is desired to cause the body 178 to be longitudinally shifted, for instance when accelerometers or other sensors indicate that a crash of the vehicle is occurring or may be imminent. The hydraulic pump can be utilized in conjunction with the bumper assemblies 240 or may be employed in lieu of such bumper assemblies and the associated fluid lines interconnecting the bumper assemblies to the linear actuators.
[0130] FIGS. 10 and 11 disclose a further embodiment of the present invention wherein vehicle 50 C includes a body 52 C mounted on a suspension system 54 C, which in turn is supported by forward wheel assemblies 56 C and rearward wheel assemblies 58 C. A tie structure 60 C is interposed between the vehicle body 52 C and the wheel assemblies 56 C and 58 C. The tie structure 60 C extends longitudinally along a lower elevation of the vehicle 50 C and is interconnected to the body through a plurality of pivoting arm assemblies 302 to enable the body to roll and pitch relative to the tie structure 60 C.
[0131] As shown in FIGS. 10 and 11 , the tie structure may be of generally rectangular construction having forward and rearward panel sections 284 and 286 interconnected by longitudinal side panel sections 288 . The tie structure 60 C may be constructed by tubular components, plates or other appropriate structural members and materials. The tie structure may be connected to hub carriers 76 C of the forward and rearward wheel assemblies 56 C and 58 C in a manner described above with respect to FIGS. 1 , 2 , and 3 . As such, the construction and operation of the pivot arm assembly 68 C will not be repeated here. Also, an anti-roll bar 289 or other device can be used between the pivot arm assemblies and the tie structure of simply between the pivot arms themselves. Such anti-roll bar 289 is shown at the rear of the vehicle. A similar anti-roll bar can be used on the front of the vehicle. Such anti-roll bar includes a central length 289 A that is mounted to the rear of the tie structure 60 C and end arms 289 B that extended rearwardly and outwardly from the central section to be attached to corresponding hub assemblies of rear wheel assemblies 58 C.
[0132] The body 52 C may be supported from the wheel hub assemblies by forward spring/shock absorber assemblies 70 C and rearward spring/shock absorber assemblies 80 C in a manner similar to that shown in FIGS. 1 and 2 . The upper ends of the spring/shock absorber assemblies are connected to a structural member(s) 72 C of the body. It will be appreciated that rather than being constructed as a solid unit, the structural member 72 C may be of tubular or other type of construction, thereby to minimize its weight while still providing sufficient structural integrity to carry the loads imposed thereon, not only by the static weight of the vehicle 50 C, but also to carry the dynamic loads imposed on the vehicle during travel, including during cornering, as well as during acceleration and braking.
[0133] As shown in FIG. 10 , the suspension system 54 C may utilize forward and rearward steering assemblies 290 and/or 292 to steer the forward and rearward wheels. The forward and rearward steering assemblies may be of similar construction, and thus, only the construction of the forward steering assembly will be described with the understanding that the rear steering assembly is of similar construction and operation. The forward steering assembly 290 may include a rack and pinion subassembly 294 . The outer ends of the rack 296 are connected to the adjacent hub carrier 76 C by steering links 298 in a manner well known in the art. The rack and pinion subassembly 294 is mounted on the forward portion of the tie structure 60 C by a pair of forward-extending mounting brackets 300 .
[0134] It is to be understood that other systems may be used to steer vehicle 50 C or the other vehicles of the present invention. For example, steering can be carried out by connecting the steering components electrically rather than using a rack and pinion. In this regard, rather than being connected to a vehicle steering wheel by a mechanical linkage arrangement, a linear actuator may be used to power the rack 296 . Moreover, electrical linear actuator may be used to power the steering arms, thereby eliminating the need for a rack.
[0135] Referring also to FIG. 13 , the body 52 C may be mounted to the tie structure 60 C by four arm assemblies 302 , located at each of the four corner portions of the tie structure 60 C. Each of the arm assemblies 302 may include a generally triangularly shaped arm structure 304 coupled to the tie structure by a pivot shaft 306 that closely engages through the interior of a tubular base member 307 to engage aligned clearance holes provided in mounting ears 308 fixed to the tie structure. The pivot shaft 306 defines a pivot axis 309 about which the arm structure 304 is able to pivot relative to the tie structure. The arm structure 304 also includes a pair of arms 310 that extend from the ends of the base 307 towards the apex of the arm structure. The distal apex ends of the arms 310 intersect a tubular collar 312 oriented substantially perpendicularly to cylindrical base member 307 but in planar alignment with the base member so that the central axis of collar 312 is in the same plane as the central axis of base member 307 . The collar 312 may be sized to receive a close-fitting cylindrical bushing 314 having a plurality of diametric cross-holes 316 formed along the bushing and spaced apart to correspond with the spacing of corresponding diametric cross-holes 318 , provided in collar 312 . Crossbolts 319 extend through the bushing cross-holes 316 and through corresponding collar cross-holes 318 to retain the bushing 314 in engagement with collar 312 at a desired relative position therebetween. It will be appreciated that the effective length of the arm structures 304 may be varied depending on which of the cross-holes 316 are in alignment with the cross-holes 318 . It will also be understood that the extent of relative engagement between bushing 314 and collar 312 may be controlled by other structures. For instance, the bushing 314 can be formed with external threads (not shown) to mate with internal threads (not shown) formed in collar 312 .
[0136] One purpose of being able to adjust the effective lengths of the arm assemblies is to change the elevation or other locations on which the arm assemblies can be mounted on the tie structure 60 C, which changes the nominal angular orientation of the arms and thus the amount that the body is allowed to roll and pitch relative to the tie structure.
[0137] Also, the nominal length of the forward arm assemblies can be changed relative to the rear arm assemblies to move the location of the pitch center of the vehicle fore and aft, as desired. This will affect the relative loading on front and rear wheel assemblies during braking and acceleration.
[0138] The arm assembly 302 also includes an end connection knuckle 320 , having a stub shaft portion 322 sized to closely and rotatably engage within a radial bearing or bushing 324 disposed within the adjacent end of bushing 314 . The stub shaft is allowed to rotate relative to the bushing 324 , but not move longitudinally relative to the bushing, being held captive by a snap ring or other well-known means (not shown). The connection knuckle 320 also includes a collar section 326 , disposed transversely to stub shaft 322 and having an aperture therein for receiving a crosspin 328 that engages through close-fitting openings formed in mounting ears 330 fixed to the body structural assembly 72 C. An elastomeric bushing 331 may be interposed between the crosspin 328 and the mounting bar ears 330 to provide some insulation therebetween. Similar bushings can be used between pivot shaft 306 and mounting ears 308 or at other joint locations of the arm assembly 302 .
[0139] As shown in FIG. 10 , the two forward arm assemblies 302 are oriented in a rearward and inward direction relative to the vehicle 50 C, and likewise, the two rearward arm assemblies 302 are oriented in the forward and inward direction. The forward arm assemblies 302 are oriented such that the central axis 329 extending through collar 312 and the apex of the arm assemblies (and perpendicular to pivot shafts 306 and shafts 328 ) will intersect substantially at the longitudinal centerline 332 of the body 52 C and tie structure 60 C. The rear arm assemblies 302 are positioned in a similar orientation.
[0140] It is to be understood that the arm assemblies can be positioned at angles other than as shown in plan view on FIG. 10 , thereby to change the location of the pitch center and/or roll center of the vehicle. For example, the arm assemblies can be positioned so that their central axes all intersect at a common point along the longitudinal center line 332 .
[0141] The body 52 C may be supported relative to the forward and rearward wheel assemblies 56 C and 58 C by forward spring/shock absorber assemblies 70 C and rearward spring/shock absorbers 80 C in a manner similar to that shown in FIGS. 1 and 2 . As such, the structure and operation of the forward and rearward spring/shock absorber assemblies will not be repeated here.
[0142] Also, the vehicle 50 C may be driven by an engine 88 C through a transmission 90 C and drive shaft 92 C in a manner similar to that shown in FIGS. 1 and 2 . Accordingly, the construction and operation of these components will also not be repeated here.
[0143] Rather than being carried by the tie structure 60 C, the engine 80 C and transmission 90 C may be carried instead by the body 72 C without departing from the spirit or scope of the present invention. In certain situations, mounting the engine and transmission on the body rather than on the tie structure might be advantageous to the construction and performance of the vehicle. For example, it may be easier to obtain access to the engine and transmission if located on the body rather than on the tie structure. Also, by locating the engine and drive train on the body, a larger portion of the weight of the vehicle rolls about the roll center and pitches about the pitch center during operation of the vehicle. This configuration can result in larger dynamic loading on the vehicle tires.
[0144] In operation, as vehicle 50 C rounds the corner, the body 52 C is capable of tilting relative to the tie structure 60 C about a longitudinal axis 332 defined by the intersection of the forward and rearward arm assemblies due to the ability of the arm assemblies to pivot relative to the tie structure and the body in the up and down directions only, as well as the connector knuckle of the arm assembly to rotate about collar 312 along axis 329 . Moreover, the elevation of the longitudinal axis 332 corresponds to the elevation in which the axes 329 of the A-arm structures 304 intersect each other, which elevation is above the center of gravity 329 A of the vehicle. Accordingly, when the vehicle 50 C rounds the corner, the body 52 C will pivot about longitudinal axis 332 in the direction inwardly of the curve (towards the center of curvature of the curve), in a manner similar to the embodiment of the present invention described above. Also, as will be appreciated, the arm assemblies 302 enable the body 52 C to pitch relative to the tie structure 60 C during braking or accelerating in the manner of previous embodiments of the present invention described above.
[0145] In addition, when vehicle 50 C is cornering, the tie structure 60 C is capable of swinging slightly outwardly due to the pivoting of the pivot arm assemblies 68 C, thereby reducing the rate of force transfer of the centrifugal force through the tie structure, thereby delaying the time that the jacking effect fully acts on the body. As a result, as described above, the effective roll reaction center of the vehicle 50 C is at an elevation below the elevation of longitudinal axis 332 , resulting in a lower jacking effect being imposed on the vehicle during cornering. Thus, the construction of vehicle 50 C can provide the same advantages when cornering as provided by the vehicles described above, including vehicles 50 and 150 .
[0146] In addition, it can be appreciated that through the present invention, the arm assemblies 302 can independently move relative to each other. Thus, for example, during cornering, the arm assemblies located on the inside of the vehicle may move to a less steep or lower angle of inclination due to the inward tilting of the body and outward tilting of the tie structure relative to the inclination of the arm assemblies at the outside of the vehicle. Also, the arm assemblies on the inside of the vehicle drop down farther than the outside arms rise up.
[0147] It will be appreciated that if the arm assemblies are nominally adjusted to have a lower angle of inclination, more body movement will be achieved per movement of the arms.
[0148] It will be appreciated that the arm assemblies 302 may be replaced with other structures, for example, a linear actuator. Such linear actuator can be extended and retracted in a manner similar to extending and retracting the arm assemblies 302 , as discussed above. Also, the arm assemblies 302 themselves can be modified so that their lengths can be automatically adjusted, for example, by the use of hydraulic or electric actuators to move the knuckle connector relative to the A-arm structure.
[0149] FIG. 13 illustrates a further embodiment of the present invention, wherein a vehicle 50 D is designed to allow a body 52 D to slide longitudinally relative to the tie structure 180 A upon an impact force applied to the vehicle in a direction away from the impact force, for instance, during a collision. In addition, the passenger seats 333 A and 333 B are designed to slide upon an impact load applied to the vehicle. The tie structure 180 A is illustrated as of generally rectangular construction similar to the construction of the tie structure 180 shown in FIGS. 6 , 7 and 8 . As such, the construction of tie structure 180 A will not be repeated here.
[0150] The vehicle 50 D may include a forward bumper assembly 334 that is shaped similarly to bumper assembly 240 shown in FIGS. 6-8 . In this regard, the bumper assembly 334 may be constructed similarly to bumper assembly 240 except that upon impact, the fluid in the bumper assembly may simply be expelled into the ambient air rather than utilized to move the body 52 D relative to the tie structure 180 A. Likewise, vehicle 50 D may include a rear bumper assembly 335 that is constructed and shaped similarly to the rear bumper assembly 264 shown in FIGS. 6-8 . The rear bumper assembly 335 can also be designed to expel the fluid therein into the ambient air rather than being utilized to shift the body 52 D relative to the tie structure 180 A.
[0151] It is to be understood that the forward and rearward bumper assemblies 332 and 334 also can be of other constructions. For instance, these bumper assemblies can be composed of crushable or collapsible material or structures to absorb at least some of the energy from collisions or other impact loads imposed on the vehicle. Also, collapsible material 337 may be mounted on body 52 D to absorb energy in case of a crash. In FIG. 13 , such material is shown at the front and back of the body 52 D.
[0152] In a manner similar to that shown in FIGS. 6-8 , the tie structure 180 A is supported by forward and rearward wheel assemblies 182 A and 184 A with the use of lower control arm assemblies 200 A that may be pinned to a mounting bracket 202 A carried by the upper side beams 188 A of the tie structure. The lower ends of the control arms 200 A are coupled to the wheel assemblies 182 A and 184 A in the same manner as in FIGS. 6-8 . Such coupling can be accomplished to enable the forward wheel assemblies 182 A to be steerable, in a conventional manner.
[0153] Forward and rearward slide assemblies 336 are imposed between the tie structure 180 A and the body 52 D. The slide assemblies 336 may be of many different constructions, including composed of a slideway 338 mounted on the upper side of tie structure top side beams 188 A to slidably receive a slide 340 secured to the underside of body 52 D. The slide assemblies 336 may be designed to require a baseline impact load to be imposed on the vehicle 50 D before permitting the body to slide relative to the tie structure. This can be accomplished in many well-known manners. For example, as a result of the threshold impact load that is imposed on the bumper assemblies 334 or 335 , the body 52 D can be permitted to continue to move somewhat in its same direction of travel rather than coming to an abrupt halt or before beginning to move away from the impact. If the impact load is applied to the body, the body can slide relative to the tie structure in the direction away from the impact force. As such, the forces imposed on the vehicle passengers is significantly less than in a conventional vehicle.
[0154] It will be appreciated that the slide assemblies 336 may be constructed to allow the body 52 D to also move laterally relative the tie structure 180 A, for example during a crash or collision. The slide assemblies can include a transverse slideway (not shown) mounted to the body that would allow lateral movement of such slideways relative to slide 340 .
[0155] In addition to, or in lieu of, the slide assemblies 336 , further slide assemblies 342 may be utilized between passenger seats 333 A, 333 B and body 52 D. The slide assemblies 342 can be of many known constructions. For example, a slideway assembly 344 may be mounted on the lower floor of the vehicle body and a slide assembly 345 attached to the lower bottom side of the passenger seats 333 A and 333 B. As with slide assemblies 336 , the slide assemblies 342 can be designed to require a threshold impact load to be imposed on the vehicle before the passenger seats 333 A and 333 B are permitted to move relative to the body 52 D. As noted above, this can be accomplished in many different ways to provide the same advantage provided by slide assembly 336 , i.e., to permit the vehicle passengers to continue to move to a certain degree along their same path of travel toward an impact load when the impact load is applied to the vehicle tie structure. In addition, the slide assemblies 342 will enable the passengers to continue to move in their direction of travel if instead of an impact load being applied to the tie structure, such impact load is applied to the body 52 D, thereby lessening the impact force imposed on the passengers. This could reduce the injuries caused to the vehicle passengers during a collision or other accident.
[0156] It will be appreciated that, rather than mounting the seats 333 A and 333 B on slide assembly 342 , the seats might instead be mounted on a four-bar linkage arrangement or other type of structure to enable the seats to swing relative to the body during a crash or other significant impact load imposed on the vehicle. It will be appreciated that to accomplish such swinging movement, parallel swing arms may extend upwardly from the vehicle floor or downwardly from the vehicle roof, or laterally from the vehicle panels or structures, to support the seats during normal use and also to permit swinging movement of the seats during a crash.
[0157] As a further alternative, seats 333 A and 333 B may be pivotally mounted to the overhead portion of the body 52 D. In this regard, a bracket may extend between the rear upper portion of the seats 333 A and 333 B and the overhead portion of the body 52 D.
[0158] It is appreciated that the body 52 D, shown in FIG. 13 , is shown schematically. The body 52 D can be of various other shapes without departing from the spirit or scope of the present invention. In this regard, the body 52 D might be shaped generally in the manner of the body 52 , shown in FIGS. 1 and 2 . Moreover, the body 52 D may be constructed to be easily removable from the tie structure 180 A. In this regard, quick-release connectors can be utilized to connect the body 52 D to the tie structure at the slide 340 .
[0159] It will be appreciated that for the body 52 D to move or slide relative to the tie structure, the body may require more structural integrity than in the typical automobile currently being manufactured. As such, it may not be necessary to design the body with crushable panels at the ends or sides thereof, although such crushable panels are an option.
[0160] FIGS. 14 , 15 and 16 schematically illustrate a further embodiment of the present invention, wherein a vehicle 960 includes a body 962 mounted on an underlying tie structure 964 , which is supported by wheel assemblies 966 . The tie structure may extend substantially the length of the body 962 or may be composed of a forward section at the forward end of the vehicle and a separate rearward section at the rearward end of the vehicle. The body is capable of rolling relative to the tie structure, which preferably extends longitudinally of the vehicle and transversely across the vehicle at a lower elevation thereof. A lower control arm assembly 968 extends outwardly from a corner of the tie structure to the underside of hub assemblies 970 of the wheel assemblies 966 .
[0161] FIGS. 14 , 15 and 16 illustrate the forward end portion of the vehicle 960 . The rearward end portion of vehicle 960 may be constructed similarly thereto. The control arm assembly 968 may be torsionally loaded relative to the tie structure 964 in a manner that is well known in the art, for instance as described above and illustrated in FIG. 3 .
[0162] Swing arm assemblies 972 extend upwardly from corner locations of the tie structure 964 to pivotally couple to the adjoining portion of body 962 . The swing arm assemblies 972 consist of longitudinally separated arms 972 A and 972 B interconnected by a pair of parallel rods or tubes 972 C. The upper end portions of the arms 972 A and 972 B are pinned to the lower portion of the body 962 , with the lower end portions of the arms pinned to side sections of the tie structure 964 . As shown in FIG. 14 , the swing arm assemblies 972 are sloped towards each other in the upward direction so that lines extending therefrom intersect at the roll center 978 of the vehicle. The swing arm assemblies 972 allow the body 962 to roll relative to the tie structure 964 while restricting relative longitudinal movement between the body and the tie structure. By this construction, the tie structures 964 and swing arm assemblies 972 can be incorporated into existing vehicles or designed into new vehicles without a radical change in design from existing vehicles.
[0163] Continuing to refer to FIGS. 14 , 15 and 16 , the vehicle 960 includes a propulsion engine/motor 974 that is carried by the tie structure 964 . A drive train 975 may be interconnected between the motor/engine 974 and the wheel assemblies 966 in a manner well known in the art. Also, the motor/engine may be located near the forward end of the vehicle, near the rearward end of the vehicle, or at a location therebetween. The body 962 may be supported by strut assemblies 976 extending upwardly from hub assemblies 970 for connection to an upper portion of the body 962 . The strut assemblies may be designed so that the roll stiffness of the body 962 is not as stiff as the roll stiffness of the tie structure.
[0164] With respect to the operation of the vehicle 960 , applicant notes that the roll center 978 of the vehicle 981 is at a location defined by the intersection of lines extending longitudinally from swing arms assemblies 972 , which is at an elevation substantially above the center of gravity 980 of the vehicle. As such, when the vehicle 960 rounds a corner, a centrifugal force is applied thereto at the center of gravity 980 , which is at an elevation below the roll center 978 . As such, the body 962 tilts inwardly toward the center curvature of the curve about the roll axis 978 . When this occurs, the tie structure simultaneously tilts, to some extent, away from the center of curvature, which tends to cause the roll center 978 to shift outwardly somewhat relative to the center of a curve being negotiated, but not far enough to negate the inward tilting motion of the body 962 . The advantage of the tie structure moving outwardly slightly during cornering is that during such movement, the roll center 978 does not serve as a roll center about which centrifugal forces act to tip the vehicle outwardly so that the rate of centrifugal force transfer through the vehicle is reduced. It will be appreciated that the relative outward tilt of the tie structure in relationship to the inward tilt of the body can be altered by controlling the various components of the vehicle suspension system, including the torsion load at the inward ends of the trailing links 968 and the load-carrying capacity and stiffness of the strut assemblies 972 .
[0165] Vehicle 960 also provides the advantage of positive dynamic camber when cornering. In this regard, as shown in FIG. 14 , the body 962 is tilted upwardly at the side thereof toward the outside of the curve while the tie structure is tilted somewhat downwardly relative to the outside of the curve, with the tilt of the tie structure being less than the tilt of the body due to the relative greater stiffness of the torsion load on arm assemblies 968 vis-a-vis the strut assemblies 976 . The upward tilt of the body will tend to move the upper portion of the inside wheel inwardly into the curve as well as move the upper portion of the outside wheel inwardly relative to the curve. As a result, both the wheels of the vehicle tend to tilt inwardly relative to the curve providing positive dynamic camber, thereby improving the traction of the vehicle during cornering.
[0166] It will also be appreciated that by mounting the motor/engine 974 and corresponding drive train components on the tie structure, less plunge is required for the drive line interconnecting the motor/engine to the drive wheels, in relationship to the plunge required if the motor/engine were mounted on the body. As noted above, vehicle 960 is designed so that the tie structure 964 tilts outwardly to a lesser degree in cornering than does the body 962 tilt inwardly during cornering. Further, by mounting the motor/engine solely on the tie structure, it would be easier to adapt the present invention to existing vehicles.
[0167] FIG. 17 diagrammatically illustrates a further embodiment of the present invention wherein a vehicle 981 includes a body 982 , mounted on an underlying tie structure 983 , which is supported by wheel assemblies 984 . As in the embodiment shown in FIGS. 14 , 15 and 16 , the tie structure 983 may extend substantially the entire length of the body 982 , or may be composed of a forward section at the forward end of the vehicle and a rearward section at the rear end of the vehicle. As also in the vehicle 960 shown in FIGS. 14 , 15 and 16 , in the vehicle 981 , the body 982 is capable of rolling relative to the tie structure.
[0168] Control arm assemblies 985 extend outwardly from the sides of the tie structure to the underside of hub assemblies 986 of wheel assemblies 984 . The control arm assemblies 985 may be torsionally loaded relative to the tie structure 983 in a manner as described above.
[0169] Swing arm assemblies 987 extend upwardly from tie structure 983 to pivotally couple through the adjacent portions of body 982 . The swing arm assemblies 987 , as illustrated, may consist of A-arm assemblies similar to those shown in FIGS. 10 , 11 and 12 . In this regard, the swing arm assemblies 987 may be positioned to extend upwardly towards the longitudinal center of the body 982 and also the forward swing arm assemblies may extend towards the rear of the vehicle 981 , whereas the rear swing arm assemblies may be oriented to slope forwardly towards the forward end of the vehicle 981 . In this manner, the swing arm assemblies 987 may allow the body 982 to roll relative to the tie structure 983 and also permit the body to pitch relative to the tie structure in a manner somewhat similar to the vehicle 500 shown in FIGS. 10 and 11 .
[0170] As in vehicle 960 shown in FIGS. 14 , 15 and 16 , the vehicle 981 may be constructed so that the stiffness of the control arm assemblies 985 is greater than the stiffness of the strut assemblies 988 used to support the body relative to the wheel assemblies 984 . In this manner, when the vehicle is rounding a corner, the centrifugal force is applied thereto at the center of gravity 989 , which is at an elevation below the roll center 989 A of the vehicle, causing the body to tilt inwardly toward the center of the curve. When this occurs, the tie structure simultaneously tilts, to some extent, away from the center of the curve, thereby tending to cause the roll center 989 A to shift outwardly somewhat relative to the center of the curve, but not far enough to negate the inward tilting motion of the body 982 . As in other embodiments of the present invention, advantageously the slightly outward movement of the tie structure during cornering prevents the roll center 989 A from serving as a roll center about which centrifugal forces act to tip the vehicle outwardly, so that the rate of centrifugal force transfer through the vehicle is reduced. This same advantage applies during vehicle pitching.
[0171] Moreover, vehicle 981 also provides the advantage of positive dynamic camber when cornering. In this regard, the vehicle 981 operates in a manner very similar to vehicle 960 , described above, and thus such description will not be repeated here.
[0172] As a further matter, in vehicle 981 , the motor/engine 989 B and the corresponding drive train components 989 C may be mounted on the tie structure 983 rather than being carried by the body or other parts of the vehicle. As a consequence, the drive train is required to accommodate less relative movement between the engine and the drive wheels than would be required if the motor/engine were mounted on the body.
[0173] FIG. 18 illustrates another embodiment of the present invention wherein a vehicle 1300 includes a body 1302 supported above an underlying tie structure 1304 by pairs of diagonal control sliders 1306 . The tie structure 1304 may be in the form of a solid axle extending transversely between wheel assemblies 1308 . Also the lower end of the control sliders 1306 may be mounted below the tie structure/axle 1304 by use of brackets 1310 thereby to lower the pitch center and/or roll center 1312 as low as possible. As in other embodiments of the present invention, the pitch center and/or roll center is defined by the intersection of lines constituting extensions of the control sliders 1306 .
[0174] The control sliders 1306 are illustrated in FIG. 19 as constituting an adjustable hydraulic or fluid spring-loaded actuator assembly having a cylinder portion 1314 housing a piston 1316 which is connected to a piston rod 1318 which extends outwardly from the cylinder. A relatively stiff spring 1320 or other type of resilient means loads the piston 1306 against stop 1322 thereby dividing the cylinder 1314 into first and second chambers 1324 and 1326 . The chambers 1324 and 1326 may be filled with a fluid that passes from one side of piston 1316 through passages 1327 that limit the speed that the piston may move relative to the cylinder 1314 , for instance if one control slider 1306 is unloaded due to its corresponding wheel 1308 hitting a pothole and at the same time the body rolling or pitching. Controlling the rate that the piston 1316 can move within cylinder 1314 will make sure that there will be resistance to such rolling or pitching action.
[0175] It will be appreciated that the control sliders 1307 and similar components described herein may be of other constructions. For example, the control sliders may be constructed with a fluid that can be changed in viscosity as desired very quickly if not almost instantaneously, so as to change the operational characteristics of the control sliders, struts or other similar components of the present invention. One example of such fluid construction includes magnetic properties that can be changed or controlled electrically or electronically.
[0176] Optionally, linear controllers 1328 may extend between the tie structure and the body to control the tilt and/or pitch of the body. The controllers have a spring rate that is “softer” than the control sliders 1306 to allow the tie structure to react to road bumps without transferring all of the “bumps” to the body. However, the function of the linear controllers 1328 may be carried out by the control sliders 1306 . In this regard, the control sliders can be of variable spring rates, perhaps having a softer spring rate when accommodating road discontinuities but having a much stiffer spring rate when the body rolls during cornering or pitches during acceleration or hard braking. Sensors can be utilized on the vehicle to sense road bumps as well as the body roll during cornering and body pitching during braking and acceleration. In response thereto, the characteristics of the control slider 1306 are automatically adjusted so as to react to the particular external force being applied to the vehicle, whether road bumps or corner rolling or pitching due to braking or accelerating. It will be appreciated that by this construction a tie structure such as described above with respect to other embodiments of the present invention, for instance shown in FIG. 17 , may not actually be required, thereby simplifying the construction of vehicles made in accordance with the present invention.
[0177] FIGS. 20 , 21 , 22 and 23 illustrate a further embodiment of the present invention, wherein vehicle 346 includes a body 348 mounted on an underlying tie structure 350 supported by wheel assemblies 352 . The tie structure 350 includes a lower hollow transverse crossmember 354 having a torsion bar 356 extending therethrough. The outer ends of the torsion bar extend beyond crossmember 354 to rigidly couple to the rearward ends of forward leading arm assemblies 358 . The opposite ends of the leading arm assemblies are pivotally coupled to the lower portions of hub assemblies 360 of a wheel assembly 352 . The torsion bar 356 allows for controlled relative vertical movement between the tie structure 350 and the wheel assemblies 352 , for instance when traveling over a bump or cornering.
[0178] The tie structure 350 is connected to the body 348 by a pair of lower swing arm assemblies 362 . The swing arm assemblies may be of numerous, different constructions. For example, in FIGS. 20 and 21 the swing arm assemblies 362 are in the form of A-arms having their lower ends coupled to the tie structure crossmember 354 by a pivot pin 364 that is carried by pivot block 366 attached to the tie structure crossmember 354 . The upper, opposite ends of the swing arms 362 are pinned to lower portions of a body structural member 368 . It will be appreciated that the swing arms 362 keep the body 348 from moving longitudinally relative to the tie structure 350 while allowing the body to move laterally as well as pivot about a longitudinal axis relative to the tie structure 350 . Also, the swing arm assemblies are oriented so that they are in alignment with the roll center 367 of the vehicle, which is at an elevation above the center of gravity 384 of the vehicle.
[0179] The tie structure 350 further includes upright posts 370 extending upwardly from the tie structure crossmember 354 . The lower ends of the posts can be attached to the crossmember 354 by bolts 357 to enable the posts to pivot in the lateral direction above the bolts. The upper ends of the posts 370 are coupled to a central location on the body structural member 368 by a pair of link arms 372 A and 372 B. The outer ends of the link arms 372 A and 372 B are pinned to the posts 370 at selective locations along the height of the posts, with the particular location of such pin connection selected for adjusting the camber imposed on the vehicle 346 . The center, inward ends of the link arms 372 A and 372 B are jointly pinned to the body structural member 368 to pivot about a longitudinal axis 374 of the vehicle. As an alternative, the link arms 372 A and 372 B may be shortened to be pinned to the body structure member 368 at laterally spaced apart locations (not shown).
[0180] The upper end portions of the posts 370 are supported by upper leading arms 376 . The inward ends of the leading arms 376 are pinned to respective posts 370 by cross pins 378 extending through a transverse opening formed in the posts and through aligned openings of a yoke formed in the trailing arm 376 . The outer, forward ends of the upper leading arms 376 are connected to wheel hub assemblies 360 by ball joints 380 in a well-known manner. It will be appreciated that from their connection to posts 370 , the upper leading arms 376 extend laterally outwardly, forwardly and downwardly to their connection with corresponding hub assemblies 360 .
[0181] The body 348 is also supported relative to the tie structure 350 by spring/shock absorber assemblies 382 . The lower ends of the spring/shock absorber assemblies are connected to lower leading arms 358 by ball joints 383 in a conventional manner, and correspondingly the upper ends of the spring/shock absorber assemblies are connected to the body structural member 368 also by ball joints 385 in a conventional manner.
[0182] In operation, when vehicle 346 rounds a corner, a centrifugal force is applied thereto at the center of gravity 384 which is at an elevation below the elevation of the roll center 367 . As such, the body 348 will tilt inwardly toward the center of curvature of the curve about axis 374 and compress the inside spring/shock absorber assemblies. When this occurs, the tie structure simultaneously tilts, to some extent, away from the center of curvature, which tends to cause the longitudinal axis 374 to shift outwardly of the center of curvature somewhat, but not far enough to negate the inward tilting of the body 348 . The advantage of the tie structure moving outwardly slightly during cornering is that during such movement the rate of force transfer through the vehicle is less than if the tie structure did not tilt. During such tie structure movement, the longitudinal axis 374 does not serve as the roll reaction center about which the forces would be acting to tip the vehicle outwardly. It will be appreciated that the relative outward tilt of the tie structure in relation to the inward tilt of the body can be altered by controlling the stiffness of the various components of the vehicle's suspension system, including the torsion bar 356 and the spring/shock absorber assemblies 382 .
[0183] FIGS. 24 , 25 and 26 diagrammatically disclose a further embodiment of the present invention wherein a vehicle 390 includes body 392 mounted on/carried by a tie structure 394 , which in turn is carried by wheel assemblies 396 . The tie structure includes a transverse crossmember subassembly 400 composed in part of a cross tube 402 . The inward base portion 404 of a lower A-arm assembly 410 engages within each end portion of the cross tube 402 . The base portion 404 is biased in the direction towards the adjacent outward end of the cross tube 402 by a compression spring 406 . The inward end of the compression spring presses against a piston 408 which is loaded toward the outer end of the cross tube 402 by any convenient means, for example by hydraulic pressure, linear actuator, etc. The opposite, outward end of the A-arm assembly 410 is coupled to a lower portion of wheel hub assembly 414 through the use of a ball joint 416 .
[0184] The body 392 is connected to the underlying tie structure 394 by diagonally oriented link arms 418 that are pinned at their lower ends to outward end portions of the cross tube 402 . The upper, inward portions of the link arms are pinned to lower portions of body structural member 420 . The link arms 418 are oriented so that if extended in the inwardly direction they would intersect at point 422 along the transverse center line of the vehicle 390 corresponding to the roll center of the body. The body 392 is also supported by upper arm assemblies 424 having their lower ends carried by hub assemblies 414 and their upper ends coupled to the body structural member 420 by ball joints 426 . Body springs 427 are connected between hub assembly 414 and body 392 .
[0185] The hub assemblies 414 may be steered by steering arms 428 that are coupled to the hub assemblies. The upper ends of the steering arms 428 extend rearwardly from the hub assemblies and are connected to the outer ends of a rod 432 extending outwardly from a center steering assembly 434 mounted at the upper portion of body structural member 420 .
[0186] It will be appreciated that the vehicle 390 , when negotiated around a corner, responds quite similarly to vehicle 348 shown in FIGS. 20-23 . In this regard, when rounding a corner a centrifugal force is laterally applied to the vehicle 390 at the center of gravity 436 which is at an elevation below intersection point 422 of the diagonal links 418 , causing the body to tilt about such intersection point inwardly toward the center of the curve to compress the inside springs. Correspondingly, the centrifugal force on the tie structure 394 tends to cause the tie structure to tilt somewhat in the outwardly direction relative to the center of the curve, which in turn tends to cause the crossmember subassembly 400 to tilt outwardly relative to the curve. During such movement of the tie structure, the intersection point 422 does not serve as a roll reaction center. The rate of centrifugal force transfer through the vehicle 390 is reduced relative to if the tie structure were not capable of such movement.
[0187] As a further matter, it will be appreciated that the nominal location of the lower A-arms 410 can be varied relative to cross tube 402 , thereby to alter the ride height of the vehicle. Also, the nominal location of the lower A-arms 410 relative to the cross tube 402 can be used to vary the relative loads carried by the cross tube and the body springs 427 .
[0188] The embodiments of the present invention shown in FIGS. 24 , 25 and 26 may be modified to provide an “active” suspension system. In this regard, the cross tube 402 and compression spring 406 may be replaced with a linear actuator, for example a hydraulic cylinder assembly (not shown) mounted transversely on tie structure 394 . Also, body springs 427 may be replaced with hydraulically actuated suspension cylinders positioned at locations corresponding to the body springs 427 . Such suspension cylinders may be controllable to increase or decrease their lengths, thereby to tilt the body 392 as desired, for instance when cornering. A control system (not shown) may be provided for sensing the direction, speed and acceleration of the vehicle 390 in controlling the roll of the vehicle as well as the lateral movement of the tie structure 394 in response to driving conditions, including cornering. For instance, when cornering, the hydraulic cylinders that replace body springs 427 , can be controlled to tilt the body inwardly into the curve rather than outwardly in the manner of a typical vehicle. Moreover, also when cornering, the linear actuators that replace the springs 402 may be activated to allow the tie structure to move somewhat laterally outwardly to prevent, at least initially, the roll center 422 of the vehicle from being the point through which the roll couple is generated, tending to tilt the vehicle about its outer wheels 396 .
[0189] FIG. 27 schematically discloses a further embodiment of the present invention, wherein a vehicle 650 includes the body portion 652 supported on an underlying tie structure 654 extending across the vehicle between wheel assemblies 656 . The tie structure 654 may be of various constructions, including those constructions described herein. The tie structure 654 is interconnected to body 654 by diagonally oriented link arms 658 that are pinned at the lower ends to a tie structure 654 and pinned at their upward, inward ends to the body 652 . The link arms 658 are oriented so that if extended in the inward direction they would intersect each other at a point 660 along the transverse centerline of the vehicle 650 corresponding to the roll center of the vehicle, which is located above the center of gravity of vehicle 662 .
[0190] The tie structure 654 is interconnected to the wheel assemblies 656 by lower control arms, also referred to as trailing arms 664 , which are pinned at their outward ends to wheel hub assembly 666 and also pinned at their inward ends to lateral portions of the tie structure. The nominal orientation of the trailing arm 664 , as well as the resistance to the pivoting of the trailing arm about its inward end portion, is accomplished by a crank arm 668 that is fixedly attached to the inward end portion of the trailing arm 664 so as to rotate about the inward connection point 667 of the trailing arm 664 . The distal end of the crank arm 668 is coupled to the distal end of a rod 670 projecting from the cylinder portion 672 of a double-acting linear control member 674 .
[0191] A push rod 676 extends upwardly from a pivot connection 677 on a trailing arm 664 to pivotally interconnect with the laterally outward end of a crank arm 678 which is pivotally attached to a lateral portion of the body 652 . The opposite end of the crank arm 678 is coupled to a relatively soft linear control member 680 , with the opposite end of the linear control member coupled to a location on the body 652 .
[0192] The body 652 is also supported by an upper control arm, such as trailing arm 682 , pinned at its inward end to the body 652 and pinned at its outward end to an upward strut extending upwardly from the wheel hub assembly 666 .
[0193] It will be appreciated that vehicle 650 operates similarly to other vehicles of the present invention as illustrated and described herein, including vehicle 390 illustrated in FIGS. 24-26 . In this regard, during cornering, the centrifugal force on the vehicle 650 acts through the center of gravity 662 , which is located below the roll center 660 of the vehicle, thereby causing the body 652 to tilt inwardly into the curve being negotiated. At the same time, the tie structure 654 tilts downwardly in the laterally outwardly direction, thereby causing a similar movement of the body and roll center 660 so that the roll center does not serve as the reaction center of the vehicle, thereby reducing the jacking effect acting on the vehicle.
[0194] A further embodiment of the present invention is schematically illustrated in FIG. 28 which includes certain aspects of the present invention shown in FIGS. 20-23 . In this regard, the vehicle 440 includes a body having a structural portion 442 supported on an underlying tie structure 444 . The tie structure includes a cross tube 446 extending laterally across the vehicle to house a torsion bar 448 extending the full length of the cross tube and extending outwardly therefrom. The end portions of the torsion bar are connected to the inward end portions of leading arm assemblies 450 , with the outward ends of the leading arms coupled to hub assemblies 452 of wheel assemblies 454 . As discussed above, including with respect to FIGS. 20-23 , the torsion bar 440 serves to support the tie structure relative to the wheel assemblies 454 and allow relative vertical movement between the tie structure and the wheel assemblies. Spring/shock absorber assemblies 456 extend upwardly from hub assemblies 452 to interconnect with overhanging portions of the body structural member 442 through the use of ball joints 458 .
[0195] The body structural portion 442 is interconnected with the tie structure 444 by diagonal link arms 460 . The upper ends of the link arms are pinned to the body structural portion 442 at one of a plurality of selected locations 462 A, 462 B and 462 C. The lower, outward ends of the link arms may be pinned at a number of different locations on slide brackets 464 carried by, and may be adapted to slide relative to, cross tube 446 by engaging within slideways 465 extending along the upper portion of the tube 446 . Any convenient means can be provided to enable the brackets 464 to be moved along the cross tube 446 . In this regard, the brackets 464 may be moved while the vehicle is in operation by a powered system so as to change the location of the roll center of the vehicle in response to road or driving conditions. It also will be appreciated that by changing the position of the upper and lower ends of the link arms 460 , the elevation of the roll center 466 of the vehicle may be altered as well as the camber of the vehicle. Moreover, the tie structure 444 may be adapted to be retrofit in different vehicles.
[0196] In operation, the vehicle 440 operates in a manner similar to vehicles 346 and 390 discussed above and results in substantially the same advantages provided by such vehicles, including the tilting of the vehicle body inwardly while cornering instead of outwardly in the manner of a traditional vehicle.
[0197] A further embodiment of the present invention is illustrated in FIG. 29 , wherein vehicle 520 may be constructed somewhat similarly to vehicles 50 and 150 , described above, but with the following differences. Vehicle 520 includes a body 522 supported by and carried above an underlying tie structure 524 which in turn is supported by wheel assemblies 526 . As in the tie structure 60 shown in FIGS. 1 and 2 , the tie structure 524 may be generally in the form of a rectangular box-type structure that extends longitudinally along the lower elevations of the vehicle 520 between the hub carriers of the forward and rearward wheels 528 and 530 . However, the tie structure 524 differs from the tie structure 60 in that the tie structure 524 includes a forward section 524 F and a rearward section 524 R that telescopically engage with center section 524 C. Both the forward section 524 F and rearward section 524 R may include top and bottom side members 532 and 534 extending along both sides of the vehicle 520 and spaced vertically apart by forward vertical members 536 and rearward vertical members 538 . The top side members 532 and bottom side members 534 are transversely interconnected by crossmembers 539 that may be similar to crossmembers 108 and 110 of FIGS. 1 and 2 . Also, as in FIGS. 1 and 2 , a plurality of intermediate crossmembers (not shown) such as crossmembers 112 shown in FIGS. 1 and 2 may also be utilized for reinforcing purposes. Further, additional reinforcing members (not shown) may be employed in the construction of the forward tie structure section 24 F and rearward tie structure section 24 R, as needed. The forward tie structure section 524 F and rearward tie structure 524 R may be constructed from any appropriate materials, such as tubing or channel stock.
[0198] The tie structure center section 524 C may be constructed somewhat similarly to the forward tie structure section 524 F and rearward tie structure section 524 R in that such center tie structure section includes top side members 532 C and bottom side members 534 C that are vertically interconnected by vertical end members 540 and vertical intermediate members 542 . Also, appropriate crossmembers (not shown) may be utilized to transversely interconnect the top side members 532 C and bottom side members 534 C. The top side members 532 C and bottom side members 534 C may be tubular or otherwise hollow to telescopically receive the rearward end portions of the top side members 532 and bottom side members 534 of the tie structure forward section 524 F as well as the forward end portions of the top side members 532 and bottom side members 534 of the tie structure rearward section 524 R. A friction fit, shear pins or other well-known means may be utilized to retain a nominal engagement between the tie structure center section 524 C and the forward section 524 F and rearward section 524 R.
[0199] The body 522 may be supported above tie structure 524 by a forward set of pivot arm assemblies 544 mounted on the tie structure center section 534 C at laterally spaced-apart locations as well as rearward pivot arm assemblies 545 also mounted on the tie structure center section 524 C at laterally spaced-apart locations. Such pivot arm assemblies may be similar in construction to pivot arm assemblies 302 , discussed above. The upper ends of the pivot arm assemblies 544 and 545 may be incorporated into a slider 546 that slidably engages within a slideway 548 incorporated into the lower portion of body 522 . Slider 546 and slideway 548 may be of various well-known constructions, some of which have been described above.
[0200] Spring/shock absorber assemblies 550 extend upwardly from either the hub carriers of wheel assemblies 528 and 530 or from the tie structure 524 to body 522 . Such spring/shock absorber assemblies 550 may be similar to spring/shock absorber assemblies described above, including part numbers 70 , 80 , 232 and 234 . The spring/shock absorber assemblies 550 may be designed to carry a select proportion of the weight of the body 522 relative to the portion of such body weight carried by the pivot arm assemblies 544 and 545 .
[0201] The vehicle 520 may include a drive system 552 preferably located at the center portion of the vehicle, though the drive system could also be positioned at the front or rear of the vehicle, if desired. The drive system may include an internal combustion engine, an electric motor, or other type of power plant. The drive system may also utilize a transmission and drive train for transmitting the drive torque from the transmission to the wheels to be driven. The drive train can be designed to accommodate the relative movement between the tie structure center section and the tie structure forward 524 F and/or rearward 524 R sections.
[0202] Rather than utilizing drive system 552 , the vehicle 50 may be powered by electric motors incorporated into the hub assemblies of the forward and rearward wheels. Such motors may be similar to those described above with respect to FIGS. 1 and 2 . An example of such electric motors is described in U.S. Pat. No. 5,438,882.
[0203] In operation, if the vehicle 520 is involved in an accident or impact load is otherwise imposed on the tie structure 524 , for instance at the forward end of the vehicle, the tie structure forward section 524 F may telescopically engage further within tie structure center section 524 C to absorb some of the impact energy, thereby reducing the effect of the crash on vehicle passengers as well as reducing the potential damage to the vehicle from the crash. As the tie structure forward section 524 F telescopes within center section 524 C, the body 522 can move rearwardly relative to the tie structure center section 524 C by virtue of the movement of the slides 546 within slideway 548 . After the crash, the forward tie structure section 524 F may be extended relative to tie structure section 524 C to resume its nominal position without extensive effort. Also, during a crash, the body 522 can move away from the point of impact on the vehicle.
[0204] It is to be appreciated that vehicle 520 can be constructed with the body 522 composed of telescoping sections to help absorb some of the energy of a crash in much the same way as the structure discussed above. Also, by this construction, the body and tie structure can be designed to telescope in unison so that relative movement is not needed between the body and tie structure at the locations that they are joined together.
[0205] FIGS. 30 and 31 schematically illustrate a vehicle 560 comprising a further embodiment of the present invention. The vehicle 560 includes a body 562 supported by an underlying tie structure 564 which may be in the form of a generally rectangular structure having longitudinal side members 566 and transverse end members 568 . The body 562 may be supported above the tie structure 564 by A-arm assemblies 570 having base portion 572 pivotally mounted on the tie structure and angled so that a line extending perpendicularly to the base portion and through the apex 576 of the arm assemblies will intersect at the pitch center 574 and roll center 575 of the vehicle, which may be at different elevations, but both of which are above the center of gravity 580 of the vehicle. The apex 576 of the arm assemblies may be coupled to the body 562 about transverse axis 578 in a manner similar to the connection of the A-arm assembly 302 to body 52 C, shown in FIG. 12 . In this manner the intersection of axis 578 from the forward and rearward A-arm assemblies 570 intersect at the roll center 580 of the vehicle. As will be appreciated, the A-arm assemblies 570 may be constructed similarly to A-arm assemblies 302 described above.
[0206] The body 562 is also supported by forward and rearward sliding pillars 582 and 584 extending upwardly from hub assemblies of forward wheel assemblies 586 and rearward hub assemblies of rear wheel assemblies 588 . The sliding pillars may include integral springs (not shown) to allow relative upright motion between the wheel hub assemblies and the body, in a well-known manner.
[0207] The tie structure 564 is adapted to move longitudinally and transversely relative to the wheel assemblies. At the rear of the vehicle a sliding axle assembly 589 allows transverse movement between the rear portion of the tie structure and the rear wheel assemblies 588 . The axle assembly 589 includes a central tube structure 590 for receiving telescoping axle stub shafts 592 therein. Springs or other means may be used to restrict the relative movement between the axle stub shafts 592 and the tube structure 590 . The outward end portions of the axle stub shafts are connected to the rear wheel hub assemblies of wheel assemblies 588 . Longitudinal slide assemblies 594 allow for relative longitudinal motion between the tie structure 564 and the rear axle assembly 589 . In this regard, the longitudinal slide assemblies include an outer tubular member 596 supported by the tie structure transverse end member 568 for receiving a slide shaft 598 extending transversely from the tube structure 590 . Again, springs or other means may be utilized to limit the relative movement between the slide shaft 598 and its corresponding tube 596 .
[0208] The structure at the forward end of the vehicle 560 is similar to that just described with respect to the rear end of the vehicle. In this regard, transverse slide assemblies 600 extend transversely outwardly from a king pin 601 mounted on a central forward subframe assembly 602 that extends forwardly from tie structure transverse member 568 . The outward end of the slide assembly 600 is coupled to a lower portion of sliding pillar 582 .
[0209] Generally longitudinally directed slide assembly 604 extends forwardly from a king pin 606 mounted at the corner portions of the tie structure 568 to also couple with the lower portion of sliding pillar 582 . The king pins 601 and 606 allow the slide assemblies 600 and 604 to pivot about a vertical axis, but restrain the slide assemblies to move in a vertical direction.
[0210] The slide assemblies 600 and 604 may be actively controlled to allow relative longitudinal and transverse motion between the forward end of the tie structure and the forward wheel assemblies 586 and to control the nominal orientation of the front wheels 586 . In this regard, the slide assemblies may be in the form of hydraulic linear actuators or electrical linear actuators or similar structures. Also, sensors 606 may be used to sense the orientation of the wheels 586 so as to maintain the desired alignment of the wheels. Such sensors are known in the art.
[0211] FIGS. 32 and 33 illustrate vehicle 700 , wherein the hub carrier 704 serves as an interconnection between the body 702 and the tie structure 706 . This interconnection is accomplished by utilizing a slide rod or pillar 708 that is fixed to hub carrier 704 in an upright orientation. The tie structure 706 is coupled to a slide collar 710 that closely engages over the slide pillar 708 through the use of a pivot joint or similar means 712 to allow relative angular movement between the tie structure and the collar 710 . A relatively stiff lower spring 714 is interposed between the bottom of the slide collar 710 and a stop 716 affixed to the lower end of the slide pillar 708 .
[0212] A body 702 is connected to an upper slide collar 718 that closely and slidably engages over the upper portion of the slide pillar 708 through the use of a ball joint 720 or similar means, thereby to enable the body to pivot relative to the slide collar springs 722 , that are relatively softer than springs 714 and are interposed between the underside of the upper slide collars 718 and the hub carrier 704 to provide spring suspension for the body.
[0213] In addition, swing arms 724 may be interposed between the tie structure 706 and the body 702 to restrict longitudinal relative movement between the body and the tie structure, as well as carrying part of the weight of the body on the tie structure in a manner similar to several of the embodiments of the present invention described above. It will be appreciated that the interconnection of lines extending upwardly from the diagonal swing arms define the roll center 726 of the body which is elevationally above the center of gravity 728 of the vehicle. As such, in the manner of the other vehicles described above, during cornering body 702 will tilt inwardly toward the center of curvature of the curve rather than outwardly in the manner of a traditional vehicle. It is to be understood that the swing arms 724 may be replaced with alternative structures, for example A-arms.
[0214] The vehicle 700 may include a steering system composed of rack and pinion assembly 730 having a tie rod 732 extending outwardly therefrom which is coupled to a steering arm 734 extending transversely from the upper end of slide pillar 708 , see FIG. 33 . As will be appreciated, as the steering rod 732 is moved in the direction of arrow 736 , the hub carrier 704 and its associated wheel assembly 740 are caused to turn about slide pillar 708 .
[0215] It will be appreciated that the slide pillar 708 , slide structure 710 , ball joint 712 , spring 714 , spring 722 , ball joint 720 , upper slide collar 718 , and other related components might be reduced in size so as to be able to fit within a diameter of the rim of a wheel 740 . In addition to other advantages, this would reduce the bending load that hub carrier 740 would have to carry. However, such structure may limit the amount of travel of springs 714 and 722 .
[0216] Another advantage of this embodiment is the achievement of positive dynamic camber. See the discussion above regarding FIGS. 20-23 . Positive dynamic camber is achieved because during cornering the tie structure 706 tilts outwardly relative to the curve while the body 702 tilts inwardly into the curve to a greater extent than the outward tilt of the tie structure. As a result of such tilting of the tie structure and body, and the interconnection of the body and side rod at ball joint 720 above the roll center, the side rods tilt inwardly into the curve while providing positive dynamic camber. As explained above, this improves the traction of the vehicle during turning and cornering.
[0217] FIG. 34 illustrates another vehicle 742 that utilizes another sliding pillar arrangement. The sliding pillar 744 may be integrally constructed with hub carrier 746 to which the vehicle wheel 748 is attached. The vehicle body 750 is supported in part by the lower A-arm assembly 752 that is coupled to a slide collar 754 that closely engages a lower portion of the pillar 744 through the use of a pivot joint 756 or similar means to allow relative angular movement between the A-arm 752 and the collar 754 . Relatively stiff spring 758 is interposed between the bottom of slide collar 754 and a stop 760 affixed to the lower end of the slide pillar 744 . The opposite ends of the A-arm assembly 752 are coupled to the lower portion of body 750 at pivot joints 762 and 764 which allow relative angular movement between the A-arm assembly and the body.
[0218] The upper portion of body 750 is supported by springs 766 that are relatively softer than springs 758 . Such springs engage over the upper portion of sliding pillar 744 , with a lower end of the springs supported by a collar stop 768 engaged over a sliding pillar 744 . The upper end of the softer upper spring 766 presses against the underside of the horizontal arm 770 that extends horizontally outwardly, and is rigidly attached to body 750 . A diagonal brace 772 extends upwardly and inwardly from an outer, distal portion of arm 770 to intersect with body 750 . The outer end of arm 770 may be attached to a slide collar 774 which allows relative angular motion between the distal end of the arm 770 and the sliding pillar 744 . In this instance, the softer spring 766 bears upwardly against the underside of the slide collar 774 .
[0219] Upright control members 776 may be interposed between the wheel hub carrier 746 and arm 770 . Such control members may be in the form of control springs of the type used in other embodiments of the present invention, as described above.
[0220] It is to be understood that the hub carrier 746 may be incorporated into a driven axle to drive the vehicle wheels 748 . Such drive may be accomplished through hydraulic motors incorporated into the hub carriers or through torque shafts extending through the hub carriers in a manner well known, for example as utilized in the front wheels of a four-wheel drive vehicle.
[0221] In addition, it is to be understood that vehicle 742 is capable of providing the same advantages as provided by the vehicle 700 as described above, including tilting the body 750 inwardly when negotiating a curve, or pitching the body rearwardly when braking. In this regard, as with other embodiments of the present invention, the A-arm assembly 752 can be oriented so that the pitch center of the vehicle as defined by the A-arm assemblies may be at an elevation that is different from the roll center of the vehicle. Also, the A-arm assemblies can be mounted on the vehicle to be adjustable in orientation and position so as to be able to change the location of the pitch and/or roll centers during vehicle operation. Moreover, the present invention as shown in FIG. 34 also provides positive dynamic camber to the wheels 748 .
[0222] FIGS. 35 and 36 depict a further sliding pillar system used in conjunction with vehicle 780 . As shown in the figures, a double sliding pillar is utilized with each of the vehicle wheels 782 . The vehicle 780 includes a hub assembly 784 having a wheel hub section 786 and a slider frame section composed of upper diagonal arms 788 that extend upwardly and diagonally outwardly from the central hub section 786 . The slider frame section also includes relatively shorter lower arms 790 that extend diagonally downwardly and outwardly from the hub section 786 . The distal ends of each of the arms 788 and 790 are in the form of a horizontal pad or boss 791 for supporting the upright pillars 792 . The lower ends of the pillars 792 may rest on the upper portion of the corresponding pads 791 of the arms 790 , whereas upright clearance openings 794 may be formed in the pads 791 of the arms 788 for reception of the pillars 792 therethrough.
[0223] The tie structure 796 may be coupled to the pillars 792 in a manner similar to that utilized in the embodiments of the present invention shown in FIGS. 32 and 33 . In this regard, relatively stiff lower springs 798 may be interposed between the underside of slide collars 800 of the tie structure 796 and the upper side of the pads 791 of the lower arms 790 . Likewise, the body 802 of vehicle 780 may be coupled to the pillars 792 in a manner similar to that employed with the embodiment of the present invention shown in FIGS. 32 and 33 . In this regard, upper, relatively softer springs 804 are disposed between the underside of body slide collars 806 and the upper surface of the upper pads 791 located at the distal ends of the upper arms 788 .
[0224] Continuing to refer to FIGS. 35 and 36 , the hub assembly 784 is specially designed to be used in conjunction with drive axle 807 connected to wheel drive shaft 808 through the use of universal joint 809 . Spaced apart bearings 810 are disposed between the drive axle 808 and the inside diameter of hub section 786 to anti-frictionally support the drive axle in a manner well known in the art.
[0225] As will be appreciated, the embodiment of the present invention shown in FIGS. 35 and 36 provide the same advantages as provided in the embodiments shown in FIGS. 32 , 33 and 34 , including the inward tilt of body 802 and outward tilt of tie structure 796 during cornering as well as the rearward tilt of body 802 and the forward tilt of tie structure 796 during hard braking. The present embodiment also provides positive dynamic camber to the wheels 782 in a manner similar to that described above.
[0226] FIG. 37 illustrates a front elevational view of a vehicle 811 in a further embodiment of the present invention, wherein vehicle 811 includes two roller cams 812 rotatably mounted on the outer ends of an axle shaft 814 extending transversely outwardly from a connector bracket 815 located along the sides at the forward and rearward end portions of body 816 . The roller cams 812 ride within arcuate cam grooves 817 formed in the longitudinal tie structure 818 L extending along the left-hand side of body 816 , shown in FIG. 37 . Although not shown, a right-hand tie structure 818 extends along the right-hand side of the body 816 .
[0227] A longitudinal cam roller 820 is mounted on the outer end portion of the stub shaft 822 that extends longitudinally from the connector bracket 815 , to engage within a close-fitting follower slot 824 formed in body 816 . A connector bracket (not shown) similar to bracket 815 , shown in FIG. 37 , is disposed on the laterally opposite side of the body at the front and rear of the body so that a connector structure is positioned adjacent each corner of the body. As such, when negotiating a corner, the centrifugal force acting through the center of gravity 826 of the vehicle 811 will cause the body to tilt inwardly toward the center of the curve, and in doing so, cam rollers 820 will roll along respective cam follower slots 824 . Likewise, during braking, the deceleration force pushing against the rear of the body will cause the body to pitch by relative movement of the cam rollers 812 along the cam slots 817 formed in the tie structure 818 , tending to lower the rear end of the vehicle and raise the upper end of the vehicle so that a high level of load is retained on the vehicle rear wheels.
[0228] It will be appreciated that rather than incorporate the cam follower slot 817 in the tie structure 818 , such slot could be incorporated into a wheel hub carrier. Alternatively, the cam roller 812 and axle shaft 814 could extend laterally inwardly from a hub carrier to engage with a cam roller slot formed in the connector bracket 815 .
[0229] FIG. 38 illustrates a further embodiment of the present invention wherein a vehicle 880 utilizes roller cams to allow the vehicle body 882 to roll relative to an underlying tie structure 884 when a side force is applied to the vehicle, for example, during cornering. As in other embodiments of the present invention, the tie structure 884 is carried by wheel assemblies 886 through the use of arm assemblies 888 . The arm assemblies may be resisted by a relatively torsion bar or linear resistor in a manner described herein. Also, the body 882 may be supported by softer control springs 890 which are mounted on the wheel assemblies 886 . The upper ends of the control springs 890 may be coupled to an overhead portion of the body 882 .
[0230] An arcuate cam slot 892 is formed in brackets 894 located at the rearward and forward ends of the tie structure along the sides thereof. The cam slots are sized to receive cam rollers 896 mounted on the body by any convenient means, for example, utilizing stub shafts or axles (not shown). The cam slots 892 and cam rollers 896 are positioned along a circle path 898 so that the cam rollers will smoothly roll within the cam slots without binding up. It will be appreciated that the center of the circle path 898 coincides with the roll center 900 of the body 882 . Because the center of gravity 902 of the vehicle is below the roll center, when the vehicle negotiates a corner, the centrifugal force imposed on a vehicle will act through the center of gravity, thereby tending to pivot the body about the roll center. As a consequence, the body will tilt toward the inside of the corner rather than towards the outside as in a typical vehicle. Moreover, as in other vehicles described above, the tie structure will tilt somewhat toward the outside of the corner (though not to the extent that the body tilts to the inside of the corner) thereby causing the roll center to also move somewhat in an outward direction and preventing the vehicle from jacking about the roll center.
[0231] It will be appreciated that the embodiment of the present invention shown in FIG. 38 can be altered to allow the vehicle to pitch instead of roll by changing the orientation of the cam slots and cam rollers 90° from that shown in FIG. 38 so that the axis of the cam rollers 896 is transverse to the length of the vehicle 880 rather than longitudinally of the length of the vehicle as shown in FIG. 38 . As a further aspect of the present invention, the brackets 894 can be constructed to be adjustable relative to the tie structure 884 to alter the radius of the circle path 898 . As a consequence, the extent to which the body 882 rolls relative to the tie structure per level of force imposed on the vehicle can be varied as desired. In addition, the structure of FIG. 37 can be incorporated into the vehicle 880 to enable the body 882 to both pitch and roll.
[0232] A further embodiment of the present invention is shown in FIG. 39 , wherein a vehicle 830 includes a body 832 supported relative to a tie structure 834 which in turn is supported by wheel assemblies 836 . The tie structure 834 may be of a rectangular box-type construction similar to those tie structures shown in FIGS. 4 , 5 , 7 , 10 and 13 . The tie structure 834 may be connected to hub assemblies 838 in a well-known manner, including in a solid axle arrangement if desired. Spring/shock absorber assemblies 840 extend diagonally, upwardly, and inwardly from the tie structure 834 to interconnect with the body 832 . Ball joints may be utilized at the upper and lower ends of the spring/shock absorber assemblies 840 in a well-known manner.
[0233] A horizontal fluid strut 842 is interconnected between the tie structure and the body at an elevation corresponding to the roll center 844 of the vehicle which is at an elevation above the center of gravity 846 of the vehicle. The strut 842 is relatively stiff compared to the stiffness of the spring/shock absorbers 840 . As such, during cornering the body 832 tilts inwardly into the curve being negotiated by the compression of the inside spring/shock absorber 840 and the extension of the outside spring/shock absorber 840 . Simultaneously, the body 832 shifts somewhat laterally outwardly against the push/pull fluid strut 842 . As a result, the rate of force transfer from the body to the tie structure is lower than in a conventional vehicle, leading to many of the same advantages as discussed above, even though, due to the horizontal orientation of the push/pull fluid strut, the roll reaction center of the vehicles is at a higher elevation than in many of the other embodiments of the present invention described herein.
[0234] The fluid strut 842 may be reactive as described above, or instead may be active to cause sideways movement of the body 832 when desired. In this regard, a fluid pump may be used to deliver fluid to the strut or remove fluid therefrom, thereby to cause the body to move laterally. Such pump may be similar to that described above. In addition, a fluid reservoir may be employed to provide fluid to the strut and receive fluid from the strut. Also, by this construction, the stiffness of the strut can be varied during travel. It is to be appreciated that the fluid strut 842 can be replaced by an electrically operated linear actuator.
[0235] FIG. 40 illustrates a further embodiment of the present invention, wherein vehicle 850 is constructed somewhat similarly to vehicle 830 , shown in FIG. 39 . However, in vehicle 850 , the body is supported by leading arms 852 extending transversely outwardly from the body 854 to couple with the upper end portions of struts 856 extending upwardly from hub carriers 858 of the wheel assemblies 860 . It is to be appreciated that the arms 852 may be of various constructions that are well known in the art. Also, the arms 852 can be replaced by other means for supporting the body. The arms 852 can be designed to twist and/or bend to accommodate road bumps and other discontinuities, thus functioning as a suspension member.
[0236] Vehicle 850 includes a tie structure 862 connected to the hub carriers 858 by ball joints 864 or similar connection members. An A-frame structure 866 may extend upwardly from the tie structure to the elevation of the roll center 868 of the vehicle which is substantially above the elevation of the center of gravity 870 of the vehicle. The upper apex of the A-frame 866 may serve as a connection point for a transverse fluid strut assembly 872 which may be similar in construction to strut 842 , shown in FIG. 39 . The opposite end of the strut assembly 872 may be coupled to the body 854 . It will be appreciated that vehicle 850 is capable of operating in a manner similar to vehicle 830 described above, including providing positive dynamic wheel camber. In this regard, ideally the strut assembly 872 is relatively stiff in comparison to the arms 852 , thereby to limit the sideways movement of the body when cornering. Also, various types of strut assemblies can be used.
[0237] FIG. 41 illustrates a further embodiment of the present invention that is similar to the vehicle 850 shown in FIG. 40 . Thus, the components of the vehicle 874 shown in FIG. 41 that are the same or similar to that shown in FIG. 40 are identified with the same part number but with the addition of a prime (′) symbol. The main difference between the vehicles shown in FIGS. 40 and 41 is that vehicle 874 utilizes torsion bars 876 and 878 that extend from the inward ends of leading arms 852 ′ across the body 854 ′, to be anchored at the opposite side of the body. Thus, the torsion bars 876 and 878 are used to accommodate relative movement between the tie structure 862 ′ and the body 854 ′ caused by road bumps or other road discontinuities. This function does not have to be borne by the leading arms 852 ′ in the manner of the vehicle 850 shown in FIG. 40 .
[0238] FIGS. 42 and 43 illustrate a further embodiment of the present invention, wherein a vehicle 1050 includes a body portion 1052 supported by a pair of forward wheel assemblies 1054 and a pair of rearward wheel assemblies 1056 . Referring initially to FIG. 42 , the rear wheel assembly 1056 includes a drive axle 1058 that may be powered by an engine (not shown) in a well-known manner. The outward ends of the drive axle 1058 are held captive within an upright slide retainer 1060 , of a rear slide assembly 1061 , which serves the function of a tie structure as described in other embodiments of the present invention. The axle 1058 is vertically “centered” in the slide retainer by upper and lower compression springs 1062 and 1064 , which also react against upper and lower portions of the slide retainer 1060 . Each of the laterally spaced apart slide retainers 1060 are coupled to the rear portion of body 1052 by upper and lower links 1066 and 1068 which are pinned to the upper and lower end portions of the slide retainer, respectively, and also pinned to vertically spaced apart locations on the rear portion of the body 1052 . A crank arm 1070 is fixed to the forward end portion of upper link 1066 so as to pivot about connection point 1072 of the upper link as the upper link 1066 pivots about such connection point. The distal end of the crank arm 1070 is pinned to the free end of shock absorber assembly 1074 , which is positioned generally perpendicularly to the length of the crank arm 1070 . The spring/shock absorber 1074 acts as a body spring for the vehicle 1050 . In this regard, when the rear wheel assembly 1056 rises relative to the rear portion of the body 1052 , the spring/shock absorber assembly 1074 is forced to compress so as to react against such relative movement.
[0239] At the forward end of the vehicle 1050 , a forward slide assembly 1076 is utilized, which may be similar in construction and operation to the rear slide assembly 1061 . Thus, the operation of the forward slide assembly 1076 will not be repeated here. One difference between the forward slide assembly 1076 and the rear slide assembly 1061 is that a body spring/shock absorber assembly similar to 1074 at the rear of the vehicle may not be used at the forward end of the vehicle. A torsion assembly (not shown) may be employed with one or both of the forward links 1078 and 1080 .
[0240] It will be appreciated that the forward links 1078 and 1080 in the rearward direction are aligned to intersect with the pitch center 1082 of the vehicle. The same is true for the rearward links 1066 and 1068 . It will also be appreciated that the pitch center 1082 of the vehicle is located at an elevation higher than the location of the center of gravity 1084 of the vehicle.
[0241] In use, when the vehicle 1050 is accelerated, a rearward force acts to the center of gravity 1084 tending to raise the rear of the vehicle since the center of gravity is below the pitch center of the vehicle. Simultaneously the pitching couple acts through the body pitch center, causing the links 1066 and 1068 to transfer the pitching couple to the ground through the rear wheel assemblies 1056 . This places a downward load on the upper link 1066 and on the lower link 1068 , thereby causing the rear slide assembly to move somewhat downwardly, thereby to apply downward load on the rear axle 1058 which in turn increases the load on the rear wheel assemblies for better traction. Also during the downward movement of the rear slide assembly, the body moves downwardly somewhat so that the pitch center does not serve as the pitch reaction center, thereby lessening the rearward pitching of the vehicle during this time period. It will be appreciated that during braking, the forces act instead on the front of the vehicle 1050 in a like manner.
[0242] FIG. 44 illustrates a vehicle 1090 that also utilizes the dynamic forces acting on the vehicle, and the corresponding movement of suspension arms, to reduce or increase the load imposed on the vehicle's support wheels 1092 and 1094 , with the magnitude of the load reduction or increase depending on the magnitude of the dynamic loads imposed on the body and the lengths of the suspension arms. The body 1096 of the vehicle is supported by body spring 1110 at each wheel assembly 1092 and 1094 .
[0243] The vehicle 1090 includes tie structure 1098 , which may be of a box-type construction in a manner described in conjunction with several of the embodiments discussed above. In this regard, the tie structure may include lower and upper side beams 1104 and 1106 that are vertically interconnected by corner posts 1108 . The tie structure may also utilize lower and upper transverse members 1110 and 1112 that transversely interconnect the forward and rearward ends of the side beams 1104 and 1106 .
[0244] The corners of the tie structure may be carried by the wheel assemblies 1092 and 1094 by use of crank arms 1114 , having a generally horizontal arm 1116 and an upright arm 1118 . At the intersection 1119 of arms 1116 and 1118 , the crank arm 1114 is pinned to the tie structure. The free end of the horizontal arm may be connected to the wheel hub assembly 1117 . The opposite end of the arm 1116 is rigidly connected to the lower end of upright arm 1118 that extends nominally upwardly from the arm 1116 . The upper end of the arm 1118 is pivotally connected to the distal end of a cylinder rod 1120 , with the inward end of the rod connected to a piston 1122 that slidably engages within a hydraulic cylinder 1124 . A spring 1125 may be positioned between the piston 1122 and the end of the cylinder 1124 to nominally position the piston within the cylinder, for example when the vehicle is stationary. The hydraulic cylinder 1124 is in hydraulic fluid connection with an upright cylinder 1126 through hydraulic lines 1128 and 1130 . The lower end of the hydraulic cylinder 1126 is fixedly attached to the structure upper side beam 1106 . The upright hydraulic cylinder 1126 includes a piston 1132 connected to the lower end of a piston rod 1134 , with the upper distal end of the rod coupled to a connecting collar 1136 , which engages over a stub shaft 1138 extending forwardly and rearwardly from the body 1096 . The coupling collar may be replaced with a U-joint assembly.
[0245] The dynamic reactive system for interconnecting the body 1096 with the wheel assemblies 1117 in FIG. 44 operates in a manner similar to the other embodiments of the present invention described herein. In this regard, when one end of the body 1096 pitches downwardly, it causes the corresponding piston 1132 to extend downwardly, in turn forcing hydraulic fluid from the bottom side of cylinder 1126 to the end of cylinder 1124 opposite rod 1120 , forcing the rod outwardly relative to the cylinder which in turn causes counterclockwise rotation of crank arm 1114 , tending to apply a downward force on wheel 1092 , whereby causing the adjacent end portion of the tie structure to raise somewhat upwardly. At the other end of the vehicle 1090 , the reactive interconnecting force acts oppositely so that hydraulic fluid is forced from cylinder 1126 through line 1128 to the side of piston 1122 corresponding to piston rod 1120 . As such, when applying a strong braking force on vehicle 1090 , significant load is maintained on the rear wheels of the vehicle to assist in maintaining control of the vehicle rather than skidding or sliding sideways.
[0246] The diameter of cylinder 1124 may be larger than the diameter of cylinder 1126 so that the amount of the body roll and/or pitch is more than the amount of wheel movement relative to the tie structure. Also, rather than being passive as described above, the cylinders 1124 and 1126 can be powered to provide an active suspension system for the vehicle 1090 . A fluid pump, as described above can be utilized in this regard. If such an active suspension system is utilized, then the post 1100 , described above, may be eliminated.
[0247] As a further matter, a torsion bar (not shown) can be utilized in conjunction with crank arms 1114 to nominally position the crank arms and also modulate the pivoting movement of the crank arms about pivot point 1119 .
[0248] FIG. 45 illustrates a further embodiment of the present invention incorporated into a semi tractor trailer 1150 . The vehicle 1150 includes a tractor 1152 composed of a cab 1154 mounted on a tractor frame 1156 which also serves as a tie structure of the tractor. The tractor may be supported by conventional front steerable wheels 1158 and rear drive wheels 1160 .
[0249] The cab 1154 may be supported on the tie structure 1156 by four diagonally disposed links 1162 which may be connected at their upper and lower ends to the cab and tie structure, respectively, by pivot joints, ball joints, universal joints or other types of joints. The links 1162 may be oriented so that if extended in the upper direction the links would intersect at a common point, which common point corresponds to the roll center and pitch center 1164 of the body. As illustrated in FIG. 37 , the roll/pitch center 1164 is at an elevation above the center of gravity 1166 of the tractor.
[0250] The cab 1154 is also supported by adjustable front control members 1168 supported by a front wheel hub assembly 1169 and rear control members 1170 , which are supported by an axle frame assembly 1171 which in turn is carried by axle members 1172 . In addition, the tie structure 1156 is supported on the front hub assembly by relatively stiff, but adjustable, air shocks or pillows 1174 , whereas the rear portion of the tie structure 1156 is supported on the rear of assembly 1173 by comparable air shocks or pillows 1175 .
[0251] A fifth wheel assembly 1173 includes a base portion 1176 that is directly supported by relatively stiff adjustable spring/slider control members 1177 as well as by relatively soft linear control members 1178 . A standard plate portion 1179 is supported by the base portion 1176 . The spring/slider control members extend upwardly from the tractor tie structure to be pivotally coupled to the underside of the fifth wheel base portion near the fore and aft center thereof. As shown in FIG. 45 , two control members 1177 may be utilized in laterally spaced-apart relationship to each other. Of course, other arrangements of the control members may be utilized. A plurality of linear control members 1178 may be utilized, as shown in FIGS. 45 , 46 and 47 , perhaps one at every quadrant of the fifth wheel base 1176 .
[0252] As in other embodiments of the present invention described above, by the foregoing construction, when the tractor 1152 rounds a corner the centrifugal force acts on the body at the center of gravity 1166 , which is below the elevation of the roll center 1164 , so that the body will tilt inwardly into the corner rather than outwardly as in a typical vehicle. Correspondingly, when quickly braking, the longitudinal force acts on the tractor at the center of gravity, which is at an elevation below the pitch center 1164 , thereby tending to cause the rearward portion of the cab to impose a downward force on the tie structure, thereby to maintain significant load on the rear tractor wheels 1160 .
[0253] During cornering, the tie structure 1156 is allowed to tilt outwardly of the curve somewhat, but not to the extent that the cab tilts inwardly. During this outward tilt of the tie structure, the roll center is shifting, so it does not serve as the reaction center of the tractor, thereby reducing the jacking effect imposed on the tractor then cornering. Likewise, during hard braking, the tie structure tilts somewhat in the forward direction, but not nearly to the extent that the cab 1154 tilts in the rearward direction. During this tilting motion of the tie structure/tractor frame 1156 , the pitch center 1164 is shifting so as to reduce the rate of force transfer through the tractor 1152 , thereby reducing the pitch jacking effect imposed on the vehicle. The combined result of the rearward tilting of the cab 1154 and the somewhat forward tilting of the tie structure/tractor frame 1156 during hard braking allows for a significant load to be maintained on the rear wheels 1160 without imposing a high pitching effect on the tractor. This can result in quicker and safer braking of the tractor 1152 .
[0254] The semi trailer 1150 includes a trailer portion 1180 that is constructed to function similarly to the tractor 1152 . In this regard, trailer 1180 includes a load platform 1182 that is supported above a rear wheel assembly 1184 . As shown in FIG. 45 , a variable resistance, relatively soft control member 1186 that is supported by a subframe 1188 carried by the rear hub assembly 1190 of the semi trailer 1180 . Lateral stability between the trailer bed 1182 and wheel hubs 1190 is achieved by struts 1189 extending forwardly from subframe 1188 to complete the lower end of a brace 1191 that extends downwardly from the bed 1182 .
[0255] As in the linear control members 1178 used in conjunction with the tractor and fifth wheel described above, the linear control members 1186 are designed to accommodate relative linear, transfers, rolling and pitching movement between the load platform 1182 and the wheel hub assembly 1190 . The rear end of the trailer frame/tie structure 1184 is supported on the hub assembly 1190 by a relatively stiff spring slider assembly 1192 that extends diagonally upwardly and forwardly from a base plate 1193 which in turn is supported above the hub assembly by an air shock 1194 , which may be similar to air shocks 1174 and 1175 of the tractor 1152 . The relatively stiff spring/slider assemblies 1177 and 1192 are angled upwardly and diagonally rearwardly and forwardly, respectively, so that lines extending colinearly of the length of such members would intersect at the pitch center 1196 of the trailer 1196 which is above the center of gravity of the trailer 1198 . It will be appreciated that by the foregoing construction, the trailer 1180 , with a load thereon, would function in a manner very similar to the cab 1152 during cornering as well as during braking and accelerating. As a result, a much more stable semi-tractor trailer is achieved than the standard semi-tractor trailers currently being utilized.
[0256] Semi trailer 1150 is illustrated and described as having a tractor with a tandem rear axle. However, the present invention could readily be incorporated with a tractor having a single rear axle. In that situation the fifth wheel assembly 1173 would be supported by a single rear axle. Such semi tractor with a single rear axle would nonetheless function in substantially the same manner as tractor 1152 described above.
[0257] It will also be appreciated that the present invention as shown in FIGS. 45-47 can be incorporated into other types of vehicles, such as rail cars, especially the structure of the fifth wheel assembly 1173 and the trailer portion 1180 .
[0258] FIG. 48 illustrates the present invention as incorporated into a motorcycle type vehicle 1201 . The motorcycle includes a tie structure 1202 that supports a body structure 1204 designed with a seat 1206 . The body structure is supported on the tie structure by forward and rearward link pairs 1208 and 1210 , on each side of the forward and rearward end portions of the tie structure. An extension of links 1208 and 1210 in the upward direction would result in their intersection at the pitch center 1212 of the motorcycle, which is substantially above the center of gravity 1214 of the cycle. The links 1208 and 1210 may be coupled to the tie structure and the body by use of pivot connections in a manner well known.
[0259] The body 1204 is also supported and stabilized relative to forward and rearward wheels 1216 and 1218 by forward and rearward relatively soft springs 1220 and 1222 . Such springs are connected between the forward and rearward wheel hubs and the body in a well-known manner. Body stops (not shown) can be incorporated into the springs to limit the pitch of the body relative to the tie structure. Also, springs 1220 and 1222 can be of other construction, as is known in the art.
[0260] The tie structure 1202 is coupled to the forward fork assembly 1224 by a forward connection arm assembly 1226 and is connected to the hub section of the rear wheel 1218 by a rearward connector arm assembly 1228 . A transverse forward torsion bar 1230 is interposed between the rearward portion of the forward connection assembly 1226 and the tie structure 1202 , whereas a transverse rearward torsion bar 1232 or other type of spring arrangement is interposed between the forward end of the rearward connector arm assembly 1228 and the adjacent portion of the tie structure. The forward and rearward torsion bars 1230 and 1232 are relatively stiff in comparison to the body springs 1220 and 1222 . Also, other types of structures can be used in place of torsion bars 1230 and 1232 , for example, a crank arm and linear control member as described herein. Also, a dampener can be used in conjunction with connection arm assemblies 1226 and 1228 ; for example, a dampener similar to that dampener 95 shown in FIG. 1 .
[0261] The motor 1234 of the motorcycle 1201 may be mounted within and supported by the tie structure 1202 . The motor can be coupled to the rear wheel 1218 of the cycle in a manner well known in the art. Alternatively, an electric motor may be incorporated into the rear and/or front wheel hubs to power the motorcycle. The battery therefor can be carried by the tie structure, for example, at the location of the engine 1234 .
[0262] In operation when accelerating or braking, a longitudinal force is imposed on the cycle 1201 through the center of gravity 1214 which is at an elevation well below the pitch center of the vehicle. As such, the body 1204 will tend to tilt forwardly during acceleration and tilt rearwardly during hard deceleration, thereby retaining a significant load on the front wheel 1216 during acceleration and a significant load on the rear wheel 1218 during braking. This is opposite to the typical situation in a motorcycle.
[0263] Also during braking, the torsion bars 1230 and 1232 allow the tie structure to tilt downwardly somewhat in the forward direction. Due to the torsion bars 1230 being stiffer than spring 1220 , the tie structure may be able to continue moving during braking after the shifting of the body has ceased. As a consequence during this tilting motion, the pitch center 1212 is shifting, thus reducing the rate of force transfer through the cycle during braking, thereby reducing the tendency of the cycle to pivot about its pitch reaction center. Conversely, during hard acceleration, the torsion bars 1230 and 1232 allow the tie structure to tilt somewhat downwardly in a rearward direction. As a consequence, the pitch center 1212 does not serve as the pitch reaction center of the cycle. As will be appreciated, through the construction of the present invention, the cycle 1201 is capable of braking and accelerating in a relatively safe manner, especially in comparison with standard, typical motorcycles.
[0264] FIG. 49 illustrates a further embodiment of a motorcycle 1240 constructed in accordance with the present invention. The motorcycle 1240 is constructed similarly to motorcycle 1201 . As such, the corresponding components of motorcycle 1240 are given the same part numbers as in motorcycle 1201 but with the addition of an “A” suffix. Construction function motorcycle 1240 that is the same or similar to motorcycle 1201 will not be repeated here.
[0265] One difference between motorcycle 1240 and motorcycle 1201 is that in motorcycle 1240 the engine 1234 A actually functions as a part of the tie structure 1202 A. In this regard, the rear links 1210 A and rear connect arm assembly 1228 A are mounted to the rear portion of the engine 1234 A. Having the engine 1234 A function as part of the tie structure 1202 A reduces the complexity and weight of the motorcycle 1240 .
[0266] As another feature of the present invention, the seat 1206 A is located at an elevation below the top of the front and rear wheels 1216 A and 1218 A. This allows a relatively low overall center of gravity for the motorcycle and rider relative to motorcycles in which the rider sits higher relative to the wheels.
[0267] FIGS. 50 and 51 illustrate the present invention being incorporated into a railway car 1250 . The railway car includes a body 1252 supported above a tie structure 1260 by corner links 1256 that extend diagonally, inwardly at the front of the tie structure and diagonally, inwardly at the rear of the tie structure. The upper ends of the links 1256 may be coupled to the body using pivot connections, ball joints, universal joints or other appropriate means. The lower ends of the corner links 1256 are coupled to mounting ears 1258 that project upwardly from tie structure 1260 , projecting forwardly and rearwardly from an axle structure 1254 . The tie structure includes a transverse torsion bar 1262 over which an elongate collar or tube 1261 engages. Bushings can be used between the inside diameter of the tube 1261 and the outside diameter of the box 1262 . Ears 1258 project upwardly from the collar. The torsion bar 1262 is coupled (for example, splined) to the outward, distal ends of arms 1264 that cantilever from the axle assembly 1254 . The inward ends of the arms 1264 are coupled to the axle assembly 1254 by ball joints or similar means to allow the arms to turn about an axis extending along the length of the arms.
[0268] As most clearly shown in FIG. 50 , the corner links 1256 may be diagonally disposed relative to the body 1252 so that if extended in their upwardly direction they would intersect at a point 1266 that functions as the roll center of the railway car. As apparent, such roll center is above the center of gravity 1268 of the railway car.
[0269] The weight of the body 1252 may also be carried in part by spring/shock absorber assemblies 1270 extending upwardly from the axle assembly 1254 and coupled to an overhead portion of the body 1252 . The characteristics of the spring/shock absorber assembly 1270 can be varied as desired so as to select the relative amount of the weight of the body 1252 being carried by the spring/shock absorber assemblies.
[0270] The axle assembly 1254 is carried by standard railway wheels 1272 which ride on standard railway tracks 1274 . The wheels 1272 can be replaced to fit different tracks. The wheels 1272 are mounted on wheel axles 1275 .
[0271] In use, when the railway car 1250 is rounding a corner, the centrifugal force is applied thereto through the center of gravity 1268 . Because the center of gravity is located below the roll center 1266 , the body 1252 will tilt inwardly into the corner as opposed to tilting outwardly in a manner of a standard railway car. Moreover, during such tilting of the body 1252 , the tie structure tilts somewhat downwardly on the outward side of the corner, but not nearly to the extent that the body 1252 is capable of tilting. This movement of the tie structure 1260 is resisted by torsion bar 1262 . Moreover, due to the torsion bar 1262 being relatively stiffer than the spring/shock absorber assemblies 1270 , the tilt of the body will be completed before the maximum tilt of the tie structure occurs. As a result, a rate of force transfer through the railway car 1250 is lower than would occur if the tie structure had “bottomed out” before the body had “bottomed out.” As a consequence, the generation of a significant roll couple tending to roll the railway car about the outward wheels 1272 during cornering is forestalled. As such, the railway car 1250 is designed to provide some of the same advantages provided by the other vehicles described herein.
[0272] A further embodiment of the present invention that is specifically designed for incorporation into a rail car 1277 is illustrated in FIG. 52 . The illustrated rail car includes a body portion 1278 supported on an underlying tie structure/axle 1279 by relatively soft air pillow structures 1280 upon which an anchoring plate 1281 pivotally supports the underside of a load bearing column structure 1282 which is interconnected by body structural members 1283 and 1284 . An axle shaft 1285 axles the tie structure 1279 to wheels 1286 which ride on conventional rails 1287 .
[0273] The body 1278 is also connected to the tie structure 1279 by diagonally disposed hydraulic sliders 1288 having their upper end pinned to body structural member 1283 and their lower end pinned to the outward end of a horizontal double piston cylinder assembly 1290 mounted on the tie structure 1279 . The outward end of the piston rods 1291 are pinned to the lower outboard ends of the hydraulic sliders 1288 . It will be appreciated that the hydraulic sliders 1288 are oriented so that lines extending colinear thereto intersect at the lateral center of the rail car at an elevation corresponding to the roll center 1292 of the rail car, which is above the center of gravity 1294 of the rail car. Moreover, by extending or contracting the cylinder rods 1290 , the vertical location of the roll center 1292 may be varied as desired, including during actual operation of the rail car.
[0274] It will be appreciated that the rail car 1277 operates in a manner similar to rail car 1250 described above, whereby when the rail car 1277 is rounding a corner, that centrifugal force is applied thereto through the center of gravity 1294 . Because the center of gravity 1294 is located below the roll center 1292 , the body 1278 will tilt inwardly into the corner as opposed to tilting outwardly in the manner of a standard rail car.
[0275] FIG. 53 illustrates a further embodiment of the present invention wherein vehicle 1400 employs a tie structure 1402 in the form of an upright structure adjacent each of the wheel assemblies 1404 of the vehicle. The vehicle includes a steerable hub carrier assembly 1406 integrated into the wheel assembly 1404 . The hub carrier assembly includes an upright inboard post portion 1408 which is coupled to a further inboard upright tie structure post 1402 by parallel upper and lower arms 1410 and 1412 . Also, a relatively stiff strut or spring assembly 1414 extends upwardly and diagonally inwardly from the lower end of hub carrier post 1408 to an upper portion of the tie structure 1402 , perhaps at the same location that the upper arm 1410 couples to the tie structure. Preferably the strut/spring assembly is double acting, so as to resist movement of the tie structure in both the upward and downward directions relative to the hub carrier assembly. It will be appreciated that the spring assembly 1414 supports the tie structure 1402 relative to the hub carrier assembly 1406 , and links 1416 and 1418 couple the tie structure to the adjacent portion of the vehicle body 1420 . As shown in FIG. 53 , the inboard ends of the links 1416 and 1418 are oriented so that lines extending colinearly with the links 1416 and 1418 intersect at the roll center 1422 of the vehicle. Also, relatively softer spring assemblies 1424 extend upwardly from hub carrier post 1408 to couple with an overhead portion of the body 1420 .
[0276] It will be appreciated that the present invention shown in FIG. 53 allows the body 1420 to tilt inwardly into a curve during cornering while allowing a controlled amount of outward movement and tilt of the tie structure 1402 so that the roll center 1422 also moves outwardly, thereby preventing the vehicle from jacking about the reaction center as roll center is moving outwardly. In this regard, when cornering the centrifugal force on the vehicle 1400 acts through the center of gravity 1426 which is below the roll center 1422 , thereby causing the body 1420 to tilt inwardly into the curve. At the same time, the force being imposed on the roll center 1422 in the direction of arrow 1428 imposes compression loads on links 1416 and 1418 , which load is resisted by spring assembly 1414 . As a result, the tie structure post 1402 tends to move downwardly. This downward motion of the tie structure post allows the roll center 1422 of the vehicle to move slightly downwardly as the vehicle is cornering, thereby preventing the vehicle from jacking about the reaction center during movement thereof. As will be appreciated, the present invention as shown in FIG. 53 provides the same advantages of other embodiments of the present invention without requiring a tie structure of a significant structure.
[0277] FIG. 54 illustrates a further embodiment of the present invention, wherein a vehicle 1450 includes a hub carrier assembly 1452 which is attached to the lower end of a MacPherson strut assembly 1454 . The upper end of the strut assembly 1454 is coupled to an overhead portion of the vehicle body 1456 in a well-known manner. A drive axle (not shown) can be incorporated into the hub carrier assembly 1452 to drive the wheel assembly 1458 in a well-known manner. Also, the wheel assembly 1458 may be steerable using a steering system similar to that described with respect to FIG. 34 , above. In this regard, an actuator assembly 1460 is connected to the upper arm 1462 of a pivot arm assembly 1464 which is pivotally mounted along the height of the MacPherson strut 1454 . The upper arm 1462 extends forwardly (out of the paper) from the upper end of the pivot arm assembly 1464 for coupling to the laterally outward end of the actuator assembly 1460 . Thus, as the actuator assembly 1460 extends and retracts, the pivot arm assembly 1464 is caused to pivot about a vertical axis. A lower arm 1468 extends forwardly (out of the paper) from the lower end of the pivot arm assembly 1464 to couple with a lateral steering arm 1470 that extends laterally from the lower arm to couple with an arm 1472 that extends forwardly (out of the paper) from steering knuckle 1474 which is integral with wheel spindle 1476 . In this way, steering is accomplished through a remote system that is actuated by this steering wheel through a hydraulic or electrical system (which is not shown but is well known in the automotive industry). It will be appreciated that other steering systems can be utilized in place of the steering system of FIG. 54 without departing from the spirit or scope of the present invention.
[0278] A relatively stiff spring slider assembly 1478 (preferably double acting) is interconnected between the lower end of the MacPherson strut assembly 1454 and an inward portion of the vehicle body 1456 . The spring/slider assembly 1478 is positioned so that a line extending colinearly therefrom passes through the roll center 1480 of the vehicle, which is located somewhat above the center of gravity 1482 of the vehicle. It will be appreciated that the spring slider assembly 1478 can be passive and thus reacting to lateral forces applied to the vehicle, or can be active so as to control the roll of the vehicle as desired.
[0279] It will be appreciated that vehicle 1450 shown in FIG. 54 provides the same advantages as vehicle 1400 shown in FIG. 53 . In this regard, during cornering, centrifugal force imposed on the vehicle 1450 acts through the center of gravity 1482 , which is below the roll center 1480 , thereby tending to cause the body 1456 to rotate inwardly during cornering about the roll center. At the same time, the centrifugal force on the body is transmitted to the wheel assembly 1458 through the roll center 1480 and through the spring/slider assembly 1478 , thereby causing compression of the spring/slider assembly and thus allowing a certain amount of lateral and downward movement of the body 1456 toward the outside of the curve. During this lateral movement, the body roll center 1480 does not serve as the reaction center about which the vehicle would typically jack, thereby reducing the jacking effect imposed on the vehicle during cornering as in the other embodiments of the present invention.
[0280] FIG. 55 shows an alternative embodiment of the spring/slider assembly 1478 of FIG. 54 . In FIG. 55 , the spring/slider assembly 1486 includes two spring/slider units 1488 that are in parallel relationship to each other, being separated by transverse connecting brackets 1490 . It will be appreciated that the construction of the spring/slider assembly 1486 shown in FIG. 55 can provide increased stability of the vehicle body relative to the steering and suspension system in the fore and aft direction. In all other respects, the present invention shown in FIG. 55 may be similar to or the same as shown in FIG. 54 .
[0281] FIG. 56 shows a further alternative embodiment of the slider/strut assembly 1478 of FIG. 54 . In the slider/strut assembly 1492 of FIG. 56 , the inboard end thereof is attached to an A-arm assembly 1494 which is coupled to the vehicle (not shown) at ball joints 1496 or similar joints. Also shown in FIG. 56 , control lines 1497 and 1498 interconnect with opposite ends of the cylinder portion 1499 of the spring/slider assembly 1492 so as to provide active control for the spring/slider assembly. In this regard, the lines 1497 and 1498 may be connected to a fluid supply system (not shown). It can be appreciated that rather than being actuated by a fluid, the spring/slider assembly 1492 may be electrically controlled in a manner that is well known. It will also be appreciated that a structure shown in FIG. 56 provides the same advantages as that shown in FIG. 54 , and operates in substantially the same manner. The use of the A frame 1494 enables the strut/slider assembly to be connected to the body at more than one location, thereby spreading out the load on the body when force is transferred between the body and the spring/slider assembly.
[0282] FIGS. 57 and 58 illustrate a further embodiment of the present invention wherein vehicle 1500 includes a body 1502 supported on a combination hub carrier and slider assembly 1504 coupled to wheel assembly 1506 . The wheel assembly 1506 may be adapted to be steered relative to the hub carrier/slider 1504 by various systems, including those described above. Pairs of upper and lower A-arms 1508 and 1510 interconnect the body 1502 to the hub carrier/slider assemblies. As shown in FIG. 57 , the A-arms 1508 and 1510 are oriented in the diagonally upwardly and laterally inwardly direction so that lines extending therefrom that bisect the two arms of each A-arm assembly intersect at the roll center of the vehicle 1512 which is above the center of gravity of the vehicle 1514 . The laterally inward ends of the A-arm assemblies 1508 and 1510 may be coupled to the body with ball joints or other types of joints. The laterally outward ends of the A-arm assemblies 1508 and 1510 are coupled to sliders 1516 and 1518 that are constrained to slide up and down a slideway 1520 formed along the height of a post portion 1522 of the hub carrier/slider assembly.
[0283] Referring to the fragmentary side elevational view shown in FIG. 58 , the A-arm assemblies 1508 and 1510 are oriented in the fore and aft direction of the vehicle 1500 so that lines extending through the connections of the A-arm assemblies to the body intersect at the pitch center 1523 of the vehicle. As described in other embodiments of the present invention, for example, the embodiment shown in FIGS. 10 and 11 , orienting the A-arm assemblies in this manner allows the vehicle to pitch about its pitch center during acceleration and braking, but in the opposite direction of a standard vehicle.
[0284] Relatively soft springs 1524 and 1526 extend between the inward hub portion 1528 of the hub carrier/slider assembly 1524 and one or both of the arms of the A-arm assemblies 1508 and 1510 . The springs 1524 and 1526 are able to support the inward ends of the A-arm assemblies relative to the slideway 1520 while allowing the A-arm assemblies to move up and down within the slideway. A stiffer linear control unit 1530 is pivotally coupled to the inward end of the hub portion 1528 and also coupled to the body 1502 , for example at, or close to, the location that the upper A-arm assembly 1508 is coupled to the body. The control unit 1530 (preferably double acting) resists the lateral movement of the body relative to the hub carrier/slider assembly 1504 .
[0285] The embodiment of the present invention shown in FIGS. 57 and 58 functions very similarly to other embodiments of the present invention. In this regard, during cornering the centrifugal force acting on the vehicle 1500 acts through the center of gravity 1514 . The longitudinal forces acting on the vehicle during braking or accelerating also act through the center of gravity 178 of the vehicle 1514 . As such, during cornering, the body 1502 will tilt inwardly toward the center of the curve. Correspondingly during braking, the body will tend to tilt downwardly in a rearward direction and during accelerating the body will tend to tilt downwardly at the forward end of the vehicle. This is contrary to the conventional direction of vehicle body roll during cornering or vehicle body pitch during acceleration or braking.
[0286] Moreover, during cornering, the centrifugal force acting on the vehicle are transmitted to the ground through the roll center 1512 through the hub carrier/slider assembly 1504 and to the wheel assemblies 1506 . As such, the adjacent portion of the body 1502 shifts somewhat downwardly and outwardly, with the sliders 1516 and 1518 sliding down slideway 1520 , causing the inward ends of the A-arms 1508 and 1510 to lower relative to the hub carrier/slider assembly 1504 . This movement of the body is resisted by the control unit 1530 which only allows a certain amount of such body movement. However, such movement is sufficient to prevent the roll center 1512 to serve as the reaction center of the vehicle, thereby reducing the jacking effect imposed on the vehicle during cornering.
[0287] The same effect is achieved during braking or accelerating, wherein during braking the body 1502 tends to shift somewhat in the forward direction and during acceleration the body tends to shift somewhat in a rearward direction relative to the hub carrier/slider assembly. Thus, during such braking or accelerating the pitch center of the vehicle does not serve as the reaction center causing the body to dive during braking or squat during accelerating, as described above in other embodiments of the present invention. However, one difference in the embodiments of the present invention shown in FIGS. 54-58 is that no tie structure per se is required in order to achieve the advantageous operating characteristics of the vehicles 1450 and 1500 . Rather, such effect is achieved by the construction and orientation of the suspension system components of these vehicles.
[0288] While the preferred embodiments of the invention have been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the invention. Also, it is to be appreciated that the present invention may be utilized in a wide range of vehicles, including passenger vehicles, SUVs, all-terrain vehicles, racing vehicles, dragsters, motorcycles, trucks, pickups, tractors as well as rail cars. Although the present invention has been illustrated in terms of wheeled vehicles, the present invention may also be incorporated into track vehicles, for instance military personnel carriers and tanks. | Enhanced vehicle handling is achieved by the improved suspension systems constructed in accordance with aspects of the present invention, in which not only do the roll couple and jacking couple oppose each other, thereby causing the body roll to counteract the jacking effect, but also the pitch couple and the pitching couple oppose each other, thereby causing the body pitch to counteract the pitching effect. This results in the improvement of the cornering traction of the vehicle, the braking traction of the vehicle, the acceleration traction of the vehicle (especially in a front-wheel-drive vehicle), the simultaneous cornering and braking traction of the vehicle, and the simultaneous cornering and acceleration traction of the vehicle. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Application No. 62/136,316, filed on Mar. 20, 2015. U.S. Pat. No. 6,421,947 is incorporated herein by reference to the extent its disclosure is not inconsistent with the present disclosure.
FIELD OF THE INVENTION
[0002] The present invention relates to a sighter for aligning the sight on a crossbow to at least approximately the location where the crossbow bolt strikes after being fired.
BACKGROUND OF THE INVENTION
[0003] This invention relates to a sighter for calibrating a crossbow sight to align with the groove axis of a crossbow for the purpose of calibrating the crossbow sight. The calibration process of a crossbow scope to align the sight with the crossbow groove axis now requires that several bolts be fired so that the sight can be gradually adjusted to align with a target point that the bolts strike. The crossbow sight can be a physical sight or an optical scope. Crossbow sights and crossbow structures are known to those skilled in the art.
SUMMARY OF THE INVENTION
[0004] A crossbow sighter for projecting an axis of a crossbow groove is used to align a crossbow's sight with the groove axis. The crossbow sighter (or “sighter”) comprises a body that minimizes errors in alignment. The body is extended so it is long enough to be positioned in the crossbow groove and to have the bow string, when in its relaxed position, rest upon the body to help retain the sighter in the groove. The body has a proximal (or first) section, in which a laser is mounted, and that is received in the groove, and a distal (or second) section, which extends past the bow string, when the string is in its relaxed position. The bow string is positioned against the side of the second section to apply cross-axial force to the sighter and help retain it in the groove.
[0005] A sighter according to the invention may have a one-piece body, or a multi-piece body. Either way, it is designed to be axially aligned with the crossbow groove when positioned in the groove. In this manner, a beam of laser light emitted from the sighter travels in a straight path along the axis of the crossbow groove. The crossbow sight is then calibrated to the point at which the laser beam strikes.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is an exploded, perspective view of the crossbow sighter according to aspects of the invention.
[0007] FIG. 2 is a side, exploded view of the crossbow sighter of FIG. 1 .
[0008] FIG. 3A is a partial, side perspective view of the crossbow sighter of FIG. 1 showing one alternative switch.
[0009] FIG. 3B is a partial, side perspective view of the crossbow sighter of FIG. 3 showing the beginning of removal of the switch assembly.
[0010] FIG. 3C is a side view of the removed switch assembly of the crossbow sighter of FIGS. 3A and 3B showing how batteries can be removed and replaced.
[0011] FIG. 3D is a partial, side perspective view of the crossbow sighter of FIGS. 3A-3C showing the switch assembly being reinstalled.
[0012] FIG. 4 is a top view of a crossbow sighter in accordance with aspects of the invention.
[0013] FIG. 5 is a side, partial cross-sectional view of the crossbow sighter of FIG. 4 .
[0014] FIG. 6 is an enlarged view of the section marked as FIG. 6 on FIG. 5 .
[0015] FIG. 7 is an enlarged view of the section marked as FIG. 7 on FIG. 5 .
[0016] FIG. 8 is a side view of a crossbow sighter in accordance with aspects of the invention, mounted in a crossbow groove.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0017] Turning now to the drawings where the purpose is to describe preferred embodiments of the invention and not to limit same, FIGS. 1 and 2 show exploded views of a preferred embodiment of a crossbow sighter 10 according to the invention.
[0018] The crossbow sighter 10 comprises an elongated body 12 having a body axis 14 . The body 12 has a proximal (or first) section 16 and a distal (or second) section 18 . The proximal section 16 and distal section 18 may have the same diameter, or (as shown) the diameter of the proximal section 16 may be different from, and greater than, the diameter of the distal section 18 .
[0019] FIGS. 5-7 are partial cross-sectional illustrations of the crossbow sighter 10 of FIGS. 1 and 2 , depicting the first cylindrical cavity. A first cavity 60 has an axis that is preferably aligned with body axis 14 , and is located in the proximal end 16 . The first cavity 60 houses a light source 62 , typically a laser, an electrically conductive spring 64 , and a rotary switch 66 . The light source 62 is permanently mounted in the housing so that it need not be removed to change batteries or to make support adjustments. The light source 62 emits a beam that is in alignment with the body axis 14 . The switch 66 is rotated to selectively connect the light source 62 to a power supply 68 . The spring 64 keeps switch 66 locked into a position, either on or off, and provides an electrical path to the laser light 62 . Proximal end 16 includes a channel 70 formed between the body surface and the first cavity 60 to expose the switch 66 . The switch 66 can be accessed for rotation through channel 70 .
[0020] Also shown in FIGS. 1 and 2 , the body proximal end 16 includes a second cylindrical cavity 60 A connected to channel 70 . The second cavity 60 A is preferably aligned with the body axis 14 to form an opening from which the light source beam is projected.
[0021] The first cavity 60 has a cavity diameter. The switch 66 is cylinder with a switch diameter that is less than the cavity diameter, so that switch 66 has the freedom to rotate (see e.g., FIG. 3A ). The switch 66 has an axis preferably substantially aligned along the body axis 14 . The switch 66 rotates to selectively connect the power source 68 to the light source 62 .
[0022] The switch 66 has a top, or first outside surface 80 which is radially disposed around the switch axis. The first surface 80 has a conductive area 84 . The first surface 80 also includes a cam 86 .
[0023] FIG. 5 is a partial cross-sectional view of the body 12 of FIG. 4 . The first cavity 60 (see FIG. 5 ) has a second surface 88 which interfaces with the switch first surface 80 , which is radially disposed inside proximal section 16 . The second surface 88 includes a second conductive area. An electrical connection is made between the body 12 and the switch 66 when the second conductive area interfaces with the first conductive area 84 . The second surface 88 is preferably cylindrical. When the second surface 88 receives the switch conductive area 84 , an electrical connection is made between first conductive area 84 and second conductive area 90 . The conductive areas are not limited to any special shape or position. As shown, the conductive areas can be centered around the axis 14 . When the switch 66 is not in the channel 70 , the first surface 80 and second surface 88 are forced apart, and no electrical connection is made.
[0024] The switch 66 has a third outside surface preferably radially disposed around the switch axis 82 , having a third conductive area. When the switch 66 operates as a passive electrical conductor, the third conductive area can be a conductive rod. In some aspects, the conductive rod may pass all the way through switch 66 from the first surface 90 to the third surface. Alternately, the switch 66 can be a metal, such as aluminum, which may be anodized or coated with an insulator, except for areas on the first surface 80 and third surface which act as conductive areas 84 and the third conductive area, so that the switch 66 may be a conductor. As explained in more detail below, the switch 66 may be a battery housing in some aspects of the invention, and the third conductive area can be the battery terminal 110 , the spring 64 , or the combination of battery and spring 64 .
[0025] The first cavity 60 may have a fourth surface preferably radially disposed around the body axis 12 , having a fourth conductive area which is not explicitly shown. The fourth surface can be a part of the inside surface of proximal end 16 , as is the second surface 88 . However, the fourth surface is actually the light source 62 electrical terminal. Also as shown, the electrically conductive spring 64 is preferably substantially aligned along the body axis 12 between the third surface and fourth surface. Therefore, when the switch 66 is in the “on,” position, the second conductive area (if used) is connected to the fourth conductive area through the switch 66 and spring 64 .
[0026] In some aspects of the invention the power supply 68 is housed elsewhere in the body 12 (not shown), but in the preferred embodiment power source 68 is housed in switch 68 . The switch 66 then acts as a selectively engagable passive conductor which completes an electrical circuit between the second conductive area and fourth conductive area from power source 68 , to the light source 62 , with the return ground path from the light source 62 through the electrically conductant inside surface of proximal end 16 . In a preferred aspect of the invention the batteries are housed in the switch 66 , as shown in FIGS. 1, 2 and 3C . Switch 66 is removable from cavity 60 through slot 70 as shown in Figures to replace batteries does not affect the accuracy of crossbow sighter 10 . The switch 66 is easily removed through channel 70 .
[0027] Power source 68 is preferably a number of (three are shown) coin batteries arranged end-to-end in a battery cavity 112 . The power source 68 can also be any other suitable source. Power source 68 has a first polarity (+) connected to the switch's first conductive area 84 and a second polarity (−) connected to the switch's third conductive area in one preferred embodiment. An axial plug 114 , with a center hole to admit spring 64 , may be used to seal the end of battery cavity 112 .
[0028] Turning again to FIGS. 1 and 2 , a brace (or cushioning device) 72 fits over distal end 62 A of laser 62 . Laser light is emitted through end 62 A. A cap 74 with a lens, which may be clear or refractory to refract the laser light into a shape such as a crosshair, or multiple projections forming an area between them, is received in cavity 60 to seal cavity 60 and the internal components. As shown, cap 74 is threadingly received in cap 60 .
[0029] Proximal end 18 has two openings 18 A that receive fasteners 19 , which are preferably thread screws. Fasteners 19 can be tightened against, or retracted from, laser 62 to move it up and down, or side to side.
[0030] FIG. 6 illustrates the crossbow sighter 10 mounted in a crossbow groove whose axis is projected by the laser light. The extended body 12 permits it to extend beyond the bow string 200 , so the bow string 200 can be positioned on the side of the distal section 18 , to press against the side of distal end 18 and help retain sighter 10 in the groove.
[0031] In a preferred embodiment, proximal end 16 has approximately the same diameter as a crossbow bolt and is received in the crossbow groove in the same manner as a bolt. Extended distal end 18 , as shown, has a diameter slightly smaller than the diameter of proximal end 16 . Body 12 can be one piece, or more than one piece, as long as it is sufficiently aligned along axis 14 so laser light emitted from laser 62 aligns with the axis 14 ad the axis of the crossbow groove. The length of body 12 is preferably 7″, or at least 5″, at least 6″, or at least 7″, or between 6½″ and 7½″. Body 12 preferably has a length that permits it to function with most, if not all, crossbows.
[0032] Some exemplary, specific examples of the invention are set forth below:
EXAMPLE 1
[0033] A crossbow sighter for projecting a beam of light along the axis of a groove used to retain a crossbow bolt, the crossbow sighter comprising a body with a length greater than the distance between the groove and the crossbow string when the string is in a relaxed position, an outer surface dimensioned to be received in the groove, and a light source to emit a beam aligned with the groove axis.
EXAMPLE 2
[0034] The crossbow sighter of example 1 wherein the body is cylindrical and has a uniform diameter.
EXAMPLE 3
[0035] The crossbow sighter of example 1 wherein the diameter of the body varies.
EXAMPLE 4
[0036] The crossbow sighter of example 3 wherein the light source is inside the body and there is an opening in an end of the body through which the light is emitted.
EXAMPLE 5
[0037] The crossbow sighter of example 4 wherein the opening is covered by a lens.
EXAMPLE 6
[0038] The crossbow sighter of any of examples 1-5 further comprising a power source connected to the light source.
EXAMPLE 7
[0039] The crossbow sighter of example 6 further comprising a switch to selectively connect the power source to the light source.
EXAMPLE 8
[0040] The crossbow sighter of example 7 wherein the body includes a first cavity to house the light source, the switch, and the power source.
EXAMPLE 9
[0041] The crossbow sighter of example 8 wherein the body includes a second cavity connected to the first cavity to form an opening from which the light source beam is projected.
EXAMPLE 10
[0042] The crossbow sighter of example 7 wherein the body includes a channel formed between the body surface and the first cavity to expose the switch.
EXAMPLE 11
[0043] The crossbow sighter of example 10 wherein the switch is a partial cylinder, and wherein the switch is rotatable to selectively connect the power source to the light source.
EXAMPLE 12
[0044] A The crossbow sighter of example 11 wherein the switch includes a first outside surface radially disposed around a switch axis and having a first conductive area and cam; wherein a first cavity of the body has a second surface radially disposed around the body axis, having a second conductive area and a channel to receive the switch cam; and wherein the switch cam cooperates with the second surface channel to selectively connect the first and second conductive areas.
EXAMPLE 13
[0045] The crossbow sighter of example 12 wherein the switch has a third outside surface radially disposed around the switch axis, having a third conductive area, and wherein the first and third conductive areas are connected through the switch; wherein the first cavity has a fourth surface radially disposed around the body axis, having a fourth conductive area; and further comprising: an electrically conductive spring substantially aligned along the body axis between the third and fourth surfaces; and wherein the second and fourth conductive areas are selectively connected through the switch and spring.
EXAMPLE 14
[0046] The crossbow sighter of example 13 wherein the body includes a conductive path, through the light sources, between the second and fourth conductive surfaces; wherein the switch includes a battery cavity; wherein the power source includes at least one battery, housed in the switch's battery cavity, having a first polarity connected to the switch's first conductive area and a second polarity connected to the switch's third conductive area; and wherein the light source is selectively powered with the battery.
EXAMPLE 15
[0047] The crossbow sighter of example 1 wherein the light source is a laser.
EXAMPLE 16
[0048] The crossbow sighter of any of examples 1-15 wherein the body is at least 5″ long, or at least 6″ long or at least 7″ long.
EXAMPLE 17
[0049] The crossbow sighter of any of examples 1-16 wherein the body is comprised of multiple sections.
EXAMPLE 18
[0050] The crossbow sighter of any of examples 1-16 wherein the body is formed of a single section.
EXAMPLE 19
[0051] The crossbow sighter of any of examples 1-18 wherein the body is comprised of aluminum, steel or plastic.
[0052] Having thus described some embodiments of the invention, other variations and embodiments that do not depart from the spirit of the invention will become apparent to those skilled in the art. The scope of the present invention is thus not limited to any particular embodiment, but is instead set forth in the appended examples and the legal equivalents thereof. Unless expressly stated in the written description or examples, the steps of any method recited in the examples may be performed in any order capable of yielding the desired result. | A crossbow sighter is used to align the sight used on a crossbow to the axis of the groove on the crossbow. In this manner, the cross bow bolt will strike close to, or at, the location sighted by the sight. The crossbow sighter fits into the groove and has a body with a length that extends past the bow string when the bow string is in its fully relaxed position. The bow string rests against the body and applies cross-axial pressure to the crossbow sighter and helps retain it in the groove while aligning the crossbow sight. | 5 |
FIELD OF THE INVENTION
[0001] The present invention relates generally to roman tub faucets and more specifically to diverter valves that are integral to the tub spout and serviceable from the exterior of the faucet mounting surface.
BACKGROUND OF THE INVENTION
[0002] A roman tub faucet is typically mounted on a horizontal surface adjacent a tub. A conventional roman tub faucet with a hand shower utilizes a diverter valve to switch the flow of water between the spout and the hand shower. The diverter valve is typically located below the horizontal mounting surface. Often, an installed roman tub is not provided with an access panel for the faucet components that are below the mounting surface. Maintenance or replacement of a diverter valve installed in this manner requires that panels or tiles in the faucet area are removed.
[0003] What is needed is a roman tub faucet with a hand shower that incorporates a diverter valve that is serviceable above the finished horizontal surface.
SUMMARY OF THE INVENTION
[0004] The present invention is directed to a roman tub outlet assembly that incorporates a diverter valve for a hand shower. In one preferred form, the present invention provides an outlet assembly that forms a tub spout and houses a diverter valve. The diverter valve is removable from the outlet assembly by a technician who has access to only the finished surface of the tub area. In another aspect, the present invention provides a diverter assembly that is located above the finished surface of the tub area.
[0005] Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:
[0007] [0007]FIG. 1 is a perspective view of an installed roman tub outlet assembly with hand shower incorporating the diverter assembly of the present invention;
[0008] [0008]FIG. 2 is an exploded perspective view of the roman tub assembly of FIG. 1 showing components that are located below the finished surface;
[0009] [0009]FIG. 3 is an exploded perspective view of the diverter assembly of the present invention;
[0010] [0010]FIG. 4 is a cross-sectional view of the outlet assembly of FIG. 1 with the diverter assembly in a first position; and
[0011] [0011]FIG. 5 is a cross-sectional view similar to FIG. 4 with the diverter assembly in a second position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0012] The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.
[0013] With reference to FIGS. 1 and 2, a roman tub faucet is generally indicated by reference numeral 10 . Roman tub faucet 10 includes an outlet assembly 12 , a hot water valve operator 14 , a cold water valve operator 16 , and a hand shower 18 . Preferably, roman tub faucet 10 is mounted to a horizontal surface 20 that is adjacent a tub 22 . Outlet assembly 12 includes a spout 24 , a diverter assembly 26 , and a knob 28 . FIG. 2 illustrates components of the roman tub faucet 10 that are located below finished surface 20 including a hot water valve 30 , a cold water valve 32 , a body 34 , an inlet or feed tube 36 , a secondary outlet tube 38 , and a flexible hose 40 . Body 34 includes a hot water inlet 42 , a cold water inlet 44 , a mixer outlet 46 , a secondary outlet tube connection 48 , and a flexible hose connection 50 . Secondary outlet tube connection 48 , and flexible hose connection 50 are connected by a passageway 52 (as best seen in FIG. 4) that extends through body 34 .
[0014] When assembled, hot water valve 30 is in fluid communication with a pressurized supply of hot water and hot water inlet 42 . Hot water valve operator 14 is coupled to hot water valve 30 . Hot water valve 30 is a conventional roman tub valve that adjusts the flow rate of hot water to body 34 . Cold water valve 34 is in fluid communication with a pressurized supply of cold water and cold water inlet 44 . Cold water valve operator 16 is coupled to cold water valve 32 . Cold water valve 32 is a conventional roman tub valve that adjusts the flow rate of cold water to body 34 . Inlet tube 36 is attached to mixer outlet 46 . Secondary outlet tube 38 is coupled to secondary outlet tube connection 48 , and flexible hose 40 is coupled to flexible hose connection 50 such that passageway 52 is in fluid communication with both secondary outlet tube 38 , and flexible hose 40 . Preferably, secondary outlet tube 38 extends concentrically through inlet tube 36 . Flexible hose 40 is connected to hand shower 18 such that secondary outlet tube 38 is in fluid communication with flexible hose 40 .
[0015] Referring now to FIGS. 3 and 4, diverter assembly 24 is located within spout 24 and operates to selectively direct fluid communication from inlet tube 36 to spout 24 or alternately to spray handle 18 via secondary outlet tube 38 . Diverter assembly 26 includes a rod 60 , a sealing chamber assembly 62 , and an anchor 64 . Sealing chamber assembly 62 includes a top coupling 66 , a spring 70 , a plunger 72 , a seal 74 , and a lower coupling 76 . O-rings 80 of various diameters are utilized to provide a leak proof seal between components of roman tub faucet 10 as discussed below.
[0016] Top coupling 66 is preferably a component that defines a portion of a sealing chamber 90 at a lower end 92 , a primary outlet 94 opening onto an exterior surface 96 , a plunger guideway 98 intersecting the sealing chamber 90 , and opening onto an upper end 100 . The central portion of top coupling 66 is intersected by plunger guideway 98 , primary outlet 94 and sealing chamber 90 . The uppermost portion of sealing chamber 90 is defined by a frusto-conical surface 104 that opens onto primary outlet 94 .
[0017] Lower coupling 76 is preferably adapted to releaseably couple at a top end 110 with top coupling 66 , as best seen in FIG. 4, such that lower coupling 76 defines the lower portion of sealing chamber 90 . Lower coupling 76 is a generally cylindrical component that includes an inlet 112 defined by an outer wall 114 , a secondary outlet 116 with an axial passageway 118 therethrough, and an inverted frusto-coaxial surface 120 defining the lower most portion of sealing chamber 90 such that axial passageway 118 is in fluid communication with inlet 112 and primary outlet 94 via sealing chamber 90 . The exterior surface 122 of secondary outlet 116 preferably has two O-ring grooves 124 .
[0018] Plunger 72 includes a first end 130 , a second end 132 , a shaft 134 , and a stop 136 . Plunger 72 is adapted to slidingly retract into plunger guideway 98 . Plunger 72 is coupled to rod 60 at first end 130 and to seal 74 at second end 132 . Spring 70 is superposed on shaft 134 to bias plunger 72 towards lower coupling 76 . Stop 136 limits the travel of spring 70 on shaft 134 and serves as a spring seat. Seal 74 is preferably constructed of a conventional polymer faucet sealing material with an annular cross section when viewed parallel to the axis of plunger 72 . Seal 74 has a configuration which is complementary to surface 104 , 120 to provide a fluid sealing interface therebetween.
[0019] When diverter assembly 26 is fully assembled, spring 70 , plunger 72 , and seal 74 are located within sealing chamber 90 . Seal 74 and plunger 72 are moveable between a first position (FIG. 4) in which seal 74 is in sealing contact with inverted frusto-conical surface 120 and a second position (FIG. 5) in which seal 74 is in sealing contact with frusto-conical surface 104 . In this manner, seal 74 , seals against frusto-conical surface 120 thereby interrupting fluid communication between sealing chamber 90 and secondary outlet 116 when in the first position. Seal 74 also seals against frusto-conical surface 104 when in the second position, thereby interrupting fluid communication between sealing chamber 90 and primary outlet 94 . As best seen in FIG. 4, seal 74 preferably cannot interrupt fluid communication between sealing chamber 90 and inlet 112 . Thus provided, water that enters inlet 112 can be diverted to either primary outlet 94 or secondary outlet 116 by moving plunger 72 and seal 74 between their first and second positions.
[0020] When outlet assembly 12 is fully assembled, inlet tube 36 is in fluid communication with inlet 112 , and secondary outlet tube 38 is in fluid communication with secondary outlet 116 . As best seen in FIG. 4, spout 24 is in fluid communication with primary outlet 94 . Plunger 72 is coupled to rod 60 which is in turn coupled to knob 28 . Thus provided, seal 74 can be moved between the first and second positions by raising and lowering knob 28 .
[0021] In operation, water flows into body 34 from hot and cold valves 30 , 32 . The water mixes in body 34 and continues through inlet tube 36 and through inlet 112 of diverter assembly 26 . When seal 74 is in the first position and fluid communication between sealing chamber 90 and secondary outlet 116 is interrupted, water flows from inlet 112 through sealing chamber 90 and through primary outlet 94 to spout 24 and into tub 22 . When seal 74 is in the second position and fluid communication between sealing chamber 90 and primary outlet 94 is interrupted, water flows from inlet 112 through sealing chamber 90 and through secondary outlet 116 to secondary outlet tube 38 and into hand shower 18 .
[0022] It would be recognized by one of ordinary skill in the art that inlet tube 36 and diverter assembly 26 combine to mix the hot and cold water such that water of an essentially consistent temperature can be supplied to either spout 24 or hand shower 18 . The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention. | A roman tub faucet with a hand shower diverter mechanism integral to the tub spout. The diverter mechanism is especially suited for applications where service access to only the outer tub finished surface is practical. The faucet eliminates the need to remove panel or tile portions from the tub area for diverter mechanism service or replacement. The faucet also eliminates the need for an additional installation hole that is required for roman tub faucets with a separate diverter mechanism and tub spout. | 4 |
FIELD OF THE INVENTION
[0001] The invention relates to endoscopy, including cystoscopy, and more particularly to a disposable device for protecting an endoscope or cystoscope from a non-sterile environment so that the endoscope or cystoscope can be used again without the necessity for sterilization.
BACKGROUND OF THE INVENTION
[0002] Endoscopes are useful for diagnostic and therapeutic indications. They have been optimized to improve performance for particular purposes. Thus, there are endoscopes for examination of esophagus, stomach, duodenum and the like. Colonoscopes are specialized for examining the colon. Cystoscopes are specialized for examining the bladder, urethra and kidneys. Angioscopes are specialized for examining blood vessels. Bronchoscopes are specialized for examining the bronchi. Laproscopes are specialized for examining the peritoneal cavity. Arthroscopes are specialized for examining joint spaces. All of these devices are endoscopes. The devices generally are expensive and used in a contaminated environment. Thus, they are not one use devices and must be sterilized between uses so as not to spread contamination such as, for example, infection or disease.
[0003] It has been known to use sheath devices providing detachable covers for the viewing tube of the endoscope that is inserted into a body cavity. U.S. Pat. No. 6,911,005 describes a detachable sheath having an inner diameter smaller than the outer diameter of the viewing tube for an endoscope having an air feeding tube that is used to feed air into the sheath for inserting the viewing tube into the sheath. It also describes sheaths having an inner diameter larger than the outer diameter of the viewing tube. The viewing tube is inserted into the sheath device which is stretched over the viewing tube to reduce the diameter of the sheath device.
[0004] U.S. Pat. No. 4,646,722 discloses creating a variety of specialized endoscopes by using protective sheaths having various special purpose medical instruments mounted at the end of a biopsy channel and operated through the channel. U.S. Pat. No. 7,081,097 discloses a sheath assembly adapted for use with an endoscopic viewing tube where the sheath has a biopsy sampling device attached to the sheath including a collection member proximate the end.
[0005] U.S. Pat. No. 4,991,565 discloses providing an endoscope with a sheath that is removably fitted over the viewing tube and appears to have a plurality of channels for passing fluids provided within the sheath, each channel having an opening on at one end near the distal end portion of the sheath and extending at the other end past the proximal end of the sheath.
[0006] U.S. Pat. No. 6,793,661 discloses an endoscopic sheath having an inflatable member coupled to and surrounding a portion of the sheath body and adapted to be inflated radially. The sheath assembly further includes an expansion-inhibiting mechanism coupled to at least one of the inflatable member and the sheath body portion. The expansion-inhibiting mechanism inhibits longitudinal expansion of the sheath body portion during inflation of the inflatable member. Optionally, the sheath assembly may include a channel that extends longitudinally along the outer surface of the sheath body portion.
[0007] U.S. Pat. No. 8,845,518 discloses apparatus and methods for attaching and forming enclosed inflatable members on an endoscope assembly with a disposable sheath. A flexible and resilient cuff is fixed on the outer surface of the disposable sheath to form an annular space for inflation through a lumen internal to the sheath.
[0008] U.S. 2003/0114732 discloses a sheath for use with intracorporeal optical imaging instruments such as imaging guidewires, catheters or endoscopes. Also disclosed are sheath devices having multiple lumens longitudinally attached to each other at an exterior portion of the lumens.
[0009] U.S. 2007/0270646 discloses a disposable sheath for use with a cystoscope or endoscope. In one aspect of the disclosure the sheath includes an exterior wall and has a first channel and a second channel within the exterior wall of the sheath.
[0010] Although disposable sheaths have been known and used for some time, it appears that they have been designed and adapted for specific endoscopes by respective endoscope manufacturers. Indeed each type of endoscope may have slightly different measurements. It would be desirable to have a disposable sheath system that is adapted to be used on more than one manufacturer's endoscope for the particular type of endoscope such as, for example, a ureteroscope. Such a disposable sheath can be more economical and avoid the necessity for suppliers to store various disposable sheaths to fit the various endoscopes made by different manufacturers.
SUMMARY OF THE INVENTION
[0011] The present invention provides a disposable sheath system for an endoscope having an insertion (viewing) tube. The disposable sheath system comprises a primary lumen, at least one secondary lumen attached to the exterior of the primary lumen, a connector for attaching the lumens to the body of the endoscope, the connector being adapted to expand longitudinally in the direction of the length of the primary lumen to accommodate a range of lengths for the viewing tubes, and at least one secondary lumen having therein a split insert commensurate in length with the secondary lumen for inserting a tool device therethrough. Optionally, the disposable sheath system also comprises an adapter piece that attaches the connector to the body of the endoscope for endoscopes having a different structure than that for which the connector is adapted to fit.
[0012] The present disposable sheath system is particularly useful in connection with a rigid cystoscope having an insertion (viewing) tube, which may have different length tubes depending upon the manufacturer. The secondary lumen is provided to insert a tool to be used in combination with the viewing tube. The split insert in the secondary lumen permits the use of a tool having a diameter slightly larger than the interior diameter of the tube defining the secondary lumen.
[0013] Potential advantages of the use of a disposable sheath system in accord with the present invention instead of a currently common (conventional) rigid cystoscopy lens include less equipment to resterilize and, thus, less chance of contamination (and avoiding risk of improper sterilization, etc.). Also, the existing process of sterilizing conventional scopes between office procedures can lead to delay in appointments. In addition, conventional process of sterilizing scopes can be an issue when the sterizilizer is broken, the sterilization process is subject to regulatory change(s) (e.g., CIDEX is no longer utilized), or when the steriziling process results in scope damage (which occurs most often in the instance of flexible scopes, when the seal/coating is broken with repeated sterilizing).
[0014] The disposable sheath of the present invention can be used with existing office equipment (no need for new lens, irrigation supplies, etc.). It provides a potentially smaller outer diameter for the sheathed scope for insertion with a closed working channel (e.g., for routine surveillance cystoscopy), and may be less traumatic/more comfortable for the patient. The softer sheath material (as compared to the conventional metallic sheath) also may be less traumatic/more comfortable for the patient. The conventional metal sheath typically encloses both the viewing tube and a tool channel. The collapsable second (tool) lumen of the present invention is exterior to the primary lumen that encloses the viewing tube. Thus, the OD (outer diameter) of the sheath system of the present invention can be smaller for insertion into the patient.
[0015] If the disposable sheath is indeed more comfortable for office cystoscopy using a conventional rigid scope, it may be a competitive alternative to flexible cystoscopy because the rigid scope lens features increased light and better optics (presently, it is understood that many urologists use flexible cystoscopy for men in the office, because it is easier and more comfortable than conventional rigid cystoscopy—this disposable sheath device may avoid that discomfort).
[0016] Flexible scopes are expensive to purchase and expensive to repair. Using a sheath in accord with the present invention may reduce repairs due to no need for sterilization, hence making this sheathed scope option more appealing.
[0017] The disposable scope sheath in accord with the present invention has a much larger working channel (second lumen) than the conventional flexible cystoscope, making it more useful in the office for office procedures. With the flexible disposable sheath design, it is much easier to use this as a catheter/drain initially to empty the bladder prior to cystoscopy. Also, the flexible sheath can potentially be used for serial urethral dilation (i.e., for urethral dilation) with insertion of stiffeners with progressively larger diameters.
[0018] Disposable sheath systems in accord with the present invention can be cheaper and more efficient to use because there would be a faster turnaround for a doctor treating multiple patients in the office. No re-sterilization is required after use. No need to use or sterilize the stainless steel equipment holding the conventional rigid scope and far less equipment required to maintain patient care. Only one scope would be needed for the doctor to treat multiple patients because a new sheath can be used for each patient. There would be no need to use one and, then, take a second one out for the next patient while the first one is being sterilized.
[0019] Additionally, with multiple external secondary lumens, for example, a guide wire could be placed through one secondary external lumen while irrigation is achieved through another secondary external lumen, and a laser fiber (or stone basket) can be used through a further secondary external lumen. This could save quite a few steps in the procedure. The expandability of the external secondary lumen potentially is useful also to extract a stone/fragment through the lumen with a basket, again saving the step of withdrawing and reinserting the scope. Yet, insertion of the scope protected by the primary lumen is relatively easy because of the smaller diameter with the secondary exterior lumens collapsed.
[0020] Other advantages of the present disposable sheath system will become apparent upon consideration of the detailed description and drawings. Although the disclosure uses a ureteroscope as an example, many of the benefits of the disposable sheath system can also be achieved when using flexible scopes.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1A is a side elevational view of one embodiment of a disposable sheath system in accord with the present invention.
[0022] FIG. 1B is an end view of the disposable sheath system of FIG. 1A from the distal end of the device.
[0023] FIG. 1C is a cross-sectional view of the disposable sheath system of FIG. 1A taken at section A-A.
[0024] FIG. 2 is an isometric view of the disposable sheath system of FIG. 1A .
[0025] FIGS. 3A-3D illustrate the insertion of an ureteroscope into the disposable sheath system of FIG. 1A to provide a sheathed ureteroscope.
[0026] FIG. 4 is an isometric illustration of the sheathed ureteroscope of FIG. 3 inserted into male anatomy.
[0027] FIGS. 5A-5B illustrate how the disposable sheath system of FIG. 1A accommodates an ureteroscope having a viewing tube of length L 1 as well as another ureteroscope having a longer viewing tube of length L 3 .
[0028] FIGS. 6A-6B illustrate how the split insert within the secondary lumen permits expansion of the diameter to permit use of a tool device having a diameter D 2 slightly larger than the interior diameter D 1 of the secondary lumen (note: gap g expands to gap g′ for accommodation of larger diameter tool).
[0029] FIGS. 7A-7B illustrate how the secondary lumen is collapsible for insertion of a sheathed ureteroscope into a patient.
[0030] FIG. 8 is an isometric illustration of the sheathed ureteroscope of FIG. 3 in male anatomy further illustrating an irrigation device inserted into the secondary lumen and irrigating the bladder.
[0031] FIG. 9A is an illustration of removing an irrigation device through the secondary lumen where the distal end of the irrigation device has a larger diameter than the interior diameter of the secondary lumen.
[0032] FIG. 9B is an illustration showing how the split insert in the secondary lumen expands to permit the distal end of the irrigation device to be withdrawn through the secondary lumen.
[0033] FIG. 10 is a partial isometric view of the proximal end of the disposable sheath system of FIG. 1A illustrating the use of an adapter to attach to the body of an ureteroscope.
DETAILED DESCRIPTION
[0034] In accord with the present invention, a disposable sheath system for an endoscope having a viewing tube, the disposable sheath system comprises a primary lumen, at least one secondary lumen attached along the length of the exterior of the primary lumen, and a connector for attaching the lumens to the body of the endoscope. The connector is adapted and arranged to expand longitudinally in the direction of the length of the primary lumen to accommodate a range of lengths for the viewing tubes. At least one secondary lumen includes therein a split insert commensurate in length with the secondary lumen for inserting a tool device therethrough. In one embodiment, the disposable sheath system also comprises an adapter piece that attaches the connector to the body of the endoscope for endoscopes having a different structure than that for which the connector is adapted to fit.
[0035] One embodiment of the present disposable sheath system will be described, for example, in more detail in connection with a ureteroscope having a viewing tube. Different manufacturers may make the ureteroscope with somewhat different length viewing tubes. Indeed each type of endoscope may have slightly different measurements. Although each type of endoscope generally will require a particular disposable sheath system, disposable sheath systems in accord with the present invention can be used to accommodate some range of differences, for example, in length of viewing tubes in the specific types of endoscopes.
[0036] With respect to a disposable sheath system for a ureteroscope in accord with the present invention, FIGS. 1A, 1B, 1C and 2 illustrate one embodiment. The disposable sheath device 10 , as illustrated in FIG. 1A , has a primary lumen 12 having a viewing window 15 at its distal end. Attached along a length on the exterior of the primary lumen 12 is a secondary lumen, generally of smaller diameter than the primary lumen. The secondary lumen has an opening at the distal end 18 and an opening provided by a fitting 19 at the proximal end. The fitting 19 at the proximal end of the secondary lumen is provided to facilitate insertion of a tool device, as needed, into the secondary lumen.
[0037] At the proximal end of the primary lumen 12 is a connector 20 that is attached to the primary lumen for attaching the disposable sheath system, for example, to a ureteroscope. The connector 20 has central opening, a body section 22 adapted and arranged to attach to a ureteroscope and a longitudinally expandable section for connecting to the primary lumen 12 . The longitudinally expandable section 24 has a spring connected to the body section 22 at one end and to an end piece at the other end which attaches to the primary lumen. The spring 25 is enclosed by a flexible covering 24 that permits the spring 25 to extend longitudinally for accommodating various length viewing tubes.
[0038] FIG. 1C illustrates the primary lumen 12 attached to the secondary lumen 17 . The secondary lumen has an insert that is split along its length (note gap in circumference of the split insert) so as not to completely encircle a device inserted therein.
[0039] As illustrated in FIGS. 3A-3D , a ureteroscope 50 having a body 51 and a viewing tube 52 is inserted into the disposable sheath system 10 . The viewing tube 52 is inserted into the disposable heath system 10 by first inserting the viewing tube into the connector 20 at the proximal end of the disposable sheath system ( FIG. 3A ). Insertion continues until the distal end of the viewing tube abuts the viewing window 15 of the primary lumen 12 ( FIGS. 3B-3C ). When the distal end of the viewing tube abuts the viewing window 15 of the primary lumen 12 , the body 51 of the ureteroscope is partially within the connector body section 22 of the sheath system (see FIG. 3C ). Two pins 55 extending radially 180 degrees apart on the body of the ureteroscope engage openings in the body section 22 of the sheath system. A 90 degree rotation of the ureteroscope body 51 with respect to the connector body section 22 ( FIG. 3D ) locks the ureteroscope and sheath system together through the pins 55 .
[0040] As illustrated in FIG. 4 , with respect to male anatomy, a healthcare professional can easily use the ureteroscope by conventional manipulation.
[0041] The longitudinally expandable section of the connector 20 conveniently allows for accommodating uretero scopes of various lengths made by different manufacturers. As illustrated in FIG. 5A , a first ureteroscope having a viewing tube of length L 1 can be inserted into a disposable sheath system in accord with the present invention with the spring of the connector having a length L 2 . When a ureteroscope having a longer viewing tube L 3 is inserted into the sheath system in accord with the present invention, the spring and flexible cover of the connector expands to a spring length of L 4 to accommodate the longer viewing tube ( FIG. 5B ).
[0042] The secondary lumen 17 is provided for the use of various tools as needed by the healthcare provider. To accommodate for tools having various exterior diameters, the secondary lumen 17 is made of a sheath material having flexibility. Further, a split insert 16 is provided ( FIG. 6A ) inside the secondary lumen sheath. The split insert 16 has a gap g in the circumference for accommodating a tool having a diameter D 1 that is equal to the interior diameter of the sheath. However, a tool having a diameter D 2 that is slightly larger than the interior diameter of the sheath can be accommodated by a radial stretching of the sheath material and an enlarging of the gap g′ of the split insert 16 in the secondary lumen ( FIG. 6B ).
[0043] As illustrated in FIGS. 7A-7B , the secondary lumen having a height H 1 (i.e., the exterior diameter of the sheath) is adapted and arranged to collapse, having a height only of H 2 , for insertion of the sheath system with ureteroscope into a patient. This is easier to insert (and more comfortable to the patient) than a conventional ureteroscope having a metal sheath that encloses both the viewing tube and a tool lumen, thus having a significantly larger diameter. The secondary lumen expands from collapsed position to full height when a tool device is inserted into the lumen as needed.
[0044] One type of tool device that may be used while the ureteroscope is inserted into a patient is an irrigator device. As shown in FIG. 8 , the irrigator device comprises a tube 60 connected to a syringe device 62 that is inserted into the secondary lumen as needed. When inserted, the irrigator may be used to irrigate a portion of tissue, or the like. The distal end 65 of the irrigator device may have a diameter that is larger than the interior diameter of the sheath of the secondary lumen 17 ( FIG. 9A ). The split insert 16 and flexible material of the sheath of the secondary lumen 17 accommodate the larger diameter of the distal end 65 of the irrigator device as illustrated in FIG. 9B .
[0045] As noted, different manufacturers may make ureteroscopes having somewhat different length viewing tubes. Also, the body of the ureteroscope may have a different configuration to which the connector of the disposable sheath system must be attached. In order to provide for various attachment configurations of different manufacturers, an adapter can be included in the sheath system. Then, the connector of the sheath system is adapted and arranged to attach to one of the configurations. An adapter is provided with the sheath system that is configured to attach at one end to the connector body section and at the other end adapted and arranged to attach to the body of the ureteroscope. For example, in FIG. 10 , an adapter 80 is illustrated. The body 51 ′ of the ureteroscope 50 ′ has a configuration comprising a planar section 90 spaced slightly from the main body section. The connector 20 of the sheath system is configured to attach to two diametrically opposed radially extending surfaces 81 , as illustrated. Therefore, the adapter must be configured at the end for attaching to the ureteroscope by having an opening to receive the planar section 90 . The adapter 80 permits insertion of the planar section 90 and rotating the adapter 90 degrees to lock the ureteroscope body to the adapter. At the opposite end of the adapter, the connector is locked on.
[0046] The primary lumen 12 encloses the viewing tube of the scope. The material for this lumen must be flexible. In view of the expandable connector piece 20 , it is not required to stretch longitudinally but preferably has some resilience to expand radially. Preferably, the primary lumen sheath material will have the properties of medium durometer, low elongation, high tear resistance and durability. Any medical device material having these properties can be used. Polyurethane film materials generally have desired properties for use in the present invention, however, but silicone films, latex or any flexible film-like material approved for medical use in a patient can be used. Controlling the wall thickness provides the desired features and the desired wall thickness can be readily determined by routine experimentation by those skilled in the art. Depending on the material used and the type of endoscope, wall thicknesses of the primary lumen sheath material can vary and can readily be determined by a person skilled in the art. Generally, for an ureteroscope as illustrated, the wall thickness is preferably from about 0.006 inch to about 0.009 inch.
[0047] The secondary lumen 17 provides access into the patient for tool devices as necessary. Materials suitable for the primary lumen sheath are also suitable for the secondary lumen sheath. However, it is highly desirable for the secondary lumen sheath material to be flexible and to stretch to expand radially to accommodate tools having an exterior diameter slightly larger than the interior diameter of the secondary lumen. Thus, the wall thickness of the secondary lumen sheath most likely will differ from that of the primary lumen. Again, polyurethane film materials generally have desired properties for use in the present invention, however, but silicone films, latex or any flexible film-like material approved for medical use in a patient can be used. Controlling the wall thickness to expand the lumen's diameter with minimal resistance when passing a tool device therethrough and to provide the desired features can be readily determined by routine experimentation by those skilled in the art. The more it is desired to permit the lumen to expand, the higher the resistance encountered by a particular material. Depending on the material used and the type of endoscope, wall thicknesses of the primary lumen sheath material can vary, for the various size tools that may be desired to be accommodated, and can readily be determined by a person skilled in the art. Generally, for an ureteroscope as illustrated, the wall thickness is preferably from about 0.003 inch to about 0.006 inch, most preferably 0.005 inch.
[0048] However, the resistance is of the secondary lumen sheath material can be reduced by using a low coefficient of friction material for the insert 16 that is positioned inside the secondary lumen and is between the tool device and the wall of the secondary lumen. The insert 16 generally will be made of a durable material having a high durometer, low elongation and high tear resistance. Because polyurethane, silicone, latex, and like materials typically have a relatively high coefficient of friction (i.e., a drag property), it is desirable to reduce the friction inside the secondary lumen for inserting or removing tools, biopsy segments, and the like through the small diameter secondary lumen. The longitudinal split of the insert 16 allows ready radial expansion inside the secondary lumen, particularly when the insert has a low coefficient of friction. A material, such as Mylar™ or the like, can provide high resistance to tear, high durometer and a relatively low coefficient of friction for the insert. Thus, the split insert 16 in the secondary lumen 17 allows tools slightly larger than the interior diameter of the secondary lumen to pass through the lumen contacting the low coefficient of friction insert and not contacting the higher coefficient of friction polyurethane, silicone, latex or the like. When in use, the insert opens the longitudinal split exposing only a small area of higher coefficient of friction material exposed by the gap (g, g′) in the expanded insert. Other low coefficient of friction materials such as a thin film of polyethylene, or the like, can be used instead of Mylar™. Again, controlling the wall thickness to expand the lumen's diameter with minimal resistance when passing a tool device therethrough and to provide the desired features can be readily determined by routine experimentation by those skilled in the art. It has been found that use, for example, of a Mylar™ insert having a wall thickness of from about 0.00025 inch to about 0.00075 inch provides desirable results inside a polyurethane secondary lumen having a wall thickness of about 0.005 inch.
[0049] In many cases, lubricants are used to resolve such high coefficient of friction issues. Lubricants are surface treatments applied to the materials and generally work well, but have a tendency to migrate off the surface when inactive. Also, the lubricant can be removed relatively easily when encountering resistance of any kind such as when the lumen is expanded by a tool or solid material. The coating can be wiped off the surface exposing the high coefficient of friction the polyurethane, silicone, latex or the like materials. The use of an insert having a relatively lower coefficient of friction avoids issues typically accompanying use of a lubricant. When used, the lubricant of course must be medically compatible for the application. Suitable lubricants include, for example, 2% lidocaine jelly (sold under the mark “Urojet”) and Surgilube™ which typically is used when patients are already under anesthesia.
[0050] Disposable sheath systems in accord with the present invention can be made by any suitable manufacturing process. One such process is described below. This is the manufacturing procedure allows one to adjust each sheath materials for the primary and secondary lumens independently to obtain the desired physical properties for that individual lumen. The sheaths when joined together create another physical property for the system that is the result of the differences in physical properties of the two sheaths joined lengthwise. With routine experimentation the resulting physical property attributes of the joined sheaths can be adjusted to create a system (joined tubes) that meets any physical requirement desired by the user. Sheath physical properties in each lumen that can be varied include durometer, elongation, wall thickness, materials and material features.
[0051] One useful manufacturing process involves the following steps:
[0052] Primary Lumen Sheath:
1. Cast a film of the desired polyurethane on a stainless steel rod. The rod will have the OD to result in the desired ID of the lumen and a length to provide a lumen for the particular type of endoscope. 2. Continue the cast films on the rod inverting each time until the proper wall thickness is achieved.
[0055] Secondary Lumen Sheath:
1. Cast a film of the desired polyurethane on a rod. The rod will have the OD to result in the desired ID of the lumen and a length equal to the length of rod used for making the primary lumen. 2. Continue the cast films on the rod inverting each time until the proper wall thickness is achieved.
[0058] Joining Lumens:
1. Join the two rods with films together at each end so they are parallel and have no spaces anywhere along there length. 2. Cast a film of the desired polyurethane on the joined rods. 3. Invert the joined rods and cast a second film. 4. Remove the films on the rods by injecting a solution between the films and rods in both lumens. 5. Slide the rods out the inside of each lumen, clean to remove release residue and let dry. 6. Trim the ends of the joined tubes so the larger lumen is longer than the smaller lumen. 7. Attach the exposed end of the larger tube to a circular ring that holds a spring at the opposite end. 8. Attach the opposite end of the spring to the small end of the hub that will hold the Scope. 9. Secure a plastic or equivalent cover to the hub and the spring's circular rings and seal. The cover will be attached loosely allowing it to expand when the spring is stretched.
[0068] Placing Mylar™ Insert into Secondary Lumen:
1. Cut a piece of Mylar™ film or equivalent to a length and width that when inserted in the small lumen of the device the width covers the lumens ID. 2. Fold and insert the Mylar™ film into the small lumen leaving a small portion of Mylar exposed outside each end the small lumen. 3. Insert a piece of tubing larger than the ID of the small lumen on the device into the small lumen's ID. The tubing will be sized to pass oversized tools into the small lumen with Mylar™. 4. The tube captures and secure the Mylar™ at the junction where the two tubes join. 5. When the small lumen is expanded as a result of insertion of an oversized tool the Mylar™ separates where the Mylar™ film meets allowing passage of the tool with minimal resistance. 6. Secure with adhesive the exposed free tube to the attached thin wall tube on the device where they meet. Trim Mylar™ as required. 7. Add a drop of polyurethane in a solvent at the distal end of the small lumen to secure the Mylar™ to the open end of the small lumen. Trim lumen at an angle and remove excess materials.
[0076] Finishing Disposable Sheath System:
1. Secure an appropriate size luer to the opposite end of the exposed free tube exiting the small lumen. 2. Insert and fix a clear viewing window to the open end of the large lumen of the device. 3. Add lubricant to internal surfaces.
[0080] Those skilled in the art can readily provide other suitable manufacturing processes.
[0081] The primary lumen typically will have a diameter to accommodate the viewing tube of the type of endoscope for which it is made. Depending on the use, endoscopes have different size (diameter) viewing scopes. For example, for the 12 Fr size of the ureteroscope, the primary lumen typically will have an ID that exceeds 0.157 inch and be less than 0.170 inch.
[0082] The secondary lumen typically will have a diameter to accommodate tools having a size from about 6 French to about 7+French. For any particular secondary lumen, the expansion typically will accommodate tools of various French sizes depending on the use of the scope (e.g., for the illustrated ureteroscope, from about 6 French to about 7+French, preferably about 6.5 French sizes).
[0083] The invention has been described in detail with specific references to a disposable sheath system for a ureteroscope. However, those skilled in the art will recognize that the disposable sheath system can be tailored for various types of endoscopes. Further, multiple secondary lumens can be attached to the primary lumen to accommodate the use of more than one tool device simultaneously.
[0084] Although the invention has been described in detail, it will be apparent that numerous modifications may be made by those skilled in the art without departing from the spirit and scope of the invention. | A disposable sheath device for use with an endoscope is disclosed. The endoscope has a body with an insertion tube having optics at its distal end. The disposable sheath device has a primary lumen and at least one secondary lumen attached to the primary lumen along a length of the lumen. The primary lumen is for covering and protecting the insertion tube from bodily contamination. The secondary lumen is for accommodating a desired tool. The secondary lumen has an insert substantially commensurate in length to the secondary lumen and has a slit longitudinally along its length. The slit permits radial expansion to accommodate tools having a radius larger than that of the secondary lumen, which preferably is made of a flexible material that expands. A connector is attached to the proximal end of the primary lumen and connects to he body of the endoscope. The connector extends longitudinally to accommodate different length insertion tubes. Optionally, an adapter can be used to attach the connector to the body of the endoscope. Varying the adapter permits the sheath device to be attached to various endoscope bodies. | 0 |
This is a continuation-in-part of application Ser. No. 07/534,376, filed June 7, 1990, which in turn is a continuation-in-part of application Ser. No. 07/306,304, filed Feb. 3, 1989, both applications being now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to oxide superconductive materials and a method of preparing such materials.
Recently, YBaCuO system materials have been reported as superconductives materials, and various tests and studies are being carried out on such materials. As a result, these materials have been reported as being very unstable and low in the critical current. Besides, the cost of such materials is high because rare earth elements are used in significant quantities, and the cost is susceptible to market fluctuations. It is desired to be improve upon these points.
More recently, new materials of an SrBiCuO system have been reported, but details are not known at the present time.
SUMMARY OF THE INVENTION
It is a primary object of this invention to present a material free from the above problems in respect to the critical current values, stability, and economic aspects of such materials.
The material of this invention is characterized firstly in the, the orientation of the C-plane of oxide superconductive materials and secondly resides in the use of ABiCuO as the principal constituents of the superconductive material (in which A comprises at least one kind of element composed of alkaline earth group metals).
This material is almost free from erosion by water or the like probably due to the nature of the orientation, since the oriented C-plane surface prevents the undesirable progress of erosion and further it does not contain rare earth elements and alkaline earth elements that causes instability as being in an unstable form. In addition, the solid solution range is estimated to be broad, and probably owing to this property, the material is stable in always containing a high temperature superconductor phase. Furthermore, since the C-plane orientation has a specific intra-plane Cu chain arrangement, it seems to contribute to the enhancement of the critical current. It seems that further excellent characteristics are obtained because a proper element-to-element distance is realized by mixing alkaline earth elements larger than and smaller than 1 Å in ion radius.
As a result, the materials of the present invention excels in economy because the materials have a high critical current and do not contain the expensive and marketably unstable rare.
While the novel features of the invention are set forth in the appended claims, the invention, both as to organization and content, will be better understood and appreciated, along with other objects and features thereof, from the following detailed description.
DETAILED DESCRIPTION OF THE INVENTION
As a result of follow-up tests on general recent YBaCuO system materials, the transition temperature was about 90° K., according to the investigation by the present inventors, even in the optimum composition of the so-called 123 (the ratio of Y/Ba/Cu). When the composition was slightly varied, an impurity phase was generated, and the characteristics fluctuated. This material was fabricated into a wire by hot extrusion at 950°, and the critical current was measured at 50° K. This value is called reference value 1 of this invention.
By contrast, according to the investigation of the present inventors, the new material possesses stable and excellent characteristics as follows.
Oxides containing at least one type each from a group of Mg, Ca of which the ion radius is 1 Å or less, and a group of Sr, Ba, and also Bi and Cu were weighed so that the ratio of the three A/Bi/Cu might be nearly 5/3/5, 3/2/3, 2/1/2 or in their vicinity, and were uniformly mixed, and temporarily sintered at 800° to 850°, crushed, formed and baked at 830° to 870°. A sintered polycrystalline material was thus-produced. The material was extruded at 800° C. A nozzle with a rectangular section having an axial ratio of 5/1 was used. It is known that the better results are obtained when this ratio is higher, but according to the experiment by the present inventors, if the ratio was 3/1 or over, a high C-plane orientation was obtained radiographically. In the X-ray diffraction diagram, the rate of (00n) intensity of the total of the oriented oxide superconductive materials is approximately over 80%.
The obtained results are shown in Table 1.
TABLE 1__________________________________________________________________________Composition Transition Current Zero-resistanceSr Ca Ba Mg Bi Cu temperature ratio Phase temperature__________________________________________________________________________ 1 3.3 1.7 0 0 3 5 105 3 Single 101 2 3.8 2.2 0 0 4 5 108 4 Single 100 3 3.5 2.5 0 0 4 5 110 6 Single 106 4 4.5 1.5 0 0 5 4 113 2 Single T 5 3.0 3.0 0 0 3 5 102 5 Single 99 6 0.5 0.5 0 0 1 1 82 1 Plural 78 7 1.5 1.5 0 0 2 2 81 2 Plural T 8 1.0 1.0 0 0 1 2 101 9 Plural T 9 2.0 2.0 0 0 2 3 84 2 Plural 8310 2.0 2.0 1 1 4 5 106 4 Single 10111 2.0 2.0 1 3 5 101 4 Single 9012 4.0 0.5 1 0.5 4 5 110 8 Single T13 2.0 1.0 0.5 0.5 2 3 101 8 Plural 9514 2.0 2 2 3 23 0 Plural 1215 1.5 1.5 2 3 105 4 Single 10316 0.5 0.5 0 0 1 1 82 2 Plural T17 1.5 1.5 0 0 2 1 81 1 Plural T18 1.0 1.0 0 0 1 1 101 6 Plural 9519 2.0 2.0 0 0 2 1 84 2 Plural T20 2.0 1.0 0.5 0.5 2 1 101 3 Plural T21 0.5 0.5 0 0 0.2 1 103 4 Single T22 0.5 0.5 0 0 1/3 1 101 4 Single 9423 0.5 1.0 0 0 0.2 1 110 9 Single T24 0.5 1.0 0 0 1/3 1 106 3 Single T25 0.5 1.0 0 0 1/4 1 113 7 Single 10826 0.5 0.5 0.2 0.2 0.3 1 105 7 Single 9627 0.3 0.6 0.2 0.1 0.3 1 101 2 Single 9028 0.2 0.9 0.1 1/4 1 102 6 Single T29 0.4 0.9 1/4 1 113 7 Single 106__________________________________________________________________________
As obvious from the table, the transition temperature was stable in all examples. Moreover, by mixing the elements of the two groups, the transition temperature was over 80° K. as compared with 20° to 30° K. in the case of a single group composition. In the humidity resistance test performed by subjecting the materials to high temperature and high humidity (60°, 60%) for a month, the so-called YBaCu system materials were whitened on the whole and were considerably decayed, whereas the new materials were only slightly whitened on the surface and were very stable. As known from Table 1, in spite of single phase and plural phases, basically, the ratio of the critical current to the reference value was remarkably improved in all materials (except for material 14), and excellent characteristics were found.
In respect to the superconductor material in Example 14 of Table 1, Sr and Ba are contained therein and have ionic radiuses larger then 1 Å. On the other hand, the other examples of this table were mixed, i.e. contained ions with a smaller ionic radius than 1 Å. Accordingly, it is presumed from the results shown therein that mixtures of components having different ionic radiuses were more effective in improving the properties of the final product than the individual components.
More precisely, a careful examination of the table shows that in the mixed states (wherein the ratios of A with a radius of 1 Å or larger in combination with an A component with an ionic radius of less than 1 Å was between 5/1-1/3) excellent results are obtained.
Further, when examining the data in Table 1, it is noted that when the averages of the ratio of Bi and Cu where computed, the ion ratio of Bi to Cu is 2/3. Further, it is noted that preferable ranges of the ion ratios are represented by 2≧A/Bi≧1.5, Bi/Cu<1, and A/Cu≦2, where A represents the sum of Sr and Ca. When such ratio exists, excellent characteristics are found within the broad scope of the materials of Table 1 in that compositions falling within this range exhibit remarkable effects as a super-conductor. Also, it is noted that excellent characteristics are found where A/Bi>4.5.
As the X-ray analysis results show, a crystal phase in a composition ratio in the vicinity of the single 3/2/3 or 5/3/5 is formed in a considerably wide range (it is estimated, as presently investigated, to be composed of a superlattice of a pseudotetragonal system with a unit cell of 5.4 Å, considering together with the results of transmission electron microscopic findings, as being nominally expressed as an orthorhombic system with lattice constants of a=5.4 Å, b=5.4×5=27.0 Å and c=15.3×2=30.6 Å), and it is known that it is very easy to cleave on the C-plane.
It is assumed that the high orientation of more than 80% is due to the cleaving characteristics of the materials. Therefore, this technology of extension can be applied to other oxide superconducting materials which shows clear cleaving characteristics.
According to the invention, materials excelling in humidity resistance, broad in the solid solution range, large in critical current, and superior in safety and reproducibility may be produced, which may be widely applied in superconductive appliances.
While specific embodiments of the invention have been illustrated and described herein, it is realized that other modifications and changes will occur to those skilled in the art. It is therefore to be understood that the appended claims are intended to cover all modifications and changes as fall within the true spirit and scope of the invention. | An oxide superconductive material comprising constituent elements mainly composed of ABiCuO in which A comprises at least one element of alkaline earth metals, and having a C-plane orientation, and a method of orienting such superconductive materials by hot extrusion from a rectangular nozzle. | 8 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to bicomponent filaments, particularly to a process for making bicomponent filaments, more particularly to a process wherein such bicomponent filaments contain a small amount of styrene polymer additive.
[0003] 2. Discussion of Background Art
[0004] Spinning of bicomponent polyester fibers has been disclosed in U.S. Pat. No. 3,671,379 (which shows a ‘snowman’ fiber cross-section in FIG. 4), Published World Patent Application WO2001-53573 and Published United States Patent Application US2001-0055683. Spinning polyester fiber containing polystyrene has been disclosed in Published Japanese Patent Application JP56-91013 and U.S. Pat. No. 4,424,258. Published Japanese Patent Application JP57-61716, misquoted in published Published Japanese Patent Application JP59-26524, discloses the use of blends of polyesters with polyacrylates, polystyrene, or polymethacrylates to make mixed filaments, in which two polymer streams are spun simultaneously but separately to form two distinct groups of different filaments. The latter application teaches away from using such blends to make side-by-side bicomponent fibers. Published Japanese Patent Application JP11-189925 discloses spinning and twisting a fiber having a small core of polystyrene/polyester blend in a sheath of the same polyester in order to avoid reported “melt fusion” in subsequent processing.
[0005] There remains a need to make high-crimp, side-by-side, bicomponent fibers at high speeds.
SUMMARY OF THE INVENTION
[0006] The present invention provides a process for making a side-by-side bicomponent filament comprising the steps of:
[0007] a) providing poly(trimethylene terephthalate);
[0008] b) providing a polyester selected from the group consisting of poly(ethylene terephthalate) and copolyesters of poly(ethylene terephthalate), in a weight ratio of about 30/70 to 70/30;
[0009] c) providing a styrene polymer having a number-average molecular weight of about 75,000 daltons to 300,000 daltons;
[0010] d) mixing the styrene polymer with at least one of the poly(trimethylene terephthalate) of step (a) and the selected polyester of step (b) to form a first melt-extrusion polymer and a second melt-extrusion polymer, respectively, wherein at least one melt-extrusion polymer contains from about 0.1 weight percent to about 5 weight percent styrene polymer;
[0011] e) melting the first melt-extrusion polymer;
[0012] f) melting the second melt-extrusion polymer;
[0013] g) spinning the first and second melt-extrusion polymers into a filament;
[0014] h) quenching the filament with gas in a manner selected from the group consisting of cross-flow and co-current flow;
[0015] i) withdrawing the filament; and
[0016] j) winding up the filament.
BRIEF DESCRIPTION OF THE FIGURES
[0017] [0017]FIG. 1 shows a quench system that can be used in a process of the invention.
[0018] [0018]FIG. 2 shows a roll system that can be used in a process of the invention.
[0019] [0019]FIG. 3 illustrates fully drawn filament crimp values obtained at various windup speeds in a process of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0020] In contrast to the disclosures of the prior art, it has now been found that side-by-side bicomponent filaments comprising poly(ethylene terephthalate) and poly(trimethylene terephthalate) with a small amount of styrene polymer additive can be spun at unexpectedly high speeds without sacrificing desirable crimp. In further contrast to the prior art, no melting or sticking was observed during processing of the filament, for example during drawing, winding, testing, and the like, even when no particular precaution was taken to prevent the polystyrene from being present at the surface of the filament. As a result of the high degree of crimp in the filament, it was not necessary to twist the filament to make it useful.
[0021] As used herein, “bicomponent filament” means a continuous filament comprising polyesters of different chemical composition, specifically poly(ethylene terephthalate) and poly(trimethylene terephthalate), adhered to each other along the length of the filament in a side-by-side relationship. “Withdrawal speed” means the speed of the feed rolls, which are positioned between the quench zone and the (optional) draw rolls and is sometimes referred to as the spinning speed. “IV” means intrinsic viscosity. “Fully drawn” filament means a bicomponent filament which is suitable for use, for example, in weaving, knitting, and preparation of nonwovens without further drawing and can exhibit useful crimp contraction values. “Partially oriented” filament means a filament which has considerable but not complete molecular orientation, for example having considerable residual draw, and which generally requires drawing or draw-texturing before it is suitable for weaving or knitting and before it can exhibit useful crimp contraction values. “Fully oriented” filament means a filament which, as-spun, requires no drawing to be useful or to exhibit useful crimp contraction values. “Co-current gas flow” means a flow of quench gas which is accelerated in the direction of filament travel.
[0022] In the process of the present invention, a small amount of styrene polymer additive is mixed with at least one of a) poly(trimethylene terephthalate) and b) poly(ethylene terephthalate) or copolyesters of poly(ethylene terephthalate). The mixture can be made by ‘salt-and-pepper’ blending, optionally followed by compounding, for example in an extruder. The poly(ethylene terephthalate) or copolyester thereof, or mixture of styrene polymer with poly(ethylene terephthalate) or copolyester thereof (the ‘second melt-extrusion polymer’), is then melt-spun with poly(trimethylene terephthalate) or mixture of styrene polymer and poly(trimethylene terephthalate) (the ‘first melt-extrusion polymer’) in a weight ratio of 70/30 to 30/70 to form a side-by-side bicomponent filament, and the filament is quenched, withdrawn, and wound up. The styrene polymer is present in one component, and can be present in both components, of the bicomponent filament. The styrene polymer additive is present at a level of 0.1 to about 5 weight percent, typically about 0.5 to about 4 weight percent, based on weight of the mixture.
[0023] The poly(ethylene terephthalate) or copolyester thereof can have an IV of about 0.45-0.80 dl/g and the poly(trimethylene terephthalate) can have an IV of about 0.85-1.50 dl/g. A copoly(ethylene terephthalate) can be used in which the comonomer used to make the copolyester is selected from the group consisting of linear, cyclic, and branched aliphatic dicarboxylic acids having 4-12 carbon atoms (for example butanedioic acid, pentanedioic acid, hexanedioic acid, dodecanedioic acid, and 1,4-cyclo-hexanedicarboxylic acid); aromatic dicarboxylic acids other than terephthalic acid and having 8-12 carbon atoms (for example isophthalic acid and 2,6-naphthalenedicarboxylic acid); linear, cyclic, and branched aliphatic diols having 3-8 carbon atoms (for example 1,3-propane diol, 1,2-propanediol, 1,4-butanediol, 3-methyl-1,5-pentanediol, 2,2-dimethyl-1,3-propanediol, 2-methyl-1,3-propanediol, and 1,4-cyclohexanediol); and aliphatic and araliphatic ether glycols having 4-10 carbon atoms (for example, hydroquinone bis(2-hydroxyethyl) ether, or a poly(ethyleneether) glycol having a molecular weight below about 460, including diethyleneether glycol). The comonomer can be present in the copolyester at levels of about 0.5-15 mole percent. Isophthalic acid, pentanedioic acid, hexanedioic acid, 1,3-propane diol, and 1,4-butanediol are preferred.
[0024] Either or both polyesters can contain minor amounts of other comonomers, provided such comonomers do not have an adverse affect on the spinning speed, filament crimp value, or other properties. Such other comonomers include 5-sodium-sulfoisophthalate, at a level of about 0.2-5 mole percent, and very small amounts of trifunctional comonomers such as trimellitic acid. Poly(ethylene terephthalate) and poly(trimethylene terephthalate) include such copolyesters thereof within their meaning
[0025] The styrene polymer additive has a number average molecular weight of at least about 75,000 daltons, typically at least about 100,000 daltons and at most about 300,000 daltons, more typically at most about 200,000 daltons. Useful styrene polymers can be isotactic, atactic, or syndiotactic; especially at higher molecular weights, atactic is preferred. The styrene polymer can be selected from the group consisting of polystyrene, alkyl- or aryl-substituted polystyrenes (for example prepared from □-methylstyrene, p-methoxystyrene, and vinyltoluene), copolymers of styrene and substituted styrene, and styrene multicomponent polymers such as styrene-butadiene copolymers. Polystyrene (“PS”) is preferred.
[0026] The poly(trimethylene terephthalate) (“3G-T”), poly(ethylene terephthalate) (“2G-T”), styrene polymer additive, and/or the mixtures thereof, can, if desired, contain additives, such as delusterants, nucleating agents, heat stabilizers, viscosity boosters, optical brighteners, pigments, and antioxidants. For example, TiO 2 or other pigments can be added to the poly(trimethylene terephthalate), the poly(ethylene terephthalate), the styrene polymer additive, the mixture(s), or during filament manufacture.
[0027] After being spun from a spinneret, the hot filament can be quenched with a gas supplied as cross-flow or co-current flow. In cross-flow, the gas can be blown across the just-spun filaments, for example from one side of a quench chamber as shown in FIG. 1. In co-current flow, quench gas can be introduced from above, for example from an annular space around the spinneret, or from the side as shown in FIG. 2 of U.S. Pat. No. 5,824,248 and FIGS. 2, 4, and 6 of Published United States Patent US-2002-0025433, which are incorporated herein by reference. The quench gas can be accelerated in the direction of filament travel, for example by supplying the gas at elevated pressure and using a constriction below the quench chamber through which both the gas and the filaments pass. The resulting superatmospheric pressure can be in the range of about 0.5-5.0 inches of water (about 1.3×10 −3 to 1.3×10 −2 kg/cm 2 . The maximum velocity of the quench gas is generally at the narrowest point of the constriction. When a constriction having a minimum inner diameter of one inch (2.54 cm) is used, the maximum gas velocity can be in the range of about 330-5,000 meters/minute. Subatmospheric pressure can also be used. Optionally, a flow of quench gas into each of two substantially coaxial quench chambers arranged in series along the path of the filaments and each chamber provided with a constriction through which gas and filaments pass, can be used.
[0028] In one embodiment of the invention, the spun filament is drawn by about 2.0X to 4.5X and heat-treated at about 140° C. to 185° C. to form a fully-drawn filament before being wound up. When the quench gas is supplied as cross-flow, the windup speed is at least about 4100 m/min, typically about 5300 to 5800 m/min. When the quench gas is supplied as co-current flow, the windup speed is at least about 6200 m/min, preferably about 8200 to 9000 m/min. Such a filament can have an after-heat-set crimp contraction value of at least about 30%.
[0029] In another embodiment of the invention, the filament is spun with quench gas supplied as cross-flow at withdrawal speeds of about 3000 to 4500 m/min, typically about 3500 to 4500 m/min, or as co-current flow at withdrawal speeds of about 3600 to 5000 m/min, typically about 4100 to 5000 m/min and wound up as a partially oriented filament, for example with little or no drawing. The partially oriented filament can be further processed later, for example drawn by about 2.0X to 4.5X and heat-treated at about 140° C. to 185° C., typically within about 35 days. At lower withdrawal speeds but still within the scope of the present invention, shorter delays between spinning and drawing/heat-treating would typically be used.
[0030] In yet another embodiment, the filament is spun with cross-flow quench at withdrawal speeds of at least about 6000 to 8000 m/min and a fully oriented filament is wound up at substantially the same speed. Such filament typically has an after-heat-set crimp contraction value of at least about 30%.
[0031] Higher levels of styrene polymer additive generally permit higher withdrawal and windup speeds, as does the use of styrene polymer additive mixed into both the poly(ethylene terephthalate) (or copolyester thereof) and the poly(trimethylene terephthalate).
[0032] The filaments can have cross-sections that are round, ‘snowman’, octalobal, scalloped oval, trilobal, tetra-channel (also known as quatra-channel), and the like.
[0033] The crimp values of the bicomponent filaments made in the Examples was measured as follows. Each sample was formed into a skein totaling 5000+/−5 denier (5550 dtex) with a skein reel at a tension of about 0.1 gpd (0.09 dN/tex). The skein was conditioned at 70+/−2° F. (21+/−1° C.) and 65+/−2% relative humidity for a minimum of 16 hours. The skein was hung substantially vertically from a stand, a 1.5 mg/den (1.35 mg/dtex) weight (e.g. 7.5 grams for a 5550 dtex skein) was hung on the bottom of the skein, the weighted skein was allowed to come to an equilibrium length, and the length of the skein was measured to within 1 mm and recorded as “C b ”. The 1.35 mg/dtex weight was left on the skein for the duration of the test. Next, a 500 gram weight (100 mg/d; 90 mg/dtex) was hung from the bottom of the skein, and the length of the skein was measured to within 1 mm and recorded as “L b ”. Crimp contraction value (percent) (before heat-setting, as described below for this test), “CC b ”, was calculated according to the formula
CC b =100×( L b −C b )/ L b
[0034] The 500 g weight was removed, and the skein was then hung on a rack and heat-set, with the 1.35 mg/dtex weight still in place, in an oven for 5 minutes at about 250° F. (121° C.), after which the rack and skein were removed from the oven and conditioned as above for two hours. This step is designed to simulate commercial dry heat-setting, which is one way to develop the final crimp in the bicomponent filament. The length of the skein was measured as above, and its length was recorded as “C a ”. The 500-gram weight was again hung from the skein, and the skein length was measured as above and recorded as “L a ”. The after heat-set crimp contraction value (percent), “CC a ”, was calculated according to the formula
CC a =100×( L a −C a ) L a .
[0035] The test was performed on five samples and the results were averaged. CC a is reported in the Tables. This crimp measurement method is estimated to be accurate to ±2 percent absolute.
[0036] The poly(trimethylene terephthalate) used in the Examples was prepared from 1,3-propanediol and dimethylterephthalate (“DMT”) in a two-vessel process using tetraisopropyl titanate catalyst, Tyzor® TPT (a registered trademark of E. I. du Pont de Nemours and Company) at 60 ppm titanium, based on polymer. Molten DMT was added to 3G and catalyst at 185° C. in a transesterification vessel, and the temperature was increased to 210° C. while methanol was removed. The resulting intermediate was transferred to a polycondensation vessel where the pressure was reduced to one millibar (10.2 kg/cm 2 ), and the temperature was increased to 255° C. When the desired melt viscosity was reached, the pressure was increased and the polymer was extruded, cooled, and cut into pellets. The pellets were further polymerized in a solid-phase polymerizer to an intrinsic viscosity of 1.03 dl/g in a tumble dryer operated at 212° C.
[0037] The polystyrene used in the Examples was ‘168 MK G2’ from BASF; it was reported to be a homopolymer and to have a melt index of 1.5 g per 10 min as determined according to ASTM 1238 on 5 kg at 200° C. and a softening point of 109° C. as determined according to ASTM-D1525. It had a number-average molecular weight of 124,000 daltons as calculated according to ASTM D 5296-97.
[0038] The spinneret used in the examples was a post-coalescence bicomponent spinneret having thirty-four pairs of capillaries arranged in a 1.75 inch (4.4 cm) diameter radially symmetric circle, an internal convergent angle between each pair of capillaries of 60°, a capillary diameter of 0.64 mm, and a capillary length of 4.24 mm.
[0039] [0039]FIG. 1 illustrates the cross-flow quench chamber used in the Examples. Quench gas 1 entered zone 2 below spinneret face 3 through plenum 4 , past hinged baffle 18 and through screens 5 the top 2.5 cm of which were not perforated, resulting in a substantially laminar gas flow across still-molten filaments 6 which were spun from capillaries (not shown) in the spinneret. Baffle 18 was hinged at the top, and its position was adjusted to give the flow of quench gas shown in Table A, measured 5 inches (12.7 cm) from screen 5 .
TABLE A Distance below Air speed spinneret (cm) (mpm) 15 8.5 30 9.4 46 9.4 61 11.0 76 11.0 91 11.3 107 11.6 122 16.5 137 34.1 152 39.6 168 29.6
[0040] Spinneret face 3 was recessed above the top of zone 2 by 0.75 inch (1.9 cm) (distance “A” in FIG. 1), so that the quench gas did not blow directly onto the face of the spinneret. The quench gas, which was unheated air, continued on past the filaments and into the space surrounding the apparatus. The filament left zone 2 through filament exit 7 . Finish was applied to the filaments by finish roll 10 , and the filaments were then passed to the rolls illustrated in FIG. 2.
[0041] As shown in FIG. 2, filament 6 was passed by finish roll 10 , around the pair of driven roll 11 and idler bearing 12 , and then around heated feed rolls 13 . The temperature of feed rolls 13 was about 60° C. The filament was drawn by heated draw rolls 14 , heat-treated at substantially constant length by rolls 15 , passed around unheated rolls 16 (which adjusted the yarn tension for satisfactory winding), and then to windup 17 . The speeds of the heat-treating rolls and draw rolls were substantially equal.
[0042] In the Examples, the draw ratio applied was the maximum possible without generating a significant increase in the number and/or frequency of broken filaments and was typically at about 90% of break-draw. In the Tables, “Comp.” indicates a comparison sample, and “CCa” represents after-heat-set contraction in percent.
EXAMPLES
Example 1
[0043] Polystyrene pellets were separately mixed with poly(ethylene terephthalate) flake (0.54 IV Crystar® 4415, a registered trademark of E. I. du Pont de Nemours and Company) and with the poly(trimethylene terephthalate) prepared as described hereinabove. The amount of polystyrene used was 2 weight percent in each case, based on total polymer. Each mixture was separately compounded using a conventional screw remelting compounder with a barrel diameter of 30 mm and a MOCA-2 screw (Werner & Pfleiderrer Corp., Ramsey, N.J.). The extrusion die was ⅛ inches (3.18 mm) in diameter with a screen filter at the die entrance. A vacuum was typically applied at the extruder throat.
[0044] For the mixture of polystyrene with poly(ethylene terephthalate), the first barrel section of the compounder was set at 170° C., the second section at 230° C., and the remaining ten sections at 220° C. The screw was operated at 150 revolutions per minute, and the melt temperature was 266° C. at the extrusion die.
[0045] For the mixture of polystyrene with poly(trimethylene terephthalate), the first heated barrel section was set at 170° C., the second at 230° C., and the remaining ten sections at 215° C. The screw was set at 150 revolutions per minute, and the melt temperature was 261° C. at the extrusion die.
[0046] In each case, the extrudant then flowed into a waterbath to solidify the mixed polymers into a monofilament. Two sets of air knives dewatered the filament, and it was passed to a cutter that sliced it into 2 mm pellets.
Example 2
[0047] The pellets of poly(ethylene terephthalate) mixed with 2 wt % polystyrene and the pellets of poly(trimethylene terephthalate) mixed with 2 wt % polystyrene, both from Example 1, were separately dried in a vacuum oven for at least 16 hours at 120° C. The dried pellets were removed from the oven and quickly dropped into separate, nitrogen blanketed supply hoppers maintained at room temperature. The pellets were fed from the hoppers to two twin screw remelters operated at maximum temperatures of 275° C. for the mixture of polystyrene with poly(ethylene terephthalate) and 245° C. for the mixture of polystyrene with poly(trimethylene terephthalate) and then to a spin pack operated at 265° C.
[0048] The mixtures were spun at a 50/50 weight ratio into a quench chamber as shown in FIG. 1. At this point the filaments of Samples 1, 2, and 3 especially, but also those of Samples 4 and 5, were judged to be partially oriented. The filaments were then passed through a roll system as shown in FIG. 2. Draw rolls 14 were heated to 90° C., and heat-treatment rolls 15 were heated to 150° C.
[0049] The resulting fully-drawn filaments had tenacities in the range of 2.5 to 4.4 g/denier (2.2 to 3.9 dN/tex) and elongations-at-break in the range of 12 to 22%, with no particular relationship to spinning speed. The relationship between windup speed (“WUS”) and after-heat-set crimp values are shown in Table I and FIG. 3, in which the ‘diamonds’ represent the data from Table I. Sample 1 was spun at a withdrawal speed of about 645 m/min.
TABLE 1 WUS, Sample m/min CCa, % Draw Ratio 1 2515 49 3.9 2 3015 51 3.7 3 3520 48 3.5 4 4020 54 3.3 5 4520 55 3.2 6 4550 53 3.2 7 5025 40 3.0 8 5540 35 2.8 Comp. 1 5850 28 2.7
[0050] Data for Samples 1, 3, and 7 were average of two spins each. Examination of the data in Table I shows that high crimp values of the fully drawn filament were maintained up to windup speeds of about 5800 m/min.
Example 3
[0051] Sample 5 was further subjected to the following tests. A skein having a denier of 27,060 was prepared and hung vertically from a stationary hook. A 50 g weight from was suspended from the bottom end of the skein, which at this point had an effective denier of 54,120. The weight was left in place for one-half minute, and the length (D) of the effectively doubled skein was determined. The 50 g weight was removed, a 4.54 kg weight was similarly hung from the skein, and the skein's length was again determined after one-half minute and labelled (B). The 4.54 kg weight was removed, and the skein was placed in a forced draft oven at 180° C. for 5 minutes, after which it was removed and allowed to cool for one minute. The skein was again hung from the hook for one-half minute with the 50 g weight suspended from its bottom end, and its length (E) was determined. Once again, the 50 g weight was removed, the 4.54 kg weight was hung from the skein, and the skein's length was determined after one-half minute and labelled (F).
The following calculations were made from the various lengths % Original Bulk =100 × [B − D]/B % Total Bulk =100 × [B − E]/B % Thermal Bulk =100 × [B − D]/D % Thermal Shrinkage =100 × [B − F]/B % Net Crimp =100 × [F − E]/F
[0052] Original Bulk is the percentage difference in length of a skein of yarn in the crimped and extended state and indicates crimp spontaneously developed during spinning. Total Bulk is Original Bulk plus the crimp developed by heating the yarn. Thermal Bulk is that portion of Total Bulk which is developed by heat and is not present in the original spun yarn. Thermal Shrinkage is the percent difference in length of the skein in the extended state before and after heating. Net Crimp is the percent difference in length of the skein in the extended and the crimped state, after having been heated.
[0053] Sample 9 was prepared by substantially the same process as Sample 5 except that it was spun and wound up at 3990 m/min without drawing or heat-treating, in other words as a partially oriented filament. It was subjected to the same additional tests. These test results for these Samples are presented in Table II.
TABLE II Original Total Thermal Thermal Net Sample Bulk, % Bulk, % Bulk, % Shrinkage, % Crimp, % 5 71 81 283 30 73 9 0 72 72 44 49
[0054] As the data in Table II shows, Total Bulk, Net Crimp, and Thermal Bulk were all very high, the last especially so in the case of fully-drawn Sample 5. For partially oriented Sample 9, the low Original Bulk can be advantageous for downstream processing, and the very high Net Crimp, especially, is what would be expected for a filament spun at only about 2500 m/min.
Example 4 (Comparison)
[0055] Poly(trimethylene terephthalate) and poly(ethylene terephthalate) (Crystar® 4415) were separately dried, melted, and spun into filaments substantially as described in Example 2, except that they contained no polystyrene additive, the maximum temperatures of the remelt extruders were 260° C. for the poly(ethylene terephthalate) and 250° C. for the poly(trimethylene terephthalate), draw rolls 14 (refer to FIG. 2) were heated to 120° C., and heat-treatment rolls 15 were heated to 140° C.
[0056] Filament tenacities were in the range of 4.1 to 4.7 g/denier (3.6 to 4.1 dN/tex), and elongations-at-break were in the range of 11 to 25%. The relationship between windup speed (“WUS”) and after-heat-set crimp values (“CCa) are shown in Table III and FIG. 3, in which the squares represent the data from Table III.
TABLE III WUS, Sample m/min CCa, % Draw Ratio Comp. 2 2500 50 3.8 Comp. 3 2800 48 3.8 Comp. 4 3200 48 3.4 Comp. 5 3800 49 2.6 Comp. 6 4100 41 2.1 Comp. 7 4475 34 1.8 Comp. 8 4965 23 1.5
[0057] Data for Comparison Sample 2 were an average of two spins. Comparison of the data in Tables I and III shows that crimp values of the fully drawn filaments began to differ significantly at windup speeds of about 4100 m/min, at which speed the filaments containing polystyrene had over 30% higher crimp values than did the filaments without polystyrene additive. The difference increased as windup speeds increased. Further, at comparable crimp values, the windup speeds in Table I were demonstrated to be about 1000 m/min higher than those in Table III, a significant and unexpected advantage. | The invention provides an improved method for making a poly(ester) bicomponent fiber wherein at least one poly(ester) contains a styrene polymer. | 3 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This is a continuation of U.S. patent application Ser. No. 09/465,607, filed Dec. 17, 1999, which is a continuation of U.S. patent application Ser. No. 09/184,571, filed Nov. 2, 1998 (now U.S. Pat. No. 6,505,174), which is a continuation-in-part of U.S. patent application Ser. No. 08/620,906, filed Mar. 25, 1996 (now U.S. Pat. No. 5,950,176), all of which are incorporated herein by reference in their entireties.
BACKGROUND OF THE INVENTION
[0002] This invention relates in general to computer-implemented financial systems, and in particular to an improved automated securities trading system.
[0003] Computer-implemented securities trading systems are well known in the art. One such system is that disclosed in U.S. Pat. No. 4,674,044, issued to Kalmus et al., entitled “Automated Securities Trading System”, and incorporated by reference herein. These computer-implemented securities trading systems obtain bid and asked trades based on the bid and asked prices. However, there is generally still a human component to such systems.
[0004] For example, most financial markets also employ one or more market makers called “specialists.” These specialists fill customer orders from the specialist's inventory position if there are no matches for the customer orders in the open market. In the prior art, the specialist function is not automated, but is performed by a firm or individual. Thus there is a need in the art for an improved computer-implemented trading system that includes an automated specialist function to create a market for the securities traded and to lessen the volatility of smaller securities markets.
BRIEF SUMMARY OF THE INVENTION
[0005] To overcome the limitations in the prior art described above, and to overcome other limitations that will become apparent upon reading and understanding the present specification, the present invention discloses method, apparatus and article of manufacture for a computer-implemented financial management system that permits the trading of securities via a network. In accordance with the present invention, a server computer receives buy and sell orders for derivative financial instruments from a plurality of client computers. The server computer matches the buy order to the sell orders and then generates a market price through the use of a virtual specialist program executed by the server computer. The virtual specialist program responds to an imbalance in the matching of the buy and sell orders.
[0006] An object of the present invention is to lessen the price volatility of derivative financial instruments traded in narrower markets.
[0007] A feature of the present invention is a virtual specialist program that engages in trading in the market to offset the price volatility and to provide liquidity to the market.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] Referring now to the drawings in which like reference numbers represent corresponding parts throughout:
[0009] FIG. 1 shows a block diagram of an exemplary hardware environment of the present invention;
[0010] FIG. 2 shows a flowchart illustrating the general logic of a first embodiment of the present invention;
[0011] FIG. 3 shows a flowchart illustrating the logic of the pricing/trading program of the first embodiment of the present invention;
[0012] FIG. 4 shows a flowchart illustrating the logic of the generate market price program of the first embodiment of the present invention;
[0013] FIG. 5 shows a flow diagram illustrating the logic of the virtual specialist program of the first embodiment of the present invention;
[0014] FIG. 6 shows a flow diagram illustrating the logic of the stop trading program of the first embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0015] According to the present invention, a computer-implemented trading system is provided for derivative financial instruments. The computer-implemented trading system accepts buy and sell orders from traders for the derivative financial instruments, sets a market price based on the supply and demand, and participates in the market as a trader in order to minimize price volatility. One embodiment of the present invention is a computer-implemented Hollywood Stock Exchange (HSX), which may be implemented as a simulation (i.e., game) or as an actual trading system for derivative financial instruments representing movies, talent, CDs, and television programs. These derivatives could be purchased with virtual currency known as Hollywood dollars (H$) which are controlled by a virtual reserve bank program.
[0016] In one representative embodiment of the present invention, the derivative financial instruments are identified by a Current Trading List displayed for the traders that comprises a list of movies in various stages of production, talent, and other entertainment-oriented assets. The list contains:
[0017] name of the derivative financial instrument;
[0018] genre of the movie (action-adventure, mystery, western, comedy, etc.);
[0019] production status (scripting, pre-production, filming, editing, release, home-video, etc.);
[0020] number of shares in circulation;
[0021] last trading price (printed every 15 minutes)
[0022] price movement (i.e. +/−H$) since the previous midnight (PST);
[0023] price movement since the previous mid-day;
[0024] price movement year to date;
[0025] Traders can view the list sorted by:
[0026] name, alphabetically;
[0027] genre, alphabetically;
[0028] productions status, alphabetically;
[0029] most active (number of shares traded yesterday);
[0030] biggest gainers;
[0031] biggest losers; and
[0032] fastest movers today (e.g., fastest 20 movers up and fastest 20 movers down).
[0033] Similar information would be provided for other derivative financial instruments offered on the Hollywood Stock Exchange.
[0034] Each trader's portfolio is identified by a Portfolio data structure that comprises the trader's account status. This information includes:
[0035] the amount of cash in the trader's account (paid interest at the system discount rate plus some increment, compounded daily);
[0036] current percentage rate paid on cash balances;
[0037] the total value of held stocks at the last selling price;
[0038] the total value of held bonds at the last selling price;
[0039] total portfolio value (TPV) (cash+bonds+stocks);
[0040] percentage of TPV in cash;
[0041] percentage of TPV in bonds; and
[0042] percentage of TPV in stocks.
[0043] Traders can generate any number of different reports for display, including:
[0044] Lists of stocks and bonds being traded (see above);
[0045] index of total Hollywood stocks (HSXI) expressed as a number, with 1000 defined as the aggregate total stock price value on opening day, wherein HSXI=(today's gross stock-value)/(opening day gross stock-value);
[0046] index of total Hollywood bonds (HBXI) expressed as a number, with 1000 defined as the aggregate total bond price value on opening day, wherein HBXI=((today's gross bond-value)/(opening day gross bond-value));
[0047] index of total Hollywood Stock Exchange (HMXI) comprised of all stocks and bonds, and expressed as a number, with 1000 as the aggregate total stock price value on opening, wherein HMXI=((today's gross market-value)/(opening day gross market-value));
[0048] lists of the top market performers, e.g., the top 10 traders in percentage portfolio growth calculated as net portfolio value−change=(% change of cash)+(% change of stocks)+(% change of bonds), and for each of the categories: yesterday (midnight to midnight), last week (7 days, ending midnight, each Thursday), last month (closes at midnight last calendar day of month), last quarter (closes at midnight on last day of last month/quarter), year-to-date (running daily total of percentage value changes)/(days for year-to-date), and annually (closes at midnight on December 31 each year);
[0049] overall market condition report, including a list of stopped issues with:
[0050] name;
[0051] last trading price;
[0052] time that stop-trade condition occurred;
[0053] percentage the issue actually moved on-the-day before the stop-trade;
[0054] number of total shares and/or bonds traded today;
[0055] dollar value of total trades today;
[0056] number of buy and sell trades today; and
[0057] number of buy and sell trades this month.
[0058] Use of the above information guides traders in making future buy and sell orders.
[0059] With reference to FIG. 1 , a block diagram illustrates an exemplary hardware environment for one embodiment of the present invention. More particularly, a typical distributed computer system is illustrated, which uses the Internet 10 to connect client computers 12 executing for example, Web browsers, to server computers 14 executing a computer program embodying the present invention. A typical combination of resources may include client computers 12 that are personal computers or work stations connected via the Internet 10 to server computers 14 that are personal computers, work stations, minicomputers, or mainframes.
[0060] Generally, both the client computers 12 and the server computers 14 are comprised of one or more CPUs 16 , various amounts of RAM storing computer programs 20 and other data, and other components typically found in computers. In addition, both the client computers 12 and the server computers 14 may include one or more monitors, and fixed or removable data storage devices 20 such as hard disk drives, floppy disk drives, and/or CD-ROM drives. Also, input devices, such as mouse pointing devices and keyboards, may be included.
[0061] Both the client computers 12 and the server computers 14 operate under the control of an operating system, such as Windows, Macintosh, UNIX, etc. Further, both the client computers 12 and the server computers 14 each execute one or more computer programs 18 under the control of their respective operating systems. The present invention is preferably implemented as one or more computer programs 18 executed by the server computer 14 , although in alternative embodiments these computer programs 18 may also be executed on the client computer 12 .
[0062] Generally, the computer programs 18 implementing the present invention are tangibly embodied in a computer-readable medium, e.g., one or more of the fixed and/or removable data storage devices 20 attached to the computer. Under control of the operating system, the computer programs 18 may be loaded from the data storage devices 20 into the RAM of the computer for subsequent execution by the CPU 16 . The computer programs 18 comprise instructions which, when read and executed by the computer, causes the computer to perform the steps necessary to execute the steps or elements of the present invention.
[0063] Those skilled in the art will recognize that the exemplary environment illustrated in FIG. 1 is not intended to limit the present invention. Indeed, those skilled in the art will recognize that other alternative hardware environments may be used without departing from the scope of the present invention.
[0064] With reference to FIG. 2 , a flowchart illustrates the general logic of one embodiment of the present invention. Block 200 represents the server computer 14 waiting for the next event to occur. Once the event occurs, control is transferred to blocks 202 - 224 to identify the event and respond accordingly.
[0065] Block 202 is a decision block that represents the server computer 14 determining whether it received a request to display data from the client computer 12 . If so, block 204 represents the server computer 14 transmitting data to the client computer 12 for subsequent display. The data transmitted for display preferably includes at least three types of data: the current list of trading derivative financial instruments, the trader's portfolio, and other reports generated by the server computer 14 .
[0066] Block 206 is a decision block that represents the server computer 14 determining whether it received a request to submit a buy order from the client computer 12 for a particular derivative financial instrument, e.g., stock or bond. If so, block 208 represents the server computer 14 processing the buy order by placing it in a queue in the memory of the server computer 14 . The buy order is a data structure comprising:
[0067] trader's account number;
[0068] trader's name;
[0069] the time and date of the order;
[0070] the stock or bond to buy;
[0071] the cash balance in the trader's account; and
[0072] a text-field where the trader may enter the total number to buy (generally in multiples of 100).
[0073] In one embodiment of the present invention, the buy order waits in the queue for the expiration of a predetermined “sweep pricing cycle.” The sweep pricing cycle occurs periodically, such as every 15 minutes, or during another specified time interval. The market price the trader actually pays for the derivative financial instrument is determined by the aggregate supply/demand for the derivative financial instrument at the end of the sweep pricing cycle during which the order was placed.
[0074] The market price is set by the pricing/trading program executed by the server computer, which is described below in FIG. 3 . The trader's account is then charged the market price for the derivative financial instrument. If the purchase uses up all available cash in the trader's account, the trader is “loaned” enough money to pay for the purchase, and their account is charged interest at a predetermined rate, e.g., 18% a year compounded daily, on the negative account balance. The interest is charged against the trader's account until they accumulate more cash to zero out the balance, either by selling stocks or buying dollars.
[0075] Block 210 is a decision block that represents the server computer 14 determining whether it received a request to submit a sell order from the client computer 12 . If so, block 212 represents the server computer 14 processing the sell order by placing it in queue in the memory of the server computer 14 . The sell order is a data structure comprising:
[0076] trader's account number;
trader's name; the time and date of the order; the stock or bond to sell; the amount of the stock or bond in the trader's account; and a text-field where the trader may enter the total number to sell (generally in multiples of 100).
[0082] Like the buy order, the sell order waits in the queue for the expiration of the predetermined sweep pricing cycle. The market price at which the trader actually sells the derivative financial instrument is determined by the aggregate supply/demand for the derivative financial instrument at the end of the sweep pricing cycle during which the order was placed. The market price is set by the pricing/trading program executed by the server computer, which is described below in FIG. 3 . The trader's account is then credited with the market price for the derivative financial instrument.
[0083] The sell order can be either produced by a trader or generated by the server computer 14 , as will be explained in more detail below. For a sell order produced by a trader, he views his list of stocks or bonds on a monitor attached to the client computer and chooses to sell a quantity at the market price.
[0084] When the trader requests to view the list of stocks, the server computer 14 transmits certain information to the client computer 12 for display, including, for each stock owned, the last trading price (LTP), the quantity of stocks, the purchase price, and the date purchased. Similarly, when viewing the list of bonds, the server computer 14 transmits certain information to the client computer 12 for display, including, for each bond owned, the last trading price (LTP), the interest rate being earned for each kind of bond, the quantity of bonds, the purchase price, and the date purchased.
[0085] Block 214 is a decision block that represents the server computer 14 determining whether an internal timer for the sweep pricing cycle has expired. If so, block 216 represents the server computer 14 executing a pricing/trading program as described in FIG. 3 .
[0086] Block 218 is a decision block that represents the server computer 14 determining whether it received a request to change the discount rate. If so, block 220 represents the server computer 14 executing a discount rate program. In order to add or subtract liquidity, the server computer 14 occasionally steps in to act as a virtual reserve bank program and adjust the discount rate. The discount rate is adjusted based on the performance of the specific industry of the market. For the Hollywood Stock Exchange, the discount rate is adjusted to add or subtract liquidity to affect the growth of the entertainment industry. When the server computer 14 lowers the discount, all the bonds seem to be a better deal, because the bonds are paying a fixed rate interest that never changes. This encourages traders to buy more bonds, and such surge in buying demand causes a correlated increase in bond prices as described above. The same thing happens to stocks, because traders are making less money on the interest being paid on the cash balance in their trading account. When the server computer 14 raises the discount rate, the bonds seem to be a worse deal, since their advantage over the discount is smaller. Thus, the server computer 14 relaxes the buying pressures or demands for bonds, which should result in additional sell orders, or at least slow the buying of bonds, thus decreasing their prices as they trade in the market. Likewise, stocks seem less attractive, since traders could make more money by keeping cash in their accounts and getting interest on it.
[0087] Block 222 is a decision block that represents the server computer 14 determining whether it received a request to revise the derivative list. If so, block 224 represents the server computer 14 executing a listing program. The server computer 14 determines whether the list of derivatives trading in the system should be revised. The list could be revised to reflect new derivative offerings, expired derivatives, and delisted derivatives.
[0088] When a new derivative is offered, the price is based on the derivative's potential value. For example, for a new stock offering, which represents a movie on the Hollywood Stock Exchange, the initial price of the stock could be based on the movie's potential box office revenue. For a bond offering, which represents talent on the Hollywood Bond Exchange, the price of the bond could be based on the Hollywood Reporter's Star Power Index. A bond representing a talent with a low Star Power Index of 15 would be issued with a higher yield than a bond representing a talent with a high Star Power Index rating.
[0089] A warrant with a strike price is attached to the new derivative when it is offered. When the derivative and warrant are first issued, the warrant is of no value until the strike price is reached. For a stock, the strike price could be reached after the movie has grossed a certain level of revenue. When a derivative is delisted from the exchange, a stock due to the movie ending its production run or a talent due to retirement or death, for example, the warrants are called and the traders are paid the value of the warrants, thus providing off-balance sheet financing for studios.
[0090] With reference to FIG. 3 , a flowchart illustrating the logic of the pricing/trading program of the present invention is shown. Block 300 represents the server computer 14 retrieving the buy and sell orders that have accumulated in the queue during the period since the prior sweep pricing cycle. Block 302 represents the server computer 14 matching the buy orders with the sell orders, although it is likely than an identical number of buy and sell orders would not have accumulated in the queue during the period. Block 304 represents the server computer 14 executing the generate market price program described in FIG. 4 to determine the market price for the derivative financial instruments. After the market price is determined, block 306 represents the server computer 14 updating the traders' portfolios to reflect the buy and sell orders in the queue being processed at the market price. Block 308 represents the end of the pricing/trading program.
[0091] With reference to FIG. 4 , a flowchart illustrating the logic of the generate market price program of the present invention is shown. One purpose of the generate market price logic is to generate a market price for a derivative financial instrument that reflects the demand or lack of demand for the derivative financial instrument in the market. Block 400 represents the server computer 14 measuring the imbalance between the buy and sell orders during the period since the prior sweep pricing cycle. Block 402 represents the server computer 14 determining the price movement of a derivative financial instrument caused by the imbalance in buy and sell orders. Block 404 represents the server computer 14 executing a virtual specialist program as described in FIG. 5 to provide stability and liquidity to the market. Block 406 represents the server computer 14 executing the stop trade program, as described in FIG. 6 , to stop trading in a derivative financial instrument if the projected price movement is excessive during the trading day and threatens the integrity of the market for that instrument. Block 408 represents the server computer 14 setting the market price, which becomes the price the pricing/trading program uses to update the traders' portfolios. Block 410 represents the end of the generate market price program.
[0092] In measuring the imbalance between buy and sell orders, as represented by block 400 , the absolute difference between the number of sells and the number of buys is defined as the net movement in sweep (NMS). A sweep increment variable (SIV) is defined as the increase or decrease in price caused by an incremental imbalance in the number of buy orders and sell orders. A lot movement variable (LMV) represents the incremental lot size that will result in a price increase or decrease of one SIV. The projected price movement (PM) can be expressed as: PM=(NMS/LMV)* SIv.
[0093] For example, with 42,000 buy orders and 30,000 sell orders for a particular stock, the NMS=(42,000−30,000)=12,000. With SIV=$0.25 and LMV=5000, the price movement of the particular stock will be (12,000/5,000)*0.25=$0.50. Thus, the market price of the particular stock will be $0.50 greater than the last trading price.
[0094] With such pricing scheme, there is the potential for great volatility in the price of a derivative financial instrument and the eventual loss of investor confidence in the market mechanism. In exchanges such as the Hollywood Stock Exchange, it would be possible for one or more individuals to pursue trading strategies that would purposely cause drastic price fluctuations.
[0095] In order to encourage growth and stability in the capital market regulated by the trading system of the present invention, a virtual specialist program is executed by the server computer, as represented by block 404 in FIG. 4 . In executing the virtual specialist program, the server computer 14 regulates the trading by actively trading in the market out of a virtual specialist portfolio (VSP). In one embodiment of the present invention, the virtual specialist program portfolio initially contains half of all the issued shares of each derivative financial instrument.
[0096] With reference to FIG. 5 , a flow diagram illustrating the logic of the virtual specialist program of the present invention is shown. Block 500 is a decision block that represents the server computer 14 determining whether the price movement during the sweep pricing cycle is greater or equal to an adjusted price movement threshold (APT). The APT is a constant in the memory of the server computer 14 . If the APT is greater than the price movement, then the server computer 14 does not trade in the market. If the price movement is greater than or equal to the APT, then the server computer 14 trades out of a virtual specialist program portfolio. The level of trading by the server computer 14 is determined by the amount that the price movement exceeded the APT. The greater the price movement, the more shares the server computer 14 trades to offset the price movement.
[0097] In an exemplary embodiment of the present invention, the ATP=1.25 and the server computer 14 performs the following steps: if PM=APT then the server computer 14 matches 10% of unmatched shares; if PM=APT+0.25 then the server computer 14 matches 20% of unmatched shares; if PM=APT+0.50 then the server computer 14 matches 30% of unmatched shares; if PM=APT+0.75 then the server computer 14 matches 40% of unmatched shares; if PM=APT+1.0 then the server computer 14 matches 50% of unmatched shares; if PM=APT+1.25 then the server computer 14 matches 60% of unmatched shares; if PM=APT+1.50 then the server computer 14 matches 70% of unmatched shares; if PM=APT+1.75 then the server computer 14 matches 80% of unmatched shares.
[0098] Block 502 represents the server computer 14 generating a buy or a sell order to offset the price movement. The buy or sell order generated by the server computer 14 is placed in the queue with the trader buy and sell orders to be processed during the next sweep cycle.
[0099] In one embodiment of the present invention, since the virtual specialist program portfolio initially includes half of all the securities traded, the server computer 14 could eventually deplete the virtual specialist program portfolio or cause the virtual specialist program portfolio to own all the shares of a stock. In order to maintain a balanced virtual specialist program portfolio, and provide some liquidity to the market, the server computer 14 generates additional buy and sell orders to offset orders generated in response to the price movement exceeding the APT. Block 504 represents the server computer 14 generating timed buy and sell orders. In one embodiment of the invention, the server computer 14 assesses each stock and each bond in the virtual specialist program portfolio. The server computer 14 determines the deficit or surplus in the item, and then places 1/288 th of the deficit as a “timed recovery order” into each successive 15 minute segment for the next 3 days. When the pricing/trading program 255 matches buy and sell orders as represented by block 320 , the pricing/trading program 255 includes any “timed recovery orders” outstanding for the last 3 days in the sweep. These orders are matched with the traders' buy and sell orders. Block 506 represents the end of the virtual specialist program.
[0100] FIG. 6 is a flow diagram illustrating the logic of the stop trading program of the present invention. Block 600 represents the server computer 14 determining the price movement of a stock caused by the imbalance in buy and sell orders. Block 602 represents the server computer 14 measuring the price movement on the day, not just during the sweep cycle period. Block 604 is a decision block that represents the server computer 14 determining whether the net price movement (NPM) within one “trading day” (i.e., midnight-midnight) is greater than 50% up or down. As represented by block 606 , the buy and sell orders are removed from the queue if the net price movement is greater than 50% for a stock trading above $20. At that point, the trading in that issue is stopped within the 15 minute period until further notice. All orders (buy and sell) for that stock during this sweep are unfilled. The trading has stopped due to “excessive order imbalance”.
[0101] For example, let it be assumed that the Last Trading Price (LTP) for “Rambo-17” is $67 (+7.5 on-the-day). During one 15-minute sweep pricing cycle, the server computer 24 receives buy orders for 655,000 shares of “Rambo-17”. In addition, the server computer 14 receives sell orders for 35,000 shares of “Rambo-17” during the same sweep pricing cycle. The server computer 14 evaluates the price movement for the sweep pricing cycle, and tests it to see if the net projected price movement “on-the-day” is greater than 50%. If it would be greater than 50%, it stops trading in that instrument only. In this example, there is a net order-imbalance of 620,000 shares, which would create an up movement in price of (+620,000/5000)*$0.25=+$31.00. Since the total movement on the day would be the $7.50 so far plus the additional $31.00, the net projected price movement on the day would be $31.00+$7.50=$38.50. If the opening price that day was $59.50, the percentage projected price movement for the day is $38.50/$59.50=64%. Since the projected net price movement would be greater than 50%, the trading is stopped for that instrument. If the projected price movement was less than 50%, the price of the instrument would be adjusted accordingly and trade in that stock continued. Block 608 represents the STOP TRADE order that issues regarding the particular stock. Traders who issued a buy or sell order for the stock are notified that the order has not been filled due to excessive order imbalance during the trading day. Finally, block 610 represents the end of the stop trading program.
[0102] While the invention has been described and illustrated in connection with preferred embodiments, many variations and modifications as will be evident to those skilled in this art may be made without departing from the spirit and scope of the invention, and the invention is thus not to be limited to the precise details of methodology or construction set forth above as such variations and modification are intended to be included within the scope of the invention. | A computer-implemented financial management system provides the trading of securities via a network using virtual currency. A server computer receives buy and sell orders for derivative financial instruments from a plurality of client computers. The server computer attempts to match the buy and sell orders and then generates a market price through the use of a virtual specialist program executed by the server computer. The virtual specialist program responds to an imbalance in the matching of buy and sell orders. The virtual currency accumulated by HSX account holders as a result of successful trading may be converted to another currency, credited towards the cost of merchandise provided through a vendor's web site, etc. | 6 |
CROSS-REFERENCE TO RELATED APPLICATION
The present application claims priority of Korean Patent Application Number 10-2009-0081874 filed Sep. 1, 2009, the entire contents of which application is incorporated herein for all purposes by this reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a stop-lamp switch that turns on/off stop lamps after sensing whether the brake pedal of a vehicle is pressed down, in detail, a technology that makes it possible to simply and stably mount a stop-lamp switch on a mounting bracket.
2. Description of Related Art
It is necessary for safe driving, such as ensuring a safety distance from the following vehicles, to indicate whether the brake pedal of a vehicle is operated, by turning on/off the stop lamps at the rear of the vehicle.
A mechanism for detecting whether a brake pedal is operated is mounted on a mounting bracket around a brake pedal in the related art. In the above mechanism, it is very important to mount the stop lamp at a relatively appropriate position with respect to the brake pedal, in order for the stop lamp to generate appropriate electric signals in accordance with the operation of the brake pedal.
The appropriate mounting position of the stop-lamp switch should be set such that the switch knob that elastically protrudes from the stop-lamp switch and the amount of protrusion changes in accordance with the movement of the brake pedal is pressed inside a cover forming the outer shape of the stop-lamp switch when the brake pedal is not pressed down, and the cover forms a gap within a few millimeters from the brake pedal to keep the switch knob sufficiently pressed inside the cover, without directly contacting with the brake pedal.
In assemblage of the vehicle, it is also very important to allow for quick and simple mounting, on the assumption that the stop-lamp switch is mounted at an appropriate position, in terms of manufacturing cost of the vehicle, and it is also a very important technical object to stably maintain the position of the stop lamp mounted as described above.
The information disclosed in this Background of the Invention section is only for enhancement of understanding of the general background of the invention and should not be taken as an acknowledgement or any form of suggestion that this information forms the prior art already known to a person skilled in the art.
BRIEF SUMMARY OF THE INVENTION
Various aspects of the present invention are directed to provide a one-touch stop-lamp switch that can contribute to reducing manufacturing costs of a vehicle and ensuring stable and durable quality by being quickly and simply mounted at an appropriate position with respect to a brake pedal and stably maintained at the position.
An aspect of the prevent invention provides a one-touch stop-lamp switch of a vehicle, which includes a mounting bracket fixed to a predetermined position with respect to a brake pedal that is in a free position, a switch cover forming the outer shape of a stop-lamp switch, a cover locker fixed to the mounting bracket and changing the position of fixing the switch cover in accordance with relative rotational angle to the switch cover, and/or a rotation-restraining locker connected to the cover locker to change relative rotatable position of the switch cover to the cover locker
The present invention can contribute to reducing manufacturing cost of a vehicle and ensuring stable and durable quality by quickly and simply mounting a stop-lamp switch at an appropriate position with respect to a brake pedal and stably maintaining the position.
The methods and apparatuses of the present invention have other features and advantages which will be apparent from or are set forth in more detail in the accompanying drawings, which are incorporated herein, and the following Detailed Description of the Invention, which together serve to explain certain principles of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view illustrating a part of the configuration of a one-touch stop-lamp switch of a vehicle according to the present invention.
FIG. 2 is a view illustrating when a switch cover is mounted in the configuration of FIG. 1 .
FIG. 3 is a view illustrating when the position of FIG. 2 is stably fixed.
FIG. 4 is a view illustrating a process of assembling the one-touch stop-lamp switch of a vehicle according to the present invention.
FIG. 5 is a view illustrating another one-touch stop-lamp switch of a vehicle of the present invention.
FIG. 6 is a view illustrating a process of assembling the one-touch stop-lamp switch of FIG. 5 .
DETAILED DESCRIPTION OF THE INVENTION
Reference will now be made in detail to various embodiments of the present invention(s), examples of which are illustrated in the accompanying drawings and described below. While the invention(s) will be described in conjunction with exemplary embodiments, it will be understood that present description is not intended to limit the invention(s) to those exemplary embodiments. On the contrary, the invention(s) is/are 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.
Referring to FIGS. 1 to 4 , various embodiments of the present invention include a mounting bracket 3 fixed to a predetermined position with respect to a brake pedal 1 that is in a free position, a switch cover 5 forming the outer shape of a stop-lamp switch, a cover locker 7 fixed to mounting bracket 3 and changing the position of fixing switch cover 5 in accordance with relative rotational angle to switch cover 5 , and a rotation-restraining locker 9 connected to cover locker 7 to change relative rotatable position of switch cover 5 to cover locker 7 .
The free position of brake pedal 1 corresponds with a position when a driver does not press down brake pedal 1 and an electric switch of which electric connection is changed by movement of a switch knob elastically protruding toward brake pedal 1 is disposed in switch cover 5 .
Cover locker 7 has a cover-mounting hole 11 that allows a portion of switch cover 5 to move straight therethrough and the portion, which is inserted in cover-mounting hole 11 , of switch cover 5 has a uniform cross section in the insertion direction while having a locking surface 13 that is perpendicular to the insertion direction and a male-threaded portion 15 that is engaged in accordance with relative rotation to cover locker 7 . Corresponding to this configuration, a female-threaded portion 17 that is engaged with male-threaded portion 15 of switch cover 5 is formed on the inner side of cover-mounting hole 11 of cover locker 7 .
That is, the portion of switch cover 5 that is inserted in cover-mounting hole 11 has a circular cross section with a portion cut by locking surface 13 , not a complete circular cross section, and accordingly, male-threaded portion 15 are partially formed, as shown in the figures.
Therefore, as shown in FIG. 4 , with cover locker 7 fixed to mounting bracket 3 , switch cover 5 is inserted into cover-mounting hole 11 such that the end of switch cover 5 contacts with brake pedal 1 , and then rotated such that male-threaded portion 15 is engaged with female-threaded portion 17 , and as a result, straight movement of switch cover 5 in cover-mounting hole 11 is restrained.
In particular, as described above, with the end of switch cover 5 inserted to contact with brake pedal 1 , as male-threaded portion 15 is engaged with female-threaded portion 17 by rotation, a gap within a few millimeters preventing direct contact between the end of switch cover 5 and brake pedal 1 is naturally formed while switch cover 5 retreats a little. Accordingly, it is possible to very quickly and simply fix switch cover 5 of the stop-lamp switch at an appropriate position with respect to brake pedal 1 .
The position of switch cover 5 ensured as described above is more stably ensured by rotation-restraining locker 9 , which is described in detail below.
In various embodiments, two locking surfaces 13 of switch cover 5 are formed at both sides of switch cover 5 in parallel with each other, and correspondingly, rotation-restraining locker 9 has locking fork portions 19 that are in surface contact with two locking surfaces 13 and combined with cover locker 7 to change the surface contact of locking fork portions 19 with locking surfaces 13 by sliding straight perpendicular to the insertion direction of switch cover 5 into cover locker 7 .
Locking fork portions 19 of rotation-restraining locker 9 are formed in a U-shaped flat plate, a guide protrusion 21 protruding from the U-shaped flat plate is formed at the separate ends of the U-shape, a guide slot 23 is formed at cover locker 7 for rotation-restraining locker 9 to slide straight, and release stoppers 25 protrude from both sides of guide slot 23 to restrain straight motion of guide protrusions 21 such that rotation-restraining locker 9 is not separated from cover locker 7 .
Snap protrusions 27 are formed at both sides of guide slot 23 to prevent rotation-restraining locker 9 from moving in the separation direction from cover locker 7 , when locking fork portions 19 are inserted to be in surface contact with locking surface 13 and guide protrusions 21 are locked after passing by elastic deformation of locking fork portions 19 .
An insertion-restraining protrusion 29 that restricts insertion depth of rotation-restraining locker 9 in cover locker 7 by contacting with cover locker 7 is formed at the connecting portion of the U-shaped flat plate of locking fork portions 19 .
Further, a grip 31 protrudes in the opposite direction to insertion-restraining protrusion 29 of rotation-restraining locker 9 to provide force for sliding straight rotation-restraining locker 9 with respect to cover locker 7 .
Therefore, as described above, with male-threaded portion 15 of switch cover 5 engaged with female-threaded portion 17 of cover-mounting hole 11 , when rotation-restraining locker 9 is inserted and locking fork portions 19 are in surface contact with locking surface 13 of switch cover 5 , switch cover 5 is prevented from rotating with respect to cover locker 7 , such that it is possible to prevent unexpected disengagement of male-threaded portion 15 and female-threaded portion 17 and changes in position of switch cover 5 .
Rotation-restraining locker 9 is assembled in advance with cover locker 7 , as shown in FIG. 1 and naturally prevents switch cover 5 from rotating, when switch cover 5 is inserted and fixed by rotation in cover-mounting hole 11 , as shown in FIG. 3 , and guide protrusions 21 are inserted through snap protrusion 27 to be restricted by insertion-restraining protrusion 29 , such that the position of switch cover 5 can be stably maintained.
On the other hand, in maintenance of a vehicle, it is possible to easily separate switch cover 5 by pulling rotation-restraining locker 9 from cover locker 7 , holding grip 31 of rotation-restraining locker 9 .
In this operation, rotation-restraining locker 9 is pulled until guide protrusions 21 are locked to release stoppers 25 and not completely separated from cover locker 7 , such that the position shown in FIG. 1 where it can be assembled again to prevent switch cover 5 from rotating is maintained.
FIGS. 5 and 6 show another embodiment of the present invention, which is different in configuration of rotation-restraining locker 9 from the above embodiment.
That is, rotation-restraining locker 9 has a locking hole 33 where the portion of switch cover 5 inserted in cover-mounting hole 11 is inserted and prevented from relatively rotating, and an anti-rotation means that fixes rotation-restraining locker 9 to cover locker 7 is included to prevent locking hole 33 from rotating with respect to cover locker 7 .
In various embodiments, rotation-restraining locker 9 is formed in a flat plate shape with locking hole 33 and the anti-rotation means has an elastic locking hook 35 protruding toward cover locker 7 and a rotation-restricting surface 37 formed such that elastic locking hook 35 is locked to cover locker 7 to be prevented from rotating.
Rotation-restricting surface 37 may be a hole formed through cover locker 7 , but in various embodiments it is formed of a locking slot 39 formed on the outer surface of cover locker 7 .
In various embodiments described above, as shown in FIG. 6 , with rotation-restraining locker 9 inserted in switch cover 5 through locking hole 33 , switch cover 5 is inserted and rotated in the locker cover to be fixed at a predetermined distance from brake pedal 1 , elastic locking hook 35 of rotation-restraining locker 9 is fitted in locking slot 39 such that anti-rotation surface 37 forming locking slot 39 can prevent rotation of elastic locking hook 35 . As a result, switch cover 5 is prevented from rotating with respect to cover locker 7 , such that switch cover 5 is stably fixed with respect to cover locker 7 .
For convenience in explanation and accurate definition in the appended claims, the terms “rear”, “inside”, and etc. are used to describe features of the exemplary embodiments with reference to the positions of such features as displayed in the figures.
The foregoing descriptions of specific exemplary embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teachings. The exemplary embodiments were chosen and described in order to explain certain principles of the invention and their practical application, to thereby enable others skilled in the art to make and utilize various exemplary embodiments of the present invention, as well as various alternatives and modifications thereof. It is intended that the scope of the invention be defined by the Claims appended hereto and their equivalents. | A one-touch stop-lamp switch of a vehicle can contribute to reducing manufacturing costs of a vehicle and ensuring stable and durable quality by quickly and simply mounting the stop-lamp switch at an appropriate position with respect to a brake pedal and stably maintaining the position. | 1 |
BACKGROUND OF THE INVENTION
This invention relates to an improved moisture detecting device.
A wide variety of moisture detecting devices have been known in the art for quite some time. For example, enuresis bedpads have been designed with thin, metal, current conducting, sensor strips bonded to one surface of a sheet-like, essentially non stretchable, relatively flexible and electrically insulative substrat. An example of such a bedpad is disclosed in Shuman U.S. Pat. No. 3,778,570 which is designed to be fabricated in large rolls and then cut into appropriate lengths. The metal sensor strips are electrically insulated from each other by the substrat itself. Sensor tapes are also known in the art as exemplified by Tom U.S. Pat. No. 4,297,686. The Tom patent discloses a water detection device comprised of a flexible plastic tape with an adhesive backing and having a surface which contains a pair of conductive metal strips. The usual design of moisture sensing devices is represented by a pair of metal screens with replaceable padding between them. Further, some designs involve dissimilar metal such as aluminum and copper used as a generator of feeble electric currents to be detected by associated detector circuits. Still other inventions relate to a pad with numerous parallel but separate wires intermeshed so that moisture will form a conductive path between two wire grids.
Each of these previous devices have common defects in that they are composed of fragile metal wires which break with extended use and which may cause injury to the user who comes in contact with a broken strand of wire, cleaning them is quite difficult, replacement of padding is inconvenient, and the sensing device itself is usually uncomfortable. In addition, there is a general deterioration of most systems due to chemical corrosion by the electrolyte which comes in contact with the metal wires in the grid. A further major defect in previous devices is that once the electrolyte comes in contact with the sensing wires, removing the electrolyte completely and restoring the system to its detecting state is extremely difficult. Even removing and completely drying previous devices leaves some amount of electrolytic residue on the sensing wires so that after repeated use, previous devices suffer a gradual yet continual deterioration of performance. Thus, there is a need in the art for providing a moisture sensing means which avoids the hazards associated with the rapid deterioration of wire systems, which is easily located in the normal bedding already in use and which is flexible and small enough so that it cannot be a source of discomfort, while at the same time being capable of complete and easy cleaning. It, therefore, is an object of this invention to provide an improved moisture sensing device which is thin and flexible enough so that it may be located in normal bedding already in use without becoming a source of discomfort.
It is another objective of this invention to provide a sealed plastic device that uses non-metallic conductors and that is easily cleaned and dried for immediate reuse.
Yet another object of this invention is to provide electrical conductivity between two parallel non-metallic conductors in the presence of an electrolyte and yet provide complete chemical isolation between the conductors and the external environment.
It is still another object of this invention to provide a simple, sure means of attaching the device to ordinary bedding so that proper control of the position of the device in the probable wet area is provided.
It is yet another object of this invention to provide a moisture sensing strip for sensing of liquid levels in storage tanks.
It is yet another object of this invention to provide a sensing strip for sensing the presence of water or other electrolyte that might be spilled on a floor.
SHORT STATEMENT OF THE INVENTION
Accordingly, the instant invention is responsive to these needs by the provision of a moisture sensing strip of any desired length which is made of a non conductive flexible material such as plastic, which is provided with two parallel grooves which run the length of the strip. A pair of non-metallic conductors are provided which are made of an electrically conductive plastic such as occurs when plastic is made with carbon particles. The two non-metallic conductors are then physically installed into the formed grooves in the surface of the sensor strip. Thereafter, heat and pressure are applied to form a smooth solid seal on the surface of the sensor strip which has no grooves or joints that might entrap moisture or electrolyte. One end is provided with a molded yoke whereby the joint between the yoke and the sensor strip containing the parallel non-metallic conductors does not have a continuous conducting path. This condition is provided by means of creating a hole in the yoke that forces the joint between the yoke and the strip to be broken into two separate loops having no common connection where fluid can be trapped and form a non cleanable continuous pathway for current. The presence of the hole assures that the only pathway for current is over either the plastic insulating sensor strip itself or the smooth surface of the molded yoke. Because these surfaces are easily cleaned and dried, restoration of the insulated integrity of the sensor to its detecting condition by removing any path of conductivity is easily accomplished. Because the non-metallic conductors are totally enclosed and protected from the environment, the problems of deposition of electrolytic residue, deterioration as a result of constant exposure to electrolytes, or breakage of wire strands are avoided.
Additionaly, the yoke junction is provided with two large value resistors to give a significant safety advantage in the event of misuse or accident.
Further, the yoke end of the sensor strip is connected to a shielded cable which has an electronic transmission plug at one end so that transmission of the resistance condition detected by the sensor strip may be made to a sensing device, known in the art, which makes up no part of this invention.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects, features and advantages of the present invention will become more fully apparrent from the following detailed description of the preferred embodiment, the appended claims and the accompanying drawings in which:
FIG. 1 is a plan view of the sensor strip device;
FIG. 2 is an end view of the sensor strip with a pair of grooves formed therein;
FIG. 3 is an end view of the sensor strip with a pair of non-metallic conductors sealed within the grooves in the sensor strip;
FIG. 4 is a schematic diagram illustrating a typical detector circuit to which the sensor strip is connected;
FIG. 5 is a plan view of the creation of the yoke end of the sensor strip in connection of resistors to the transmission cable shown without the yoke covering;
FIG. 6 is an end view of the sensor strip without the yoke covering;
FIG. 7 is a plan view of the sensor strip and connection of resistors to the transmission cable shown in dashed lines while covered with the yoke; and
FIG. 8 is an end view of the sensor strip with the yoke in place.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The preferred embodiment of the present invention is illustrated by way of example in FIGS. 1-8. With specific reference to FIG. 1, moisture sensing strip 10 is illustrated which includes non conductive extruded insulating sensor strip 12 and oppositely positioned non-metallic conductors 14 and 16. Molded yoke 18 is shown as securely attached to sensor strip 12 and the electrically isolating opening 20 is also disclosed. Shielded wire transmission cable 22 is illustrated with electrical transmission plug 24 attached.
Referring to FIG. 5, the creation of the yoke end of invention 10 is disclosed. To begin with, electrically isolating opening 20 is punched in snsor strip 12 between non-metallic conductors 14 and 16. Then rectangular cable opening 23 is cut into the end of sensor strip 12 and cable 22 securely attached therein by means of hot melt plastic glue 25 well known in the art shown as dashed lines. Next, shielded wire transmission cable 2 is attached at points 26 and 28 to isolation resistors 30 and 32 which are connected in turn to non-metallic conductors 14 and 16 respectively. This "attachment" consists of embedding resistors 30 and 32 in grooves 38 & 40 and connecting leads from resistors 30 and 32 into non-metallic conductors 14 and 16. Resistors 30 and 32 are of high resistance, typically 220,000 OHMS, which provide a very high impedance path for isolating the user from any possible current that might be inadvertantly introduced into the shielded cable 22. An end view of FIG. 5 is shown in FIG. 6. Referring to FIG. 7, molded yoke 18 is shown securely attached so that it encapsulates sensor strip 12, connection points 26 and 28, resistors 30 and 32 and some small portion of the shielded wire transmission cable 22. As can be seen by FIG. 7, electrically isolating opening 20 in yoke 18 forces the joint between yoke 18 and sensor strip 12 to be broken into two separate loops, 34 and 36, which have no common connection where moisture can be trapped and form a non cleanable, continuous pathway for current. The presence of the electrically isolated opening 20 assures that any pathway for current must pass over either the non conductive sensor strip 12 or the non conductive smooth surface of molded yoke 18. These surfaces are obviously easy to clean and dry thereby making positive restoration of the insulating condition of the device 10 simple after use. FIG. 8 is an end view of FIG. 7.
Electrically isolating opening 20 also provides a functional location for securing an attachment of clip of ordinary design, not shown, if desired, for retention of sensor strip 12 in a selected location.
Referring to FIG. 2 device 10 is illustrated with sensor strip 12 shown from an end view. Also illustrated are oppositely positioned retaining grooves 38 and 40. These grooves 38 and 40 are specifically designed and created to physically retain non-metallic conductors 14 and 16 once the conductors 14 and 16 are placed therein. Referring to FIG. 3, conductors 14 and 16 are shown located in grooves 38 and 40 and, after heat and pressure are added, forming a smooth electrically conductive surface 42. Electrically conductive non-metallic conductors 14 and 16 are made electrically conductive by the formulation of a plastic, such as polyvinyl chloride (PVC), with microscopic particles of carbon in the form of lamp-black. An example of this material is that made currently under the trade name "Bakelite" number HFDA-0580 produced by the Union Carbide Company. Similar products are also made by other suppliers and electrically conductive material is not described further herein since material of this type is available commercially and is well known to those of ordinary skill in the art. After physically installing the non-metallic conductors 14 and 16 into a fixed parallel relationship in formed grooves 38 and 40 the sensor strip 12 is subjected to heat and pressure to seal the non-metallic conductors 14 and 16 into the surface of the sensor strip 12 thereby forming a slick smooth surface 42 without grooves or joints that might entrap moisture or electrolytes. Because non-metallic conductors 14 and 16 are exposed, by means of electrically conductive material, and because the conductors have no fragile or potentially harmful metal wires, the device is safe, easily cleaned, long lasting and durable.
Referring to FIG. 4, a typical detector circuit is illustrated. Sensor strip 12 is not shown, although the connection to shielded cable 22 is demonstrated. The electronic circuit suitable for the alarm sensing will be familiar to anyone skilled in the electronic art. The figure shows a threshold detector consisting of two NOR gates 44 and 46 constructed from low current CMOS technology. The voltage at the input gate 48 is set by the feedback 1 Meg ohm resistor 50 from the output 52 and the resistance of the sensor strip through connector plug 24 connected through sensitivity adjustment resistors 54 and 56 to the plus battery supply 58. Initially the voltage is low at input gate 48, held down by the output 52 voltage being at the minus supply 60. When conduction occurs in the Sensor strip 12, the voltage at input 48 rises until it reaches about one half of the battery voltage. At this time the first stage 44 trips to the low output condition and the second stage 46 trips to the high output 52 condition causing input 48 to switch to the high voltage condition by means of feedback resistor 50 to the input 48. This sudden switching of voltage is a very sensitive detection point for the external resistance provided by the conduction in the electrolyte path between the non-metallic conductors 14 and 16 in the sensor strip 12. When the conduction path is removed, the threshold condition can be reset by means of the pushbutton connection 62 that connects the input 48 to the minus bus of the battery supply 60. Removing the conduction path does not reset this threshold sensor circuit.
As can be seen, invention 10 relates to a moisture or liquid electrolyte sensor that can serve to detect the presence of moisture by forming a conductive path for very small DC currents in the range of 10 microamps between parallel non-metallic conductors 14 and 16 in a construction isolated chemically and physically by electrically conductive material from the liquid conduction path. For the primary application of sensing urine, sensing strip 12 is placed in the bedding within an absorbant pad between the sensor strip 12 and the patient. Normally, the sensor has a high resistivity, such as several meg ohms, when it is dry but when electrolyte is present, the resistivity lowers to a much smaller value, such as 450K ohms. This effect can be used to trip an alarm provided the sensing circuit is adjusted, by means of sensitivity adjustment resistors 54 and 56, as illustrated in FIG. 4, to operate at the appropriate values of current in the range of 10 microamps. Such a sensing circuit is illustrated in FIG. 4 and is not discussed further herein since they are obvious to one ordinarily skilled in the art.
It is understood that the current used to operate this sensor strip 12 will be limited to safe values, in the range of 10 microamps, as described in the American Association of Medical Instruments standard number SCL12/79 and the design requirements for Nurse Call Systems promulgated by the Underwriters Laboratory, 1069, hereby incorporated by reference. In addition, it is most important for the sensor 12 to be easily installed, comfortable to the patient and be easily cleaned and dried. Because of the combination of molded yoke 18 and electrically isolating opening 20, a continuous joint is absolutely avoided. Instead, two separate loops 34 and 36 are provided and the "rearming" of the strip is easily accomplished by simply wiping the sensor strip 12 and the molded yoke 18 dry.
As described, the present invention has as its main objective the care of elderly patients who have lost control of certain bodily functions and will likely never regain such control again. The sensor 12, in conjunction with the appropriate electronic system, provides an alarm for professional nurses and other attendants given charge of elderly patient care. Many other applications of this invention are obvious. For instance, another application for this invention is the sensing of liquid levels in storage tanks. For this use the sensor strip 12 is suspended vertically such that when the liquid level changes, the amount of the strip exposed to the electrolyte changes, thus altering the amount of conductivity. Still another application of the invention is the sensing of the presence of other electrolytes that might be spilled on the floor. Because of its unique construction, flexibility and lack of potentially harmful wires, the invention can even be used in wheel chairs and other places where the patient actually sits on the device.
Further, it is obvious that sensor strip 12 and non-metallic conductors 14 and 16 could be formed together in one step, by currently available injection molding processes, thereby eliminating the necessity of forming grooves 38 and 40.
While the present invention has been disclosed in connection with the preferred embodiment thereof, it should be understood that there may be other embodiments which fall within the spirit and scope of the invention as defined by the following claims. | A moisture sensing system for sensing the presence of moisture, with a molded yoke and opening which assures positive separation of electronic connections, with non-metalic conductors composed of electrically conductive plastic. Isolating resistors are provided so that the sensor strip may be safely used without fear of electrical shock from inadvertant feedback. | 6 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application claims priority of Korean Patent Application Number 10-2013-0025571 filed Mar. 11, 2013, the entire contents of which application are incorporated herein for all purposes by this reference.
BACKGROUND OF INVENTION
[0002] 1. Field of Invention
[0003] The present invention relates to a vehicle having a variable hydraulic pump that variably changes load of hydraulic pump for generating hydraulic pressure that is necessary for an engine or a transmission to reduce energy loss and cost.
[0004] 2. Description of Related Art
[0005] Recently, fuel consumption saving art has been researched to reduce CO2, and an ISG (Idle stop and go) system turns off engine in a predetermined stop condition and restarts the engine in a predetermine restart condition.
[0006] The ISG (Idle Stop and Go) system uses information such as vehicle speed, engine rotation speed, coolant temperature, and so on to stop the engine in a predetermined condition and thereafter enables normal driving by restarting engine in a case that the restarting of the engine is demanded by a vehicle condition.
[0007] The ISG system stops an engine to enter into an idle stop condition when an engine is sufficiently warmed up, a coolant temperature is higher than a predetermined value, a condition that a vehicle speed is low or at zero (0), a shifting position of a transmission is neural, and a brake pedal is operated for a predetermined time.
[0008] The ISG device can increase fuel consumption efficiency of a vehicle up to 5 to 15%. Generally, an automatic transmission (AT) has to have a motorized hydraulic pump that supplied oil pressure thereto in an idle stop condition of a vehicle having ISG system.
[0009] Accordingly, the vehicle having an automatic transmission and an ISG system includes a mechanical pump that is disposed in the automatic transmission to be operated by an engine in the ISG none operation condition and generates hydraulic pressure necessary for controlling the automatic transmission and an auxiliary motorized hydraulic pump that is operated in the ISG operation condition to generate hydraulic pressure for the automatic transmission.
[0010] The vehicle having the automatic transmission and the ISG system has two pumps that are a mechanical pump and an auxiliary motorized hydraulic pump, wherein the mechanical pump is operated during the operation of the engine and the auxiliary motorized hydraulic pump is alternatively operated during the none-operation of the engine.
[0011] The vehicle having the automatic transmission and the ISG system has to have two pumps having equal functions, and therefore vehicle cost is increased, vehicle weight is also increased, and the fuel consumption is deteriorated.
[0012] The information disclosed in this Background section is only for enhancement of understanding of the general background of the invention and should not be taken as an acknowledgement or any form of suggestion that this information forms the prior art already known to a person skilled in the art.
SUMMARY OF INVENTION
[0013] The present invention has been made in an effort to provide a vehicle having a variable hydraulic pump having advantages of minimizing energy lost by hydraulic pump, fuel consumption, and fluctuation of hydraulic pressure by optimally controlling the load of hydraulic pump.
[0014] A vehicle having a variable hydraulic pump according to various aspects of the present invention may include a sun gear that receives a torque from a power source through an input shaft, a ring gear of which an interior circumference is with a distance from an exterior circumference of the sun gear, a planetary gear that is disposed between the interior circumference of the ring gear and the exterior circumference of the sun gear, a carrier that connects with an output shaft, a hydraulic pump that pumps oil through the output shaft that is connected to the carrier, and a motor that is disposed outside the ring gear to selectively rotate the ring gear.
[0015] The vehicle having a variable hydraulic pump may further include a shaft one way clutch that has the input shaft rotate in one direction, and a ring gear one way clutch that has the ring gear rotate in the other direction. The power source may be an internal combustion engine or a motor.
[0016] The vehicle having a variable hydraulic pump may further include a controller that controls the motor depending on a rotation speed of the input shaft such that the hydraulic pump is controlled at a predetermined optimized speed. The motor may be operated at a predetermined rotation speed such that the pump is operated at a minimum rotation speed in an idle stop condition. A compensation value may be applied to a target rotation speed of the hydraulic pump depending on a temperature of the oil, when the power source is operated.
[0017] In a vehicle having a variable hydraulic pump according to various aspects of the present invention, the rotation speed of the hydraulic pump is optimally controlled by a motor in accordance with the rotation speed or driving conditions of an engine to be able to reduce lost energy. Also, the fluctuation of hydraulic pressure that is formed by the hydraulic pump is reduced to be able to improve the stability. Further, compensation value is applied in accordance with oil temperature to be able to safely generate hydraulic pressure and one motor is used to optimally control the load of the hydraulic pump.
[0018] The methods and apparatuses of the present invention have other features and advantages which will be apparent from or are set forth in more detail in the accompanying drawings, which are incorporated herein, and the following Detailed Description, which together serve to explain certain principles of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is a schematic cross-sectional view of an exemplary variable hydraulic pump that is disposed in a vehicle according to the present invention.
[0020] FIG. 2 is a schematic diagram of an exemplary variable hydraulic pump that is disposed in a vehicle according to the present invention.
[0021] FIG. 3 is a schematic diagram showing an operational method of an exemplary variable hydraulic pump that is disposed in a vehicle according to the present invention.
[0022] FIG. 4 is a graph showing a compensation value that varies depending on oil temperature in an exemplary variable hydraulic pump according to the present invention.
[0023] FIG. 5 is a flowchart showing a control method of an exemplary variable hydraulic pump that is disposed in a vehicle according to the present invention.
[0024] FIGS. 6A , 6 B, 6 C and 6 D are schematic diagrams showing operational conditions of a variable hydraulic pump of a vehicle according to the present invention.
DETAILED DESCRIPTION
[0025] Reference will now be made in detail to various embodiments of the present invention(s), examples of which are illustrated in the accompanying drawings and described below. While the invention(s) will be described in conjunction with exemplary embodiments, it will be understood that present description is not intended to limit the invention(s) to those exemplary embodiments. On the contrary, the invention(s) is/are 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.
[0026] FIG. 1 is a schematic cross-sectional view of a variable hydraulic pump that is disposed in a vehicle, and FIG. 2 is a schematic diagram of a variable hydraulic pump that is disposed in a vehicle according to various embodiments of the present invention. Referring to FIG. 1 and FIG. 2 , a variable hydraulic pump of a vehicle includes an engine 100 as a power source, an input shaft 160 , a shaft one way clutch 155 , a sun gear 110 , a planetary gear 105 , a ring gear 140 , a ring gear one way clutch 150 , a motor 145 , a carrier 115 , an output shaft 120 , a hydraulic pump 135 , and a pump housing 165 . Further, the pump housing 165 includes a suction passage 125 through which oil is sucked to the hydraulic pump 135 and a discharge passage 130 through which oil is discharged.
[0027] The torque of the engine 100 is input to the sun gear 110 of the variable hydraulic pump through the input shaft 160 , and the shaft one way clutch 155 is disposed on an exterior circumference of the input shaft 160 to have the input shaft 160 rotate only in one rotation direction. The ring gear one way clutch 150 is disposed on an exterior circumference of the ring gear 140 to have the ring gear 140 rotate only in the other rotation direction. The motor 145 rotates the ring gear 140 in the other rotation direction.
[0028] The torque that is input to the input shaft 160 is transmitted to the sun gear 110 , the planetary gear 105 , the ring gear 140 , the carrier 115 , and the output shaft 120 such that the hydraulic pump 135 pumps oil. When the engine 100 stops its operating, the motor 145 rotates the ring gear 140 to operate the hydraulic pump 135 in a minimum load, and when the engine 100 rotates the input shaft 160 slower than a predetermined velocity, the motor 145 operates the hydraulic pump 135 in a predetermined optimized load.
[0029] Referring to FIG. 2 , the hydraulic pump 135 can be one of various types of pumps. For example, the hydraulic pump according to various embodiments of the present invention can use trochoid type internal gear.
[0030] FIG. 3 is a schematic diagram showing an operational method of a variable hydraulic pump that is disposed in a vehicle according to various embodiments of the present invention. Referring to FIG. 3 , Ne denotes a rotation speed if the engine 100 or a rotation speed of the output shaft 120 or a rotation speed of the sun gear 110 , Np denotes a rotation speed of the hydraulic pump 135 or the carrier 115 , Nm denotes a rotation speed of the motor 145 or the ring gear 140 , Zs denotes the number of the gear of the sun gear 110 , and Zr denotes the number of the gear of the ring gear 140 .
[0031] A rotation speed Np of the hydraulic pump 130 is determined by a lever principle, that is, Np can be determined by a rotation speed Ne of the engine 100 , a rotation speed Nm of the motor 145 , the number Zs the gear of the sun gear 110 and the number Zr of the gear of the ring gear 140 . That is, if the rotation speed of the motor 145 is increased in a condition that the rotation speed of the engine 100 is fixed, the rotation speed of the hydraulic pump 135 is increased, and if the rotation speed of the engine 100 is increased in a condition that the rotation speed of the motor 145 is fixed, the rotation speed of the hydraulic pump 135 is increased.
[0032] FIG. 4 is a graph showing a compensation value that varies depending on oil temperature in a variable hydraulic pump according to various embodiments of the present invention. Referring to FIG. 4 , a horizontal axis denotes oil temperature, and a vertical axis denotes alpha (a) value as a compensation value. The alpha value is used to control the target rotation speed of the hydraulic pump 135 . Referring to FIG. 5 , the usage method of the compensation value will be further described.
[0033] FIG. 5 is a flowchart showing a control method of a variable hydraulic pump that is disposed in a vehicle according to various embodiments of the present invention. Referring to FIG. 5 , a control is started in S 500 , and it is determined whether the motor 145 is normal or not in S 510 . The method for determining whether the motor 145 is normal or not refers to disclosed arts and the detailed description thereof will be omitted in the present invention. If it is determined that the motor 145 is abnormal, a fail code is generated in S 570 , and the engine 100 is operated in a predetermined fail mode in S 580 . Here, the motor 145 is not operated, and the hydraulic pump 135 is operated by the engine 100 .
[0034] It is determined whether a vehicle is in an idle stop (ISG) condition in S 520 and S 530 . The idle stop condition (a condition that an engine is stopped in an idle condition) can be determined by a vehicle speed and a brake operating force. For example, the ISG condition is satisfied when a vehicle speed is less than or equal to a predetermined base value (ISG reference value) and a brake operating force is larger than or equal to a predetermined value (ISG reference value). If the vehicle is not in an idle stop condition, S 550 is performed, and if the vehicle is in an idle stop condition, S 540 is performed.
[0035] If it is determined that the engine 100 is stopped and Ne is zero (0) in S 540 , S 590 is performed. The rotation speed (Nm) of the motor 145 is maintained at a predetermined value (N_isg) in S 590 . If it is determined that the rotation speed Ne of the engine 100 is not zero (0) in S 540 , it is determined whether oil temperature is larger than a reference value in S 550 . If it is determined that oil temperature is larger than a reference value, S 560 is performed, and if it is determined that oil temperature is less than a reference value, S 595 is performed.
[0036] A rotation speed (Nm) of the motor 145 is calculated by a controller through a formula −Zs/Zr*(Ne−(Np+α))−(Np+α) in S 560 . And, a rotation speed (Nm) of the motor 145 is calculated by a controller through a formula −Zs/Zr*(Ne−Np)−Np in S 595 .
[0037] FIGS. 6A , 6 B, 6 C and 6 D are schematic diagrams showing operational conditions of a variable hydraulic pump of a vehicle according to various embodiments of the present invention.
[0038] FIG. 6A shows that an engine 100 is operated in an idle condition, wherein the rotation speed of the motor 145 is maintained to a relatively high state such that the rotation speed of the hydraulic pump 135 is maintained to a predetermined optimized value.
[0039] FIG. 6B shows that an engine 100 is operated in a low load condition, wherein the rotation speed of the motor 145 is maintained to a relatively middle state such that the rotation speed of the hydraulic pump 135 is maintained to a predetermined optimized value.
[0040] FIG. 6C shows that an engine 100 is operated in a high load condition, wherein the rotation speed of the motor 145 is maintained to a relatively low state or not operated such that the rotation speed of the hydraulic pump 135 is maintained to a predetermined optimized value.
[0041] FIG. 6D shows that an engine 100 is stopped to be operated, wherein the rotation speed of the motor 145 is maintained to an idle state such that the rotation speed of the hydraulic pump 135 is maintained to a predetermined optimized value.
[0042] In various embodiments of the present invention, the motor can be regarded as a stator of a general motor unit and the ring gear can be regarded as a rotor of the motor unit.
[0043] For convenience in explanation and accurate definition in the appended claims, the terms “interior” or “exterior”, and etc. are used to describe features of the exemplary embodiments with reference to the positions of such features as displayed in the figures.
[0044] The foregoing descriptions of specific exemplary embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teachings. The exemplary embodiments were chosen and described in order to explain certain principles of the invention and their practical application, to thereby enable others skilled in the art to make and utilize various exemplary embodiments of the present invention, as well as various alternatives and modifications thereof. It is intended that the scope of the invention be defined by the Claims appended hereto and their equivalents. | A vehicle having a variable hydraulic pump may include a sun gear that receives a torque from a power source through an input shaft, a ring gear of which an interior circumference is with a distance from an exterior circumference of the sun gear, a planetary gear that is disposed between the interior circumference of the ring gear and the exterior circumference of the sun gear, a carrier that connects with an output shaft, a hydraulic pump that pumps oil through the output shaft that is connected to the carrier, and a motor that is disposed outside the ring gear to selectively rotate the ring gear. | 5 |
BACKGROUND OF THE INVENTION
The invention relates to a device for the weft selection on a weaving machine. Such a device is also called a weft change motion.
More particularly, the invention relates to a weft change motion comprising at least two drop wires which are fixed rotatably in planes lying above one another, and which are provided with a bent part having a thread feed-through eye. In the operational set-up, each drop wire is rotatable by control means to a presentation position and to a retracted position. In this operational set-up a weft thread is passed through the feed-through eye of each drop wire. The abovementioned presentation position of a drop wire is the position in which the weft thread extending through the feed-through eye of said drop wire has been taken within the reach of a gripper of the weaving machine, ready for weft insertion. The abovementioned retracted position of a drop wire is the position in which the weft thread extending through the feed-through eye of said drop wire has been taken beyond the reach of a gripper of the weaving machine, and will thus not be inserted.
On a weaving machine a fabric is formed by forming a shed between the warp threads a large number of times in succession and inserting a weft thread in said shed. In the process, the warp threads and weft threads come to rest virtually at right angles to each other in the fabric and run alternately above and below one another according to a predetermined weave pattern. The various warp threads are therefore taken into a specific position during the formation of the shed, so that they are situated above or below the weft thread, according to the desired weave pattern.
The gripper of the weaving machine takes the respective weft threads--in a direction at right angles to the direction of the warp threads--into the shed, so that said weft threads extend over the full width of the fabric.
A weaving machine can be provided with one or more sets of grippers (or other devices for the insertion of weft threads).
If several sets of grippers are provided, they are disposed above one another in such a way that each gripper can insert weft threads at a different level. Such weaving machines with several grippers are used for the production of fabrics for which the insertion of weft threads at several levels is necessary, as is the case for, for example, face-to-face pile fabrics, which are produced by simultaneously weaving two ground fabrics above each other, while pile warp threads are interlaced alternately in the top and the bottom fabric, by inserting them respectively above and below a weft thread of said two fabrics. Two separate pile fabrics are obtained when the pile warp threads running from one fabric to the other are out through between the two fabrics.
Each weft thread which has to be inserted in a shed must, of course, be taken within the reach of a gripper, so that it can be carried along by said gripper.
However, it may be necessary to insert into the same fabric, at the same level, weft threads which differ from each other. Said differences may be in, for example, the colour, the thickness or the material of the yarns used.
In order to weave a particular design in a fabric, it may be necessary, for example, to insert weft threads of different colours at different points in the fabric, according to the colour of that design. It may also be necessary, for example, to insert a weft thread of different thickness or number, or also to insert a thread with S and Z twist direction.
Since weft threads have to be inserted into a shed at the same level by the same gripper, when there is a weft change a weft thread differing from the previous one therefore has to be taken within the reach of that same gripper.
In the case of weaving machines with several grippers, for example double-gripper weaving machines and three-gripper or four-gripper weaving machines, it may be necessary to do this for each gripper.
Weft thread change motions are used in order to make this changing of weft threads possible without stopping the weaving machine.
A known weft change motion for double-gripper weaving machines comprises e.g. four, six or eight flat drop wires which are disposed in such a way that they can rotate about a vertical shaft, and which at one end are provided with a feed-through eye situated in the plane of the drop wire, and at the other end are provided with a bearing point on a common through-running shaft. A weft thread extends through each feed-through eye. Each of the drop wires can be rotated about the shaft by means of an electromagnet with plunger. The weft change motion is disposed with the shaft virtually vertical in the vicinity of the grippers. Two, three or four drop wires are positioned in such a way here that they can take a weft thread within the reach of the top gripper (in the presentation position of the drop wires), while the two, three or four other drop wires are positioned in such a way that they can take a weft thread within the reach of the bottom gripper (in the presentation position of the drop wires). By rotating the drop wires, these weft threads can also be taken beyond the reach of the respective grippers (in the retracted position of the drop wires).
The operation of the weft change motion is designed in such a way that for each gripper one of the drop wires is taken into the presentation position in each case, while the other drop wire is taken into the retracted position. In this way the desired weft thread can be taken by the gripper into the shed in each case. The plunger magnets are controlled in a known manner by means which are programmable according to the required sequence of various weft threads, in order to produce the desired fabric.
Each weft thread is also passed through a guide eye, which is disposed on the weaving machine in the vicinity of the weft change motion.
For a weaving machine with three or more grippers, a weft change motion provided with e.g. two drop wires per gripper is set up in a similar way.
If more than two different weft threads have to be inserted in the same fabric at the same level, a number of drop wires corresponding to the number of different weft threads are set up, while said drop wires interact with the gripper at that level.
The set-up and operation for the rest is identical to the set-up and operation of a weft change motion with two drop wires per gripper.
These known weft change motions have the disadvantage that, after their passage through the respective feed-through eyes, the weft threads have to be bent through too great an angle in order to assume their working position relative to the weaving machine. This causes too much friction in the case of flexure-resistant yarns, with the result that the weft is pulled out of the clamping elements.
In the case of the known devices weft threads are in fact supplied from the side to the feed-through eyes, along the vertical shaft for the drop wires, so that their supply direction to the feed-through eyes differs greatly from the direction in which they have to extend after their passage through the feed-through eyes. The known devices consequently take up more space.
DE-OS-25 09 664 discloses such a weft change motion with weft-passing pins which are provided with a curved part having a feed-through eye. A weft thread extends through the feed-through eye of each weft-passing pin. The weft threads are supplied to the respective feed-through eyes next to the weft change motion by way of respective guide eyes. Before the weft threads reach the feed-through eyes, they are bent against a stop plate. Due to the fact that the point of rotation of the weft-passing pins lies completely outside the line along which the weft threads are supplied (this known weft change motion is disposed next to the weft thread supply), this device takes up a large amount of space.
Besides, in the case of this weft change motion also, the weft threads have to be bent through too great an angle after their passage through the respective feed-through eyes, in order to assume their working position relative to the weaving machine. The friction of the weft threads against the side walls of the feed-through eyes and against the stop plate is a particular disadvantage.
Furthermore, this weft change motion is also not suitable for coarse yarns, for the weft-passing pins are too weak to make coarser weft yarns deflect.
In the case of the known weft change motions, it is therefore a particular disadvantage that the weft threads, which slide through the feed-through eye at great speed when they are being inserted into the shed, rub against the side edges of the feed-through eye.
If the weft thread has laterally projecting fibres, it may also become caught up in the feed-through eye.
The abovementioned disadvantages are all the greater when coarse and relatively rigid yarns are used (for example, Jute, canvas, hemp, fibrillated polypropylene, glass fibre and carbon fibre, and yarns with a metric count ranging between 7/2 and 0.75/2), and they are the reason for the known weft change motions failing to function when such yarns are used. Due to their low flexibility, such yarns are in fact subjected to very great friction against the side edges of the feed-through eye, and they very easily become caught up, due to the projecting fibres. This friction increases as the yarns undergo a great bending in the feed-through eye.
SUMMARY OF THE INVENTION
The object of this invention is to overcome the above-described disadvantages. This object is achieved with a weft change motion according to this invention, in which the drop wires are provided in pairs on common fixing means, while the top and the bottom drop wire are bent upwards and downwards respectively, and a free space is provided above and below the abovementioned fixing means respectively, in order to allow through unimpeded the weft threads extending through the respective feed-through eyes, in the retracted position of each drop wire.
This set-up allows the weft threads to be supplied in a direction which deviates less from the direction in which they have to extend after their passage through the feed-through eyes. This device also takes up less space. The device is disposed, as it were, between the weft threads.
A weft change motion is preferably provided with a fixed guide eye for each weft thread. These fixed guide eyes according to the invention are fixed in such a way that the point of rotation of each drop wire is situated virtually on the bisector of the angle formed by the two extreme positions of a weft thread extending through the feed-through eye of said drop wire and through the corresponding fixed guide eye, while said extreme positions are obtained by placing said drop wire in the presentation position and in the retracted position respectively.
This set-up method makes it possible for the feed-through eye of the drop wire in the presentation position to lie virtually on the line from the gripper head hook to the corresponding fixed guide eye. The run-through speed of the weft thread is at the maximum in this presentation position. Since the weft thread is virtually not bent at all in this position, the friction resistance is minimal after the passage through the feed-through eye.
In the other extreme position of the drop wires, the "retracted position", the run-through speed of the weft thread is virtually zero.
Each drop wire in the presentation position and in the retracted position forms an angle which is virtually the same size on either side of said bisector. The weft thread is thus equally tensioned in those two extreme positions, and this occurs without great bending of the weft thread.
The angle of bend of the weft threads is kept to a minimum in this way, in particular if the run-through speed is the maximum.
The points of rotation of the drop wires can also be placed in such a way that during their movement to the selection position and back the weft threads cross the the axis of rotation of the drop wires. This means that the device can be of more compact construction.
Furthermore, with this set-up equal tension is obtained in the two extreme positions of the weft thread. This is an additional advantage particularly when stiff yarns are being used, since a tension compensator cannot be used efficiently on such yarns. In addition to a reduction in the friction resistance at the level of the feed-through eye and a reduction in the risk of the yarns becoming caught up, the weft change motion thus also ensures more efficient operation when stiff yarns are being used.
A preferred embodiment of the above-described weft change motion according to this invention is obtained by fixing two drop wires rotatably on the same shaft An each case, while said shaft is supported on bearings between the two legs of a U-shaped bracket.
A particularly preferred embodiment of said weft change motion is designed in such a way that of the two drop wires fixed rotatably on the same shaft the top drop wire has an end bent upwards and the bottom drop wire has an end bent downwards, while a feed-through eye is provided in each case in the bent ends concerned.
An electromagnet with plunger, of the type used in the known weft change motion for controlling the various drop wires, has the disadvantage that sufficient changing force cannot be developed with it to ensure rapid and efficient operation.
In order to overcome this problem, the weft change motion according to this invention is provided with double-acting pneumatic cylinders. These cylinders can in turn be driven by a rapid-acting compressed air valve, which in a preferred embodiment can be operated by microprocessor control or some other programmable device. Stepping motors, which impose a rotary movement on the drop wires, can also be used.
In order to limit the friction resistance to an absolute minimum at the level of the feed-through eye, a feed-through eye of ceramic material is preferably used.
The features and the advantages of this invention are further clarified by means of a detailed description of a preferred embodiment of a weft change motion according to the invention. The invention is in no way restricted to this possible embodiment by this description.
BRIEF DESCRIPTION OF THE DRAWINGS
In this description reference is made to the appended figures, in which:
FIG. 1 shows in perspective a weft change motion for a double-gripper weaving machine, in the operational set-up;
FIG. 2 shows in perspective the weft change motion of FIG. 1 and also a number of essential parts (incl. the weaving reed and the grippers) of a double-gripper weaving machine on which the weft change motion is disposed in order to interact therewith.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A preferred embodiment of a weft change motion according to the invention (see FIG. 1) comprises a bearing structure (30), which is provided with means (34, 35, 36) for the fixing, which means are movable in the breadthwise direction on a fixed part of a weaving machine.
This bearing structure comprises (in the operational position) essentially a horizontal bearing plate (31) and a fixing section (32) which is situated virtually at right angles to the top surface of said bearing plate (31).
Two U-shaped brackets (20), (22) are fixed above one another on the fixing section (32), so that their legs extend horizontally above one another and above the top surface of the bearing plate (31). A space is provided between the two brackets (20), (22) and between the bottom bracket (22) and the bearing plate (31), by leaving a vertical distance between them. A shaft (19), (21) is supported on bearings in each of the two brackets (20), (22), which shaft extends virtually at right angles between the legs of each bracket (20), (22). The two shafts (19), (21) lie in line with each other in a direction which is virtually at right angles to the top surface of the bearing plate (31).
Two drop wires (1), (2), (3), (4) are fixed above one another on each of these shafts (19), (21), so that all drop wires (1), (2), (3), (4) are fixed rotatably in planes situated above one another.
The top drop wires (1), (3) on the respective shafts (19), (21) have ends which are bent upwards, and in which a feed-through eye (5), (7) is provided.
The bottom drop wires (2), (4) on the respective shafts (19), (21) have ends which are bent downwards, and in which a feed-through eye (6), (8) is provided. Each feed-through eye (5), (6), (7), (8) is made of ceramic material.
The weft change motion according to the invention also comprises a bearing bar (33) which is provided with means (37) for the fixing, which means are fixed on a bearing shaft (34) on the weaving machine in such a way that they are movable in the breadthwise direction. In the operational position said bearing bar (33) is disposed so that it is virtually vertical. Four fixed guide eyes (23), (24), (25), (26) are fixed above one another on said bearing bar (33).
Each of said fixed guide eyes (23), (24), (25), (26) is fixed at a height which corresponds to the height of the eye (5), (6), (7), (8) of one of the drop wires (1), (2), (3), (4).
In the operational set-up of the weft change motion four weft threads (13), (14), 15), (16) extend through respective guide eyes (23), (24), (25), (26) and through the respective feed-through eyes (5), (6), (7), (8) of the drop wires (1), (2), (3), (4), which feed-through eyes are at the corresponding height in each case.
The piston part of a double-acting pneumatic mini-cylinder (9), (10) is fixed to each drop wire (1), (2), (3), (4), the cylinder part of which is then fixed to the fixing plate (32).
Each drop wire (1), (2), (3), (4) can be rotated about its point of rotation (19), (21) by individually controlling each of these pneumatic cylinders (9), (10).
Each drop wire (1), (2), (3), (4) can be moved by these pistons into a presentation position and into a retracted position.
Each drop wire (1), (2), (3), (4) can be moved into a presentation position or into a retracted position by a stepping motor with appropriate mechanism.
In the operational set-up the weft change motion is set up in such a way that the weft threads (13), (14), which are carried along by the two drop wires (1), (2) on the top shaft (19), can be taken within the reach of the top gripper of a double-gripper weaving machine by placing said drop wires (1), (2) in the presentation position, and that the weft threads (15), (16), which are carried along by the two drop wires (3), (4) on the bottom shaft (21), can be taken within the reach of the bottom gripper by placing said drop wires (3), (4) in the presentation position.
When the respective drop wires (1), (2); (3), (4) are in the retracted position, they are beyond the reach of the respective grippers with which they interact.
The positions of a weft thread corresponding to the presentation position and the retracted position of the corresponding drop wire (1), (2), (3), (4) are known as the extreme positions of said weft thread. The whole structure is designed in such a way that the shafts (19), (21) are situated virtually on the bisector (b) of the angle formed by the two extreme positions of each weft thread (13), (14), 15), (16) which extends through a drop wire eye (5), (6), (7), (8) and the corresponding guide eyes (23), (24), (25), (26). This feature is most clearly seen in FIG. 2.
The presentation position and the retracted position of each drop wire are also virtually symmetrical relative to said bisector.
The bent end of each drop wire (1), (2), (3), (4) means that:
when the top drop wire (1), interacting with the top gripper, goes into the retracted position, the weft thread (13) is pulled by said drop wire (1) above the top surface of the top bracket (20);
when the bottom drop wire (2), interacting with the top gripper, goes into the retracted position, the weft thread (14) is pulled by said drop wire (2) into the space between the two brackets (20), (22);
when the top drop wire (3), interacting with the bottom gripper, goes into the retracted position, the weft thread (13) is pulled by said drop wire (3) into the space between the two brackets (20), (22); and
when the bottom drop wire (4), interacting with the bottom gripper, goes into the retracted position, the weft thread (16) is pulled by said drop wire (4) into the space between the bottom bracket (22) and the bearing plate (31).
The bent end of the drop wires (1), (2), (3), (4) means that the friction resistance and the chance of threads becoming caught up at the level of the drop wire eyes (5), (6), (7), (8) are greatly reduced.
The set-up in pairs on common shafts (19), (21) with spaces between them and the fact that the drop wires (1), (2), (3), (4) are bent alternately upwards and downwards also permits an arrangement which minimizes the bending angle of the weft threads and ensures uniform tensioning of the weft threads in the two extreme positions.
To overcome the problem of electromagnet plungers of known weft change motion for controlling various drop wires not having sufficient changing force, the present invention has double-acting pneumatic cylinders. These cylinders can in turn be driven by a rapid-acting compressed valve, which in a preferred embodiment is operated by microprocessor control or some other programmable device.
Eliminating all these disadvantages means that the weft change motion according to this invention is particularly suitable for coarse and stiff yarns with projecting fibres.
However, this weft change motion can, of course, be used equally well for other yarns.
A weaving machine provided with a device for the insertion of a weft thread which does not have a gripper, but another means for carrying along a weft thread through the shed, can also interact with a weft change motion according to this invention.
It is clear that this weft change motion can also be extended for use with three-gripper or four-gripper weaving machines by placing additional brackets with drop wires above one another. | A weft selection device for a weaving machine has at least two drop wires with feed-through eyes. The drop wires are fixed rotatably in two planes lying above one another to take a weft thread extending through the feed-through eye within or beyond the reach of a gripper. Each drop wire has a bent end containing the feed-through eye. The drop wires are fixed rotatably in pairs on common fixing device. The top drop wire of each pair is bent upwards and the bottom drop wire of each pair is bent downwards. A free space is provided above and below the fixing device of each pair to allow through unimpeded the weft threads. Thus, it allows for an arrangement with a minimum angle of bend of the weft threads after they have passed through the feed-through eyes. The present weft change motion is suitable for coarse and stiff yarn. | 3 |
BACKGROUND OF THE INVENTION
This invention relates to papermakers' fabrics and especially to papermaking fabrics for the forming section of a papermaking machine.
In the conventional papermaking process, a water slurry or suspension of cellulose fibers, known as the paper "stock", is fed onto the top of the upper run of a traveling endless forming belt. The forming belt provides a papermaking surface and operates as a filter to separate the cellulosic fibers from the aqueous medium to form a wet paper web. In forming the paper web, the forming belt serves as a filter element to separate the aqueous medium from the cellulosic fibers by providing for the drainage of the aqueous medium through its mesh openings, also known as drainage holes, by vacuum means or the like located on the drainage side of the fabric.
After leaving the forming medium, the somewhat self-supporting paper web is transferred to the press section of the machine and onto a press felt, where still more of its water content is removed by passing it through a series of pressure nips formed by cooperating press rolls, these press rolls serving to compact the web as well.
Subsequently, the paper web is transferred to a dryer section where it is passed about and held in heat transfer relation with a series of heated, generally cylindrical rolls to remove still further amounts of water therefrom.
Over the years, papermakers have sought improvements in the forming fabric, not only with respect to the operating life of the fabric, but also with respect to the quality of the paper sheet produced on it. Triple layer fabrics were introduced for this purpose. The triple layer fabric has two generally distinct surfaces. The top surface is one integral fabric structure designed specifically for papermaking to achieve the best possible sheet quality and machine efficiency. This top fabric is manufactured as an integral part of a woven structure with a completely separate bottom fabric designed specifically for mechanical stability and fabric life. The purpose of triple layer fabric development is to eliminate the compromises which exist with both single and double layer forming fabrics so that papermakers can produce the best possible paper sheet for top quality at reduced cost without sacrificing the wear characteristics of the papermaking fabric.
The paper produced on the papermaking machine is described in part with relation to its formation and wire mark. Formation is most commonly described as the difference in density of a sheet of paper when looking through the sheet. The ideal formation is a sheet which has completely uniform density. Sheets with areas of varying density are said to be flocky or cloudy. The word formation is generally used to describe macro scale areas of varying density which can be easily seen by the human eye. Headbox design and performance have the most effect on large scale formation. This, together with the turbulence created by stationary elements, principally dictates the final large scale sheet formation. Wire mark, on the other hand, is used to explain the micro or finer levels of density difference, often caused by the structure of the forming fabric on which the sheet was produced.
The initial fiber mat formed on a papermaking fabric, which becomes the paper sheet, is very greatly influenced by the surface structure of the filtering medium on which it settles. It follows that a fine, uniform support grid will give a more uniform initial fiber mat than a coarse non-uniform support grid. This degree of uniformity in fact influences subsequent layers of fiber as the sheet is formed, and eventually, the paper sheet produced.
The papermaking fabric is essentially a filter by which the cellulose fibers, of varying lengths, are separated from the water component of the paper stock. A completely closed fabric, or 100 percent closed fabric, would have no drainage and would therefore be unworkable. The fabric must be opened from this maximum, to create an orifice effect to allow drainage. A forming fabric which is 100% open is also no good as it will not retain fibers from the stock solution to form a sheet. Opening the fabric, additionally, often accomplished by reducing the diameter of the yarns used to weave the fabric, creates density differences.
The effect of differences in density of the paper sheet, whether caused by large scale flock or finer scale wire mark, is to vary the degree to which ink penetrates the paper sheet. FIG. 1 illustrates the way in which this phenomenon is caused. FIG. 1A illustrates that when a sheet is being formed on an open forming medium, the sheet will be made up of thick areas over the holes and thin areas over the knuckles. In FIG. 1B, during pressing and calendering, the thick areas are compressed more than the thin areas, which results in a sheet having differences in density. The paper of the resulting sheet, as shown in FIG. 1C, will have a high gloss, be very smooth and have low porosity in the areas of high density. These areas, when printed, will have low ink penetration which will result in a print in this areas which will have high gloss and possibly high offset. On the other hand, the areas of the sheet over the knuckles will have low density, low gloss, be rougher and have higher porosity. When printed, these areas will have greater ink penetration, which will result in a matt finish compared to the dense areas over the holes of the fabric, and with the high porosity, print strike through may occur to the opposite side of the sheet. Whether differences in density of the sheet are caused by large scale flock or fine scale wire mark, the effect on the final print quality of high and low gloss through variation in ink penetration is the same. Terms used to describe these effects are "galvanizing" or "mottle".
The type and pattern of wire mark that will be produced by any fabric can be easily shown by taking a surface impression of the papermaking surface of the fabric It has been found that the high knuckles of a fabric, around which the stock slurry flows and settles lower down in the fabric body, leave light areas. The degree of wire mark that hits the eye, therefore, is determined by the frequency and continuity of the pattern formed by the knuckles of the fabric. Openness of the fabric will, of course, affect these density variations and the surface impression.
For example, a coarse single layer fabric has low frequency, and each hole formed by the knuckle will therefore show up more than when compared to the higher frequency of the finer mesh. Further, if the wire mark pattern is a straight twill line, as compared to a broken satin, it will strike the eye to an even greater extent. The degree of differences in density of a sheet caused by wire mark, therefore, can be said to be affected by the frequency, or number of knuckles/square inch, and the continuity and coarseness of the pattern.
At the present time, there is a great need for a paper sheet with more uniform formation, and equal printing properties on both sides for every printing grade. It has been found that the micro density differences of the paper sheet, resulting from the knuckles of the yarns on the forming fabric, are the main cause of the problem. The perfect print is one where all the ink applied absorbs into the sheet at the same rate. To date, surfaces are far from uniform, as explained above, thus leading to differences in contact and absorption of ink depending on whether it lands on a light area over a knuckle or a heavy area over a hole. When the ink hits a particular area over a knuckle, it penetrates the sheet very easily, and if the volume is sufficient, will strike through to the other side. To achieve the best print, the printer has to modify his printing conditions to strike a balance between the two extremes.
It has been found that the key to the reduction, or elimination, of these printing problems can be achieved by careful selection of the papermaking fabric upon which a paper sheet is to be produced.
It is therefore an object of the present invention to prepare a papermaking fabric that produces a paper sheet of superior print quality.
Another object of the present invention is to provide a papermaking fabric that combines good drainage capability with an optimal paper sheet surface.
It is another object of the present invention to provide a papermaking fabric in which density differences are minimized in order to optimize the printing properties of the paper sheet formed thereon.
A further object of the present invention is to provide a papermaking fabric with good wear life and abrasion resistance that produces a paper sheet with optimal printing properties.
A further object of the present invention is to provide a method for making a paper sheet having minimal density differences.
It is a further object of the present invention to provide a papermaking fabric which relates its drainage orifice dimensions to the average length of the fibers to be used to form the sheet of paper.
Still another object of the present invention is to relate drainage orifice dimensions to average fiber length in order to control the degree of retention of fibers.
SUMMARY OF THE INVENTION
To reduce and/or eliminate the problem of density differences in a paper sheet when these differences are related to the knuckles of the forming fabric, a novel triple layer fabric is provided herein. The triple layer papermaking fabric of the present invention includes a top fabric layer of a plain weave of interwoven machine direction yarns and cross machine direction yarns having an open area selected to maximize initial fiber retention and control the rate of water passage for that purpose as well, according to the following formula:
(1-N.sub.c ×D.sub.c)×(1-N.sub.m ×D.sub.m)×100
where
N c =number of CMD yarns per inch
N m =number of MD yarns per inch
D c and D m are corresponding yarn diameters.
The invention is further illustrated with reference to the following detailed description of the invention, and to the figures, in which like references numbers refer to like members through the various views.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1, including FIGS. 1A, 1B and 1C, illustrate how differences in the density of a paper sheet are formed and the effect these differences in density have on print;
FIG. 2A illustrates a top view of one embodiment of the fabric of the present invention, with a portion of the top fabric layer removed;
FIG. 2B illustrates a cross machine direction view of the fabric shown in FIG. 2A, taken along the line 2B--2B in FIG. 2A;
FIG. 2C illustrates a machine direction view of the fabric shown in FIGS. 2A and 2B, taken along the line 2C--2C in FIG. 2A;
FIG. 3A illustrates a top view of one embodiment of the fabric of the present invention, with a portion of the top fabric layer removed;
FIG. 3B illustrates a cross machine direction view of the fabric shown in FIG. 3A, taken along the line 3B--3B in FIG. 3A;
FIG. 3C illustrates a machine direction view of the fabric shown in FIGS. 3A and 3B, taken along the line 3C--3C in FIG. 3A; and
FIG. 4 is a diagrammatic representation that illustrates the effects of use of a fabric according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is a triple layer forming fabric having a top fabric layer with a superior papermaking surface and a bottom fabric layer with superior wear and abrasion resistance characteristics. The papermaking fabric of the present invention forms a more uniform paper sheet because the selection of yarn diameters, weave patterns, and number of yarns is based on the interrelationship of the following
Fiber length to supporting spans between yarns.
Selection of weave pattern for optimum fiber support.
Selection of mesh together with yarn diameters to maximize support for fibers of known length.
Selection of yarn diameters together with mesh and weave pattern to give a controlled drainage rate in order to minimize sheet density differences.
Selection of yarn diameters to minimize the degree of penetration into the sheet which in turn will minimize density differences.
A sheet of paper is formed when a solution of water which contains suspended fibers is passed through a woven structure. The fibers are retained on the yarns of the woven structure while the water passes through the holes in the structure.
The number of fibers retained will be influenced by not only their length but also the distance between the yarns (support spans) of the woven structure. The rate of passage of the water through the woven structure will be influenced by the size of holes (orifices) which are formed by the yarns of the woven structure.
With reference to FIG. 1, it is clear that due to fiber build-up over a span between yarns, ink penetration will be light. The fiber build up over a yarn will be less, and thus ink penetration at that point will be higher. As explained above, the difference in the depth of ink penetration into the sheet is referred to as density difference in the sheet and caused by the topography of the fabric on which the sheet is formed.
Both the amount of fiber retained and the speed of drainage are very important in the process of papermaking. The other important factor is the uniformity of fiber distribution in the final sheet of paper produced, as this directly affects the rate of penetration of the printing ink into the sheet of paper. The degree and uniformity of ink penetration into the sheet directly influences the uniformity and quality of the final print.
It has been discovered that forming fabric parameters can be set in relation to the fiber lengths that are being used to produce a sheet having uniform density which when printed will have uniform print quality.
The solution to be filtered, commonly referred to as paper stock, includes generally water as the medium in which cellulosic fibers of varying lengths are suspended. The length of the fibers vary with the species of wood being used, the pulping processes and the final sheet of paper to be produced and while an average length of fiber can be found for any paper stock solution, fibers longer and shorter than that average will be present.
During the initial part of the filtering process a fiber will be separated out from the suspension to start the formation of the sheet of paper when it is forced to lay across one or more yarns that are being used to form the woven structure. The distance between these yarns (span) in relation to the length of fiber to be separated from the stock slurry will dictate how efficient the woven strucutre is in filtering out these fibers. (The closer the span and longer the fiber, the greater will be the filtering efficiency.) As soon as one fiber is caught on the support spans of the yarns, it in itself then becomes a part of the support structure and therefore forms a span across which subsequent fibers can lay. The original support span distance formed by the original fabric construction is the critical factor in dictating the length of the first fibers retained which in turn directly influences the length and pattern of subsequent fibers that are retained. A papermaking fabric, then, is chosen having a span between yarns to effectuate the most efficient initial fiber retention. The distance between spans dictates how much of the initial fibers will drop through with the water suspension and how much will be retained on the fabirc surface to form the intital part of the sheet. It has been discovered that if a greater amount of fibers are supported on the papermaking fabric, and a fewer amount drop through, a paper sheet having little or no density difference is created.
In a woven structure the distance between yarns (the span) is dictated by the woven mesh count in both directions per unit width. A typical mesh count in a plain weave structure could be expressed as "74×70 mesh". This would mean 74 yarns per unit width in one direction woven into 70 yarns per unit width in a direction at 90° to the original 74 yarns. The distance between yarns or span would then be expressed as unit width in one direction and unit width in the other direction, or 74×70.
The mesh or span distance chosen is left to those skilled in the art of selection to suit the fiber lengths that are required to be retained.
The yarns utilized in the fabric of the present invention will vary depending upon the desired properties of the final papermaking fabric, and of the paper sheet to be formed on that fabric. For example, the yarns may be multifilament yarns, monofilament yarns, twisted multifilament or monofilament yarns, spun yarns or any combination of the above. It is within the skill of those practicing in the relevant art to select a yarn type, depending on the purpose of the desired fabric, to utilize with the concepts of the present invention.
Yarn types selected for use in the fabric of the present invention may be those commonly used in papermaking fabrics. The yarns could be cotton, wool, polypropylenes, polyesters, aramids or nylon. Again, one skilled in the relevant art will select a yarn material according to the particular application of the final fabric. A commonly used yarn which can be used to great advantage in weaving fabrics in accordance with the present invention is a polyester monofilament yarn, sold by Hoechst Celanese Fiber Industries under the trademark "Trevira".
The bottom fabric layer of the papermaking fabric of the present invention may be any fabric chosen for its wear and abrasion resistance characteristics. One skilled in the relevant art can select a fabric to suit the particular needs at hand. Preferably, the bottom fabric layer will be a four or five harness sateen weave, characterized by long floats in the machine direction yarns. The preferred yarns for the bottom fabric layer of the present invention has a diameter in the machine direction of 0.20 mm and 0.25 mm for the diameter of yarns in the cross machine direction.
When fibers are carried in a water suspension they have no definite orientation, hence, when the stock slurry is being filtered to form a sheet, a fiber could fall in any direction over a yarn or a hole in the forming fabric structure. Therefore, in order to optimize the retention of fibers from the stock slurry, the fabric should be woven in a square structure having yarns in both directions evenly spaced and in a symmetrical knuckle pattern. The only weave pattern that will produce this configuration is a plain weave when yarns in both direction alternate over and under the opposite direction yarns. This weave pattern produces square holes and uniform knuckles in both directions. It is for this reason that the plain weave top surface is chosen to give the most uniform support to the fibers during filtering in order to produce the most uniform sheet of paper possible.
When yarns are woven in a plain weave pattern they produce holes, the minimum area (orifice) of which is approximately at the center line point of the yarns forming each side of the hole. In a woven structure, the total unit area of these holes can be expressed as a percentage of the whole area and can be calculated using the following formula:
(1-N.sub.c ×D.sub.c)×(1-N.sub.m ×D.sub.m)×100
where
N c =number of CMD yarns per inch
N m =number of MD yarns per inch
D c and D m are the corresponding diameters.
An embodiment of the fabric of the present invention is shown in FIGS. 2A-2C. FIG. 2A illustrates the top surface of the top fabric layer 10, including machine direction yarns, 11, 13, and cross machine direction yarns 12 and 14 interwoven in a plain weave structure. A portion of the top fabric layer is removed to illustrate the top surface of the bottom fabric layer 20, including machine direction yarns 21, 23, 25, 27 and 29 interwoven with cross machine direction yarns 22, 24, 26 and 28 in a sateen weave. FIG. 2B shows a view of the cross machine direction yarns, taken at line 2B--2B in FIG. 2A. FIG. 2C shown a view of the machine direction yarns taken at line 2C--2C in FIG. 2A. Binder yarns 16-19 are included in each of the figures.
An additional embodiment of the fabric of the present invention is shown in FIGS. 3A-3C. FIG. 3A illustrates the top surface of the top fabric layer 30, including machine direction yarns 31, 33 and cross machine direction yarns 32, 34 woven in a plain weave structure. A portion of the top fabric layer is removed to illustrate the top surface of the bottom fabric layer 40, including machine direction yarns 41, 43, 45, 47 and cross machine direction yarns 42, 44, 46, 48 in a 3:1 weave. FIG. 3B shows a view of the cross machine direction yarns, taken at line 3B--3B in FIG. 3A. FIG. 3C shows a view of the machine direction yarns, taken at line 3C--3C in FIG. 3A. Binder yarns 35, 36, 37 and 38 are included in the figures.
It has been discovered that the rate of water flow at constant pressure drop through any forming fabric will be directly proportional to the percentage open area of the top surface of that fabric structure. It therefore follows that, in order to pass a constant or required volume through a woven structure having a lower percentage top surface open area will require a higher force or pressure which will result in a higher velocity through the holes to achieve the same constant or required volume to pass.
The higher the velocity of the initial water passing through the holes of the forming fabric, the harder it will be to retain the initial fibers which will start the formation of the matt which will eventually be the basis of the sheet.
It therefore follows, the greater the top surface open area, the lower the pressure that is required to achieve a desired flow and the easier it will be to retain the fibers on the yarns of the fabric structure. Using the concepts of the present invention, those skilled in the art will select the open area of the top fabric to retain more of the initial fibers from the stock.
With the relationship as determined by the formula, open area as affected by the mesh or number of yarns per unit area and also by the diameter of the yarns in both directions, those skilled in the art can select an open area such that the distance span between yarns will suit the fiber length that is being used and/or such that the open area will suit the volume and rate of flow that is required.
It has been discovered that where a sheet is formed on a fabric structure it follows the topography of the top surface of that fabric structure. On looking through a sheet of paper formed on a fabric structure, density differences will be seen which follow the pattern of the fabric on which it was formed. As described earlier, the shorter the fibers that make up the sheet or the greater the span between yarns that make up the woven structure, the greater will be the density differences in the sheet corresponding to the pattern of the top surface of the fabric on which it was formed. It also follows as described earlier, the lower the top surface open area, the greater the density differences due to flow velocities passing through the fabric, drawing fiber with it.
There is yet another area which affects density differences in a final sheet and that is in the yarn volume or unit area contained in the cubic volume from the center line or orifice point to the top of the sheet. This can be best described by referring to FIG. 4 which shows a cross selection through two sheets of paper formed on three yarns of equal spacing (span) but of different diameters.
It can now be seen that as the diameter of the yarns are reduced, the differences in density will be reduced as well. Furthermore, as the diameter of the yarns decrease, two results occur, as shown in FIG. 4. A fabric with larger diameter yarns has a smaller open area "oa" between yarns, and the yarns penetrate into the paper sheet to a greater depth "p". As the yarns are reduced in diameter, the open area between them increases, and the level of penetration of each yarn into the paper sheet will decrease, thus reducing the density differences in the paper sheet created.
EXAMPLE I
A top fabric layer is prepared of a polyester monofilament yarn having a diameter of 0.13 mm in the machine direction and 0.11 mm in the cross machine direction. The mesh of the fabric is 74×70 (MD×CMD yarns). As such, using the formula above, an open area of 43.3 percent is achieved. When combined with a bottom fabric layer, a superior drainage triple layer papermaking fabric is achieved.
EXAMPLE II
A top fabric layer is prepared of a polyester monofilament yarn having a diameter of 0.13 mm in the machine direction and 0.11 mm in the cross machine direction. The mesh of the fabric will be 74×80 (MD×CMD yarns). As such, an open area of 41 percent is achieved. When combined with a bottom fabric layer, a superior drainage triple layer papermaking fabric is achieved.
With any particular paper stock, a papermaking fabric can be selected to provide optimal drainage utilizing the concepts of the present invention.
The average fiber length is determined, as with the use of an optical scanner, such as the KAJAANI FIBER LENGTH ANALYZER, available from Valmet Automation (Canada) Ltde./Ltd. of Kirkland, Quebec. Using the average fiber length, a triple layer papermaking fabric will be selected so that its top fabric layer has an open area of at least 40 percent, as determined by the formula above, and the span between yarns is approximately one third of the average fiber length. When used to filter the paper stock in the forming section of a papermaking machine, the fabric has good drainage yet provides effective support for more of the fibers in the stock, especially the initial fibers being filtered. More of the fibers filtered will be retained at the orifices.
The embodiments which have been described herein are but some of the several which utilize this invention and are set forth here by way of illustration but not of limitation. It is obvious that many other embodiments which will be readily apparent to those skilled in the art may be made without departing materially from the spirit and scope of this invention. | A triple layer papermaking fabric having top and bottom fabric layers joined by a binder yarn, the top fabric layer including machine direction and cross machine direction yarns interwoven in a plain weave having an open area determined by the formula:
(1-N.sub.c ×D.sub.c)×(1-N.sub.m ×D.sub.m)×100
where
N c =number of Cross Machine Direction yarns per inch
N m =number of Machine Direction yarns per inch
D c =number of Cross Machine Direction yarns
D m =diameter of Machine Direction yarns
The configuration of the papermaking fabric reduces or eliminates density differences in the finished paper sheet produced on it. | 8 |
DETAILED DESCRIPTION OF THE INVENTION
1. Field of the Invention
The present invention relates to microbe cultures, a process for producing the same, and utilization thereof. More particularly, the invention relates to microbe cultures containing anaerobic and aerobic microbes, which cannot hitherto live in symbiosis with each other, living in symbiosis with each other, and enzymes, which are metabolites of these microbes, the process for producing the same, carriers and absorbing materials containing the active ingredients of the culture and their applications to agricultural and environmental fields.
2. Background Arts
In recent years, applications of microbes to agricultural and environmental fields have received considerable attention from ecological viewpoint.
Attempts have been made to apply soil improving materials based on microbe technologies to soil which has become exhausted due to the use of a large amount of agricultural chemicals, and dormant soil in crop rotation.
For example, Japanese Examined Patent Publication No. 4-42355 discloses that a mixture obtained by injecting root nodule bacteria and Azotobacter or photosynthetic bacteria and Thiobacillus to a culture comprising an aqueous sterile plant solution having sucrose or maltose added thereto, cultivating the bacteria at approximately 25 C., and mixing the culture with a separately prepared culture composed of nitrifying bacteria, yeast, thermophiles, Bacillus subtilis, and bacteria belonging to Pseudomonas has the ability to accelerate thermal maturing, to increase the effects of fertilizer, to make remaining chemicals harmless, and to suppress insects causing damage to crops.
However, the conventional method is disadvantageous in that the soil to which it can be applied is restricted to soil stained by chemicals or dormant soil in crop rotation, and yeast which can be used is also restricted to that from rice bran. In addition, it takes a very long period of time to return the soil to normal soil.
Recently, the environment is increasingly being destroyed due to desertification or acidic rains, and such phenomena have become worldwide problems.
In order to plant such an exhausted area with trees, an effort has been made to plant trees by placing a high water absorbing polymer as a base material, and applying water to the base material in order to grow trees. However, the high water absorbing polymer is expensive and plants to be applied are restricted. In addition, the soil which has been desertified is never returned to the original soil.
Similarly, man-made destruction of the environment such as that due to slash and burn farming and haphazard deforestation creates serious problems in terms of plant environment. No process has yet been found in which the soil whose crumb structure has been lost due to the man-made destruction of environment can be returned to the original state.
Moreover, there is a need to utilize soils containing salt such as a sandy beach, sandy soils such as residing around rivers, etc. as soils where desired crops can be planted, but there is no technique at present.
In addition to agriculture, gardening such as cultivating dwarf trees, gardening as a pastime, etc has become popularized. Ornamental plants, vegetables, herbs and other plants are cultivated not only by breeders but also household. In cultivating these plants, generally a solid medium for cultivating plants is incorporated into a container such as a flowerpot, a planter, and then seeds or tubers are embedded into the medium or young plants are transplanted.
However, the solid medium which has hitherto been utilized in the cultivation of such plants contains a considerable amount of insects carrying disease germs and eggs thereof, fungi, etc., which have an adverse influence upon the plants to be cultivated. Specifically, due to the eggs of insects, the insects themselves, or pathogenic bacteria, such as lead scald, powdery mildews, root knots, root rot, brown canker, rust and the like, plants often are infected from the solid medium such as soil. Depending upon the origin of the medium, the medium often contains agricultural chemicals and some other harmful substances. Moreover, insects etc. are oviposited into the medium or onto a plant during the cultivation of the plant, and the bred insects sometimes adversely affect the plant.
In order to eliminate such insects, mildews etc. existing on or into the solid medium, agricultural chemicals are conventionally applied to the medium. However, if the crumb structure inherent to the soil should be lost when the insects and harmful microorganisms are eliminated by the spraying of agricultural chemicals, this makes the soil inappropriate for the cultivation of plants. Particularly, in the case of the cultivation of plants in a container, excess water flows out when a plant in a container is watered; the agricultural chemicals unduly remain in the water which flows out. Further, in the case of the cultivation of edible plants, the agricultural chemicals cause an adverse effect to the human body.
When the plants are cultivated, solid or liquid fertilizers are incorporated into the medium. These fertilizers are mainly chemically synthesized fertilizers and thus, the medium in which chemical fertilizers are incorporated is greatly different from the original medium for cultivating the plants. In this case, the period of fertilization and the amount of fertilizer to be applied should be strictly controlled.
Similar to the cultivation of plants, solid media such as sawdust or decayed wood are used for cultivating mushrooms, and such medium also contains Eumycetes, insects, and their eggs.
Japanese Examined Patent Publication No. 4-42355 discloses the admixture of microorganisms with the medium or plants themselves. According to this publication, a mixture obtained by injecting root nodule bacteria and Azotobacter or photosynthetic bacteria and Thiobacillus to a culture comprising an aqueous sterile plant solution having sucrose or maltose added thereto, cultivating the bacteria at approximately 25 C., and mixing the culture with a separately prepared culture composed of nitrifying bacteria, yeast, thermophiles, Bacillus subtilis, and bacteria belonging to Pseudomonas has the ability to accelerate thermal maturing, to increase in effects of fertilizer, to make remaining chemicals harmless, and to suppress insects causing damage to crops.
However, in the application of such a group of bacteria there are disadvantages in that it takes a very long period of time to take the effect after the application of these bacteria, and that the effect is last only a short time. Also, the group of bacteria cannot be applied to a plant cultivated in a container.
Also, the solid medium after the cultivation of an annual plant or the solid medium after plants have been harvested cannot be utilized again if these bacteria are used.
Moreover, these bacteria do not have an effect to activate any withering plant.
Meanwhile, various processes for taking measures to cope with bad smells based on the functions of bacteria have been known.
For example, Japanese Unexamined Patent Publication No. 6-277684 discloses a process for deodorizing a bad smelling gas utilizing bacteria.
Also, Japanese Unexamined Patent Publication Nos. 51-129865, 53-58375, and 60-34799 disclose processes for decoloring and deodorizing sewage disposal, excreta, etc.
However, these processes are disadvantageous in requiring at least two stages, due to the use of different kinds of bacteria, i.e., anaerobic and aerobic bacteria.
In recent years, processes for treating waste water, for improving soils, etc. and insecticides utilizing Effective Microbes called EM which have living anaerobic bacteria and aerobic bacteria together with each other, mainly containing lactobacilli have been developed. However, substantially aerobic bacteria and facultative bacteria are used in EM and, thus the synergism of both bacteria is little. In the use of EM, fermentation material call EM material should be utilized and making the application of EM is severely restricted.
Meanwhile, a large amount of seston is contained in lakes, marshes, rivers, etc. Seston is a general term for granular substances suspended in water and indicates organic seston originated in floating living bodies and inorganic seston originated in earth and sand or particles. In many cases, sestons are together with each other to make up as agglomeration. The organic seston sometimes serves as a place habitable for small creatures. However, it changes the transparency of water for the worse, and becomes a factor in the generation of water blooms due to the rotting of the organic seston and, thus, it is desirable to remove the organic seston. The inorganic seston contained in exhaust water from chemical factories, etc. is a mass containing harmful substances and, it is also desirable to remove it.
Conventionally, in order to treat the water containing the seston, seston is aggregated by the use of a flocculant such as aluminum sulfate, and the seston is removed by the filtration of settling substances or floating substances. However, in the treatment utilizing such a flocculent, the flocculant utilized should be subjected to secondary treatment, and the performance of the flocculant is insufficient. Moreover, there is a possibility that the flocculant causes an adverse influence upon the ecologic system and, thus the use of the flocculant is not assumed to be a good method. In addition, since there are various kinds of water to be treated such as organic exhausts inclusive in the exhaust water from sewage disposal, exhaust water from food processing, exhaust water containing excreta such as pig-breeding and stockbreeding, and water from eutrophic lakes and marshes; inorganic exhausts such as exhaust water from chemical industries, there are various kinds of sestons, and they cannot be treated by one flocculent.
In treating water from a lake or marsh, the stage for removing harmful substances contained in the water, the stage for decoloration, and the deodorization stage should be required in addition to the removal of seston.
In light of the above situations, it is desired to develop a flocculant (1) that requires no secondary treatment such as removal of the flocculant; (2) that has no adverse influence upon the ecological system; (3) that can be widely applied irrelevant to the origin of the seston, i.e., organic and inorganic sestons; and (4) that can treat harmful substances, and decolor and deodorize subjective substances at the same time.
It is desirable that water blooms occurring onto and into the hydrosphere, which have been eutrophicified, be removed. Also, it is desirable to remove petroleum flowing in the sea area, for example, due to a shipping accident such as an accident of a tanker; thus, it is desirable to develop an effective treating means.
In addition, a biological treatment of filthy water containing excrements and urines exhausted from various stockbreeding fields such as pick-breeding fields, cowsheds, and chicken farms as well as household exhaust water, exhaust water from chemical industries, food industries and the like containing various components has recently drawn considerable attention.
For example, Japanese Unexamined Patent Publication Nos. 55-86593, 60-137492, 6-71293, 9-20678, and the like disclose processes of separately treating exhaust water with anaerobic bacteria and aerobic bacteria. However, these processes can only treat exhaust water in a restricted manner and are not assumed to be effective. No process has been developed which can treat pollutants originating from different sources all at once.
Efforts have been made to develop a biological process for converting harmful substances into harmless ones.
Many halogen compounds having chlorine or bromine, etc. are specified as specific chemical compounds and specified chemical compounds, and many of them are sources causing an environmental problem. Typical examples include halogenated aromatic compounds such as dioxins, polychlorobiphenyls, and chlorobenzenes; and aliphatic halogen compounds such as tetrachloroethylene, trichloroethylene, dichlorometahne, carbon tetrachloride, 1,2-dichloroethylene, 1,1-dichloroethylene, cis-1,2-dichloroethylene, 1,1,1-trichloroethane, and 1,1,2-trichloroethane, 1,3-dichloropropene.
Various suggestions have been made to decompose these organic halogen compounds based on the functions of bacteria.
With regard to the decomposition of organic aliphatic compounds, a process for removing an organic chlorine compound comprising injecting ammonia-oxidizing bacteria with a polluted portion contaminated with organic chlorine substances such as soil or contaminated groundwater to allow the contaminants to be in contact with the ammonium-oxidizing bacteria is described in Japanese Unexamined Patent Publication No. 10-180237.
A process for purifying a substance contaminated with organic chlorine compounds comprising declorinating the chlorine contaminating compounds under a reduction atmosphere under neutral conditions in the presence of at least one heterotrophic bacterium and iron is described in Japanese Unexamined Patent Publication No. 10-216694. The heterotrophic bacteria exemplified therein include metanogens (for example, Methanosarcina, Methanothrix, Methanobacterium, Methanobrevibacter, etc.); sulfate reduction bacteria (for example, Desulfovibrio, Desulfotomaculum, Desulfobacterium, Desulfobacte, Desulfococcus, etc); acid production bacteria (for example, Clostridium, Acetivibrio, Bacteroides, Ruminococcus, etc.) and faculative anaerobic bacteria (for example, Bacillus, Lactobacillus, Aeromonas, Streptococcus, Micrococcus, etc.).
However, such processes can only be applied to restricted systems such as soil and aqueous solutions, and are problematic in treating efficiency, cost, convenience, etc. In order to maintain the activity of the bacteria for the treatment, the temperature, pH level, nutrient salts, the amount of dissolved oxygen, and the like should be controlled in an appropriate manner and, thus, the process is disadvantageous when an apparatus is required for an environment where oxygen or nutrient salts are continuously being added.
As a process for decomposing an aromatic halogen compound, there is a process for decomposing PCBs utilizing microorganisms. However, the microorganisms which can be utilized depend upon the substitution position of chlorines, and the decomposition is imperfect, i.e., the conventional microorganisms can decompose PCB only to chlorobenzene. Also, the PCB decomposition utilizing the microorganisms can only be applied to a restricted area. The decomposition of other organic halogen compounds such as dioxins utilizing microorganisms has not yet been found, and these compounds are decomposed by a chemical or physical process.
Solids and liquids such as burned ash, soda glass, soil, exhaust liquid from semiconductor processing, and exhaust liquid from plating contain various kinds of heavy metals such as chromium, manganese, cobalt, nickel, zinc, lead, and mercury in various concentrations, and it is required that these metals are removed through the functions of microorganisms.
Furthermore, photographic exhaust liquids can also be mentioned as those which contains various harmful substances.
There are a series of stages from the development of photographic film to the printing of the developed film. First, a photographic film such as a negative film, positive film, or reversal film is developed, the developed film is fixed, washed with water, and dried to prepare a film for printing; thereafter, the developed film is printed onto print out paper. At present, photo-finishing service has been popularized in which these stages are carried out all at once.
Photographic films, print-out paper, and various solutions for treating them generally contain various chemicals such as a silver halide emulsion as a photosensitive material (e.g., silver bromide, silver iodide, silver iodide bromide, etc.); stabilizers (e.g., benzotriazole, azaindolysines, etc.); color sensitizers (e.g., orthochromatic, panchromatic sensitizers, super-panchromatic sensitizers etc.); hardening agents (e.g., aldehyde compounds, etc.).
Specifically, developing the film and printing the developed film onto the print-out paper are carried out via various stages such as a color developing stage, washing with running water, development adjustment and hardening, hardening, stopping, first fixation, washing with running water, second fixation, removal of water droplets, and drying, and various organic and inorganic compounds are used in each stage.
As described above, in developing the film and printing the developed film onto the print out paper, an exhaust liquid containing various compounds in which these compounds react with each other are discharged.
Depending upon the situation of the development, an auxiliary operation, for example, using chromium compounds such as potassium dichromate or mercury compounds such as mercuric chloride or a reducing operation, for example, by mixing potassium ferricyanide with sodium thiosulfate or potassium permamganate, is carried out in some cases.
As photography has been increasingly popularized and the frequency of taking photos has increased, the amount of the exhaust liquids has also increased significantly. However, with regard to the treatment of the exhaust liquid, although silver, which is a relatively expensive material, is recovered, since the compounds other than silver are of many kinds, the printing treatments depend upon the companies, and the concentration and kinds of the compounds are different according to the company, and no process for treating them which can decompose them all at once has yet been determined.
As a substance which requires conversion of chemical substances into harmless ones, porous absorbing material can be mentioned.
The porous absorbing materials represented by activated carbon have been utilized in various fields such as filters for water treatment or deodorizing filters, such as absorbing materials for treating harmful substances.
These absorbing materials exhibit their absorbing function by absorbing substances to be absorbed within many pores possessed by the absorbing material, but their function is decreased when a certain amount of the substances are absorbed.
The used porous absorbing materials are usually collected and recovered. In this case, the harmful substances absorbed are discharged out of the system. For this reason, it is necessary to take some measure to convert the discharged harmful substances, which are discharged out of the system, into harmless ones, requiring a huge cost.
At present, river sands have been utilized as fine aggregates, but the supply amount of the river sands has increasingly decreased. Also, the river sands themselves have been contaminated and, thus, contain various harmful substances.
In such a situation, there is a tendency that burned ash and waste glasses are, recycled for use as aggregates.
Since the burned ash contains harmful substances such as lead, zinc, other heavy metals, and organic chlorine compounds, these substances are treated and the burned ash is utilized as an aggregate in the form of slug. However, in some cases, harmful substances such as organic chlorine still remain in the burned ash even after the treatment and, thus, it is required to remove such hard-to-treat substances as a pretreatment. Also, in other cases, the removal of heavy metals in the burned ash is not sufficient enough. The burned ash can only be used as an aggregate having a large particle size, and cannot be utilized as a fine aggregate.
The process for pulverizing waste glasses into sands is problematic in that there are contents of impurities such as lead, and a high cost is required to carry out pulverization into fine aggregates.
Sands containing salts such as sea sands cannot be utilized as fine aggregates.
In recent years, a process has been developed for increasing the performance for purifying water such as that from sewage by the introduction of microorganisms into concrete. For example, there is a structural material comprising a cement and tourmaline with which Effective Microbe solution and EM material are admixed. However, this structural material utilizes expensive tourmaline, exhibits insufficient water purification performance, and requires the introduction of an EM material such as rice bran. Also, there is a disclosure that aggregates may be used instead of tourmaline. However, according to the examination, the effect of water purification in this case is worse in comparison with the use of tourmaline, and the effect obtained by the introduction of the microorganisms cannot be observed.
For this reason, aggregates which can impart water purification performance to the structural material are required.
As a possible field for making use of microorganisms, garbage treatment can be mentioned.
Wastes are generally classified into household wastes and business wastes, and these wastes are dumped into landfills or are burned in furnaces at present. However, the treatment of the waste becomes serious in terms of making the landfill safe, treating harmful gases discharged from the furnaces, and treating harmful substances contained in the burned ash.
Of these wastes, it is said that approximately 60% of wastes are made up of garbage such as leftovers and residues of cooking. Also, a large amount of garbage is discharged from restaurants, grocers, grocery stores, convenience stores, inns, hotels, hospitals, etc. It is said that approximately 30% of wastes are garbage originating both from households and businesses.
Consequently, an effective treatment of the garbage is a very serious problem in terms of the treatment of the wastes and becomes one of the most important problems in many local self-governing bodies.
As one effective treatment of the garbage, processes for treating garbage based on the functions of the decomposition and fermentation of the garbage by microorganisms can be mentioned.
These process for treating garbage utilizing microorganisms are roughly divided into (1) a process for converting the garbage into compost; and (2) a process of decreasing the volume of the garbage or essentially eliminating garbage by decomposing the garbage into CO 2 and H 2 O.
The process for converting the garbage into compost is carried out in a container for conversion into compost called a composter or a so-called compo-planter, serving the composter and a planter at the same time. The composter is composed of a body of container comprising a vent, a space, a heat-retention layer, and a cap. First, a medium (medium for cultivation) such as chaff is spread over the interior of the body; garbage is then spread over the medium at approximately the same depth as the medium; and a material containing Bacillus, actinomycete, etc. is incorporated thereon. The medium and garbage are alternatively laminated to promote the fermentation of the garbage in order to carry out the conversion of the garbage into compost. After approximately 1 month, the garbage in the composter is fermented to produce compost.
The process for converting garbage into compost utilizing microorganisms can be carried out in the inexpensive installation as described above, but it unduly takes 1 month or more for the conversion of the garbage into compost, and the amount of the garbage which can be utilized in one treatment is restricted. Moreover, the fertilizer resulting in the treatment of the garbage smells bad, and the application of the fertilizer thus obtained sometimes causes the generation of Fusarium.
On the other hand, an apparatus for treating a relatively small amount of garbage utilizing microorganisms has been developed for use in households, restaurants, etc. This apparatus is mainly composed of a sealable container equipped with a vent, a heat-retention layer, an aeration means, a drain and a stirrer, and the bottom of the container is divided by a porous plate. A material for improving the breathability is spread over the porous plate, over which sawdust etc. is spread for the purpose of making a residence for microorganisms and adjusting the water contained in the garbage. Predetermined microorganisms are incorporated into the container, the garbage is thrown in the container, the container is sealed, and the contents are mixed with aeration being carried out by means of a vent such as a pump, whereby the garbage is decomposed into carbon dioxide and water to decrease the volume of the garbage.
According to this apparatus, approximately one kilogram of garbage can be treated daily. However, the ratio of decrease in the actual garbage is as low as from 60 to 80%. Also, the media and microorganisms utilized should be replaced every 3 to 4 months. In this apparatus, sulfurous acid, nitrogen oxides, etc. which should be removed occur in the decomposition of the garbage, and the device for removing them is very expensive.
An apparatus for decreasing a large volume of garbage has also been developed. This apparatus is composed of approximately a 500-600 liter volume sealable container having a stirring means, a vent, a deodorizing means, etc. The container is substantially filled with wooden chips such as cedar chips as a material. Then, approximately 20 kg of the garbage is incorporated into the container, the contents are intermittently mixed while supplying 100 to 300 liters of air per minute to decompose the garbage with the microorganisms contained in the chips.
However, such an apparatus for decreasing a large volume of garbage is very expensive, and sulfurous acid, nitrogen oxides, etc. which should be removed occur in the decomposition of the garbage, similar to the case of the small size apparatus described above.
As described above, the processes for converting garbage into compost leave something to be improved.
Meanwhile, many efforts have been made to convert seawater into freshwater. As processes for converting seawater into freshwater, a multiple flushing process, a multiple effect evaporation, and a reverse osmosis process can be mentioned. The multiple flushing process and the multiple effect evaporation are effective on a very large scale such as construction of a national plant, but the reverse osmosis process, which requires only a small investment in plant and equipment, has been popularized.
As processes for converting seawater into freshwater utilizing reverse osmosis, Japanese Unexamined Patent Publication No. 10-128325 discloses a process for obtaining freshwater having a low concentration of boron by running seawater through two reverse osmosis apparatuses placed in series by means of one pump; Japanese Unexamined Patent Publication No. 10-128325 discloses an apparatus for converting seawater into freshwater composed of a reverse osmosis module, and a storage pump for pumping water produced in a water collecting pipe of the reverse osmosis.
However, these processes for converting seawater into freshwater by the reverse osmosis require a large amount of energy and complicated equipment. Also, in such processes, the amount which can be treated has severely restricted. Furthermore, the reverse osmosis itself is very expensive and the maintenance of the apparatus requires high costs.
Consequently, in addition to these approaches, there is a demand for developing a process for converting seawater into fresh water on the basis of the function of microorganisms.
As described above, microorganisms can be applied to various field in a wide variety of manners. However, in the field expected to benefit from the application of microorganisms, there has not yet been any technique which has been completed, or such a technique said to be completed only has a small effect.
From such viewpoints, as one expected group of microorganisms, a culture containing anaerobic microorganisms and aerobic microorganisms living together with each other filed by the present inventor as Japanese Patent Application No. 9-291467 can be mentioned. In this patent application, a suggestion has been made to convert chemical hazards such as dioxins into harmless substances through the function of the culture. However, the group of the microorganisms contained therein leaves something to be improved in terms of the productivity of cellulase and reducing power. Furthermore, there is a demand to utilize the group of the microorganisms as carried on a carrier.
SUMMARY OF THF INVENTION
Consequently, an object of the present invention is to determine microbiological techniques applicable to these applications and to provide microorganisms and metabolites having good effects in agricultural fields and environmental fields.
Another object of the present invention is to provide a process for applying these microorganisms and metabolites to these agricultural fields and environmental fields.
Still another object of the present invention is to find a novel process which apply these microbiological techniques.
The present invention concerns the following items:
1. A microorganism culture containing (a) aerobic microorganisms, (b) anaerobic microorganisms, (c) at least one Basidiomycetes belonging to Pleurotus coruncopiae, living in symbiosis with each other, and enzymes produced as their metabolites.
2. The microorganism culture as described in the above Item (1), wherein Basidiomycetes is obtained by mating Pleurotus coruncopiae with Pleurotus coruncopiae.
3. The microorganism culture as described in the above Item (1), which further contains photosynthetic bacteria.
4. The microorganism culture as described in the above Item (3), which further contains enzymes for decomposing carbon.
5. A process for producing the microorganism culture as described in the above Item (1), which comprises the following stages:
(1) incorporating a source of aerobic microorganisms and an essence of Basidiomycetes containing at least Pleurotus coruncopiae into a solution obtained by pulverizing proteins mainly comprising animal proteins, adding grain and yeast to the pulverized substances to undergo fermentation, heating the fermented products, pulverizing the heated product, adding a Lactobacillaceae culture or a Bacillus subtilis culture to the pulverized products and fermenting the culture under aerobic conditions, and culturing the microorganisms under aerobic conditions at normal temperature and normal pressure until the solution becomes transparent; and
(2) incorporating a source of anaerobic microorganisms to the above culture and culturing the mixture under anaerobic conditions at normal temperature and normal pressure.
6. A process for producing the microorganism culture as described in the above Item (3), which comprises the following stages:
(1) incorporating a source of aerobic microorganisms and an essence of Basidiomycetes containing at least Pleurotus coruncopiae into a solution obtained by pulverizing proteins mainly comprising animal proteins, adding grain and yeast to the pulverized substances to undergo fermentation, heating the fermented products, pulverizing the heated product, adding a Lactobacillaceae culture or a Bacillus subtilis culture to the pulverized products and fermenting the culture under aerobic conditions, and culturing the microorganisms under aerobic conditions at normal temperature and normal pressure until the solution becomes transparent;
(2) incorporating a source of anaerobic microorganisms to the above culture and culturing the mixture under anaerobic conditions at normal temperature and normal pressure, and
(3) adding photosynthetic bacteria to the culture and further continuing the culturing.
7. A process for producing the microorganism culture as described in the above Item (4), which comprises the following stages:
(1) incorporating a source of aerobic microorganisms and an essence of Basidiomycetes containing at least Pleurotus coruncopiae into a solution obtained by pulverizing proteins mainly comprising animal proteins, adding grain and yeast to the pulverized substances to undergo fermentation, heating the fermented products, pulverizing the heated product, adding a Lactobacillaceae culture or a Bacillus subtilis culture to the pulverized products and fermenting the culture under aerobic conditions, and culturing the microorganisms under aerobic conditions at normal temperature and normal pressure until the solution becomes transparent;
(2) incorporating a source of anaerobic microorganisms to the above culture and culturing the mixture under anaerobic conditions at normal temperature and normal pressure,
(3) adding photosynthetic bacteria to the culture and further continuing the culturing.
(4) adding a carbon source originating from plants to the culture and further continuing the culturing, and
(5) diluting the culture obtained in Stage (4) 2 to 4 times with the culture obtained in Stage (3).
8. A carbonaceous carrier containing microorganisms and enzymes originating from these microorganisms contained in the culture of the above Item (4) in a dissolved carbon.
9. A process for producing the carrier of the above Item (8), which comprises impregnation of finely divided carbon with the culture of the above Item (4) or its diluted solution diluted with water to incorporate the active components of the culture of the above Item (4) and at the same time to dissolve the carbon.
10. A porous absorbing material containing microorganisms and enzymes originating from these microorganisms contained in the culture of the above Item (4).
11. The porous absorbing material of the above Item (10), wherein the porous absorbing material is based on an activated carbon.
12. A process for producing the porous absorbing material of the above Item (11), which comprising impregnation of a porous absorbing material with the culture of the above Item (4) or its diluted solution diluted with water to incorporate the active components of the culture of the above Item (4).
13. The process for producing the porous absorbing material of the above Item (12), wherein the porous absorbing material is based on an activated carbon.
14. The process for producing the porous absorbing material of the above Item (12), wherein said porous absorbing material is a used material, and the material is impregnated with the culture of the above Item (4) or its diluted solution diluted with water for a period sufficient for decomposing the ingredients absorbed into the porous absorbing material to simultaneously carry out the recovery of the used porous absorbing material.
15. A filter containing the porous absorbing material of the above Item (10).
16. A soil improving material obtained by spraying or impregnating in the microbiological culture of any of the above Items (1) to (4) a fibrous substance originating from plants.
17. The soil improving material of the above Item (16), wherein said fibrous substance originating from plants is sawdust of needle leaf trees, pulverized substances of logged trees, rice chaff, buckwheat chaff, construction material having been primarily treated, or a mixture thereof.
18. A process for improving soil which comprises mixing the soil improving material of the above Item (16) or (17) with a fertilizer, and placing the mixture on soil to be treated at a height of from 1 to 100 cm.
19. The process of the above Item (18), wherein said soil to be treated is soil whose crumb structure has been lost.
20. The process of the above Item (18), wherein said soil to be treated is desertified soil or soil containing salts.
21. A process for improving soil which comprises placing a fibrous substance originating from plants mixed with a fertilizer at a height of from 1 to 100 cm, and spraying the culture of any of the above Items (1) to (4) or its diluted solution diluted with water.
22. The process as described in the above Item (21), wherein said soil to be treated is soil whose crumb structure has been lost.
23. The process as described in the above Item (21), wherein said soil to be treated is desertified soil or soil containing salts.
24. A process for optimizing a plant system composed of a container for cultivating a plant, a medium for cultivating a plant, and a plant to be cultivated; which process comprises:
incorporating said plant system into a sealed container, filling the sealed container with the culture of any of the above Items (1) to (4) diluted with water, sealing the sealed container, and leaving the sealed container stand for a period sufficient for killing disease carriers and eggs thereof existing in the system.
25. The process for optimizing a plant system as described in the above Item 24, wherein said plants to be cultivated are somewhat withered, and the revival of the plants is carried out at the same time.
26. A process for reviving a plant attacked by a pathogenic organism, which comprises:
(a) a stage of digging up the plant, and washing the whole of the plant with a solution of the microorganism culture described in any of the above Items (1) to (4) diluted with water,
(b) a stage of spraying a solution of the microorganism culture described in any of the above Items (1) to (4) diluted with water on the soil thus dug, and
(c) a stage for newly planting the plant and applying soil in which a solution of the microorganism culture described in any of the above Items (1) to (4) diluted with water is impregnated.
27. The process for reviving a plant as described in the above Item (26), wherein said plant is injured by stem canker, and which process further comprises a stage of surgically removing the portion infected with the stem canker, applying the slurry of the above Item (8), followed by drying.
28. The process for reviving a plant as described in the above Item (26), wherein said a pathogenic organism causes drop ( Sclerotinia sclerotiorum ), clubroot, mottled spot, brown canker, mildew, and rust.
29. An organic fertilizer obtained by adding feces and urine of livestock to a solution of the microorganism culture described in any of the above Items (1) to (4) diluted with water.
30. The fertilizer as described in the above Item (29), which has sawdust of needle leaf trees further added.
31. The process for improving soil as described in the above Item (29), wherein the fertilizer comprises the fertilizer as described in any of the above Items (18) to (21).
32. A garbage decomposing material obtained by impregnating fibrous substances originating from plants with a solution of the microorganism solution as described in any of the above Items (1) to (4).
33. The garbage decomposing material as described in the above Item (32), wherein said fibrous substances originating from plants contain hard-to-decompose substances.
34. A process for treating garbage which composes: incorporating garbage to be treated into the garbage treating material as described in the above Item (32) or (33), and stirring the mixture to decompose the garbage in an odorless manner.
35. A liquid fertilizer comprising an odorless liquid obtained from the process of the above Item 34.
36. A process for treating solid substances containing harmful substances or salts which comprises: mixing the carrier of the above Item (8) with the solid to be treated, and stirring the mixture, followed by washing with water.
37. The process as described in the above Item (36), wherein said solid substances to be treated are sands containing harmful substances or salts.
38. The process as described in the above Item (36), wherein said solid substances to be treated are burned ash or fly ash containing harmful substances.
39. A fine aggregate comprising the sand treated according the process of the above Item (37).
40. A reduction type construction material obtained from the fine aggregate of the above Item (39).
41. A fine aggregate comprising the burned ash or fly ash treated in the process of the above Item (38).
42. A reduction type construction material obtained from the fine aggregate of the above Item (41).
43. A reduction type construction material comprising the carrier of the above Item (8).
44. A process for removing water bloom which comprises spraying a solution of the microorganism solution as described in any of the above Items (1) to (4) diluted with water onto water bloom caused by eutrophication.
45. A process for treating seston which comprises incorporating the carrier of the above Item (8) into water containing seston to aggregate the seston.
46. A process for treating water containing polluted sediments comprising incorporating the carrier of the above Item (8) into water containing polluted sediments to decompose the polluted sediments.
47. An aggregating agent comprising the carrier of the above Item (8).
48. A process for treating a liquid containing salts which comprises passing water containing salts through a filter containing the absorbing material of the above Item (15) once or more times to remove the salts.
49. A process for treating a liquid containing salts which comprises incorporating the carrier of the above Item (8) into water containing salts, followed by stirring.
50. The process of the above Item (49) or (50), wherein said water contains seawater, and conversion of seawater into freshwater is carried out.
51. A process for treating a liquid containing harmful substances which comprises incorporating the carrier of the above Item (8) into a liquid containing harmful substances.
52. A process for treating a liquid containing harmful substances which comprises incorporating the carrier of the above Item (8) into a liquid containing harmful substances, followed by stirring.
53. A process for treating a liquid containing harmful substances which comprises passing a liquid containing harmful substances through a filter containing the absorbing material of the above Item (15) once or more times to remove the salts.
54. A process for treating a liquid containing harmful substances which comprises:
a) incorporating the carrier of the above Item (8) into a liquid containing harmful substances, and
b) passing the liquid containing harmful substances through the filter of the above Item (15) containing the absorbing material once or more times to remove the salts.
55. The process of the above Item (54), wherein Stage (a) is carried out while stirring.
56. The process described in any of the above Items (51) to (55), wherein said liquid containing harmful substances is an exhaust liquid containing heavy metals, organic halogen compounds or petroleum, an exhaust liquid from plating, an exhaust liquid from semiconductor processing, an exhaust liquid from developing photos, an exhaust liquid containing dyestuffs, exhaust water from sewage, and an exhaust liquid containing the mixtures of harmful substances.
56. An apparatus for treating a liquid comprising:
an inlet for supplying water to be treated,
a filtering portion comprising the filter of the above Item (15) containing at least one absorbing material, and
a receiver which stores the treated water.
57. The apparatus of the above Item (56) which further comprises means for supplying the treated liquid to said filter, which is connected to the receiver, whereby the treated water is supplied to the filter after several treatment to recover the filter.
58. The apparatus of the above Item (56) or (57), which further comprises a water tank having a stirring portion for a pretreatment, and a transportation means for transporting the pretreated water to the filtering portion.
59. A process for treating a gas which comprises: a solution of the microorganism solution as described in any of the above Items (1) to (4) diluted with water to a gas to be treated.
60. A process for treating a gas which comprises the absorbing material of the above Item (15).
61. The process of the above Item (59) or (60), wherein the gas to be treated is selected from among bad smells originating from organic or inorganic compounds, and gases containing organic or inorganic chemical hazards.
62. A deodorizer comprising a solution of the microorganism solution as described in any of the above Items (1) to (4) diluted with water.
63. A liquid agent for decolorization of a liquid comprising a solution of the microorganism solution as described in any of the above Items (1) to (4) diluted with water.
64. A process for removing harmful substances from a construction material which comprises spraying or impregnating a construction material with a solution of the microorganism solution as described in any of the above Items (1) to (4) diluted with water.
65. A mildew-proofing agent comprising a solution of the microorganism solution as described in any of the above Items (1) to (4) diluted with water.
66. An agent for reviving plants comprising a solution of the microorganism solution as described in any of the above Items (1) to (4) diluted with water.
67. A deodorizer comprising the carrier of the above Item (4).
68. A deodorizer comprising the absorbing material of the above Item (10).
69. A filter for treating water comprising the filter of above Item (15) containing the absorbing material.
70. An apparatus for purifying water comprising the filter of the above Item (15) containing the absorbing material.
71. A showerhead comprising the filter for treating water of the above Item (69).
72. A water-purifying agent comprising the carrier of the above Item (8).
73. A water-purifying agent comprising the absorbing material of the above Item (10).
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross sectional view showing one example of an apparatus for treating insects according to one embodiment of the present invention;
FIGS. 2 and 3 are cross sectional views, each showing an apparatus for treating liquid according to one embodiment of the present invention;
FIGS. 4 ( a ) to 4 ( b ) each shows a graph for comparing the absorbing performance of the absorbing material of the present invention with that of the conventional material, wherein FIG. 4 ( a ) is a graph showing the results of absorbing formaldehyde into the absorbing material of the present invention; FIG. 4 ( b ) is a graph showing the results of absorbing formaldehyde into the conventional absorbing material; FIG. 4 ( c ) is a graph showing the results of absorbing ammonia into the absorbing material of the present invention; and FIG. 4 ( d ) is a graph showing the results of absorbing ammonia into the conventional absorbing material.
BEST MODES FOR CARRYING OUT THE INVENTION
The present invention will now be described in detail.
Mixture of Microorganisms and Enzymes (OME)
According to the first aspect of the present invention, there is provided a microorganism culture containing (a) aerobic microorganisms, (b) anaerobic microorganisms, (c) at least one Basidiomycetes belonging to Pleurotus coruncopiae, living in symbiosis with each other, and enzymes produced as their metabolites (hereinafter referred to as “OM”), and a microorganism culture of OM which further comprising a carbon decomposing enzyme by the addition of a carbon source originating from plants to OM (hereinafter referred to as “OME”).
(Organism Active Agent)
In preparation of OME according to the present invention, first a source of aerobic microorganisms and an essence of Basidiomycetes at least containing Pleurotus coruncopiae are cultured in a microorganism active agent under aerobic conditions, i.e., under aeration at normal temperature and at normal pressure for from two to five weeks, preferably from 20 to 30 days. The organism active agent used herein is prepared by (1) pulverizing proteins mainly comprising animal proteins, (2) adding grain and yeast to the pulverized substances to undergo fermentation, (3) heating the fermented products, (4) pulverizing the heated product, (5) adding a Lactobacillaceae culture or a Bacillus subtilis culture to the pulverized products obtained from Stage (4) and fermenting the culture under aerobic conditions as described in my Japanese Unexamined Patent Publication No. 5-244962. Also, such an organism active agent can be obtained from Orient Green Co., Ltd. under the trade name of Vitaly Aminon.
(Aerobic Microorganisms)
In the present invention, a source of aerobic microorganisms and an essence of Basidiomycetes are incorporated into the above-mentioned organic active agent to initiate the culturing. In this case, the term “aerobic microorganisms” intended herein means all aerobic microorganisms existing in soil. Typical examples of aerobic microorganisms include, but are not restricted to, those generally existing in nature such as Bacillus, Pseudomonas, Cytophaga, Cellulpmonas belonging to gram-negative aerobic microorganisms, aerobic spore bacteria, and gliding true bacteria, and the present invention is not restricted thereto as long as they do not inhibit the effects of the present invention. The most popularized source of the aerobic microorganisms include humus obtained by converting leaves of broadleaf trees etc. into humus in nature, and preference is given to the use of humus whose conversion is in progress. With regard to the amount of the source for the aerobic microorganisms incorporated into the organism active agent, humus is generally incorporated in an amount of from 1 to 7% by weight, and preferably from 2 to 6% by weight, based on 1 ton of the organism active agent. If the amount is less than 2% by weight, the culture progresses slowly. Conversely, if the amount exceeds the upper limit, the resulting culture thickens, resulting in bad ventilation of air, and causing spots in the culture.
(Basidiomycetes)
As the Basidinomycetes incorporated together with the aerobic microorganisms, Pleurotus coruncopiae, preferably new mushroom (called Pleurotus N ) described in my Japanese Unexamined Patent Publication No. 5-252842 are used as essential components. Other Basidinomycetes can be incorporated as long as they do not impair the effects and the functions of the present invention. It is usual to incorporate such Basidinomycetes as an essence. The amount of the Basidinomycetes incorporated is freely selected depending upon the situation, like the amount of the aerobic microorganisms, and preferably the essence is incorporated in an amount of 1 to 7 liters, more preferably from 1 to 5 liters, per ton of the organism active agent. The incorporation of such specific Basidinomycetes extremely enhances the productivity of cellulase.
(Aerobic Culturing of Aerobic Microorganisms and Basidinomycetes)
The aerobic microorganisms and the Basidinomycetes are incorporated in the organism active agent under aerobic conditions, i.e., under aeration, at normal temperature and normal pressure, for 2 to 5 weeks, preferably from 20 to 30 days, to carry out their culturing. When the culturing is completed, the culture which has bad smells is deodorized (hereinafter this culture is referred to as “OM mother liquid”). The OM mother liquid is a culture containing the aerobic microorganisms, Basidinomycetes, and their metabolites.
(Anaerobic Microorganisms)
Consequently, anaerobic microorganisms are incorporated in the OM mother liquid thus prepared to continue the culturing. The anaerobic microorganisms incorporated at this time essentially contain bacteria belonging to gram true bacteria and gram positive fermentative bacteria. As a source for such anaerobic bacteria, a sludge from sewage can be mentioned. The amount of the source of the anaerobic bacteria incorporated in the organism active agent is from 1 to 7% by weight, preferably from 2 to 6% by weight, based on one ton of the OM mother liquid. If the amount is less than the above range, the culturing proceeds too slowly. Conversely, if it exceeds the above range, the consistency, for example, caused by the sludge substances, is increased, which will become a factor for preventing a progress in the next stage. After the source for the anaerobic bacteria is incorporated in the OM mother liquid, the culturing is continued under anaerobic conditions, i.e., left standing without aeration, usually at normal temperature and at normal pressure for two to five weeks, preferably from 20 to 30 days. When the culturing is continued as described above, the odor originating from the source disappears to obtain odorless OM liquid. In addition to the above components, the microorganisms and their metabolites are contained in this OM liquid.
(Photosynthetic Bacteria: Option)
Optionally, at the same time with the culturing of the anaerobic bacteria, during the culturing or after culturing, photosynthetic bacteria may be added to continue the culturing under dark anaerobic conditions. Examples of the photosynthetic bacteria include cyanobacteria, green sulfur bacteria, green non-sulfur bacteria, and purple sulfur bacteria, the culturing together with these photosynthetic bacteria increases the reducing power. The amount of these optional photosynthetic bacteria is from 1 to 10 liters, preferably from 2 to 5 liters, per one ton of the OM liquid.
To the OM liquid thus obtained, carbonaceous substances originating from plants are added and the culturing is continued under anaerobic conditions for approximately 3 to 10 weeks to produce OME mother liquid in which carbon decomposing catalyst is produced.
By diluting the OME mother liquid thus obtained with the OM liquid in an amount approximately 2 to 4 times the OME mother liquid, OME culture (hereinafter referred to as “OME”) is obtained.
OME may also be diluted with water preferably from 300 to 5000 times, and more preferably from 500 to 3000 times its own volume (hereinafter referred to as “OME diluent”).
Also, OME can be absorbed in a carrier as described herein below.
(DCP: OME-containing Powdery Carrier)
According to the second aspect of the present invention, an OME components-containing carrier (hereinafter referred to as “DCP”)obtained by treating finely pulverized carbonaceous substances with OME or OME diluent to dissolve the carbon is provided.
As one characteristic of OME, OME contains an enzyme which dissolves carbon as described above. Specifically, when finely pulverized carbonaceous substances are treated with OME (an undiluted or diluted solution diluted with an aqueous medium), the carbonaceous substances are dissolved by the action of the carbon decomposing catalyst contained in the OM active components, to absorb OME active components (enzymes and microorganisms) in the dissolved carbonaceous substances, to thereby obtain a carrier containing OME active components, which carries out special functions.
The finely pulverized carbonaceous substances used in the production of DCP mean fine powders of graphite carbon and amorphous carbon. Generally, they are obtained by burning a carbon source at a low temperature, preferably at a temperature of not more than approximately 400 C. The origin is not specifically restricted as long as the objects of the present invention can be attained.
As the carbon source for DCP, cellulose carbons such as from woods, pulverized products thereof, wood shavings, chips, plants, plant carbons originating from plants containing hydrocarbon, protein type carbons originating from plants and animals containing proteins, and petroleum carbons from petroleum can be mentioned. They can be used alone or as a mixture of two or more thereof. Preference is given to use carbons originating from various sources, which are discharged as garbage.
When the carbonaceous substances and OME (or diluent thereof) are mixed with stirring, the proportion of the carbonaceous substances to OME is not restricted as long as it does not impair the objects and effects of the present invention. Also, with regard to the method of mixing them, it is possible to introduce the microorganism culture into the carbonaceous substances or to introduce the carbonaceous substances into the microorganism culture. Preference is given to the mixing of the finely pulverized carbonaceous substances with an aqueous solution containing the microorganisms with stirring.
When the finely pulverized carbonaceous substances are mixed with an aqueous solution containing the microorganisms with stirring, the carbonaceous substances gradually decompose. When the stirring is continued for 1 to 4 weeks, the carbonaceous substances are in the form of a cake or sludge in which the carbonaceous substances come to be in a syrupy state, in which case the load of the stirring is moderated.
The cake carrier or the sludge carrier can be used as it is, and it is also possible to utilize it as a sludge carrier having a desired water content by exposing the wet carrier to the sun or spontaneously drying the wet carrier. Also, the OME carrier can be used as a fine powder.
(RCS: Porous Absorbing Material)
The third aspect of the present invention relates to a porous absorbing material containing active components of OME in the pores thereof (hereinafter referred to as “RCS”) by impregnating a porous absorbing material with OME or OME diluent.
Porous absorbing materials in RCS may not be specifically restricted as long as the active components of OME can be introduced into the pores, and examples include active charcoal, SOG sands, porous minerals such as tourmaline, various ceramics, and preferably active charcoal. The shape of the porous absorbing material used in the present invention is also not specifically restricted, and the porous absorbing material may be in a granular form, a fibrous form, or a shaped form. The granular form is particularly preferable.
The porosity of the porous absorbing material used in the present invention is also not specifically restricted as long as it is possible to inhabit the microorganisms of OME in the pores as the habitat and absorb the enzymes of OME to introduce active components into the pores.
When the used porous absorbing material is impregnated with OME or OME diluent, the recovery of the used absorbing material can be carried out at the same time.
Although the conditions for impregnation of the porous absorbing material with OME or OME diluent are not specifically restricted, the porous absorbing material having been washed with water may be impregnated usually for at least 8 hours, preferably for at least 24 hours, at normal temperature and normal pressure, with or without aeration. In the case of utilizing the used porous absorbing material, it is preferably impregnated for from 24 to 72 hours. When the activated carbon is utilized as the porous absorbing material, impregnation for a period exceeding 72 hours is not preferable, because the carbon is dissolved.
Characteristics of OM/OME/DCP/RCS
1. OM cultured in the present invention contains OM active components, i.e., aerobic bacteria, anaerobic bacteria, specific Basidiomycetes, photosynthetic bacteria, as well as enzymes which are metabolites thereof.
Surprisingly, aerobic bacteria can live in symbiosis with anaerobic bacteria in our culture, which is impossible in the prior art. What is more, OM containing such bacteria and enzymes has the following unique characteristics through the synergism thereof. In addition to the characteristics of OM, OME has the feature of decomposing carbon. It is assumed that OME contains carbon-decomposing enzymes. For this reason, OME can be used as the unique carrier (DCP) and the unique absorbing material (RCS).
2. Due to the actions of enzymes and bacteria, OM, OME, and OME-alpha selectively cause the following reactions with target substances.
I. Hydrolysis
RCO—NHR′+H 2 O→RCOOH+R′NH 3 a.
RCO—OR′+H 2 O→RCOOH+4R′OH b.
RCO—SR′+H 2 O→RCOOH+4R′SH c.
R—CH—OR′+H 2 O→RH+HO—CH—OR′ d.
(where R and R′ are independently a hydrocarbon group, which may be substituted)
II. Cleavage
RCOOH→RH+CO 2 a.
HOCRH—CR′H—OH→RCH 2 OH+R′CHO b.
(where R and R′ are independently a hydrocarbon group, which may be substituted)
III. Oxidation/Reduction
AH 2 +B→A+BH 2 a.
AH 2 +O 2 →A+H 2 O 2 b.
IV. Dehydrogenation
CRR′H—CR″H—OH→RR′C═CR″H+H 2 O a.
CRR′H—CR″H—NH 2 →RR′C═CR″H+NH 2 b.
(where R, R′ and R″ are independently a hydrocarbon group, which may be substituted)
V. Dehydrohaloganation
RCX—CR′H→RC═CR′+HX a.
(where R is a hydrocarbon group which may be substituted, and X is a halogen)
VI. Substitution
RXCH 2 +H 2 O→RCH 2 OH+HX a.
RXCH 2 +HS − →RCH 2 SH+X − b.
(where R is a hydrocarbon group which may be substituted, and X is a halogen)
Eliminating phenolic OH and halogen bonded to aromatic ring:
4. Decomposition of Hard-to-Decompose Substances
Sawdust and bark, etc. of needle-leaf trees contain phenols, tannin, essential oils, and other substances which inhibit the growth of plants. Phenolic acids, non-phenolic acids, and high fatty acids in green sawdust inhibit the growth of seed roots and side roots. Particularly, the ligneous substances of ligneous sawdust have an extremely high C/N ratio of from 100 to 1,500, and they are hardly decomposed due to the tight bond between cellulose and lignin. Such vegetable residue can be gradually decomposed by means of continuous co-metabolism of gliding genuine bacteria, myxo cytes, acthinomycetes, filamentous fungi, and the like in OM, OME, and OME-alpha. OM, OME, and OME-alpha serve as co-substrate substances for symbiosis biological active substances.
5. Removal of Heavy Metals
OME has functions for removing heavy metals such as zinc, lead, tin, nickel, chromium, copper, cobalt, manganese, mercury, cadmium, and dross in semiconductor liquids. Although the mechanism for removing heavy metals by OME is unclear, such functions have been found on the basis of experiments of my treatments of exhaust liquids from plating and semiconductor production.
6. Decomposition of Organic Substances (Conversion of Harmful Organic Substances into Harmless Substances, Decoloration and Deodorization)
Due to the function of decomposing halogens possessed by OME, organic halogen compounds, e.g., halogenated aromatic compounds such as dioxins, polychlorobiphenyls, and chlorobenzene; and halogenated aliphatic compounds such as tetrachloroethylene, trichloroethylene, dichloromethane, carbon tetrachloride, 1,2-dichloroethylene, 1,1-dichloroethylene, cis-1,2-dichloroethylene, 1,1,1-trichloroethane, 1,1,2-trichloroethane, and 1,3-dichloropropene can be decomposed. Also, dyestuffs such as azo dyestuffs, as well as odorous substances such as methylmercaptan, captans, indoles, and statoles can be decomposed.
7. Decomposition of Inorganic Substances
Reduction of Nitrogen
Anaerobic or facultative anaerobic chemical synthesis-dependent nutrition bacteria (chemoheterotrophs) contained in OM and OME have either or both functions of anaerobic breath and fermentation. The anaerobic breath has substantially the same biochemical route as that of aerobic metabolism (aerobic breath), and the final electron-receptor of the electron-transmitting chain is nitrate (NO 3− ), sulfate (SO 4 3− ), fumaric acid or trimethylamine oxide instead of oxygen. In the case of NO 3− or SO 4 3− , the reduced products also act as the final electron-receptors.
In reducing NO 3− , NO 3− is reduced into NO 2− through denitrifying bacteria, and further into N 2 O and finally converted into N 2 gas as the final product. Typical bacteria having the denitrifying function contained in OME include Rohodobacter, Cyanobacteria, Cytophaga, etc.
Decomposition of Ammonia
Ammonia is decomposed in the presence of OME according to the following reactions:
2NH 3 +H 2 O→(NH 4 ) 2 CO 3
2(NH 4 OH)+H 2 O+CO 2 →(NH 4 ) 2 CO 3 +2H 2 O
Decomposition of Hydrogen Sulfide
Hydrogen sulfide is reacted with oxygen under an aerobic condition to become water and sulfur which are harmless, and the sulfur is further oxidized into sulfur ions.
2H 2 S+O 2 →2H 2 O+2S
Decomposition of Methyl Mercaptan (CH 3 SH)
Methyl mercaptan becomes methyl alcohol and sulfur via a two-stage oxidation, and further becomes carbon dioxide and water.
2CH 3 SH+O 2 →2CH 3 OH+2S
2CH 3 OH+O 2 →2CO 2 +H 2 O
8. Desalting
As a result of our repeated experiments, OME has been confirmed to substantially decompose sodium chloride (see Example below).
9. Removal of Water Bloom
When OME is sprayed onto algae or water bloom generated due to enrichment, water bloom can instantly be decomposed and removed.
10. Prevention of Diseases in Plants
When OME is applied to a plant which has been affected with stem canker, clubroot, ring spot, target spot, brown canker, powdery mildew, rust, or any other diseases-causing germs, particularly to the root of the plant and rhizosphere of the plant to wash the affected portion, this changes the state of the plant into reduced conditions to stop the growth of the disease causing germs. In addition, due to the actions of the gliding Eubacteria and of Basidiomycetes contained in OME, these germs undergo hydrolysis, and are removed thereby.
11. Aggregation of Seston
DCP has a function of aggregating seston regardless of the kinds of seston.
12. Decomposition of Polluted Sediment and Sludge
DCP has a function of decomposing the polluted sediments and sludge deposited on the bottom of the water. Although the reaction mechanisms for decomposing the polluted sediments and sludge are not clear, this function has been repeatedly confirmed by actual applications. To be specific, the polluted sediments and sludge deposited on the bottom of the water are decomposed about 2 weeks to 1 month after the application of DCP.
13. Applicability in All pH Ranges and Neutralization
OME functions over all pH ranges. Also, OME has a function of changing the pH to neutral (see Example below). According to my experiments, from very strong acidic condition in the case of treating exhaust water from the production of pickled plum to strong alkaline conditions having pH level over 14, such as treatment of NaOH, OME exhibits its functions and turns the pH level toward neutral.
14. Decrease in BOD/COD
OME can decrease BOD/COD.
15. Harmlessness
According to acute toxic testing utilizing mice, OME has been proven to be harmless (see Example 1 below)
Application of OME/DCP/RCS
OME, DCP, and DCP having the unique characteristics as described above can be applied as follows:
A: Application to Agricultural Fields
OME, OME enzymes, OME diluent, DCP and RCS can be applied to various fields among the agricultural fields. Typical applications are summarized in the following Table 1.
TABLE 1
Application of OME/DCP/RCS (1): Application to Agricultural Fields
Techniques to be
applied
Application
Contents
1
Soil Conversion
OME
Sawdust of needle leaf trees, thinned out
material, Activation of
1) Physical
trees, fallen trees, buckwheat chaff, and
Crumb structure,
pulverization, and
primarily treated exhaust material from
Fertilization of Exhaust
then
construction are utilized as soil base
Soil, Desert Seashore
decomposition of
material. The soil base material is spread
soil, etc.
Cellulose and
over exhaust soil, desert, seashore, etc, on
Lignin by OME
which OME is sprayed, and a small
amount of chicken droppings is added.
2
Prevention from
OME
Treatment of a plant system with OME
disease in plants
diluent
3
Prevention of
OME
Treatment of a plant system with OME
microorganisms attack
diluent
against plants/revival
from damping off
4
Composting feces and
OME/DCP
OME diluent and/or DCP is (are) added
urine of livestock,
to feces and urine originating from
including pigs, and
livestock.
poultry
5
Provision of soil base
OM/OME
Sawdust, an exhaust medium from the
material without
cultivation of mushrooms made of
agricultural chemicals
needle leaf trees, garbage, or weeds are
or chemical fertilizers
hydrolyzed by OME, and the
decomposed liquid is used as a liquid
fertilizer.
(A-1: OME Soil Base Material)
The term “soil base material” used in this embodiment means a cellulose substance that can be applied to a soil to revive the crumb structure of the soil and whose cellulose is decomposed by OME or OME diluent to become soil. Examples of such cellulose substances include sawdust, dried leaves, bark, husks (e.g., chaff, buckwheat chaff), cut straw, primarily treated exhaust wood from construction, fallen wood, and the like, and they can be used singly or as a mixture of two or more thereof. In terms of ready availability and inexpensive cost, sawdust, particularly sawdust of needle leaf trees, which has been difficult to decompose, is preferable. In the case of utilizing relatively large materials such as exhaust wood from construction and fallen wood, they can be used after pulverization into appropriate pieces.
In this embodiment, the soil base material is applied to the soil to be treated, the soil applicable in this embodiment including normal soils, soils exhausted by the application of agricultural chemicals, dormant soil in crop rotation, acidified soil due to acidic rain etc., desertified soils, sandy soils around rivers, seashore deserts and beaches containing salts.
The amount of the soil base material to be spread depends upon the types of soils to be treated, climates, plants to be cultivated, and generally a depth of from 1 cm to 100 cm, preferably from 2 cm to 50 cm, is used.
Subsequently, OME, preferably OME whose productivity of cellulase is enhanced, is sprayed onto the soil where the soil base material has been spread over.
According to my experiments, even if the conventional culture composed of anaerobic bacteria and aerobic bacteria living together with each other and having an ability to decompose cellulose is utilized, the effect of the present invention cannot be obtained. In contrast, although the difference cannot be recognized, it comes as a surprise that the culture utilizing the specific Basidiomvcotina at the same time can obtain the objective effect for the first time.
Although OME can be utilized as an undiluted solution, it is usually diluted with water by 500 to 2,000 times, preferably approximately 1,000 times. In the present invention, OME diluent may be sprayed on the dried soil until it is in a perfectly wet state.
When the soil base material of the present invention is applied to the soil to be treated and when OME, preferably OME whose cellulase productivity has been enhanced, is sprayed on the material, and the soil is left standing for at least several days, preferably at least one month, more preferably at least two months, the soil is improved to be able to cultivate plants. In the case where improvement in the soil proceeds slowly, additional OME may be sprayed thereon. The spraying may be repeated once to three times as occasion demands. In this case, by mixing sewage sludge or feces and urine of livestock with the soil base material, and turning the soil upside-down once to three times per month, a very good organic soil can be obtained.
These soil base materials have a first feature of being able to perfectly decompose harmful substances, for example contained in fibrous materials or garbage to be treated. For example, when OME diluent is sprayed onto fallen leaves of fruits and straw which have been sprayed with any agricultural chemicals, and fibrous material from plants which have been cultivated utilizing feces and urine of livestock having been bred with the injection of antibiotics etc as fertilizer, the harmful substances can be converted into harmless ones. The second feature of this embodiment resides in that in addition to the usual soil, OME diluent may be applied to soil exhausted due to the application of agricultural chemicals, dormant soil in crop rotation, acidified soil due to acidic rain etc., desertified soils, sandy soils around rivers, and seashore deserts or beaches containing salts to convert these soils into good soils capable of cultivating crops in a good manner.
By the use of the soil base material, the soil is converted into a reduced type soil, which can produce crops and fruits, etc., while preventing insects and disease causing germs.
It has been particularly surprising that various crops can be cultivated even on sandy soil containing salts, i.e., seashores and beaches.
Whereas OME diluent is sprayed on cellulose substances originating from plants as the soil base material previously spread over the soil in one embodiment, the cellulose substances may be previously admixed with OME to be ready for use in another embodiment.
A-2 Suppression of Insects and Disease Causing Germs
A process for optimizing a plant system composed of a container for cultivating plants (planter), a solid medium for cultivating plants, and (a) plant(s) is provided. Specifically, the system is incorporated into a sealable container, which is then filled with OME or OME diluent, and the container is sealed. When the system is held in the sealable container for a period sufficient for killing the insects and eggs thereof existing in the medium or on the plant(s), the insects and their eggs can be suppressed.
It is also possible that OME treats non-healthy plants, i.e., withering plants. In the preferred embodiment, the sealable container is transparent, and the plants in the sealable container are held while being exposed to the sunshine.
Similarly, OME can also treat a solid medium for plants or mushrooms. Specifically, the medium is impregnated in OME or OME diluent for a period sufficient for killing insects and their eggs contained in the medium.
Suppression of insects causing damage to plants by using OME or OME diluent will now be described by referring to the drawing.
FIG. 1 is a cross-sectional view illustrating an inventive process for optimizing a plant system composed of a container for cultivating plants, a medium for cultivating plants, and a plant to be cultivated.
As shown in FIG. 1, in the suppression of insects according to this embodiment, a plant system S composed of a container 1 for cultivating plants (pot 1 ), a medium 2 for cultivating plants, and a potted plant 3 is incorporated in a sealable container 4 . The plant system S applicable in the present invention is not specifically restricted, and all potted plants 3 which are cultivated in the medium 2 contained in the pot 1 are applicable. Typical examples of plants applicable to the present invention include, but are not restricted to, trees such as pine and plum; various annual and perennial plants; various herbs, edible plants such as potatoes, tomatoes, parsley, and eggplants. The medium for cultivating plants include, for example, black soil, humus obtained by decaying fallen leaves, and the like. Usually, an optimal medium is selected corresponding to the plant 3 to be cultivated. Various pots 1 can be used for cultivating the plant 3 in the present invention, and examples include flowerpots, planters made of ceramics or wood, etc.
Such a plant system S is incorporated into the sealable container in the present invention. The material and shape of the sealable container are not specifically restricted as long as the plant system can be perfectly inserted and then sealed, and no liquid leaks out after filling with the culture or the diluent. A plastic-made container or a bag can be utilized. From the viewpoint of being capable of having exposure to sunshine after being filled with the culture or its diluent, and to observe the situations of the plant system, at least part of, preferably the whole of, the sealable container is transparent. One plant system S is inserted in the container, but if there is room, two or more systems S may also be inserted.
In this embodiment, the sealable container 4 is filled with OME or OME diluent 5 .
OME (diluent) 5 possesses the capability to kill the insects and eggs thereof causing damage to plants, to decompose chemical substances such as agricultural chemicals, and to improve the medium such as soil. If the plant system S is impregnated in usual water or the culture described in Japanese Examined Patent Publication No. 4-42355, the root of the plant is rotted, but in the case of using OME 5 , surprisingly no root is found to be rotted.
After the container 4 containing the plant system S is filled with OME (diluent) 5 as described above, the container is sealed and left standing for a prescribed period. The treatment time is a period sufficient for killing the insects and their eggs contained in the medium and depends upon type of the plant, the type of the medium, and the conditions for generating the insects causing damage to plants. Usually, it is held for from several minutes to several hours, e.g., from 2 minutes to 10 hours. By the impregnation of the plant system S in OME (diluent) 5 as described above, the insects and their eggs are killed and, at the same time, the medium is activated.
The operation may be carried out once, but two or more operations can also be carried out at several day intervals. In the case where withering of the plant 3 proceeds, the plant can be activated and revived by this treatment. The solid medium 2 can be repeatedly utilized after the lifetime of the plant is ended by the treatment described above.
In this embodiment, in addition to the plant system, the medium itself, such as the medium for cultivating plants or mushrooms, is treated with OME to carry out the suppression of the insects. Since how to treat the medium is the same as how to treat the plant system except for there being no requirement of the sealable container and a much longer time being required to carry out the treatment in order to perfectly activate the medium due to there being no plant, repeated description is omitted. In the case of the medium for cultivating mushrooms, ticks and other harmful insects spread over the medium can be removed and the treated medium can be repeatedly used.
The treatment described above can kill the insects and their eggs contained in the medium, to suppress their breeding and, at the same time, continue the suppression effect over a prolong period of time. Also, by this treatment, the solid medium can be repeatedly used.
A-3 Suppression of Pathogenic Organisms in Plant System
Similarly, portions of roots of the plant and the soil can be washed with OME to revive a plant attacked by various pathogenic microorganisms such as root rot and stem canker, sometimes even in the situation where rotting is in progress.
In this embodiment, a plant attacked by photogenic microorganisms such as stem canker, root nodule, root rot, brown canker, powdery mildew, and rust can be revived, particularly by spraying OM or OME to the root atmosphere of the plant, and washing the root atmosphere with OM or OME to convert the root atmosphere, which has become acidic and in a hard state, into a soft and reduced state. This makes it possible to prevent the spread of the photogenic microorganisms. The photogenic microorganisms are killed due to the attack of the Basidoimycetes, which is one of the active components of OME, and then hydrolyzed by the hydrolytic enzyme contained in OME.
Specifically, the whole of the plant infected with these photogenic microorganisms is impregnated in OME diluent. This revives the plant.
In the case of the plant attacked by stem canker, the infected portions are shaved off, DCP slurry is preferably applied to the shaved portions, dried to cover the shaved portions with dried DCP.
A-4 Composting of Feces and Urine Originating from Livestock and Poultry
When OME diluent or DCP is added to the feces and urine of livestock, these feces and urine are deodorized and converted into excellent compost. Ideal compost can be obtained by mixing and stirring the resulting compost with the sawdust of needle leaf trees.
B. Application to Environmental Fields (Including Conversion of Seawater into Freshwater)
In addition to the applications to the agricultural fields, OME, OME diluent, DCP and RCS are applicable to various applications in the environmental fields.
Examples of Applications to Environments based on OME active components are listed in the following Table 2.
TABLE 2
Application (2) of OME/DCP/RCS
Application to Environmental Field
(Application to Solids)
Application
Applica-
Technique
tion
Contents
1
Production and
OME
Similar to the production of RCS
recovery of porous
Immersion of Absorbing Material in OME
absorbing materials
2
Garbage treatment
OME
Garbage decomposing material produced by adding
a cellulose substance similar to that of the soil base
material to OME
3
Treatment of sands,
DCP
Addition of DCP; and washing with water, etc. to
particularly salty
remove salts and harmful substances from salty
sands
sands, etc.
4
Treatment of burned
DCP
Addition of DCP and washing with water, etc.
ash and fly Ash
B-1) Production and Recovery of Porous Absorbing Material
With regard to the production of the recovery of porous absorbing material, the details are omitted because the description has been made in the column of RCS, including the recovery of used absorbing material.
B-2) Treatment of Garbage
In this embodiment, a garbage treating material (garbage decomposing material) produced on the basis of OME is used to treat garbage.
(Cellulose Substances Originating from Plants)
The garbage treating material according to the present invention is based on the cellulose substances originating from plants. Examples of the cellulose substances originating from plants are those described in the soil base material described in Column A-1 above and an exhaust medium for cultivating mushrooms. It is preferable to add hard-to-decompose substances such as chaff to the cellulose substances, preferably in a proportion of approximately 1 to 0.3-1, in order to obtain good ventilation.
When OME or OME diluent is applied to the cellulose substances originating from the plants described above, aerobic bacteria and anaerobic bacteria live in symbiosis with each other in the cellulose substances as their habitant. In the present invention, such a system is referred to as the “garbage treating material (garbage decomposing material).”
(Process for Treating Garbage)
When the garbage treating material thus produced is allowed to come in contact with garbage, hydraulic enzymes and microorganisms contained in OME described above decompose and ferment the garbage and, at the same time, bad smells contained in the garbage are deodorized with perfectly decomposed sulfur oxides and nitrogen oxides which are sources of bad smells.
In the process for treating the garbage according to this embodiment, garbage can merely be incorporated in a place on which the garbage treating material is placed and then stirred to treat the garbage in an odorless state. Conversely, it is also possible to further place the cellulose substances originating from the plants on the garbage, and to further spray OME liquid onto the cellulose substances. Alternatively, it is possible to directly place the garbage treating material according to this embodiment on the garbage. Particularly, if the cellulose substances are placed on the garbage and then OME liquid is sprayed thereon or the garbage treating material of the present invention is directly placed on the garbage, bad smells are preferably removed in the treatment of the garbage.
Also, it is preferable to intermittently stir the mixture of the material and the garbage twice or three times per day, each time for a period of from 5 to 10 minutes. This treatment can be carried out in an open system or in a sealed container, and the selection may be desirably made. Of course, it is also possible to use the garbage treating material of this embodiment instead of the existing material for the composter or compo-planter. Also, it is preferable that the lower portion of the container is divided by a porous plate, and an outlet for discharging the decomposed liquid is provided on the container. Greater preference is given to the use of a container equipped with means for stirring.
Consequently, the process for treating the garbage according to this embodiment may be carried out in the existing composter or compo-planter. For example, it is also possible that the garbage treating material according to the present invention is applied to a landfill to treat the garbage in situ. This treatment makes it possible to treat the garbage without generating any bad smell.
Depending upon the components in the garbage, when the garbage incorporated in the garbage treating material of this embodiment is left standing for several hours, the decomposition of the garbage is started immediately after the incorporation, and the garbage is completely turned into liquid approximately 24-36 hours after the incorporation.
According this embodiment, the following outstanding effects can be obtained as described above.
1) The garbage treating material according to this embodiment can be produced in a simple manner where the cellulose substances originating from plants are impregnated in OME or OME diluent.
2) The garbage treating material can also be utilized as the garbage decomposing material for the existing compositer, compo-planter, and garbage decomposer as is.
3) When the resulting material for treating the garbage is allowed to come in contact with the garbage, the garbage can be decomposed into a liquid without generation of any bad smell, making it possible to treat the garbage in an inexpensive and simple manner.
4) The resulting liquid can be utilized as a good, odorless liquid fertilizer.
B-3 and 4 Solid Treatment With DCP
DCP can be mixed with and stirred together with sands containing at least one component to be removed, selected from the group consisting of salts, organic harmful substances and heavy metals, to substantially remove the component(s) to be removed.
The term “sands containing at least one component to be removed, selected from the group consisting of salts, organic harmful substances and heavy metals” used in this embodiment means sands containing salts such as sea sands and/or sands containing heavy metals such as zinc, cadmium, and nickel; and/or harmful substances such as aromatic halogen compounds (e.g., PCBs and dioxins); aliphatic halogen compounds (e.g., dichloromethane, trichloromethane, carbon tetrachloride), and azo compounds. The term “substantially remove” means the removal at a level not higher than the level decided in administrative guidance according to a local self-governing body.
This treatment allows for the substantial removal of the salts and harmful substances from the sands containing them. When the resulting mixture comprising the treated sands and DCP is partially or entirely utilized as fine aggregations for construction material such as concrete, a reduced type construction body excelling in purification of water can be obtained.
DCP is mixed and stirred with burned ash to substantially remove the harmful substances contained in the burned ash.
The treatment as described above can substantially remove heavy metals such as lead and zinc and harmful substances such as organic halogen compounds contained in the burned ash, and the treated burned ash can be reused as fine aggregate for construction materials such as concrete. In this case, a resulting construction material of a reduced type and excelling in purification of water can be obtained.
DCP is mixed with and stirred together with exhaust glass containing at least one substance to be removed selected from the group consisting of salts, organic harmful substances, and heavy metals or exhaust glass discharged in the process of the glass production to substantially remove the substances to be removed.
When exhaust glasses, such as soda-lime glass or a by-product cake mainly composed of calcium carbonate discharged from a plant for producing calcined soda in the glass production, is treated with DCP, as described above, sodium chloride, lead, soda ash, and the like can be removed from the glass, etc., which can then be used as a rough aggregate such as slug or a fine aggregate through the pulverization.
B-3 Sands Containing Salts
In this embodiment, DCP can be utilized to carry out the treatment of and mixing with sands containing salts, burned ash, river sands, etc. to be used as a fine aggregation mixture comprising DCP and sands, etc.
If the sand containing salts is treated, at least 1 kg, preferably from 1 to 4 kg, of DCP is mixed per ton of the sands. When the sands containing salts are mixed and stirred with DCP, salts such as sodium chloride are removed from the sands. If the amount of DCP is less than the above range, the removal of salts becomes insufficient. The reason why no upper limit of DCP is set is that the amount of DCP can freely be selected depending upon the requirements of the application, such as in the case of the application to fine aggregation, e.g., for the production of a strongly reduced type of construction material, and in the case of requiring only removal of salts. Generally, it is enough to utilize 2 to 5 kg of DCP per ton of sands. The mixing and stirring may be carried out in a dry state, but it is preferable to add water to the sands to be in the state of slurry. For example, a usual kneader or mixer, or an apparatus marketed under the trade name of MD Cyclone from Daiki Rubber Co. Ltd. may be used to mix and stir the slurry of DCP and sands which are to have substances removed.
Sands Containing Harmful Substances
In this embodiment, it is possible to treat river or sea sands containing harmful substances with DCP. The harmful substances which can be removed in this embodiment include heavy metals such as zinc, lead, chromium, and cadmium; and chemical hazards such as organic halogen compounds (e.g., aromatic halogen compounds such as PCBs, dioxins, and chlorophenols; mono- or poly-halogenated aliphatic compounds), and the like. In this case, the amount of DCP is suitably selected depending upon the kinds and concentration of the harmful substances, and usually the amount is similar to that in the case of the treatment of the sands containing salts.
It is also the subject matter of this embodiment to treat river sands containing a small amount of salts or harmful substances.
Specifically, this embodiment encompasses all the mixtures of sands with DCP, which can be utilized as fine aggregations for producing an excellent reduced type construction material, described later on.
B-4 Burned Ash
In this embodiment, DCP can also be utilized to treat burned ashes similar to the sands containing salts or harmful substances. The term “burned ash” used herein means all burned ash including fly ash. This burned ash sometimes contain metals, such as lead, zinc chromium, mercury, or some other heavy metals, or chemical hazards, such as dioxins and PCBs. The amount of DCP used in the treatment of the burned ash depends upon the types and amounts of the harmful substances contained. However, DCP is generally used in an amount of from approximately 1 to 5 kg per ton of the burned ash. The treatment makes it possible to absorb the metals such as zinc, lead, chromium or some other heavy metals into a stable state and to substantially remove organic halogen compounds such as dioxins and PCB.
In this embodiment, the treated mixture of burned ashes with DCP can be used as a fine aggregation, and also this treatment can be applied as a pretreatment of the usual treatment of the burned ash, such as reclaiming after the removal of the metals by DCP.
Since the pH level of the mixture of the burned ash with DCP is automatically adjusted by the function of the microorganisms and the enzymes contained in DCP, the mixture can be used as a fine aggregation and as reclaiming materials in a safety manner. The treatment of the burned ash may be similar to that of sands. The treatment of the burned ash with DCP may be applied to the treatment of sands. In the case where a higher safety level is required for the construction, the used RCS is again impregnated in the OME liquid for mixing.
(Characteristics of DCP Mixture)
The mixture of DCP with sands or burned ash described above has excellent properties similar to OME, DCP, RCS, etc.
Consequently, when a construction produced from the DCP mixture having the function of the neutralization of pH, and of reducing BOD/COD can be used in a usual drainage ditch or irrigation canal, etc., it can be very useful in terms of purification of sewage. A construction having similar effects can be obtained if DCP is directly added to freshly mixed concrete.
While the embodiments where the sands or burned ash containing salts and harmful substances are treated with DCP and the resulting mixture is mainly used as a fine aggregation have been described, it is also within the scope of the present invention, for example, when part or all of the sands or burned ash containing salts and harmful substances are used as fine aggregations and DCP and usual raw materials for producing concrete are mixed and treated, for example, in a kneader or a concrete mixer for the removal of the harmful substances to be carried out at the same time as the production of freshly mixed concrete. According to this process, there is a merit in having no need for drying the slurrized sands or burned ash.
According to the first embodiment of the present invention as described above, the salts and harmful substances can be substantially removed from the sands or burned ash in a simple manner where DCP is added to and mixed with the sands or burned ash, and the resulting mixture can be utilized as a suitable fine aggregation.
According to another embodiment of the present invention, the harmful substances contained in the burned ash can be removed only in a simple manner where DCP is added to and mixed with the burned ash. The treated burned ash can easily be secondarily treated in the conventional manner or can be directly utilized as a fine aggregation.
The resulting DCP mixture can be utilized as a fine aggregate for producing a reduced type construction material excelling in water purification.
In this embodiment, it is also possible to remove salts and harmful substances and, at the same time to produce freshly mixed concrete for a reduced type construction material. This makes it possible to directly produce without any drying stage at the same time as the treatment.
40. A reduced type construction material obtained from the fine aggregates of claim 39.
2) Application to Liquids
Application to Environmental Fields (Including Conversion of Seawater into Freshwater)
Examples of applications of the present invention to liquids based on the functions of OME active components are listed in the following
TABLE 3
Applications (3) of OME/DCP/RCS: Applied to Environmental Fields
(Applied to Liquids)
Applicable
Applica-
Technologics
tion
Method
Contents
6
Removal of
OME
a
Spraying of OME
waterbBloom
7
Aggregation of
DCP
b
Spraying of DCP
seston
8
Removal of
DCP
b
Spraying of DCP
Polluted Sludge
9
Treatment of
DCP/
b/c
Spraying of DCP, and passing the liquid
the sea area
RCS
though RCS filter
polluted, e.g.,
with petroleum
10
Conversion of
DCP/
b/c
Pretreatment with DCP and passing the liquid
Seawater into
RCS
though RCS filter
Freshwater
11
Treatment of
DCP/
b/c
Pretreatment with DCP and passing the liquid
Exhaust Liquids
RCS
though RCS filter. Applicable to treatment of
exhaust liquids from chemical industries such
as developing photo, semiconductor
processing, plating industry; from food
processing such as pickling; pigment
containing exhaust liquids, etc. to be converted
into harmless, deodorized. Also applicable to
purification of exhaust liquid from stock
breeding, pig breeding, chicken breeding,
sewage, etc.
The treatment of liquids according to the present invention is roughly divided into three processes: (a) a process including spraying OME (e.g., removal of water bloom (Cyano bacteria/Microcystis); (b) a process including spraying DCP; and (c) a process including optional spraying of DCP as a pretreatment and passing the liquid through (a) filter(s) containing RCS.
B-6 Removal of Water Bloom: Process (a)
When OME diluent is sprayed onto the surface of water on which algae (Cyano bacteria/Microcystis), such as water bloom generated due to eutrophication of lakes and marshes are floating, the water bloom etc., is instantly removed.
B-7 Aggregation of Seston: Process (b)
In this embodiment, through the application of DCP to water containing seston, such as organic exhaust water including exhaust water from sewage, exhaust water from food processing, exhaust water of feces and urine from livestock breeding such as pig breeding, eutrophicated lakes and marshes; inorganic exhaust water e.g., from a chemical plant, the seston is aggregated, and the aggregates float on the surface of the water or precipitate at the bottom of the water depending upon their specific gravities. The floating substances and/or the precipitates can be separated, for example, by filtration. In contrast to the conventional macromolecular aggregates or aluminum sulfate, this process does not requires any secondary treatment. In the present invention, irrelevant of whether water is inorganic or organic, various types of sestons can be treated. For example, when several milligrams of DCP is applied to ton of a muddy lake or marsh containing a large amount of sestons and then agitated, the transparency of the water is increased and, the floating substances and the precipitates due to the application of DCP are observed on the upper and the lower layers, respectively.
B-8 Removal of Polluted Sediment: Process (b)
DCP further has a function of decomposing polluted sediment deposited on the bottom. Although the mechanism for decomposing the polluted sediment by means of the microorganisms-containing carrier of the present invention has not yet been understood, when the microorganisms-containing carrier of the present invention is applied to the water having polluted sediment deposited on the bottom thereof, the polluted sediment has been found to be gradually decomposed two weeks or 1 month after the application.
B-9 Treatment of Water Containing Petroleum: Process (b)
DCP can be used to remove heavy oil from petroleum-containing water, particularly from seawater or river water polluted with heavy oil, in a manner similar to the treatment of seston. Specifically, DCP selectively absorbs the heavy oil. The heavy oil absorbed on the carrier of the present invention is decomposed into carbon dioxide and water, which are harmless, due to the function of the active components of OME. With regard to the sulfur contained in the heavy oil, sulfur components such as sulfur dioxide can also be instantly decomposed through the function of sulfur bacteria existing in seawater. Although hydrogen sulfide somewhat occurs due to the interaction of sulfate oxidation bacteria and sulfate reduction bacteria, hydrogen sulfide thus generated can be instantly decomposed into a harmless state by the spraying of OME diluent. Since the active components of OME have a function of decomposing halogens, heavy oil containing them can be decomposed into a harmless state.
B-10 Conversion of Seawater into Freshwater: Process (c)
It is possible to convert seawater into freshwater by
(a) incorporating an appropriate amount of DCP into seawater to be treated under forcedly stirring conditions, and forcedly stirring for an appropriate period; and
(b) after optionally repeating stage (a) once or several times, passing the seawater through a filter comprising RCS.
(Stage for Treating Seawater with DCP)
As a result of the investigations, it has been found that DCP has a function of removing salts in seawater under specific conditions.
Specifically, according to this embodiment, DCP is mixed and forcibly stirred together with the seawater. The stirring means used in this case is not specifically restricted as long as DCP can be sufficiently in contact with the seawater to carry out the conversion of seawater into freshwater by the function of DCP. Examples include stirring by means of a mixer and stirring by means of a jet water stream. Particularly preference is given to the use of a forcible stirring by means of OHR line mixer produced from Seika Sangyo Co. Ltd. The stage for having DCP to come into contact with seawater with forcible stirring may be carried out once, but it may be repeated several times as required.
The OHR line mixer is a forcible stirrer in which a process of two different fluids each passing through spiral paths collide with each other take place. In the case where this process is applied in the present invention, a fluid A, in which DCP is previously added to a part of seawater is made to come into contact with untreated seawater B to be reacted.
When seawater comes in contact with DCP in this manner, approximately 80% of the salt in the seawater can be removed. Since DCP has a very high performance for removing various harmful substances, the polluted substances, even contained in the seawater, can be advantageously removed.
(Treatment with RCS)
The water from which approximately 80% of the salts are removed is passed through a filter containing RCS. When the seawater treated in the former stage is passed through the filter containing RCS, the seawater is perfectly converted into freshwater. It is also noted that seawater which is not so polluted can be converted into freshwater only by passing it through the RCS filter to remove salts.
B-11 Treatment of Exhaust Liquid
DCP, RCS or a combination of them can be used to purify various kinds of exhaust water containing various harmful substances, exhaust water whose pH level is strongly acidic or strongly alkaline, exhaust water containing metals, bad smelling exhaust water, colored exhaust water, and exhaust water in combination of two or more thereof.
a) Purification of Exhaust Water with DCP
DCP which is a powdery carrier is sprayed to carry out the purification of the exhaust water. DCP is sprayed (1) for purifying exhaust water whose pollution degree is relatively low; (2) for purifying exhaust water which is difficult to be purified by being passed through the RCS filter described later on, such as lakes or marches having a relatively wide area, and rivers; and (3) to carry out a pretreatment for the treatment with the RCS filter which is described later on.
b) Purification of Exhaust Water with RCS
The purification of exhaust water with RCS, in which the exhaust water is passed through a filter or filters containing RCS, is carried out as the final treatment. Exhaust water whose polluted degree is extremely high can be purified by passing the exhaust water through RCS filters several times.
The water purification using DCP, RCS or the combination thereof is carried out in essentially the same manner as in the case of conversion of seawater into freshwater.
Examples of water purification include, but are not restricted to, purification of exhaust water from chemical plants, particularly exhaust water from plating industries, photographic exhaust water, exhaust water containing dyestuffs, exhaust water containing PCBs, dioxins, or any other harmful substances, exhaust water from food processing, such as salted plum exhaust water discharged in the course of producing pickled plums, and the like.
This seawater and harmful substances can be purified, for example, with apparatuses as shown in FIGS. 2 to 4 . The apparatus as shown in FIG. 1 is composed of an inlet 2 for supplying exhaust water to be treated, a filtering portion F comprising RCS filter or filters, and a water receiver 3 for receiving the purified water. In a preferred embodiment as shown in FIG. 2, the apparatus is further composed of a means for supplying the purified water to the filtering portion F, which is connected to the water receiver 3 , whereby the purified water is supplied to the filter or filters to recover (activate) the filter(s). In a more preferable embodiment, the apparatus further comprises a water tank 5 having a stirrer 6 in which the exhaust water is pretreated with DCP, and the water tank is connected to the filtering portion F by means of a liquid transfer portion 7 such as a pump.
3) Application to Gas
TABLE 4
Applications (4) of OME/DCP/RCS: Applied to Environmental Fields
(Applied to Gases)
Applicable
techniques
Application
Contents
12
Deodorization of
OME/DCP/RCS
a. Spraying of OME
organic and
Diluent
inorganic gases,
b. Application of OME
Adsorption,
Diluent containing DCP to
absorption and
source of the gas generation
decomposition of
c. Passing the gas through
harmful substances
RCS filter
in gases
B-12 Absorption, Adsorption, Decomposition and Deodorization of Gas
In this embodiment, bad smells originating from organic compounds, such as bad smells due to rotten animals or plants, due to feces and urine of animals, and methane, mercaptans; bad smells originating from inorganic compounds such as ammonia, and hydrogen sulfide; or harmful substances contained in the atmosphere such as dioxins, PCB, nitrogen oxides can be absorbed, adsorbed, decomposed, and/or deodorized.
The treating processes are roughly divided into (a) a process for spraying OME diluent to a gas; (b) a process for applying DCP introduced into OME diluent to a source of generating a gas; and in the case where the gas to be treated is in a closed environment such as a gas passing through a flue (c) a process for passing the gas through an RCS filter or RCS filters. In the case of treating dioxins, etc., the gas can be similarly treated by means of a mist trap or a process described in Japanese Patent Application No. 9-291467.
C) Other Applications
In addition to the above applications, OME, DCP, and RCS according to the present invention can be used in various forms. Examples are as follows:
Due to its deodorization effect as described above, OME diluent can be incorporated in a spraying container, such as an atomizer, to be used, for example, as a liquid deodorizer in the stockbreeding, household, or chemical industries.
OME diluent can also be incorporated in a spraying container, such as an atomizer, to be used, for example, as an agent for removing photogenic bacteria for plants, and as an activator for plants.
By impregnating wood in OME diluent for a short period, preferably within 1 day, the prevention of insects can be imparted to the wood. In this case, care should be taken since the cellulose in the wood starts to decompose if the wood is impregnated in OME diluent for a prolonged period of time.
DCP, RCS or a mixture thereof can be used as a powdery deodorizer for a refrigerator or shoes.
Since RCS possesses the function of removing harmful substances, particularly chlorine and the sterilizing function at the same time, the filter in which RCS is introduced can be used as a filter for a water purification apparatus for drinking or as a filter for showering with the introduction of a shower head, or as a filter for an air conditioner.
DCP can be introduced into a non-woven fabric, for example into a bag such as a tea bag, to be used as a purifier for a water tank, a pond, or a bath.
Concrete formed from fine aggregations containing DCP may be used to in the construction of a water tank, a construction for conditioning water properties.
Furthermore, when RCS is used in a material as the filter for a purifier of an ornamental water tank, a transparent state can be maintained over 1 month without changing the water.
EXAMPLES
The present invention will now be described in more detail by referring to Examples, which do not restrict the scope of the present invention.
Example 1 Production OM/OME
To an organism-activating agent, marketed under the trade name of VITARY AMINON from ORIENT GREEN CO. LTD, were added 5% by weight of humus based on broadleaf trees as a source of aerobic microorganisms and 5% by weight of extract of Basidiomycetes obtained by mating Pleurotus coruncopiae with Pleurotus coruncopiae to carry out the culture over a period of 30 days under aeration conditions at normal temperature and normal pressure. At the start of the culturing, the culture had smells, but 30 days after the culturing has began, the smell had disappeared from the culture.
After this 30-day period, the aeration was terminated, and 5% by weight of sludge from sewage as a source of anaerobic microorganisms was added per ton of the culture to continue the culturing over a period of 30 days at normal temperature and normal pressure. Similarly, the smells from the sewage had disappeared after this 30 days.
Photosynthesis bacteria available from ORIENT GREEN CO. LTD under the trade names of GREEN AMINON and RED AMINON were added to the culture each in an amount of 1.5 liter per ton of the culture to continue the culturing over a period of another 30 days. This produced OM liquid.
Moreover, carbon power (10 kg) was added to the OM liquid and the culturing was continued for another 60 days, at which time the carbon power was observed to be decomposed.
The culture obtained as described above was diluted three times with the OM liquid which had been previously obtained to produce OME liquid.
According to a standard for toxicity of chemical products (1987), OME is tested for oral acute toxicity in mice. When OME was administrated to mice at the maximum dosage of OME defined in this standard (2 ml per 100 g weight (20 m/kg)), no mice died. Consequently, the lethal dose in the sample mice was determined to be greater than 20 ml/kg both in the case of males and females.
Comparative Example 1
Production of Comparative Culture
A culture containing both aerobic bacteria and anaerobic bacteria described in Japanese Patent Application No. 9-291467 was produced with the same method as in Example 1 except that there was no introduction of basidiomycetes.
When carbon powder was added to the resulting culture, no decomposition of carbon powder was found.
Example 2
PRODUCTION OF DCP
Carbon from plants having been burned at a low temperature was impregnated in an aqueous solution in which OME obtained from Example 1 was diluted 1000 times with water. After about 3 to 7 days, the carbonaceous substances became muddy to give DCP. (DCP slurry). The DCP slurry was spontaneously dried to give DCP powder.
Similarly, when the carbon having been burned at a low temperature was impregnated in an aqueous solution in which the culture obtained from Comparative Example 1 was diluted 1000 times with water, the carbonaceous substance was not changed even after 30 dyas.
Example 3
PRODUCTION OF RCS
Activated carbon was impregnated in the OME liquid obtained from Example 1 for 3 to 7 days to produce RCS.
Applications to Agricultural Fields
Example 4, Comparative Example 2, Control 1
Improvement in Sandy Soil Containing Salts
Sandy soil containing salts from the beach of Nijinomatsubara Beach Kaigan, Saga, Japan was improved.
First, the sawdust of needle-leaf trees as a soil base material was laid on the seashore so as to be approximately 5 to 10 cm in height. Slight amounts of chicken droppings were added thereto, and a diluted OME in which OME obtained in Example 1 was diluted 1000 times with water, was sprayed thereon so as to sufficiently wet the soil base material (Example 4). Similarly, a microorganisms' culture conventionally said to have a performance for decomposing cellulose as described in Japanese Examined Patent Publication No. 4-42355 (Comparative Example 2), and the culture from Comparative Example 1 (Comparative Example 3) were sprayed on two respective parts of the soil. As a control soil, only chicken droppings were added (Control 1).
After being left standing for two weeks, tomato, green soybeans, watermelon, pumpkin, eggplant, Brassica campestris, and sweet potato were cultivated on each soil. As a result, good crops could be harvested from the soil of Example 4, but no crop could be harvested from the soils of Comparative Examples 2 and 3, and Control 1.
Example 5, Comparative Examples 4 and 5, Control 2
Treatment of Various Soils
As for sandy soil composed of commercially available sands, soils whose crumb structure had been lost due to the application of agricultural chemicals, acidified soil, and burned soil, similar bacterial treatments were carried out in the same manners as in Example 1, Comparative Examples 2 and 3 and Control 1, respectively, and the crops were cultivated. As a result, good crops could be harvested from the soil of Example 5, but no crop could be harvested from the soils of Comparative Examples 4 and 5, and Control 2.
From these results, it has been understood that the process according to the present invention could exhibit significant effects within a short period of time. It should be noted that the progress of converting the sandy soil into fertilized soil could be observed by the necked eye (approximately 30% of the sands being converted into fertilized soil after three months).
Example 6
Rescue of Plants with Stem Canker and Mottled Spot
An approximately 80 years old Japanese red pine affected with stem canker was dug up, and the affected parts were surgically removed. The whole of the red pine was thoroughly washed with a diluent of OME diluted 1000 times using the OME obtained from Example 1. Thereafter, DCP slurry was applied to the surgically operated portions and then dried. Furthermore, the soil was well washed with the diluent of OME diluted 1000 times using the OME obtained from Example 1. Two hours after the treatment, the appearance of new buds could be observed.
As for an approximately 30 years old pear tree affected with stem canker, a pear tree affected with root rot, an approximately 20 years old apple tree affected with stem canker, and an apple tree affected with root rot, the same treatment as described above was carried out. They were found to form buds after two to three hours.
Example 7
Treatment of Powdery Mildew
In this example, a diluent of OME diluted 1000 times using the OME obtained from Example 1 was used for the treatment. Cucumbers at the final stage of cultivation affected with powdery mildew were treated with the diluent of OME diluted 1000 times using the OME obtained from Example 1. Specifically, the diluent (300 liters) was sprayed on the surfaces of leaves and the soil (8 Acres) for cultivating the cucumbers. After one week, the spread of the powdery mildew was found to be suppressed. Two weeks after the treatment, OME diluent was similarly sprayed on the surfaces of the leaves and soil in an amount of 100 liters. After another one week, the treated plants were able to yield as many cucumbers as those which were not affected with powdery mildew.
Example 8
Extermination of Harmful Insects
In this example, four of greenhouses for strawberries affected with caterpillars of Mamestra brassicae among 20 Acres were treated with a diluent of OME diluted 1000 times using the OME obtained from Example 1 to exterminate the harmful insects. The OME diluent was sprayed onto the surfaces of the leaves and soil in an amount of 200 liters. One week after the spraying, the growth of the plants was observed in comparison with the plant having not yet been treated. At that time, the leaves and stems of the strawberries having been treated were found to be elastic. Three weeks after the treatment, carcasses of the insects were observed. Since damage due to the insects had started in the untreated portions, both OME diluent (350 liters) was sprayed and the OM diluent was sprinkled in an amount of 500 liters over the leaves and soil of all of greenhouses. Similarly, after 1 week, OM diluent was sprayed in an amount of 350 liters to the whole of the houses, and OM diluent was sprinkled in an amount of 500 liters all of greenhouse. It was found that no caterpillars remained.
Application to Environmental Fields: Application to
Solids
Example 9
Garbage Treatment
A diluent of OME diluted 1000 times with the OME obtained from Example 1 was applied to a 1:1 mixture of sawdust from needle-leaf trees and chaff, and the mixture was stirred to produce a garbage decomposing material.
A 30-liter volume plastic bucket having a wire net laid on the bottom was filled with approximately 25 liters of the garbage decomposing material. Thereafter, household garbage (3 liters) was incorporated in the bucket and the contents were mixed well. Immediately after the treatment, bad smells from the garbage disappeared, and the garbage perfectly disappeared after 1 to 3 days. On the bottom of the bucket, a liquid due to the fermentation and decomposition of the garage was collected. This liquid contained minerals and could be used as a good liquid fertilizer.
Example 10
Removal of Lead in Burned Ash With OM
Two hundred grams of burned ashes containing approximately 0.6 mg of lead was washed with a diluent produced by diluting 3cc of the OM obtained from Example 1 with 600 cc of water. The washing was repeated twice. As a result, the content of the lead in the burned ashes was decreased to 0.015 mg/l (measured according to JIS K0102 31.2).
Example 11
Removal of Heavy Metals in Burned Ash with OM
The procedure of Example 10 was repeated to remove heavy metals contained in burned ashes shown in Table 5. Table 5 shows the amounts of heavy metals before washing with OME and after the treatment.
TABLE 5
Unit: mg/kg
Before
Treated with
After
Components
Treatment
OM
Treatment
Calcium
1300000
2200
16
Iron
23000
19
N.D.
Sodium
13000
570
14
Magnesium
11000
24
2.6
Zinc
3500
11
0.06
Copper
2400
7.7
0.02
Lead
1100
7.2
N.D
Cadmium
9.7
0.05
N.D
*Determined by an atomic absorption process
**N.D. means not determined.
Liquid Treatment
Example 12
Removal of Water Bloom
Onto and into water containing water bloom, such as a water reservoir for hydroponics, a river into which exhaust water from pig breeding was spilt, and a pond of a golf course, a diluent of the OME obtained from Example 1 diluted 1000 times with water was sprayed. Immediately after spraying, the water blooms were instantly removed.
Example 13
Decomposition of Azo Dyestuffs
Into 2-liter volume transparent containers was incorporated approximately 1 liter of tap water each, and 1 g of azo dyestuff such as indigo dyestuff, an orange dyestuff, a red dyestuff, a yellow dyestuff, or a blue dyestuff was added respectively. The contents were thoroughly stirred to prepare a sample exhaust waters. To each of the samples was added 3 mg of DCP. When each container was stirred by means of a magnet stirrer, the samples were found to become perfectly colorless after 2 to 5 minutes. BOD/COD measurement showed that BOD having having 650 before treatment was reduced to be not more than 5, and approximately COD having 450 was reduced to be not more than 5, after the treatment respectively.
Example 14
Treatment of Photographic Exhaust Water
Exhaust water (1 liter) containing cyan, acetic acid, and mercury from a small-scale photo finishing service shop was incorporated in a 2-liter volume transparent container, 3 mg of the DCP obtained in Example 2 was incorporated, and the mixture was stirred with a magnet stirrer for 10 minutes. The treatment removed harmful substances and the exhaust was perfectly deodorized. Thereafter, the exhaust water treated with DCP was passed through a funnel filled with the RCS obtained in Example 3. The results of measuring the total nitrogen content, BOD, and COD before treatment, after the treatment with DCP, and after the treatment with RCS are shown in Table 6.
TABLE 6
(mg/l)
Before
Treated
Treated with
treatment
with DCP
RCS
Method
BOD
200
26
5
JIS K 0102 21 32.3
COD Mn
16000
1300
23
JIS K 0102 17
All nitrogen
8900
1200
7.0
JIS K 0102 45.2
Example 15
Treatment of Polluted Area of Water
Water (1 liter) containing seston and polluted sludge from a lake or a marsh was incorporated in a 2-liter volume transparent, container, 3 mg of the DCP obtained in Example 2 was incorporated, and the mixture was stirred with a magnet stirrer for 10 minutes. The water after the treatment had become perfectly colorless. The polluted sludge was gradually decomposed after the treatment, and could not be observed by the necked eye after 1 month.
Example 16
Treatment of Exhaust Water from Sewage
Water (1 liter) from exhaust water from sewage having been filtered through a filter was incorporated in a 2-liter volume transparent container, 3 mg of the DCP obtained in Example 2 was incorporated, and the mixture was stirred with a magnet stirrer for 10 minutes. The water after the treatment had become perfectly colorless. The water giving off a sickening smell before the treatment was deodorized by incorporating DCP followed by stirring to an extent where no smell was noticable.
Example 17
Exhaust Liquid Containing PCB
The same treatment as in Example 16 was carried out using an exhaust liquid containing 40000 mg/liter of PCB. As a result, the content of PCB was reduced to be 0.1 ppm.
Example 18
Exhaust Liquid from Plating
The same treatment as in Example 16 was carried out using a lead acetate exhaust liquid having 22000 ppm of COD, a Pb content of 164000 ppm and a pH level of 8.7. As a result, COD was reduced to 320 ppm, but the precipitation of Pb was observed. When the same procedure was repeated one more time, the content of Pb was found to be from 1 to 2 ppm and COD was found to be further reduced to 4 ppm, and the pH level also became 7.7.
Example 19
Conversion of Seawater into Freshwater
Seawater (10 liter) from Sagami Bay was incorporated in a mixer, 3 g of DCP was incorporated with stirring, and the stirring of the mixture was continued for approximately 30 seconds. As a result, the salts in the seawater were found to be reduced approximately 80%.
The seawater treated as described above was passed through a filter with which the RCS obtained in Example 3 was filled to perfectly remove the salts. The results are shown in Table 7. When this experiment was repeated several times, similar results were obtained.
TABLE 7
Before treatment
After treatment Method
Cl
17 g/L
240 mg/L
JIS K 0102-35-1
Na +
13 g/L
90 mg/L
JIS K 0102-48-2
Example 20
Treatment of Salted Plum Juice
To exhaust water (1 ton) containing salted plum juice exhausted in the course of producing pickled plums and having the following characteristics was added 4 liters of the DCP obtained in Example 2, and the mixture were well stirred. The mixture was filtered once through sand, and then twice through a filter which was filled with 4 liters of the RCS obtained in Example 2. The results are shown in Table 8.
TABLE 8
Before Treatment
After Treatment
Titrated Acidity (as Citric
30.02 g/L
ND
Acid)
Sugar Content
30.1
0
Ca
296 mg/L
ND
Na
43.3 g/L
39 mg/L
Salt (as Na)
113 g/L
99 mg/L
K
2.05 g/L
30 mg/L
Mg
161 mg/L
ND
Sucrose
3.14%
ND
BOD
160000 mg/L
13 mg/L
COD
120000 mg/L
16 mg/L
pH
2.6 (20 C)
6.3(21 C)
From the results shown in Table 8, it can be understood that DCP effectively functioned even at a pH level of 2.6, and had functions for reducing BOD and COD.
Example 20
Treatment of Exhaust from Plating
Into a plating mixed bath composed of 100 ml of nickel plating liquid (Watt bath), 100 ml of soldering bath, 100 ml of electrolytic copper bath, 100 ml of an alkaline degreasing liquid (Ace Clean 200 10 solution), 100 ml of 5% sodium tertiary phosphate solution, and 100 ml of 5% sulfuric acid diluted with 2 liters of tap water, 10 g of the DCP obtained in Example 2 was incorporated, and the liquid was filtered through a filter containing the RCS obtained in Example 3. The results are shown in Table 9.
TABLE 9
Type Exhaust Water
pH
COD Mn
Pb
Lead Acetate Exhaust Water
3.7
22000
164000
After Treatment
6.7
3
1 or less
Nylon Exhaust Water
10.6
284000
None
After Treatment
6.4
8
None
Example 21
Treatment of Exhaust Liquid Containing Harmful Substances
Into a liquid, which was expelled from a plant after final treatment of its industrial waste, containing the following substances, 10 g of the DCP obtained in Example 2 was incorporated, and then the liquid was passed twice through a filter containing the RCS obtained in Example 3. The results are shown in Table 10.
TABLE 10
(mg/L)
Before
Treated with
Harmful Substances
Treatment
DCP
Tetravalent Chromium Compounds
0.6(T—Cr)
—
1,1-dichloroethylene
0.02
—
Living Environment
pH
7.16(25° C.)
5.84
BOD
22300
5.15
COS
3640
5.00
SS
271
—
n-Hexane Extract
0
—
- (Mineral Oils)
3.4
—
- (Vegetable/Animal Oils)
338
2.42
N
1.6
—
P
5.02
—
F
0.6
—
Cr
1.75
—
Soluble Fe
1.72
—
Soluble Mn
23.0
—
Phenol
<1.0
—
Cu
0.43
—
Zn
Others
NH 4 + —N—
3170
—
Cl −
28900
90.
Na +
11200
10.1
Ca
1830
—
Applications to Gases
Example 22
Removal of Odors Oriented from Rotten Proteins
Rotten Washington clams were introduced in a conical flask. Subsequently, an untreated sample and a sample treated by dropping a drop of a 1000 times diluent of the OM obtained in Example 1 were collected in bags by means of a sampling pump. The collected samples are measured by a gas detector (Kitagwa Type). The results are shown in Table 11.
TABLE 11
Before
After
Hydrogen Sulfide
400 ppm
N.D.
Methylmercaptan
120 ppm
N.D.
Propylene
60 ppm
N.D.
Ethylmercaptan
3 ppm
N.D.
Example 22 and Comparative Example 6
A Comparison of Gas Adsorption of RCS with that of Activated Carbon
Formadehyde and ammonia were adsorbed in the RCS obtained in Example 3 and untreated activated carbon to compare their adsorption performances. The results are shown in FIG. 4 .
It is clear from FIG. 4 that the adsorption performances of these substances in RCS are significantly higher than those of untreated RCS.
INDUSTRIAL APPLICABILITY
As described above, the present invention has the following excellent advantages.
A microorganism culture containing aerobic microorganisms, anaerobic microorganisms, at least one Basidiomycetes belonging to Pleurotus coruncopiae living in symbiosis with each other, and enzymes produced as their metabolites, a carrier obtained by absorbing the active components of the culture on the finely pulverized carbon, and a porous absorbing material having the active components of the culture adsorbed thereon has capabilities of absorption, adsorption, decomposition, deodorization, decoloring of harmful substances and, thus, they can be used in various agricultural fields and environmental fields. | Solutions containing microorganisms differing in characteristics from each other and living in symbiosis with each other and enzymes characterized by containing aerobic microorganisms, anaerobic microorganisms and at least one basidiomycete belonging to the family Pleurotaceae living in symbiosis, metabolites thereof and enzymes; carriers obtained by adsorbing the components of the above solutions onto finely ground carbonaceous materials; and porous materials obtained by adsorbing the components of the above solutions onto porous materials. Because of having various effects of absorbing, adsorbing and decomposing harmful matters, deodorizing, decolorizing, etc., these materials are applicable to various uses in the fields of agriculture and environment. | 8 |
FIELD OF THE INVENTION
This invention relates to golf-putters.
BACKGROUND OF THE INVENTION
It is known that even if a golf ball is putted with a ‘perfect robot’ (or any other form of precision mechanism) on a ‘perfect putting surface’, there will still be significant variation in the resulting ball-direction. The variation may be caused by spherical asymmetry in the mass and/or shape of the ball and by surface irregularities, in particular, in the dimpled-surface pattern. The dimpled pattern is an inherent part of golf-ball design and is provided to enhance aerodynamic performance.
In putting, the impact footprint (that is, the area of contact between ball and putter) has a span of the order of 5 millimeters, which is comparable with dimple-diameter. Since dimples cause voids in the contact between the impact face of the putter and the golf-ball surface, the impact footprint is rarely symmetrical. Moreover, the distribution of the striking force is not uniform across the footprint, but is a maximum at the initial point of contact, falling off rapidly towards the outer extremities of the footprint. Thus, the resultant striking force imparted by the putter on the ball is generally displaced from the ball-centre by a small, random amount. The degree and sense with which this gives rise to directional error in the resulting track of the ball from the line of strike, depends upon the extent to which the ball is struck more to one side than the other of the ideal centre-impact point; striking the ball more to the left of this point, propels it more to the right, and vice versa.
In addition to left/right (azimuthal) directional errors, the dimples similarly cause slight variations in the initial elevation trajectory. These errors can normally be ignored since they amount to slight variations in impact loft but do not measurably affect launch velocity or distance of putt. Accordingly, references to dimple-effect errors in the present context are to be understood to relate to errors in azimuth.
The errors due to the dimple effect are greater for hard-covered balls than for soft-covered balls, and less significant for long putts where the impact footprints are larger (because the striking force required is greater) so as to give a less asymmetric force distribution. Nonetheless, although dimple-effect errors are in any event small in relation to overall putting performance, they are significant because scoring in golf is heavily weighted by putt strokes.
One method of reducing dimple-effect errors is to provide golf balls with specially designed dimple patterns that distribute the impact force more evenly across the contact area. These modified dimple patterns may either cover the entire ball-surface or be limited to certain, identifiable zones; however, improving the dimple pattern for putting purposes, generally degrades the aerodynamic performance of the ball. A more practical approach instead, is to modify the impact face of the putter head itself to improve striking-force distribution so that the putter can be used advantageously with any make or pattern of golf ball.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a golf-putter head of improved form for reducing dimple-effect error.
According to one aspect of the present invention there is provided a golf-putter head having an impact face for striking the dimpled surface of a golf ball, the impact face being defined by a multiplicity of substantially parallel ridges which extend substantially lengthwise of the head and which are for impacting the ball-surface in areas of contact that are distributed around dimples of that surface to tend collectively to centralise the resultant striking force on the ball, wherein the ridges are of a profile, width, pitch and hardness which in combination result in said head realising a reduction of at least 15% in the standard deviation of the dimple-effect error distribution in putting with an initial velocity of 2.5 meters per second of a ball that when putted at that initial velocity by a head having a plain, flat impact face exhibits a standard deviation of dimple-effect error distribution within the range 0.69 degrees to 0.75 degrees.
Measurements show that dimple-effect errors in hard-covered golf balls have a standard deviation of about 0.7 degrees at one-STIMPMETER® putt strength when putted using a conventional metal putter having a plain, flat impact face. (The STIMPMETER® is a device for measuring the ‘speed’ or rolling friction of a putting surface; it also gives a measure of absolute putt strength.) Similarly, the standard deviation for dimple-effect errors with soft-covered (for example, balata) golf balls is found to be between 0.3 degrees to 0.4 degrees at one-STIMPMETER® putt strength. The standard deviations are found to increase by about 20% to 30% at half-STIMPMETER® strength, and it has been found that a golf ball with initial putt velocity of 2.5 meters per second and no initial spin travels very nearly the same distance as a ball launched from the STIMPMETER®. Since initial velocity can be determined very accurately, it is preferable to use this as a standard for putt strength.
Further measurements show that modifications to the impact face can markedly alter the degree of dimple error. It is possible to reduce dimple-effect errors significantly by altering the shape and/or the material of the impact face of the putter so as to improve impact-force distribution across the contact area. However, in some cases altering the shape of the impact surface increases rather than reduces the degree of error; this occurs when the impact face of the putter contains features that concentrate the striking force.
It has been estimated that a typical world-class golfer has on average a line error (i.e. directional error) of 1.3% and a length error of 6.5%. (Tierney, D. E. and Coop, R. H. 1999. A Bivariate Probability Model for Putting Proficiency, Science and Golf III, ed. A. J. Cochran and M. R. Farrally, 385-394, United Kingdom: Human Kinetics.) An average line error of 1.3% equates to a standard deviation from the ideal putt direction of 0.93 degrees. Other research indicates that players with a medium handicap have comparable chances of sinking putts at typically only half the range of world-class players (Beauchamp, P. H. et al. 1994. Towards putting performance enhancement: a methodology using quantitative feedback, Science and Golf II, ed. A. J. Cochran and M. R. Farrally, 174-179, London: E. & F. N. Spon.) From this, and assuming that skill level in both line and length are reduced in equal proportions, medium handicap players have typically 41% greater line error and 41% greater length error compared with world-class players. Thus, as a rough estimate, medium handicap players typically have a standard deviation of about 1.3 degrees in directional accuracy for putting. Most golfers will deviate above or below these values, but they give a basis for estimating the dimple-effect contribution to overall directional errors.
The separate contributions to overall directional error combine as the root mean square of magnitude. In the hypothetical case of the ‘average’ medium-handicap player, the standard deviation in degrees for non-dimple effect errors is given by:
( 1.3 2 - 0.7 2 ) 1 2 = 1.1
so dimple-effect increases average directional errors by 18%. By substituting the putter head with a type that reduces the dimple-effect standard deviation by 40% to 0.42 degrees, the degradation (i.e. increase in errors) in the above case is reduced to 7%. Conversely, a putter that increases the dimple-effect standard deviation by just 10% to 0.77 degrees increases the degradation to 22%.
Other forms of ridge-faced (or groove-faced) putters are known where the ridges are provided to increase the friction between ball and putter. The ridges in such putters are normally biased horizontally so that friction is especially increased in the vertical direction; it is asserted by the proponents of such ridges that they impart topspin to the ball at impact and that this improves putting accuracy. In some instances, dimple-effect errors are reduced by such ridges, but the improvement is small.
According to another aspect of the present invention, there is provided a golf-putter head having an impact face for striking the dimpled surface of a golf ball, the impact face being defined by a multiplicity of substantially parallel ridges which extend substantially lengthwise of the head with a pitch p, and which each have a width w that is measured at 67% of ridge-depth from the apex where the ridge-depth is 0.3 millimeters or less, but otherwise measured at a depth of 0.2 millimeters from the apex, a hardness h and a profile represented by a parameter TSF, related to p, h, and w as follows:
1.0 <p< 400/(h+100)
w< 0.4 ×p[ 80/( h− 20)]
0.5 <TSF< (0.91−0.003 ×h )
for p not exceeding 3.5, w not exceeding (p−0.4) and TSF not exceeding 0.72, where h is measured in durometer Shore D scale, w and p in millimeters and TSF is the ratio of the cross-sectional area of the ridge-profile measured to a depth of 0.1 millimeters from the apex to its cross-sectional area measured to a depth of 0.15 millimeters from the apex.
The ridges of the putter-head according to both aspects of the invention specified above may be curved or slanted, but are preferably straight and parallel to the heel-toe axis of the head. Discontinuities along the length of the ridges may be used for cosmetic effect, but such discontinuities should not encroach within the normal ball-contact zone of the impact face, as these would tend to increase lateral friction in a random manner.
The ridges form impact surfaces having raised elements, which provide a plurality of separate contact areas with the golf ball such that increased depth of deformation of contacting surfaces occurs during impact with the ball and the width of each contact area is substantially smaller than the overall footprint span. For a given golf-ball cover-material and a given putter impact face material, the maximum deformation depth according to the present invention is more than the maximum depth obtained with a conventional plain, flat-faced putter and an equal putt strength. Thus, using a putter according to the present invention increases the overall footprint area.
The reduction of dimple-effect errors depends on the distribution of impact force being more evenly distributed laterally about the ideal centre of impact (that is to say, the centre of impact that would be obtained with a perfectly smooth and spherical ball). This more even distribution is provided by the present invention, in which the concentration of force that occurs near the centre of impact with a conventional flat-faced putter is replaced by a plurality of separate forces arranged to act on narrow elongate horizontal areas that act on different parts of the golf-ball dimple patter. The random error components from each of the separate forces will tend to cancel one another, provided that these separate forces are of roughly similar magnitude. However, if one contact force from, for example, a ridge-faced putter is dominant, then such random cancellation is not effective.
It is found with ridge-faced putters that dimple-effect errors are sensitive to the position of the ridges relative to the centre of impact. With horizontal ridges, worst case errors occur when one ridge is coincident with the centre of impact and the two adjacent ridges are displaced by one pitch distance, one above and the other below the centre of impact. This impact condition maximises the ‘dominant ridge effect’, which tends to increase dimple-effect errors. Conversely, if the centre of the gap between two ridges is coincident with the centre of impact, dimple-effect reduction is greatest. The difference between the worst and best case ridge alignments can be large. When measuring the effectiveness of a given ridge configuration, it is preferable to arrange for the test set-up to give worst case positioning of the ridges. This results in an underestimate of the overall dimple-effect improvement but gives a much more sensitive and reliable indication of the relative performance of different ridge-configurations.
A further advantage of horizontal ridges is that greater vertical traction between the putter and the golf ball is provided. Such modification enhances the ability of a putter to transmit topspin to a ball at impact. The ability of a putter to impart topspin at impact is generally considered advantageous and it is said that increased topspin at impact improves putting accuracy.
The deeper deformation in separate contact areas gives rise to higher localised stress levels and tends to increase the degree of plastic deformation during impact. Preferably, plastic deformation in a golf ball should be minimised so that most of the deformation is elastic. Thus, it is found that one form of ridged impact surface can make deeper deformation compared to a second form at the same putt strength yet exhibit less dimple-effect improvement.
Dimple-effect performance cannot be predicted by theoretical means or known design rules, so improved impact surfaces are developed using experiment and measurement. The applicants have devised a preferred measurement technique involving ballistic measurement. This replicates the required putt conditions (for example, a ball launch velocity of 2.5 meters per second with zero imparted spin) but at a known height and position above ground level. The direction of the ball trajectory through the air is then accurately measured using mechanical or electronic means. This technique ensures that errors from putting surface defects and mass imbalance effects in the ball are excluded.
The dimple-effect performance of a putter is preferably evaluated at one standard putt condition and with one golf ball category. Thus a standard putt condition with an initial launch velocity of 2.5 meters per second and zero imparted spin is adopted. Small deviations from this standard putt condition can be ignored, since dimple-effect errors vary slowly with change in impact energy. The preferred ball category includes any hard-covered golf ball that exhibits a standard deviation for dimple-effect errors of about 0.72 degrees at 2.5 meters per second putt strengths. This standard deviation of dimple errors is common to a wide range of golf balls of different brands.
The standard putt condition and golf ball category provides a reliable indicator of overall dimple-effect performance. Tests carried out by the applicants show that ridge-faced putter-heads with improved dimple-effect performance using hard-covered golf balls also exhibit improved performance using soft-covered golf balls, although the degree of improvement is not generally as great as with hard-covered golf balls. Tests also show that such heads exhibit very little degradation in elevation angle errors (that is in vertical launch-angle variations resulting from the dimples).
The putter face and the ridges may be fabricated from a hard rigid material, a soft resilient material or any material intermediate these. The ridges can be of the same material as the remainder or bulk of the putter-head, or formed of a different material. Thus, the ridges can be provided as individual raised inserts embedded into the base material of the putter face. Alternatively, the individual raised inserts can comprise several elements or pixels in a ridge-like structure, with uniform or varying element properties along the length of the ridge.
It is found that dimple errors are significant for impact deformation depths of about 0.15 millimeters, whereas the errors with impact depths of 0.4 millimeters to 0.5 millimeters or greater are negligible. Thus, the invention is particularly concerned with the shape and dimensions of ridge extremities ranging from the outer contacting surface—the apex—of the ridge, down to a depth of 0.5 millimeters from the apex. The shape of the tip of the ridge, in the sense of the shape of that part of the outer extremity of the ridge extending down to a depth of 0.15 millimeters from the apex, is relevant. The width of the ridge is also relevant in terms of its cross-sectional thickness as measured at 67% of ridge-depth from the apex in those circumstances where the ridge-depth is 0.3 millimeters or less, but otherwise measured at a depth of 0.2 millimeters from the apex.
In practice, the preferred width and pitch of the ridges are a function of the hardness or softness of the ridge material. Thus, the preferred width and pitch vary continuously throughout the range of material hardness, as do the preferred tip shapes.
With hard ridges it is preferable to have significantly smaller widths when the ridges are closely spaced (for example, when the pitch is 1.2 millimeters or less). The much smaller widths slightly reduce the force contributions from individual ridges, which compensates for the close spacing. Typically, the width w for hard ridges is within a range specified by:
w< 0.4×( p− 0.4)
where width w and pitch p are in millimeters.
Thus, with a ridge spacing of 1.2 millimeters the preferred ridge widths are 0.32 millimeters or less, whereas with a pitch of 1.6 millimeters the preferred ridge widths can increase to 0.48 millimeters. In general, the widths for hard ridges as a function of pitch can extend within the range:
w< 0.4 ×p
where width w and pitch p are in millimeters.
A preferred range for ridge pitch in soft materials is 1.5 millimeters to 2.5 millimeters, but otherwise the range may extend from 1 millimeters to 3.5 millimeters. With softer material significant deformation depth can be achieved with relatively wide ridges and there is greater scope to enlarge impact footprint areas. It is also preferable to increase the width in proportion to the softness and flexibility of the ridge material to avoid a delicate structure that would tend to collapse on impact. Preferably, the maximum ridge-width w in millimeters in any material is:
w< 0.4 ×p×[ 801( h− 20)]
where p is ridge-pitch in millimeters and h is hardness measured in durometer Shore D scale.
As with hard ridges, the problem of widely spaced contact points arises if the pitch is greater than 2 millimeters or so. In a preferred embodiment for soft compliant ridges the ridges are flat-topped with the outer contact surface comprising at least 50% of the overall contact area. By this means, bulges or projections that would otherwise create a dominant contact are avoided. For the full range of possible material hardness h, the preferred TSF ratio is specified as follows:
where h>44 Shore D: TSF ratio>0.8−0.003×h where h<44 Shore D: TSF ratio is nominally ⅔.
The TSF ratio for hard ridges should be greater than 0.5 and less than 0.61, but is preferably between 0.53 and 0.59.
A re-entrant ridge-profile (profile narrowing with depth) can be used with soft materials; in this case the TSF can be as large as 0.72. Also, the gaps between ridges may be filled or partially filled with a material that is softer than the ridge material; this prevents extraneous matter from collecting inside the narrow gaps separating ridges. Furthermore, the impact surface may be provided as a replaceable member; this increases the scope for performance improvement designs using more delicate surface structures that can be renewed as required.
BRIEF DESCRIPTION OF THE DRAWINGS
Golf-putter heads in accordance with the present invention will now be described, byway of example, with reference to the accompanying drawings, in which:
FIG. 1 shows the general configuration of a golf-putter head in accordance with the invention;
FIG. 2 is an enlarged vertical section of part of the golf-putter head of FIG. 1 , illustrating one example of ridge-configuration according to the invention for the impact face of the putter-head and identifying certain variables associated therewith;
FIGS. 3 to 6 illustrate, respectively, additional examples of ridge-configurations according to the invention;
FIGS. 7 and 8 are enlarged views of footprint traces that result respectively from striking a golf ball having a dimpled soft-cover with a plain, flat-faced putter-head, and with a ridge-faced putter-head according to the present invention;
FIGS. 9 and 10 are graphical representations of the peak impact force contributions from two series of ridges according to the present invention, for which the ridge-spacings are different;
FIGS. 11 and 12 are, respectively, a schematic plan and side view of apparatus used for measuring dimple-effect errors;
FIGS. 13 and 14 are illustrative of recordings made with the apparatus of FIGS. 11 and 12 ;
FIG. 15 is a histogram showing the distribution of dimple errors typical of putts on a hard-covered golf ball using a standard flat-faced putter;
FIG. 16 is a histogram corresponding to that of FIG. 15 , showing the distribution of dimple errors typical of putts on a hard-covered golf ball using a ridge-faced putter according to the present invention;
FIGS. 17 and 18 together tabulate the characteristics of nine impact-faces tested; and
FIGS. 19 to 21 illustrate, respectively, further examples of ride configurations according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1 , the putter-head 1 is attached at its heel 2 to a putter-shaft 3 via a neck 4 . The head 1 has an impact face 5 , located between its heel 2 and toe 6 , which is grooved to define a multiplicity of parallel ridges 7 that extend substantially lengthwise of the head 1 , that is to say in the general direction from heel 2 to toe 6 . The ridges 7 are of a high-impact material, being in the present example integral with the stainless-steel or brass head 1 , and, as illustrated in FIG. 2 , are spaced from one another by gaps larger than the widths of the ridges.
Referring to FIG. 2 , the distance between corresponding points of adjacent ridges 7 is identified as their pitch p, and the distance between the apex 8 and base 9 of each ridge 7 as its depth d (measured normal to the impact face 5 ). The width w of each ridge 7 is its thickness measured at 0.2 millimeters below its apex, and its radius r is the radius of the ridge 7 at its apex. In this specific example, the pitch p of the ridges 7 is 1.6 millimeters being in this regard within the preferred range of 1.4 millimeters to 1.8 millimeters. An overall range of 1.0 millimeters to 2.0 millimeters is applicable provided the cross-sectional area of the ridge 7 is substantially less than the cross-sectional area of the gap separating adjacent ridges 7 .
A wide spacing ensures that when adjacent ridges 7 strike the dimpled golf ball, they come into contact with different edge orientations of the same dimple, or with edges of adjacent dimples, so as to spread the force distribution at impact over a number of separate contact points with the ball. However, very wide spacing is counterproductive because the force contributions of ridges other than the central ridge or ridge pair, diminish rapidly and do not provide a well-distributed impact force. The improvement is unpredictable by theory so experimental methods have been adopted to determine optimum designs.
It is intended according to the invention that the ridges 7 penetrate deeply into the cover of the golf ball, preferably without cutting the cover. To this end, the radius r is ideally in the range 0.05 millimeters to 0.25 millimeters, but the radius can be increased up to 0.50 millimeters over a small section of the ridge tip provided the width is small enough to allow penetration. A cylindrical top surface for each ridge is preferred (as illustrated), but other ridge sections including polygons with various corner radil may be used.
The thickness of a ridge 7 near its base may be significantly greater than the average thickness since impact deformation near the base contributes little to the overall impact force; the nominal ‘base’ is located where the thickness of the ridge cross-section equals three times the thickness at 0.15 millimeters depth from the apex 54 . Another consideration is that the ridges 7 are not prone to damage by accidental impact with hard objects. Thus it is advisable, but not a necessity, that the ratio d/w is less than three, and also that the depth d is just sufficient to allow impact penetration to the desired maximum depth. Because the contact-area pattern of the ridges 7 on a dimpled golf ball surface is random, excessive damage of the ridges 7 is required before significant performance degradation occurs.
It has been found that, compared with a plain, flat-faced putter-head, the ridge-faced putter according to the invention gives a perceptibly ‘softer’ impact (that is, with lower transient acoustic intensity, especially for high frequency components). This ‘softer’ characteristic derives from the more gradual application of impact energy to the ball, and the hardness of the ridge material has negligible effect. It is thus advantageous to fabricate the ridges, and the putter-head as a whole, of an extremely hard and durable material; this is not traditionally desirable in flat-faced putter designs. For example, a steel ridge-faced putter-head can be deep case hardened using a nitride hardening process and further surface protection can be provided with a titanium nitride (TiN) vacuum deposited coating. In addition to high resistance to wear, titanium-nitride coatings have an attractive metallic gold appearance, very high chemical inertness and low coefficient of friction, all of which enhance putter-head design.
The following formula gives a fairly accurate relationship between the maximum depth (millimeters) of a footprint and its span (millimeters) for golf balls:
footprint depth=0.006×(footprint span) 2
Here, the footprint span is taken to be equal to the diameter of a circular footprint that would be obtained with a flat putter on a smooth-surfaced golf ball. Thus, a footprint having a span of 5 millimeters (typical of a short putt with a hard covered golf ball) has a maximum footprint depth of only 0.15 millimeters. It has been found that dimple errors reduce to negligible levels with footprints having spans above 9 millimeters. A span of 9 millimeters equates to a footprint depth of 0.486 millimeters, and from this it can be determined that there is advantage in limiting ridge-depth to between 0.4 millimeters to 0.5 millimeters. Thus, in a typical embodiment, the following set of dimensions would obtain:
p
1.60 millimeters
d
0.40 millimeters
w
0.36 millimeters
r
0.18 millimeters
The outermost surfaces of the ridges are desirably substantially coplanar throughout the impact face. Where a convex design of overall putter face is involved, the outermost surfaces of the ridges desirably conform to substantially smooth surfaces of relevant curvature.
The ridges are normally of uniform cross-sectional dimensions and pitch throughout the putter face, but pitch and/or profile may be graduated in order to impart shaped force distribution properties to the impact area.
FIGS. 3 to 6 show ridge-configurations that may be used as alternatives to that of FIG. 2 , in the putter-head 1 of FIG. 1 .
Referring to FIG. 3 , the ridges 10 in this case have a symmetrical profile with a flat-top apex 11 , flat main flanks 12 and flat intermediate flanks 13 . The main flanks 12 may be angled, as shown, to converge towards the apex 11 , or may be parallel to one another.
In FIG. 4 , the ridges 14 have a profile that involves a curved, cylindrical tip 15 together with convergent flat-flanks 16 that are tangential to the tip 15 . Similarly, in FIG. 5 , ridges 17 have a profile that is curved at the apex 18 and has convergent flat-flanks 19 , but in this case the flanks 19 are not tangential to the curve.
FIG. 6 illustrates a further ridge-profile in which the ridges 20 have a flat-top apex 21 and flat flanks 22 to give a substantially rectangular cross-section.
Footprint traces that result from striking a golf ball having a dimpled soft-cover with a plain, flat-faced putter-head, and with a ridge-faced putter-head according to the invention, are illustrated in FIGS. 7 and 8 respectively, for comparison purposes. The ball is struck in each case to produce an initial ball velocity of about 3 meters per second, and the ridges of the ridged putter-head have a pitch of about 1.4 millimeters.
As illustrated in FIG. 7 , the footprint 23 of the flat-faced putter-head was delimited in practice by a circle 24 having a diameter of 7.0 millimeters. On the other hand, the circle 25 , illustrated in FIG. 8 , delimiting the footprint 26 of the ridge-faced putter-head was found to be 8.3 millimeters. This larger diameter for the footprint 26 indicates that penetration of the golf-ball surface by the ridge-faced putter-head was 40% deeper than by the flat-faced putter-head.
It is to be noted that the greater part of the contact area (black) of footprint 23 of FIG. 7 is contained left of centre of the circle 24 . This means that in this (random) instance, the effective impact force was biased to the left of centre with the result that the ball would veer slightly to the right. In comparison, the total contact area for the ridge-faced putter-head in footprint 22 of FIG. 8 , has a better lateral distribution throughout the circle 25 , and comprises separate, substantially-horizontal contact areas made with the ball by six individual ridges of the head.
The dominant ridges (that is to say, those at or near the centre of the footprint) form relatively deep impact indentations, which, being generally horizontal, impede vertical slippage between the impact face and the ball during impact. Conversely, the ball is more able to slip laterally, along the length of the rounded and smooth topped ridges. These conditions are optimum for imparting topspin while at the same time minimising errors due to incorrect swing path.
FIGS. 9 and 10 are bar graphs showing computed peak-force contributions as a percentage of total peak impact-force for adjacent ridges of putter-heads according to the present invention, in respect, respectively, of two different ridge configurations. For simplicity, use of a smooth-surfaced ball with diameter 42.7 millimeters (as for a golf ball) is considered, and it is assumed that the Hertz law of contact approximates the force-deformation relation. Thus, the force contribution from each ridge is taken as proportional to its depth of penetration raised to the power 3/2.
In the circumstances represented by FIG. 9 the ridge spacing is 1.4 millimeters and the depth of penetration is 0.41 millimeters (maximum), with six ridges contributing to the impact. This replicates the general impact conditions that obtained with footprint 26 of FIG. 8 .
The ridge spacing for the circumstances represented in FIG. 10 , is 1.0 millimeters and eight ridges contribute to the impact. From this it is revealed that a maximum depth of penetration of 0.34 millimeters is required to develop the same total peak force as obtained in the circumstances of FIG. 9 . The peak depth of penetration is only 19% greater than that obtained with the flat-faced putter in footprint 23 of FIG. 7 , whereas with the ridge spacing of 1.4 millimeters applicable to FIG. 9 a penetration 40% larger is achieved. Thus, with a ridge spacing of 1 millimeters or less, the increase in penetration relative to a flat-faced putter is significantly less than that obtained with a ridge spacing of 1.4 millimeters or more (all other factors being equal). Since increasing the depth of a footprint reduces dimple-effect errors, it is revealed that the ridge spacing of 1.4 millimeters is an improvement compared with the ridge spacing of 1.0 millimeters.
Measurement of dimple-effect error and obtaining statistical results for ridge-faced putter-heads according to the invention, can be readily carried out using the apparatus of FIGS. 11 and 12 .
Referring to FIGS. 11 and 12 , the apparatus includes a fixture 31 for positioning the ball in front of an impact block 32 that is coupled to a linear actuator 33 via parallel drive shafts 34 . An impact-face member 35 under test is releasably attachable to the block 32 and a drop-impact recording plate 36 is used as a platform for recording results of the test.
The ball-position fixture 31 and the linear actuator 33 are mounted above floor-level with the plate 36 on the floor in front of them. A golf ball 37 is placed on the fixture 31 and the linear actuator 33 is then operated so that the ball 37 is hit by the member 35 under test. As struck by the member 35 , the ball 37 is propelled through the air to drop onto the drop-impact plate 36 where the position of its landing is recorded as a mark on impact-sensitive paper. The process can be repeated to accumulate a series of test results for the relevant member 35 , and then for other configurations of impact-face members substituted for the member 35 .
The actuator 33 can be set to give precisely repeatable strokes and arranged to launch the golf ball 117 with initial linear velocity of 2.5 meters per second and negligible imparted spin. In the absence of dimple-effect error, the direction of ball-launch is initially along a horizontal Y-axis direction normal to the plane of the impact-face of the member 35 , and the drop from the initial position of the golf ball to the landing position on the plate 36 is a known distance H measured along a vertical Z-axis. For a ball travelling horizontally with a velocity of 2.5 meters per second, the length L along the Y axis between its initial resting position and its impact on the plate 36 can be readily calculated. In particular, assuming that the local value of gravity is 9.81 meters per second per second, the value of L is calculated from:
L= 1.129×H 1/2
Thus when the height H is 0.785 meters the length L is 1.00 meter for an initial horizontal velocity of the ball of 2.5 meters per second.
With dimple-effect errors, the landing spot changes. Directional (that is, azimuthal) errors give rise to displacements along a horizontal X-axis transverse to the Y-axis, with the degree of angular error approximately proportional to the X-axis displacement and inversely proportional to L. Angular errors in launch elevation give rise to variations along the Y-axis, but the magnitude of these errors is approximately a quadratic function of L.
The apparatus of FIGS. 11 and 12 demonstrates the principle of ballistic techniques for measuring putter characteristics, and provides a very accurate means for determining dimple-effect errors. The use of a linear actuator in this is much preferred to other means using a mechanically-swung putter since it is difficult to maintain precisely repeatable impact conditions with a mechanically swung putter.
The accuracy of the apparatus of FIGS. 11 and 12 can be validated using a billiard ball, which has high spherical symmetry. In practice it is found that impact energy and angular errors in such a measurement system are very small compared with dimple-effect errors. The apparatus allows rapid testing of a ball or sample of balls. The drop impact recording plate 36 can with advantage be replaced by electro-optical means for measuring the ball displacement along the X-axis.
The design of the initial ball-position fixture 31 is critical. It is important that the ball 37 is placed in a fixed and stable initial rest position for each shot but the fixture 31 should not significantly interfere with the movement of the ball at impact. In this regard it has been found advantageous to form the member 31 of foam rubber and bond to it a nylon washer 38 ( FIG. 12 ) having a hole diameter of 6.5 millimeters for seating the ball; this is sufficient for accurate location but also provides a very shallow seating. During impact, very little force is required to depress the washer 38 into the foam-rubber member 31 and so allow the ball to move virtually unimpeded.
The height of the fixture member 31 can be finely adjusted with shims (not shown) and this allows very accurate positioning of the initial position of the ball along the Z-axis. This is required to ensure that the height of the initial position of the ball relative to the impact-face member 35 is adjusted for worst case impact, that is to say, with the centre of a ridge coincident with the centre of impact. This condition can be verified using a smooth-surfaced golf ball substitute, having the same diameter as the test golf balls and recording the impact footprint of the impact-face member 35 on the smooth-surfaced ball. It is found that the arrangement of FIG. 12 gives very stable and precise control of the impact position along the Z-axis so that worst case impact can be reliably tested.
The ambient temperature of the test area should be monitored and controlled during measurement and comparative measurements of different impact-face members should be carried out at the same nominal ambient temperature. Handling of the test sample of balls should be minimised to ensure that they remain at ambient temperature during the testing.
In practice various refinements are required so that error results of several hundred or even thousands of shots can be efficiently recorded. It is believed that the dimple-effect characteristics of a given impact-face configuration and a given golf ball type are best evaluated by taking large measurement samples with random initial golf-ball orientations. The sample size depends on the degree of confidence and precision required in the statistical measurement. Random initial golf-ball positions are easily obtained since it is very difficult to orientate a golf ball to ensure either a minimum or maximum dimple-effect error.
The present invention seeks to provide reduction in dimple-effect errors relative to a hard flat-faced putter-head with specified ball type and putt strength. This reduction is measured as the difference in the standard deviations of dimple-effect errors for a putter-head according to the invention relative to a hard flat-faced putter-head. Preferably 99% confidence limits should apply. The upper limit of standard deviation for error measurements obtained with the improved dimple-effect impact-face should be a given percentage (85% or less) of the lower limit of standard deviation for dimple-effect error measurements obtained with the hard, flat-faced putter-head. In practice this means that the sample size (that is to say, the number of measurements) can vary depending on the margins of improvement obtained.
FIGS. 13 and 14 show records of dimple-effect errors for two different impact-face members. These records are in the form of scatter graphs showing deviations of landing spots on the recording plate 36 of FIGS. 11 and 12 . FIG. 13 shows the deviations (due to dimple-effect errors) for a standard hard, flat-faced impact-face member for fifty shots, whereas FIG. 14 shows the results under the same measurement conditions as FIG. 13 except that the impact-face member, although again hard, was of the form of FIG. 3 with ridge widths of 0.4 millimeters and pitch of 3.0 millimeters. In FIG. 13 , the overall range of X-axis deviations is marked as 41 and the overall range of Y-axis deviations as 42 . Similarly in FIG. 14 , the overall range of X-axis deviations is marked as 43 , and Y-axis deviations as 44 . It is to be noted that the marker 43 is about 10% longer than the marker 41 indicating that directional errors due to dimple-effect are slightly greater. Also, the marker 44 is about 140% longer than marker 42 , showing that the impact-face member of the form applied in FIG. 14 degrades dimple-effect performance for elevation errors.
The scatter graphs of FIGS. 13 and 14 give an example where small samples of measurements are sufficient to differentiate between good and bad performance. The impact-face member that was used to obtain the results in FIG. 14 was of a ridge-faced form with pitch dimension of 3.0 millimeters. This pitch dimension is found to be too large as it introduces a strong dominant ridge effect that concentrates the initial contact force and produces gross inconsistencies in elevation performance as well as degrading rather than improving directional accuracy.
The scatter graph form of measurement is useful for quick initial evaluation of impact faces. For more detailed measurements, the position along the X-axis of each landing spot on the drop-impact recording plate 36 is required. Using a long strip or roll of impact-recording paper and shifting the Y-axis position of the paper after each shot can accomplish this. Successive shots are then separate and stretched out along the length of the paper. Y-axis information is lost, but the X-axis position of each shot is recorded and can be measured relative to the edge or other Y-axis reference on the strip or roll of paper. This technique has been used to analyze dimple-effect errors for a large variety of impact-face configurations, and further test results will now be described with reference to FIGS. 15 and 16 .
FIG. 15 is a histogram showing the distribution of dimple errors from a SURLYN® covered golf ball using a standard flat-faced putter. The measurements were taken with the precision putting apparatus of FIGS. 11 and 12 , recording the angular error of each putt. Measurements for a sample of five hundred putts were taken and the results sorted into bins of 0.4 degrees. Each bar in the histogram represents the number of putts per bin as a percentage of the total sample. The errors appear approximately normally distributed with measured standard deviation of 0.66 degrees.
FIG. 16 correspondingly shows the distribution of dimple errors in a sample of two hundred and fifty putts (bin size 0.4 degrees) on the same SURLYN® covered golf ball using a ridge-faced putter-head of the form of FIG. 2 . The ridges had a pitch of 1.6 millimeters, width of 0.32 millimeters and a depth of 0.32 millimeters. The tip shape was semi-cylindrical with a TSF of 0.58. The errors appear approximately normally distributed with measured standard deviation of 0.40 degrees—a reduction of about 40% compared with the results represented in FIG. 15 . It is to be noted that the measurements of FIG. 16 were obtained with the height of the initial-ball position fixture 31 varied throughout the test to give an average of worst-case and best-case impact positions.
The characteristics of a variety of hard and soft ridge-faced impact faces are recorded in FIGS. 17 and 18 , the results for six hard impact-faces being tabulated in FIG. 17 , and for three soft impact-faces (all of the same grade of softness) in FIG. 18 . The standard deviation s determined from each test using a sample size N, is indicated in the last line of each table. All measurements were carried out using one type of hard-covered golf ball with a launch velocity of 2.50 meters per second ±1% and with the impact-face member 35 of the apparatus of FIGS. 11 and 12 positioned so that a ridge centre was substantially coincident with the centre of impact. Ambient temperature was maintained in the range 16 to 18 degrees Celsius.
Referring to FIG. 17 , test No. 1 relates to a hard flat-face putter. This test used a large sample (N=1055) in order to establish the basic dimple-effect performance of the ball-type used. The ball used was such as sold under the trade mark DUNLOP DDH 110 , and the standard deviation of the sample was found to be 0.72 degrees. The measurements give 90% confidence that the population standard deviation for dimple-effect errors lie within the limits 0.69 to 0.75 degrees at 17 degrees Celsius. Preferably, all estimates of the performance of an impact surface should be carried out with a sample of golf balls whose standard deviation for dimple-effect errors lie within the above limits or equals that of the ball used, to within ±4%.
Test No. 2 relates to the ridge configuration of a currently-marketed putter. The ridge profile (which as with all profiles shown in FIG. 17 , is represented with a 15× magnification) has a flat apex giving a high value of TSF outside the preferred range for hard ridges. The improvement in worst-ase dimple-effect errors is only about 8%.
Test No. 3 relates to an experimental ridge configuration comprising a semi-cylindrical tip (radius 0.34 millimeters) with width slightly larger than the ridge shape of test No. 2 but with reduced TSF. Although the width is greater (which would tend to reduce improvement) the reduced TSF results in a significant improvement compared with test No. 2.
Test No. 4 relates to a second experimental ridge configuration with radius reduced to 0.18 millimeters giving a width of 0.36 millimeters. It can be seen that the reduction in width significantly improves performance. Worst-case performance in the sample was measured as 26% below that of test No. 1 and overall performance is expected to be about 40% below or better.
Tests No. 5 and 6 used very small TSF ridges and were fabricated using precision wire erosion machining. The data indicates that the lower TSF resulting from the smaller tip radii (0.05 millimeters in both cases) does not reduce dimple-effect errors to the same degree as the ridge configuration of test No. 4, or in any case provides limited improvement. It is believed that this is due to higher plastic deformation at impact and it is therefore considered that TSF values below 0.5 do not meet the aims of the invention.
Referring now to FIG. 18 , test No. 7 relates to a flat-faced putter with one type of soft material, which was also used to fabricate rectangular-section ridge configurations (with TSF of 0.667) used for test Nos. 8 and 9. This material gave a nominally 15% improvement in dimple-effect performance relative to the hard surface of test No. 1.
Test No. 8 demonstrates the dominant ridge effect in soft materials. The second design (again based on FIG. 7 ) has a pitch of 3.3 millimeters and a ridge-width of 1.4 millimeters. These measurements show a very severe degradation of 26% increased standard deviation compared with the flat-faced face of the same material, and are also worse than a flat-faced hard impact face.
Test No. 9 shows that reducing the pitch to 1.6 millimeters (in this particular material) and slightly reducing the width improves performance significantly, namely 10% better than the flat-faced impact-face of the same material and 24% better than the standard hard face.
The measurements of FIG. 18 demonstrate that when using soft impact-faces with rectangular-profile ridges performance is strongly affected by the dimensions used.
Three alternative ridge-profiles are illustrated in FIGS. 19 to 21 and will now be described.
Referring to FIG. 19 , a ridge 50 in this case has an asymmetric profile for use with hard material. The ridge 50 has upper and lower flanks 51 and 52 and a tip 53 (distinguished by crosshatching). The tip 53 , which extends from the apex 174 to a depth of 0.15 millimeters, comprises a variety of shape features, namely a sharp cornered apex 54 , an outer, angled flat 55 and a rounded corner 56 . The nominal base 57 (Indicated by dashed-line) of the ridge 50 extends parallel to the putter face 58 being (in accordance with the definition of “base”) located where the thickness of the ridge cross-section equals three times the thickness at 0.15 millimeters depth from the apex 54 . In most practical forms of ridge construction, mechanical features at depths beyond the defined base have negligible effect on putting performance.
FIG. 20 shows an arrangement Involving soft resilient-ridges according to the invention.
Referring to FIG. 20 , the ridges 60 in this case are of a rectangular profile having a flat-top apex 61 . The gaps between the ridges 60 are filled with material 62 of several durometer points softer than the ridges 60 , which themselves may be softer than the golf ball. The purpose of the filling material 62 is to prevent ingress of dirt inside the narrow deep gaps or grooves between ridges. Different colour materials may be used for the ridges 60 and filler material 62 for cosmetic effect. The filling material 62 may protrude or be flush with the apex 61 , or may be under-flush (as shown).
Most of the impact force on a golf ball by the impact-face of FIG. 20 , is transmitted via the ridges 60 . The filling material 62 does not prevent deflection of the ridges 60 when subject to vertical shear forces or to lateral expansion under normal deformation forces. Thus, the filling material 62 contributes only a minor part of the impact forces on the ball. In this context, the gap between ridges 60 is defined as the thickness of the filling material 62 at a depth of 0.2 millimeters from the apex 61 .
FIG. 21 shows an arrangement in which hard ridges 63 are embedded in a soft resilient base 64 . In a preferred arrangement, each ridge 63 is separately formed from strip steel or other hard material and is embedded into the resilient base 64 with its outer surface or apex substantially coplanar with that of each other ridge 63 and such as to create an array of substantially parallel horizontal ridges of uniform pitch. The ridges 63 may be interconnected with one another to facilitate assembly.
The projecting parts of the ridges 63 are preferably dimensioned in a corresponding manner to the ridges of FIGS. 2 to 5 . The ridges 63 preferably extend deeply into the base 64 so that they are firmly embedded, and may be bonded to the base 64 or a tight fit into mating slots in it (allowing individual ridges 63 to be replaced). | A golf-putter head ( 1 ) has a grooved impact face ( 5 ) defining lengthwise ridges ( 7 ) for impacting a dimpled golf-ball in areas of contact that are distributed around the dimples for improvement of putt accuracy by collectively centralizing the resultant striking force on the ball. The profile, width w and pitch p of the ridges ( 7 ) are selected according to hardness h and with p and w not exceeding 3.5 mm and (p−0.4) mm respectively, to reduce the standard deviation of dimple-effect error distribution by at least 15% in putting with initial ball-velocity of 2.5 m/s. Ridge-profile is symmetrically rounded (FIGS. 2,4,5,21 ), flat (FIG. 6,20 ) or segmented-flat (FIG. 3 ), or asymmetrical (FIG. 19 ), and test apparatus (FIGS. 11, 12 ) uses a linear actuator ( 33 ) for projecting the ball repeatedly to drop onto an impact-recording plate ( 36 ) to reveal scatter due to dimple-effect error. | 0 |
FIELD OF THE INVENTION
[0001] The present invention relates generally to multi-barbed devices for maintaining tissue in apposition to promote wound closure and healing or for attaching tissue to adjacent structures or organs, and methods of use of such devices.
BACKGROUND OF THE INVENTION
[0002] Several types of wound closure devices and methods are known, and typically include sutures, staples, surgical tapes and tissue adhesives. Application of most of these wound closure devices is time consuming, and requires considerable manual dexterity and patience. In addition, while these methods are functionally adequate, some may take too long to provide effective wound closure, or be cosmetically unappealing.
[0003] Most prevalent is the use of needles and sutures. Sutures provide high tensile strength, a low incidence of reopening, and can provide minimal cosmetic scarring. Application of sutures is by far the slowest method of obtaining wound closure, the sutures typically require removal and the use of anesthetic and have the highest tissue reactivity and application cost.
[0004] Surgical staples have the advantages of rapid application, low tissue reactivity, low cost, and reduced risk of needle-sticks (and hence transmission of blood borne disease) to the surgeon and attending staff. Staples generally have low tensile strength than sutures, generally must be removed, and may interfere with certain imaging modalities, such as MRI or CT scanning. In addition, because staples typically present smaller contact areas to the tissue being closed, they present a higher risk of the wound being torn open.
[0005] Surgical tapes provide the least tissue reactivity, rapid application, low infection rates and low cost, reduced risk of needle-sticks, and a high degree of patient comfort. Because such tapes are topically applied, they provide much lower tensile strength than sutures, and thus the highest incidence of inadvertent reopening. In addition, such tapes generally cannot be used in hairy body areas, and must be kept dry.
[0006] Tissue adhesives and sealants offer advantages of rapid application, low cost, and a high degree of patient comfort. In addition, such adhesives do not need to be removed. Drawbacks associated with tissue adhesives include low tensile strength and high incidence of wound reopening when applied in areas subject to high tensile loads.
[0007] Most biologically derived sealants adhere to tissue by participating in the normal clotting cascade. Fibrin glues, for example, are generally used to control bleeding or to reinforce suture or staple lines rather than to make tissues adhere, thus functioning more as hemostatic agents than glues. While several new technologies are under development that offer the potential for use in diffuse bleeding sites, fibrin glues generally are most effective in areas of inactive bleeding.
[0008] Drawbacks common to many previously known wound closure techniques, such as sutures and staples, typically involve the skin in one way or another and therefore cause disfigurement of the skin (i.e. the suture penetration points). In addition, because such devices only hold the tissue together at certain points, they do not take advantage of the entire tissue surface area to create a strong bond.
[0009] Drawbacks associated with tissue adhesives and sealants are that most of these glues take several minutes to set, may not work in a wet environments and provide only limited tensile strength. Such glues work by binding with individual molecules on either side of the wound and therefore recruiting a large surface area in the act of binding the two surfaces together. This is an improvement over the needle and suture method where discrete “points” or tracks defined by the puncture sites of the needle where the suture passes through or the puncture site of the staple have the role of providing support for the coaptation of the two surfaces.
[0010] In view of the foregoing, it would be desirable to provide wound closure devices and methods that merge the desirable features of previously known wound closure systems, i.e. to take advantage of the entire surface in coaptation as well as utilizing a mechanical element to retain the tissue portions in apposition.
[0011] It further would be desirable to provide wound closure devices and methods that allow a surgeon to close a wound rapidly and effectively without damaging the skin surface adjacent the wound, thus creating a scar.
[0012] It also would be desirable to provide wound closure devices and methods that provide a high-tensile strength bond and are not visible from outside the skin.
[0013] It still further would be desirable to provide wound closure devices and methods that may be used not only to establish and retain tissue portions in apposition, but which also may be used to provide adhesion to a large surface area, e.g., such as for hernia repair or attaching large skin grafts onto the surface of the body.
[0014] It also would be desirable to provide wound closure devices and methods wherein the devices may be configured in different shapes for different applications, including such shapes as a sheath, a cylinder, a ball a strip or a long rod like shape, and may be used intraoperatively or laparoscopically.
[0015] It yet further be desirable to provide wound closure devices and methods that can be used in wet or bleeding environments without significant loss of intended function.
[0016] It also would be desirable to provide wound closure devices that can be doped with a therapeutic agent, e.g., growth factor or thrombin, to aid wound healing or a clot enhancement.
SUMMARY OF THE INVENTION
[0017] In view of the foregoing, it is an object of the present invention to provide multi-barbed wound closure devices and methods for establishing and maintaining two sides of a wound in apposition.
[0018] It is another object of this invention to provide wound closure devices and methods that merge the desirable features of previously known wound closure systems, for example, by taking advantage of the entire surface in coaptation as well as utilizing a mechanical element to retain the tissue portions in apposition.
[0019] It is another object of the present invention to provide wound closure devices and methods that allow a surgeon to close a wound rapidly and effectively without damaging the skin surface adjacent the wound.
[0020] It also is an object of this invention to provide wound closure devices and methods that provide a high-tensile strength bond and are not visible from outside the skin.
[0021] It further is an object of the present invention to provide wound closure devices and methods that may be used not only to establish and retain tissue portions in apposition, but which also may be used to provide adhesion to a large surface area, e.g., such as for hernia repair or attaching large skin grafts onto the surface of the body.
[0022] It still further is an object of the present invention to provide wound closure devices and methods wherein the devices may be configured in different shapes for different applications, including such shapes as a sheath, a cylinder, a ball a strip or a long rod like shape, and may be used intraoperatively or laparoscopically.
[0023] It yet further is an object of the present invention to provide wound closure devices and methods that can be used in wet or bleeding environments without significant loss of intended function.
[0024] It also is an object of this invention to provide wound closure devices that can be doped with a therapeutic agent, e.g., growth factor or thrombin, to aid wound healing or a clot enhancement.
[0025] In accordance with the principles of the present invention, the wound closure device comprises a substrate having a plurality of biodegradable barbs extending from at least one surface of the substrate. The multi-barbed device therefore permits closure of a wound in a timely, cosmetic and convenient manner.
[0026] The substrate generally is in the form of a thin strip of bioabsorbable polymer, and may be solid or have perforations forming a mesh. Where provided, the perforations allow the tissue and body fluids to contact the other side and enhance the healing process.
[0027] Where designed for applications in bringing the tissue edges of a wound into apposition and maintaining the tissue in fixed relation during healing, the substrate is provided with a multiplicity of barbs projecting from opposing sides of the substrate. The barbs have a sharpened distal end to facilitate tissue penetration, and hooks that grasp the tissue penetrated. Alternatively, the multiplicity of barbs may project from only one side of the substrate, for example, where the device is to be used to mend large areas of tissue, e.g., in hernia repair.
[0028] In accordance with the methods of the present invention, the multi-barbed device of the present invention is inserted within a wound or underneath the skin, and mechanically attaches to and brings the opposing tissue sides together.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] The above and other objects and advantages of the present invention will be apparent upon consideration of the following detailed description, taken in conjunction with the accompanying drawings, in which like reference characters refer to like parts throughout, and in which:
[0030] [0030]FIG. 1 is a perspective view of an illustrative wound closure device constructed in accordance with the principles of the present invention;
[0031] [0031]FIG. 2 is a side view of the device of FIG. 1;
[0032] [0032]FIG. 3 is a detailed view of various embodiments of barbs suitable for use with the device of the present invention;
[0033] [0033]FIG. 4 is a perspective view of a preferred method of employing the device of FIG. 1 to close a wound in a human body;
[0034] [0034]FIG. 5 is a perspective view, partly in section, of a tube constructed in accordance with the present invention;
[0035] [0035]FIG. 6 is a perspective view of an alternative tube constructed in accordance with the present invention;
[0036] [0036]FIG. 7 is a view showing insertion of an artificial cartilage including the multi-barbed device of the present invention within a human knee;
[0037] [0037]FIG. 8 is a view showing placement of an intervertebral disk including the multi-barbed device of the present invention within a human vertebrae;
[0038] [0038]FIG. 9 is a perspective view of several components of the present invention in the form of a clamshell;
[0039] [0039]FIGS. 10A and 10B are, respectively, perspective and side views of the present invention in the form of two halves that are attachable by sutures;
[0040] [0040]FIG. 11 is a side view of an anastomosis device including the multi-barbed device of the present invention suitable for use in coronary artery bypass grafting;
[0041] [0041]FIG. 12 is a side view of an embodiment of the present invention providing longitudinal flexibility;
[0042] [0042]FIG. 13 is a perspective view of an alternative embodiment of the device of the present invention formed by stamping the barbs from the substrate material; and
[0043] [0043]FIG. 14 is a side view of the alternative embodiment of the present invention in the form of a flexible rod coated with a plurality of the barbs.
DETAILED DESCRIPTION OF THE INVENTION
[0044] Referring to FIGS. 1 to 4 , a preferred embodiment of multi-barbed, multi-sided device 20 of the present invention is described for attaching coapting and maintaining two sides of a wound. Device 20 comprises substrate 21 having multiplicity of barbs 22 projecting from opposite sides 23 and 24 . Barbs 22 have sharpened distal ends 25 that enable the barbs to penetrate tissue.
[0045] Substrate 21 may be either rigid or flexible, and preferably comprises a thin sheet or strip of a bioabsorbable polymer that can be absorbed by the body such as polylactic acid, polyglycolic acid, polycaprolactone, polyethylene glycol, or other bioabsorbable polymers known in the art. Substrate 21 may by either solid or include mesh-like perforations 26 that permit the wound edges to communicate with one another, thereby facilitating the healing process. Depending upon the intended application, substrate 21 may be made sufficiently flexible to conform to the tissue to be joined.
[0046] In the embodiment of FIGS. 1 - 4 , barbs 22 project substantially orthogonally away from the plane of substrate 21 , and include distal tissue-piercing end 25 and shank 27 . Barbs 22 preferably are dull enough to not penetrate a surgical glove yet sharp enough to penetrate tissue. Distal ends 25 of barbs 22 may have a harpoon configuration ( 25 a in FIG. 3), an arrow configuration ( 25 b in FIG. 3) or being conically shaped ( 25 c in FIG. 3). In addition, barbs 22 may include additional ribs, hooks or projections 28 disposed along shanks 27 to further enhance the gripping ability of the barbs.
[0047] Barbs 22 preferably comprise a material that is sufficiently rigid to penetrate tissue during application, and is capable of withstanding the tensile forces expected during normal use, i.e., so the barbs cannot be pulled out and shanks 27 will not fracture in large numbers. Barbs 22 may comprise a bioabsorbable polymer, metal, or metal alloy. Barbs 22 may be made having shank lengths ranging from a fraction of a millimeter, e.g., for plastic surgery, to many millimeters, e.g., for large operations or veterinarian use.
[0048] Perforations 26 in device 20 reduce concerns that the substrate would be a barrier to healing, and instead allow the tissue edges and body fluids to contact one another across through substrate 21 , thereby accelerating the healing process. The perforations are passageways for the tissue and body fluids to have free communication from one side to the other. Perforations 26 may comprise up 90% or more of the area of substrate 21 .
[0049] In addition, substrate 21 and/or barbs 22 may be coated or impregnated with an anesthetic to reduce pain during wound healing. Alternatively, device 20 may include other drugs or therapeutic agents that provide some therapeutic effect during healing, for example, angiogenic agents or growth factors to facilitate wound healing, anti-inflammatory agents to reduce swelling or antibiotics to reduce infection.
[0050] Device 20 , and the alternative embodiments described hereinafter, have a number of applications, including:
[0051] Routine surgical wound closure;
[0052] Orthopedic procedures such as meniscal repair;
[0053] Wartime field use for fast wound closure;
[0054] Plastic surgery where it is cosmetically desirable to avoid the use of sutures; and
[0055] Grafting a large piece of planar tissue, such as fascia or skin, onto an area of the body.
[0056] Still referring to device 20 to FIG. 1, device 20 preferably comprises a biodegradable polymer such as polyglycolic acid or polylactic acid, and is preferably flexible to conform to curved surfaces. Barbs 22 may be constructed of the same material or a different material and preferably also are bioabsorbable. The whole device 20 , including substrate 21 and barbs 22 , may be molded out of one of the foregoing polymers. Perforations 26 enable the two sides of the wound to communicate with one another to facilitate healing of the wound, as described above.
[0057] In FIG. 4, device 20 is shown disposed within wound W. In accordance with a method of the present invention, device 29 is placed into the wound, and the two edges of the wound are approximated and squeezed together onto the multiplicity of barbs 22 so that tissue adhesion occurs. Barbs 22 thereby penetrate the tissue on both sides of substrate 21 and maintain the two edges of the wound firmly together.
[0058] Referring now to FIGS. 5A and 5B, an alternative embodiment of the present invention in form of a tube is described. Tube 30 , shown partly in section, includes a multiplicity of internal barbs 32 that project radially inward. The wall of tube 30 may comprise a solid material, such as a metallic or polymeric material, or may be in the form of a mesh.
[0059] Barbs 32 may be disposed only in regions adjacent to the ends of tube 30 , or as shown in FIG. 5A, may extend for along the entire length of the interior of tube 30 . Barbs 32 may project substantially orthogonally from the interior surface of tube 30 , or may in addition be angled towards the mid-point of the tube.
[0060] In accordance with the methods of the present invention, if a blood vessel or a tendon is inserted into tube 30 , it will be firmly engaged by the plurality of barbs 32 , and will be unable to come back out of the tube. Thus, two ends of a torn tendon may be inserted into the tube 30 to provide a strong connection.
[0061] In FIG. 6, an alternative embodiment is depicted in which the multiplicity of barbs is disposed on the exterior of the tube. Tube 40 may have a solid or hollow cross-section, and may comprise either a rigid or flexible material. Barbs 42 allow a tubular structure, such as a vessel, to be pulled over tube 40 like a sock and be firmly gripped. Examples of applications include rejoining of a fallopian tube or vas deferens anastomosis to reverse sterilization in a female or male subject.
[0062] In FIG. 7, an embodiment of the multi-barbed substrate of the present invention is described for use in joint repair to anchor artificial cartilage to the tibial chondyle. In this embodiment, artificial cartilage 50 is prepared having substrate 51 anchored to its lower surface. Substrate 51 includes multiplicity of barbs 52 , as described hereinabove, projecting from substrate 51 .
[0063] Artificial cartilage 50 is introduced arthroscopically in a contracted condition. Once disposed within in the knee space, artificial cartilage 50 , including substrate 51 , is unrolled over the tibial chondyle. High-pressure balloon 55 , or some other mechanical means, e.g., a mallet, is then used to apply a force on the surface of the artificial cartilage and substrate, thereby forcing the multiplicity of barbs 52 into engagement with bone B.
[0064] Similarly, FIG. 8 depicts use of the structures and principles of the present invention for use in intervertebral disc replacement. Replacement disc 60 includes a multiplicity of barbs 62 on its upper and lower surfaces. Barbs 62 penetrate the vertebral end plate and stabilize it, thereby preventing rotation of the vertebrae and facilitating fusion. Replacement disc 60 preferably includes perforations, as described above, to aid in bone migration. Additionally, replacement disc 60 or barbs 62 , or both, may be coated or impregnated with hydroxy apatite, as well as growth factors, to aid in the fusion process.
[0065] [0065]FIG. 9 depicts another embodiment of a device constructed in accordance with the present invention, in which the barbs of the device are shielded until it is desired to implant the device. Substrate halves 70 a and 70 b each carry a multiplicity of barbs 72 . Substrate halves 70 are configured to be disposed within shield portions 74 a and 74 b . Shield portions 74 a and 74 b each include a multiplicity of openings 75 aligned with barbs 72 . Balloon 76 is configured to be disposed between substrate halves 70 a and 70 b , so that upon application of an outward force by balloon 76 , the barbs are driven through openings 75 in shield portions 74 a and 74 b and into the target tissue.
[0066] With respect to FIGS. 10A and 10B, another alternative embodiment is described. Device 80 includes substrate portions 81 a and 81 b , each carrying a multiplicity of barbs 82 as described above. Each of substrate halves 81 a and 81 b includes a plurality of suture eyelets 83 . In accordance with the methods of the present invention, device 80 is employed by individually adhering the substrate halves 81 a and 81 b to the edges of the wound. A suture 85 is then threaded through eyelets 83 in substrate halves 81 a and 81 b , and the wound is closed by pulling the suture connecting the two halves to bring substrate halves 81 a and 81 b into apposition, as depicted in FIG. 10B. Suture 85 is then knotted, and any excess suture material removed.
[0067] [0067]FIG. 11 depicts an embodiment of the present invention wherein stent-like structure 90 is used to side anastomose a blood vessel. Structure 90 includes non-barbed section 91 that is inserted into the parent vessel. Barbed portion 92 is then used to attach a bypass graft vessel.
[0068] [0068]FIG. 12 depicts yet another alternative embodiment of the wound closure device of the present invention. In this embodiment, substrate 91 comprises a rigid material including a multiplicity of barbs 92 . To ensure that the substrate is capable of flexing, however, substrate 91 is divided into a series of jointed and interlinked units 91 a , 91 b and 91 c . Joints 92 enable units 91 a - 91 c to rotate relative to one another, thereby providing a degree of flexibility to the overall device.
[0069] [0069]FIG. 13 depicts a method of manufacturing a multi-barbed device of the present invention. Device 100 comprises substrate 101 formed from a thin sheet of biocompatible polymer or metal alloy. Barbs 102 are die cut from substrate 101 , and then bent out of the plane of substrate 101 to expose sharpened distal ends 103 .
[0070] [0070]FIG. 14 depicts an alternative embodiment to that shown in FIG. 6. Device 110 , which may made available for dispensing in the form of a reel, comprises flexible substrate 111 carrying a multiplicity of barbs 112 on its exterior surface. Device 110 therefore may be unrolled and cut to length depending upon the specific desired application. For example, for non-medical industrial applications, in which it is desired to adhere two separate sheets together quickly, substrate 111 may comprise a strong plastic, e.g., Nylon, and the barbs 112 may comprise stainless steel or another metal alloy.
[0071] With respect to the above description, 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.
[0072] Although preferred illustrative embodiments of the present invention are described above, it will be evident to one skilled in the art that various changes and modifications may be made without departing from the invention. It is intended in the appended claims to cover all such changes and modifications that fall within the true spirit and scope of the invention. | A multi-barbed apparatus is provided, and methods of use, for penetrating two sides of a wound and holding the edges in apposition. The apparatus may be inserted within a wound or underneath the skin, and mechanically adheres the two sides of the wound together. The apparatus includes a biocompatible substrate carrying a multiplicity of tissue penetrating barbs on a least one side thereof, and may be formed as a rigid or flexible sheet, tube or other shape. | 0 |
BACKGROUND
[0001] 1. Technical Field The present disclosure relates to a device for assisting disabled or elderly people ascend or descend a staircase. More specifically, the present disclosure relates to a device which can be fitted onto an existing handrail of a staircase to assist a person ascending or descending the staircase.
[0002] 2. Background
[0003] The use of elevators or lifts to transport the elderly or disabled up or down a staircase are well known. Such lifts or elevators typically include a platform upon which a person, with or without a wheelchair, is supported. Such lifts or elevators are expensive, require professional installation and may be obtrusive within ones home. Although elevators and/or lifts are necessary for those incapable of walking or supporting their own weight, such a complex heavy duty system may not be required for those merely needing some degree of assistance in traversing a staircase.
[0004] Accordingly, for those merely requiring some assistance in traversing a staircase, a low cost, easily installable, less obtrusive device for assisting a person in traversing a staircase would be desireable.
SUMMARY
[0005] A stairs assistance device is disclosed which includes a body defining a handgrip and a recess dimensioned and configured to slidably receive a staircase handrail. The body supports at least one drive member, which may be in the form of a drive roller, and a motor for driving the drive member. In one embodiment, the device includes at least one guide member which is positioned to guide the device along the handrail and retain the device on the handrail. One or more guide members and/or drive members may be provided, e.g., two or three. Both the at least one drive member and the at least one guide member are positioned to engage the handrail to facilitate movement of the device along the handrail.
[0006] In one embodiment, the motor is reversible and the device includes at least one switch for selectively operating the motor in a forward or rearward direction to effect movement of the device either up a handrail or down a handrail. Preferably, the device includes a pair of switches which are positioned adjacent the handgrip.
[0007] In one embodiment, the body includes a rear body portion and a forward body portion which are pivotally connected. The pivotal connection facilitates movement of the device along non-linear handrails.
[0008] In one embodiment, the motor is battery powered. The batteries can be supported on the device and can be rechargeable. A battery charger can be supported at a top and/or bottom of the handrail to facilitate automatic recharging of the battery when the device is at the top and/or bottom of the handrail.
[0009] In another embodiment, the device includes a two way control button for operating the motor in the forward and reverse directions. The handgrip is configured for left hand and right hand use.
[0010] In yet another embodiment, the device includes an anti-rollback device for preventing accidental movement of the device down a handrail.
BRIEF DESCRIPTION OF DRAWINGS
[0011] Various embodiments of the presently disclosed stairs assistance device are disclosed herein with reference to the drawings, wherein:
[0012] FIG. 1 is a side view of one embodiment of the presently disclosed stairs assistance device positioned on a handrail;
[0013] FIG. 2 is a transverse cross-sectional view through a portion of the body of the stairs assistance device shown in FIG. 1 ;
[0014] FIG. 3 is a side view of another embodiment of the presently disclosed stairs assistance device positioned on a handrail;
[0015] FIG. 4 is a transverse cross-sectional view through a portion of the body of the stairs assistance device shown in FIG. 3 ;
[0016] FIG. 5 is a schematic view of the stairs assistance device and handrail with a battery charger positioned at one end of the handrail;
[0017] FIG. 6 is a side perspective view of another embodiment of the presently disclosed stairs assistance device positioned on a handrail;
[0018] FIG. 7 is a transverse schematic view of the stairs assistance device shown in FIG. 6 ;
[0019] FIG. 8 is a side view of yet another embodiment of the presently disclosed stairs assistance device positioned on a handrail shown during left hand operation;
[0020] FIG. 9 is a side view of the stairs assistance device shown in FIG. 8 during right hand operation; and
[0021] FIG. 10 is a schematic drawing of an anti-rollback device usable with any of the presently disclosed stairs assistance devices.
DETAILED DESCRIPTION OF EMBODIMENTS
[0022] Embodiments of the presently disclosed staircase assistance device will now be described in detail with reference to the drawings in which like numerals designate identical or corresponding elements in each of the several views.
[0023] FIG. 1 illustrates a first embodiment of the presently disclosed stairs assistance device shown generally as 10 . Stairs assistance device 10 includes a handgrip assembly 12 adapted to be mounted on an existing handrail 14 of a staircase (not shown). Handgrip assembly 12 includes a body 16 having a grip portion 18 , at least one drive member or roller 20 , and one or more guide members or rollers 22 . A battery powered motor assembly 24 is provided to drive driven roller 20 .
[0024] Referring also to FIG. 2 , in one embodiment, body 16 is configured to be mounted on a handrail 14 having an oval or circular cross-section. Body 16 includes forward and rear portions 16 a and 16 b having substantially U-shaped configurations which are interconnected by grip portion 18 . A recess 23 ( FIG. 2 ) defined by forward and rear U-shaped portions 16 a and 16 b is dimensioned to receive handrail 14 . At least one of forward and rear portions 16 a and 16 b supports driven roller 20 in a position to engage a top surface of handrail 14 . In one preferred embodiment, a driven roller 20 is supported on both forward and rear portions 16 a and 16 b.
[0025] Guide rollers 22 are positioned to extend across a bottom of recess 22 of forward and rear portions 16 a and 16 b and engage a bottom surface of handrail 14 . Guide rollers 22 prevent stairs assistance device 10 from becoming disengaged from handrail 14 . Stops (not shown) may be provided on each end of handrail 14 to prevent device 10 from rolling off the ends of handrail 14 .
[0026] Motor assembly 24 is a battery driven reversible motor which is preferably driven by a rechargeable battery. A pair of switches 30 a and 30 b are mounted on body 16 to facilitate operation of device 10 in two directions, i.e., up the staircase and down the staircase. Switch 30 a, which is preferably labeled “UP” is positioned adjacent one end of grip portion 18 and is actuable by pressing or sliding the switch to operate driven roller 20 to advance device 10 up handrail 14 . Switch 30 b is positioned on an opposite side of grip portion 18 to operate driven roller 20 to move device 10 down handrail 14 . In one embodiment, switches 30 a and 30 b are of the type which must be continually depressed to operate the driven roller. The exact location of switches 30 a and 30 b and the particular configuration of the body of device 10 may be selectively altered to provide a more ergonomic device which can be operated easily with a single hand and mounted to any handrail configuration.
[0027] FIGS. 3-5 illustrate a second embodiment of the presently disclosed stairs assistance device shown generally as 100 . Stairs assistance device 100 is similar to stairs assistance device 10 in that it includes a body 116 having a grip portion 118 , at least one driven roller 120 , at least one guide roller 122 and a battery powered motor assembly 124 . Body 116 includes forward and rear portions 116 a and 116 b which are pivotally secured together about a pivot member 117 . Pivot member 117 allows device 100 to move around bends or curves in handrail 114 . Body 116 defines a U-shaped recess 122 dimensioned and configured to receive a handrail 114 . As illustrated, driven roller(s) 120 and guide roller(s) 122 are positioned to engage a handrail 114 having an irregular shape. Preferably, driven roller 120 is positioned to engage a top surface of handrail 114 and guide rollers 122 are positioned within concavities 115 formed in the sidewalls of handrail 114 . Guide rollers 122 function to guide stairs assistance device 110 along handrail 114 and to prevent disengagement of stairs assistance device 110 from handrail 114 . Alternately, the positions of guide rollers 122 and driven roller(s) 120 can be reversed or changed without departing from the scope of the invention.
[0028] As illustrated in FIG. 5 , a battery charger 150 may be provided on one or both ends of handrail 114 . Stairs assistance device 110 includes contacts 152 which engage battery charger 150 whenever stairs assistance device 110 is positioned at either or both ends of handrail 114 . Stair assistance device 110 also includes switches 130 a and 130 b for operating motor assembly 124 and driven roller 120 to move stairs assistance device 100 either up a staircase or down a staircase.
[0029] FIG. 6 illustrates another embodiment of the presently disclosed stairs assistance device shown generally as 200 . Stairs assistance device 200 is similar to devices 10 and 100 but also includes a grip portion 218 which can be grasped by both hands of a person using stairs assistance device 200 . It is noted that grip portion 218 (or grip portions 18 and 118 ) may include non-slip or textured surfaces 260 to prevent a user's hand from slipping off the grip portion.
[0030] FIGS. 7-9 illustrate yet another embodiment of the presently disclosed stairs assistance device shown generally as 300 . Stairs assistance device 300 is mounted on a handrail 314 which is supported by a baluster 315 . Stairs assistance device 300 includes a housing 312 having a cover 316 and a handle 318 . A two way control button 330 is provided adjacent handle 318 and is actuable to operate a motor 324 .
[0031] Motor 324 drives stairs assistance device 300 via a transmission 332 and a friction pulley or drive member 334 . In one embodiment, friction pulley or drive member 334 is formed from a soft and/or flexible material, e.g., rubber, polyethylene, or porous or spongy material, etc., which may be solid or hollow. A concave stabilizer guide member 336 is provided to guide assistance device 300 along rail 314 . An adjuster device 340 supports stabilizer member 336 and urges stabilizer member into rail 314 . By doing so, drive member 334 is pulled into frictional engagement with rail 314 . As shown, this may cause partial deformation of drive member 334 . This deformation increases the contact area of drive member 334 with handrail 314 . Although not shown, two or more stabilizer members 336 and drive members 334 may be provided to assure good reliable contact between handrail 314 and stairs assistance device 300 . Further, an adjustable side support roller 344 may be provided to increase the stability of device 300 .
[0032] Stairs assistance device 300 may also include a rechargeable battery 350 . Battery 350 may be removable to facilitate recharging. Alternately, as discussed above with respect to device 100 , a battery charger may be provided on each end of rail 314 .
[0033] As illustrated in FIGS. 8 and 9 , control button 330 is ergonomically positioned adjacent a top portion of handle 318 to facilitate operation of button 330 by the thumb 360 of an operator 370 . Actuation of button 330 from left to right, as illustrated in FIG. 8 , causes stairs assistance device 300 to move to the right along rail 314 . Actuation of button 330 from right to left, as illustrated in FIG. 9 , causes stairs assistance device 300 to move to the left along rail 314 . In one embodiment, control button 330 will only operate motor 324 only when control button 330 is held in one of its two actuated positions. In another embodiment, the speed of the motor, and, thus, the speed of device 300 along rail 314 , can be controlled by varying the pressure applied to control button 330 , i.e., increased actuation pressure increases the speed of device 300 along rail 314 .
[0034] FIG. 10 illustrates a schematic drawing of an anti-rollback device 400 which can be incorporated into any of the presently disclosed stairs assistance devices to prevent the stairs assistance devices from accidentally rolling down a handrail (“accidental rollback”). Accidental rollback may occur as a result of an uneven or worn handrail or a worn roller. Anti-rollback device 400 includes a latch module 403 , a latch member 401 and a solenoid 406 . A first end 401 a of latch 401 is pivotally supported to a body of latch module 403 about a pivot member 404 . A second end 401 b of latch member 401 includes a slip resistant pad 402 positioned to engage a surface of handrail 14 . Pad 402 may be formed of rubber or the like and is secured to latch member 401 using any known fastening technique, e.g., molding, adhesives, screws, etc. Alternately, latch member 401 can be formed with an integral slip resistant surface. A biasing member, e.g., spring 405 is positioned between an inner wall of module 403 and latch member 401 in tension to urge latch member 401 to a position in which pad 402 engages handrail 14 . A solenoid 406 or the like is attached to latch member 401 directly or via a link 410 and is actuable to urge latch member 401 to a position in which pad 402 is moved off of handrail 14 .
[0035] In use, when a user is moving up a staircase, latch member 401 is maintained in sliding contact with an exterior surface of handrail 14 . If for any reason stairs assistance device 10 begins to slide downwardly along handrail 14 during upward operation of stairs assistance device 10 , pad 402 wedges against handrail 14 to prevent downward movement of stairs assistance device 10 along handrail 14 .
[0036] When stairs assistance device 10 is operated to move down a staircase handrail 14 , solenoid 406 is actuated to disengage pad 402 from handrail 14 to allow device 10 to move down the handrail. In one embodiment, solenoid 406 is powered in response to operation of switch 30 b which actuates motor assembly 24 for driving driven roller 20 (See FIGS. 1 and 2 ). As such, when switch 30 b is released, whether accidentally or intentionally, solenoid 406 is de-energized and releases latch member 401 . When latch member 401 is released by solenoid 406 , spring 405 pivots latch member 401 to move pad 402 into engagement with handrail 14 to prevent further downward movement of device 10 along handrail 14 .
[0037] In one embodiment, solenoid 406 is connected in parallel with motor assembly 24 . A diode 407 is provided to allow energizing of solenoid 406 only when device 10 is operated to move down a handrail.
[0038] Anti-rollback device 400 can be formed independently of the presently disclosed stairs assistance devices and secured to a side, front or rear thereof using known securement techniques. Alternately, anti-rollback device 400 can be integrally formed with any one or all of the presently disclosed stairs assistance devices.
[0039] It will be understood that various modifications may be made to the embodiments disclosed herein. For example, the body of the stairs assistance device may be reconfigured to engage any handrail configuration. Also, although not disclosed herein, gearing or a gear arrangement will have to be provided to connect the motor assembly to the driven roller or rollers. Many different gear arrangements suitable for use in this device will be obvious to one of ordinary skill in the art. Further, the materials used to form this device may be selected from plastics, metals or any other materials meeting the requisite strength requirements. Therefore, the above description should not be construed as limiting, but merely as exemplifications of embodiments. Those skilled in the art will envision other modifications within the scope and spirit of the claims appended hereto. | A stairs assistance device is provided for assisting persons attempting to ascend or descend a staircase. The device is configured to be mounted on an existing staircase handrail and includes, inter alia, a handgrip and a drive member for advancing the device upwardly or downwardly along the handrail. | 4 |
This application is a division of application Ser. No. 778,093 filed Sept. 20, 1985 now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to apparatus for assembling wires into electrical connectors to form wire harnesses. In particular, the present invention relates to semi-automatic bench termination equipment for such assembly.
2. Description of the Prior Art
Several arrangements have been disclosed for forming electrical harnesses of the type consisting of an electrical connector terminated to a plurality of wires of either the discrete or flat cable type. Various improvements have been made to such apparatus, as well as to the connectors and cables employed in making the harnesses. Commonly owned U.S. patent application Ser. No. 698,504 filed Feb. 4, 1985 discloses an improved electrical connector, adapted for mass termination to a plurality of wires. The connector has two rows of terminals placed one on top of the other in a staggered configuration, so as to allow all of the terminals to be mass terminated from a top surface of the connector. The connector also includes an opposed bottom surface having two series of recesses, aligned with the two rows of terminals.
When smaller quantities of electrical harnesses are needed on short notice, fully automatic termination equipment may not be suitable to meet the demand. Accordingly, bench termination equipment is typically provided to form electrical harnesses in these situations. Equipment of this type is intended for small production runs, in that it is less efficient than fully automatic machines, being more labor intensive. Typically, an operator is required to carry out each harness making cycle.
One typical arrangement provided by the owner of the present invention is designated the CAM III machine, a semi-automatic harness making apparatus. In this machine, the operator inserts a discrete wire for each terminal of the electrical connector. The machine feeds a serial succession of connectors before the operator who inserts a wire conductor above the first terminal presented, and operates a switch initiating the termination cycle for a given connector. The machine automatically indexes the connector presenting the next terminal to the operator for a successive termination cycle. Arrangements of this type are not suitable for dual row connectors, in that two termination assemblies must be provided, one for each row.
An example of a machine that does provide single-step mass termination for a dual-row staggered connector is described in U.S. Pat. No. 4,091,531 issued May 30, 1978. In that arrangement, an arbor press is provided having a lower stationary tool head, and an opposed upper moveable tool head. A connector having dual-row staggered wire receiving portions is loaded in the upper moveable head. A series of plates having particularly configured upper serrated edges are stacked together in an array which is mounted in the lower tool head. The blades provide terminal supporting, wire inserting, and wire guiding functions. A plurality of discrete wires are then fed between the upper and lower tool heads, and the upper head is lowered, so as to compress the wire between the connector, and the upper edges of the plate array. This machine is adapted for use with a connector having relatively open, unsupported wire receiving portions. It cannot be used with connectors having fully enclosed wire receiving portions, which offer significant advantages in supporting and protecting the terminals received therein.
Another termination apparatus is disclosed in commonly owned Great Britian Patent application No. 8,412,827 filed May 18 1984. The apparatus disclosed is of the wire stitcher type, wherein discrete wires are terminated one at time to a multi-terminal connector. The apparatus includes a single wire feed and terminator head. The connector to which the patent application is directed has two rows of wire receiving terminals, which are staggered in two different directions. The machine includes an indexing table for indexing a connector nest in three mutually orthogonal directions, so as to present a serial succession of terminals at a fixed position beneath the terminator blade. The indexing table for this type of apparatus is complex and somewhat costly, particularly if the wire receiving terminal portions are staggered in only one direction.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide an apparatus for terminating multiple wires to a dual-row staggered connector.
It is another object of the present invention to provide an apparatus for terminating wires in a dual-row connector, having upper and lower rows of staggered terminals, with a single wire terminator having a constant insertion stroke. This object is provided in a machine for the manufacture of electrical cable harnesses including at least one insulation-clad wire electrically terminated in a connector including a housing having at least one terminal receiving cavity with an insulation displacing terminal mounted therein, the machine including a terminator adjacent the connector having a reciprocating actuator extensible a constant predetermined amount, and at least one wire insertion blade mounted to the actuator to travel a predetermined termination stroke toward the connector so as to insert a wire in the terminal thereof, and a connector support surface for supporting said connector during termination, predeterminedly spaced from said actuator. The improvement comprises a pressure limit means between the actuator and blade which automatically limits the insertion force applied by the insertion blade, to a predetermined terminating force independent of the termination stroke, whereby the machine can automatically terminate a series of different connector arrangements requiring different termination strokes equal to or less than said predetermined stroke.
Still another object of the present invention is to provide an improved apparatus for indexing a connector to present successive terminals to a termination station. This object of the present invention is provided in a machine for the manufacture of electrical cable harnesses including an insulation-clad wire terminated in a connector having a housing with at least one terminal receiving cavity and an insulation displacing terminal mounted therein, and a bottom surface with a series of recesses formed therein, an indexing means cooperating with the housing recesses is provided for indexing the connector in a forward direction to present the terminals of the connector one at a time to a termination station. The improvement includes said indexing means wherein said connector bottom surface having at least two parallel spaced-apart series of recesses extending in the forward direction and staggered with respect to each other in the forward direction, said recesses aligned with said terminals in a predetermined orientation. The improvement comprises at least two spaced-apart indexing pawl means rotatably mounted to a reciprocating drive member movable in the forward direction, each pawl means associated with a particular series of recesses, and said pawl means alternately engageable and disengageable with the recesses of its respective series in response to movement of said drive member, such that only one pawl means is engaged with a recess at any one time, whereby upon movement of said drive means, said connector is displaced predetermined amounts in the forward direction to present a succession of terminals to the termination station.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings, wherein like elements are referenced alike,
FIG. 1 is a perspective view of a dual-row staggered connector for use with the present invention;
FIG. 2 is a perspective view illustrating the connector indexing technique of the present invention;
FIG. 3 is a front view of a termination machine showing the improved terminator and connector indexing features of the present invention;
FIG. 4 shows the machine of FIG. 3 terminating a wire in a lower connector row;
FIG. 5 shows the machine of FIGS. 3 and 4 terminating a wire in an upper connector row; and
FIG. 6 is a side view of the machine of FIGS. 3-5.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a dual-row staggered connector disclosed in a commonly owned U.S. patent application Ser. No. 698,504 filed Feb. 4, 1985. The connector, generally indicated at 10, includes upper and lower rows of terminal receiving cavities 12, 14 each having a plurality of terminal receiving cavities 16 with insulation displacement type terminals therein, not visible in this figure.
In the particular embodiment of connector 10 shown in FIG. 1, the connector has pin-receiving terminals designed to mate with pins 36 secured to a printed circuit board 38. A plurality of discrete insulation clad wires 18 are shown terminated to each terminal of connector 10.
Rows 12, 14 are arranged one on top of the other, in a staggered configuration wherein the terminal receiving cavities of one row are positioned between the terminal receiving cavity of the other row. Further, the terminal receiving cavities 16 of the upper row include sidewalls 20 forming wire receiving channels 22 guiding wires to be terminated in the lower row 14. All of the wires 18 can be terminated to both rows 12, 14 from a single upper side of the housing. Connector 10 has a mating end not visible in the figure, and an opposed wire receiving end 23.
The bottom surface 24 of connector 10, visible in FIG. 1, comprises the bottom cavity walls 26 positioned between the sidewalls 20 of each lower row terminal receiving cavity. Also, shown in the bottom surface of connector 10, are two series of recesses 30, 32 aligned with the center line progression of top and bottom rows 12, 14 respectively. Recesses 30 lie beneath the terminal receiving cavities of upper row 12, and are formed between adjacent terminal receiving cavities 16 of lower row 14. As will be explained herein, recesses 30, 32 are employed in the improved connector indexing arrangement of the present invention.
Referring now to FIG. 2, the indexing arrangement of the present invention is illustrated with a pair of pawl means 40, 42 which are joined together for simultaneous back and forth movement in the directions of arrow 50. The tip of pawl 40 is received in the recesses 30 of connector 10, and pawl 42 is received in recesses 32. The view of FIG. 2 is taken from the underside of the machine of the present invention, for purposes of illustration. Accordingly, connector 10 is shown upside-down, being slid along a guide track 46 with an incremental motion (see displacement "x" below) provided by pawls 40, 42.
In the preferred embodiment, recesses 30, 32 are aligned with the progression of upper and lower terminal rows. The offset distance between terminal rows is designated by the letter "x". Pawls 40, 42 are oscillated back and forth in the directions of arrow 50 in an amount equal to the displacement "x". As will be described herein, pawls 40, 42 are spring loaded and pivotally mounted, so as to be readily engaged and disengaged from the series of recesses which they track, to provide a "walking" motion of connector 10, in the direction of arrow 52.
Referring now to FIG. 3, terminating machine 60 according to the present invention is shown comprising upper and lower tooling assemblies 62, 64, respectively. Lower tooling assembly 64 is mounted on a support table T or other supporting surface. Upper tooling portion 62 is mounted on an upper die assembly 66 of a reciprocating press 68, such as that commonly found in bench-type crimp terminator machines. Press 68 reciprocates upper tooling head 66 in the vertical directions of arrow 69, with a constant displacement stroke indicated by the letter "z".
Tooling portion 62 comprises a pnuematic piston or cylinder 70, having a moveable piston rod 72. A compressed air line 110 is provided for operation of the piston. A mounting block 74, in turn, connected to the lower free end of piston rod 72. A conventional wire insertion blade 76 is secured in mounting block 74 to engage and insert wires 18 in connector terminals 86 which are visible in side view in FIG. 3 (which shows the wire engaging end wall 23 of connector 10).
Also mounted to upper die 66 is an elongated indexing blade 80 having a lower cam surface 82. Blade 80, securely attached to upper die assembly 66, travels the full extent of displacement "z". However, as will be explained herein, wire insertion blade 76, under the selectively collapsible action of piston 70, can travel the full distance "z", or any fraction thereof, in an insertion stroke of predetermined desired length.
Also shown in FIG. 3, are pawls 40, 42 and their common mounting pin 92, about which they pivot in the direction of arrow 94. Pawls 40, 42 are biased in an upward direction by compression spring 96, which urges the pawl tips upwardly toward their respective recesses 30, 32. Pawls 40, 42 are pinned to a sliding mounting rail 98 by pin 92, for reciprocal movement in the direction of double-headed arrow 100. Rail 98 is biased for movement in the direction of arrow 52, by compression spring 101.
In FIG. 3, upper tooling portion 62 is shown in its uppermost position, with blade 80 thereof clearing a rounded drive peg 104, rigidly fastened to rail 98. As shown in FIGS. 4 and 5, upper tooling portion 62 is depressed to its lowermost position, having travelled its constant displacement "Z", with blade 80 engaging drive peg 104, thereby displacing the drive peg, and rail 98, an incremental distance "x" opposite that of arrow 52. Upon this movement, pawls 40, 42 are advanced in a direction opposite that of arrow 52, with the pawl tip of member 40 becoming disengaged from its recess 30 (thereby pressing against surface 24), and with the pawl tip of member 42 engaging the adjacent upstream recess 32. At this point, connector 10 has not yet been indexed. However, upon subsequent retraction of upper tooling portion 62, with blade 80 upwardly disengaging drive peg 104, the drive peg and the moving plate 98 attached thereto are free to move a distance "x" in the direction of arrow 52, under the force of spring 101, thereby indexing connector 10. Only one pawl lip is engaged in a recess at any one time.
Upper tooling portion 62 is secured to upper die 66, always travelling the constant vertical displacement "z". FIG. 4, shows a termination stroke wherein a wire 18 is terminated to lower row 14, connector 10 having been indexed to present a terminal-receiving cavity 16 of lower row 14 beneath termination blade 76. An operator positions a wire 18 immediately above the terminal of the lower row, and operates a foot switch to begin the termination cycle. The foot switch in effect controls a cycling operation of reciprocating press 68 so that, upon reaching its lowermost extent, insertion blade 76 inserts wire 18 in the terminal. The insertion force of press 68 is imparted through piston 70 and piston rod 72 to termination blade 76.
The press then automatically raises upper die 66, and accordingly, insertion blade 76 is retracted to its upward position of FIG. 3. Upon elevation of the upper die block, blade 80 is retracted, releasing drive peg 104 and rail 98 for leftward movement in the direction of arrow 52. Connector 10 is thereby indexed to present the next consecutive terminal, that of upper row 12, beneath insertion blade 76.
With reference to FIG. 5, the operator positions another wire 18 above the terminal of the upper row, and operates the foot switch to begin another termination cycle. As far as press 68 is concerned, the cycle of the termination operation is identical to that described above, upper die 66 being displaced a constant distance "x". However, the bottom end of termination blade 76 engages the wire 18, and the upper terminal receiving cavity of the connector housing, prior to the full downward travel of upper die 66. Pressure on the termination blade 76 increases as wire 18 is inserted in the terminal of the upper row cavity.
At this point, downward travel of insertion blade 76 would otherwise continue, destroying the upper row terminal receiving cavity, but for the operation of piston 70, which includes a predetermined pressure relief setting. As pressure imparted by insertion blade 76 to piston 70 increases beyond its set point, air pressure in piston 70 is forced back to the supply along line 110, allowing the piston to collapse, providing substantially free travel to piston rod 72. This allows upper die 66 to continue its full downward deflection of length "z", while allowing insertion blade 76 to travel only a portion of that downward deflection as shown by the dimension DL in FIG. 4 for cavities 16 in the lower row of cavities 14 and by the dimension Du in FIG. 5 for the upper row of cavities 12, thereby limiting the insertion force applied by blade 76 to the connector 10, to a predetermined amount. The pressure release setting of cylinder 70 is infinitely variable over a predetermined range, thereby allowing any desired number of insertion force limit settings for blade 76. Cylinder 70 is of a commercially available type. For example, cylinder 70 can comprise a FABCO PANCAKE model No. C-121.
Thus, it can be seen that the terminator arrangement of the present invention provides a reciprocating press or actuator 68 extensible in the "z" direction with a constant insertion stroke of predetermined length, and a terminating force limit means 70 between press 68 and wire insertion blade 76. Further, the terminating force limit means of piston 70 is automatically responsive to the engagement between insertion blade 76, and upper terminal row 12. Wires 18 can thereby be terminated to the terminals of each row of connector 10, with a predetermined terminating force, but using a single termination stroke of predetemined length "z".
While the indexing arrangement of the present invention has been described with respect to a wire insertion termination station, it is equally advantageous when used with other types of work stations, where the cavities of a housing must be indexed one-at-a-time for presentation to the work station. The connector could, for example, be loaded with crimp-type terminals, presented one-at-a-time to a crimp-type termination station. The indexing arrangement could also be employed in conjunction with a terminal voiding station, where selected terminals are removed from a housing. | An improved apparatus for terminating single conductors to an electrical connector having two rows of terminals, one on top of the other. The rows are staggered so that the terminals of one row are located between the terminals of the other row. An improved terminator is used to terminate wires to both upper and lower connector rows with an actuator of constant predetermined downward deflection.
The apparatus also includes an improved index means for advancing a succession of terminals to a termination station. | 8 |
This is a continuing application of Ser. No. 07/962,718, filed Oct. 19, 1992 now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to a method for applying a liquid solution to a running web for use in producing photographic films, photographic printing paper, etc., (hereinafter referred to collectively as "photographic light-sensitive elements"), and particularly relates to a multi-layer simultaneous coating method.
In producing photographic light-sensitive elements, generally, emulsions of a so-called oil-in-water dispersion type are used. In producing such an emulsion, sometimes a low boiling point solvent such as ethyl acetate, butanol, or the like is used as an auxiliary solvent. When a liquid coating containing such a low boiling point solvent is used to form the outermost layer in a multi-layer simultaneous coating method, it is difficult to obtain a stable and uniform film coating. This is because if such a low boiling point solvent is contained even in small amounts in the outermost layer, the solvent in the liquid surface can easily be evaporated by contacting only a very weak flow of air. The nonuniform distribution of surface tension in the free surface of the coating composition caused thereby produces disorder in the liquid films and hence unevenness of coating.
To prevent such uneven coating from occurring, the following methods have been proposed:
(1) a method whereby the content of an organic solvent contained in the coating composition is not more than 5 wt % (see, for example, Japanese Unexamined Patent Publication No. Hei. 3-92846); and
(2) a method whereby the content of a solvent in the outermost layer is not more than 1 wt %, or a method using an apparatus for weakening the air flow over the coating portion by use of an air shield (see, for example, Japanese Patent Application No. Hei. 1-320640).
However, in the case where the distance from the outermost vapor-liquid surface to the silver halide containing layer is small, or in the case where a large quantity of a low boiling point solvent is contained in the layer next to the innermost layer, it is not sufficient to use only the above-mentioned stabilizing method, even if the content of low boiling point solvent in the outermost layer is not more than 1 wt %. Uneven coating still results because of the uneven surface tension distribution caused by nonuniform evaporation on the liquid surface of the low boiling point solvent. Therefore, in the case where the silver halide containing layer is close to the liquid surface, when any thickness unevenness in coating occurs, even if it is slight, the thickness of the silver halide containing layer will also be nonuniform.
If the distance between the liquid surface and the silver halide containing layer is lengthened, no unevenness in coating occurs, even if the content of the low boiling point solvent in the outermost layer is about 1 wt %. In the case where a larger quantity of low boiling point solvent is contained in the inner layer next to the outermost layer, on the other hand, the low boiling point solvent contained in the inner layer will diffuse to the outermost layer liquid surface and evaporate to thereby cause unevenness in coating before the liquid film is deposited on the web and gels thereon, even if the content of the low boiling point solvent in the outermost layer is zero.
Such uneven coating can be reduced by appropriately selecting the type and content of the surface-active agent in the outermost layer. This is because such uneven coating is caused by the uneven surface tension distribution produced on the liquid surface. Such surface tension distribution is apt to be produced particularly in the case where the liquid surface is expanded. Therefore, uneven coating can be reduced by appropriately selecting the type and content of the surface-active agent so as to relieve the surface tension when the liquid surface is expanded.
SUMMARY OF THE INVENTION
It is accordingly an object of the present invention to provide a coating method in which coating can be carried out without producing any unevenness in the applied coating, even if at least one layer of the coating composition includes a low boiling point solvent as part of the outermost layer thereof and the coating composition is applied at a high speed by the use of a multi-layer simultaneous coating method.
The foregoing and other objects of the present invention are attained by a multi-layer simultaneous coating method for performing coating of a photographic light-sensitive element constituted by at least two layers, characterized in that the following relationship is satisfied.
C<0.2L
where C (wt %) represents the concentration of a low boiling point solvent in the coating composition for the outermost layer, and L (cc/m 2 ) represents the quantity of wet coating per web unit area within the thickness from the inner surface of the outermost layer adjacent to the outer surface of the silver halide layer to the surface of the outermost liquid layer.
Also, the concentration of a low boiling point solvent in an inner layer next to the outermost layer is preferably not less than 0.5 wt % nor more than 7 wt %.
The surface-active agent in the outermost layer may be of a type and be supplied in such a quantity that a difference of surface tension between points of film heights 0 and 6 cm measured by a film breaking method is within a range of not more than 5 dyne/cm.
For the multi-layer simultaneous coating method to be used in the present invention, known methods may be used. That is, a slide hopper coating method, for example, as disclosed in Japanese Examined Patent Publication No. Sho. 33-8977 or the like may be used. Also, a curtain coating method, for example, as disclosed in Japanese Examined Patent Publication No. Sho. 49-24133 may be used.
Examples of the web to be used in the practice of the present invention include paper, plastic films, resin coated paper, synthetic paper, and the like. Examples of the plastic film materials include, for example, polyolefins such as polyethylene, polypropylene, etc.; vinyl polymers such as polyvinyl acetate, polystyrene, etc.; polyamides Such as 6,6-nylon, 6-nylon, etc.; polyesters such as polyethylene terephthalate, 6-naphthalate, etc.; polycarbonate; and cellulose acetates such as cellulose triacetate, cellulose diacetate, etc. As for resin used for resin coated paper, polyolefins such as polyethylene, etc., are typically used, but the invention is not so limited. As for paper, polyolefin-laminated paper may be used, and the surface of the paper may be either smooth or embossed.
Examples of the coating composition containing a low boiling point solvent include various liquid composites selected according to usage, for example, a coating composition containing water soluble binders such as a silver halide emulsion layer, a primer coating layer, a protective layer, a filter layer, a backing layer, etc., in the case of photographic light-sensitive elements.
Examples of the low boiling point solvent to be used in the present invention include, for example, alcohols such as methanol, ethanol, n-propanol, etc.; ketones such as acetone, methylketone, etc.; and esters such as methyl acetate, ethyl acetate, n-butyl acetate, etc.
Examples of the surface-active agent to be used in the present invention include, for example, a nonionic surface-active agent such as glycidol derivatives, fatty-acid esters of multi-valent alcohol, alkyl esters of sugar, etc.; an anionic surface-active agent containing a base such as a carboxyl group, a sulfo group, a phosphoric group, a sulfuric ester group, etc.; and a fluorine-containing surface-active agent. Examples of the above-mentioned anionic surface-active agent include, for example, agents such as those as disclosed in Japanese Unexamined Patent Publication No. Sho. 53-21922 such as the organic sulfonic acid composition comprising at least one of the compounds represented by general formula (I)
A-SO.sub.3 M (I)
wherein A represents a monovalent residue of an unsaturated hydrocarbon having one double bond and containing 8 to 18 carbon atoms, and M represents a hydrogen atom, an alkali metal atom, an alkaline earth metal atom, an ammonium group or an alkylammonium group; and at least one of compounds represented by the general formula II ##STR1## wherein B represents a monovalent residue of a saturated hydrocarbon containing 6 to 16 carbon atoms, n is 1, 2 or 3, and M has the same meaning as M in the above general formula (I), and Japanese Examined Patent Publication No. Sho. 56-1617, such as anionic surface-active agents of the following formulas: ##STR2## R 1 : alkyl having 1-18 carbons; R 2 : hydrogen or alkyl having 1-18 carbons and when R 2 is hydrogen, R 1 is C 1-7 alkyl; M: cation, n: 1-50 (these anionic surface-active agents have the features of increasing the coatability and preventing foaming of the phototreating solution of the alkylaryl-polyethersulfate-type compound; preferably, the alkyl group has two branches), and sulfate of alcohol, an alkyl sulfonate, dialkyl sulfo-succinate, α-sulfonate, and the like. Examples of the fluorine-containing surface-active agent include such agents as disclosed, for example, in Japanese Examined Patent Publication Nos. Sho. 47-9303 such as anionic perfluoro compounds corresponding to the following formula: ##STR3## and above all ##STR4## R f represents an alkyl residue which is perfluorinated in the manner indicated, R 1 represents an alkylene residue, R 2 represents a hydrogen atom or an alkyl residue and X represents a hydrogen atom or an alkali metal atom, and Sho. 52-25087, such as fluorine-containing surface active agents of the following formula: ##STR5## In the above formula,
A: --O(CH 2 CH 2 O) m H, --OCH 2 (CF 2 CF 2 ) 1 H, ##STR6## --SO 3 M,
B: H, (CH 2 CH 2 O) m H;
M is cation, m: 1˜100, n & 1: 1˜9)
(this agent is added in a coating liquid so as to reduce the surface tension thereof. Therefore, the agent improves the coating ability of the coating liquid) and EP 0 144844 B1.
According to the present invention, the feature that the relationship of C<0.2L is satisfied, where C (wt %) represents the concentration of a low boiling point solvent in the outermost layer and L (cc/m 2 ) represents the quantity of wet coating per web unit area, results in reducing the unevenness in coating to a level where there is no problem in practical use. However, it is more preferable that the relationship of C<0.08L-0.4 be satisfied. On the other hand, if C and L are such as to satisfy the relationship of C≧0.2L, extreme unevenness occurs in coating to the extent of causing severe problems in practical use.
According to the present invention, that the concentration of a low boiling point solvent contained in an inner layer next to the outermost layer is made to be not more than 7 wt % reflects the facts that the amount of unevenness in coating becomes a problem in a practical use with a concentration of not less than 7 wt %, but that there is no problem if the concentration is not more than 7 wt %. It is more preferable to select the concentration to be not more than 3 wt %.
To reduce the concentration of the solvent in the coating composition, for example, in the case where the coating composition contains oil-in-water dispersion type emulsions produced by the use of a low boiling point solvent as an auxiliary solvent, there has been employed a desolvent treatment of the emulsion. As for the desolvent treatment of the emulsion, treatments which have been known for stabilizing emulsions, particularly for stabilization in passing time may be used, as disclosed, for example, in Japanese Examined Patent Publication No. Sho. 61-56010 and Japanese Unexamined Patent Publication Nos. Sho. 53-112731 and Sho. 53-74031. In this case, generally, the desolvent agent is limited to the extent of 10 wt % of the initial content in an oil-in-water dispersion type emulsion. Further, since the coating composition containing such an emulsion can be diluted with a silver halide emulsion, water soluble binder, water, or the like, the concentration of the solvent can be reduced.
Increasing the distance between the outermost layer liquid surface and the outermost layer side boundary of the silver halide containing layer can be realized by adding water to the outermost layer or a layer between the outermost layer and the outermost silver halide containing layer. Particularly in the case where the outermost layer contains much low boiling point solvent, the addition of water to the outermost layer may provide effects such that not only can the distance be increased, but also the concentration of the low boiling point solvent can be reduced.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram for distinguishing states of unevenness of coating in the relationship between the distance (expressed by the quantity of coating cc/m 2 ) from the surface of the outermost layer to the outermost layer side boundary of a colored layer; and
FIG. 2 is a diagram illustrating the relationship between film height and surface tension for different types of surface-active agents.
FIGS. 3 to 6 relate to an apparatus for measuring surface tension by a film breaking method described in Japanese Unexamined Patent Publication No. Hei. 3-20640.
FIG. 3 is a schematic illustration of an apparatus for measuring surface tension according to Hei. 3-20640.
FIG. 4 is a schematic diagram of a liquid-film branching bar equipped with an air jet for causing the branching of a free-falling liquid film according to Hei. 3-20640: (a) a side view; and (b) a sectional view.
FIG. 5 is a schematic illustration of the principle of measuring the configuration of the edge of a liquid film by means of a CCD camera as in Hei. 3-20640.
FIG. 6 is a schematic illustration of the image processing principle using the CCD camera as in Hei. 3-20640.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The effects of the present invention can be confirmed by the use of colored layers, which can indicate unevenness of coating more clearly than silver halide containing layers.
COMPARATIVE EXAMPLE 1
Simultaneous coating of two layers was performed with the composition shown in Table 1 using a slide hopper coating apparatus.
TABLE 1______________________________________ No. 1 No. 1 colored outermostComponent layer (wt %) layer (wt %)______________________________________Gelatin 8.0% 8.0%H.sub.2 O 90.7% 89.6%Ethyl acetate (low boiling 0.0% 2.0%point solvent)Anionic surface-active agent 0.0% 0.05%dodecyl benzene sodiumsulfonateWater soluble dyestuff 1.0% 0.0%Water soluble thickener 0.3% 0.3%Viscosity (centipoise) 50 50Quantity of coating (cc/m.sup.2) 60 10.2______________________________________
With the concentration of ethyl acetate in the outermost layer being 2.0 wt % under the concentration of a low boiling point solvent C, multi-layer simultaneous coating was performed on a cellulose triacetate film under the conditions that the coating quantity of the colored layer was 60 cc/m 2 the coating quantity of the outermost layer was 10.2 cc/m 2 , and the coating speed was 100 m/min. As a result, coating unevenness in the form of parallel-streaks or streaks slightly shifted parallel to the advancing direction was strongly produced in the coated surface. The relationship between C and L was C=2=2.04=0.2L.
EXAMPLE 1
Using the colored layer as in Comparative Example 1, while changing the liquid composition and the coating quantity of the outermost layer as shown in Table 2, two layer simultaneous coating was performed twice with respect to two types of outermost layer in connection with the same colored layer.
TABLE 2______________________________________ (wt %) No. 2 No. 3 outermost outermostComponent layer layer______________________________________Gelatin 6.0% 4.0%H.sub.2 O 92.2% 94.4%Ethyl acetate (low boiling 1.3% 1.0%point solvent)Anionic surface-active 0.05% 0.05%agent dodecyl benzenesodium sulfonateWater soluble thickener 0.4% 0.5%Viscosity (centipoise) 50 50Quantity of coating (cc/m.sup.2) 19.8 30______________________________________
With respect to the concentration C of the low boiling point solvent, the concentration of ethyl acetate was 1.3 wt % in the second outermost layer and 1.0 wt % in the third outermost layer. The coating quantity was 19.8 cc/m 2 for the second outermost layer and 30 cc/m 2 in the third outermost layer. the valuation on the result of coating was as follows:
In the second outermost layer, unevenness in coating was hardly seen, and the relationship between C and L was C=1.3<3.96.
In the third outermost layer, no unevenness at all in coating was observed, and the relationship between C and L was C=1.0<6.00.
In general, the more the values of C and 0.2L were separated, the better the obtained result in the coating unevenness.
Further, FIG. 1 shows results obtained by detailed investigations into the influence on the production of coating unevenness by the concentration of a solvent in the outermost layer, and the distance from the outermost layer side boundary of a colored layer further interior than the outermost layer with respect to the liquid surface under the above-mentioned conditions.
EXAMPLE 2
Setting the coating quantities of the outermost layer and the colored layer to 10.2 cc/m 2 and 50 cc/m 2 , respectively, using the same composition for the outermost layer as in Comparative Example 1, while changing the composition of the colored layer among the three types shown in Table 3, two layer simultaneous coating was performed three times with respect to the three types of colored layers in connection with the same outermost layer.
TABLE 3______________________________________ (wt %) Outermost Colored layer layerComponent No. 2 No. 3 No. 4 No. 4______________________________________Gelatin 8.0% 8.0% 8.0% 8.0%H.sub.2 O 90.7% 83.7% 80.7% 90.6%Ethyl acetate/ 0.0% 7.0% 10.0% 1.0%methanol (l/l)Anionic surface- 0.0% 0.0% 0.0% 0.05%active agent dodecylbenzene sodiumsulfonateWater soluble 1.0% 1.0% 1.0% 0.0%dyestuffWater soluble 0.3% 0.3% 0.3% 0.3%thickener agentCoating quantity 60 10.2(cc/m.sup.2)______________________________________
The content of a low boiling point solvent in the colored layer was set to 0 wt %, 7 wt %, and 10 wt %, while the content of the low boiling point solvent in the outermost layer was 1.0 wt %.
As a result, in the second colored layer, streaked unevenness of coating was hardly seen, in the third colored layer, streaked unevenness was present in the coating but to an extent producing no problem in practical use, and in the fourth colored layer, strong streaked unevenness in the coating was produced.
The relationship between C and 0.2L was C=1<2.04 in each case.
It can be understood from the above that good results can be obtained if the content of the low boiling point solvent in the colored layer is not more than 7 wt %, and streaked unevenness is reduced if the content of the low boiling point solvent in an inner layer next to the outermost layer is also made not more than 7 wt %.
EXAMPLE 3
The surface-active agent p-dodecyl benzene sodium sulfonate was replaced by
a: polyoxyethylene octyl phenyl ether ethane sodium sulfonate of equivalent mole;
b: dioctyl sulfo sodium succinate of equivalent mole; and
c: dioctyl sulfo sodium succinate of five-fold moles.
The other conditions of the liquid composition were the same as in Comparative Example 1.
When coating was performed under these conditions, for the surface-active agent a, streaked unevenness of the resulting coating was produced, but to an extent that there would be no problem in practical use. For the surface-active agent b, streaked unevenness of the resulting coating was hardly observed, while for the surface-active agent c, no streaked unevenness of the resulting coating was observed at all.
Further, the surface tension in each case was measured by a film breaking method. As shown in FIG. 2, the amount of streaked unevenness of coating is reduced if the conditions are set such as to reduce the change of surface tension. Although this result was obtained in the case of using 2 wt % ethyl acetate, almost the same result can be obtained in the range of 0 to 7 wt %. As for C and L, to eliminate problems of streaked unevenness in practical use for various surface-active agents, the following conditions should be maintained:
Comparative Example 1 (p-dodecyl benzene sodium sulfonate):
C<0.2L
a. (polyoxyethylene octyl phenyl ether ethane sodium sulfonate):
C<0.25L
b. (dioctyl sulfo sodium succinate):
C<0.3L
Unevenness of coating can be improved if a surface-active agent having a small change of surface tension is used.
The film breaking method used herein is a method for measuring surface tension, as disclosed, for example, in detail in Japanese Unexamined Patent Publication No. Hei. 3-20640. The measuring apparatus discussed in Hei. 3-20640 for measuring the surface tension comprises: two-dimensional optical sensor system containing an optical axis perpendicular to the liquid film through a subject portion to measurement of the liquid film; A/D (analog/digital convertor); and calculating circuit to calculate an angle of the subject portion to subject a digital signal from the A/D convertor to approximation relating to a shape of the edge of the liquid film by a multiple dimensional curve. Since the measuring apparatus can calculate the measured value in a moment corresponding to the shape of the edge of the broken liquid film by image processing, it is able to provide an apparatus realizing a precision measurement of the surface tension and increasing the number of kinds of measured subjects. Namely, the above apparatus determines a measurement according to the following formula:
2σ=Q.u.sin.sup.2 Θ+p.S.g.sinΘ-p.S.v.sup.2 /R
wherein, Q: flow rate in unit width, u: falling velocity, Θ: inclination of an edge of a liquid, σ: surface retention, S: cross section of a liquid film at the edge of the broken film, p: density of the liquid, v: velocity in the edge of the liquid film, R: radius of curvature of a liquid edge.
In greater detail, Hei. 3-20640 describes a method and apparatus for measuring surface tension and more particularly a method and apparatus effective in measuring surface tension of coating liquid to be spread on a surface using a free-falling liquid film. Prior to Hei. 3-20640, in reference to a method of measuring surface tension by putting a poor-wetting bar in a free-falling liquid film to cause the branching of the liquid film and then measuring the surface tension from the configuration of the liquid film that has thus branched off, Lin., S. P. has proposed, in J. Col. Int. Sci. (1980), to use the equilibrium between the surface tension and inertia force of the liquid.
Hei. 3-20640 describes a method of measuring surface tension by perpendicularly putting a poor-wetting bar in a free-falling liquid film to cause the branching of the liquid film and then measuring the surface tension from the configuration of the liquid film that has thus branched off, wherein, instead of a poor-wetting round bar as an insert bar, a poor-wetting bar having a recess which is perpendicularly open downward and from which air jets are sent out along the underside of the insert bar is put in for measuring purposes and employs as an apparatus for measuring surface tension, an apparatus comprising an insert which is perpendicularly put in a free-falling liquid film to cause the branching of the liquid film and a means for measuring the configuration of the liquid film that has thus branched off, wherein the insert is a poor-wetting bar having a recess which is perpendicularly open downward and embraces an air jet nozzle; and more particularly, an apparatus for measuring surface tension wherein the means for measuring the configuration of the liquid film that has thus branched off is provided with a two-dimensional sensor optical system having an optical axis perpendicular to the liquid film via the measuring portion thereof, an A/D converter and an operational circuit for computing the angle of the measuring portion, using a multidimensional curve to approximate the configuration of the end portion of the liquid film from digital electrical signals.
The poor-wetting bar having the recess which is perpendicularly open downward and from which air jets are sent out along the underside of the insert bar according to Hei. 3-20640 is not necessarily cylindrical but may be tubular. It is essential that the air jets are sent out along the underside of the insert bar. The poor-wetting means that the coating liquid has poor wetting properties and use is made of high polymer, which is preferably polytetrafluoroethylene, polychlorotrifluoroethylene or the like.
Since the insert of the apparatus for measuring surface tension according to Hei. 3-20640 is formed with the poor-wetting bar having the recess which is perpendicularly open downward and embraces the air jet nozzle, a reagent solution is blown off by air jets and prevented from sticking to the underside of the bar. The reagent solution is also prevented from reaching the underside of the poor-wetting bar as an air film is held on the underside thereof. Since the bar is so configured as to have the recess perpendicularly open downward, the underside of the bar hardly becomes wetted with the liquid. Therefore, the use of the insert according to Hei. 3-20640 prevents the liquid from thoroughly wetting the underside of the round bar and the branching of the liquid film from becoming indistinct as in the conventional method. In other words, the branching of the liquid film can thus be implemented quickly and stably. Measurement can also be made on the surface with the long lapse of time even in the case of viscous liquids.
Since the means for measuring the configuration of the liquid film that has thus branched off according to Hei. 3-20640 is provided with the two-dimensional sensor optical system having an optical axis perpendicular to the liquid film via the measuring portion thereof, the A/D converter and the operational circuit computing the angle of the measuring portion, using the multidimensional curve to approximate the configuration of the end portion of the liquid film from the digital electrical signals, the configuration of the edge of the liquid film that has thus branched off can instantly be imaged so as to obtain measured values. Consequently, it is made feasible to measure surface tension with accuracy as compared with the prior art method and to enlarge a range of intended measurements.
More specifically, the following expression has been used to calculate surface tension from the configuration of the edge of the film caused to branch off in the conventional measuring method:
2σQ.μ.sin.sup.2 Θ
where
Q: mass flow rate per unit width film;
μ: free falling velocity;
Θ: branching angle; and
σ: surface tension.
On the other hand, the measuring apparatus according to Hei. 3-20640 makes usable a calculating expression as noted above in which more factors have been taken into consideration:
2σ=Q.μ.sin.sup.2 Θ+p.S.g.sin Θ-p.S.v.sup.2 /R
where
S: sectional area of the edge of the liquid film caused to branch off (the cross section of the edge being columnar);
p: liquid density;
g: acceleration of gravity; and
v: curvature radius of the edge of the liquid film caused to branch off (though a read sensor is hardly usable for finding out the curvature from a photograph, the two-dimensional image sensors can make it available through image processing).
FIG. 3 depicts an apparatus for measuring surface tension according to Hei. 3-20640. FIG. 4(a) and 4(b) depict an insert bar to be put in a free-falling liquid film according to Hei 3-20640. FIG. 5 is a schematic illustration of the principle of measuring the configuration of the edge of a liquid film by means of a CCD camera. FIG. 6 is a flow chart for processing a signal from the CCD camera.
In FIG. 3, a liquid injected from a slit 2 of an extrusion type injector 1 forms a thin film 4 which is supported by a free fall supporting member 3. The thin film 4 is broken as like an arch 6 by a low-wetting type bar 5 which is inserted into the thin film 4. In the measuring method, an inclination Θ of an edge of a liquid at a measuring point 7 for the surface tension is subject to image processing by a two dimensional charged-coupled device camera 9 to display an image thereof on a monitor 10 and for calculation of the surface tension by a calculator 11. In order to measure the surface tension which varies in passing time due to the reorientation of the surfactant on the film surface, the measurement is conducted by changing the film height, i.e., changing the vertical distance between the slit 2 of the injector 1 and the low-wetting type bar 5 by which the film 4 is broken. A light source 12 is placed on the opposite side of the CCD camera 9 with the liquid film held therebetween.
FIG. 5 is a schematic illustration of the image sensors of the CCD camera and an image processing method.
As shown in FIG. 5, 512×512 of sensors 21 μm square are laid lengthwise and breadthwise. The configuration of the edge of the liquid film is determined by the intensity of light incident on the group of image sensors. The portion shown by oblique lines represents what is not transmitted by light because of the liquid film.
FIG. 6 is a flow chart showing a processing procedure in the operational circuit until the configuration of the edge of the liquid film is obtained from the signals taken in the group of image sensors.
The intensity X of light sensed by the image sensor is converted to a digital value X (i, i) in proportion to the intensity. Whether or not the liquid film exists in the part caught by one image sensor is determined by whether or not the digital signal is greater than a preset threshold value X". If the signal is greater than the threshold value, for example, no liquid film is present in that place. Subsequently, the image sensor that has caught the liquid film edge is defined by coordinates as shown in FIG. 5 and then a multidimensional curve is used to approximate the coordinates. The branching angle Θ is obtainable through the linear differential of the curve.
Moreover, the bar for effecting the branching of the film should preferably be made of poor-wetting material; the smaller its diameter is, the less it is affected by wetting. When a round bar is used for the branching of the liquid film, however, the reagent solution may go around the bar, thus making it impossible to measure the surface tension as the branching of the film is restrained. Therefore, as depicted by FIG. 4, a hollow bar 13 formed by removing its lower half portion and fitting an air jet nozzle 14 in that hollow portion is employed for the branching of the liquid film according to Hei. 3-20640. When the branching of the liquid film is conducted, an adequate quantity of air is steadily jetted from the air jet nozzle in proportion of the thickness of the liquid film so as to destroy the film in contact with the bar beforehand and then the bar proper is used to complete the branching of the film. As a result, this method ensures that the branching of the film is instantly conducted.
The condition that the difference of surface tension measured at two points of the film heights 0 and 6 cm from the slit 2 of the injector 1 in FIG. 3 is not more than 5 dyne/cm by use of values of surface tension measured by the film breaking method may be used as a standard to select the type of density of a surface-active agent having a small change of surface tension in passing time on the surface.
Structural formulae of the surface-active agents used in this example are shown in the following formulas 1 to 3. ##STR7##
According to the coating method of the present invention, it is possible to perform coating without producing unevenness of coating, even if the coating is performed at a high speed by use of a multi-layer simultaneous coating method. | A coating method for producing a photographic light-sensitive element without unevenness of coating, even when coating is carried out with at least one coating composition containing a low boiling point solvent as an outermost layer and coating is carried out at a high speed using a multi-layer simultaneous coating method. In accordance with the invention, the following relationship is maintained:
C<0.2L
where C (wt %) is the concentration of a low boiling point solvent in a coating composition forming an outermost one of the coating layers, and L (cc/m 2 ) is a quantity of a wet coating per web unit area in a thickness from an inner surface of the outermost layer adjacent to the outer surface of the silver halide layer to a surface of said outermost layer. | 6 |
BACKGROUND OF THE INVENTION
[0001] Elastomeric yarns consist of single or multiple elastomeric fibers that are manufactured in fiber-spinning processes. By “elastomeric fiber” is meant a continuous filament which, free of diluents, has a break elongation in excess of 100% independent of any crimp, and which, when stretched to twice its length, held for one minute, and then released, retracts to less than 1.5 times its original length within one minute of being released. Such elastomeric fibers are formed from polymers including, but not limited to, rubber, spandex, polyetherester, and elastoester. Elastomeric fibers differ from “elastic fibers” or “stretch fibers,” which have been treated in such a manner as to have the capacity to elongate and contract. “Elastic fibers” or “stretch fibers” have modest power in contraction, and include, but are not necessarily limited to, fibers formed by false-twist texturing, crimping, etc.
[0002] Elastomeric yarns can be formed with elastomeric fibers produced from fiber-spinning processes, such as dry spinning, wet spinning, or melt spinning. In particular, dry spinning is the process of forcing a polymer solution through spinneret orifices into a chamber to form a filament or filaments. Heated inert gas is passed through the chamber, evaporating the solvent from a filament as the filament passes through the chamber. Multiple filaments are coalesced together while passing through the chamber, thereby forming an elastomeric yarn.
[0003] As shown in FIGS. 1 to 7 (Prior Art), continuous-filament elastomeric single filaments or yarns produced by any of these spinning technologies generally are wound onto individual cylindrical tube cores 10 to form supply packages 20 of required size and weight. Package dimensions and weight depend, for example, on the yarn denier, the end-use requirements of the yarn, and the winding equipment employed in the process. The yarn length 12 wound around a core 10 to form a package 20 has a proximal or beginning end 14 and a distal or terminal end 18 . The beginning end 14 is located on or adjacent to the outer circumferential surface of the tube core 10 , which core 10 supports the inside diameter of the wound yarn package 20 . This beginning end 14 is also called a “transfer tail.”
[0004] The transfer tail 14 preferably is located on the tube core 10 in a position outside the body of the package 20 as illustrated in FIG. 5. To begin winding a yarn package 20 , the transfer tail 14 is formed by winding a number of wraps of yarn in a single location along the tube core 10 to form a bunch on the tube core. This bunch holds the transfer tail 14 in place. Then, the yarn 12 is wound or coiled over the tube core 10 in a yarn-traverse motion to form the yarn package 20 .
[0005] Although the transfer tail 14 is preferably located outside the body of the package 20 , as described above, it is more usually trapped under the yarn windings in the yarn package as illustrated in FIG. 3. This is normally the result of equipment or process limitations. When the yarn package has a desired diameter, the yarn is broken by the action of the winding equipment to leave a terminal or distal end 18 . The terminal end 18 of the yarn length is located on the outside-diameter surface of the yarn package (FIGS. 3 and 4).
[0006] All individually wound packages of elastomeric yarns must be unwound for use in subsequent processes, such as, for example, covering, knitting, and weaving. Currently, packages of elastomeric yarn are unwound by beginning at the outside of the yarn package and pulling the yarn from its terminal or distal end 18 . This method of unwinding will be designated herein as “outside in” because the yarn package 20 is unwound continuously from the outside until reaching the outer circumferential surface of the tube core 10 and the distal or beginning end 14 (transfer tail) of the yarn length.
[0007] To continuously unwind multiple packages of elastomeric yarn for uninterrupted delivery to subsequent processes, one must be able to fix or tie an end of a yarn length from a first package to an end of a yarn length from a second package, and so on. Generally, the transfer tail of the first package is tied to the terminal or distal end of the second package. One method for continuous unwinding of yarn from multiple yarn packages is called “overend outside-in unwinding” and is shown schematically in FIG. 7. With such unwinding method, the yarn is pulled away from the package in a direction along the axis of the tubular core and is unwound over the end of the package. In the example shown in FIG. 7, the tube cores 10 a , 10 b and 10 c of three yarn packages 20 a , 20 b and 20 c , are loaded onto spools 24 a , 24 b and 24 c . Before the unwinding begins, the transfer tail 14 a is tied by knot 13 a to the beginning end 12 b of the second yarn package 20 b , and the transfer tail 14 b of the second yarn package 20 b is tied by knot 13 b to the beginning end 12 c of the third yarn package 20 c . The yarn 12 a from first yarn package 20 a is unwound from the outside in. After all yarn has been unwound from the first yarn package 20 a , the unwinding process continues by next unwinding yarn from the second yarn package 20 b , and so on.
[0008] Continuous unwinding processes where elastomeric yarns are unwound from the outside-in have encountered problems. If the transfer tail of a package is trapped, it is generally not possible or practical to retrieve the trapped end for tying it together to the beginning end of a next yarn package. The yarn tension necessary to unwind the yarn in an overend outside-in method is related to factors such as the yarn takeoff speed, the denier of the yarn, the dimensions of the package and the tackiness of the yarn surface, to name some important variables. For elastomeric yarns, it is desirable and necessary to keep the pulling tension low and minimize variations in that tension during unwinding, because elastomeric yarns have a low modulus of elasticity and are very sensitive to tension. Variable yarn elongation during unwinding can affect subsequent product quality. Furthermore, when the unwinding yarn is transferred to another package by means of a transfer tail tied to the beginning end of the next package, there is normally a sharp increase in yarn tension for a very short time interval—i.e., a tension spike. This tension spike occurs while unwinding the last few wraps of the yarn on the tube core. The spike affects unwound-yarn quality and can also cause the yarn to break, which is an expensive interruption to the process.
[0009] As mentioned above, the unwinding tension is related to the tackiness of the yarn, or the tendency for the yarn to stick to itself and to other materials. All elastomeric yarns, as spun and without special chemical additives or surface finishes, have some degree of surface tackiness. This tackiness is especially evident with wound packages of dry-spun spandex, where the compressive pressure on underlying yarns can be very high due to the stretch and tension of the yarn as it is being spun and wound, which is a natural requirement of the process. The compressive pressure is greatest on the yarn wound near the core of the package. This can make it especially difficult to unwind and use yarn wound near the core of the package, where conditions are most extreme. In addition, time and temperature contribute to tackiness, so that packages of spandex that have been stored, for example for months, are more difficult to unwind and experience significantly more core waste than freshly spun and wound packages.
[0010] Reducing the tackiness and the resulting waste would improve the economics of spandex yarn and filament production. For some spandex-yarn applications, however, methods to reduce tackiness are not acceptable because the yarns will be made into garments using adhesives that must adhere effectively to the elastomer yarn surface. Moreover, even if a transfer tail is available, continuous unwinding of multiple packages of high tack yarns generally has not been practical because the severe tension spike during package transfer will often break the yarn. Especially for tacky elastomeric yarns, new methods of unwinding with reduced and more uniform yarn tensions are needed for improved process continuity and product quality.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] [0011]FIG. 1 is a schematic view in front elevation of the beginning windings of elastomeric yarn around a tube core;
[0012] [0012]FIG. 2 is a schematic view in side elevation of the beginning windings around a tube core of FIG. 1;
[0013] [0013]FIG. 3 is a schematic view in front elevation of a wound yarn package where the yarn has been wound over the transfer tail thus trapping the transfer tail and preventing access thereto;
[0014] [0014]FIG. 4 is a schematic view in side elevation of the yarn package of FIG. 3;
[0015] [0015]FIG. 5 is a schematic view in front elevation of a wound yarn package where the transfer tail is accessible along the surface of the tube core;
[0016] [0016]FIG. 6 is a schematic view in side elevation of the yarn package of FIG. 5;
[0017] [0017]FIG. 7 is a schematic view in front elevation of a series of three yarn packages mounted to spools and having yarn ends attached together for continuous overend outside-in unwinding;
[0018] [0018]FIG. 8 is a schematic cross-sectional view in front elevation of a yarn package within a cooling chamber and showing removal of the tube core as a first step in a method for unwinding the yarn from the inside out;
[0019] [0019]FIG. 9 is a schematic perspective view of a yarn package in which a loop of yarn is pulled axially from the package within a certain distance from the outer diameter of the package as a second step in a method for unwinding the yarn from the inside out;
[0020] [0020]FIG. 10 is a schematic perspective view of two yarn packages in which the newly created terminal end of the yarn length of the first yarn package has been tied to the newly created beginning end of the second yarn package as a third step in a method for unwinding the yarn from the inside out;
[0021] [0021]FIG. 11 is a schematic view in front elevation of three yarn packages seated within sleeves and having yarn ends tied together for continuous inside out unwinding;
[0022] [0022]FIG. 12 is a schematic perspective view of the waste portion of the yarn package after unwinding according to the method of the invention;
[0023] [0023]FIG. 13 is a graph depicting the yarn tension versus yarn delivered for overend outside in unwinding according to the prior art and inside out unwinding according to the invention;
[0024] [0024]FIG. 14 is a schematic view of an apparatus for measuring unwinding threadline tension;
[0025] [0025]FIG. 15 is a graph depicting the threadline tension versus time for overend outside in unwinding according to the prior art, showing a pronounced tension spike at transition to next package; and
[0026] [0026]FIG. 16 is a graph depicting the threadline tension versus time for inside out unwinding according to the invention, showing a reduced tension spike at transition to next package (compared with tension spike experienced with prior art unwinding as shown in FIG. 15).
SUMMARY OF THE INVENTION
[0027] The invention concerns methods for continuous unwinding of elastomeric yarns from one or multiple coiled yarn packages. Distinguishing from prior art unwinding methods that unwound yarn from the outside diameter toward the transfer tail at the inside diameter, the inventive methods unwind the yarn from the inside diameter of the package toward the outside diameter of the package.
[0028] According to a first method of the invention, elastomeric yarns from multiple yarn packages of the same or different elastomeric materials are connected together so that the yarns may be unwound in series. Each yarn package has an inner diameter and an outer diameter and the yarn has been wound or coiled around a generally tubular core. The yarn packages preferably are readied for unwinding. Optionally, the outer circumferential peripheral surface of each yarn package may be coated or wrapped with a stabilizing film. A sufficient portion of the tubular core from each coiled yarn package, preferably the entire tubular core, is removed to expose the inner diameter surface of each annular yarn package, or cake. A beginning end of a yarn strand at the exposed inner diameter of each yarn package is located. A loop of a strand of yarn from within a first yarn package at a point between the inner diameter and the outer diameter of the first yarn package is exposed and cut to form a first cut end and a second cut end. The first cut end of the first yarn package is connected to the beginning end of a next yarn package. Where more than two yarn packages will be unwound in series, the step of connecting the first cut end of an adjacent yarn package to the beginning end of a next yarn package is continued until the strands from all of the yarn packages have been connected in series.
[0029] Unwinding proceeds by first drawing the beginning end of the first yarn package away from the first package. Preferably, the yarn is unwound from the first yarn package by pulling the yarn generally axially with the unwinding proceeding first by pulling yarn from the inner diameter of the first yarn package. Once the first yarn package has been substantially completely unwound, the connection between the first cut end of the first yarn package and the beginning end of the next yarn package is reached. Unwinding then continues with the unwinding of elastomeric yarn from the next yarn package. The unwinding of the next yarn package is from the beginning end at the inner diameter outward toward the outer diameter of the next yarn package. A shell portion of the first package comprising a length of the yarn from the second cut end to the outer diameter of the yarn package is not unwound. The shell portion preferably constitutes the annular periphery of the yarn package and has an outer diameter that is from about 2 to about 5 mm larger than its inner diameter.
[0030] Unlike with the prior art, during the transfer of unwinding between the first and next yarn packages, the unwinding proceeds at a more constant tension without a pronounced tension spike as had frequently occurred with prior unwinding methods. It is desirable to keep the unwinding tension as low as possible. Preferably, for elastomeric yarns the unwinding tension is kept below about 20 grams, most preferably below about 10 grams.
[0031] Preferably, the entire tubular core is removed from the yarn package by (i) chilling the yarn package to a temperature at least a few degrees below the melting point or glass transition temperature of the soft segment of the polymer, which is sufficient to cause the polymer to expand and create a gap between the outer circumference of the tubular core and the windings; and (ii) separating the core from the yarn package. The tubular core can be removed axially. In view of the material property changes upon chilling the elastomeric material, it is preferred that the yarn package be returned to ambient temperature before locating the beginning end or transfer tail, forming the loop to create the terminal end or unwinding yarn from the yarn package.
[0032] Preferably, the yarn packages contain an elastomeric yarn formed from filaments of a polymeric material selected from the group consisting of: rubber, spandex, polyetherester and elastoester. Most preferably, the yarn packages are of yarns formed from filaments of tacky dry spun spandex with a nominal denier in the range of 120 to 3600 that have not been coated with a surface finish or formed from a polymer that incorporates anti-tack additives.
[0033] According to a second aspect of the invention, the inside-out unwinding method minimizes tension spikes when unwinding an elastomeric yarn having a tacky surface. The method may be used in connection with unwinding a single yarn package or unwinding multiple yarn packages that have had the yarn strands therefrom connected in series. According to this method, at least a portion of the tubular core from the coiled yarn package is removed to expose an inner diameter of the yarn package. A beginning end of a yarn strand at the inner diameter portion of the yarn package is located. Before unwinding, the elastomeric yarn strand is cut at a position along its length to form a terminal end of the strand within the yarn package between the inner diameter and the outer diameter. Preferably, the terminal end is formed by cutting the yarn strand in the yarn package at a location within about 2 to about 5 mm from the outer diameter of the yarn package.
[0034] To unwind the elastomeric yarn, the beginning end of the yarn package is drawn away from the yarn package so that unwinding proceeds from the inner diameter toward the outer diameter. Preferably, at any point during the unwinding the instantaneous unwinding threadline tension remains within a range that is not more than double and not less than one-half of the average unwinding threadline tension of the elastomeric yarn as such yarn is unwound at or near the midpoint of the yarn package. Preferably, the average unwinding threadline tension is measured over 30 seconds at about 100 meters per minute withdrawal speed. The unwinding threadline tension does not exhibit pronounced spikes during unwinding a single package or during transfer from a first to a next yarn package.
[0035] The methods of the invention have particular application for unwinding yarn packages of spandex having a denier greater than about 120, where the yarn package has a package weight of between about 1 to 5 kilograms, with an inside diameter of between about 7 to about 9 cm, an outside diameter of between about 10 to about 40 cm, and a width of between about 8 to about 25 cm.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0036] During manufacturing, continuous-filament elastomeric yarn 12 is wound onto a cylindrical tube core 10 while the yarn 12 is under a condition of some stretch and tension to produce a yarn package 20 . The yarn 12 is wound very tightly onto the tube core 10 , and under ambient conditions it is not possible to remove the tube core without damaging or destroying the yarn in the yarn package. As noted previously, conventional unwinding proceeded “outside in”, where the yarn strand was unwound from the outside diameter of the yarn package first.
[0037] To unwind elastomeric yarn from a package from the “inside out”, one needs to have access to the beginning end of the yarn strand that has been wrapped over the core. To obtain such access, the tube core must be removed from the package without damaging the yarn.
[0038] One preferred method for removing the tubular core is to chill the yarn package (with its core therein). Once chilled, a gap forms between the tubular core and the elastomeric yarn around such core. It is then possible to remove the tubular core from the chilled package.
[0039] One possible method for removing the tube core 40 is illustrated in FIG. 8. A yarn package 30 having a continuous yarn strand 32 wrapped about the core 40 is placed into a cooling chamber 52 of cooling equipment 50 . The yarn package 30 is held within an annular sleeve 58 formed in the floor of chamber 52 . The cooling chamber 52 is surrounded at its periphery with cooling coils 54 sufficient to cool the chamber 52 to a desired chilling temperature. An exit chamber 56 is located below the floor of chamber 52 .
[0040] Once the yarn package 30 has reached the desired chilling temperature, the yarn 32 separates from the core 40 and a small gap forms between the yarn 32 and the core 40 . As shown in FIG. 8, a ram 60 is actuated to push the core 40 axially out of the yarn package 30 and into the exit chamber 56 through a passage 62 between the cooling chamber 52 and the exit chamber 56 . For many yarn packages, the gap between the yarn 32 and the core 40 may be large enough to allow the core to drop out of the yarn package simply in response to gravitational force, without applying a ramming force. The core 40 is then discarded. The yarn package 30 now separated from the core 40 is removed from the cooling chamber 52 and installed in a fixture or holder to prepare for unwinding. Preferably, the chilling temperature should be at least a few degrees below that at which the elastic modulus of the elastic yarn changes rapidly. This temperature depends on the composition of the elastomeric fiber, but the effect is the same once the proper temperature is attained. For example, the chilling temperature for most spandex yarns should be at or below about −[minus] 8° C. For spandex yarn based on 1800 molecular weight poly(tetramethylene glycol) or poly (tetrahydrofuran), the soft segment melting point is about −[minus] 8° C., and the core is easily removed after the yarn package has been cooled to about −[minus] 25° C. For other elastomeric yarns, the glass transition temperature of the soft segment is below −[minus] 8° C. (e.g., spandex based on a tetrahydrofuran/3-methyl-tetrahydrofuran copolymer) and the chilling temperature may need to be lower.
[0041] After the tube core 40 has been removed, the package 30 is a yarn “cake” that defines an inner diameter and an outer diameter. The “cake” has a hollow cylindrical interior where the starting end 34 , or transfer tail, of the yarn 32 is located. The other end of the continuous yarn in the package 30 is on the outer circumferential surface of the package at the outside diameter.
[0042] The transfer tail 34 is now fully accessible, whether or not it was previously trapped under the body of yarn wrapped over the core to form the package. Once the transfer tail is located by visual inspection, it can then be pulled out a distance of several meters to remove the transfer-tail “bunch” and to confirm that the yarn is free to be pulled and unwound without snagging or tangling. The single yarn cake can be positioned within a fixture or holder and yarn can be unwound from the cake from the inside out. Preferably, the beginning end or transfer tail 34 is retrieved and the unwinding begins after the yarn package 30 has returned to ambient conditions, or room temperature.
[0043] For commercial operations which use the elastomeric yarn by unwinding, it is economically advantageous to tie packages of yarn together so that unwinding can proceed from one package to another in series, without interruption, and thereby maintain process operation continuity. In conventional “outside in” unwinding methods, this is accomplished by tying the transfer tail of one package to the outside-diameter end of another package.
[0044] Unwinding of yarn from the “inside out”, however, proceeds from the inside of the cake thereby further hollowing out the standalone cake until smaller and smaller amounts of yarn remain in the “shell” of the package. As shown in FIG. 12, the shell 80 has a thickness “A” and an outer diameter substantially the same as the yarn package 30 . At some point the shell 80 no longer will self-stand, but will partially collapse, or slump, thereby causing yarn not yet unwound to entangle, thus foreclosing unwinding 100% of the yarn and uninterrupted transfer between packages.
[0045] According to one aspect of the invention herein, however, uninterrupted and continuous unwinding of multiple packages from “inside out” is accomplished. The method is illustrated schematically in FIGS. 9 to 11 .
[0046] First, as shown in FIG. 9, a loop 42 of yarn is pulled from the side of the wound yarn package 30 , at distance, “A”, that is appropriate to assure standalone shell stability of the particular package. While the distance “A” may be at any spacing between the inner diameter and outer diameter of the yarn package 30 , a smaller distance “A” translates into a smaller shell thickness and reduces the amount of wasted yarn from the yarn package. A particularly preferred shell thickness “A” is 5 mm or less, most preferably from about 2 mm to about 5 mm. The minimum required standalone-shell thickness “A” depends on a number of factors, including, but not limited to, the elastomeric yarn denier, package dimensions and weight, and yarn tackiness.
[0047] Referring next to FIG. 10, the loop 42 is then cut, resulting in two ends 44 and 46 . The first cut end 44 is then attached, such as by tying, to the transfer tail or beginning end 34 of another package. The chosen end 44 must be the one that is connected to the body of the package, and not the end 46 connected to the shell of the package. One can determine the correct end from the first package to attach to the transfer tail of the next package by observing the direction of rotation, clockwise or counterclockwise, of the first package's transfer tail as it is pulled from the inner diameter of the package. From this, one can thereby ascertain which of the cut ends 44 , 46 would first be intercepted by this transfer tail if the yarn strand were fully unwound to that point. The end 44 that would be first intercepted is the end to be tied. After tying, the packages can be unwound sequentially from the inside out as illustrated in FIG. 10.
[0048] Referring next to FIG. 11, a series of three yarn packages 30 a , 30 b , and 30 c forms a yarn unwinding or delivery system 70 . Each of the yarn packages has been installed in its own upstanding annular sleeve 72 that supports the yarn package during unwinding. Before unwinding begins, the first cut end 44 a of the first yarn package is tied to the beginning end 34 b of the second yarn package 30 b . In addition, the first cut end 44 b of the second yarn package 30 b is tied to the beginning end 34 c of the third yarn package 30 c.
[0049] When unwinding begins, the beginning end 34 a of the first yarn package 30 a is the first to be pulled generally axially away from the yarn package to unwind the yarn from the inside out. Once the first yarn package 30 a has been substantially completely unwound, unwinding continues without interruption to the second yarn package 30 b via the cut end 44 a tied to the beginning end 34 b of the second yarn package 30 b . The second yarn package 30 b is unwound from the inside out until the second yarn package has been substantially completely unwound. Unwinding then continues without interruption to the third yarn package 30 c via the cut end 44 b tied to the beginning end 34 c of the third yarn package 30 c.
[0050] Upon completing unwinding of all three yarn packages, the shell 80 of yarn from the second cut end to the outer diameter of each yarn package, as shown in FIG. 12, comprises waste and is not unwound. Such shells 80 are removed and discarded. While FIG. 11 shows three yarn packages, the invention is not limited to any specific number of yarn packages. Multiple yarn packages may be attached in series and continuously unwound according to the method of the present invention. Indeed, even with a limited number of sleeves 72 , such as shown in FIG. 11, unwinding of multiple packages could be continued after removing the spent shells 80 and installing in their place additional yarn packages that may have their respective beginning ends connected to the respective cut ends of preceding yarn packages.
[0051] Preferably, the yarn packages contain an elastomeric yarn formed from filaments of a polymeric material selected from the group consisting of: rubber, spandex, polyetherester and elastoester. Most preferably, the yarn packages are of yarns formed from filaments of tacky dry spun spandex with a nominal denier in the range of 120 to 3600 that have not been coated with a surface finish or formed from a polymer that incorporates anti-tack additives.
[0052] As yarn is unwound from the inside, the remaining shell 80 becomes thinner and thinner until it reaches a point where it no longer has the structural integrity to stand and thus collapses. Inside-out unwinding then should be stopped or transferred to another package before collapse, and before yarn entanglement, occurs. Although it would be advantageous to unwind 100% of the yarn strand 32 forming the yarn package 30 , this is not required for purposes of the present invention.
[0053] The cylindrical shell 80 of elastomeric yarn can be stabilized to delay collapse or slumping by coating the outside surface of the yarn package 30 with an adhesive coating, or by wrapping and gluing an appropriate sleeve or film to the outside surface of the package 30 before unwinding. Preferred sleeves or films comprise adhesive-backed paper such as used for shipping labels, package sealing tape, fiberglass-reinforced strapping tape and masking tape.
[0054] Once the outer surface of the yarn package is coated, more of the yarn may be unwound (e.g. the distance “A” of the shell left after winding may be smaller) than with an uncoated yarn package. The package sleeve material can provide independent columnar strength to the cake shell by adhesively connecting outer layers of the elastomeric fibers to the sleeve. Ideally, an adhesive that does not penetrate many multiple winding layers of wound fiber is best. With the proper adhesive or sleeve or film, the near-outside end can located at a distance “A” that is less than 5 mm, and preferably less than 2 mm, and more of the yarn may be unwound from the package, thus minimizing waste.
[0055] A particularly difficult elastomeric yarn to unwind is a dry-spun spandex yarn of greater than 120 denier without applied surface finish, which yarn was formed without addition of any anti-tack substances to the polymer solution. This yarn exhibits high-tackiness, or high-tack. Such dry-spun spandex generally is formed into a yarn package that has a net cake weight of between about 1 and 5 kilograms, with an outside cake diameter typically between about 17 to 40 centimeters, an internal cake diameter from about 7.5 to 8.5 centimeters; and a cake width, L, from about 8.5 to 25 centimeters. The yarn can either be freshly spun, or stored for a period of time. Surprisingly, under these conditions the integrity of the package shell is sufficient so that the wall thickness, “A”, can be chosen to be 5 millimeters or less and still avoid shell collapse and yarn entanglement.
EXAMPLES
[0056] #1 Single-Package Unwinding
[0057] Tensions were measured at multiple points throughout the unwinding of a nominal 700-denier Lycra® spandex yarn with no surface finish and no anti-tack additives. The Lycra® spandex packages had an initial net weight of three kilograms, and were aged two months from manufacture. Yarn tension and tension variability were compared between inside-out unwinding and control outside-in unwinding. The yarn takeoff speed was 100 meters/minute. The results are shown in Table I below and graphically in FIG. 13.
[0058] For this Example #1, the unwinding equipment and associated tensiometer are shown schematically in FIG. 14. The yarn package 90 comprised a winding of the spandex yarn held within a sleeve. A threadline 94 taken from the inside core of the package 90 was passed through a pigtail guide 96 and over a series of roller guides 98 to a take-up roll 102 . The threadline was passed through a tensiometer 100 before it was wound up on the take-up roll 102 . A Rothschild Tensiometer from Rothschild Instrument of Zurich, Switzerland was used. The tensiometer 100 had a range of tension measurement from 0 to 40 g, and typically samples and stores five (5) tension readings per second. The tensiometer interfaces with a computer that plots or charts tension data over time. The tensiometer can be operated in various modes to provide graphical representations of tension data. Two common modes are (1) a 30 second run with a report of the average tension over that time; and (2) an extended (30 to 90 minute) run with a running plot of the sampled (five per second) tension measurements. Each data point in FIG. 13 is a mode (1) result.
TABLE I Conventional Overend Center Pull-out Delivery Yarn delivered Delivery tension Yarn delivered tension 0 4.36 0 10.02 60 5.74 3.13 9.42 560 7.88 6.25 9.17 1060 7.04 9.38 8.46 1560 6.80 12.5 8.50 2060 6.70 15.63 8.18 2560 7.00 18.75 8.29 2660 6.97 21.90 7.79 2760 6.68 25 7.40 2820 7.33 120 6.16 2860 8.50 220 5.87 2870 8.28 320 5.64 2880 8.45 420 5.06 2900 10.11 520 4.96 2910 12.20 1020 4.78 2920 13.28 2020 4.03 2930 15.68 2520 3.78 2940 19.21 2620 3.61 2943 17.38 2720 3.43 2945 16.03 2920 2.64
[0059] As shown in the data in Table I and graphically in FIG. 13, the yarn tension for the inside-out unwinding according to the invention remained at about 10.0 grams or below throughout the unwinding of the yarn package. In contrast, the yarn tension spiked to well over 10.0 grams at the end of the unwinding for the example according to conventional outside-in unwinding. The Example unwound according to the invention experienced more consistent drawing tension and did not experience a pronounced yarn tension spike at the end of the unwinding.
[0060] #2 Multiple-Package Unwinding
[0061] Yarn packages were tied together per the method of the invention, whereby the internal end of a second cake was tied to a near-outside end (about 5 millimeters from outside) of a first cake and so on, such as illustrated in FIG. 11. The yarn was a nominal 700-denier Lycra® spandex yarn with no finish and ho anti-tack additive. The yarn cakes had an initial net weight of three kilograms, and were aged two months from manufacture. The yarn takeoff speed was 100 meters/minute. Yarn tension was measured just before and after the transfer of unwinding between cakes, in order to measure the tension “spike” at transfer.
[0062] A second set of packages was tied together in a conventional way, whereby the internal yarn end of one package was tied to the outside-surface end of an adjacent package. Unwinding was the standard outside in, per FIG. 7, and tension spikes at transfer were measured for comparison.
[0063] [0063]FIGS. 15 and 16 graphically represent the tension data obtained during unwinding of the yarn packages of Example #2. The Rothschild Tensiometer was in extended run mode (mode (2) with a running plot of sampled tension measurements at five measurements per second). The standard resolution available on the tensiometer was used.
[0064] As shown in FIG. 15, the outside-in unwinding tension averaged about 13 to 15 grams prior to the transfer to the next yarn package, at which point the unwinding tension was from yarn near the inner diameter of the yarn package. At about 1300 seconds of unwinding time when the unwinding transferred from the first package to the next for outside-in unwinding according to the prior art, the unwinding tension spiked to over 30 grams, which was more than double the average unwinding tension experienced prior to the transfer. A spike of this magnitude can be severe enough to break the threadline for many elastomeric yarns. Following the transfer spike, the unwinding tension dropped to an average between about 5 and 8 grams when unwinding the next yarn package from near the starting outside diameter.
[0065] In contrast, as shown in FIG. 16, the inside-out unwinding tension averaged between about 5 to 7 grams before the transfer when unwinding from near the outside diameter of the yarn package. At about 2500 seconds, the unwinding tension rose to about 18 grams, which remained below about 20 grams for inside out unwinding according to the invention. The unwinding tension did not have a pronounced spike as with the prior art, but elevated to the somewhat higher tension level experienced between unwinding from an outer portion of the package (lower tack) to the inside core of the next package (higher tack). The unwinding tension at the inner diameter of the next yarn package averaged about 12 to 13 grams as unwinding continued. | A method for unwinding tacky elastomeric yarn from one or multiple coiled yarn packages includes the steps of (a) removing tubular cores from each yarn package to expose the beginning end of the yarn strand at the inner diameter of the yarn package; (b) forming a terminal end of the yarn strand at a position along the length of the strand between the inner diameter and outer diameter of the yarn package; (c) when unwinding multiple coiled yarn packages, attaching the terminal end of the first yarn package to a beginning end of a next yarn package; and (d) unwinding by pulling the beginning end of the first yarn package in a generally axial direction to remove yarn from the inside of the package from the inner diameter toward the outer diameter. This method provides inside-out unwinding of a single package, or continuous unwinding of multiple packages of elastomeric yarn at a reduced overall yarn tension, and minimizes unwinding tension spikes. | 1 |
BACKGROUND OF THE INVENTION
This invention relates to cleaning apparatus for curved filter screens and more particularly to such apparatus which includes a boom mounted for pivotal movement about the center from which the arcuate shape of the screen is struck, by means of a reversible drive unit, and a cleaner pivotally connected to the boom and movable up and down on the screen by pivoting the boom and being tiltable relatively to the boom by drive means between a return and/or throw-off position tilted away from the screen and a cleaning position on the screen, which are respectively determined by stops.
A cleaning device of this type is disclosed in German Pat. No. 2 502 725, wherein separate drive devices are provided for pivoting the boom and for tilting the cleaner, which may be in the form of hydraulic cylinders or shafts driven by electric motors. Due to these two separate drive devices and to the necessary mutual coordination of their controls, such prior art apparatus is complicated and expensive.
SUMMARY OF THE INVENTION
It is an object of my invention to simplify the drive means for imparting pivotal movement to the pivot boom and tilting movement to the cleaner. This is achieved according to my invention by providing a single reversible drive unit for pivoting the boom and for tilting the cleaner with the drive unit being connected to the cleaner in such a way that its force exerts a tilting force upon the cleaner which is then transmitted to the boom as a pivoting force. After the cleaner has completed its tilting stroke it is anchored rigidly by abutment against a stop on the boom.
My improved drive unit thus utilizes a structure wherein it acts solely upon and tilts the cleaner without thereby transmitting a driving force to the boom. It then exerts a pivoting force upon the boom as soon as the cleaner has completed its tilting stroke and abuts against a stop to thereby rigidly connect the drive means to the boom. In comparison to the prior art apparatus mentioned above, my improved drive unit is more economical to manufacture and use and eliminates the requirement of means for the mutual coordination of two separate drives. The coordination of the tilting and pivoting movements is obtained automatically due to the fact that during the tilting of the cleaner the boom is not driven whereby the force of the drive unit is exerted as a pivoting movement for the boom only after the cleaner has completed its tilting stroke.
According to a preferred embodiment of my invention, the stop determining the cleaning position of the cleaner is constructed so that it ceases to function as a stop at the end of the upward movement of the boom, so that after the cleaner is released it is once more tiltable relative to the boom into a throw-off position by the force of the drive unit continuing to act upon it. Accordingly, without providing additional drive means, I provide a throw-off movement of the cleaner to throw off the screen material collected by it, and at the same time no stripper is necessary to strip the screen material out of the cleaner. Since this tilting movement occurs abruptly, the screen material not only slides off, but is actually thrown off. Also, a great throw-off height can be achieved by this means.
In a preferred embodiment of my invention, the stop determining the cleaning position of the cleaner comprises guide members on the screen, which are engaged by sliding or rolling elements carried by the cleaner. Such guide members may be carried by the outermost grating bars of the curved screen, which may conveniently be in the form of projections which extend upwardly and downwardly beyond the upper and lower ends of the screen. There is an advantage in this construction in that the cleaning device is also suitable for use with inaccurately curved or inaccurately installed screens, since the cleaner can immediately follow the inaccuracies. Such inaccuracies may also be in the form of short straight screen sections.
Instead of the cleaner abutting against the screen, the work position of the cleaner relative to the boom may also be determined by means of a releasable stop or ratchet which rigidly anchors the cleaner, or a member connecting it to the drive unit, to the boom and which is releasable at the upper end of travel of the boom.
DESCRIPTION OF THE DRAWINGS
Apparatus embodying features of my invention is illustrated in the accompanying drawings forming a part of this application, in which:
FIG. 1 is a schematic side elevational view, partly in section, showing a curved filter screen associated with cleaning apparatus according to one embodiment of my invention with the cleaner in the cleaning position;
FIG. 2 is a view corresponding generally to FIG. 1 but showing the cleaner in the throw-off position;
FIG. 3 is a view similar to FIG. 1 showing another embodiment of my invention; and
FIG. 4 is a view similar to FIG. 1, showing a further embodiment of my invention.
DETAILED DESCRIPTION
Referring now to FIG. 1, I show a curved filter screen 10 having the usual curved grating bars 11. The filter screen 10 is mounted in a channel 12 through which the sewage to be purified flows with the screen 10 continuing above the liquid level and above the operating platform 13. An apron 14 is provided at the upper end of the screen, as shown. Also, a bucket truck 15 is provided as a collecting and transport device.
A boom 16 is mounted for free rotation on a shaft 17 driven by a gear motor 18. The shaft 17 is located as accurately as possible at the center from which the arcuate shape of the curved screen 10 is struck. The driven shaft 17 is connected rigidly to a crank arm 19. Pivotally connected to the free end of the crank arm 19 is a connecting rod 21, which in turn is pivotally connected at its other end to a cleaner fork 22 which is pivotally attached to the boom 16 whereby the cleaner fork is tiltable relative to the boom. In FIG. 1 the boom 16 is shown as having a projection 23 which extends beyond its pivot point and carries a counterweight 24.
FIG. 4 shows an alternative for the counterweight 24 wherein the boom 16 may be braked during downward pivotal movement thereof by a conventional type brake 25, which acts through a freewheel to engage the hub for the boom only when the boom is rotating in a direction for the free end thereof carrying the cleaner fork 22 to be lowered.
In the position illustrated in solid lines in FIG. 1 during upward travel of the cleaner fork 22, the driving force of the motor 18 acts through the connecting rod 21 upon the cleaner fork 22 and urges the latter against the screen 10. Through suitable sliding elements 22a, rollers or the like the driving force of the motor 18 acts upon certain screen bars, preferably the two outermost bars, which thus constitute guide members 26 that extend upwardly as far as a throw-off point, as shown. So long as the cleaner fork 22 is in abutment against the guide members 26, the crank arm 19, connecting rod 21, cleaner fork 22 and boom 16 constitute a rigid four-bar linkage, through which the force of the motor 18 is transmitted to impart upward pivotal movement to the boom 6. By selecting the proper pivot points, the cleaner fork 22 may be urged more firmly against the screen bars 11 with increased cleaning resistance, so that even jammed screen material can be eliminated in a reliable manner.
At the upper end of the apron 14 the stop for the cleaner fork 22 terminates, so that the boom 16 is no longer driven and thus stands still. The connecting rod 21 then tilts the cleaner fork 22 forward beyond the arc of the curved screen whereupon the screen material is automatically discharged into the bucket truck 15, as shown in FIG. 2. Accordingly, chutes or similar guide members are eliminated. During tilting movement of the cleaner fork 22 it may slide over a rounded upper extremity of the apron 14, or pass over a roller 27 which supports the cleaner fork without preventing fibers suspended from the fork tines from being thrown off, as shown in FIG. 2.
At the end of the tilting movement of the cleaner fork 22, a limit switch 28 is actuated which reverses the direction of rotation of the motor 18. Due to the fact that the boom 16 with its counterweight 24 is weighted in such a way that a dead-weight force acts in the upward direction of rotation, or counterclockwise as viewed in FIG. 2, the cleaner fork 22 is initially tilted back with no movement of the boom 16. That is, it is tilted backward beyond its work position into the return position, where it is retained by a stop 29. Accordingly, a rigid four-bar linkage is again produced, so that the driving force of the motor 18 now also pivots the boom 16 downwards. In the backward tilted position the cleaner fork 22 is spaced a sufficient distance from the grating 11, so that all layer thicknesses of screen material occurring in practice are passed over.
In the lower limit position, in which the counterweight force is practically nil, the direction of rotation of the motor 18 is again reversed by a further limit switch 31, whereby the cleaner fork is automatically tilted into the cleaning position as shown in FIG. 1. In this position outer support elements of the cleaner fork 22 come to bear upon guide members 26a defined by the lower ends of the two outermost bars 11, which extend beyond the lower ends of the remaining grating bars 11 for this purpose.
The reversible motor 18 may be an electric, hydraulic or pneumatic motor, which may drive the shaft 17 through a gear of a desired construction. The drive means may also be a hydraulic or pneumatic cylinder which engages the crank arm 19 directly or another crank for imparting pivotal movement to the cleaner fork 22. The length proportions and positions of the pivot points of the four-bar linkage are chosen so that, on the one hand, a sufficient cleaning force can be built up, while on the other hand, the drive means does not become blocked by an increase in the frictional force created by the cleaning resistance.
In the embodiment shown in FIG. 3 the front side 30 of a cleaner fork 20 has a fork rail 32 which extends upwardly and then forwardly toward the screen 11 so that the working edge of the fork rail engages the screen at a very acute angle relative to a line approximately tangent to the arcuate interior profile of the screen. The screen material is thus peeled off correctly and jamming cannot occur. The bottom of the cleaner fork 20 is trough-shaped with its bottom wall 33 and lower section of its rear wall 34 containing drip apertures 36 for preliminary drainage of the screen material. Apertures, preferably in the form of vertical slits 37, are provided in the front wall 30 so that they do not obstruct the throw-off of the screen material onto a conveyor 40.
The connecting rod 21 of the embodiment shown in FIG. 3 is provided with a ratchet having a locking nose 38 which cooperates with a catch lever 39 whereby the cleaner fork is maintained at a short distance from the screen 10 during its cleaning travel. The locking nose 38 is mounted on the connecting rod 21 and the catch lever 39 is connected to the boom 16. The catch member 39 is retained in its upper position by a tension spring 41 whereby it limits movement of the connecting rod 21 as it travels forward to pivot the fork 20 inward. Just before reaching the top throw-off position the catch lever 39 is unlocked by a fixed stop lever 42. Accordingly, the connecting rod 21 can travel forwardly and initiate the throw-off operation. The stop bar 42 is drawn against an upper stop 43 by a tension spring 44. The stop bar 42 can escape downwardly from the catch lever 39 which is resiliently held from above by the spring 44.
In the embodiment shown in FIG. 3 having the ratchet and trough-shaped cleaner fork 20, an apron at the upper end of the screen 10 is unnecessary. The uppermost position of the boom 16 can be obtained and precisely maintained by a fixed stop 45.
In all embodiments, the apparatus is switched on from the rest position of the boom 16 as shown in dotted lines in FIG. 1, by the limit switch 31 whereby after throwing off the screen material and being switched back to return, the cleaner fork is tilted fully backwardly, while the boom still occupies the top position. In automatic operation switching on may occur in the usual manner as a function of the level difference or by a work time/pause control. | A boom is mounted for pivotal movement about the center from which the arcuate shape of a filter screen is struck and a cleaner is pivoted to the free end of the boom. A single reversible drive unit is operatively connected to the cleaner for exerting a force thereto to tilt the cleaner toward a cleaning position. A stop operatively and rigidly connects the cleaner to the boom to transmit force from the cleaner to the boom as a pivotal force only after the cleaner is tilted to the cleaning position to thus rigidly connect the drive unit and cleaner to the boom. | 4 |
FIELD OF THE INVENTION
The present invention relates generally to devices for propping-open doors and more particularly, to a device which is designed to be readily accessible to service personnel by attaching the door stop device to an item of clothing worn by a user of the device.
BACKGROUND OF THE INVENTION
Many modern hotels and motels in the resort industry are equipped with automatic closing doors. While these doors serve security and fire suppression functions when they are closed, there are many circumstances when it is beneficial to keep such doors open for brief periods of time. Hotel employees such as bellmen, room service, housekeeping, engineering, security and convention service personnel, all have occasions when regular passage through these doors is convenient. In those instances, it is beneficial to use a door prop device to keep the door open for the brief periods of time necessary. Bellmen, for example must enter rooms many times a day carrying bags for patrons. Their service is most conveniently performed when the door to the room being accessed can be held open by a door prop device. Conventional door prop devices however, are not designed to be easily and conveniently carried on the person of the service provider.
Conventional door stop devices are not suitable for the heavy fire-proof and security doors found in the modern luxury resort industry and most are not suitable for use where the exterior finish of the door must be protected from marks, scratches and dents.
Thus, there is a continuing need in the resort industry for a simple, economical and professional appearing door prop that can be easily carried on the person of service personnel in resorts of the highest quality and which is suitable for the needs of the modern hotel industry.
SUMMARY OF THE INVENTION
The door prop device of the present invention is designed to be readily accessible and available for immediate use by those who primarily work in, or provide services to, the resort hotel and motel industries. The door prop device is designed to always be readily accessible to the service personnel by attaching it to an item of clothing, preferably a sash or belt of the kind typically worn by personnel in these industries and yet still look professional. In order to adequately prop open the typically heavy, self closing doors of the resort industry, the device is constructed to slide over the top of a hinge pin and down alongside the hinge plates that attach the door to the door frame. Placement of the device on the center hinge of a door ensures that the door remains securely in the open position.
Also, the device is made of high quality durable rubber or plastic that will not mark even the most expensive finishes found in the high quality resort industry. The embodiments of the present invention are further directed to a method for improving access to a door chock device by resort industry personnel.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective bottom view of a first embodiment of the present invention;
FIG. 2 is a perspective top view of the first embodiment of the present invention showing its placement into a position to obstruct a door from closing;
FIG. 3 is a top view of the first embodiment of the present invention showing a swivel collar attachment;
FIG. 4 is a side view of the first embodiment of the present invention showing the swivel collar attachment;
FIG. 5 a is a plan view of the swivel collar;
FIG. 5 b is a cross-sectional view of the swivel collar;
FIG. 6 is a bottom view of the first embodiment of the present invention showing a receiving channel;
FIG. 7 is a perspective bottom view of a second embodiment of the present invention showing an attachment recess;
FIG. 8 is a bottom view of the second embodiment of the present invention; and
FIG. 9 is a side view of the second embodiment of the present invention.
DETAILED DESCRIPTION
The device of the present invention is discussed herein with reference to an embodiment to be used in propping open a typical door equipped with an automatic closing device.
With reference to the drawings, a new and improved door prop device embodying the principles and concepts of the present invention and generally designated by the reference numeral 10 will be described. FIGS. 1 through 9 , illustrate an improved door prop device 10 , comprising a block member 100 and a securing member 110 contiguous with the block member 100 . The block member 100 and the securing member 110 each have a top surface 120 and a bottom surface 130 . These designations apply with the understanding that when the door prop device 10 is placed onto a vertically mounted hinge 140 , having hinge pin 150 and hinge plates 160 & 170 , best seen in FIG. 2 . The bottom surface 130 of block member 100 is beneath the top surface 120 of the block member 100 . The block member 100 contains at least two bumper walls 180 & 190 .
A receiving channel 200 is formed intermediate the block member 100 and securing member 110 . Receiving channel 200 is constructed of sufficient dimensions to fit over and otherwise engage hinge pin 150 and similar type pins.
Turning now to FIG. 2 , in practice, securing member 110 is placed into door space 210 by a user of the door prop device 10 , such that the bottom surface 130 of block member 100 contacts the hinge pin 150 . The user of door prop device 10 places downward pressure onto the top surface 120 of block member 100 and/or the top surface 120 of securing member 110 causing receiving channel 200 to engage a portion of hinge pin 150 and a portion of hinge plates 160 & 170 . As the user continues downward pressure on top surface 120 of block member 110 the receiving channel 200 slideably engages the hinge pin 150 and hinge plates 160 & 170 .
Referring now to FIGS. 1 & 4 , receiving channel 200 has a depth, defined as the distance between the intersection of underside 220 of securing member 110 and the bottom surface 130 of bumper walls 180 & 190 . The depth of the receiving channel 200 is sufficient to extend below a top portion of hinge pin 150 allowing bumper walls 180 & 190 to slide down alongside hinge plates 160 & 170 , best seen in FIG. 2 , until the underside 220 of receiving channel 200 abuts against a top portion of hinge pin 150 .
At least two bumper walls 180 & 190 of block member 100 act as an abutment against hinge plates 160 & 170 of a door jam 230 thus preventing the automatic door 290 from closing against a door jam 230 . In one embodiment, best seen in FIG. 6 , concave surfaces 240 & 250 are formed along a portion of the depth of the receiving channel 200 . This embodiment facilitates placement and engagement of the door prop device 10 over hinge pin 150 .
One embodiment of the present invention includes an attaching element 260 , best seen in FIGS. 3 & 4 , integrated on the door stop device 10 . The attaching element 260 facilitates removably attaching door prop device 10 to an item of clothing worn by a user of the door prop device 10 . In one embodiment, attaching element 260 is disposed along a top surface 120 of block member 100 and/or securing member 110 . In alternative embodiments however, attaching element 260 is disposed along a bottom surface 130 of door stop device 10 . As shown in FIGS. 5 a & 5 b , attaching element 260 is a swivel collar 270 that is coupleable with a receptive device worn on the clothing or tool belt of a user. Swivel collar 270 couples with a corresponding U-shaped cavity 280 of the receptive device capable of being attached to a typical tool belt (not shown).
In an alternative embodiment shown in FIGS. 7 & 8 , a recess 300 integrated on bottom surface 130 accommodates an attaching element. Alternatively, the recess 300 may be integrated on the top surface 120 . In this embodiment, the attaching element is an independent element that is affixed to the molded door stop device 10 rather than integrated therewith. The attaching element may be affixed using glue, epoxy, VELCRO® or any similar secure affixation means. The independent attaching element facilitates a simpler and more reliable door stop manufacturing process. That is, the molding process is more conducive to a compact unit not having extruding members such as the integrated attaching element 260 .
In any embodiment, attaching element 260 or the independent attaching element can be any means for removably attaching the door stop device 10 to an item of clothing. Said means include a hook, a button, snap, strap, carabiner, hook and loop fasteners such as VELCRO®, or any other suitable means.
In alternative embodiments as shown in FIGS. 7-9 , block member 100 and securing member 110 vary in size and dimensions to accommodate different sizes and configurations of doors 290 and door jams 230 . Also, as shown in FIGS. 7-9 certain edges 310 of the door stop 10 may be rounded. In one embodiment, block member 100 is fabricated of a solid slab of hard rubber or a synthetic polymer composition and it may be molded or constructed from any number of suitable materials. Such materials prevent the door stop device 10 from marking the exterior finish surface of the door 110 or the hinge plates 160 & 170 when the door 290 closes against bumper walls 180 & 190 of the door prop device 10 .
In order to reduce the weight of the door prop device 10 , tapered corners 282 , 284 , 286 & 288 , best seen in FIGS. 1 , 3 & 6 , are formed in door prop device 10 . Tapered corners 282 , 284 , 286 & 288 of securing member 110 facilitate placement of the door prop device 10 into open space 210 between the door 290 and the door jamb 230 .
It should be understood that the particular embodiments described above are only illustrative of the principles of the present invention, and various modifications could be made by those skilled in the art without departing from the scope and spirit of the invention, thus, the scope of the present invention is limited only by the claims that follow. | A door stop device comprising a block member, a receiving channel to facilitate placement of the device onto a door hinge, and an attaching means suitable for removably attaching the door stop device to an item of clothing worn by a user. The door prop device of the present invention is designed to be readily accessible and available for immediate use by those who primarily work in, or provide service to, the resort, hotel and motel industries. | 4 |
BACKGROUND OF THE INVENTION
The present invention relates generally to an oven, and in particular to an oven, of the type employed to bake products, preferably food products and which incorporates heating means, and some turbines that propel hot air towards the oven interior.
The ovens that are known at present time incorporate a turbine that propels the heated air through some heating means and projects it towards the interior area of the oven through a plurality of openings or grooves made in the walls thereof, in such a way that permits the heating of such interior area of the oven where a trayholder carriage is placed which serves as support of the product to be baked.
With the object of obtaining a uniform distribution of the heat in the interior of the heating chamber, this type of oven has a large number of openings for the hot air outlet, in the lateral side of its limit, since on the contrary the heat will project itself in some definite points of the product, and for this reason the baking will not be uniform; furthermore this large number of outlets are placed both in the rotative ovens, in which the carriage rotates over a central shaft, as well as in static ovens in which the trayholder carriage does not move during the baking process of the product.
The problem that this type of ovens offers is the large number of outlets placed in the lateral sides of the heating chamber, which make difficult its manufacturing and which consequently make it more expensive; on the other hand their capacity is limited since in its interior only one trayholder carriage can be placed.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a baking oven which avoids the disadvantages of the prior art.
In keeping with these objects and with others which will become apparent hereinafter, one feature of the present invention resides, briefly stated, in a baking oven which presents the peculiar characteristic of having a hollow bridge in the interior of the heating chamber, with a reduced number of openings vertically distributed in the interior lateral thereof, this hollow bridge is mounted on some parallel guides on which it can be longitudinally shifted to describe alternative movements with a run of equal length to the existing one between two consecutive hot air outlet openings.
This hollow bridge internally defines some dimensions that allow the location in its interior of at least one trayholder carriage with the product to be baked.
The hollow bridge has a hot air inlet opening on which an interior duct in coupled through which circulates a hot fluid collected from the heating means and propelled by a turbine; the coupling between the hollow bridge and the hot fluid circulation duct is sliding, in such a way that the bridge can be displaced describing the shifting movements already mentioned, maintaining the coupling with the hot air circulation fixed duct.
It has been foreseen that the shifting displacements of the bridge on the guides should be carried out by means of a movement transmission mechanism driven by a motor element, which allows that when the bridge describes such shifting movements, the outlets will be able to displace themselves from their original position until they reach the position previously occupied by the consecutive outlet in the forward heading direction making successive sweepings with the hot fluid on the product, reaching a uniform baking thereof with a reduced number of outlets.
Furthermore this oven has the advantage that the total length may be as high as you wish, incorporating in the interior of the heating chamber different hollow bridges, with their corresponding means of heating, turbines and movement transmitting mechanisms, all the bridges moving simultaneously to form a baking tunnel in which interior different trayholder carriages with the product to be baked are aligned.
In the case that a baking tunnel is formed, it has been foreseen that in the interior of the heating chamber some carriages dragging means are available to facilitate the introduction and extraction thereof.
The novel features which are considered as characteristic for the invention are set forth in particular in the appended claims. The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an elevational view, sectioned by a vertical plane, of the improved oven, object of this invention, with only one bridge.
FIG. 2 shows a plant view, sectioned by a horizontal plane, of the oven with two bridges aligned to form a baking tunnel.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As it is noted in the above mentioned figures, the oven of the invention incorporates a heating chamber (1), in which the baking of the product is performed, producing the heating thereof by the introduction of hot air; moreover this oven incorporates an annexe compartment (2) in which the heating means (3) are located, and a turbine (4) in charge of propelling the hot air towards the interior of the chamber (1).
In the interior of such chamber (1) it is available at least one hollow bridge (5) which defines in its confronted interior laterals different vertical outlets (6) equidistant, through which the hot fluid emerges propelled by the turbine (4).
The turbine (4) and the bridge (5) are in relation with each other by means of a fixed duct (7) that introduces itself in the interior of the heating chamber (1) and such end is coupled with shifting possibility on the exterior wall of the bridge (5);. To carry out this coupling it is provided that the duct (7) tops out by the mouth which is introduced in the interior of the bridge (5) in a plane peripheral frame, and that the bridge wall (5) defines an opening of greater dimension than the section of the duct (7) and smaller than the defined surface by such peripheral frame arranged in the duct (7);. In this way the bridge (5) will maintain itself connected with the duct (7) independently of the running position that occupies, allowing the entry of hot fluid propelled by the turbine.
The bridge (5) is supported with shifting possibility on some lower guides (8) with the possibility that can make shifting movements which run coincides with the distance that separates two consecutive outlets (6).
For displacing the bridge (5) on the guides (8) the driving is produced by a motor element (9) through a transmission mechanism of movement, It is formed by a zip fastener (10) linked to the bridge (5), and on which is acting a driven pinion (11) controlled by a motor element (9).
The bridge (5) defines some appropriate dimensions to permit the location in its interior of at least a trayholder carriage (12) designed to support the product that is going to be baked in the interior of the heating chamber (1).
In the areas near the heating means (3), the heating chamber (1) and the annexe compartment (2) are separated by a humidifier chamber (13), having an outlet at 13a for discharging vapor into the air to be heated. An opening (14) under it allows the passage of the hot fluid from the heating chamber (1) to the annexe compartment (2), in such a way that the hot fluid contained in the heating chamber (1) is sucked out by the turbine (4), passing through the opening (14) and the heating means (3), in order to be newly propelled through the duct interior (7) towards the bridge (5) emerging through the opening (6) defined in the bridge (5). In this way a continuous circulation of the fluid is originated producing the oven high performance.
It has been foreseen that the heating chamber (1) presents two confronted inlets (15) and (16) that can be opened to the exterior, closed through some fixed transparent plates (17) or lowerable ones (18).
Given the design of the elements which form the oven and the fact that the bridges (5) are shiftable to allow the hot air to emerge through the outlets (6), making swifts on the product covering the total surface of the product, this oven allows that the heating chamber (1) defines such large length as desired, being able to incorporate various aligned bridges, as it is represented in FIG. 2, in order to make the simultaneous baking of the product contained in different trayholder carriages (12) since once they are introduced in the interior of the oven they remain static, being the hollow bridges simultaneously shifted (5).
With the object of carrying out the introduction and extraction of the trayholder carriages (12) in the interior of the baking tunnel the oven incorporates some dragging means preferably formed by a chain (19) with some means of fastening to the carriage.
In the case of forming a baking tunnel each of the bridges (5) will incorporate the corresponding baking means (3), turbines (4) and shifting means.
Once the nature of the invention is sufficiently described, as well as the practical embodiment thereof, it is stated that some changes can be introduced considering that they are appropriate, whenever the essential characteristics that are claimed below do not change.
It will be understood that each of the elements described above, or two or more together, may also find a useful application in other types of constructions differing from the types described above.
While the invention has been illustrated and described as embodied in a baking oven, it is not intended to be limited to the details shown, since various modifications and structural changes may be made without departing in any way from the spirit of the present invention.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention.
What is claimed as new and desired to be protected by Letters Patent is set forth in the appended claims. | A baking oven comprises means forming an oven heating chamber, a heating means, a turbine that propels hot air toward the heating chamber, at least one hollow bridge located in the heating chamber and provided with hot air outlets, guides which guide the hollow bridge so as to shift the hollow bridge, and a bridge shifting unit arranged so as to force the bridge to make shifting movements on the guides. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] None.
FIELD OF THE INVENTION
[0002] The present invention generally relates to hunting primarily using an archery system, such as compound bows and crossbows. In particular, the invention relates to a hunting method for creating a hunting field by placing an array of markers at predetermined ranges and combining the marked field with a sight to improve the speed of sighting and accuracy of the hunter.
SUMMARY OF THE INVENTION
[0003] The present invention generally relates to hunting primarily using an archery system, such as compound bows and crossbows, though it could also be used with a rifle. In particular, the invention relates to a method for placing an array of color-coded distance markers at predetermined distances from a central point such as a hunting stand or blind and coordinating the color-coded range designators in the weapon's sight corresponding to color-coded distance markers enabling a hunter to quickly determine the estimated distance to a target based on the color-coded distance marker pairs and allowing the hunter to further refine their aim based on the proximity of the target to at least one of the distance markers while maintaining both hands on the weapon.
[0004] Most bow hunting takes place with a hunter in a tree stand in the woods or the hunter in some type of blind. Range estimation by a hunter is usually accomplished through the hunters own experience and his trained eye. This method has accuracy limitations based on the hunters experience, eyesight, and ability to accurately estimate distance. The greater the inaccuracy this method of the range estimation then the greater possibility of missing the target or far worse injuring or crippling the target and it escaping. An improvement to this method was adding a bow sight with colored-coded range designators, which increases the accuracy of the archer but still has limitations with respect to range estimation. To counter this problem, many hunters do course range estimations to geographical features such as trees, rocks, or any distinguishable item in their hunting area but most bow sight range designators are set at 5 yards or 10 yards with multiples thereof. Most geographical features are not at one of these specific distances, so the archer must estimate the distance to the target based on their chosen geographical feature location and make additional estimations within the range designators when aiming to correct for the geographical feature being at a non-uniform distances. Another additional improvement to this method is to use a range finder to calculate the actual distance to the target but for this to be accomplished, an archer must remove at least one hand from the bow to operate the device, which is likely to be detected by the target causing the target to flee. Additionally, a rangefinder could be mounted on the bow adding extra weight to the already heavy bow and changing the balance of the bow, which affects accuracy.
SUMMARY OF THE INVENTION
[0005] The present invention generally relates to hunting primarily using an archery system, such as compound bows and crossbows. In particular, the invention relates to a method for placing an array of color-coded distance markers at predetermined distances and color coordinating the range designators in the sight to the color-coded distance markers in the field enabling an archer to quickly determine the estimated distance to a target based on the color-coded distance marker pairs and allowing the archer to further refine their aim based on the proximity of the target to one of the selected distance markers while maintaining both hands on the bow.
[0006] The U.S. Army Field Manual for Mortars 3-22.90 teaches methods and a system using aiming posts arrayed in a field of fire to establish a reference line. These posts are used the set mortar in position and provide a frame of reference for indirect fire. This use of aiming posts is targeted for use with indirect fire systems such as mortars and howitzers.
[0007] U.S. Pat. Pub. No. 2012/0246992 to Peters, teaches methods and systems for range finding and aiming. Peters teaches the use of a handheld laser rangefinder that compensates for ballistic drop. Peters requires the user to have at least one hand free in order to operate the device.
[0008] U.S. Pat. Pub. No. 2011/0296699 to Mainsonneuve, teaches an archery bow sighting device that incorporates a laser range finder, an automatically adjusting sight pin, trigger control, and distance indicator. The device incorporates imbedded electronics and a gearing mechanism to adjust a sighting pin based on distance to target and calibrated distance data. Mainsonneuve's gearing mechanism to drive the single sighting pin will have audible sounds detectable by the game and adds to the complexity of the device, thus reducing the reliability in the field.
[0009] U.S. Pat. No. 2,491,476 to Brown teaches a fire control method for indirectly aiming a cannon. Brown provides an improved method and means for setting or adjusting the azimuth of cannon in indirect firing or indirect laying. In indirect firing the target is not visible from the cannon and the adjustment of the azimuth or traverse and the elevation of the cannon is made in accordance with data or instructions received from an observer who is situated at a point or location from which the effect of the fire, the hits or misses, can be observed. U.S. Pat. No. 2,437,677 also to Brown teaches a gun aiming post with a reflecting surface. This invention eliminates errors introduced in the azimuth calculation caused by recoil of the cannon when fired. This use of aiming posts with indirect fire systems provide precise point of impact of a high explosive shells and minimizes errors when putting friendly troops in harm's way.
[0010] U.S. Pat. No. 8,371,059 to Tillinghast teaches an improved aiming post light configuration with an integral light and luminescent material. The luminescent material is periodically recharged using an LED thereby extending the life of the battery on the battlefield. This invention is targeted at extending the life of the battery and providing a light for night firing.
[0011] The present invention overcomes these shortcomings in the prior art by providing a method for direct fire using aiming posts to determine and refine the estimated range to the target, using color-coded indicators at predetermined distances in a field, each indicator may have battery powered lights not integral to the aiming posts, the field indicators used in coordination with similar color-coded sighting pins avoiding adding heavy, complex, and noisy devices to the bow, or requiring the archer to remove a hand from the bow to operate such a device.
[0012] The present invention fulfills the need for providing a range estimation method for quickly and more accurately determining the range to a target maximizing the lethality of the shot due increased accuracy thus preventing the maiming or injuring of a game animal.
[0013] There have thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto.
[0014] 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 this 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 description and should not be regarded as limiting. As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods, and systems for carrying out the several purposes of the present invention. Additional benefits and advantages of the present invention will become apparent to those skilled in the art to which the present invention relates from the subsequent description of the preferred embodiment and the appended claims, taken in conjunction with the accompanying drawings. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
[0015] Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientist, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The abstract is neither intended to define the invention of the application, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way.
DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a diagrammatic representation of an embodiment of the hunting method.
[0017] FIG. 2 is a diagram illustrating the hunting field.
[0018] FIG. 3 is a perspective view of the system in an archery embodiment.
[0019] FIG. 4 is a side view of the left side of the fixed distance marker.
[0020] FIG. 5 is a side view of the left side of the telescoping distance marker.
[0021] FIG. 6 is a diagrammatic representation of range determination for the distance marker using a range finder.
DETAILED DESCRIPTION OF THE INVENTION
[0022] FIG. 1 is a diagrammatic representation of an embodiment of the hunting method 100 including four components: color-coded range designators 106 in a sight 104 , color-coded distance markers 108 , and a target 110 . This figure illustrates how a hunter would use the hunting method 100 to make range estimations to a target 110 . The hunter grasps the bow 102 , looks through the bow sight 104 at the target 110 . As the archer looks through the bow sight 102 , the archer views the color-coded range designators 106 in the bow sight 104 that are color-coded to match the color-coded distance markers 108 placed at varying ranges in the hunting field 200 also seen through the bow sight 104 . The archer looks through the bow sight 104 , selects the desired impact point of the arrow on the target 110 , then compares the color-coded range designators 106 to the distance markers' 108 color coding to choose which color-coded range designators 106 should be used to estimate the desired point of impact for the arrow. Once the archer chooses at least one color-coded range designator 106 to use, then the archer may make a second estimation as to which distance marker 108 the target 110 may be closest, allowing the archer to adjust their sight picture using the color-coded range designators 106 based on this estimation.
[0023] FIG. 2 is a diagram illustrating the hunting field 200 highlighting four features: distance markers 108 , ranges 204 , a hunting stand 202 , and a target 110 . This figure illustrates the position of the hunting stand 202 with respect to the different distance markers 104 placed at varying ranges 204 from the hunting stand 202 . It also illustrates the varying ranges 204 form concentric arcs with a target 110 contained therein. FIG. 2 shows the illustration wherein the color-coded distance markers 108 are in a straight line extending from the focal point a hunting stand 202 and placed at various ranges were the last marker may be placed at the archery systems 300 effective range. Typically, the ranges are set at 10 yards, 20 yards, 30 yards, 40 yards, 50 yards, and 60 yards but one skilled in the art may chose different range increments based on the bow sight 104 and the number of color-coded range designators 106 contained therein, the power of the archery system 300 , hunting field 200 , hunting conditions, and the overall skill of the archer. Placing the distance markers 108 in a straight line is but one method of arranging the distance markers 108 within the hunting field 200 . Based on the conditions of the hunting field, the archer may place the distance markers 108 in a line as demonstrated above or the distance markers 108 could be placed at different positions within the hunting field 200 due to its natural geographical features. The target 110 is placed between the 20 and 30 yard distance markers 108 to illustrate that an archer could use the corresponding color-coded range designators 106 on the bow sight 104 to make a course estimation of the targets distance. Additionally, since the target 110 is placed approximately equidistant to both distance markers 108 , the archer may place the impact point half way between the selected range designators 106 . This method provides a more refined method of range estimation thus providing for a more accurate shot.
[0024] FIG. 3 is a perspective view of a bow 102 and bow sight 104 . The bow 102 in this preferred embodiment is a compound bow, however, other bows such as recurve or crossbows could also be used as part of an archery system 300 . The bow sight 104 typically consists of a set of color-coded range designators 106 placed at varying heights within the bow sight 104 . The color-coded range designators 106 have been set for specific distances by the archer providing the desired angle of the bow in order for an arrow to hit the desired impact point. The preferred embodiment of the range designators 106 are fiber-optic horizontal pins. However, range designators 106 in the bow sight 104 may include sights such as horizontal pins, vertical dots, reticles, horizontal lines, pendulums, and fiber optics but not limited to, other methods of sighting as will be apparent to one skilled in the art.
[0025] FIG. 4 is a side view of an embodiment of the distance marker 108 , which is a fixed height. The distance marker 108 may consist of a translucent marker upper portion 400 , a marker outer shaft 402 , and an anchor 404 . The marker upper portion 400 can be color coded to the range designators 106 in the bow sight 104 using methods including tape, colored reflectors, colored paint, chemiluminescence and colored lights but not limited to other methods of color coding the upper portion that will be apparent to one skilled in the art. The preferred embodiment consists of placing different colored chemiluminescence sticks inside of the translucent upper portions 400 of the distance markers 108 to provide the corresponding color-coding to the range designators 106 . The marker upper portion 400 may be constructed of materials known to one skilled in the art that provide translucence allowing for the light to be seen by the archer.
[0026] FIG. 4 also illustrates a fixed height distance marker 108 using a fixed marker outer shaft 402 to connect the marker upper portion 400 to the anchor 404 . The marker outer shaft 402 may be constructed of materials known to one skilled in the art that are semi-rigid to rigid and resistant to wind, other lateral forces, and environmental conditions. The anchor 404 may be selected from materials that will maintain the marker outer shaft 402 and the marker upper portion 400 in a vertical position enabling the archer to see it from the hunting stand 202 . The material used to create the anchor 404 is dependent on the area in which the archer plans to hunt. If the hunting field 200 has predominately sand-type soil, then the anchor 404 may need to have a larger surface in order to maintain the distance marker 108 upright due to propensity of the soft sand to give way allowing the marker to fall. If the hunting field 200 is rocky, then the anchor 404 may be smaller and more pointed to enable it to be more easily inserted into the ground. Finally, if the soil has high clay content then some type of anchor 404 in between the one used for the sandy soil and the one used for rocky area soil would be appropriate. Additionally other concerns such as the amount of moisture the field has had recently may also determine the type of anchor that may be needed to maintain the marker in the vertical position. One skilled in the art could determine the type of anchor 404 needed based on factors such as type of soil, weather conditions, durability, and the hunting field but is not limited to these factors.
[0027] FIG. 5 is a side view of a telescoping distance marker 108 . The distance marker 108 may allow the height to be varied based on the conditions of the hunting field. For example if the archer is hunting in a field that has grain growing, then the archer may need to vary the height of the distance marker 108 sufficiently to exceed the height of the grain that is currently growing in order to see the distance marker 108 . The height of the distance marker 108 may be changed by one skilled in the art to a desired height based on the conditions of the hunting field 200 . The telescoping height of the distance marker 108 may be accomplished by using an outer shaft 402 , a concentric inner shaft 510 , and a positioning pin 512 . The marker outer shaft 402 may slide over the inner shaft 510 in a telescoping action extending upward from the anchor 404 to the desired position in order to change the height of the distance marker 108 wherein a positioning pin 512 may be inserted into the alignment holes to maintain the height. This is the preferred embodiment of the adjustable distance marker. One skilled in the art may choose other methods to make the height adjustable including telescoping, sectional, and folding but is not limited to these methods. The telescoping action allows one skilled in the art is to create a distance marker 108 such that is more easily transportable and can accommodate a wide range of field conditions. The removable anchor 514 in this embodiment is removable from the shaft making it more easily transportable by the archer transversing the hunting field.
[0028] Another possible feature of the distance marker 108 is the color-coding of the marker upper portion 400 using colored lights connected to a battery 502 . Thus providing electricity to the light, which may be needed during dawn and dusk hunting periods. The battery 502 may be replaceable or it may be rechargeable using a solar panel 500 , which may be connected to the top of the upper portion 400 and recharge the battery 502 stored within the upper portion 400 . The solar panel 500 and the rechargeable battery 502 allow the distance markers 108 to be positioned in the field without having to disturb them during the hunting season in order to change the batteries.
[0029] An additional feature is an attachment point 506 to attach a scent dispenser 508 to the distance marker 108 . This scent dispenser 508 may draw the target closer to a specific distance marker 108 as desired by the archer thereby making a shot of the archer more accurate by reducing the estimation needed due to having an almost known distance, the closer the target is to a distance marker 108 .
[0030] FIG. 6 is a diagrammatic representation of range determination 600 from the distance marker 108 using a range finder 602 to the hunting stand 202 . To determine the ranges to set the distance markers 108 by an archer in the field, he may use a range finder 602 with an associated range reflector 604 attached to a distance marker 108 . The range reflector 604 is more specifically affixed to the upper portion 400 . The archer stands at the hunting stand 202 and operates the range finder by ranging to the distance marker 108 with the reflector 604 to determine the distance. If the initial range determination is not within the desired range, the archer may move the distance marker 108 closer or farther to correspond to the actual range setting on the bow sight 104 . This task may be accomplished for each distance marker 108 that is deployed in the field. One skilled may use other methods to place the distance markers in the field including measuring to a single point from the field but not limited to this method. | A hunting method comprising a weapon with a sight having at least one colored range designator, color-coding at least one distance marker to correspond to at least one colored range designator, placing at least one color-coded marker at a range in a hunting field, the color of each marker corresponding to a range designator, identifying a range to a target in the hunting field by visual comparison to at least one marker, aiming using at least one color-coded designator corresponding to at least one color-coded marker, whereby a hunter can quickly determine the estimated distance to a target while maintaining both hands on the weapon during the ranging and shooting. | 5 |
BACKGROUND OF THE INVENTION
The present invention relates to an elastic strip with internal electric contacts for the detection of vehicle transit, comprising a structural shape made of rubber or the like with cavities for metal contact elements, which operate through the structural shape deformation when a load is applied thereto.
SUMMARY OF THE INVENTION
According to the invention, in order to increase the resistance to wear, the top surface of the structural shape is provided with a protective longitudinal armor-like surface part made of metal or other suitable material, which comes in contact with the wheels of the transit vehicles.
In one embodiment the protective surface part is a metal plate. The plate may be limited in width to ensure the structural shape deformation, especially in the fillet or joining zones sideways defining the cavity. The plate and the plate-like contact elements may be made integral with the strip upon the molding operation of the rubber structural shape of the same strip.
Preferably, the structural shape cross section comprises a portion with the approximate configuration of an isosceles trapezoid. Atop the trapezoid-like section there is provided an upper portion with a semi-circular shape with the base thereof adjacent a side of the trapezoidal portion. A cavity is located generally below the trapezoid where a pair of contact plates are mounted. The upper contact plate corresponds to the lower side of the trapezoid, parallel to the base of the circular portion. On the sides of the cavity a pair of channels is provided in order to improve the flexing properties of the device.
BRIEF DESCRIPTION OF THE DRAWINGS
The drawing shows one embodiment of the invention elastic strip and in particular:
FIG. 1 shows a sectional schematic view of the strip for the detection of transit vehicles according to the invention; and
FIG. 2 shows a view similar to the one in FIG. 1, but schematically illustrating the arrangement of the strip cross section as it is deformed by the load due to the transit vehicle wheels.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In the accompanying drawing, there is shown a strip with inside electrical contacts for the detection of transit vehicles, generally indicated by 1. The strip is formed is of a segment of suitable length (generally equal to about the roadway width) of a structural shape 3 made of rubber or other elastomer having suitable characteristics, the cross-section of which is shown in FIG. 1. The cross-section comprises a lower portion 5 approximately with the shape of an isosceles trapezoid with the vertices being radiused--delimited in the drawing, by way of illustration only, in the upper part, by a partition chain line. Portion 5 is surmounted by a portion 7 whose shape is approximately that of a semi circle. Suitable strips 8 join the outlines of portions 5 and 7. To the arc-shaped part of portion 7 protective surface plate 11 is applied, and positioned so as to come in contact with the wheels of the transit vehicles. The plate 11 is mostly metallic and follows the approximate arc shape of part 9 and, owing to the above described cross section of the structural-shape 3 (i.e. the portion 7 has a base which matches a side of the portion 5) ensures the structural shape deformations pattern in the presence of a load, especially in the fillet or joining zones 5R. The fillet zones 5R are located sideways in the cross-section and define an inner cavity 13, in which the horizontal plate-like contact elements 17 and 17 are located plate 11 may be made of metal or other suitable material such as nylon, reinforced plastic material, or others still with the purpose to avoid the direct contact between the wheels of the transit vehicles and the rubber of the structural-shape. In some cases this object can be obtained, rather than by a curved plate as in the drawing, by means of a narrow slat embedded in the cross-section portion 7, having preferably an arc-shaped upper configuration. As can be seen in FIG. 2--in which by a dashed line the deformed arrangement of the structural shape cross section 3 due to the load of a transit wheel is indicated--such deformations, owing also to the configuration of the side portions 13L of the cavity 13, give rise to stresses of almost exclusively compression type in the material of the structural shape. On the other hand shear and tensile stresses are of modest or even negligeable magnitude. This is very important for extended strip life. Inside the structural shape 3 the cavity 13 extends longitudinally, the cross section of which has a central portion 13C with the upper and lower edges being substantially parallel. Side portions 13L of cavity 13 have a curvilinear routine and, with respect to a horizontal center line, are asymmetric. The outline of each portion 13L defines, at the inside of structural shape 3, an upper channel 19 and a lower channel 21, opposite to each other. The cross section of channel 19 is substantially wider and also slightly deeper than that of channel 21. The structural shape 3 is obtained by compression molding and, simultaneously to the molding operation, it is provided with the metallic plate 11 as well as the plate-like contact elements 15 and 17, which accordingly are anchored at the rubber. In some cases the anchorage of the plate-like elements 15 and 17 at the rubber is carried out by means of adhesive. As a rule, the metallic plate 11 is made of stainless steel, whereas the elements 15 and 17 are made of carbon steel or other suitable material with, if so desired surface treatment. Because of the repeated stresses to which the plate 11 is subjected to in use, it became even more anchored to the material of lower portion 7 by flaps 11R bent almost at right angle, that is, radially with respect to portion 7. Since the contacts inside each strip must be waterproof, the ends of cavity 13 are sealed at one extremity by a rubber closing element fixed by means of vulcanization, while at the other extremity there is applied an analogous rubber closing terminal, also fixed by means of vulcanization. The closing terminal has a bipolar small cable whose leads are each connected to one of the two plates 15 and 17. The cable connects the strip to an electric or electronic device for detecting the passage of vehicles over the strip.
The advantages of the strip according to the invention should be apparent. The presence of the plate 11 reduces, and in fact eliminates the wear of the strip contact ridge part, which, instead, is the plate 11 eliminates also the possibility that the ridge of the strip will be perforated or cut by the passage of wheels with skid chains or riveted tires perforations or cuts cause electric insulation loss which might short circuit or otherwise render the strip ineffective. Finally, it is very important to note the deformation pattern shown in FIG. 2, where deformation due to a load is shown in dotted lines. In FIG. 2 lines T and T' indicate respectively the deformation about the zones 5R. As may be seen from the Figure, on which about half the load acting on the strip at the passage of a transit wheel is directed sideways (and about perpendicularly to lines T and T'). As it will be readily seen, lines T and T' are substantially parallel, which shows that the fillet zones 5R are mainly compression stressed, whereby the bending and shear stresses, if present in significant amounts at all, are relatively small. This condition assures a strip life markedly longer than that of the conventional strips, whose wear (with consequent flaws or tearings) was mostly due, in the zones flanking the ridge part, to bending and shear stresses. | An elastic strip with inside electrical contacts and trapezoidal geometry for the detection of the transit of vehicles includes a deformable body made of an elastomeric material with a central cavity for metal contact elements. About the central cavity are a pair of channels which operate through structural shape deformation during compression to minimize shear stress on the strip. The upper surface of the strip is provided with a protective longitudinal armor-like surface part, made of metal or other suitable material which comes in contact with the wheels of vehicles. | 6 |
TECHNICAL FIELD OF THE INVENTION
The present invention relates to novel enzymes. More specifically, the invention relates to novel fungal cellulases and methods of obtaining the DNA encoding them.
BACKGROUND
There is an increasing interest in glucanases in the food and feed industries. These enzymes find application for instance in the fruit juice industry for liquefaction of plant cell wall material (pending application EP 94202442.3). They may also serve as processing aids to reduce fouling of membranes. In the feed industry the role of β-glucanases in reducing the viscosity of various sorts of grains is well established. Many of the enzyme preparations used in the food and feed area are derived from Aspergillus species, usually Aspergillus niger. This is a safe host which produces a large variety of enzymes such as pectinases and hemicellulases with characteristics which make them suitable for applications at moderate temperatures and at neutral to acidic pH. In contrast to pectinases and hemicellulases, cellulases are usually derived from Trichoderma. Trichoderma species such as reesei, viride or longibrachiatum are good producers of cellulolytic enzymes. However, Trichoderma enzymes cannot be used everywhere due to regulatory constraints. Thus, it would be of considerable economic value to have a good source of Aspergillus enzymes. However, up till now, it has not been possible to clone the genes encoding glucanases from A. niger using the traditional method involving enzyme purification, partial amino acid sequencing and isolation of the gene or cDNA for the enzyme of interest by the derived DNA sequence.
SUMMARY
The present invention provides polypeptides with cellulase activity, corresponding DNA sequences, vectors, transformed hosts and a method for the production of these polypeptides which are obtainable from Aspergillus niger var. niger or Aspergillus niger var. tubigensis.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows viscosity reduction due to CMCase activity of Aspergillus niger cellulases.
FIG. 2 shows viscosity reduction due to β-glucanase activity of Aspergillus niger cellulases.
DETAILED DESCRIPTION
The present invention relates to novel fungal cellulases and to methods of identifying the DNA which encodes these fungal cellulases.
In the method according to the invention, fungal cellulases are cloned by expression cloning using a cDNA library in the form of prokaryotic host cells which have been transformed with DNA which is obtainable from fungi. Screening of the host cells is performed after the cDNA has been inserted into a plasmid. The prokaryotic host cells are preferably bacterial cells, more preferably E. coli.
In the present context, the term ‘cellulase’ refers to an enzyme which degrades carboxymethyl cellulose (CMC) and/or β-1,3-glucan and/or β-1,4 glycan and/or xyloglucan.
In contrast to existing methods, the method according to the invention is quick, straightforward and efficient. Surprisingly high numbers of cellulase-positive clones are found by screening 10 2 -10 4 clones, rather than 10 5 -10 6 which is the case for existing methods (Dalbøge & Heldt-Hansen (1994) Mol. Gen. Genet. 243: 253-260).
Another surprising advantage of the method is that in contrast to most existing colony screening methods, there is no need to subsequently lyse bacterial colonies to release their contents, including possible gene products of interest.
Expression cloning according to the invention may be carried out in prokaryotic cells, there is no need to transfer genetic material into an eukaryotic organism anywhere during the cloning procedure.
The cDNA library is prepared from the mRNA of a fungus of interest. Examples of fungi of particular interest are those of the genus Aspergillus, more specifically Aspergillus niger var. niger or A. niger var. tubigensis.
The mRNA which is used to prepare cDNA may be constitutively present or its expression may be induced. The method according to the invention is so effective that a large percentage of colonies will produce the cellulase of interest.
The library is constructed in a vector. This vector may be any vehicle suitable for the transfer and/or expression of genetic material, including plasmid and phage vectors.
In a preferred embodiment, the library is constructed in a phage vector, preferably a ZAP™ vector or a derivative thereof, more preferably λ Uni-ZAP™ XR. The primary library which is obtained in this way is amplified using a suitable host cell, preferably E. coli, more preferably E. coli XL1 Blue MRF′.
The phages are then converted into phagemids, preferably by superinfection with a filamentous helper phage and an E. coli host strain, such as E. coli SOLR. In this way a double stranded phagemid is created. Herein, the term ‘phagemid’ refers to a phage genome which has been converted into a plasmid. Since all plaques are converted into phagemids prior to screening, clones showing cellulase activity with low mRNA level are not mistakenly rejected as negative for activity. Hence, it will be clear to the skilled addressee that screening in the plaque stage is superfluous.
In the identification method according to the invention, DNA encoding cellulases is cloned by screening for expression of the cellulase, i.e. cellulase activity, rather than by going through the tedious tasks of purifying the protein, amino acid sequencing and molecular cloning of the gene. One technique of expression cloning is a plate assay, wherein a cDNA library is plated on to a medium of a composition which enables screening for cellulase-positive colonies. Screening for cellulases does not require pure protein, only the availability of a suitable assay for the detection of cellulase activity. This may be a standard assay; for example, cellulase activity may be detected using an overlay containing carboxymethyl celullose, followed by visualisation by staining with Congo Red. However, any other kind of assay which allows the identification of DNA by expression of the protein it encodes may be used in the method according to the invention.
Alternatively, a purpose-made assay may be developed for the detection of protein activity, for example where a suitable standard assay is not available.
In addition to cellulases, other enzymes may be detected, such as amylases, arabinoxylan degrading enzymes, catalases, galactanases, lipases, oxidases, pectinases, phosphatases, proteases and xylanases. Activity of these enzymes may be detected using methods known in the art.
The present invention also provides isolated nucleic acid fragments comprising a sequence encoding a polypeptide of the invention, i.e., a cellulase obtainable from Aspergillus niger var. niger or A. niger var. tubigensis.
The nucleic acid fragments of the invention may comprise DNA or RNA, preferably DNA. Two preferred DNA fragments of the invention are those whose nucleic acid sequences are given in SEQ ID. No. 1 and 3. The nucleic acid fragments of the invention are not, however, limited to these preferred fragments. Rather, the invention also encompasses variants of SEQ ID No. 1 and 3 obtainable from Aspergillus niger var. niger or Aspergillus niger var. tubigensis encoding polypeptides having cellulase activity. For example, therefore, the invention provides degenerate variants of SEQ ID. No. 1 or 3 that encode the polypeptides of SEQ ID No. 2 or 4. Similarly, such variant nucleic acid fragments may code for variants of the polypeptides of SEQ ID. No. 2 or 4, which variant polypeptides differ from SEQ ID NO. 2 or 4 by the deletion, insertion or substitution of one or more amino acids, as long as the deletion, insertion or substitution does not abolish the cellulase activity of the polypeptide. Thus, the variant polypeptides of the invention retain some or all of the activity, typically substantially the activity, of the polypeptide of SEQ ID NO. 2 or 4.
Also, the invention provides variant isolated nucleic acid, preferably DNA, fragments having a high degree of sequence identity with the nucleic acid sequences of SEQ ID. No. 1 or 3. Thus they are typically substantially homologous to SEQ ID. NO. 1 or 3. Typically, such variant fragments have at least 90% sequence identity with SEQ ID No. 1 or 3. Similarly, such variant fragments may differ from SEQ ID No. 1 or 3 by the deletion, substitution or insertion of one or more amino acids, as long as the deletion, substitution or insertion does not abolish the cellulase activity of the encoded polypeptide. Thus, the encoded polypeptide retains some or all of the cellulase activity of the polypeptide of SEQ ID No. 2 or 4.
Variant nucleic acid fragments of the invention may be obtained from any organism, although they are preferably obtained from fungi or yeasts, more preferably fungi of the genus Aspergillus, most preferably A. niger or A. tubigensis.
The invention also provides recombinant nucleic acids, preferably DNA, comprising the nucleic acid fragments of the invention. Typically, these are in the form of recombinant nucleic acid vectors.
A vector of the invention may be of any type known in the art, and may comprise DNA or RNA, as appropriate. For example, the construct may be in linear or circular form. Plasmids are one preferred type of vector. Vectors of the invention may be cloning vectors; these are useful in multiplying the nucleic acid fragments of the invention, and in the isolation and identification of nucleic acids of the invention. Vectors of the invention may also be expression vectors; these are useful for identifying nucleic acids of the invention by expression cloning, and for producing polypeptides of the invention. The same vector can act, when appropriate, as a cloning vector and an expression vector for expression cloning, as described herein for λ phage vectors.
Those of skill in the art will be able to prepare suitable vectors of the invention starting with widely available vectors which will be modified by genetic engineering techniques known in the art, such as those described by Sambrook et al (Molecular cloning: a Laboratory Manual; 1989).
A vector according to the invention typically comprises one or more origins of replication so that it can be replicated in a host cell, such as a bacterial, yeast or fungal cell (this enables constructs to be replicated and manipulated, for example in E. coli, by standard techniques of molecular biology). A vector, especially an expression vector, also typically comprises at least the following elements, usually in a 5′ to 3′ arrangement: a promoter for directing expression of the nucleic acid sequence and optionally a regulator of the promoter, a transcription start site, a translational start codon, and a nucleic acid sequence of the invention.
The vector may also contain one or more selectable marker genes, for example one or more antibiotic resistance genes. Such marker genes allow identification of transformants. Optionally, the construct may also comprise an enhancer for the promoter. The vector may also comprise a polyadenylation signal, typically 3′ to the nucleic acid encoding the functional polypeptide. The vector may also comprise a transcriptional terminator 3′ to the sequence encoding the polypeptide of interest.
The vector may also comprise one or more introns or other non-coding sequences, for example 3′ to the sequence encoding the polypeptide of the invention.
In a typical vector, the nucleic acid sequence of the invention is operably linked to a promoter capable of expressing the sequence. “Operably linked” refers to a juxtaposition wherein the promoter and the nucleic acid sequence encoding the polypeptide or protein are in a relationship permitting the coding sequence to be expressed under the control of the promoter. Thus, there may be elements such as 5′ non-coding sequence between the promoter and coding sequence. Such sequences can be included in the vector if they enhance or do not impair the correct control of the coding sequence by the promoter.
Any suitable promoter that is capable of directing expression of the nucleic acid encoding the polypeptide of the invention may be included in the vector. For example, the promoter may be a bacterial, eukaryotic or viral promoter. The promoter may be constitutive or inducible.
The invention also provides recombinant host cells harbouring recombinant nucleic acids of the invention, either integrated into the host cell genome or free in the cell. The host cell may be of any suitable type. For example the host cell may be a bacterial (e.g. E. coli ), yeast (e.g. K. lactis ), fungal (e.g. Aspergillus), animal (e.g. insect or mammalian) or plant cell. Bacterial host cells are, for example, useful in the expression cloning of DNA fragments of the invention. Bacterial and other cell types may be useful in producing polypeptides of the invention.
The recombinant nucleic acid of the invention may be introduced into the host cell by any means known in the art. For example, the host cell may be transformed or transfected by any suitable method, such as the methods disclosed by Sambrook et al (Molecular cloning: A Laboratory Manual; 1989). For example, recombinant nucleic acids comprising nucleic acid sequences according to the invention may be packaged into infectious viral particles, such as retroviral particles. The recombinant nucleic acids may also be introduced, for example, by electroporation, calcium phosphate precipitation, lipofection, biolistic methods or by contacting naked recombinant nucleic acids with the host cell.
The invention also provides polypeptides encoded by the nucleic acids of the invention. These polypeptides have cellulase activity, as defined herein. Two preferred polypeptides of the invention are those whose sequences are given in SEQ ID NO. 2 and 4. However, the invention is not limited to these sequences; rather, it encompasses all polypeptides encoded by the nucleic acid fragments of the invention, that have cellulase activity, as defined herein.
In particular, the invention provides variant polypeptides having sequences related to those of SEQ ID NO. 2 and 4. Typically, such variants have a high degree of sequence identity with SEQ ID NO. 2 or 4, for example at least 70% sequence identity, thus, they are typically substantially homologous to the polypeptides of SEQ ID NO. 2 or 4. Similarly, variant polypeptides of the invention may differ from SEQ ID NO. 2 or 4 by the deletion, insertion or substitution of one or more amino acids, as long as the deletion, insertion or substitution does not abolish the cellulase activity of the polypeptide. Thus, the variant polypeptides of the invention retain some or all of the activity, typically substantially the activity, of the polypeptide of SEQ ID NO. 2 or 4.
Polypeptides of the invention may be in isolated form. For example they may be substantially or completely isolated.
The invention also provides methods of producing polypeptides of the invention. These comprise culturing host cells of the invention under conditions that permit the expression of polypeptides of the invention from the recombinant nucleic acids of the invention; and, optionally, recovering the polypeptide thus produced.
The polypeptide may be recovered by any suitable means known in the art.
Utility
Cellulases according to the invention may be used, alone or in combination with other enzymes, in the food industry, e.g. for the liquefaction of plant cell material, e.g. in vegetable or fruit juice manufacturing, or as processing aids to reduce fouling of membranes.
The cellulases may also be used in the feed industry. Examples of applications are their use for the improvement of feed utilization by breaking down cell walls and or reducing the viscosity of various kind of grains.
Another application is in the textile industry for the treatment of both woven and knitted fabric, e.g. to achieve quality improvement or special effects (worn look).
Yet another application is in the detergent industry, e.g. in a detergent composition. The detergent composition may be formulated in any convenient form, such as powder, liquid, etc. The detergent composition may contain one or more other enzymes and other ingredients known in the art, such as builders, bleaching agents, perfumes etc.
The cellulases according to the invention may also be used in the pulp and paper industry for biopulping and biobleaching.
Experimental
Standard recombinant DNA technology such as bacterial growth, DNA isolation, hybridisation, restriction enzyme digestion and DNA sequencing are according to Sambrook et al. (1989): Molecular cloning, a laboratory manual, Cold Spring Harbor Laboratory Press, New York.).
EXAMPLES
Example I
Construction of Aspergillus niger cDNA Expression Library in E. coli
Example I.1
Induction and Isolation of mRNA
A. niger N400 cultures were grown for 69 and 81 h respectively, as described in EP-A-0 463 706 without yeast extract and with 2% crude wheat arabinoxylan fraction instead of oat spelt xylan, after which the mycelium was harvested by filtration and then washed with sterile saline. The mycelium was subsequently frozen in liquid nitrogen after which it was powdered using a Microdismembrator (Braun). Total RNA was isolated from mycelial powder in accordance with the guanidium thiocyanate/CsCl protocol described in Sambrook et al. (1989), except that the RNA was centrifuged twice using a C 5 Cl gradient. Poly A + mRNA was isolated from 5 mg of total RNA by oligo (dT)-cellulose chromatography (Aviv and Leder, 1972, Sambrook et al., 1989) with the following modifications: SDS is omitted from all solutions and the loading buffer was supplemented with 9% (v/v) dimethylsulfoxide.
Example I.2
Construction of the cDNA Library
cDNA was synthesized from 7 μg poly A + mRNA and ligated into bacteriophage lambda λ Uni-ZAP XR using the ZAP™-cDNA synthesis kit (Stratagene) according to the manufacturer's instructions. After ligation of the cDNA into Uni-ZAP XR vector-arms, the phage DNA was packaged using Packagene™ extracts (Promega) according to the manufacturers instructions. Ligation of 120 ng cDNA in 1.2 μg vector arms and subsequent packaging of the reaction mixture resulted in a primary library consisting of 3.5×10 4 recombinant phages. This primary library was amplified using E.coli XL1-Blue MRF′, titrated and stored at 4° C.
Example I.3
Conversion of Phages Into Phagemids
Phages were propagated by plating them in NZYCM topagarose containing 0.7% agarose on 85 mm diameter NZYCM (1.5% agar) plates as described by Maniatis et al. (Maniatis et al. (1982): Molecular cloning, a laboratory manual, Cold Spring Harbor Laboratory, Cold Spring Harbor, N.Y. pp64) using E. coli BB4 as plating bacteria. After overnight incubation at 37° C. confluent plates were obtained from which the phages were eluted by adding 5 ml SM buffer and storing the plate for 2 hrs at 4° C. with intermittent shaking. After collection of the supernatant, the bacteria were removed from the solution by centrifugation at 4.000×g at 4° C. for 10 min. To the supernatant, 0.3% chloroform was added and the number of plaque forming units (pfu) was determined. The phage stock contained approximately 10 10 pfu/ml.
The recombinant Uni-ZAP XR clones containing A. niger cDNA were converted to Bluescript phagemids using superinfection with the filamentous helper phage EXASSIST™ and E. coli SOLR strain which are included in the cDNA synthesis kit from Stratagene, according to the manufacturer's instructions. For long term storage a glycerol stock containing about 100 colonies per μl of suspension was stored at −80° C.
Example II
Screening of a Plasmid cDNA Library for Cellulase-Producing Colonies
The screening procedure was modified from Wood et al. (Methods in Enzymology 160, 59-74). Plates contained 20 ml 2×TY, 0.2% CMC (Sigma C-4888), 1.50% agar and 100 μg ampicillin per ml. Cells were plated in an overlay of 5 ml containing about 200 colonies per plate. The overlay was kept at 50° C. and contains 2×TY, 0.2% CMC, 0.75% agar and 100 μg ampicillin per ml. Plates were covered with 5 ml 0.5% agarose, 0.2% CMC and 100 μg ampicillin per ml kept at 50° C. after drying, the plates were incubated for 48 hrs at 37° C. Next, 5 ml 0.1% Congo Red (Aldrich no C8, 445.3) was poured on the plates. After staining for 1-2 hrs plates were destained with 5 ml 5M NaCl for 0.5-1 hrs.
About 12.000 colonies from A. niger cDNA library (Example I) were plated. Screening on CMC resulted in 89 colonies giving a halo after staining with Congo Red. Colonies were subdivided in 3 classes with a large, intermediate and a small halo. From each class 3 colonies were grown up, plasmids isolated and cDNAs sequenced. All contained a full length cDNA copy. The plasmids fell into two separate classes. From each class a colony was deposited at the CBS, Baarn, the Netherlands. A colony giving a small halo was deposited on Aug. 3, 1995 and designated CBS 589.95 (cDNA 12). A colony giving a large halo was deposited on Sep. 21, 1995 and designated CBS 662.95 (cDNA 64). The DNA sequences of the inserts are presented in SEQ ID No. 1 and 3, together with the amino acid sequences encoded by them.
The above shows that DNA fragments encoding fungal cellulases can be identified by expression cloning in prokaryotic host cells using a plasmid vector. The following examples illustrate how cDNAs thus identified can be used to construct strains overproducing cellulases.
Example III
Overexpression of Fungal Cellulases in Aspergillus
Overexpression of cellulases may be obtained in any suitable manner, e.g., in a similar way as has been described for phytase in EP-A-0 420 358 or xylanase in EP-A-0 463 706. The following elements from these applications are relevant for overexpression.
The A. niger amyloglucosidase (AG) promoter which ensures high level expression of cellulase cDNAs.
A terminator for transcription can be taken from the xylanase or phytase genes. A sequence about 400-500 bp is sufficient for termination.
The A. nidulans AmdS marker from pGW 325 (Wernars K 1986, Thesis, Agricultural University of Wageningen, the Netherlands).
A. niger strain CBS 513.88 is a suitable receptor strain. The connection between the AG promoter and the cellulase cDNAs can be made using a fusion PCR (polymerase chain reaction) as described. Typically, fusion oligonucleotides are about 36 bases long and overlap both sequences at the start codon for transcription. The fusion PCR gives rise to a DNA fragment which can be cleaved using restriction enzymes and subsequently ligated in an E. coli vector. Similarly, a fusion experiment can be performed fusing the stop codon for translation of the cellulase cDNAs to the terminators of xylanase or phytase. Sequences for these terminators have been published in EP-A-0 420 358 and EP-A-0 463 706.
The fragments from the fusion PCR experiments are sequenced to check for possible errors and subsequently the DNA fragments are ligated in a plasmid containing cellulase cDNA under control of the AG promoter and a suitable terminator. The AmdS marker can be added to this construct at any stage. All construction work is performed in E. coli.
The DNA fragment is transformed to A. niger CBS 413.88 as described in Tilburn et al. (1983) Gene 26:205-221 and Kelly & Hynes (1985) EMBO J 4:475-479, modified as described in EP-A-0 463 706.
Example IV
Overexpression of Fungal Cellulases in K. lactis
Example IV.1
Construction of Expression Vectors
Starting vector pGBHSA20 was deposited at the CBS, Baarn, the Netherlands, on Oct. 3, 1996, and designated CBS 997.96. This vector contains the promoter and terminator sequence of the lactase gene (lac4) of K. lactis and a G418 selection marker. The present cDNA insert encoding HSA (human serum albumin) was replaced by cellulase encoding cDNA12 and cDNA64 from A. niger. For cloning the A. niger cDNA12, a 3′ Xhol site was present. The 5′ HindIII site was created by subcloning a Kpnl/EcoR1 fragment containing the full length cDNA12, in the corresponding sites of vector pMTL22P. Digestion with HindIII, adjacent to the EcoRI site of the cDNA, and a subsequent partial digestion with Xhol (cDNA12 contains an internal Xhol site) released HindIII/Xhol fragment which was cloned in the unique HindIII/Xhol sites of pGBHSA20. The resulting construct, in which the HSA encoding cDNA was replaced by cDNA12, was named pCVlac12. The same cloning strategy was followed for cDNA64, resulting in expression vector pCVlac64.
Example IV.2
Transformation of K. lactis
Prior to transformation vectors pCVlac12 and pCVlac64 were linearized with Hpal having a unique site in the lactase promoter which is required for homologous integration. K. lactis strain CBS 2359 was transformed with 15 μg vector DNA using the LiCl method as described by Ito et al. (1983) J. Bact. 153: 163-168. Transformants were selected on YePD plates (10 g/l yeast extract, 20 g/l Bacto-peptone, 20 g/l glucose, 20 g/l Bacto-agar) containing 50 μg/ml G418.
Example IV.3
Screening for Cellulase Producing K. lactis Transformants
K. lactis transformants were screened for expression of the cellulases 12 and 64 in an enzyme assay using Cellazyme C tablets containing AZCL-hemicellulose colour complex (Megazyme, Australia). Cellulases release a blue AZCL compound which can be quantified by measuring the absorbance at 590 nm. To determine the cellulase activity in culture filtrate, transformants were grown in YePD at 30° C., 200 rpm, overnight. Next day culture fluid was harvested by pelleting the cells by centrifugation. Cellulase activity in the supernatant was variable for independent transformants and cDNA64 containing transformants showed very low levels of enzyme activity compared to the cDNA12 transformants. Expression of the cellulase cDNAs was enhanced when transformants were grown on lactose instead of glucose.
Example IV.4
Mass Production of Cellulase
K. lactis transformants containing the pCVlac12 or pCVlac64 construct and with highest cellulase activity as determined in the above mentioned assays, were grown in 1 liter of YeP with 2% lactose, at 30° C., 200 rpm during two days. Subsequently cells were pelleted by centrifugation and the supernatant was harvested for further characterization of enzyme activities, as described before.
Example V
Characterisation of Cloned Cellulases from Aspergillus
Example V.1
Determination of Enzyme Activity
The activity of the products from pCVlac12 (L12) and pCVlac64 (L64) towards CMC, xyloglucan and β-glucan was determined by treating 250 μg of the substrate in 200 μL of a 50 mM NaOAc buffer pH 5 containing 0.01% (w/v) NaN 3 for 1 h at 40° C. The release of reducing end groups was measured according to the method of Nelson-Somogyi et al. (1952) J. Biol. Chem. 195, 19-23.
CMC
Xyloglucan
β-glucan
L12
600
29
1923
L64
458
57
729
Example V.2
Determination of pH Optimum
The pH optimum of L12 and L64 was determined using viscosity reduction.
Sample Preparation
Culture filtrate from K. lactis CBS 2359 containing (pCVlac12)T10 and K.lactis CBS 2359 containing (pVClac64)T41. Samples were concentrated by ultrafiltration prior to use.
Substrates Used
Carboxymethylcellulose ([CMC] Sigma), β-glucan from barley ([βGluc] Megazyme).
Viscosimetric Method Using a “Viscorobot”
Solutions (0.4% CMC and 0.75% β-gluc) of the substrate were made in buffers of different pH. The solutions (20 ml and up to 7 at the same time) were placed in a temperature controlled Gilson sample changer Model 222 specially programmed for this task. The substrate solutions were mixed with the sample (L12 or L64). Buffer was used as blank. At regular time intervals samples were withdrawn from the mixture at constant speed, using a Gilson Dilutor 401 controlled by the sample changer. On withdrawal the sample was forced through a piece of cappilair tubing, thus creating an underpressure in the system, which was free of any air. Pressure difference were proportional to viscosity of the sample. Pressure differences were registered by a pressure transducer. Signals are send to an integrator which collects the data. Data is send to a computer linked to the integrator. Viscosity reduction was plotted against time using a home made computerprogram. Relative viscosity after a fixed time interval was plotted against the pH of the solutions used.
FIGS. 1 and 2 show the results obtained with CMC and β-glucan. As can be seen from the figures, the CMCase pH optimum of both L12 and L64 is about pH 3.5. As can be seen from the FIG. 2, β-glucanase of both L12 and L64 is about pH 5.5
Example VI
Small Scale Cloudy Apple Juice Production
After removing the peel and core, apples were homogenized in a Braun kitchen machine (MX32, Frankfurt, Germany; 5 mm blade). One g of apple was incubated (40° C.; 150 rpm) with 3 mL of a 200 mM NaOAc buffer (pH 4) containing 0.01% (w/v) NaN 3 , 1% (w/v) ascorbic acid, 50 mU pectin lyase and an amount of cellulase L12 preparation which was equivalent to 29 mU CMCase activity. After 24 h, a cloudy juice was obtained. This cloud remained stable for several months.
4
1017 base pairs
nucleic acid
double
linear
cDNA
NO
NO
Aspergillus niger
N400
CBS120.49
Coding Sequence
57...773
product=“Cellulase”
1
GAATTCGGCA CGAGCGAATT TCCCTTGATT GCCGCTCCTC CGCTCTAACG CCCAAC ATG 59
Met
1
AAG CTC CCC GTG TCA CTT GCT ATG CTT GCG GCC ACC GCC ATG GGC CAG 107
Lys Leu Pro Val Ser Leu Ala Met Leu Ala Ala Thr Ala Met Gly Gln
5 10 15
ACG ATG TGC TCT CAA TAT GAC AGT GCC TCG AGC CCC CCG TAT TCA GTG 155
Thr Met Cys Ser Gln Tyr Asp Ser Ala Ser Ser Pro Pro Tyr Ser Val
20 25 30
AAC CAG AAC CTC TGG GGC GAG TAC CAA GGC ACC GGC AGC CAG TGT GTA 203
Asn Gln Asn Leu Trp Gly Glu Tyr Gln Gly Thr Gly Ser Gln Cys Val
35 40 45
TAT GTC GAC AAA CTC TCC AGC AGT GGT GCA TCC TGG CAC ACC GAA TGG 251
Tyr Val Asp Lys Leu Ser Ser Ser Gly Ala Ser Trp His Thr Glu Trp
50 55 60 65
ACC TGG AGC GGT GGT GAG GGA ACA GTG AAA AGC TAC TCT AAC TCT GGC 299
Thr Trp Ser Gly Gly Glu Gly Thr Val Lys Ser Tyr Ser Asn Ser Gly
70 75 80
GTT ACA TTT AAC AAG AAG CTC GTG AGT GAT GTA TCA AGC ATC CCC ACC 347
Val Thr Phe Asn Lys Lys Leu Val Ser Asp Val Ser Ser Ile Pro Thr
85 90 95
TCG GTG GAA TGG AAG CAG GAC AAC ACC AAC GTC AAC GCC GAT GTC GCG 395
Ser Val Glu Trp Lys Gln Asp Asn Thr Asn Val Asn Ala Asp Val Ala
100 105 110
TAT GAT CTT TTC ACC GCG GCG AAT GTG GAC CAT GCC ACT TCT AGC GGC 443
Tyr Asp Leu Phe Thr Ala Ala Asn Val Asp His Ala Thr Ser Ser Gly
115 120 125
GAC TAT GAA CTG ATG ATT TGG CTT GCC CGC TAC GGC AAC ATC CAG CCC 491
Asp Tyr Glu Leu Met Ile Trp Leu Ala Arg Tyr Gly Asn Ile Gln Pro
130 135 140 145
ATT GGC AAG CAA ATT GCC ACG GCC ACA GTG GGA GGC AAG TCC TGG GAG 539
Ile Gly Lys Gln Ile Ala Thr Ala Thr Val Gly Gly Lys Ser Trp Glu
150 155 160
GTG TGG TAT GGC AGC ACC ACC CAG GCC GGT GCG GAG CAG AGG ACA TAC 587
Val Trp Tyr Gly Ser Thr Thr Gln Ala Gly Ala Glu Gln Arg Thr Tyr
165 170 175
AGC TTC GTG TCA GAA AGC CCT ATC AAC TCA TAC AGT GGG GAC ATC AAT 635
Ser Phe Val Ser Glu Ser Pro Ile Asn Ser Tyr Ser Gly Asp Ile Asn
180 185 190
GCA TTT TTC AGC TAT CTC ACT CAG AAC CAA GGC TTT CCC GCC AGC TCT 683
Ala Phe Phe Ser Tyr Leu Thr Gln Asn Gln Gly Phe Pro Ala Ser Ser
195 200 205
CAG TAC TTG ATC AAT CTG CAG TTT GGA ACT GAG GCG TTC ACC GGG GGC 731
Gln Tyr Leu Ile Asn Leu Gln Phe Gly Thr Glu Ala Phe Thr Gly Gly
210 215 220 225
CCG GCA ACC TTC ACG GTT GAC AAC TGG ACC GCC AGT GTC AAC TAGGGTTCT 782
Pro Ala Thr Phe Thr Val Asp Asn Trp Thr Ala Ser Val Asn
230 235
AGAAGTAGCC TTTGAGGCAG AATCTGGGTA AATTGACTCC AGCTCGGGAG AATGATAGCT 842
TGTTTCTTCG TTCTGGAACG TTGGGCGTGT GAGAGCTAAA AAGTCGTACC CACTCTGATT 902
GGAAAGACTT ATTCAACATT GGTCCTTCCC TTCTGTTGGG CAAGGCATAG TTAGTGATTA 962
GACAAGTCAA GGTCATGGTG GATCCCTTGT AAAAAAAAAA AAAAAAAAAC TCGAG 1017
239 amino acids
amino acid
single
linear
protein
internal
unknown
2
Met Lys Leu Pro Val Ser Leu Ala Met Leu Ala Ala Thr Ala Met Gly
1 5 10 15
Gln Thr Met Cys Ser Gln Tyr Asp Ser Ala Ser Ser Pro Pro Tyr Ser
20 25 30
Val Asn Gln Asn Leu Trp Gly Glu Tyr Gln Gly Thr Gly Ser Gln Cys
35 40 45
Val Tyr Val Asp Lys Leu Ser Ser Ser Gly Ala Ser Trp His Thr Glu
50 55 60
Trp Thr Trp Ser Gly Gly Glu Gly Thr Val Lys Ser Tyr Ser Asn Ser
65 70 75 80
Gly Val Thr Phe Asn Lys Lys Leu Val Ser Asp Val Ser Ser Ile Pro
85 90 95
Thr Ser Val Glu Trp Lys Gln Asp Asn Thr Asn Val Asn Ala Asp Val
100 105 110
Ala Tyr Asp Leu Phe Thr Ala Ala Asn Val Asp His Ala Thr Ser Ser
115 120 125
Gly Asp Tyr Glu Leu Met Ile Trp Leu Ala Arg Tyr Gly Asn Ile Gln
130 135 140
Pro Ile Gly Lys Gln Ile Ala Thr Ala Thr Val Gly Gly Lys Ser Trp
145 150 155 160
Glu Val Trp Tyr Gly Ser Thr Thr Gln Ala Gly Ala Glu Gln Arg Thr
165 170 175
Tyr Ser Phe Val Ser Glu Ser Pro Ile Asn Ser Tyr Ser Gly Asp Ile
180 185 190
Asn Ala Phe Phe Ser Tyr Leu Thr Gln Asn Gln Gly Phe Pro Ala Ser
195 200 205
Ser Gln Tyr Leu Ile Asn Leu Gln Phe Gly Thr Glu Ala Phe Thr Gly
210 215 220
Gly Pro Ala Thr Phe Thr Val Asp Asn Trp Thr Ala Ser Val Asn
225 230 235
1198 base pairs
nucleic acid
double
linear
cDNA
NO
NO
Aspergillus niger
N400
CBS120.49
Coding Sequence
32...1024
product=“Cellulase”
3
GAATTCGGCA CGAGATCGAG CAGTCGTAGC G ATG AAG TTT CAG AGC ACT TTG 52
Met Lys Phe Gln Ser Thr Leu
1 5
CTT CTT GCC GCC GCG GCT GGT TCC GCG TTG GCT GTG CCT CAT GGC TCC 100
Leu Leu Ala Ala Ala Ala Gly Ser Ala Leu Ala Val Pro His Gly Ser
10 15 20
GGA CAT AAG AAG AGG GCG TCT GTG TTT GAA TGG TTC GGA TCG AAC GAG 148
Gly His Lys Lys Arg Ala Ser Val Phe Glu Trp Phe Gly Ser Asn Glu
25 30 35
TCT GGT GCT GAA TTT GGG ACC AAT ATC CCA GGC GTC TGG GGA ACC GAC 196
Ser Gly Ala Glu Phe Gly Thr Asn Ile Pro Gly Val Trp Gly Thr Asp
40 45 50 55
TAC ATC TTC CCC GAC CCC TCG ACC ATC TCT ACG TTG ATT GGC AAG GGA 244
Tyr Ile Phe Pro Asp Pro Ser Thr Ile Ser Thr Leu Ile Gly Lys Gly
60 65 70
ATG AAC TTC TTC CGC GTC CAG TTC ATG ATG GAG AGG TTG CTT CCT GAC 292
Met Asn Phe Phe Arg Val Gln Phe Met Met Glu Arg Leu Leu Pro Asp
75 80 85
TCG ATG ACT GGT TCA TAC GAC GAG GAG TAT CTG GCC AAC TTG ACG ACT 340
Ser Met Thr Gly Ser Tyr Asp Glu Glu Tyr Leu Ala Asn Leu Thr Thr
90 95 100
GTG GTG AAA GCG GTC ACG GAT GGA GGC GCG CAT GCG CTC ATC GAC CCT 388
Val Val Lys Ala Val Thr Asp Gly Gly Ala His Ala Leu Ile Asp Pro
105 110 115
CAT AAC TAT GGC AGA TAC AAC GGG GAG ATC ATC TCC AGT ACA TCG GAT 436
His Asn Tyr Gly Arg Tyr Asn Gly Glu Ile Ile Ser Ser Thr Ser Asp
120 125 130 135
TTC CAG ACT TTC TGG CAG AAT CTG GCG GGC CAG TAC AAA GAT AAC GAC 484
Phe Gln Thr Phe Trp Gln Asn Leu Ala Gly Gln Tyr Lys Asp Asn Asp
140 145 150
TTG GTC ATG TTT GAT ACC AAC AAC GAA TAC TAC GAC ATG GAC CAG GAT 532
Leu Val Met Phe Asp Thr Asn Asn Glu Tyr Tyr Asp Met Asp Gln Asp
155 160 165
CTC GTG CTG AAT CTC AAC CAA GCA GCC ATT AAC GGC ATC CGC GCT GCA 580
Leu Val Leu Asn Leu Asn Gln Ala Ala Ile Asn Gly Ile Arg Ala Ala
170 175 180
GGT GCA AGC CAG TAC ATT TTC GTC GAA GGC AAC TCC TGG ACC GGA GCT 628
Gly Ala Ser Gln Tyr Ile Phe Val Glu Gly Asn Ser Trp Thr Gly Ala
185 190 195
TGG ACA TGG GTC GAT GTC AAC GAT AAT ATG AAG AAT TTG ACC GAC CCA 676
Trp Thr Trp Val Asp Val Asn Asp Asn Met Lys Asn Leu Thr Asp Pro
200 205 210 215
GAA GAC AAG ATC GTC TAT GAA ATG CAC CAG TAC CTA GAC TCC GAC GGT 724
Glu Asp Lys Ile Val Tyr Glu Met His Gln Tyr Leu Asp Ser Asp Gly
220 225 230
TCC GGC ACT TCG GAG ACC TGT GTC TCC GGG ACA ATC GGA AAG GAG CGG 772
Ser Gly Thr Ser Glu Thr Cys Val Ser Gly Thr Ile Gly Lys Glu Arg
235 240 245
ATC ACT GAT GCT ACA CAG TGG CTC AAG GAC AAT AAG AAG GTC GGC TTC 820
Ile Thr Asp Ala Thr Gln Trp Leu Lys Asp Asn Lys Lys Val Gly Phe
250 255 260
ATC GGC GAA TAT GCC GGG GGG TCC AAT GAT GTG TGT CGG AGT GCC GTG 868
Ile Gly Glu Tyr Ala Gly Gly Ser Asn Asp Val Cys Arg Ser Ala Val
265 270 275
TCC GGG ATG CTA GAG TAC ATG GCG AAC AAC ACC GAC GTA TGG AAG GGT 916
Ser Gly Met Leu Glu Tyr Met Ala Asn Asn Thr Asp Val Trp Lys Gly
280 285 290 295
GCG TCG TGG TGG GCA GCC GGG CCA TGG TGG GGA GAC TAC ATT TTC AGC 964
Ala Ser Trp Trp Ala Ala Gly Pro Trp Trp Gly Asp Tyr Ile Phe Ser
300 305 310
CTG GAG CCC CCA GAT GGA ACT GCT TAC ACG GGT ATG CTG GAT ATC CTG 1012
Leu Glu Pro Pro Asp Gly Thr Ala Tyr Thr Gly Met Leu Asp Ile Leu
315 320 325
GAG ACG TAT CTC TGAGAACTGG GTGGGGTCGC AGATGCGGTG CGTCGGAGAA CTATA 1069
Glu Thr Tyr Leu
330
CGGAGTTTCT TATCAGAGTG GACGGTGGTG GTACAGAGAG GCGTACTAGA ATGAATTAGT 1129
GGCAGCGCAC TGACTGACGT CACAAGACAT TGCTTTTTTT GTGAAAAAAA AAAAAAAAAA 1189
AAACTCGAG 1198
331 amino acids
amino acid
single
linear
protein
internal
unknown
4
Met Lys Phe Gln Ser Thr Leu Leu Leu Ala Ala Ala Ala Gly Ser Ala
1 5 10 15
Leu Ala Val Pro His Gly Ser Gly His Lys Lys Arg Ala Ser Val Phe
20 25 30
Glu Trp Phe Gly Ser Asn Glu Ser Gly Ala Glu Phe Gly Thr Asn Ile
35 40 45
Pro Gly Val Trp Gly Thr Asp Tyr Ile Phe Pro Asp Pro Ser Thr Ile
50 55 60
Ser Thr Leu Ile Gly Lys Gly Met Asn Phe Phe Arg Val Gln Phe Met
65 70 75 80
Met Glu Arg Leu Leu Pro Asp Ser Met Thr Gly Ser Tyr Asp Glu Glu
85 90 95
Tyr Leu Ala Asn Leu Thr Thr Val Val Lys Ala Val Thr Asp Gly Gly
100 105 110
Ala His Ala Leu Ile Asp Pro His Asn Tyr Gly Arg Tyr Asn Gly Glu
115 120 125
Ile Ile Ser Ser Thr Ser Asp Phe Gln Thr Phe Trp Gln Asn Leu Ala
130 135 140
Gly Gln Tyr Lys Asp Asn Asp Leu Val Met Phe Asp Thr Asn Asn Glu
145 150 155 160
Tyr Tyr Asp Met Asp Gln Asp Leu Val Leu Asn Leu Asn Gln Ala Ala
165 170 175
Ile Asn Gly Ile Arg Ala Ala Gly Ala Ser Gln Tyr Ile Phe Val Glu
180 185 190
Gly Asn Ser Trp Thr Gly Ala Trp Thr Trp Val Asp Val Asn Asp Asn
195 200 205
Met Lys Asn Leu Thr Asp Pro Glu Asp Lys Ile Val Tyr Glu Met His
210 215 220
Gln Tyr Leu Asp Ser Asp Gly Ser Gly Thr Ser Glu Thr Cys Val Ser
225 230 235 240
Gly Thr Ile Gly Lys Glu Arg Ile Thr Asp Ala Thr Gln Trp Leu Lys
245 250 255
Asp Asn Lys Lys Val Gly Phe Ile Gly Glu Tyr Ala Gly Gly Ser Asn
260 265 270
Asp Val Cys Arg Ser Ala Val Ser Gly Met Leu Glu Tyr Met Ala Asn
275 280 285
Asn Thr Asp Val Trp Lys Gly Ala Ser Trp Trp Ala Ala Gly Pro Trp
290 295 300
Trp Gly Asp Tyr Ile Phe Ser Leu Glu Pro Pro Asp Gly Thr Ala Tyr
305 310 315 320
Thr Gly Met Leu Asp Ile Leu Glu Thr Tyr Leu
325 330 | The present invention relates to peptides with multiple enzymatic activitives: carboxymethyl cellusase(CMCase), endoglucanase and β-glucanase, corresponding nucleotides, vectors and transformed hosts, methods of preparation and use. The peptide is used in the food industry for the liquefaction of plant cell material, e.g., in vegetable or fruit juice manufacture, or as processing aids to reduce the fouling of membranes. | 2 |
BACKGROUND OF THE INVENTION
This invention relates to a variable-speed pulley and clutch adapted for use in snowmobiles and other small vehicles. Such pulleys are connected to the engine shaft and may operate at high speeds which subject the rotating parts to high centrifugal forces. The parts must be designed and constructed to withstand high centrifugal forces, and the pulley must be smooth and reliable in its response to operator-controlled changes in the engine shaft speed and to variations in operating conditions. The present invention relates especially to pulleys of the type in which centrifugal weights between the movable pulley flange and a reaction cone connected to the fixed pulley flange force the flange together and provide torque drive between the cone and the movable flange.
In accordance with the present invention, the fixed pulley flange is mounted on a pulley hub which has a cylindrical primary bearing surface at the opposite side of the pulley groove from the flange and has a hub extension of reduced diameter extending therebeyond and providing an elongated outboard bearing surface. The movable pulley flange is carried by a sleeve hub slidably and rotatably mounted on the pulley hub and its extension by means of an inboard bearing surface engaged with the primary bearing and an outboard bearing spaced therefrom and engaged with the bearing surface of the hub extension. The two hubs are counterbored at the inner diameter of the sleeve hub to define a spring chamber about the hub extension which contains a spring that acts on the hubs to urge the flanges apart. To prevent metal-to-metal contact between the two pulley flanges and consequent wear from relative rotation of such flanges, the two hubs are formed with axially-facing thrust faces, radially inward of the primary bearing sleeve and radially outward of the spring, which come together to limit closing movement of the pulley flanges.
The movable pulley flange is urged toward the fixed flange by a selected number of symmetrically disposed plate-like centrifugal weights mounted between the movable flange and a reaction cone fixed to the outer end of the hub extension. The weights are desirably molded plastic disks disposed in radial channels on the face of either the reaction cone or preferably the movable pulley flange, and frictionally engage a surface of revolution on the other of such cone and flange. The limit of opening movement of the flanges is determined by the engagement of the retracted centrifugal weights with the cone and flange, and in consequence the opening-limit position is fixed by the position of the reaction cone which is fixed on the hub extension. The spring applies a preload to the centrifugal weights so as to produce an initial frictional drive between the driven reaction cone and the rotatably mounted movable flange. The movable flange thus has a limited throw, between the closing-limit position determined by engagement of the thrust faces on the hubs and the opening-limit position determined by the position of the reaction cone.
Selective insertion of one or more spacers between the hub thrust faces will shift the closing limit position and thereby open the spacing between the flanges to suit wider belts. Corresponding selective insertion of spacers between the hub extension and the pulley hub, or otherwise in the connection between the reaction cone and the fixed pulley flange, will correspondingly shift the position of the opening limit of the movable flange, by moving the position of the reaction cone. Suitable selection of spacers will maintain the same or secure a different throw of the movable flange in response to action of the centrifugal weights.
Desirably, the hub extension is connected to the main hub by a threaded joint at which axially-facing faces on the two parts come together and which permits the insertion of the spacers between such faces so as to axially adjust the extension (and the reaction cone it carries) relative to the main hub and its fixed pulley flange. This joint is desirably at the end of the spring chamber and the spacers extend under the end of the spring. This has the effect of maintaining the same effective spring length, and the same preload on the centrifugal weights.
The pulley is adaptable to various applications, as by changing the number or mass of centrifugal weights, by shifting the opening limit or the closing limit or both limits of movement of the movable flange, by varying the shape of the reaction cone, etc. In one illustrated modification, the reaction cone is formed with an annular groove which restrains the centrifugal weights until a desired engine speed is attained.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings illustrate the invention, and show a preferred embodiment. In such drawings:
FIG. 1 is an axial section of a variable-speed pulley and clutch embodying the invention, shown in open position and mounted on a power shaft;
FIG. 2 is an axial section of a driven pulley of a type commonly used with centrifugal driving pulleys, shown in operative relation with the pulley of FIG. 1;
FIG. 3 is an end elevation of the movable pulley flange of FIG. 1, shown with three disk weights symmetrically disposed in its nine weight-receiving channels;
FIG. 4 is an isometric view of a disk weight of the type shown in FIGS. 1 and 3;
FIG. 5 is an axial section like FIG. 1, but with the movable pulley flange shown in closed position;
FIGS. 6 and 7 are partial axial sections showing open and closed positions of a pulley like FIG. 1 but with weights of different shape and with spacers between the hub parts;
FIG. 8 is an isometric view of the weight of FIG. 6;
FIG. 9 is a partial axial section, like FIG. 1, but showing a modified reaction cone; and
FIG. 10 is a section of a modified weight.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In the drive mechanism represented in FIGS. 1 and 2, the driven pulley 10 comprises a fixed pulley flange 12 carried by a hub 14 fixed on a driven shaft 16 and having a helical cam 18 mounted at its free end. A movable pulley flange 20 is fixed to a hub 22 slidable and rotatable on the hub 14 and formed with helical cam faces 24 for cooperation with cam follower pads 26 on the cam member 18. The pulley flanges 12 and 20 define a variable width V-groove to receive a belt 28 and are normally urged toward closed position, as shown, by a torsion spring 25 acting between the cam member 18 and the hub 22.
Centrifugal actuation of the speed-responsive pulley of FIG. 1 tends to pull the belt 28 deeper into the V-groove of the driven pulley 10 and force its flanges 12 and 20 apart, with concurrent rotation of the flange 20 relative to the fixed flange 12 so as to cause the helical cam 24 to back off and permit such separation. Increased torque reaction from the output shaft 16 actuates the cams to force the flanges 12 and 20 together, and this forces the belt 28 outward in the V-groove of the driven pulley 10 and increases the drive ratio to permit the power train to handle the increased torque. Further discussion of this torque-responsive driven mechanism is to be found in my U.S. Pat. No. 3,625,079.
The variable-speed pulley 30 shown in FIG. 1 comprises a fixed pulley flange 36 and a movable pulley flange 52 normally biased to open position (FIG. 1) by a spring 57 and moved toward closed position (FIG. 5) by the action of centrifugal weights 76 acting between the movable flange and a reaction member fixedly connected to the fixed flange.
The fixed pulley flange 36 is fixed to one end of a hollow hub 32 mounted on a power shaft 34. The hub 32 has a grooved cylindrical portion 38 immediately adjacent the pulley flange 36, and therebeyond has a cylindrical primary bearing 40 of slightly greater diameter than the grooved portion 38 and of substantial axial length. The bearing terminates at an axially-facing thrust face 64. A counterbore 42 in such hub defines one end of a spring chamber 58. In operation, the grooved portion provides clearance for belt dust which might otherwise obstruct the bearing. A hub extension 44 is threaded into a central bore 46 of the hub 32. Such hub extension 44 is of larger diameter than the bore 46 and is formed with a shoulder 48 which seats against the face 50 at the bottom of the counterbore 42 in the hub 32. The male part of the threaded joint is relatively long, to permit the insertion of spacers between the shoulder and face, as described below. The hub extension provides an elongated bearing surface at its outer circumference.
The movable pulley flange 52 is integral with a hollow sleeve hub 54, which in pulley-open position extends from the face of the pulley flange 52 axially substantially to the end of the hub extension 44. Its outer end contains an outboard bearing sleeve 56 in bearing engagement with the outer surface of the hub extension 44. Over an intermediate length, the movable hub 54 is counterbored to provide the right end of the spring chamber 58. The left end of the movable hub 54, adjacent the pulley flange 52, is formed to receive an elongated bearing sleeve 60 which slidably and rotationally engages the bearing 40 on the hub 32. Such length is sufficient to provide bearing support on the bearing 40 throughout the axial throw of the movable flange. At the inner end of the bearing sleeve 60, a hardened thrust washer 62 is mounted between the end of such sleeve 60 and the abutting shoulder 63 of the sleeve hub. The face of that thrust washer 62 is spaced from the end face 64 of the hub 32 a distance slightly less than the normal open distance between the inner peripheral portions of the two pulley flanges 36 and 52, so that when the movable pulley flange 52 moves toward the fixed pulley flange 36, the thrust faces 62 and 64 will engage before the pulley flanges 36 and 52 come together. The hub 32 is normally of steel or other wear-resistant material, and the thrust washer 62 is of a material with good wear resistance against the steel end face 64, whereas the pulley flanges 36 and 52 may be of die cast aluminum with poor wear characteristics.
As shown in FIG. 3, the rear face of the movable pulley flange 52 is formed with a plurality of angularly spaced weight-receiving channels 70, defined between pairs of parallel ribs 72 which are integral with the hub 54 and the flange wall 52 and extend from the hub 54 outward to points adjacent the rim of the movable flange 52. As shown in FIGS. 1 and 5, the ribs 72 are of sufficient axial width to contain and stabilize the centrifugal weights which they receive, both when such weights are retracted as in FIG. 1 and when they are at their outward limit of centrifugal movement as in FIG. 5. The bottoms of the weight-receiving channels 70 are desirably formed with ramp surfaces 74 at an angle to give the desired pulley flange movement in response to centrifugal movement of the weights, which may be a different angle from that of the belt-engaging face of the pulley flange 52. In the embodiment shown, the ramp angle is approximately 55° from the axis of the pulley 30.
The weight-receiving channels 70 receive plate-like centrifugal weights 76 which in the preferred embodiment of FIGS. 1-5 are in the form of circular disks. These are desirably molded of wear-resistant plastic material. By way of example, it has been found satisfactory to use disks 76 molded of a thermoplastic material obtainable from E. I. DuPont deNemours & Co., Wilmington, Del., under the trademark "Minlon". The disk weights 76 should be molded to fit with a free-sliding fit between the ribs 72, and with a diameter such that when retracted, as shown in FIG. 1, they lie engaged between the outer surface of the movable sleeve hub 54, the ramp surface 74, and the inner face of the reaction cone 80 more fully described below. In this position they determine the limit of opening movement of the movable pulley flange 52, and are under preload from the spring 57 in the spring chamber 58. With such preload they at all times exert some frictional pressure against the face of the reaction cone 80 which is driven with the fixed pulley flange 36, and this provides a frictional driving connection between that cone 80 and the movable pulley flange 52 which is otherwise free to rotate on the hub 32 of the fixed flange 36 and its hub extension 44.
The reaction cone 80 is a generally conical member having an inner face defined by a surface of revolution about the axis of the hub 32. The cone is fitted at its apex to a drive washer 82, and the two are welded together so that the cone will be rotatably driven with the drive washer 82. The drive washer 82 is mounted on the end of the hub extension 44, as by engagement with a flatted end portion thereof so that the drive washer 82 and the reaction cone 80 are rigid with the hub extension 44 and rotatably driven thereby. The outer or working portion 84 of the cone is engaged by and takes the reaction of the centrifugal weights 76 in the operation of the pulley. As shown in FIGS. 1-5, this working portion 84 has an inner face which is a section of a regular cone and has a uniform slope throughout its axial extent. In the embodiment shown, that slope is at 40° to the axis of the shaft.
The operation of the pulley shown in FIGS. 1-5 is as follows. The movable pulley flange 52 and its hub 54 are normally urged to the right by the spring 57. The limit of its opening movement is determined by engagement of the weights 76 with the surrounding surfaces, especially that of the reaction cone 80, and the end of the sleeve hub 54 clears the reaction cone 80. The pulley then lies in open position as shown in FIG. 1, with the belt 28 loosely received at the bottom of the pulley groove and free from driving relation with the pulley. The weights 76 are under a preload exerted by the spring 57, and are held in their channels 70 and stabilized by the ribs 72 defining those channels. They have frictional engagement with the conical working portion 84 of the reaction cone 80, and this is sufficient to transmit torque from the cone 80 to the weights 76 and through them to the movable flange 52 of the pulley. When the pulley 30 is driven by the drive shaft 34, the hub 32 and its extension 44, the fixed pulley flange 36, and the reaction cone 80 are all positively driven. The reaction cone 80 transmits frictional drive to the weights 76 and they in turn drive the movable pulley flange 52. As centrifugal force on the weights 76 increases, the rotational drive between those elements continues and the weights 76 are driven outward along the reaction cone 80 and the ramps 74 of the flange 52, and this drives the movable flange 52 toward the fixed flange 36. The pulley then engages the belt 28 to clutch the two together, and thereafter to force the belt outward in the pulley groove toward the position shown in FIG. 5.
Closing movement of the movable flange 52 and its hub 54 toward the fixed pulley flange 36 is limited by engagement of the thrust washer 62 against the thrust face 64, and this stops the movement of the pulley flanges toward each other at a point which leaves some clearance between their inner peripheries so that they will not be subjected to wear at that point. As seen in FIG. 5, when the pulley flanges are fully closed, the weights 76 are trapped between the outer end of the ramps 74 on the movable pulley flange 52 and the outer portion of the cone 80.
As shown in FIGS. 1-5, the pulley is adapted and arranged for use with a belt of predetermined narrow width, for example, a belt having a nominal width of 1 3/16 inches, as indicated at the top of FIG. 5. The same pulley may be adapted for use with wider belts by the insertion of certain spacers, as shown in FIGS. 6 and 7. At the threaded joint between hub extension 44 and the hub 34, a selected number of spacer washers 90 (here shown as five) are inserted between that shoulder 48 on the extension 44 and the end face 50 of the hub 32, so that the hub extension 44 then extends farther outward from the hub 32. Such washers are desirably large enough to extend under the end of the spring 57, so as to maintain the same spring length. One or more spacers 92 are also inserted within the bearing sleeve 60 and against the thrust washer 62, but in this case a single spacer 92 of selected length is desirably used instead of separate washers, since the spacer will be loose between the thrust faces 62 and 64. The spacers 90 have the effect of shifting the limit of opening movement of the movable pulley flange 52 to the right. The spacer 92 similarly shifts to the right the limit of closing movement of the flange 52. When the spacers 90 and 92 are of equal length, they maintain the throw or travel of the movable flange the same, and likewise maintain the length of the spring chamber containing the spring 57 the same, since both ends of such chamber are moved the same distance.
Instead of the disk-shaped weights 76 shown in FIGS. 1-5, plate weights of other shapes may be used, for example, as shown in FIGS. 6-8. Here, the weights 176 are plates of irregular hexagonal shape. Each plate has a flat shoulder 174 to mate with the ramp 74 of the channel in which it is mounted, has a shoulder 180 to mate with the working portion 84 of the reaction cone 80, and a bottom 182 to fit against the outer surface of the hub 54 of the movable pulley flange 52. When that flange is in open position as shown in FIG. 6, each weight 176 has its shoulders and bottom seated against their mating faces, and the weight is held under a preload by reason of the presence of the spring 57, in the same manner as the weights in FIGS. 1-4. The hexagonal weights provide somewhat greater surface area of contact between the weights and their mating surfaces than is the case with the disk-shaped weights 76.
The pulley of FIGS. 6-8 operates in substantially the same way as that of FIGS. 1-5. As centrifugal force drives the weights 176 outward, their shoulders 174 and 180 slide on the ramps 74 of the flange 52 and on working portion 84 of the cone 80, so as to force the movable pulley flange 52 toward closed position as shown in FIG. 7. Closing movement is limited by engagement of the thrust washer 62 and thrust face 60 against the spacer 92, and the pulley flanges are then held in a spacing suitable for the wider belt. The principal difference of operation is that the spacers adapt the pulley for use with a wider belt, for example, a belt of 11/2 inch width as shown at the bottom of FIG. 7 instead of the 1 3/16 inch belt shown in FIG. 5.
Instead of using a reaction cone 80 having a straight conical working portion 84 as shown in FIGS. 1-5, the shape of the working portion of the cone may be modified to produce special operating results. For example, under some operating conditions of snowmobile drives, it is desirable to maintain the driven belt 28 deep in the pulley groove so as to obtain high torque multiplication as the speed of the engine is increased to a desired point on the power curve of the engine. For this purpose, a circumferential bulge 200 is formed in the reaction cone 280 of FIG. 9, the cone being otherwise similar to the cone 80 of FIG. 1. This provides a shallow circumferential groove 202 in the inner face of the working portion 284 of the reaction cone, into which the weights 76 will enter as they begin outward movement under centrifugal force, and in which they will be restrained from further outward movement until the desired shaft speed has been built up and sufficient centrifugal force generated to carry them out of the groove. In order to preserve the desired preload, without otherwise modifying the structure shown in FIG. 1, the circumferential groove 202 is not positioned to conform to the periphery of the weights 76 in their retracted position, but is displaced slightly outward from such position so as to leave undisturbed that portion of the cone which engages the weights in their retracted position shown in FIG. 9. As shown in FIG. 9, the circumferential groove 202 is desirably of the same arcuate shape, on the same radius, as the periphery of the weights 76, but is offset outward and curved about a center 204 somewhat displaced from the center of the weights 76. This locates the groove 202 in a position to be entered by the weight as it begins to move outward along the surface of the reaction cone 280.
In operation of the pulley of FIG. 9, having a groove 202 in the face of the reaction cone, the weights 76 will be held under preload in their normal retracted position when the pulley is wide open. As the centrifugal action of the pulley moves the weights outward, they enter the groove 202, and are there temporarily restrained and trapped until the shaft speed has increased to the desired point. The increased speed increases the centrifugal force on the weights 76, and they then move outward beyond the circumferential groove 202 so as to force the pulley flanges toward each other and to move the belt 28 to its outermost position in the same manner as before.
The action of the pulley may be varied in other ways to suit different power requirements and different applications. The structure permits change in the arrangement and mass of the weights used. Thus, the nine channels 70 of the movable flange of FIG. 3 may be fitted with either three weights as shown, or with six or with nine weights in arrangements which are symmetrical about the axis and avoid unbalance. The mass of the weights may be changed by molding metal inserts in them. As shown in FIG. 10, the weight 276 consists of a central metal insert 278 of spool shape, about which an annulus 280 of plastic material is molded. The metal increases the mass. Alternatively, different molding compositions may be used which include fillers of heavier or lighter weight.
The pulley may be adapted for use with belts of different width by inserting spacers 90 and 92 of selected lengths. The throw of the movable flange 52 may be varied by inserting spacers 92 of one length and inserting no spacers or shorter spacers 90. The pulley of this invention is thus adapted to a wide variety of uses by relatively simple modifications without major changes in the basic structure. | A centrifugal clutch and variable-speed pulley has a movable pulley flange mounted for both axial and rotational movement relative to a fixed flange. The fixed flange hub has a cylindrical primary bearing at the opposite side of the pulley groove from the flange and has a hub extension of reduced diameter which provides an elongated outboard bearing surface. The movable flange is on a hub sleeve which has an elongated internal bearing liner engaging the primary bearing and has an outboard bearing riding on the hub extension surface. The hubs have counterbores defining a spring chamber about the hub extension, where a spring acts to urge the flanges apart. Thrust faces on the hubs, radially outward of the spring, come together to limit flange closing movement. Plastic disk-shaped centrifugal weights mounted in angularly spaced channels on the back of the movable flange are normally under preload against a reaction cone on the hub extension, to limit opening movement of the flanges and to provide initial frictional torque drive between the movable flange and the cone. Centrifugal force drives the weights outward along the cone to urge the flanges together. A threaded joint between the hub extension and the fixed flange hub receives spacers to shift the opening limit while maintaining the preload and initial torque drive. A spacer between the hub thrust faces shifts the closing limit position. Equal spacers maintain the same throw while varying the pulley groove width to suit different width belts. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the field of wireless communication.
2. Prior Art
Zero-IF receivers for wireless communication use AC coupling in the I and Q base band signal paths to block the unwanted DC levels due to local oscillator (LO) leakage and circuit implementation. After adjusting the receiver gain, the AC coupling is switched to DC coupling in order to improve the signal to noise ratio (S/N). In doing this, a large DC step may be observed in the I and Q signal paths due to the series capacitor retaining some signal dependent charge existing at the moment of switching. This can result in clipping of the I and Q A/D inputs and also in impairment of the S/N.
A prior art circuit for DC cancellation is shown in FIG. 1 a. V DC is the unwanted DC offset that is blocked by C 1 when the switch S 1 is in the AC position. The R 1 C 1 time constant implements a high-pass filter (AC coupling) with a 3 dB corner frequency
f HP = 1 2 π R 1 C 1 .
If the wanted signal has a frequency component V AC at a much lower frequency f 1 <<f HP , then C 1 will charge up close to the instantaneous value of that frequency component in V AC and the AC voltage across C 1 , i.e., V C 1AC , will follow that frequency component in V AC . When the switch S 1 is opened (DC position) for implementing DC coupling, the instantaneous voltage across C 1 will be V DC +V C 1AC (t=0), assuming the switching is done at time t=0. The V DC component of voltage across the capacitor C 1 is the desired blocking of the unwanted DC offsets. However the output V OUT will now have a DC kick equal to V C 1AC (t=0), which in the worst case will be nearly as large as the amplitude of V AC at f 1 .
The applicable waveforms are shown in FIGS. 1 b through 1 f FIG. 1 b shows the wanted input signal V AC , FIG. 1 c a representative DC offset level V DC , and FIG. 1 d, the input voltage V IN to the high pass filter (R 1 ,C 1 ), which is the sum of the wanted input signal V AC and the representative DC offset level V DC . Assuming the wanted signal V IN is at a frequency of f 1 <<f HP , the voltage V C1ac across the capacitor C 1 prior to switching switch S 1 ( FIG. 1 a ) to the DC position will substantially follow the wanted signal V IN , as shown in FIG. 1 e. At the moment of switching (t=0), that signal may have an amplitude anywhere within its maximum amplitude. FIG. 1 e illustrates an arbitrary value at the time of switching that is V step above the V DC level. This unwanted DC step of V step =V C 1AC (t=0) then is coupled to the next functional element in the signal path, as shown in FIG. 1 f.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 a illustrates a prior art circuit for DC cancellation in a zero-IF receiver for wireless communication.
FIG. 1 b illustrates a waveform for a wanted signal V AC .
FIG. 1 c illustrates an unwanted DC offset V DC .
FIG. 1 d illustrates the combination of signals of FIGS. 1 b and 1 c.
FIG. 1 e illustrates the switching to DC coupling at time T=0 when there is an arbitrary part of the signal voltage V IN on the coupling capacitor C 1 of FIG. 1 .
FIG. 1 f illustrates the output voltage having a zero average value before t=0, and an average value of V step after t=0.
FIG. 2 is a diagram illustrating an embodiment of the present invention.
FIG. 3 illustrates a fast settling circuit for high pass filters that may be used with the present invention.
FIGS. 4 a through 4 c illustrate a conventional low pass filter and a fast settling low pass filter circuit for low pass filters that may be used with the present invention.
FIG. 5 illustrates in a single Figure, details of a preferred embodiment of the present invention.
FIG. 6 is a block diagram of an exemplary wireless transceiver incorporating the present invention.
FIG. 7 is an exemplary logic flow diagram for an embodiment of the present invention intended for use in IEEE 802.11a/g WLAN, IEEE802.16, Cellular Phone and Korean WiBro products.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
An embodiment of the present invention DC cancellation circuit shown in FIG. 2 removes the unwanted DC kick of V step that was present in the prior art. According to this invention, the voltage across C 1 is measured, and the component of this voltage that corresponds to V step is subtracted at the output. Initially the switches S 1 and S 2 are in the AC positions, and the Sample/Hold switch is closed. The voltage across the capacitor C 1 is monitored by the summing point A 1 . As before, this voltage may be expressed as V DC +V C 1AC . However the unwanted V step is simply the value of V C 1AC at time t=0. Therefore in order to separate the V step component from the V DC component, the voltage across C 1 is low-pas filtered in low pass filter F 1 and then subtracted at summing point A 2 from the instantaneous voltage that is across C 1 to provide the voltage V C 1AC to the Sample/Hold capacitor C SH tracking that voltage. The combination of the low pass filter F 1 and the summing point A 2 acts as a high pass filter.
At t=0, the coupling changes from AC to DC. Switches S 1 and S 2 change from the AC to the DC positions and the Sample/Hold switch is opened. The Sample/Hold capacitor C SH now holds the output of summing point A 2 that existed at t=0, which is the voltage V C 1AC at T=0 or V step . This value is coupled through switch S 2 to summing point A 3 , and finally subtracted at the output Vout by summing point A 3 . Thus the voltage V step occurring on switching from AC to DC has also been stored and subtracted from the output Vout, thereby substantially eliminating the effect of V step from the output V vout.
In order to speed up the DC settling of the I and Q receiver base band paths after switching to the receive mode or after changing the front-end RF gain (which produces large changes in V DC ), the resistor R 1 of FIG. 2 may be momentarily made very small as shown in FIG. 3 , where a shunt resistor R 2 may be momentarily placed in parallel with resistor R 1 through switch S 3 . By doing this, capacitor C 1 charges to V DC very quickly with a time constant of approximately R 2 C 1 , which is much smaller than the regular time constant R 1 C 1 of the high pass filter.
This feature may also be implemented in the low pass filter F 1 of FIG. 2 . In particular, the low pass filter F 1 , schematically shown in FIG. 4 a, may be implemented as the RC filter R 3 C 3 of FIG. 4 b, though preferably, with the addition of switch S 4 and resistor R 4 of FIG. 4 c, where R 4 <<R 3 of FIG. 4 b, switch S 4 may be momentarily closed at time t=0 to implement fast charging in the low pass filter F 1 .
FIG. 5 shows the coupling capacitor circuit of FIG. 2 incorporating the fast charging circuits previously described.
An example of a wireless transceiver incorporating an embodiment of the present invention is shown in FIG. 6 . This Figure illustrates a bridge switch for switching between two antennas, though a single antennae may be used as desired. For the transmitter side, the I(n) and Q(n) signals to be transmitted are converted to analog form in the D/A converters, filtered in the filters AF 1 and AF 2 , mixed in mixers M 3 and M 4 with an RF carrier generated by a voltage controlled oscillator (VCO) controlled through a phase locked loop (PLL), summed, and amplified by variable gain amplifier TXVGA and power amplifier PA, and finally low pass filtered (LPF) for coupling to an antennae.
For the receiver side, a received signal from an antennae is coupled to a band pass filter BPF, through a variable gain low noise amplifier LNA and mixed with the local oscillator frequency in mixers M 1 and M 2 to directly convert the received RF signal to I and Q base band channel signals. The base band signals are filtered in channel filters CF 1 and CF 2 , dynamically AC and DC coupled by blocks AC 1 through AC 4 , amplified by variable gain amplifiers VGA 1 and VGA 2 , and then converted to the digital signals I(n) and Q(n) by the A/D converters. The channel filters CF 1 and CF 2 may be fixed filters, or alternatively, may be programmable filters. In this embodiment, the blocks AC 1 , AC 2 , AC 3 and AC 4 implement the DC cancellation of the present invention, and preferably are generally in accordance with FIG. 5 .
Now referring to FIG. 6 , a flow chart showing an exemplary sequence of operations for the receiver portion of a wireless transceiver such as that shown in FIG. 5 may be seen. For purpose of specificity, this exemplary sequence of operations is for products conforming to the IEEE 802.11a/g WLAN standards. When the receiver is first turned on, the receiver is set at maximum gain, that is, the gains of the low noise amplifier LNA and of the variable gain amplifiers VGA 1 and VGA 2 are set at a maximum. Typically the DC offset V DC will equal the wanted signal V AC plus approximately 40 dB. On receiver power turn on, switches S 1 and S 2 ( FIGS. 2 and 5 ) will be in the AC position and switches S 3 and S 4 ( FIGS. 3 , 4 and 5 ) will be closed for fast charging of the respective capacitors. The Sample/Hold switch ( FIGS. 2 and 5 ) will be closed, putting the Sample/Hold circuit in the track mode, wherein the voltage on the capacitor C SH will track the voltage V C 1AC .
The switches are left in the stated positions for 112 nanoseconds to allow the capacitors C 1 ( FIGS. 3 and 5 ) and C 3 ( FIGS. 4 and 5 ) to charge to V DC . This time period is approximately seven times the applicable RC time constants, assuming RC time constant is approximately 16 nanoseconds, or the high pass corner frequency F HP is 10 megahertz. At the end of the 112 nanosecond delay, switches S 3 and S 4 are opened to put the receiver in the normal AC coupled mode, wherein the receiver is ready for signal acquisition. When the switches S 3 and S 4 are open, the low pass filter corner frequency F LP equals 112 KHz and the high pass filter corner frequency is 600 KHz. Also by this time, the DC offset output to the A/D converters will be approximately equal to V AC −20 dB.
Now the inphase and quadrature channel values are read, typically through the output of the A/D converters, and the gain of the receiver is adjusted. In that regard, such adjustment may be by way of adjusting the gain of the low noise amplifier LNA or the variable gain amplifiers VGA 1 and VGA 2 , or a combination of the two, normally in accordance with a predetermined regimen. If the low noise amplifier LNA gain has changed, the DC offset in the output can change by as much as 30 dB. Consequently, in accordance with the sequence being described, switches S 3 and S 4 ( FIGS. 3 , 4 and 5 ) are turned on for 350 nanoseconds for fast charging of the respective capacitors, after which switches S 3 and S 4 are turned off and the inphase and quadrature values are again measured and gain adjusted, if required. If the gain of the low noise amplifier LNA is adjusted again, this loop again repeats. If it was not adjusted or changed, but the gain of the variable gain amplifiers VGA 1 and VGA 2 was changed, the inphase and quadrature values are again read and further gain adjustments are made, if necessary. Because the variable gain amplifiers VGA 1 and VGA 2 do not inject significant DC offset in the system, fast DC offset zeroing is not again required after their gain has been changed.
In order to adequately read the inphase and quadrature values for gain control purposes, once no further changes in the gain of the low noise amplifier LNA or in the variable gain amplifiers VGA 1 and VGA 2 are made, a delay of approximately 4 microseconds is imposed, which delay represents the remaining time available in the short sequence of the OFDM packet heading of the IEEE 802.11 specification. The 4 microsecond delay is required for the output of F 1 to settle to V DC , so that a more accurate AC component estimate is available at A 2 output at t=0. Thereafter, the sample/hold switch is opened to hold the voltage equal to V step on the capacitor C SH and switches S 1 and S 2 are changed to the DC position. With switch S 2 in the DC position, the DC voltage V step that happened to exist on capacitor C 1 ( FIG. 2 ) is subtracted from the output Vout, completing the gain adjustment and DC cancellation.
In the above embodiment, gain adjustments are made based on the I and Q value read at the output of the A/D converters. Alternatively or in addition, an RSSI (received signal strength indicator) circuit may be used. Such circuits normally monitor the analog signal strength prior to the A/D converters and provide an output responsive to the log of the signal level. Such circuits are not as accurate as using the output of the A/D converters, though could be used, or alternatively, could be used for course gain correction, with the output of the A/D converters being used for the final gain corrections.
Thus in accordance with the present invention, DC components appearing at the input to a coupling capacitor are blocked as in the prior art. However in addition, the instantaneous AC component that may appear across the coupling capacitor at the time of switching to DC coupling is sensed, held and subtracted from the signal path, eliminating the additional DC offset component that would otherwise be imposed by that AC component. Embodiments of the invention disclosed herein subtract the voltage component from the signal path after the point of sensing the voltage across the coupling capacitor, though this is not a limitation of the invention, as the correction could be made at a point in the signal path prior to the point of sensing the voltage across the coupling capacitor, provide care was taken to not subtract the corrective value prior to decoupling the sample and hold capacitor from the signal path. Also embodiments of the present invention hereinbefore described have been described with respect to the IEEE 802.11a/g WLAN standards. However the invention is applicable to other direct conversion wireless applications also. By way of example, for CDMA cell phones using FDD (frequency division duplexing), the receiver gain is controlled from the base station in a closed loop, with an update rate of less than 1 kHz, i.e. an update interval of less than 1000 μsec. Every time the receiver gain is to be changed, the I and Q receive paths are switched to the AC-coupling mode hereinbefore described just before the actual gain change is done. For WCDMA, the AC coupling can be 100-200 kHz (−3 dB corner) to enable fast settling of gain and DC offsets (that are due to gain changes). About 10-20 μsec after gain is changed, the I and Q paths are switched back to DC coupling. The 10-20 μsec is sufficient to bring the output of F 1 ( FIG. 2 ) to the new input DC condition, in order to produce a more accurate signal estimate at A 2 output for sampling by C SH . Fast charging can also be enabled momentarily in the beginning of the 10-20 μsec interval, for both C 1 and C 3 . The 10-20 μsec AC coupling of 100-200 kHz every 1000 μsec does not significantly hurt the speech quality of WCDMA. By removing the DC step of the prior art, it actually improves the speech quality. Thus while certain preferred embodiments of the present invention have been disclosed and described herein for purposes of illustration and not for purposes of limitation, it will be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention. | Improved DC cancellation in zero-IF receivers for eliminating the DC offset that otherwise would be caused by the AC voltage on a coupling capacitor at the time of switching from AC coupling to DC coupling. The coupling capacitor normally is connected first as a high pass filter to block any DC component, and then directly coupled as a direct or DC coupler. However any AC component of voltage on the coupling capacitor at the moment of switching normally remains as a DC offset. In accordance with the invention, the component of AC voltage on a coupling capacitor is tracked, and when switched to DC coupling, the component of AC voltage on the capacitor at the time of switching is held and subtracted from the signal path, thereby canceling the DC offset component that otherwise would be caused. Alternate embodiments are disclosed, including embodiments for accelerating capacitance charging for speed-up of the method. | 7 |
CROSS REFERENCE TO RELATED APPLICATION
This application discloses an improvement on the invention disclosed in the application of Heinz H. Busta, Robert E. Lajos and Kul H. Bhasin for A Method and Apparatus for End Point Detection During Plasma Etching filed Dec. 5, 1977 under Ser. No. 857,384. The contents of this earlier application are hereby incorporated by reference into the present application.
BACKGROUND OF THE INVENTION
DESCRIPTION OF THE PRIOR ART
In the manufacture of integrated circuits and similar devices, it is common practice to etch through a first thin layer in a prescribed or predetermined pattern to expose an underlying substrate. When the thin layer is of electrically insulating material, the substrate typically will be either a metal or a semi-conductive material. After the prescribed pattern has been etched through the layer of insulation, another layer of metal or semi-conductive material may be applied over the insulation to come into contact with exposed portions of the underlying substrate. During initial and/or subsequent etching processes, after the outermost layer of material is etched away, an overetching condition begins to take place, the magnitude of which is a function of the plasma etching parameters. If the etching process is not terminated soon after overetching begins, a defective unit may result.
Typically, light reflected from an insulation material undergoing etching will produce a low frequency signal in the order of about 0.005 Hz from an optical detector. This low frequency or undulating signal is produced by constructive and destructive interference of the reflected light waves. When an insulation layer is completely etched away to expose a metal layer, the detector will produce an essentially constant or DC signal to indicate the presence of metal. Prior art systems are known which can detect the transition from insulation to metal but not the transition from metal to insulation. Also, prior art systems of the type incorporating digital signal analysis techniques employ analog to digital converters whose conversion times have no relationship to the process being controlled. Such systems typically require both analog and digital filtering circuitry because of the low frequency signal obtained from the detector.
Various techniques have been developed in the past for monitoring the progress of an etching process to determine when a surface layer has been etched away to reveal an underlying substrate. An etch end-point detector was disclosed by R. N. Price in IBM Technical Disclosure Bulletin Vol. 15, No. 11, pp 3532-33, dated April, 1973, in which light reflected from a surface undergoing etching is monitored to detect changes in the light characteristics indicative of the desired end point. An output signal is generated when the derivative of the light signal with respect to time is zero for a period of time. Thus, etching through an insulation layer to an underlying metal layer may be monitored. Another such end-point detection system was disclosed by J. C. Collins and P. J. Pavone in IBM Technical Disclosure Bulletin Vol. 17, No. 5, pp 1342-43, dated October, 1974; however, this system is not readily adaptable to detect transitions from low derivative to high derivative of the light signal. A related technique also was disclosed by H. Moritz in IBM Technical Disclosure Bulletin Vol. 19, No. 7, pp 2579-80, dated December, 1976, in which the intensity of reflected light is recorded and observed to detect end-point. Finally, R. C. Lewis in U.S. Pat. No. 4,041,404, Apparatus and Method for Detecting When a Measured Variable Represented By a String of Digital Pulses Reaches a Plateau, issued Aug. 9, 1977, disclosed a system for monitoring changes in the derivative of a time-varying signal.
While these prior art end-point detection systems each have certain advantages, none of them provides a closed loop control function which will terminate the etching process when the desired end-point has been reached. Moreover, they appear to be rather sensitive to circuit noise from typical electrical noise sources and also provide no flexibility in analog-to-digital conversion times which would permit the system to track various etching processes having differing characteristics. Finally, their capability to detect the end-point of metal-to-insulation or insulation-to-insulation etching is rather doubtful.
OBJECTS OF THE INVENTION
An object of the present invention is to provide a closed-loop end-point detection system for use in wet or plasma etching systems.
Another object of the invention is to provide such a detection system which is relatively insensitive to typical electrical noise.
A further object of the invention is to provide such a system which is useful with a wide variety of etching processes which proceed at differing rates.
Yet another object of the invention is to provide such a system which will detect the end-point of metal-to-metal, insulation-to-insulation, metal-to-insulation and insulation-to-metal etching processes and control the processes accordingly.
These objects are only exemplary; thus, other desirable objectives inherently achieved by the disclosed process and apparatus may occur to those skilled in the art. Nonetheless, the scope of the invention is to be limited only by the appended claims.
SUMMARY OF THE INVENTION
The above objects and other desirable advantages are achieved by the method and apparatus of the invention in which a layer undergoing etching is caused to reflect a beam of radiation and the reflected radiation is monitored by a suitable detector to produce a signal. The time derivative of the signal is determined for successive intervals and compared to predetermined criteria indicative of end point. When the criteria are satisfied, the etching process is terminated automatically. End points reached while etching a variety of material pairs, may be detected.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram illustrating apparatus used to carry out the method of this invention;
FIG. 2 illustrates detector signal amplitude vs. etch time of etching through one metal to expose another metal;
FIG. 3 illustrates detector signal amplitude vs. etch time of etching through metal to expose insulation;
FIG. 4 illustrates detector signal amplitude vs. etch time of etching through insulation to expose metal; and
FIG. 5 illustrates detector signal amplitude vs. etch time of etching through one type of insulation to expose another type of insulation.
DETAILED DESCRIPTION OF THE INVENTION
The apparatus of the present invention is illustrated in FIG. 1. A plasma etching chamber 10 is provided in which a unit 12 forms a support body for one or more layers of insulation or metal or both, in any combination or sequence. For example, unit 12 may comprise a first, underlying layer 14 of insulation and a second, overlying layer 16 of metal.
Layers 14 and 16 are plasma etched, in predetermined patterns using a conventional plasma etch source 18 and photolithographic techniques. The invention may also be used with wet etching systems. A plasma etch source 18 directs a plasma beam 20 onto the surface of the layer to be etched so that eventually the underlying substrate is exposed. Preferably, the plasma beam composition is tailored to etch only the outermost layer; however, this is not possible for all material combinations.
A laser source 22 or other coherent light source directs a light beam 24 on the surface of the layer being etched. Reflected light beam 26 impinges upon a photodetector 28 to produce an electrical output signal. For example, when the plasma beam 20 is etching through metal, the electrical signal produced by detector 28 will be essentially a DC signal. On the other hand, when the plasma beam 20 is etching through insulation, the electrical signal produced by detector 28 will be a very low frequency or undulating signal proportional to the etch rate. For example, the signal frequency is about 0.005 Hz when etching tantalum oxide at a rate of approximately 1000 Angstroms per minute. The signal sensed by detector 28 is amplified by an amplifier 30 coupled to a voltage-to-frequency converter 32. The frequency of the output of converter 32 will be a function of the magnitude of the voltage applied to the converter. The output pulses are fed to a counter 34 which is enabled by an adjustable timer 35. The counting or enable period of timer 35 preferably is chosen in the range of 1 to 5 seconds so as to optimize noise rejection of typical electrical noise sources and still maintain good transient response when detecting the end point. If the output voltage of amplifier 30 changes during the next counting period or time frame, so also does the frequency of the output pulses from converter 32.
The output of the counter 34 during an initial counting period is applied to a memory circuit 36; and the output during the next counting perod, to a subtractor circuit 38. The initial count stored in memory circuit 36 is applied to subtractor circuit 38 simultaneously with the next count from counter 34. The next or present count of pulses is subtracted from the initial or previous count, so that the difference is proportional to the derivative or slope of the signal sensed by detector 28. It will be understood that the operation of subtractor circuit 38 may be reversed and the initial or previous count subtracted from the next or present count to provide equally useful derivative information. Sequencing of counter 34, memory 36 and subtractor 38 is achieved by timer 35 in a manner well known in the art. In accordance with this invention, timer 35 is provided with adjusting means 39 so that the enable or counting period of the counter 34 can be selected in accordance with the process being used. To extend the range of operation of the present invention, a divide by N circuit 40 is connected between the voltage-to-frequency converter 32 and the counter circuit 34. The divider circuit 40 will allow a higher number of pulses to be generated within the converter 32 without requiring expansion of the counter 34, when using long counter periods for slow etch rates.
The output of subtractor 38 is applied to one input of a digital comparator 42. Another input of the comparator 42 receives signals from an end point criteria generator 44 which may be any suitable programmer of the keyboard type. When the signals from subtractor 38 correspond to the information in generator 44, comparator 42 will produce a control signal on output line 46. This control signal is applied to plasma etch source 18 to terminate it operation before an overetch condition can occur.
For a better understanding of the present invention refer now to FIGS. 2, 3, 4 and 5, where various detector signals are shown. FIG. 2 illustrates a time vs. amplitude signal obtained from the detector 28 when etching through one type of metal to expose another type of metal. The portion 50 of the signal trace representing one metal is substantially a straight line as is the portion 51 which represents another metal. The derivative of horizontal straight line portions 50 and 51 each is zero or substantially zero. However, the curved portion 52, connecting the straight portions 50 and 51, has a derivative which is non-zero. The circuitry shown in FIG. 1 detects the transition from zero slope to non-zero slope as an indication of the end point and terminates operation of plasma etch source 18. While FIG. 2 shows a process of etching through one metal to expose another metal in which the signal increases with time, it will be understood that the signal may decrease with time to indicate the transition.
FIG. 3 illustrates a time vs. amplitude signal obtained from detector 28 when etching through metal to expose insulation. The straight line portion 54 represents metal being etched away, and during this etching process the derivative of the detector signal is substantially zero. At point 56 the straight line portion 54 begins to vary at a low frequency, typically about 0.005 Hz, as indicated by reference numeral 58. The initial portion 58a has a substantially non-zero derivative which causes a control signal to appear at the output of comparator 42, thus terminating operation of plasma etch source 18. Therefore, as soon as the system of the present invention senses full exposure of the insulation substrate, etching is stopped and overetching is prevented.
FIG. 4 illustrates a time vs. amplitude signal obtained from the detector 28 when etching through insulation to expose metal. Here a low frequency signal 60, typically about 0.005 Hz, indicates that insulation material is being etched. The derivative of such a signal is always non-zero except at the minima and maxima points 60a and 60b, respectively. However, the time interval of the minima and maxima points is short compared to preselected information set into criteria generator 44. Therefore, no control signal is generated and plasma etching continues. When etching of insulation is completed, and metal is fully exposed, a DC signal 62 is sensed by detector 28. The DC signal 62 produces a zero derivative during a time interval much longer than that during which zero derivative was sensed at minima and maxima points 60a and 60b; so that the requirements of criteria generator 44 are met and a control signal is generated to terminate operation of the etching apparatus, thereby eliminating overetching of the exposed metal substrate.
FIG. 5 illustrates a time vs. amplitude signal obtained from the detector 28 when etching through one type of insulation to expose another type of insulation. The curved portion 64 represents detector response for the insulation initially etched away; and curved portion 66, for the insulation subsequently exposed. Curved portion 64 is here shown as being of a higher frequency than curved portion 66, the difference being caused by the plasma composition which yields different etch rates for different materials. The transition point 68 between the two curved portions 64 and 66 is sensed by detector 28 and the preselected condition, as set into the criteria 44, will cause a control signal to be generated and terminate operation of the etching apparatus, as the portion of the curve 66 has an average derivative whose magnitude is less than that generated while on the portion 64 of the curve.
The criteria generator 44 receives input information regarding the number of consecutive time frame units during which an indication of end-point conditions must be sensed before a control signal is released on line 46. In one embodiment five time frames are required to confirm the existence of the desired condition, each time frame being from one to five seconds, more or less, in length. This long time frame arrangement integrates out contributions due to typical electrical noise sources of less than 10 Hz. In addition, when subtraction is performed by subtractor 38 DC errors such as that obtained by component drift are also eliminated.
The end point information used by criteria generator 44 are inserted manually or by other suitable means and are based on experimental data. The changes in detector output illustrated in FIGS. 2 to 5 follow the general forms shown; however, those skilled in the art will appreciate that signal magnitudes, frequencies and the like will vary depending on the process parameters and the materials involved. For the conditions of FIGS. 2 to 4, a sample of the layers of interest is placed in a plasma etcher and then deliberately etched beyond the end point, as noted on the analog recording of the detector output. Provided actual etching conditions are maintained close to those of such a calibration run, the analog trace will be representative of future etching runs as well. The system of FIG. 1 is set so that a change in count of at least 10 (the threshold) is required to indicate an end point, and such a change must be recorded at least ten times in succession (the pass number). The difference counts recorded during the actual calibration run are compared to the recorded trace. For an insulator-to-metal etch such as in FIG. 4, the low derivative or threshold value indicative of end point is determined by the difference count values following end point; and the number of successful sequential tests required, the pass number, is determined by that number which is necessary to avoid triggering at the minimum or maximum points. The counter enable time is selected based on the maximum acceptable overetch beyond the first layer into the second. For example, if the particular plasma etching process will yield an etch rate of "A" Angstroms per unit time into the second layer and the maximum acceptable overetch is "B" Angstroms, then the maximum allowable increment of time, within which the system according to the invention must be able to determine whether end point has arrived, is "B/A" units of time. If the pass number for the process is "C" consecutive indications of end-point, then the enable time is chosen to be "B/2AC" since each indication of end point requires comparison of two consecutive counts. As mentioned previously, the provision of adjustment means 30 on timer 35 permits selecting the counter enable time as necessary to suit the particular process being controlled and thereby to ensure that a maximum permissable overetch is not exceeded. Similar techniques are used for the cases illustrated in FIGS. 2 and 3. Using such criteria, overetch is estimated at less than 1000 A.
For the case shown in FIG. 5, a somewhat different technique usually is required to determine the end point criteria since the change in detector signal usually is less dramatic. Where the etch rates of the two insulators are quite different, say, by a factor of 10, then the previously described technique is applicable. However, where the etch rates of the two materials are similar, the time between maxima or minima is monitored. The derivative of the detector output will undergo a sign change at these regularly spaced points. However, when the end point has passed, the spacing between maxima or minima will change, signalling end point. That is, prior to end point, a slope sign change will occur during each time increment, provided the increments are chosen to always include a maximum or a minimum. After end point, the apparatus will continue to look for a sign change in each time increment, the absence of the change in a selected number of increments being indicative of end point.
While a single system is illustrated to perform the method of this invention it will be understood variation and modification may be effected without departing from the spirit and scope of the following claims. | A method and apparatus are disclosed for controlling plasma etching processes in which a thin layer is etched away to expose a substrate. Coherent light is directed onto the surface being etched, so that the change in reflectivity of the surface upon exposure of the underlying substrate produces a detectable change in the characteristics of the light reflected. A derivative detector having a variable timer is provided to sample continuously the reflected light and provide a control signal in response to a predetermined change in the characteristics of the light reflected, which is used to terminate the plasma etch process before an overetch condition occurs. The method and apparatus of the invention will detect a desired end point of etching through insulation to an underlying metal substrate, through metal to an underlying insulation substrate, through one insulation type to an underlying substrate of another insulation type and through one metal to an underlying substrate of another metal. | 2 |
TECHNICAL FIELD
[0001] The present invention is related to systems for depositing material onto workpieces in reaction chambers and methods for removing byproducts from reaction chambers.
BACKGROUND
[0002] Thin film deposition techniques are widely used in the manufacturing of microfeatures to form a coating on a workpiece that closely conforms to the surface topography. The size of the individual components in the workpiece is constantly decreasing, and the number of layers in the workpiece is increasing. As a result, both the density of components and the aspect ratios of depressions (i.e., the ratio of the depth to the size of the opening) are increasing. Thin film deposition techniques accordingly strive to produce highly uniform conformal layers that cover the sidewalls, bottoms, and corners in deep depressions that have very small openings.
[0003] One widely used thin film deposition technique is Chemical Vapor Deposition (CVD). In a CVD system, one or more precursors that are capable of reacting to form a solid thin film are mixed while in a gaseous or vaporous state, and then the precursor mixture is presented to the surface of the workpiece. The surface of the workpiece catalyzes the reaction between the precursors to form a solid thin film at the workpiece surface. A common way to catalyze the reaction at the surface of the workpiece is to heat the workpiece to a temperature that causes the reaction.
[0004] Although CVD techniques are useful in many applications, they also have several drawbacks. For example, if the precursors are not highly reactive, then a high workpiece temperature is needed to achieve a reasonable deposition rate. Such high temperatures are not typically desirable because heating the workpiece can be detrimental to the structures and other materials already formed on the workpiece. Implanted or doped materials, for example, can migrate within the silicon substrate at higher temperatures. On the other hand, if more reactive precursors are used so that the workpiece temperature can be lower, then reactions may occur prematurely in the gas phase before reaching the substrate. This is undesirable because the film quality and uniformity may suffer, and also because it limits the types of precursors that can be used.
[0005] Atomic Layer Deposition (ALD) is another thin film deposition technique. FIGS. 1A and 1B schematically illustrate the basic operation of ALD processes. Referring to FIG. 1A , a layer of gas molecules A coats the surface of a workpiece W. The layer of A molecules is formed by exposing the workpiece W to a precursor gas containing A molecules and then purging the chamber with a purge gas to remove excess A molecules. This process can form a monolayer of A molecules on the surface of the workpiece W because the A molecules at the surface are held in place during the purge cycle by physical adsorption forces at moderate temperatures or chemisorption forces at higher temperatures. Referring to FIG. 1B , the layer of A molecules is then exposed to another precursor gas containing B molecules. The A molecules react with the B molecules to form an extremely thin layer of solid material on the workpiece W. The chamber is then purged again with a purge gas to remove excess B molecules.
[0006] FIG. 2 illustrates the stages of one cycle for forming a thin solid layer using ALD techniques. A typical cycle includes (a) exposing the workpiece to the first precursor A, (b) purging excess A molecules, (c) exposing the workpiece to the second precursor B, and then (d) purging excess B molecules. In actual processing, several cycles are repeated to build a thin film on a workpiece having the desired thickness. For example, each cycle may form a layer having a thickness of approximately 0.5-1.0 Å, and thus several cycles are required to form a solid layer having a thickness of approximately 60 Å.
[0007] FIG. 3 schematically illustrates a single-wafer ALD reactor 10 having a reaction chamber 20 coupled to a gas supply 30 and a vacuum 40 . The reactor 10 also includes a heater 50 that supports the workpiece W and a gas dispenser 60 in the reaction chamber 20 . The gas dispenser 60 includes a plenum 62 operably coupled to the gas supply 30 and a distributor plate 70 having a plurality of holes 72 . In operation, the heater 50 heats the workpiece W to a desired temperature, and the gas supply 30 selectively injects the first precursor A, the purge gas, and the second precursor B, as shown above in FIG. 2 . The vacuum 40 maintains a negative pressure in the reaction chamber 20 to draw the gases from the gas dispenser 60 across the workpiece W and then through an outlet of the reaction chamber 20 . A trap 80 captures and collects the byproducts from the reaction chamber 20 to prevent fouling of the vacuum 40 .
[0008] One drawback of ALD processing is that it has a relatively low throughput compared to CVD techniques. For example, each A-purge-B-purge cycle can take several seconds. This results in a total process time of several minutes to form a single thin layer of only 60 Å. In contrast to ALD processing, CVD techniques require only about one minute to form a 60 Å thick layer. The low throughput limits the utility of the ALD technology in its current state because ALD may create a bottleneck in the overall manufacturing process.
[0009] Another drawback of both ALD and CVD processing is the downtime required to service or replace the trap. As the trap collects byproducts from the reaction chamber, the byproducts restrict the flow from the reaction chamber 20 to the vacuum 40 , and consequently, the pressure in the chamber increases. The increased pressure in the reaction chamber impairs effective removal of the byproducts from the reaction chamber. Accordingly, the trap is cleaned or replaced periodically to avoid significant increases in the pressure in the reaction chamber. Servicing the trap requires that the reactor be shut down, which results in a reduction in throughput. One approach to reduce the downtime of the reactor includes increasing the size of the trap. Although this approach reduces the downtime, a significant need still exists to eliminate the downtime required to service the trap and to maintain a consistent pressure in the reaction chamber.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIGS. 1A and 1B are schematic cross-sectional views of stages in ALD processing in accordance with the prior art.
[0011] FIG. 2 is a graph illustrating a cycle for forming a layer using ALD techniques in accordance with the prior art.
[0012] FIG. 3 is a schematic representation of a system including a reactor for depositing material onto a microfeature workpiece in accordance with the prior art.
[0013] FIG. 4 is a schematic representation of a system for depositing material onto a microfeature workpiece in accordance with one embodiment of the invention.
[0014] FIG. 5 is a schematic representation of a portion of a system for depositing material onto a workpiece in accordance with another embodiment of the invention.
[0015] FIG. 6 is a schematic representation of a portion of a system for depositing material onto a workpiece in accordance with another embodiment of the invention.
DETAILED DESCRIPTION
[0000] A. Overview
[0016] The following disclosure describes several embodiments of systems for depositing material onto workpieces in reaction chambers and methods for removing byproducts from reaction chambers. Many specific details of the invention are described below with reference to single-wafer reactors for depositing material onto microfeature workpieces, but several embodiments can be used in batch systems for processing a plurality of workpieces simultaneously. Moreover, several embodiments can be used for depositing material onto workpieces other than microfeature workpieces. The term “microfeature workpiece” is used throughout to include substrates upon which and/or in which microelectronic devices, micromechanical devices, data storage elements, read/write components, and other features are fabricated. For example, microfeature workpieces can be semiconductor wafers such as silicon or gallium arsenide wafers, glass substrates, insulative substrates, and many other types of materials. Furthermore, the term “gas” is used throughout to include any form of matter that has no fixed shape and will conform in volume to the space available, which specifically includes vapors (i.e., a gas having a temperature less than the critical temperature so that it may be liquefied or solidified by compression at a constant temperature). Several embodiments in accordance with the invention are set forth in FIGS. 4-6 and the following text to provide a thorough understanding of particular embodiments of the invention. A person skilled in the art will understand, however, that the invention may have additional embodiments, or that the invention may be practiced without several of the details of the embodiments shown in FIGS. 4-6 .
[0017] One aspect of the invention is directed to systems for depositing material onto workpieces in reaction chambers. In one embodiment, a system includes a gas phase reaction chamber, a first exhaust line coupled to the reaction chamber, first and second traps each in fluid communication with the first exhaust line, and a vacuum pump coupled to the first exhaust line to remove gases from the reaction chamber. The first and second traps are operable independently to individually and/or jointly collect byproducts from the reaction chamber. In one aspect of this embodiment, the first exhaust line includes a first branchline and a second branchline each downstream from the reaction chamber. The first trap can be disposed in the first branchline and the second trap can be disposed in the second branchline. The first and second branchlines can be configured in a parallel arrangement. In another aspect of this embodiment, the system further includes a throttling valve in the second branchline, a pressure monitor, and a controller operably coupled to the throttling valve and the pressure monitor. The pressure monitor can determine the difference between the pressure in the first exhaust line upstream from the first trap and the pressure in the first exhaust line downstream from the first trap. The controller can operate the throttling valve to control the flow of byproducts into the second branchline to maintain the pressure differential in the first exhaust line within a desired range.
[0018] In another embodiment, a system includes a gas phase reaction chamber, a first exhaust line coupled to the reaction chamber, a trap in the first exhaust line to collect byproducts from the reaction chamber, and first and second vacuum pumps. The first and second vacuum pumps are each in fluid communication with the first exhaust line and positioned downstream from the trap. The first and second vacuum pumps are operable independently to individually and/or jointly exhaust byproducts from the reaction chamber. In one aspect of this embodiment, the first exhaust line includes a first branchline and a second branchline each downstream from the reaction chamber. The first vacuum pump can be coupled to the first branchline and the second vacuum pump can be coupled to the second branchline. The system can also include a throttling valve in the second branchline to control the pressure in the first exhaust line.
[0019] Another aspect of the invention is directed to methods for removing byproducts from a reaction chamber through a first mainline. The first mainline has first and second branchlines downstream from the reaction chamber. In one embodiment, the method includes exhausting byproducts from the reaction chamber through the first mainline and dynamically controlling the flow of byproducts into the second branchline of the first mainline to maintain a pressure differential in the first mainline within a desired range. In one aspect of this embodiment, the method further includes collecting byproducts in a first trap in the first branchline of the first mainline and collecting byproducts in a second trap in the second branchline of the first mainline. In another aspect of this embodiment, the method further includes monitoring the difference between the pressure in the first mainline upstream from the first trap and the pressure in the first mainline downstream from the first trap. In response to the monitored pressure differential, a throttling valve in the second branchline can be regulated to maintain the pressure differential within the desired range.
[0000] B. Deposition Systems
[0020] FIG. 4 is a schematic representation of a system 100 for depositing material onto a microfeature workpiece W in accordance with one embodiment of the invention. In this embodiment, the system 100 includes a reactor 110 having a reaction chamber 120 coupled to a gas supply 130 and a vacuum pump 140 . The reactor 110 also includes a gas distributor 160 coupled to the reaction chamber 120 and the gas supply 130 to dispense gas(es) into the reaction chamber 120 and onto the workpiece W. Byproducts including excess and/or unreacted gas molecules are removed from the reaction chamber 120 by the vacuum pump 140 and injecting a purge gas into the chamber 120 .
[0021] The gas supply 130 includes a plurality of gas sources 132 (identified individually as 132 a - c ) and a plurality of gas lines 136 coupled to the gas sources 132 . The gas sources 132 can include a first gas source 132 a for providing a first gas, a second gas source 132 b for providing a second gas, and a third gas source 132 c for providing a third gas. The first and second gases can be first and second precursors, respectively. The third gas can be a purge gas. The first and second precursors are the gas and/or vapor phase constituents that react to form the thin, solid layer on the workpiece W. The purge gas can be a suitable type of gas that is compatible with the reaction chamber 120 and the workpiece W. In other embodiments, the gas supply 130 can include a different number of gas sources 132 for applications that require additional precursors or purge gases. In additional embodiments, the gas sources 132 can include one or more etchants for deposition onto a microfeature workpiece during etching.
[0022] The system 100 of the illustrated embodiment further includes a valve assembly 133 coupled to the gas lines 136 and a controller 134 operably coupled to the valve assembly 133 . The controller 134 generates signals to operate the valve assembly 133 to control the flow of gases into the reaction chamber 120 for ALD and CVD applications. For example, the controller 134 can be programmed to operate the valve assembly 133 to pulse the gases individually through the gas distributor 160 in ALD applications or to mix selected precursors in the gas distributor 160 in CVD applications. More specifically, in one embodiment of an ALD process, the controller 134 directs the valve assembly 133 to dispense a pulse of the first gas (e.g., the first precursor) into the reaction chamber 120 . Next, the controller 134 directs the valve assembly 133 to dispense a pulse of the third gas (e.g., the purge gas) to purge excess molecules of the first gas from the reaction chamber 120 . The controller 134 then directs the valve assembly 133 to dispense a pulse of the second gas (e.g., the second precursor), followed by a pulse of the third gas. In one embodiment of a pulsed CVD process, the controller 134 directs the valve assembly 133 to dispense a pulse of the first and second gases (e.g., the first and second precursors) into the reaction chamber 120 . Next, the controller 134 directs the valve assembly 133 to dispense a pulse of the third gas (e.g., the purge gas) into the reaction chamber 120 . In other embodiments, the controller 134 can dispense the gases in other sequences.
[0023] In the illustrated embodiment, the reactor 110 also includes a workpiece support 150 to hold the workpiece W in the reaction chamber 120 . In one aspect of this embodiment, the workpiece support 150 can be heated to bring the workpiece W to a desired temperature for catalyzing the reaction between the first gas and the second gas at the surface of the workpiece W. For example, the workpiece support 150 can be a plate with a heating element. The workpiece support 150 , however, may not be heated in other applications.
[0024] The system 100 further includes an exhaust mainline 170 coupled to the vacuum pump 140 and the reaction chamber 120 to remove byproducts, including excess and/or unreacted gas molecules, from the reaction chamber 120 . The mainline 170 includes an upstream portion 170 a, a downstream portion 170 b, a first branchline 172 a, and a second branchline 172 b. The branchlines 172 a - b can be configured in a parallel arrangement and coupled to the upstream and downstream portions 170 a - b. Accordingly, discrete byproducts flow through either the first branchline 172 a or the second branchline 172 b. In this embodiment, the system 100 further includes a first trap 180 a disposed in the first branchline 172 a and a second trap 180 b disposed in the second branchline 172 b. The traps 180 a - b capture and collect byproducts in the branchlines 172 a - b to prevent damage to the vacuum pump 140 . In other embodiments, the system can include a different number of branchlines and/or traps.
[0025] In one aspect of this embodiment, the system 100 further includes a throttling valve 190 in the second branchline 172 b, a valve controller 194 operably coupled to the throttling valve 190 , and a pressure monitor 198 operably coupled to the valve controller 194 . The throttling valve 190 and the valve controller 194 regulate the flow of byproducts into the second branchline 172 b, and the pressure monitor 198 determines the pressure difference between the upstream and downstream portions 170 a - b of the mainline 170 . The throttling valve 190 , the valve controller 194 , and the pressure monitor 198 can operate together to maintain the pressure in the upstream portion 170 a of the mainline 170 within a desired range. For example, the pressure differential across the first trap 180 a increases as the first trap 180 a collects byproducts because the byproducts in the first trap 180 a obstruct the flow from the reaction chamber 120 to the vacuum pump 140 . The pressure monitor 198 detects this increase in the pressure differential across the first trap 180 a and sends a signal to the valve controller 194 . In response to the signal, the valve controller 194 at least partially opens the throttling valve 190 to allow some of the flow of byproducts to pass through the second branchline 172 b. The throttling valve 190 is opened sufficiently to reduce the pressure differential in the upstream and downstream portions 170 a - b of the mainline 170 to within the desired range. In additional embodiments, the system 100 can include a throttling valve in the first branchline 172 a that is coupled to the valve controller 194 .
[0026] One feature of this embodiment of the system 100 is that it maintains the pressure differential between the upstream and downstream portions 170 a - b of the mainline 170 as the traps 180 a - b collect byproducts. Accordingly, the pressure in the upstream portion 170 a and the reaction chamber 120 can remain generally consistent. An advantage of this feature is that a consistent pressure in the reaction chamber 120 helps create a consistent flow through the reaction chamber 120 . More specifically, a consistent pressure facilitates the consistent, effective removal of byproducts, including excess and/or unreacted gas molecules, from the reaction chamber 120 . In contrast, the pressure in many prior art reaction chambers increases as the trap collects byproducts that obstruct the exhaust line. This increase in pressure (i.e., decrease in negative pressure) in the prior art reaction chambers impairs consistent, effective removal of the byproducts from the reaction chambers, and consequently, the byproducts may react with incoming gases.
[0027] In another aspect of the illustrated embodiment, the system 100 can include a plurality of valves 192 (identified individually as 192 a - c ) to selectively isolate the first and/or second traps 180 a - b for service or replacement. The first branchline 172 a, for example, can include a first valve 192 a (shown in hidden lines) upstream from the first trap 180 a and a second valve 192 b (shown in hidden lines) downstream from the first trap 180 a. The first and second valves 192 a - b can be closed to allow the first trap 180 a to be serviced or replaced without interrupting the deposition process of the system 100 . For example, when the first and second valves 192 a - b are closed, the throttle valve 190 can be opened enough to exhaust the byproducts solely through the second branchline 172 b of the mainline 170 . The first trap 180 a can then be replaced with a new trap without shutting down the system 100 . Similarly, the second branchline 172 b can include a third valve 192 c (shown in hidden lines) downstream from the second trap 180 b. The throttling valve 190 and the third valve 192 c can be closed to allow the second trap 180 b to be serviced or replaced without interrupting the deposition process of the system 100 . In other embodiments, the system 100 may not include the valves 192 .
[0028] One feature of the illustrated embodiment is that the system 100 does not need to be shut down to replace and/or service the traps 180 . Each trap 180 can be isolated for service or replacement, and while one trap 180 is serviced, the other trap 180 can collect byproducts. An advantage of this feature is that the throughput of the system 100 is increased because the downtime resulting from servicing the traps 180 is reduced or eliminated.
[0000] C. Other Systems to Remove Byproducts
[0029] FIG. 5 is a schematic representation of a portion of a system 200 for depositing material onto a workpiece in accordance with another embodiment of the invention. The system 200 can be generally similar to the system 100 described above with reference to FIG. 4 . For example, the system 200 includes a reaction chamber 120 , a mainline 270 coupled to the reaction chamber 120 , and a trap 180 in the mainline 270 to capture and collect the byproducts from the reaction chamber 120 . The mainline 270 includes a first branchline 272 a and a second branchline 272 b each downstream from the trap 180 . The system 200 further includes a first vacuum pump 140 a coupled to the first branchline 272 a and a second vacuum pump 140 b coupled to the second branchline 272 b.
[0030] In one aspect of this embodiment, the system 200 includes a throttling valve 190 in the second branchline 272 b, a valve controller 194 operably coupled to the throttling valve 190 , and a pressure monitor 298 operably coupled to the valve controller 194 to determine the pressure in the mainline 270 downstream from the trap 180 . The throttling valve 190 , the valve controller 194 , and the pressure monitor 298 can operate together to maintain a consistent pressure in the mainline 270 and/or maintain a consistent mass flow rate and/or fluid velocity of byproducts through the mainline 270 . For example, in one embodiment, if the first vacuum pump 140 a is fouled because the trap 180 fails to capture all the byproducts in the mainline 270 , the pressure in the mainline 270 will increase and the throughput of byproducts through the mainline 270 will decrease. The pressure monitor 298 detects the pressure increase and sends a signal to the valve controller 194 . In response to the signal, the valve controller 194 opens the throttling valve 190 sufficiently to allow the second vacuum pump 140 b to reduce the pressure in the mainline 270 to a desired range and to increase the throughput of byproducts in the mainline 270 to a consistent level. In other embodiments, the pressure monitor 298 can monitor the pressure differential in the mainline 270 upstream and downstream of the trap 180 (shown in broken line). In this embodiment, if the trap 180 is fouled, the pressure upstream from the trap 180 will increase. The valve controller 194 can accordingly open the valve 190 to reduce the pressure downstream from the trap 180 and thus increase the flow rate across the trap 180 . The system 200 can include a different number of branchlines and vacuum pumps than shown in FIG. 5 , or the system 200 can include a throttling valve in the first branchline 272 a in still another embodiment.
[0031] In one aspect of this embodiment, the first branchline 272 a can include a valve 192 (shown in hidden lines) to control the flow through the first branchline 272 a. The valve 192 allows the first vacuum pump 140 a to be serviced or replaced without interrupting the deposition process of the system 200 . For example, when the valve 192 is closed to service or replace the first vacuum pump 140 a, the second vacuum pump 140 b can continue to remove byproducts from the reaction chamber 120 .
[0032] One feature of the embodiment illustrated in FIG. 5 is that the system 200 does not need to be shut down to replace and/or service one of the vacuum pumps 140 because the valves 190 and 192 can isolate the vacuum pump 140 . An advantage of this feature is that the throughput of the system 200 is increased because the downtime for servicing the vacuum pumps 140 is reduced or eliminated. Another feature of this embodiment is that a consistent pressure can be maintained in the mainline 270 , and consequently, byproducts can be removed from the reaction chamber 120 at a consistent rate. An advantage of this feature is that removing byproducts from the reaction chamber 120 at a consistent rate results in a more consistent deposition process and reduces the likelihood that byproducts may recirculate in the reaction chamber 120 and react with incoming gases.
[0033] FIG. 6 is a schematic representation of a portion of a system 300 for depositing material onto a workpiece in accordance with another embodiment of the invention. The system 300 can be generally similar to the systems 100 and 200 described above with reference to FIGS. 4 and 5 . For example, the system 300 includes a reaction chamber 120 , a mainline 370 coupled to the reaction chamber 120 , a plurality of traps 180 (identified individually as 180 a - b ) in the mainline 370 , and a plurality of vacuum pumps 140 (identified individually as 140 a - b ) coupled to the mainline 370 . The mainline 370 includes first and second branchlines 372 a - b configured in a parallel arrangement and third and fourth branchlines 372 c - d configured in a parallel arrangement downstream from the first and second branchlines 372 a - b. In the illustrated embodiment, a first trap 180 a is disposed in the first branchline 372 a, a second trap 180 b is disposed in the second branchline 372 b, a first vacuum pump 140 a is coupled to the third branchline 372 c, and a second vacuum pump 140 b is coupled to the fourth branchline 372 d.
[0034] The system 300 of the illustrated embodiment can further include a first throttling valve 190 a in the second branchline 372 b, a second throttling valve 190 b in the fourth branchline 372 d, a valve controller 194 operably coupled to the throttling valves 190 a - b, and a pressure monitor 198 coupled to the valve controller 194 . The pressure monitor 198 monitors the pressure difference between an upstream portion 370 a of the mainline 370 and a downstream portion 370 b of the mainline 370 . As described above with reference to FIG. 4 , the valve controller 194 can regulate the first throttling valve 190 a to create a desired pressure differential in the upstream and downstream portions 370 a - b of the mainline 370 . Moreover, as described above with reference to FIG. 5 , the valve controller 194 can regulate the second throttling valve 190 b to create a consistent pressure in the mainline 370 if the first vacuum pump 140 a is fouled. The system 300 can further include a plurality of valves 192 (identified individually as 192 a - d ) to isolate the traps 180 a - b and/or vacuum pumps 140 a - b so that the traps 180 a - b and vacuum pumps 140 a - b can be serviced or replaced without interrupting the deposition process in the system 300 , as described above with reference to FIGS. 4 and 5 . In other embodiments, the system can include additional traps, vacuums, and/or branchlines.
[0035] From the foregoing, it will be appreciated that specific embodiments of the invention have been described herein for purposes of illustration but that various modifications may be made without deviating from the spirit and scope of the invention. Accordingly, the invention is not limited, except as by the appended claims. | Systems for depositing material onto workpieces in reaction chambers and methods for removing byproducts from reaction chambers are disclosed herein. In one embodiment, the system includes a gas phase reaction chamber, a first exhaust line coupled to the reaction chamber, first and second traps each in fluid communication with the first exhaust line, and a vacuum pump coupled to the first exhaust line to remove gases from the reaction chamber. The first and second traps are operable independently to individually and/or jointly collect byproducts from the reaction chamber. It is emphasized that this Abstract is provided to comply with the rules requiring an abstract. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. | 8 |
FIELD OF THE INVENTION
The invention refers to a solenoid, in particular for media-controlling valves where in an armature space a mobile supported armature acting on a tappet and a coil carrying windings of a wire flown through by electricity are provided, and the magnetic core delimiting the armature space has a tappet boring incorporating the axially moving tappet, and a boundary element consisting at least partly of elastic material that is media- and liquid-proof, respectively, is provided between the tappet and the magnetic core.
BACKGROUND OF THE INVENTION
In the state of the art solenoids of this kind are sufficiently known, for example for operating valves. The range of use of the valves is often very different. They are used, for example, for controlling aggressive media flows (liquid or gas). What is often undesired here is that the aggressive medium (for example soiling in the medium, changed viscosity, the medium to be controlled is chemically incompatible with the material of the magnet, for example it dissolves it) gets in the armature space. Therefore, it is known to fill the armature space with defined liquid, and to provide a boundary element at a suitable point between the armature space and the valve space. In the state of the art a separating membrane is used as boundary element. By filling the armature space with an armature space liquid the pressure of the membrane is compensated, and the possibly considerable pressure stress of the solenoid (this may be, for example with hydraulic application cases, up to 200 bar and more) does not have any influence on the compressive strength of the solenoid.
In the known solutions the essentially disc-like separating membrane is fastened, on the one hand, to the tappet, and radial on the outside at the magnetic core, in particular in the tappet boring. The movement of the tappet, that is, on the one hand, caused by the electro-magnetic effect (the wire windings of the coil, flown through by electricity, generate a magnetic field that moves the armature in the armature space, and this movement is transferred to the tappet, or the restoring movement is carried out, for example, by a pole reversal of the solenoid, or by suitable mechanic elements, for example, a readjusting spring or the like), is here essentially rectangular to the plane, disc-like arrangement of the separating membrane. The stroke of a few tenths of millimeters, millimeters or up to 5-8 millimeters caused by the armature or tappet then has also to be carried out by the separating membrane in a suitable way, leading to a corresponding mechanic stress of the separating membrane. The known separating membranes consist here of elastic material, and it can be seen that the maximum deformation forms in the area of the smallest radius or the smallest cross section in the separating membrane, that means, the separating membrane is considerably stressed in particular in the fastening area at the tappet by a hinge-like movement. Furthermore, it has to be taken into consideration that the tappet movement is derived from the armature movement (the tappet is, for example, connected fixedly with the armature, or mounted floating on it with appropriate readjusting elements), and exchanging the tappet from the interior of the solenoid leads to a volume compensation in the armature space and the tappet boring necessarily connected with the armature space. This relative change of volume has to be compensated accordingly by the boundary element and leads to a compensation movement of the separating membrane. In the known arrangements the armature movement and the compensation movement of the separating membrane is in opposite direction. This leads to a considerably additional mechanic stress of the separating membrane by shearing forces leading to a significant reduction of the life, on the one hand, or to a restriction of the possible stroke, on the other hand.
Referring to this state of the art, it is the object of the present invention to overcome at least one of the before-mentioned disadvantages.
BRIEF DESCRIPTION
In order to solve the problem of the invention, the invention refers to a solenoid as described in the beginning, and suggests that the boundary element comprises a fastening area for a sealing connection of the boundary element with the tappet, a connection area with a sealing connection of the boundary element with the magnetic core, and an intermediate part provided between the fastening area and the connection area, and the intermediate part surrounds at least part of the length of the tappet like a hose or sleeve.
In contrast to the separating membrane of the state of the art that is configured essentially planar as boundary element, now, in the solution according to the invention, a considerably modified configuration of the boundary element is suggested. The high light of the invention is the fact that in the boundary element an intermediate part is provided that surrounds at least part of the length of the tappet like a hose or a sleeve. Cleverly, the entire boundary element is manufactured in one piece from an elastomer, however, without restricting the invention to this. The intermediate part extends essentially parallel to the tappet, and is here accordingly stressed mechanically, when the tappet moves. An essential advantage of the invention is in particular the fact that the relative stress of the boundary element can be influenced by the length of the intermediate part, or the stroke of the solenoid according to the invention can be enlarged by lengthening the intermediate part. In the rather long intermediate part the position change of the tappet (its stroke), that has to be compensated, is distributed to a larger area. This has the consequence that the mechanical stress of the elastomer in the intermediate part is less. This fact can be used, of course, for realizing also solenoids with rather large stroke that can be employed in aggressive media, and wherein the armature space does not have to be impinged with these media.
The compensation movement of the membrane is now not carried out hinge-like and with an appropriate stress of the smallest diameter—that is the fastening area of the boundary element at the tappet—but preferably essentially in the intermediate part where also for this accordingly more elastic material is provided. The result of the suggestion according to the invention is, that the movement portions acting on the boundary element during the movement of the armature and the tappet, respectively, on the one hand, and the compensation movement for the volume, on the other hand, are steady. An elastic deformation occurs in the hose- or sleeve-like intermediate part of the boundary element, wherein during stretching this hose- or sleeve-like intermediate part the diameter of the intermediate part being is reduced, that is the intermediate part is in tighter contact with the tappet. During this movement, a part of the tappet emerges from the tappet boring, the sum of the volumes of the armature space and tappet boring, that can be filled with armature space liquid, would enlarge while the volume of the armature space liquid remains the same, what is compensated by the tighter fit of the intermediate part.
The compensation movement occurring in the modification according to the invention, however, is not contra-directional to the movement of the armature, and does not lead to an additional mechanic stress of the boundary element. The elastic deformation is distributed quite uniform to the hose- or sleeve-like intermediate part of the boundary element. This increases the life considerably as the constructive weaknesses of the solutions of the state of the art are avoided completely, and, at the same time, the solenoid according to the invention reaches faster switching times while the basic conditions remain the same. The resistances to be overcome are in addition clearly smaller. Also the durability of the suggestion according to the invention is improved considerably, the solenoid according to the invention achieves clearly higher switching numbers.
In a preferred embodiment of the invention it is provided that the intermediate part is arranged essentially parallel or coaxially to the tappet. A configuration of this type makes it possible that the material stress in the intermediate part is as low as possible, and no shearing forces and so on occur that are responsible for a clear reduction of life of the solutions of the state of the art. Because of the hose- or sleeve-like configuration of the intermediate part, also the fastening area as well as the connection area are shifted axially—with reference to the longitudinal extension of the tappet or its direction of movement—, and the magnetic core provided for the magnetic guide incorporates in a space-saving way, for example, in the interior the connection area of the boundary element for fastening purposes.
In an advantageous configuration of the suggestion it is provided, that the intermediate part has a length of at least one, preferably at least two, in particular at least three diameters of the tappet boring. It is provided here in the same way, that the intermediate part has a length of at least one, preferably at least two, in particular at least three diameters of the tappet boring or the widening to the tappet boring. It is provided here, that the intermediate part comprises preferably at least five or at least ten, at least 20, at least 30, at least 50 or at least 70 or 80 percent of the thickness of the magnetic core. The thickness of the magnetic core is here defined by the distance of the valve space to the armature space between which the magnetic core is located in the construction. The magnetic core can take over here also a supporting function for the tappet, alternatively, however, the tappet is also guided axially either in the armature itself or in an assembly provided in the valve. The advantage of the different, possible lengths of the intermediate part, surrounding the tappet like a hose or sleeve, is the fact that by means of this the boundary element suggested according to the invention can be adjusted to the respective characteristics of the solenoid. When the solenoid is stressed strongly, for example because of high switching numbers and/or a large stroke, a rather long intermediate part will be chosen in the boundary element.
In a clever way the suggestion achieves that a movement of the tappet stresses, that means loads or guides mechanically, the material of the intermediate part parallel to the direction of the tappet movement. A flexing or hinge movement is avoided by the suggestion, and this contributes decisively to an appropriate increase of the life.
When the hose-like area is lengthened, for example to a multiple (2, 3, 4, 5, 6 or 7 times of the tappet diameter or tappet boring diameter, or a part of more than 20% of the thickness of the magnetic core), also large magnetic strokes, that is large strokes of the tappet, when the stretching percents, in particular of the intermediate part of the boundary element, remain the same, can be realized.
Preferably a homogenous, uniform wall thickness of the intermediate part is used that results in—seen in the direction of the circumference—a behaviour of the boundary element as steady as possible that stresses the support and guide elements of the tappet in a uniform way. At the same time, the homogenous, uniform cross section also contributes to a homogenous, steady stress of the intermediate part.
Preferably, it is provided as an alternative, that the cross section of the intermediate part, seen in longitudinal direction, is homogenous and uniform, wherein this characteristic refers to the either non-switched or switched condition of the solenoid, and does not describe the situation of the compensation movement. In unstressed, not-guided condition of the boundary element a homogenous uniform cross section of the intermediate part is again convenient for a steady stress of the intermediate part and the resulting life span of the entire solenoid suggested according to the invention.
Preferably, the fastening area is designed as ring, bead or ring bead protruding inwards compared with the intermediate part. The connection area, provided for a sealed connection of the boundary element with the magnetic core, is configured as flange or ring flange protruding outward compared with the intermediate part. Because of specific changes of the respective material thickness—in radial as well as in axial direction—it is effected that, on the one hand, the ring bead or ring, on the other hand, the flange or the ring flange, can be defined in a suitable way at the corresponding elements, and because of the resulting “stiffer” configuration, lengthening or stretching of the boundary element during the movement of the tappet is essentially guaranteed by the intermediate part, that is optimized, as described, for this task.
According to the suggestion, a number of different connection modifications is provided for a sealing and mechanically stressed connection, on the one hand, of the connection area with the magnetic core, on the other hand of the connection area with the tappet. Besides strictly mechanically acting connection options, such as for example a press or clamping connection, however, also material connections can be employed such as welding or vulcanizing connections or a gluing connection, where also an additional layer can be provided for the connection. By arranging a fastening collar or fastening groove at the tappet, the fastening point during mounting the boundary element can be defined exactly. At the same time, a fastening collar or a fastening groove also serves as counter bearing, for example in a press or clamping connection.
The same goes for the connection of the connection area in the tappet boring, or a widening provided at the tappet boring on the side opposite the armature space serving for incorporating the intermediate part. Thus, for example, in the tappet boring or the widening a connection collar or a connection groove is provided for fastening the connection area.
Cleverly, the boundary element, provided according to the invention, is manufactured in one piece, and consists each time on the end side of the fastening area and the connection area that hold between each other the sleeve- or hose-like intermediate part. Basically, it is provided in the frame of the invention, that the boundary element has a fastening area and an end area consisting of a separate element, that have between each other the essentially elastic intermediate part. In this case, the boundary element consists at least partly of elastic material. In this respect, it is also provided, according to the invention, that the boundary element consists of several parts that have been manufactured separately and are assembled after that in an appropriate way. Thus, it is basically also possible that the boundary element does not only consist of homogenous identical material, but the boundary element has material qualities that are optimized to the respective field of application, and is therefore heterogeneous in this regard.
Preferably, the boundary element is manufactured of an elastomer or thermoplastic elastomer. These may be, for example, the following materials:
Hydrated acrylonitril-butadiene rubber (HNBR) Acrylonitrile-butadiene rubber (NBR) Silicone rubber (VMQ) Fluorsilicone rubber (FVMQ) Ethylene-propylene-diene rubber (EPDM) Fluor-polymere rubber (FPM, FKM) Polytetrafluor ethylene (PTFE) Thermoplastic elastomers (TPE) Acrylate rubber (ACM) Chloroprene rubber (CR) Ethyleneacrylate rubber (AEM) Perfluorinated rubber (FFKM) Polyester urethane rubber (AU) Styrene-butadiene rubber (SBR) Natural rubber (NR)
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawing the invention is shown schematically, in particular in an embodiment. In the figures:
FIG. 1 a and FIG. 2 a each show in a sectional view different modifications of the solenoid according to the invention
FIG. 1 b and FIG. 2 b each show detailed views of the tappet boring provided in the solenoid.
In the figures identical or corresponding elements each are referred to by the same reference numbers, and therefore are, if not useful, not described anew.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The solenoid according to the invention is shown in the figures schematically in different modifications. The solenoid 1 shown in FIGS. 1 a and 1 b serves in particular for controlling a valve 24 . The solenoid 1 has an armature space 2 in which a mobile supported armature 4 is provided. This armature 4 acts on a tappet 3 connected with the armature 4 fixedly or floating. The armature space 2 is surrounded by a coil 5 that can be electrified and that carries the windings of a wire that can be flown through by electricity. When the solenoid is operated, the coil 5 generates a corresponding magnetic field that causes the movement of the armature 4 and thus of the tappet 3 . According to the generated magnetic field, the armature 4 is shifted axially so that then the operation, that is, in the simplest form, opening or closing of the valve 24 , is carried out. The magnetic core 7 is connected to the armature space 2 , and limits it in the direction of the valve 24 associated with the solenoid 1 . The magnetic core 7 has a tappet boring 15 incorporating the axially movable tappet 3 .
The solenoid 1 shown in respectively preferred embodiments in FIGS. 1 a and 2 a serves for controlling a valve 24 . Such a valve 24 can be used, for example, for controlling aggressive or corrosive media. In order to prevent the media controlled by the valve 24 from penetrating in the solenoid 1 , and thus in particular in the armature space 2 and causing here soiling and corrosion, a boundary element 8 is provided. This boundary element 8 is formed of elastic material, and extends axially to the tappet 3 in the tappet boring 15 . By means of the boundary element 8 a liquid-proof sealing of the armature 2 towards the valve 24 operated by the solenoid 1 can be reached. The boundary element 8 surrounds the part of the tappet 3 that is in direct active connection with the valve 24 in the way of a sleeve or a hose. Because of the elastic quality of the boundary element, this can be stretched or compressed by moving the tappet in the direction 12 of tappet movement, and can guarantee a permanent sealing. FIGS. 1 a and 2 a show the part of the tappet 3 that is in direct active connection with the valve 24 , as well as the boundary element 8 surrounding it. The boundary element 8 surrounds the tappet like a hose or a sleeve. The fastening element 8 has, on the one hand, a fastening area 9 that is in connection with the tappet 3 and that is in tight, liquid-proof contact with the tappet 3 . On the other hand, at the boundary element 8 a connection area 10 is provided that is connected with the magnetic core 7 . Here a liquid-proof connection of boundary element 8 and magnetic core 7 is provided.
A radial projection 25 , forming a shoulder 26 , that is in engagement with the fastening area 9 , is provided at the tappet. The fastening area 9 is formed as bead-like thickening of the boundary element 8 in the example of FIGS. 1 b and 2 b . It extends, compared with the intermediate part 11 of the boundary element radial in the direction towards the tappet 3 . In order to guarantee securing the fastening area 9 , and to prevent the fastening area 9 from being detached from the radial projection 25 , a clamping ring 19 is provided. This is slipped on the tappet 3 after arranging the boundary element 8 in the magnetic core 7 and after or during introducing the tappet 3 in the boundary element 8 , and secures the boundary element or the fastening area 9 against an unintended slipping-off of the tappet 3 .
The radial projection 25 extends axially to the direction of movement of the tappet in the direction of the armature 4 , and forms a encircling fastening collar 18 to which a part of the boundary element 8 is in tight contact. The fastening collar has in its further course a chamfer that runs toward a taper of the diameter of the tappet 3 . The end of the tappet 3 projecting beyond the magnetic core extends into a valve 24 that is connected to the solenoid 1 in the direction 12 of the tappet movement, and operates it. The tappet 3 is guided through the tappet boring 15 in the magnetic core 7 , and is there in connection with the armature 4 (see FIGS. 1 a and 2 a ).
The essential functional parts of the solenoids 1 shown in FIGS. 1 a and 2 a correspond with each other. Both have a cable 17 arranged laterally at the magnet housing that supplies the coil 6 with power. Also the rest of the solenoids, the way of function of which is known, correspond with each other. However, the solenoids 1 shown in FIGS. 1 a and 2 b differ in the way of assembling the boundary element 8 and the magnetic core 7 , respectively. In the embodiment, as shown in FIG. 1 a , first of all a solenoid 1 is provided where the magnetic core 7 has already be set in the position shown in FIG. 1 a . The tappet 3 is also here already in the tappet boring 15 and exceeds the magnetic core or the tappet boring 15 provided in it. In an assembling step, the boundary element 8 is slid on the tappet 3 and put in the magnetic core 7 . To secure the connection collar 21 , that is in contact with the magnetic core 7 , then a cover plate 27 is put on the magnetic core 7 . This cover plate has a sleeve-like extension configured as clamping sleeve 22 that projects in the tappet boring 15 and is in contact with the connection collar 21 . This creates, after connecting the cover plate 27 , a clamping safety device for the boundary element 8 in the tappet boring 15 or at the magnetic core 7 . The boundary element 8 or its center part 11 extends at the section of the tappet 3 exceeding the tappet boring 15 along parallel to it, and ends in the bead-like designed ring 13 that is in engagement with the fastening collar 18 or the radial projection 25 , and prevents the boundary element 8 from slipping off the tappet. An additional safety is created by the clamping ring 19 that is also slid on the tappet 3 , and defines the ring 13 at the tappet 3 or presses or jams it together with this.
In contrast to that, assembling of the solenoid 1 shown in FIG. 2 a is carried out in such a way that an assembly comprising the tappet 3 with joined boundary element 8 is provided. This is put in the magnetic core 7 through the tappet boring 15 , and, after that, secured with the clamping disc 23 . In the magnetic core 7 a connection collar 21 is provided for this purpose on which the flange 14 , arranged at the boundary element 8 and forming also its connection area 10 , is supported. An additional safety is reached here by putting-on the clamping disc 23 . This prevents the connection area 10 from slipping off the connection collar 21 . At the tappet 3 itself the intermediate part 11 of the boundary element 8 extends co-axially to it along the tappet 3 , and grips over the fastening collar 18 provided at the tappet 3 that is also configured with a radial projection 25 and a shoulder 26 with which the ring 13 or the fastening area 9 of the boundary element 8 is in engagement. On the side of the tappet the boundary element 8 is secured by a clamping ring 19 , already described in connection with FIG. 1 b . In this example, a clamping sleeve 22 , as shown in connection with FIG. 1 b , is not provided and not necessary in order to carry out a securing of the boundary element 8 . Mounting the boundary element 8 is done here in direction of arrow B, while in the example of FIG. 1 mounting is done in direction of arrow A.
FIGS. 1 b and 2 b show detailed views of the boundary element 8 that has been put in the tappet boring 15 . The boundary element 8 is in both shown embodiments connected with the tappet 3 via a clamping connection. A clamping connection is also provided between the magnetic core 7 and the connection area 10 of the boundary element 8 .
The boundary element 8 shows an intermediate part 11 besides the connection area 10 , that is in engagement with the magnetic core 7 , and besides the fastening area 9 that is in contact or in engagement with the tappet 3 . The intermediate part 11 is arranged essentially parallel or coaxially to the tappet 3 . In order to provide a sufficient sealing function and to create sufficient space for stretching the intermediate part 11 or for a sufficient enlargement of the area of the tappet boring 15 that can be flown through by fluid, the intermediate part 11 has a length corresponding with three tappet diameters. When the tappet 3 moves in the direction 12 of the tappet movement, the boundary element 8 manufactured from elastic material is stretched. Simultaneously, the diameter is radial reduced by lengthening the boundary element 8 . Thus the boundary element 8 or its center part 11 moves in the direction of the tappet 3 . Because of the design of the boundary element 8 as sleeve or hose or hose section, the reduction of diameter is uniform. Thus the wall thickness is reduced uniformly over the entire intermediate part 11 when the boundary element 8 is stretched. At the same time the radial diameter reduction of the boundary element 8 enlarges the space provided for the medium flowing in the tappet boring 15 .
When the tappet 3 moves in reverse direction, the boundary element 8 is shortened and the tappet 3 recedes, that means the diameter of the boundary element 8 is radial enlarged. This additionally presses the fluid penetrated in the tappet boring 15 out of it.
The boundary element 8 has in the embodiment a bead- or ring-shaped fastening area 9 . This projects, compared with the center part 11 , radial inwards, that means it extends radial in the direction of the tappet 3 . The connection area 10 of the boundary element 8 is at the end of the intermediate part 11 opposite the fastening area 9 , and is configured as flange 14 protruding radial outwards, compared with the intermediate part 11 . The flange 14 is here annularly arranged around the intermediate part 11 , and has a shaping corresponding with the connection collar 21 , so that here the connection collar 21 reaches partially behind the flange 14 . In order to put in the boundary element 8 , it is slid from below, that is in arrow direction A (see FIG. 1 a ), in the magnetic core 7 .
In contrast to this, in the embodiment shown in FIG. 2 b , the assembly consisting of tappet 3 with boundary element 8 arranged at it, is slid in from the side of the armature in the direction of arrow B (see FIG. 2 a ) in the magnetic core 7 , and, after that, secured with the clamping disc 23 . The embodiment shown in FIG. 2 b has the advantage that here the assembly, consisting of armature 4 , tappet 3 and boundary element 8 , can be provided as one assembly that only has to be inserted in the magnetic core 7 or the assembly comprising the magnetic core 7 .
In order to secure in the embodiment shown in FIG. 1 a the boundary element 8 and a fluid-proof arrangement of the boundary element 8 in the tappet boring 15 or in the magnetic armature 7 , here an additional cover plate 27 is provided comprising a clamping sleeve 22 that is brought into engagement with the connection area 10 of the boundary element 8 , and secures the boundary element 8 in the tappet boring 15 or in the magnetic core 7 against unintended falling out. At the same time, this ensures the fluid-proof sealing. The cover plate 27 is additionally secured in the magnetic core 7 , for example by a clamping, catching, screw or other appropriate connection.
In the example, the boundary element 8 is made of an elastomer and dimensioned in such a way that a high number of switching operations can be carried out without symptoms of fatigue or embrittlement occurring at the boundary element 8 . The elastomer material is also resistant against aggressive or corrosive media that are controlled with the valve 24 joining the solenoid 1 .
Besides the options of arranging the boundary element 8 or the grip of fastening area 9 across a fastening collar provided at the tappet 3 shown in FIGS. 1 b and 2 b there is also the option of providing a groove here in which the widened ring of the fastening area 9 engages. Furthermore, all other ways of fastening known to a person skilled in the art can be realized in the same way here.
In FIGS. 1 a and 2 a , as well as in FIGS. 1 b and 2 b , the solenoid 1 is shown in the basic position, that means that the boundary element 8 is not stretched or lengthened. If the solenoid 1 is electrified, the armature 4 shifts in the armature space 2 . Thus the tappet 3 is introduced further in the tappet boring 15 and projects over the magnet housing more than shown in the figures. Because of the fact that the boundary element 8 is defined in the magnetic core 7 , this is stretched or lengthened. Thus, a stress of the boundary element 8 occurs in longitudinal direction. However, there is no stress in a direction that is vertical or essentially vertical to it, so that there is no double impingement of the elastomer material here. This contributes to a long life of the boundary element 8 , and thus to an increased operation period of the entire solenoid 1 . Additionally, assembling the solenoid becomes easier as the boundary element 8 is provided as molded part that can be introduced or inserted in a simple way in the tappet boring 15 .
Although this invention has been shown and described with respect to the detailed embodiments thereof, it will be understood by those skilled in the art that the detailed embodiments are merely exemplary illustrations of the inventive concept, and that various changes in form and detail thereof may be made without departing from the spirit and the scope of the invention. | A solenoid, in particular for media-controlling valves, includes in an armature space an armature movably acting on a tappet, and a coil carrying windings of a conductor. The magnetic core delimiting the armature space has a tappet boring that incorporates the axially moving tappet, and a boundary element, that consists of at least partly elastic material and is media- and liquid-proof, is provided between the tappet and the magnetic core. The boundary element includes a fastening area for a sealing connection of the boundary element with the tappet, a connection area for a sealing connection of the boundary element with the magnetic core, and an intermediate part provided between the fastening area and the connection area. The intermediate part surrounds at least part of the length of the tappet like a hose or sleeve. | 5 |
BACKGROUND
[0001] Optical character recognition (OCR) is a computer-based translation of an image of text into digital form as machine-editable text, generally in a standard encoding scheme. This process eliminates the need to manually type the document into the computer system. A number of different problems can arise due to poor image quality, imperfections caused by the scanning process, and the like. For example, a conventional OCR engine may be coupled to a flatbed scanner which scans a page of text. Because the page is placed flush against a scanning face of the scanner, an image generated by the scanner typically exhibits even contrast and illumination, reduced skew and distortion, and high resolution. Thus, the OCR engine can easily translate the text in the image into the machine-editable text. However, when the image is of a lesser quality with regard to contrast, illumination, skew, etc., performance of the OCR engine may be degraded and the processing time may be increased due to processing of all pixels in the image. This may be the case, for instance, when the image is obtained from a book or when it is generated by an imager-based scanner, because in these cases the text/picture is scanned from a distance, from varying orientations, and in varying illumination. Even if the performance of scanning process is good, the performance of the OCR engine may be degraded when a relatively low quality page of text is being scanned.
SUMMARY
[0002] Optical character recognition requires the identification of the text lines in the textual image in order to identify individual words and characters. The text lines can be characterized by their base-line, mean-line and x-height. Determining these features may be become difficult when the text lines are not perfectly horizontal, which may arise when scanning some classes of documents (for example a thick book) in which the image suffers from non-linear distortions. In such a case, the base-line and mean-line may not be constant over an entire text line.
[0003] To overcome these problems, in one implementation the base-line for at least one text line in the image is determined by finding a parametric curve that maximizes a first fitness function that depends on the values of pixels through which the parametric curve passes and pixels below the parametric curve. The base-line corresponds to the parametric curve for which the first fitness function is maximized. The first fitness function is designed so that it increases with increasing lightless or brightness of pixels immediately below the parametric curve while also increasing with decreasing lightness of pixels through which the parametric curve passes.
[0004] In some implementations the mean-line can be determined by incrementally shifting the base-line upward by predetermined amounts (e.g., a single pixel) until a second fitness function for the shifted base-line is maximized. The second fitness function is essentially the inverse of the first fitness function. Specifically, the second fitness function increases with increasing lightless of pixels immediately above the shifted base-line while also increasing with decreasing lightness of pixels through which the shifted base-line passes.
[0005] In some implementations the x-height can be determined from the base-line and the mean-line which have already been calculated. In particular, the x-height is equal to the predetermined amount by which the base-line is shifted upward in order to maximize the second fitness function.
[0006] This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 shows one illustrative example of a system 5 for optical character recognition (OCR) in an image.
[0008] FIG. 2 shows an example of a text-line in a scanned image which is not perfectly horizontal.
[0009] FIG. 3 illustrates the base-line for the text-line of a single word in a scanned image.
[0010] FIG. 4 is a flowchart illustrating a process of determining the x-height for different groups of text lines.
[0011] FIG. 5 shows one example of an image processing apparatus that may perform the process of extracting information concerning the text-lines in a textual image.
DETAILED DESCRIPTION
[0012] FIG. 1 shows one illustrative example of a system 5 for optical character recognition (OCR) in an image which includes a data capture arrangement (e.g., a scanner 10 ) that generates an image of a document 15 . The scanner 10 may be an imager-based scanner which utilizes a charge-coupled device as an image sensor to generate the image. The scanner 10 processes the image to generate input data, and transmits the input data to a processing arrangement (e.g., an OCR engine 20 ) for character recognition within the image. In this particular example the OCR engine 20 is incorporated into the scanner 10 . In other examples, however, the OCR engine 20 may be a separate unit such as stand-alone unit or a unit that is incorporated into another device such as a PC, server, or the like.
[0013] The OCR engine 20 receives a textual image as a bitmap of text lines. Three parameters of those text lines that need to be determined are the “base-line,” “mean-line,” and the “x-height.” The “base-line” is defined as a horizontal line passing through the bottom ends of a majority of the characters in a line of text (excluding descenders). Second, the “mean-line” is defined as a horizontal line which passes through the top ends of a majority of the characters in a line of text (excluding ascenders). Third, the “x-height” is defined as the vertical distance between the base-line and the mean-line, which corresponds to the height of a majority of lowercase letters in the line (excluding non-descenders and non-ascenders).
[0014] Knowing the precise base-line and x-height is important for a number of reasons, particularly in differentiating between capital and lowercase letters of the same shape. If a text-line is perfectly horizontal and contains only one font style and size, base-line and x-height will hold a constant value over the entire line. Computing these values for a perfectly horizontal text-line is not a difficult task. However, when scanning some classes of documents (for example a thick book), the document image can suffer from non-linear distortions. In such a case, the base-line coordinate is not going to be constant over an entire text line.
[0015] An example of a text line containing this artifact is shown in the FIG. 2 . It can be seen that the text has a “wavy” appearance, which is caused by the decrease in the average letter position from the line's middle towards the left or right. Artifacts of this nature make it more difficult to determine the base-line.
[0016] Extracting x-height information from a textual image can also be problematic. For instance, sometimes a majority of a text line (or even an entire text line) is composed of capital letters or numbers. In such a case, extracting the x-height using the line's bitmap as a unique information source is not reliable. FIG. 2 also shows the base-line, mean-line and x-height.
[0017] As detailed below, a method is provided to compute the base-line of a deformed text-line in the form of a parametric curve. Moreover, the most probable x-height value of a given line is estimated using context information obtained from the entire image.
[0018] Base-Line Computation
[0019] At the outset, two observations can be made from the base-line's definition:
Due to the nature of most fonts, the base-line will overlap with a significant amount of dark pixels originating from letter bottoms. Immediately below the base-line there are no dark pixels (except for descending letter parts).
Regardless of whether or not the base-line is strictly horizontal or (in case of non-linear deformations) “wavy,” it should be possible to establish a simple fitness function based on at least two properties obtained from these observations.
Property 1: As the pixels immediately below the baseline become lighter (i.e., brighter), the value of the fitness function will increase (and vice versa). Property 2: As the pixels overlapping with the baseline become darker, the value of the fitness function will increase (and vice versa).
[0024] The goal of finding the base-line in a given text-line bitmap translates to the problem of finding a (curved) line with a maximal fitness function value.
[0025] A rasterized base-line can be implemented as an array: for each x-coordinate of an input bitmap, there should be one and only y-coordinate describing the local baseline value. Keeping this in mind, a simple proposal for the fitness function is:
[0000]
fitness
(
baseline
)
=
∑
x
=
0
width
-
1
img
[
baseline
[
x
]
+
1
,
x
]
-
∑
x
=
0
width
-
1
img
[
baseline
[
x
]
,
x
]
Where:
[0000]
x and y are horizontal and vertical pixel coordinates respectively (with the origin is at top-left corner)
img[y, x] is the input bitmap's pixel value at location (y, x)
width is the input bitmap's width
baseline [x] is a y-coordinate of the base-line at position x
[0030] It can be observed that the formula for the fitness function satisfies both Property 1 and Property 2. Since the pixel colors in a typical gray-scale image vary from black (value: 0) to white (value: 255), the following will hold true:
As the pixels immediately below the baseline become lighter, the first addend in the formula will become larger. As the pixels on the baseline become darker, the second addend in the formula will become larger.
[0033] A simple diagram of text illustrating this idea is presented in FIG. 3 . It can be observed from FIG. 3 that the base-line overlaps with a relatively large number of dark pixels, while pixels immediately below the base-line are completely white.
[0034] After defining the criteria that the baseline should fulfill, another question that arises is how “fast” the baseline should change across the text-line width when maximizing the fitness function. Clearly, this rate of change should be sufficient to track the line's “waviness”.
[0035] On the other hand, the rate of change should not be too fast, because it is not desirable for the bottoms of descending characters to affect the base-line shape. One way to address this issue is to define a base-line candidate through a small set of control parameters, and limiting the range of values each parameter can take. In this way the shape of the base-line candidate can be changed by changing its control parameters.
[0036] A curve maximizing the fitness function can be parameterized by defining it through a set of control points connected with straight line segments. The curve's shape can be varied by moving its control points. One way to control the movement of the control point in a manner that achieves good performance results is to only allow the control point to have freedom of movement in the vertical direction. This approach has shown that a set of 4-6 equidistant control points does a good job in modeling a common “wavy” baseline.
[0037] A second way of parameterizing the curve for the base-line is by defining it as a B-spline. Changing its shape can be done by varying the spline coefficients.
[0038] In general, finding the exact shape that maximizes some fitness function can be thought of as a classical optimization problem which can be solved using well-known techniques. Depending on the nature and number of parameters used to describe the base-line curve, a genetic search, dynamic programming, or some other technique can be used.
[0039] If a genetic search is performed, an initial population can be a set of curves with parameters randomly set within some reasonable range. New offspring can be formed by taking two high-fitness curves and mixing their parameters into a new curve. Mutation can be done by slightly varying curve parameters.
[0040] The curve parameters can be optimized by dynamic programming as well. The solution requires finding an optimal path starting at the text-line's left side and moving towards its right side, while obeying the spatial constraints imposed by the common curve shape.
X-Height Computation
[0041] The mean-line (a line determining where non-ascending lowercase letters terminate) can be computed in a way quite similar to the base-line computation procedure described above. Actually, it is enough to invert the fitness function described above and re-run the algorithm. That is, the fitness function for the mean-line should satisfy the following two properties:
Property 1: As the pixels immediately above the baseline become lighter, the value of the fitness function will increase (and vice versa). Property 2: As the pixels overlapping with the baseline become darker, the value of the fitness function will increase (and vice versa).
[0044] Once the mean-line is determined, the x-height can then be extracted by simply subtracting the corresponding mean-line and base-line coordinates. However, this process introduces an additional computational load, effectively doubling the entire feature extraction execution time.
[0045] In practice, non-linear deformations of the type discussed herein have no influence on individual letter dimensions. In other words, the x-height does not change across the “wavy” text-line, provided that the line contains letters of the same font style and size. This conclusion facilitates the process of computing the x-height since it directly implies that the curves for the mean-line and the base-line will have exactly the same shape. Accordingly, the mean-line can be computed in the following way: the curve for the base-line is shifted pixel by pixel towards the text-line's top, and the inverted fitness function is computed each time the curve is shifted upward. The shifted curve that results when the fitness function reaches its maximum value will be the mean-line. The number of pixels by which the base-line curve is shifted upward to obtain the mean-line is equal to the x-height.
[0046] Sometimes an input bitmap of an individual text-line cannot be used as the only source of information to obtain a single value for x-height over an entire image. For example, some text lines may be short lines composed of numbers only. Another example is a caption that is in all capital letters. Because of such cases, the x-height computation may sometimes be performed in a somewhat more sophisticated manner.
[0047] In this implementation, before computing the x-height, it is determined whether the text-lines in the images should be divided into different groups that are each likely to contain text-lines with different x-heights. Such text-line groups may be determined in a variety of different ways. For instance, text-lines may be grouped according to their dominant letter stroke width. This approach essentially assumes that different x-heights arise from the use of different fonts and font sizes and that each such font and font size is characterized by a different dominant stroke width. Thus, groups of text lines with a common dominant stroke width likely have a common x-height.
[0048] The dominant stroke width may be determined at this stage of the OCR process or it may have been determined in an earlier stage of processing which precedes the text line analysis described herein. One example of a method for determining stroke width is shown in U.S. patent application Ser. No. ______ [Docket No. 328299.01], which is hereby incorporated by reference in its entirety.
[0049] In one alternative, instead of grouping text lines by their dominant stroke width, individual words can be divided into their own groups.
[0050] To determine the x-height of a particular group, begin by defining a mean-line candidate [j] as a base-line's curve shifted by j pixels up. Next, for each group, a common buffer is established. For each text-line in a group, an inverted fitness function of the mean-line candidate [j] is added to the buffer. At the end of the process, the buffer's element j will contain a sum of inverted fitness functions for all the mean-line candidates [j] within the particular group. The most-probable x-height value for the particular group corresponds to the value of j for which the buffer has its maximum value.
[0051] A flowchart illustrating the process of determining the x-height for different groups of text lines is shown in FIG. 4 . The process begins in step 105 when the text-lines in an image are divided into groups by any appropriate criterion such as font size, dominant stroke width, or the like. For each group, the process continues from step 110 to step 115 in which an accumulation buffer is established and initialized to a value of zero. Next, for each text line within the group the process proceeds from step 120 to step 125 in which j is initialized to zero and the mean-line candidate is initialized to the base-line. The value of j is incremented by 1 in step 135 , which corresponds to shifting the base-line curve upwards by one pixel. The fitness function for this mean-line (which corresponds to the inverse fitness function of the base-line) is calculated in step 140 . Also in step 140 , the accumulation buffer is defined as the sum of its previous value and the value of the fitness function that has just been calculated. Decision step 145 then determines if the maximum value of the accumulation buffer has been reached. If so, then in step 150 the current value of j corresponding to this maximum value is determined to be the x-height for this group. Alternatively, if the maximum value of the accumulation buffer has not been reached, the process proceeds from decision step 145 back to step 130 in which the current mean-line is shifted upward by 1 pixel. This process continues until the maximum value of the accumulation buffer has been reached. Once the x-height value has been determined for this group the process returns to step 120 and repeats for any remaining groups of text lines, finally ending at step 155 .
[0052] FIG. 5 shows one example of an image processing apparatus 300 that may perform the process of extracting information concerning the text-lines in a textual image. The apparatus, which may be incorporated in an OCR engine, can be used by the OCR engine to determine the base-line, mean-line and x-height of the text lines in the image. The apparatus includes an input component 302 for receiving an input image and a parameterizing engine 310 for finding parametric curves that correspond to the base-line and the mean-line of the text lines in the image. The parameterizing engine 310 includes a base-line determination component 322 , a mean-line determination component 324 and an x-height determination component 324 . The apparatus 300 also includes an output component 330 that generates the information concerning the text-lines in a form that allows it to be employed by subsequent components of the OCR engine.
[0053] As used in this application, the terms “component,” “module,” “engine,” “system,” “apparatus,” “interface,” or the like are generally intended to refer to a computer-related entity, either hardware, a combination of hardware and software, software, or software in execution. For example, a component may be, but is not limited to being, a process running on a processor, a processor, an object, an executable, a thread of execution, a program, and/or a computer. By way of illustration, both an application running on a controller and the controller can be a component. One or more components may reside within a process and/or thread of execution and a component may be localized on one computer and/or distributed between two or more computers.
[0054] Furthermore, the claimed subject matter may be implemented as a method, apparatus, or article of manufacture using standard programming and/or engineering techniques to produce software, firmware, hardware, or any combination thereof to control a computer to implement the disclosed subject matter. The term “article of manufacture” as used herein is intended to encompass a computer program accessible from any computer-readable device, carrier, or media. For example, computer readable media can include but are not limited to magnetic storage devices (e.g., hard disk, floppy disk, magnetic strips . . . ), optical disks (e.g., compact disk (CD), digital versatile disk (DVD) . . . ), smart cards, and flash memory devices (e.g., card, stick, key drive . . . ). Of course, those skilled in the art will recognize many modifications may be made to this configuration without departing from the scope or spirit of the claimed subject matter.
[0000] Although the subject matter has been described in language specific to structural features and/or methodological acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described above. Rather, the specific features and acts described above are disclosed as example forms of implementing the claims. | An optical character recognition process characterizes text lines in a textual image by their base-line, mean-line and x-height. The base-line for at least one text line in the image is determined by finding a parametric curve that maximizes a first fitness function that depends on the values of pixels through which the parametric curve passes and pixels below the parametric curve. The base-line corresponds to the parametric curve for which the first fitness function is maximized. The first fitness function is designed so that it increases with increasing lightless or brightness of pixels immediately below the parametric curve while also increasing with decreasing lightness of pixels through which the parametric curve passes. The mean-line is determined by incrementally shifting the base-line upward by predetermined amounts (e.g., a single pixel) until a second fitness function for the shifted base-line is maximized. The second fitness function is essentially the inverse of the first fitness function. Specifically, the second fitness function increases with increasing lightless of pixels immediately above the shifted base-line while also increasing with decreasing lightness of pixels through which the shifted base-line passes. The x-height is equal to the sum of the predetermined amounts by which the base-line is shifted upward in order to maximize the second fitness function. In some cases different groups of text-lines in the textual image may be characterized differently from one another. For example, each group may be characterized by a most probable x-height for that group. | 6 |
CROSS-REFERENCED APPLICATIONS
[0001] This application is related to commonly owned, concurrently filed application Ser. No. 12/835,603 entitled “AUTOMATIC OPTIMAL INTEGRATED CIRCUIT GENERATOR FROM ALGORITHMS AND SPECIFICATION”, application Ser. No. 12/835,621 entitled “AUTOMATIC OPTIMAL INTEGRATED CIRCUIT GENERATOR FROM ALGORITHMS AND SPECIFICATION”, application Ser. No. 12/835,628 entitled “APPLICATION DRIVEN POWER GATING”, application Ser. No. 12/835,631 entitled “SYSTEM, ARCHITECTURE AND MICRO-ARCHITECTURE (SAMA) REPRESENTATION OF AN INTEGRATED CIRCUIT”, and application Ser. No. 12/835,640 entitled “ARCHITECTURAL LEVEL POWER-AWARE OPTIMIZATION AND RISK MITIGATION”, the contents of which are incorporated by reference.
BACKGROUND
[0002] The present invention relates to a method for designing a custom integrated circuit or an application-specific integrated circuit (ASIC).
[0003] Modern electronic appliances and industrial products rely on electronic devices such as standard and custom integrated circuits (ICs). An IC designed and manufactured for specific purposes is called an ASIC. The number of functions, which translates to transistors, included in each of those ICs has been rapidly growing year after year due to advances in semiconductor technology. Reflecting such trends, methods of designing ICs have been changing. In the past, an IC used to be designed as a mere combination of a number of general-purpose ICs. Recently, however, the designer needs to create his or her original IC such that the IC can perform any function as required. In general, unit costs and sizes are decreasing while design functionality is increasing.
[0004] Normally the chip design process begins when algorithm designers specify all the functionality that the chip must perform. This is usually done in a language like C or Matlab. Then it takes a team of chip specialists, tools engineers, verification engineers and firmware engineers many man-years to map the algorithm to a hardware chip and associated firmware. This is a very expensive process and also fraught with lot of risks.
[0005] Today's designs are increasingly complex, requiring superior functionality combined with constant reductions in size, cost and power. Power consumption, signal interactions, advancing complexity, and worsening parasitics all contribute to more complicated chip design methodology. Design trends point to even higher levels of integration, with transistor counts exceeding millions of transistors for digital designs. With current technology, advanced simulation tools and the ability to reuse data are falling behind such complex designs.
[0006] Developing cutting-edge custom IC designs has introduced several issues that need to be resolved. Higher processing speeds have introduced conditions into the analog domain that were formerly purely digital in nature, such as multiple clock regions, increasingly complex clock multiplication and synchronization techniques, noise control, and high-speed I/O. Impediments occur in the design and verification cycle because design complexity continues to increase while designers have less time to bring their products to market, resulting in reduced amortization for design costs. Another effect of increased design complexity is the additional number of production turns that may be needed to achieve a successful design. Yet another issue is the availability of skilled workers. The rapid growth in ASIC circuit design has coincided with a shortage of skilled IC engineers.
SUMMARY
[0007] In one aspect, a method to automatically design a custom integrated circuit based on algorithmic process or code as input and using highly automated tools that requires virtually no human involvement is disclosed.
[0008] The method includes receiving a specification of the custom integrated circuit including computer readable code and one or more constraints on the custom integrated circuit; automatically generating a computer architecture for the computer readable code that best fits the constraints; automatically determining an instruction execution sequence based on the code profile and reassigning or delaying the instruction sequence to spread operation over one or more processing blocks to reduce hot spots; continuously evaluating and optimizing one or more factors including physical implementation, and local and global area, timing, or power at an architecture level above RTL or gate-level synthesis; automatically generating a software development kit (SDK) and the associated firmware automatically to execute the computer readable code on the custom integrated circuit; automatically generating associated test suites and vectors for the computer readable code on the custom integrated circuit; and automatically synthesizing the designed architecture and generating a computer readable description of the custom integrated circuit for semiconductor fabrication.
[0009] In another aspect, a method to automatically design a custom integrated circuit with minimal human involvement includes receiving a specification of the custom integrated circuit including computer readable code and one or more constraints on the custom integrated circuit; automatically devising a processor architecture and generating a processor chip specification uniquely customized to the computer readable code which satisfies the constraints; and synthesizing the chip specification into a layout of the custom integrated circuit. This aspect is also performed using highly automated tools that require virtually no human involvement.
[0010] Implementations of the above aspects may include one or more of the following. The system includes performing static profiling of the computer readable code and/or dynamic profiling of the computer readable code. A system chip specification is designed based on the profiles of the computer readable code. The chip specification can be further optimized incrementally based on static and dynamic profiling of the computer readable code. The computer readable code can be compiled into optimal assembly code, which is linked to generate firmware for the selected architecture. A simulator can perform cycle accurate simulation of the firmware. The system can perform dynamic profiling of the firmware. The method includes optimizing the chip specification further based on profiled firmware or based on the assembly code. The system can automatically generate register transfer level (RTL) code for the designed chip specification. The system can also perform synthesis of the RTL code to fabricate silicon.
[0011] Advantages of the preferred embodiments of the system may include one or more of the following. The system alleviates the problems of chip design and makes it a simple process. The embodiments shift the focus of product development process back from the hardware implementation process back to product specification and computer readable code or algorithm design. Instead of being tied down to specific hardware choices, the computer readable code or algorithm can be implemented on a processor that is optimized specifically for that application. The preferred embodiment generates an optimized processor automatically along with all the associated software tools and firmware applications. This process can be done in a matter of days instead of years as is conventional. The system is a complete shift in paradigm in the way hardware chip solutions are designed.
[0012] The instant system removes the risk and makes chip design an automatic process so that the algorithm designers themselves can directly make the hardware chip without any chip design knowledge. The primary input to the system would be the computer readable code or algorithm specification in higher-level languages like C or Matlab.
[0013] Of the many benefits, the benefits of using the system may include
1) Schedule: If chip design cycles become measured in weeks instead of years, the companies using The instant system can penetrate rapidly changing markets by bringing their products quickly to the market. 2) Cost: The numerous engineers that are usually needed to be employed to implement chips are made redundant. This brings about tremendous cost savings to the companies using The instant system. 3) Optimality : The chips designed using The instant system product have superior performance, Area and Power consumption.
[0017] The instant system is a complete shift in paradigm in methodology used in design of systems that have a digital chip component to it. The system is a completely automated software product that generates digital hardware from algorithms described in C/Matlab. The system uses a unique approach to the process of taking a high level language such as C or Matlab to realizable hardware chip. In a nutshell, it makes chip design a completely automated software process.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 shows an exemplary system to automatically generate a custom IC.
[0019] FIG. 2 shows an exemplary workflow to automatically generate a custom IC.
[0020] FIG. 3 shows an exemplary process to automatically generate a custom IC.
[0021] FIG. 4 shows an exemplary C code profile.
[0022] FIG. 5 shows a base level chip specification.
[0023] FIG. 6 shows a first architecture from the chip specification of FIG. 5 .
[0024] FIG. 7 shows a second architecture from chip specification of FIG. 5 .
DESCRIPTION
[0025] FIG. 1 shows an exemplary system to automatically generate a custom IC. The system of FIG. 1 supports an automatic generation of the optimal custom integrated circuit solution for the chosen target application. The target application specification is usually done through algorithm expressed as computer readable code in a high-level language like C, Matlab, SystemC, Fortran, Ada, or any other language. The specification includes the description of the target application and also one or more constraints such as the desired cost, area, power, speed, performance and other attributes of the hardware solution.
[0026] In FIG. 1 , an IC customer generates a product specification 102 . Typically there is an initial product specification that captures all the main functionality of a desired product. From the product, algorithm experts identify the computer readable code or algorithms that are needed for the product. Some of these algorithms might be available as IP from third parties or from standard development committees. Some of them have to be developed as part of the product development. In this manner, the product specification 102 is further detailed in a computer readable code or algorithm 104 that can be expressed as a program such as C program or a math model such as a Matlab model, among others. The product specification 102 also contains requirements 106 such as cost, area, power, process type, library, and memory type, among others.
[0027] The computer readable code or algorithm 104 and requirement 106 are provided to an automated IC generator 110 . Based only on the code or algorithm 104 and the constraints placed on the chip design, the IC generator 110 uses the process of FIG. 2 to automatically generate with no human involvement an output that includes a GDS file 112 , firmware 114 to run the IC, a software development kit (SDK) 116 , and/or a test suite 118 . The GDS file 112 is used to fabricate a custom chip 120 . The firmware 114 is then run on this fabricated chip to implement the customer product specification 102
[0028] The instant system alleviates the issues of chip design and makes it a simple process. The system shifts the focus of product development process back from the hardware implementation process back to product specification and algorithm design. Instead of being tied down to specific hardware choices, the algorithm can always be implemented on a digital chip processor that is optimized specifically for that application. The system generates this optimized processor automatically along with all the associated software tools and firmware applications. This whole process can be done in a matter of days instead of years that it takes now. In a nutshell the system makes the digital chip design portion of the product development in to a black box.
[0029] In one embodiment, the instant system product can take as input the following:
[0030] Computer readable code or algorithm defined in C/Matlab
[0031] Peripherals required
[0032] IO Specification
[0033] Area Target
[0034] Power Target
[0035] Margin Target (how much overhead to build in for future firmware updates and increases in complexity)
[0036] Process Choice
[0037] Standard Cell library Choice
[0038] Memory compiler Choice
[0039] Testability (scan, tap controller, bist etc)
[0040] The output of the system may be a Digital Hard macro along with all the associated firmware. A software development kit (SDK) optimized for this Digital Hard macro is also automatically generated so that future upgrades to firmware are implemented without having to change the processor.
[0041] FIG. 2 shows an exemplary workflow to automatically generate a custom IC. This system performs automatic generation of the complete and optimal hardware solution for any chosen target application. While the common target applications are in the embedded applications space they are not necessarily restricted to that.
[0042] Referring to FIG. 2 , an ASIC customer generates a product specification 202 . The product specification 202 is further detailed in a computer readable code or algorithm 204 that can be expressed as a program such as C program or a math model such as a Matlab model, among others. The product specification 202 also contains product parameters and requirements 206 such as cost, area, power, process type, library, and memory type, among others. The computer readable code or algorithm 204 and product parameters 206 are provided to an automated IC generator 110 including an Automatic Optimal Instruction Set Architecture Generator (AOISAG) ( 210 ). The generator 210 controls an Automatic Optimal RTL Generator (AORTLG) 242 , which drives an Automatic Optimal Chip Generator (AOCHIPG) 244 . The output of AOCHIPG 244 and AORTLG 242 is provided in a feedback loop to the AOISAG 210 . The AOISAG 210 also controls an Automatic Optimal Firmware Tools Generator (AOFTG) 246 whose output is provided to an Automatic Optimal Firmware Generator (AOFG) 248 . The AOFG 248 output is also provided in a feedback loop to the AOISAG.
[0043] The IC generator 110 generates as output a GDS file 212 , firmware 214 to run the IC, a software development kit (SDK) 216 . The GDS file 212 and firmware 214 are provided to an IC fabricator 230 such as TSMC or UMC to fabricate a custom chip 220 .
[0044] In one embodiment, the system is completely automated. No manual intervention or guidance is needed. The system is optimized. The tool will automatically generate the optimal solution. In other embodiments, the user can intervene to provide human guidance if needed.
[0045] The AOISAG 210 can automatically generate an optimal instruction set architecture (called ISA). The ISA is defined to be every single detail that is required to realize the programmable hardware solution and encompasses the entire digital chip specification. The details can include one or more of the following exemplary factors:
[0046] 1) Instruction set functionality, encoding and compression
[0047] 2) Co-processor/multi-processor architecture
[0048] 3) Scalarity
[0049] 4) Register file size and width. Access latency and ports
[0050] 5) Fixed point sizes
[0051] 6) Static and dynamic branch prediction
[0052] 7) Control registers
[0053] 8) Stack operations
[0054] 9) Loops
[0055] 10) Circular buffers
[0056] 11) Data addressing
[0057] 12) Pipeline depth and functionality
[0058] 13) Circular buffers
[0059] 14) Peripherals
[0060] 15) Memory access/latency/width/ports
[0061] 16) Scan/tap controller
[0062] 17) Specialized accelerator modules
[0063] 18) Clock specifications
[0064] 19) Data Memory and Cache system
[0065] 20) Data pre-fetch Mechanism
[0066] 21) Program memory and cache system
[0067] 22) Program pre-fetch mechanism
[0068] The AORTLG 242 is the Automatic Optimal RTL Generator providing an automatic generation of the hardware solution in Register Transfer Language (RTL) from the optimal ISA. The AORTLG 242 is completely automated. No manual intervention or guidance is needed. The tool will automatically generate the optimal solution. The RTL generated is synthesizable and compilable.
[0069] The AOCHIPG 244 is the Automatic Optimal Chip Generator that provides automatic generation of the GDSII hardware solution from the optimal RTL. The tool 244 is completely automated. No manual intervention or guidance is needed. The tool will automatically generate the optimal solution. The chip generated is completely functional and can be manufactured using standard FABs without modification.
[0070] The AOFTG 246 is the Automatic Optimal Firmware Tools Generator for an automatic generation of software tools needed to develop firmware code on the hardware solution. It is completely automated. No manual intervention or guidance is needed. The tool will automatically generate the optimal solution. Standard tools such as compiler, assembler, linker, functional simulator, cycle accurate simulator can be automatically generated based on the digital chip specification. The AOFG 248 is the Automatic Optimal Firmware Generator, which performs the automatic generation of the firmware needed to be executed by the resulting chip 120 . The tool is completely automated. No manual intervention or guidance is needed. Additionally, the tool will automatically generate the optimal solution. An optimized Real Time Operating System (RTOS) can also be automatically generated.
[0071] The chip specification defines the exact functional units that are needed to execute the customer application. It also defines exactly the inherent parallelism so that the number of these units that are used in parallel is determined. All the complexity of micro and macro level parallelism is extracted from the profiling information and hence the chip specification is designed with this knowledge. Hence the chip specification is designed optimally and not over designed or under-designed as such could be the case when a chip specification is designed without such profiling information.
[0072] During the dynamic profiling the branch statistics are gathered and based on this information the branch prediction mechanism is optimally designed. Also all the dependency checks between successive instructions are known from the profiling and hence the pipeline and all instruction scheduling aspects of the chip specification are optimally designed.
[0073] The chip specification can provide options such as:
Hardware modulo addressing, allowing circular buffers to be implemented without having to constantly test for wrapping. Memory architecture designed for streaming data, using DMA extensively and expecting code to be written to know about cache hierarchies and the associated delays. Driving multiple arithmetic units may require memory architectures to support several accesses per instruction cycle Separate program and data memories (Harvard architecture), and sometimes concurrent access on multiple data busses Special SIMD (single instruction, multiple data) operations Some processors use VLIW techniques so each instruction drives multiple arithmetic units in parallel Special arithmetic operations, such as fast multiply-accumulates (MACs). Bit-reversed addressing, a special addressing mode useful for calculating FFTs Special loop controls, such as architectural support for executing a few instruction words in a very tight loop without overhead for instruction fetches or exit testing Special Pre-fetch instructions coupled with Data pre-fetch mechanism so that the execution units are never stalled for lack of data. So the memory bandwidth is designed optimally for the given execution units and the scheduling of instructions using such execution units. Optimal Variable/Multi-Discrete length instruction encoding to get optimal performance and at the same time achieve very compact instruction footprint for the given application.
[0085] FIG. 3 shows an exemplary process flow for automatically generating the custom chip 120 of FIG. 1 . Turning now to FIG. 3 , a customer product specification is generated ( 302 ). The customer product specification 302 is further detailed in a computer readable code or algorithm 304 that can be expressed as a program such as C program or a math model such as a Matlab model, among others.
[0086] The customer algorithm 304 is profiled statically 316 and dynamically 318 . The statistics gathered from this profiling is used in the architecture optimizer unit 320 . This unit also receives the customer specification 302 . The base functions generator 314 decides on the basic operations or execution units that will be needed to implement the customer algorithm 304 . The base function generators 314 output is also fed to the architecture optimizer 320 . The architecture optimizer 320 , armed with the area, timing, and power information from base function generators along with internal implementation analysis to minimize area, timing, and power.
[0087] Based on the architecture optimizer 320 outputs and initial chip specification is defined as the architecture 322 . This is then fed to the tools generator 332 unit to automatically generate the compiler 306 , the Assembler 308 , the linker 310 , the cycle accurate simulator 338 . Then using the tools chain the customer algorithm 304 is converted to firmware 312 that can run on the architecture 322 .
[0088] The output of the assembler 308 is profiled statically 334 and the output of the cycle accurate simulator 338 is profiled dynamically 340 . These profile information is then used by the architecture optimizer 342 to refine and improve the architecture 322 .
[0089] The feedback loop from 322 to 332 to 306 to 308 to 310 to 312 to 338 to 340 to 342 to 322 and the feedback loop from 322 to 332 to 306 to 308 to 334 to 342 to 322 is executed repeatedly till the customer specifications are satisfied. These feedback loops happen automatically with no human intervention and hence the optimal solution is arrived at automatically.
[0090] The architecture optimizer 342 also is based on the architecture floor-planner 336 and synthesis and P&R 328 feedback. Architecture decisions are made in consultation with not only the application profiling information but also the physical place and route information. The architecture optimization is accurate and there are no surprises when the backend design of the designed architecture takes place. For example if the architecture optimizer chooses to use a multiplier unit that takes two 16 bit operands as input and generates a 32 bit result. The architecture optimizer 342 knows the exact timing delay between the application of the operands and the availability of the result from the floor-planner 336 and the synthesis 328 . The architecture optimizer 342 also knows the exact area when this multiplier is placed and routed in the actual chip. So the architecture decision for using this multiplier is not only based on the need of this multiplier from the profiling data, but also based on the cost associated with this multiplier in terms of area, timing delay (also called performance) and power.
[0091] In another example, to speed up the performance if performance is a constraint on the custom chip, the compiler 306 takes a program, code or algorithm that takes long time to run on a serial processor, and given a new architecture containing multiple processing units that can operate concurrently the objective is to shorten the running time of the program by breaking it up into pieces that can be processed in parallel or in overlapped fashion in multiprocessing units. An additional task of front end is to look for parallelism and that of back end is to schedule it in such a manner that correct result and improved performance is obtained. The system determines what kind of pieces a program should be divided into and how these pieces may be rearranged. This involves
granularity, level, and degree of parallelism analysis of the dependencies among the candidates of parallel execution.
[0094] In another example, if space or power is a constraint on the custom chip, the compiler would generate a single low power processor/DSP that executes the code sequentially to save power and chip real estate requirement, for example.
[0095] From the architecture block 322 , the process can generate RTL using an RTL generator ( 324 ). RTL code is generated ( 326 ) and the RTL code can be provided to a synthesis placement and routing block ( 328 ). Information from an architecture floor planner can also be considered ( 336 ). The layout can be generated ( 330 ). The layout can be GDSII file format, for example.
[0096] One aspect of the invention also is the unified architecture 322 representation that is created so that both the software tools generator 332 and the hardware RTL generator 324 can use this representation. This representation is called as SAMA (system, architecture and micro-architecture).
[0097] The architecture design operation is based on analyzing the program, code or algorithm to be executed by the custom chip. In one implementation, given a program that takes long time to run on a uniscalar processor the system can improve performance by breaking the processing requirement into pieces that can be processed in parallel or in overlapped fashion in multiprocessing units. Additional task of front end is to look for parallelism and that of back end is to schedule it in such a manner that correct result and improved performance is obtained. The system can determine what kind of pieces a program should be divided into and how these pieces may be rearranged. This involves granularity, degree of parallelism, as well as an analysis of the dependencies among the candidates of parallel execution. Since program pieces and the multiple processing units come in a range of sizes, a fair number of combinations are possible, requiring different compiling approaches.
[0098] For these combinations the chip specification is done in such a way that the data bandwidth that is needed to support the compute units is correctly designed so that there is no over or under design. The Architecture Optimizer 342 first identifies potential parallel units in the program then performs dependency analysis on them to find those segments which are independent of each other and can be executed concurrently.
[0099] The architecture optimizer 342 identifies parallelism at granularity level of machine instruction. For example addition of two N-element vectors on an ordinary scalar processor will execute one instruction at a time. But on a vector processor all N instructions can be executed on N separate processor which reduces the total time to slightly more than N times that needed to execute a single addition. The architecture optimizer takes the sequential statements equivalent to the vector statement and performs a translation into vector machine instruction. The condition that allows vectorization is that the elements of the source operands must be independent of the result operands. For example, in the code:
[0000] DO 100 J = 1,N DO 100 I = 1,N DO 100 K = 1,N C(I,J) = C(I,J) + A(I,K) * B(K,J) 100 CONTINUE
In this matrix multiplication example at each iteration C(I,J) is calculated using previous value of C(I,J) calculated in previous iteration so vectorization is not possible. If performance is desired, the system transforms the code into:
[0000]
DO 100 J = 1,N
DO 100 K = 1,N
DO 100 I = 1,N
C(I,J) = C(I,J) + A(I,K) * B(K,J)
100 CONTINUE
[0100] In this case vectorization is possible because consecutive instructions calculate C(I-1,J) and C(I,J) which are independent of each other and can be executed concurrently on different processors. Thus dependency analysis at instruction level can help to recognize operand level dependencies and apply appropriate optimization to allow vectorization.
[0101] FIGS. 4-6 show an exemplary process for performing custom chip specification design for the following algorithm expressed as C code:
[0000]
for (i=0; i < ilimit; i++) {
a[i] = b[i] + 2 * c[i];
t = t + a[i];
}
[0102] FIG. 4 shows an exemplary static profiling using the gimple static profiling. In profiling, a form of dynamic program analysis (as opposed to static code analysis), investigates a program's behavior using information gathered as the program executes. The usual purpose of this analysis is to determine which sections of a program to optimize—to increase its overall speed, decrease its memory requirement or sometimes both. A (code) profiler is a performance analysis tool that, most commonly, measures only the frequency and duration of function calls, but there are other specific types of profilers (e.g. memory profilers) in addition to more comprehensive profilers, capable of gathering extensive performance data.
[0103] In the example of FIG. 4 , the C code is reduced to a series of two operand operations. Thus, the first four operations perform a[i]=b[i]+2*c[i]+t, and in parallel the last four operations perform a[i]=b[i]+2*c[i]+t for the next value of i and the result of both groups are summed in the last operation.
[0104] FIG. 5 shows a simple base level chip specification to implement the above application. Each variable i, a[i], b[i], c[i], t, and tmp are characterized as being read or written. Thus, at time 502 , i is read and checked against a predetermined limit. In 504 , I in incremented and written, while c[i] is fetched. In 506 , b[i] is read while a tmp variable is written to store the result of 2*c[i] and read from to prepare for next operation. In 508 , a[i] is written to store the result of tmp added to b[i], and t is retrieved. In 510 , t is written to store the result of the addition in 508 , and i is read. From 512 - 520 , the sequence in 502 - 510 is repeated for the next i.
[0105] FIG. 6 shows a first architecture from the base line architecture of FIG. 5 . In 604 , variables I and c[i] are read. In 606 , i is incremented and the new value is stored. B[i] is read, while tmp stores the result of 2*c[i] and then read for next operation. In 608 , b[i] is added to tmp and stored in a[i], and the new a[i] and t are read for next operation. In 610 , t is added to a[i], and the result is stored in t. In 612 - 618 , a similar sequence is repeated for the next value of i.
[0106] FIG. 7 shows a second architecture from the base line architecture of FIG. 5 . In this architecture, the architecture optimizer detects that operations 702 and 704 can be combined into one operation with a suitable hardware. This hardware can also handle operations 706 - 708 in one operation. As a result, using the second architecture, i is checked to see if it exceeds a limit, and auto-incremented in one operation. Next, operations 706 - 708 are combined into one operation to do 2*c[i]+b[i] and storing the result as a[i]. In the third operation, t is added to a[i]. A similar 3 operation is performed for the next value of i.
[0107] The second architecture leverages knowledge of the hardware with auto-increment operation and multiply-accumulate operation to do several transactions in one step. Thus, the system can optimize for performance to the architecture.
[0108] Since program pieces and the multiple processing units come in a range of sizes, a fair number of combinations are possible, requiring different optimizing approaches. The architecture optimizer first identifies potential parallel units in the program then performs dependency analysis on them to find those segments which are independent of each other and can be executed concurrently.
[0109] Another embodiment of the concurrent optimization allowed in such system is the mitigation of Voltage Drop/IR Hot Spots. The process associates every machine instruction with an associated hardware execution path, which is a collection of on-chip logic and interconnect structures. The execution path can be thought of as the hardware “foot-print” of the instruction. The data model maintains a record of all possible execution paths and their associated instructions. The data model receives a statistical profile of the various machine instructions and extracts from this a steady state probability that an instruction is executed in any given cycle. The data model can create an estimated topological layout for each instruction execution path. Layout estimation is performed using a variety of physical design models based on a pre-determined protocol to select the appropriate level of abstraction needed for the physical design modeling. The data model associates instructions' steady state probability of execution to the topology of its execution path. The data model creates sub-regions of the layout and for each sub-region there is a collection of intersecting execution paths which yields a collection of execution path probabilities which is used to compute a sub-region weight. The sub-region weight distribution (over the entire region) is used to estimate power hot-spot locations. The data model identifies impacted instructions whose execution paths intersect power hot-spots. Power hot-spot regions are then modeled as virtual restricted capacity resources. The data model arranges for scheduler to see the impacted instructions as dependent on the restricted capacity resources. Restricted capacity translates to limiting the number of execution paths in a sub-region that should be allowed to activate in close succession. Such a resource dependency can be readily added to resource allocation tables of a scheduler. The scheduler optimization will then consider the virtual resources created above in conjunction with other performance cost functions. Thus power and performance are simultaneously optimized. The system can generate functional block usage statistics from the profile. The system can track usage of different processing blocks as a function of time. The system can speculatively shut down power for one or more processing blocks and automatically switch power on for turned off processing blocks when needed. An instruction decoder can determine when power is to be applied to each power domain. Software tools for the custom IC to run the application code can be automatically generated. The tools include one or more of: Compiler, Assembler, Linker, Cycle-Based Simulator. The tool automatically generates firmware. The tools can profile the firmware and providing the firmware profile as feedback to optimizing the architecture. The instruction scheduler of the compiler can arrange the order of instructions, armed with this power optimization scheme, to maximize the benefit.
[0110] The key idea is to anticipate the physical constraints and effects by estimation and virtually constructing the physical design with only architectural abstract blocks. In one example, it is possible to construct a floorplan based on a set of black boxes of estimated area. Having such construction at architecture level allows the system to consider any congestion, timing, area, etc. before the realization of RTL. In another example, certain shape or arrangement of black boxes may yield better floorplan and therefore, better timing, congestion, etc. Thus, it provides the opportunities to mitigate these issues at architecture level itself. Analogy to the physical world, an architect may consider how a house functions by considering the arrangement of different rooms without knowing the exact dimensions of aspect ratio, nor the content of the rooms.
[0111] The system alleviates the problems of chip design and makes it a simple process. The embodiments shift the focus of product development process back from the hardware implementation process back to product specification and computer readable code or algorithm design. Instead of being tied down to specific hardware choices, the computer readable code or algorithm can always be implemented on a processor that is optimized specifically for that application. The preferred embodiment generates an optimized processor automatically along with all the associated software tools and firmware applications. This process can be done in a matter of days instead of years as is conventional. The system is a complete shift in paradigm in the way hardware chip solutions are designed. Of the many benefits, the three benefits of using the preferred embodiment of the system include
1) Schedule: If chip design cycles become measured in weeks instead of years, the user can penetrate rapidly changing markets by bringing products quickly to the market; and 2) Cost: The numerous engineers that are usually needed to be employed to implement chips are made redundant. This brings about tremendous cost savings to the companies using system. 3) Optimality : The chips designed using The instant system product have superior performance, Area and Power consumption.
[0115] By way of example, a computer to support the automated chip design system is discussed next. The computer preferably includes a processor, random access memory (RAM), a program memory (preferably a writable read-only memory (ROM) such as a flash ROM) and an input/output (I/O) controller coupled by a CPU bus. The computer may optionally include a hard drive controller which is coupled to a hard disk and CPU bus. Hard disk may be used for storing application programs, such as the present invention, and data. Alternatively, application programs may be stored in RAM or ROM. I/O controller is coupled by means of an I/O bus to an I/O interface. I/O interface receives and transmits data in analog or digital form over communication links such as a serial link, local area network, wireless link, and parallel link. Optionally, a display, a keyboard and a pointing device (mouse) may also be connected to I/O bus. Alternatively, separate connections (separate buses) may be used for I/O interface, display, keyboard and pointing device. Programmable processing system may be preprogrammed or it may be programmed (and reprogrammed) by downloading a program from another source (e.g., a floppy disk, CD-ROM, or another computer).
[0116] Each computer program is tangibly stored in a machine-readable storage media or device (e.g., program memory or magnetic disk) readable by a general or special purpose programmable computer, for configuring and controlling operation of a computer when the storage media or device is read by the computer to perform the procedures described herein. The inventive system may also be considered to be embodied in a computer-readable storage medium, configured with a computer program, where the storage medium so configured causes a computer to operate in a specific and predefined manner to perform the functions described herein.
[0117] The invention has been described herein in considerable detail in order to comply with the patent Statutes and to provide those skilled in the art with the information needed to apply the novel principles and to construct and use such specialized components as are required. However, it is to be understood that the invention can be carried out by specifically different equipment and devices, and that various modifications, both as to the equipment details and operating procedures, can be accomplished without departing from the scope of the invention itself | Systems and methods are disclosed to automatically design a custom integrated circuit based on algorithmic process or code as input and using highly automated tools that requires virtually no human involvement is disclosed. The method includes receiving a specification of the custom integrated circuit including computer readable code and one or more constraints on the custom integrated circuit; automatically generating a computer architecture for the computer readable code that best fits the constraints; automatically determining an instruction execution sequence based on the code profile and reassigning or delaying the instruction sequence to spread operation over one or more processing blocks to reduce hot spots; continuously evaluating and optimizing one or more factors including physical implementation, and local and global area, timing, or power at an architecture level above RTL or gate-level synthesis; automatically generating a software development kit (SDK) and the associated firmware automatically to execute the computer readable code on the custom integrated circuit; automatically generating associated test suites and vectors for the computer readable code on the custom integrated circuit; and automatically synthesizing the designed architecture and generating a computer readable description of the custom integrated circuit for semiconductor fabrication. | 6 |
BACKGROUND OF THE INVENTION
This invention relates to voice compression, and in particular, to code excited linear prediction (CELP) vocoding.
A voice encoder/decoder (vocoder) compresses speech signals in order to reduce the transmission bandwidth required in a communications channel. By reducing the transmission bandwidth required per call, it is possible to increase the number of calls over the same communication channel. Early speech coding techniques, such as the linear predictive coding (LPC) technique, use a filter to remove the signal redundancy and hence compress the speech signal. The LPC filter reproduces a spectral envelope that attempts to model the human voice. Furthermore, the LPC filter is excited by receiving quasi periodic inputs for nasal and vowel sounds, while receiving noise-like inputs for unvoiced sounds.
There exists a class of vocoders known as code excited linear prediction (CELP) vocoders. CELP vocoding is primarily a speech data compression technique that at 4-8 kbps can achieve speech quality comparable to other 32 kbps speech coding techniques. The CELP vocoder has two improvements over the earlier LPC techniques. First, the CELP vocoder attempts to capture more voice detail by extracting the pitch information using a pitch predictor. Secondly, the CELP vocoder excites the LPC filter with a noise like signal derived from a residual signal created from the actual speech waveform.
CELP vocoders contain three main components; 1) short term predictive filter, 2) long term predictive filter, also known as pitch predictor or adaptive codebook, and 3) fixed codebook. Compression is achieved by assigning a certain number of bits to each component which is less than the number of bits used to represent the original speech signal. The first component uses linear prediction to remove short term redundancies in the speech signal. The error, or residual, signal that results from the short term predictor becomes the target signal for the long term predictor.
Voiced speech has a quasi-periodic nature and the long term predictor extracts a pitch period from the residual and removes the information that can be predicted from the previous period. After the long term and short term predictive filters, the resulting residual signal is a mostly noise-like signal. Using analysis-by-synthesis, a fixed codebook search finds a best match to replace the noise-like residual with an entry from its library of vectors. The code representing the best matching vector is transmitted in place of the noisy residual. In algebraic CELP (ACELP) vocoders, the fixed codebook consists of a few non-zero pulses and is represented by the locations and signs (e.g. +1 or −1) of the pulses.
In a typical implementation, a CELP vocoder will block or divide the incoming speech signal into frames, updating the short term predictor's LPC coefficients once per frame. The LPC residual is then divided into subframes for the long term predictor and the fixed codebook search. For example, the input speech may be blocked into a 160 sample frame for the short term predictor. The resulting frame may then be broken up into subframes of 53 samples, 53 samples, and 54 samples. Each subframe is then processed by the long term predictor and the fixed codebook search.
Referring to FIG. 1, an example of a single frame of a speech signal 100 is shown. The speech signal 100 is made up of voiced and unvoiced signals of different pitches. The speech signal 100 is received by a CELP vocoder having an LPC filter. The first step of the CELP vocoder is to remove short term redundancies in the speech signal. The resulting signal with the short term redundancies removed is the residual speech signal 200 , FIG. 2 .
The LPC filter is unable to remove all of the redundant information and the remaining quasi-periodic peeks and valleys in the filtered speech signal 200 are referred to as pitch pulses. The short term predictive filter is then applied to speech signal 200 resulting in the short term filtered signal 300 , FIG. 3 . The long term predictor filter removes the quasi-periodic pitch pulses from the residual speech signal 300 , FIG. 3, resulting in a mostly noise-like signal 400 , FIG. 4, which becomes the target signal for the fixed codebook search. FIG. 4 is a plot of a 160 sample frame of a fixed codebook target signal 350 divided into three subframes 354 , 356 , 358 . The code value is then transmitted across the communication network.
In FIG. 5, the lookup table 470 that maps the position of the pulses in a subframe is shown. The pulses within the subframe are constrained to lie in one of sixteen possible positions 402 within the lookup table. Because each track 404 has sixteen possible positions 402 , only four bits are required to identify each pulse location. Each pulse mapping occurs in an individual track 404 . Therefore, two tracks 406 , 408 enables the mapping of the pulse positions of two signal pulses from the subframe.
In the current example, the subframe 354 , FIG. 4, has only 53 samples in the excitation, making position 0 - 52 the only valid positions. Because of the way the tracks 406 , 408 , FIG. 5, are divided positions that exceed the length of the original excitation are present in each track. Positions 56 and 60 in track 1 , and positions 57 and 61 in track 2 are invalid and unused. The location of the first two pulses 310 , 312 , FIG. 4, corresponds to sample thirteen and sample seventeen. By using the table 400 , FIG. 5, it is determined that sample thirteen lies in position three 410 in the first track 406 . The second pulse is in sample seventeen and lies in second track 408 at position four 412 . Therefore, the pulses can be represented and transmitted as four bits each respectively. The other pulses 314 , FIG. 4, 316 , 318 , 320 and 322 in the subframe 354 are ignored because the code book has only two tracks.
The pulse position is constrained by the absolute pulse position in the tracks. Disadvantageously, the CELP vocoder tends to place pulses in adjacent positions in the tracks. By placing the pulses in adjacent positions in the tracks, the start of the speech sound is encoded rather than a more balance encoding of the utterance. Additionally, as the bit rate for the vocoder decreases and fewer pulses are used, the voice quality is adversely affected by inefficient placement of pulses into tracks. What is needed is a method to reduce the occurrence of pulses being placed in adjacent track positions.
SUMMARY OF THE INVENTION
The inefficiency of absolute track positions placement is eliminated by the implementation of placement of a signal pulse in a second track relative to the position of a signal pulse in the first track. Implementing relative positioning of the N+1 signal pulses in the N+1 tracks during encoding of a signal pulse results in increased signal quality of the decoded signal. The increased signal quality is achieved by more precise placement of pulses in the tracks and by reducing the occurrence of adjacent placement of signal pulse positions within the tracks.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing objects and advantageous features of the invention will be explained in greater detail and others will be made apparent from the detailed description of the present invention, which is given with reference to the several figures of the drawing, in which:
FIG. 1 illustrates a single frame of a speech signal;
FIG. 2 illustrates a short term periodic filtered single speech frame;
FIG. 3 illustrates an adaptive code book filtered single speech frame;
FIG. 4 illustrates a known method of structuring 160 sample speech frame divided into three subframes;
FIG. 5 is a diagram of a known CELP vocoder codebook lookup table with signal pulses constrained to one of sixteen possible pulse positions;
FIG. 6 is a diagram of a CELP vocoder codebook having relative constrained pulse positions in accordance with an embodiment of the invention;
FIG. 7 is a diagram of a communication system with a transmitting device and receiver device using CELP vocoding in accordance with an embodiment of the invention;
FIG. 8 is a diagram of the transmitting device having a CELP vocoder encoding a voice signal in accordance with an embodiment of the invention;
FIG. 9 is a diagram of the receiving device have a CELP vocoder in accordance with an embodiment of the invention; and
FIG. 10 is a flow chart of a method of vocoding a voice signal in accordance with an embodiment of the invention.
DETAILED DESCRIPTION
In FIG. 6, a two track codebook table with relative constrained pulse positions is shown. Table 500 contains two pulse position tracks 502 , 504 (commonly referred to as “tracks”) identifying sixteen possible signal pulse positions 506 for each track. The fixed codebook entries zero through thirteen 508 in track one 502 and track two 504 are possible valid pulse positions. The pulse table positions fourteen 510 and fifteen 512 in the codebook are unused in both tracks. Additionally, the possible first pulse positions in the first track is constrained to lie at a pulse position divisible by four (i.e. 0, 4, 8, . . . , 52). The second pulse position in the second track is relative to the index position 506 of the first signal pulse in the first track.
Rather than encoding signal pulses in adjacent track positions, a relative positioning of the second signal pulse occurs. By having fewer adjacent signal pulses encoded in the track, the signal pulses are better able to reproduce the bursts energy which improves the voice quality of the signal decoded by the vocoder. A single signal pulse is encoded in each of the two tracks 502 and 504 in the present embodiment. By positions the second signal pulse in the second track in relation to the first signal pulse in the first track an increase in the quality of the decoded utterance is achieved. In an alternate embodiment, the codebook table contains more than two tracks and the additional signal pulses in tracks are relative to an earlier track position of an earlier signal pulse.
In the present embodiment the relative location of the second signal pulse in the second track is to the first signal pulse in the first track. In an alternate embodiment the relative position of the second signal pulse in the second track is relative to the first signal pulse sample position. In yet another embodiment, the signal pulse position in the second track may be grouped in a non-sequential order (i.e. 1, −1, 7, −7, 2, −2, 6, −6, 3, −3, 5, −5, 4, −4).
Turning to FIG. 7, a communication system 600 having a transmitter device 602 and a receiver device 604 is shown. The transmitter and receiver communication devices 602 , 604 are coupled together by a communication path 606 . The communication path 606 may selectively be a wire based network (such as a local area network, wide area network, the Internet, ATM network, or public telephone network) or a wireless network (such as cellular, microwave, or satellite network). The main requirement of the communication path 606 is the ability to transfer digital data between the transmitter 602 and the receiver 604 .
Each device 602 , 604 has a respective signal input/output units 608 , 610 . Units 608 , 610 are shown as telephonic devices that transfer analog voice signals to and from the transmitter device 602 and receiver device 604 . The signal input/output unit 608 is coupled to the transmitter device 602 by a two-wire communication path 612 . Similarly, the other signal input/output unit 610 is coupled to the receiver device 604 over another two-wire communication path 614 . In an alternate embodiment, the signal input unit is incorporated in the transmitting and receiving communication devices (i.e. speakers and microphones built into the transmitting and receiving devices)or communicate over a wireless communication path (i.e. cordless telephone).
The transmitter device 602 contains an analog signal port 616 coupled to the two-wire communication path 612 , a CELP vocoder 618 , and a controller 620 . The controller 620 is coupled to the analog signal port 616 , the vocoder 618 , and a network interface 622 . Additionally, the network interface 622 is coupled to the vocoder 618 , the controller 620 , and the communication path 606 .
Similarly, the receiver device 604 has another network interface 624 coupled to another controller 626 , the communication path 606 , and another vocoder 628 . The other controller 626 is coupled to the other vocoder 628 , the other network interface 624 , and another analog signal port 630 . Additionally, the other analog signal port 630 is coupled to the other two-wire communication path 614 .
A voice signal is received at the analog port 616 from the signal input device 608 . The controller 620 provides the control and timing signals for the transmitter device 602 and enables the analog port 161 to transfer the received signal to the vocoder 618 for signal compression. The vocoder 618 has a fixed codebook with a data structure shown in FIG. 6 for compressing the received signal. The data structure 500 , FIG. 6, associates the first signal pulse from the filtered signal to a pulse position within the first track. Furthermore, a second signal pulse is associated with a second pulse position and is determined relative to the first pulse position of the first signal pulse in the first track.
Two signal pulses are kept from being adjacently assigned in the tracks by assignment of the second pulse position relative to the first pulse position. The first signal pulse is encoded and assigned a pulse position in the first track 502 and the pulse position of the second signal pulse in the second track 504 is encoded relative to the first track 502 . The relative encoding of the second pulse position results in a compressed signal having a greater likelihood that the first pulse position is not adjacent to the second pulse position. The compressed signal is then sent from the vocoder 618 , FIG. 7, to the network interface 622 . The network interface 622 transmits the compressed signal across the communication path 606 to the receiver device 604 .
The other network interface 624 located in the receiver device 604 receives the compressed signal. The receiver controller 626 enables the received compressed signal to be transferred to the receiver vocoder 628 . The receiver vocoder 628 decodes the compressed signal by using a lookup table 500 , FIG. 6 . The vocoder 628 , FIG. 7, regenerates an analog signal from the received compressed signal using the lookup table 500 , FIG. 6 . The lookup table reproduces the fixed codebook contribution and is then filtered by the long term and short term predictor. The analog signal is sent via the receiver analog signal port 630 , FIG. 7, to the receiver signal input/output device 610 .
Turning to FIG. 8, the signal processing of the analog speech signal by the transmitter 602 is shown. A preprocessor 710 has an input for receiving an analog signal and is coupled to an LP filter 714 , and a signal combiner 712 . The signal combiner 712 combines the signal from the preprocessor 710 and a synthesis filter 716 . The output of the signal combiner 712 is coupled to the perceptional weighting processor 718 . The synthesis filter 716 is coupled to the LP analysis filter 714 , signal combiner 712 , another signal combiner 720 , an adaptive codebook 732 , and a pitch analyzer 722 . The pitch analyzer 722 is coupled to the perceptional weighting processor 718 , a fixed codebook search 734 , an adaptive codebook 732 , the synthesis filter 716 , the other signal combiner 720 , and a parameter encoder 724 . The parameter encoder 724 is coupled to a transmitter 728 , the fixed codebook search 734 , fixed codebook 730 , the LP filter 714 , and the pitch analyzer 722 .
The analog signal is received at the preprocessor 710 from the analog device 608 , FIG. 7 . The preprocessor 710 , FIG. 8, processes the signal and adjusts the gain and other signal characteristics. The signal from the preprocessor 710 is then routed to both the LP analysis filter 714 and the signal combiner 712 . The coefficient information generated by the LP analysis filter 714 is sent to the synthesis filter 716 , the perceptual weighting processor 718 , and the parameter encoder 724 . The synthesis filter 716 receives the LP coefficient information from the LP filter 714 and a signal from the other signal combiner 720 . The synthesis filter 716 , which models the coarse short term spectral shape of speech, generates a signal that is combined with the output of the preprocessor 710 by the signal combiner 712 . The resulting signal from the signal combiner 712 is filtered by the perceptual weighting processor 718 . The perceptual weighting processor 718 also receives LP coefficient information from the LP filter 714 . The perceptual weighting processor 718 is a post-filter in which the coding distortions are effectively “masked” by amplifying the signal spectra at frequencies that contain high speech energy, and attenuating those frequencies that contain less speech energy.
The output of the perceptual weighting processor 718 is sent to the fixed codebook search 734 and the pitch analyzer 722 . The fixed codebook search 734 generates the code values that are sent to the parameter encoder 724 and the fixed codebook 730 . The fixed codebook search 734 is shown separate from the fix codebook 730 , but may alternatively be included in the fixed codebook 730 and does not have to be implemented separately. Additionally, the fixed codebook search has access to the data structure of the lookup table 500 , FIG. 6, and the determination of the second pulse position relative to the first pulse position allows for more precise pulse signal information to be encoded and reduces the occurrences of the code book encoding adjacent pulses.
The pitch analyzer 722 , FIG. 8, generates pitch data that is sent to the parameter encoder 724 and the adaptive codebook 732 . The adaptive codebook 732 receives the pitch data from the pitch analyzer 722 , and a feedback signal from the signal combiner 720 to model the long term (or periodic) component of the speech signal. The output of the adaptive codebook signal is combined with the output of the fixed codebook 730 by the signal combiner 720 .
The fixed codebook 730 receives the code values generated by the fixed codebook search 734 and regenerates a signal. The generated signal is combined with the signal from the adaptive codebook 732 by signal combiner 720 . The resulting combined signal is then used by the synthesis filter 716 to model the short term spectral shape of the speech signal and fed back to the adaptive codebook 732 .
The parameter encoder receives parameters from the fixed codebook search 734 , the pitch analyzer 722 , and the LP filter 714 . The parameter encoder using the received parameters generates the compressed signal. The compressed signal is then transmitted by the transmitter 728 across the network.
In an alternate embodiment of the above system, the encoder and decoder portions of the vocoder reside in the same device, such as a digital answering machine. A communication path in such an embodiment is a data bus that allows the compressed signal to be stored and retrieved from a memory.
In FIG. 9, a diagram of the receiver device having a CELP vocoder in accordance with an embodiment of the invention is shown. The receiver device 604 has a network interface 661 coupled to a receiver 802 . A fixed codebook 804 is coupled to the receiver 802 and a gain factor “c” 812 . The signal combiner 806 is coupled to a synthesis filter 808 , the gain factor “p” 811 and a gain factor “c” 812 . The adaptive codebook 810 is coupled to the gain factor “p” 811 and the output of the signal combiner 806 . The synthesis filter 808 is connected to the output of the signal combiner 806 and a perceptual post filter 814 . The perceptual post filter is coupled to the other analog port 630 and the synthesis filter 808 .
The compressed signal is received by the receiver device 604 at the network interface 616 . The receiver 802 unpacks the data from the compressed signal received at the network interface 616 . The data consists of a fixed codebook index, a fixed codebook gain, an adaptive codebook index, adaptive codebook gain, and an index for the LP coefficients. The fixed codebook 804 contains a lookup table 500 , FIG. 6, data structure. The fixed codebook 804 , FIG. 9, generates a signal that is combined by signal combiner 806 with the signal from the adaptive codebook 810 and the gain factor 812 . The combined signal from the signal combiner 806 is then received at the synthesis filter 808 and fed back into the adaptive codebook 810 . The synthesis filter 808 uses the combined signal to regenerate the speech signal. The regenerated speech signal is passed through the perceptual post filter 814 that adjusts the speech signal. The speech signal is then sent by the analog port 630 to the receiver that has a similar codebook.
Turning to FIG. 10, a flow chart illustrating a method of vocoding using a lookup table or codebook having pulse position in the N+1tracks relative to the prior pulse positions is shown. In step 902 , an input signal (e.g. an analog voice signal) is received at the receiver device 604 , FIG. 7 . The input signal is divided into signal frames in step 903 , FIG. 10, so discrete signal portions can be processed. Each signal frame is processed by a filter 714 , FIG. 8, in step 904 , FIG. 10, resulting in a filtered input signal that is referred to as a residual signal.
The filtered residual signal is further filtered by a long term filter, in step 906 , FIG. 10 and the adaptive codebook 732 , FIG. 8, translates or removes the long term signal redundancy from the filtered input signal having signal pulses. In step 908 , FIG. 10, the fixed codebook index identifies the location of the first signal pulses within a first track. The fixed codebook 730 , FIG. 8, contains a lookup table 500 , FIG. 6, and the relative mapping of the second pulse position in the second track to the first pulse position in the first track. In step 909 , the offset of the second pulse position is determined relative to the first pulse position and results in greater placement precision of the second pulse.
The lookup table 500 is used by the fixed codebook 730 , FIG. 8, to generate a binary pattern that represents remaining pulse signals from the signal. A binary pattern is then encoded into a signal containing the index of the pulse positions, step 910 , FIG. 10 . The encoded signal is then transmitted across the communication path in step 912 .
Current state of technology allows general purpose digital signal processors to be combined with other electronic elements in order to make a CELP vocoder that is configured by software. Therefore, a computer readable signal bearing medium may contain software code to implement a vocoder having additional constraints for restricting pulse positions in a codebook.
While the invention has been particularly shown and described with reference to a particular embodiment, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention and it is intended that all such changes come within the scope of the following claims. | An apparatus and method for vocoding an input signal comprising a linear predictive filter for generating a filtered signal with a first signal pulse and a second signal pulse in response to receiving the input signal and a processor having a lookup table with a plurality of track positions. The first signal pulse is associated with a first track position and the second signal pulse is associated with a second track position relative to the first signal pulse resulting in a plurality of excitation parameters. Additionally, the apparatus has a transmitter which transmits the plurality of excitation parameters in a transmission signal in response to receiving the plurality of excitation parameters from the processor. | 6 |
BACKGROUND OF THE INVENTION
The present invention relates generally to an ultra-sonic sensor to be employed in an automotive suspension control system. More specifically, the invention relates to an ultra-sonic sensor system suitable for detecting rolling and/or pitching motion of the vehicle and controlling the automotive suspension in accordance with the intensity of rolling and/or pitching.
In the recent years, various automotive suspension control systems attempting to improve riding comfort without affecting driving stability have been proposed and developed. Some of such suspension control systems control damping characteristics of the suspension system depending upon the magnitude of rolling and/or pitching motion of the vehicle.
Conventionally, such rolling and/or pitching motion of the vehicle have been monitored indirectly using various vehicular driving parameters other than the vehicle body behaviour per se. For instance, in order to detect rolling motion of the vehicle, lateral force, steering angular displacement and so forth are observed. On the other hand, in order to detect vehicular pitching motion, application of the brakes, acceleration and deceleration of the vehicle and so forth are observed.
On the other hand, the co-pending U.S. patent application Ser. No. 647,648, filed on Sept. 6, 1984 now abandoned and assigned to the assignee of the present invention discloses an electronic suspension control system employing an ultra-sonic sensor for monitoring road surface conditions for use in road roughness dependent suspension control. In the disclosed system, ultra-sonic waves are transmitted toward the road surface and the ultra-sonic waves reflected by the road surface are received. In theory, the ultra-sonic sensor system measures the elapsed time between an ultra-sonic waves transmission and reflected ultra-sonic waves reception. Based on the measured elapsed time and the known propagation speed of the ultra-sonic waves, the distance can be arithmetically derived. In practice, the measurement of the elapsed time starts in response to the onset of transmission of the ultra-sonic waves. In order to avoid the influence of noise, an ultra-sonic waves receiver signal, the signal value of which is dependent upon the received intensity of ultra-sonic waves, is compared with a predetermined threshold value. When the receiver signal level exceeds the threshold level, the measurement of the elapsed time is terminated and the measured elapsed time value is latched. However, the received intensity of ultra-sonic wave tends to fluctuate depending upon the external condition, such as atmospheric temperature and so forth. This makes the result of measurement of the elapsed time inaccurate.
SUMMARY OF THE INVENTION
In view of the above-mentioned defects in the prior art, it is an object to provide an ultra-sonic sensor system which can satisfactorily and successfully avoid the influences of the noise and/or influences of the external condition.
It is another object of the present invention to provide an ultra-sonic sensor system which can monitor vehicular rolling and/or pitching motion by monitoring the distance between the vehicle body and the road surface.
In order to accomplish the aforementioned and other objects, an ultra-sonic sensor system, according to the present invention, comprises at least two ultra-sonic sensors arranged in lateral or longitudinal alignment on the vehicle body. Each ultra-sonic sensor has a transmitter for transmitting ultra-sonic waves toward the road surface and a receiver for receiving ultra-sonic waves reflected by the road surface. The transmitters of both or all ultra-sonic sensors are controlled so that the ultra-sonic waves are transmitted by all of the transmitters at substantially the same time. The receivers output receiver signals having values depending upon the intensity of the received, reflected ultra-sonic waves. Elapsed times between transmission of the ultra-sonic waves and the peaks of the receiver signals for each of the ultra-sonic sensors are compared to each other to derive the difference therebetween. The difference between the elapsed times measured by neighboring ultra-sonic sensors is used as a measure of roll or pitch intensity for use in controlling the automotive suspension.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a block diagram of the preferred embodiment of an ultra-sonic sensor system according to the present invention;
FIG. 2 is a timing chart of operation of an ultra-sonic sensor according to the preferred embodiment of the ultra-sonic sensor system of FIG. 1;
FIG. 3 is a graph of a typical input and output of a comparator employed in each of the sensor circuits of the ultra-sonic sensors;
FIG. 4 is a graph of comparator output timing at various receiver signal levels;
FIG. 5 is a graph of the relationship between the roll angle of the vehicle body and the output of a phase difference detector in the ultra-sonic sensor system of FIG. 1;
FIG. 6 is a graph of the relationship between the roll angle of the vehicle body and the lateral acceleration exerted on the vehicle body;
FIG. 7 is a longitudinal section through a shock absorber suited for roll suspension using roll information provided by the sensor system of FIG. 1;
FIG. 8 is a side elevation of the vehicle having the preferred embodiment of the ultra-sonic sensor system with a pair of ultra-sonic sensors in longitudinal alignment; and
FIG. 9 is a front elevation of the vehicle having the preferred embodiment of the ultra-sonic sensor system with a pair of ultra-sonic sensors in lateral alignment.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, particularly to FIG. 1, the preferred embodiment of an ultra-sonic sensor system, according to the present invention, will be described in terms of vehicular rolling detection and lateral profile monitor. However, it should be appreciated that the ultra-sonic sensor system of the invention can also be used to monitor vehicular pitching motion and/or longitudinal profile.
As shown in FIG. 1, the preferred embodiment of the ultra-sonic sensor system employs a pair of ultra-sonic sensors. The ultra-sonic sensors are arranged on opposite sides of the vehicle body in lateral alignment. The ultra-sonic sensors have ultra-sonic waves transmitter elements 13a and 13b and ultra-sonic waves receiver elements 14a and 14b. The transmitter elements 13a and 13b are connected to a common oscillator 12 which is activated at controlled timings to output an oscillation signal a to both of the transmitter elements 13a and 13b. The transmitter elements 13a and 13b are responsive to the oscillation signal a from the oscillator 12 to transmit ultra-sonic waves toward the road surface 9.
It should be noted that, in the preferred embodiment, the oscillator 12 produces oscillation signals a in the ultra-sonic frequency range, e.g., equal to or higher than 20 kHz.
The receiver element 14a receives reflected ultra-sonic waves originally transmitted by the transmitter element 13a and reflected by the road surface 9. The receiver element 14a produces a receiver signal b having a value depending upon the received intensity of the reflected ultra-sonic waves. The receiver signal b from the receiver element 14a is sent to a pre-amplifier 15a. The pre-amplifier 15a amplifies the receiver signal level to a predetermined extent. The pre-amplifier 15a includes a low-pass filter for filtering high-frequency components out of the receiver signal and so picks up only the envelope of the receiver signal b. Thus, the pre-amplifier 15a outputs an envelope signal c. The envelope signal c is sent to an inverted input terminal of a comparator 17a and to a delay circuit 16a. The delay circuit 16a sends a delayed envelope signal d to a non-inverting input terminal of the comparator 17a after a given delay time. The delay τ imposed by the delay circuit must be relatively short so that a positive comparator signal e seals approximately at the peak of the envelope signal c.
The comparator 17a is connected for output of a comparator signal e to a phase difference detector circuit 18.
Similarly, the receiver element 14b is connected to a pre-amplifier 15b. The pre-amplifier 15b has substantially the same function as the pre-amplifier 15a, i.e. it produces a envelope signal representative of the low-frequency envelope of the receiver signal from the receiver element 14b. The envelope signal from the pre-amplifier 15b is sent to the inverting input terminal and to the non-inverting input terminal of a comparator 17b. The input at the non-inverting terminal of the comparator 17b is delayed by a delay circuit 16b. The comparator 17b outputs a comparator signal to the phase difference detector circuit 18.
The phase difference detector circuit 18 derives the phase difference between the comparator signals from the comparators 17a and 17b. Since the derived phase difference of the comparator signal represents the difference between the elapsed times between transmission of the ultra-sonic waves and reception of the reflected ultra-sonic waves of the two ultra-sonic sensors, and thus is representative of the difference between the distances between the vehicle body and the road surface at the two sensor positions, the vehicular lateral profile can be detected by monitoring the phase difference. The phase difference detector circuit 18 produces a phase difference indicative signal F. The phase difference indicative signal f is sent to an indicator 19 which displays the lateral profile of the vehicle. The indicator 19, employed in the shown embodiment, may be a roll gauge graphically displaying the lateral inclination of the vehicle.
Also, the phase difference indicative signal f from the phase difference detector circuit 19 is transmitted to an automotive suspension control system which automatically controls the damping characteristics of the vehicular suspension system. The suspension control system 20 is responsive to the phase difference indicative signal f from the phase difference detector circuit 18 of the ultra-sonic sensor system to perform roll-suppressive suspension control.
FIG. 2 is a timing chart of operation of the above-mentioned ultra-sonic sensor system according to the present invention. In FIG. 2, the oscillator 12 is activated at a timing t 1 to output the oscillation signal a to the transmitter elements 13a and 13b. From a timing t 2 , the receiver element 14a starts to receive the reflected ultra-sonic waves. The received intensity varies as illustrated increasing toward a peak and then decreasing monotonically. Therefore, the receiver signal b varies according to variation of the received intensity. This causes the envelope signal c of the pre-amplifier 15a to vary as illustrated. After the given delay τ, the delayed envelope signal d is input to the comparator 17a. As shown in FIGS. 2 and 3, assuming the envelope signal reaches its peak value at time t 3 and the delayed envelope signal d reaches the peak at time t 4 , the comparator signal e goes HIGH at time t 5 which is inbetween time t 3 and t 4 .
Although FIG. 2 only shows the operation of the sensor circuit connected to the receiver element 13a, the sensor circuit for the receiver element 13b has substantially the same function. Therefore, shortly after the peak of the envelope signal produced by the pre-amplifier 15b, the comparator signal of the comparator 17b goes HIGH.
The phase difference detector circuit 18 receives the comparator signals from the comparators 17a and 17b and detects the timing offset between the leading edges of the HIGH-level comparator signals. The phase difference signal value corresponds to this timing difference and represents the lateral inclination of the vehicle body.
As shown in FIG. 4, the receiver signal amplitude may fluctuate due to external conditions, such as weather, temperature, road surface conditions, vehicle driving speed and so forth. Therefore, if the reception timing of the reflected ultra-sonic waves is detected when the receiver signal level exceeds a predetermined threshold for use in deriving the elapsed time between transmission of the ultra-sonic waves and reception of the reflected ultra-sonic waves in order to derive the distance from the vehicle body to the road surface, the resultant distance indicative value will tend to fluctuate with external conditions. Therefore, when distance values derived in the manner set forth above are compared to monitor the lateral inclination of the vehicle, erroneous readings will result due to the errors in the distance-indicative values. In the preferred embodiment, since the timing of the peak of the receiver signal is not influenced by external conditions, the peak of the received ultra-sonic waves can be detected with satisfactory precision.
As shown in FIG. 5, the preferred embodiment of the phase difference detector circuit 18 outputs the phase difference indicative signal f in the form of an analog voltage signal related linearly to the detected phase difference. The voltage of the phase difference indicative signal f thus varies linearly with the roll angle φ of the vehicle body. On the other hand, the vehicle body roll angle φ is related to the vehicular lateral acceleration as illustrated in FIG. 6. Therefore, the lateral acceleration exerted on the vehicle can be derived on the basis of the phase difference indicative signal from the phase difference detector circuit 19.
The automotive suspension control system may perform rolling suppressive suspension control based on the phase difference indicative signal which serves as roll-intensity signal. FIG. 7 shows an example of the automotive shock absorber implementing rolling magnitude dependent suspension control.
In order to allow adjustment of the shock absorbing characteristics, the shock absorber 114 generally comprises an inner and an outer hollow cylinders 120 and 122 arranged coaxially, and a piston 124 fitting flush within the hollow space in the inner cylinder 120, as shown in FIG. 7. The piston 124 defines upper and lower fluid chambers 126 and 128 within the inner cylinder 120. The inner and outer cylinders define an annular fluid reservoir chamber 130.
The piston 124 is connected to the vehicle body (not shown) by means of a piston rod which is generally referred to by the reference number 132. The piston rod 132 is formed with an axially extending through opening 138.
The piston 124 defines flow-restrictive fluid passages 158 and 160. The upper end of the fluid passage 158 is closed by a resilient flow-restricting valve 162. Similarly, the lower end of the fluid passage 160 is closed by a flow-restricting valve 164. The flow-restricting valves 162 and 164 serve as check valves for establishing one-way fluid communication in opposite directions. In addition, since the flow-restriction valves 162 and 164 are biased toward the ends of the fluid passages 158 and 160, they open to allow fluid communication between the upper and lower fluid chambers 126 and 128 only when the fluid pressure difference between the upper and lower chambers 126 and 128 overcomes the effective pressure of the valves.
The piston 124 has a central through opening 124a. Upper end of the opening 124a engages the lower end of the piston rod 132. The lower end of the opening 124a receives the upper end of a sleeve 152. The sleeve 152 has an axially extending bore 152a, which receives a flow control valve spool 155, and a plurality of radially extending orifices 154. The sleeve 152 is further formed with an annular groove 160b extending around its inner periphery. The radially extending orifices 154 open into the annular groove 160b. The outer ends of the orifices 154 opens toward the lower fluid chamber 128.
The valve spool 155 is formed with annular groove 160a on the outer periphery thereof. The annular groove 160a is in communication with the upper fluid chamber 126 through a fluid passage 136 defined through the piston body and the sleeve. The annular groove 160a is located at a vertical position at which it opposes the annular groove 160b of the sleeve 152 at the lower position of the spool and does not overlap the annular groove 160b at all at the upper position of the spool.
The spool 155 is normally biased upwards by means of a bias spring 146d of an actuator 146 which comprises an electromagnetic coil 146a housed in an enclosed casing 146b and a yoke 146c. The casing 146b engages the sleeve 152 at its upper end so that the actuator 146 can be firmly mounted on the piston 124. When the electromagnetic coil 146a is energized, it pulls the spool 155 downwardly to move the spool to its lower position.
When the spool is in the lower position, fluid can flow between the upper and lower fluid chambers 126 and 128 through the fluid passage 156, the grooves 160a and 160b and orifices 154. Therefore, the total flow area for fluid communication between the upper and lower chambers 126 and 128 is increased. As a result, there is less resistance to flow, which softens the damping characteristics of the vehicle. On the other hand, when the spool is in the upper position, fluid communication between the upper and lower fluid chambers 126 and 128 through the fluid passage 156 is blocked. Therefore, at this position, fluid communication between the upper and lower fluid chambers 126 and 128 is possible only by way of the fluid passages 156 and 158. Thus, the fluid flow area is decreased so as to exert higher resistance to fluid flow. Therefore, the damping force of the shock absorber 114 is increased.
As will be appreciated herefrom, when the controller orders SOFT mode when the phase difference indicative signal have is smaller than a predetermined value, the actuator 146 is energized to lower the spool to establish fluid communication between the upper and lower fluid chambers 126 and 128 through the fluid passage 156. On the other hand, when the controller orders HARD mode in response to the phase difference indicative signal is equal to or greater than the predetermined value, the actuator 146 is deenergized to move the spool 155 to its upper position by means of the bias spring 146d. Thus, fluid communication between the upper and lower fluid chambers 126 and 128 via the fluid passage 156 is blocked.
It should be appreciated that the following description of the automotive suspension control system is merely an example of application of the phase difference signal derived by the preferred embodiment of the ultra-sonic sensor system. Therefore, it should be understood that the phase difference signal is applicable to various suspension control systems and other systems which require roll information and/or the lateral acceleration exerted on the vehicle as parameters.
FIGS. 8 and 9 show examples of arrangement of the ultra-sonic sensors for detecting pitching and rolling of the vehicle. For instance, when the ultra-sonic sensors are arranged in longitudinal alignment as shown in FIG. 8, the phase difference represents the difference of the vehicular height at the front and rear ends of the vehicle and thus represents vehicular pitching. On the other hand, when the ultra-sonic sensors are arranged in a lateral alignment, the phase difference represents a difference of the vehicular height at both lateral sides of the vehicle and thus represents magnitude of vehicular rolling.
Although the peak value of the envelope signal has been disclosed as being detected by comparing the envelope signal value with a delayed envelope signal value in the shown embodiment, it would be possible to arithmetically derive the timing of the peak of the envelope signal by differentiating the envelope signal and detecting zero-crossing of the differentiated value. Also, the peak detection of the envelope signal can be implemented in various ways. Therefore, the specific manner disclosed in the discussion of the preferred embodiment of the invention should not be taken as a feature specifying the invention.
Furthermore, the present invention can be embodied in various ways other than the shown embodiment. Therefore, the invention should not be interpreted as being limited to the features disclosed in the preferred embodiment. | An ultra-sonic senor system suitable for monitoring movement of a vehicle, relative to the horizontal employs two or more coordinated ultra-sonic sensors. The sensors may be mounted at opposite ends or on opposite sides of the vehicle, depending on whether pitch or roll respectively is to be monitored. Each sensor broadcasts ultra-sonic waves and receives ultra-sonic waves reflected by the road surface. The transmission time is known; the reception time is measured upon detection of the peak of the reflected waves. The difference between the two above times yields the distance between the vehicle and the road. The difference between the distances measured by two sensor yields the inclination of the vehicle relative to the horizontal plane. | 8 |
TECHNICAL FIELD
This invention relates generally to scintillation or gamma cameras and in particular to a species of such cameras designed to rotate about a patient for emission computed axial tomography sometimes referred to as ECT or ECAT or SPECT, for single photon emission computed tomography.
BACKGROUND ART
Traditionally nuclear medicine focused on the generation of two-dimensional images constructed from a volume of interest, although a variety of imaging devices have been proposed to perform three-dimensional imaging using an Anger type gamma camera. Since about 1980, several nuclear camera manufacturers have commercially introduced rotational type nuclear camera systems featuring a rotatable detector or camera head having a parallel hole collimator for data collection and an associated digital computer. The computer processes the collected data and performs known CT-type algorithms for reconstructing tomograms, i.e., two-dimensional images of a patient along a plane intersecting the patient.
One such ECT system is described in U.S. Pat. No. 4,426,578 to Bradcovich, et al. and assigned to the assignee of the instant application. Bradcovich, et al. invented a system that features a counterbalanced C-arm supporting a camera head at one end thereof for rotation about a longitudinal axis through a patient. The radial distance between the camera head and the longitudinal axis is rendered adjustable by displacement of the C-arm along a circumferential path relative to a so-called carrier member which rotatably attaches the C-arm to a stationary base. Another ECT apparatus is described in U.S. Pat. No. 4,216,381 to Lange which features a rotatable detector head supported by a pair of elongated frame members that pivotally support the detector head as it rotates about a longitudinal axis through a patient. In the Lange arrangement, the radial distance between the longitudinal axis and the detector head is adjusted by tilting the elongated frame pair which are mounted within a circular frame supported, in turn, by a pair of upright stanchions.
Regardless of the type of apparatus used to support the rotatable camera head, the reconstruction algorithms are always based on the collection of projection data acquired at a set of viewing angles about the patient by the rotating detector and subsequent back-projection of the data by means of the computer. For a detailed discussion of the general approach see, for example, Keyes Jr., "Computed tomography in nuclear medicine". Accurate retracing of projection lines during back-projection is essential to assuring good image resolution and quality. In ECT operation a major degradation in image quality is caused by deviations between the actual photon paths of the data collected and their paths traced during back-projection.
Regardless of the specific type of reconstruction algorithm used to generate the desired planar images or tomograms, the techniques uniformly assume that the camera head always follows the expected path. In practice, however, the actual path of the detector deviates from the expected path so that its position at each angle will exhibit some offset due mostly to mechanical flex in the detector support system and, to a lesser degree, to electronic image plane shift. This is caused by slight variances among the camera's Photo Multiplier Tubes' operation which originates from the varying orientation between the detector plane and the earth/ambient magnetic field. These deviations have largely been ignored resulting in errors in the reconstructed image.
Errors of this sort are generally unavoidable. It has been found, however, that they are nonetheless predictable since the amount of deviation in any particular system is measurable. While the amount of deviation varies as a function of viewing angle the errors tend to be relatively constant from rotation to rotation over a long period of time.
SUMMARY OF THE INVENTION We have invented a method of correcting for deviations in the actual detector position of a rotating gamma camera from the expected position at each angle of rotation by having the location of each gamma event shifted by a known offset amount in the x,y directions at each viewing angle on an event-by-event basis. The application of the method involves the calibration of a gamma camera which includes generating a set of pairs of value for a plurality of viewing angles, each pair including an x and y offset value and altering, in real time, the detected location of each event by the appropriate offset values previously measured for the corresponding viewing angle.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic perspective view of a prior art ECT apparatus featuring a rotatable camera head supported by a movable counterbalanced C-arm which provides for adjustment of the radius of rotation;
FIG. 2 is a diagrammatic perspective view of another prior art ECT apparatus featuring a rotatable camera head supported by a pair of elongated frame members tiltably mounted within a circular frame wherein the degree of tilt of said frame member defines the radial distance between the camera head and the axis of rotation;
FIG. 3 is a diagrammatic geometric illustration showing, in phantom, an ideal cylindrical path of the planar face of the detector head of FIG. 1 and also showing deviations in both the x and y directions of the location of the face of said detector head at three angular locations;
FIG. 4 is a diagrammatic representation of a set of planar images illustrating the lack of registration introduced by deviations in the location of the detector head relative to an assumed path, such as illustrated in FIG. 3;
FIG. 5 is a diagram similar to FIG. 4 illustrating projections of data in registration;
FIG. 6 is a diagrammatic flow chart of the correction method in accordance with the present invention; and
FIG. 7 is an illustration of a look-up table generated during the calibration phase of the method outlined in FIG. 6.
DETAILED DESCRIPTION
The apparatus illustrated in FIG. 1 is a prior ECT nuclear camera system commercially available under the name Omega 500 from Technicare Corporation, Solon, Ohio 44139. A detailed description of the Omega 500 is included in the '578 patent to Bradcovich, et al., the specification of which is incorporated herein by reference. Briefly, the nuclear camera comprises a base member 10 which is retained stationary for tomographic studies. Attached to base member 10 is carrier member 20 which is rotatable about a longitudinal axis x. Carrier member 20 is provided with a wide central groove for engaging a counterbalanced C-shaped support member or C-arm 30. One end of the C-arm 30 terminates in a yoke 40 to which a scintillation detector or camera head 50 is pivotally attached. To the other end of C-arm 30 is attached a counterweight 60. The patient being diagnosed is placed on a cantilevered patient support 70 which is secured to patient table 80. In operation, scintillation detector 50 is placed as close to the patient as possible while permitting clearance between the detector and the patient and the patient support during rotation of the camera and rotated about the patient along a defined path, generally circular. Data is acquired at a plurality of viewing angles or continuously as the camera head is rotated about the patient, typically by a motorized mechanism. The data collected from the various viewing angles is subsequently reconstructed by an associated digital computer (not shown) and tomographic images of desired planar slices of the patient are generated. The radius of rotation of the detector head is adjustable by moving the C-arm 30 relative to carrier member 20.
Another example of a prior art ECT nuclear camera is shown in FIG. 2. Although the principles of the invention are equally applicable to a system such as illustrated in FIG. 2, the following description will be with reference to the system of FIG. 1. In the system shown in FIG. 1, the detector head 50 is an Anger camera which includes a rectangular sodium iodide crystal 52 which defines a large planar rectangular viewing face. Located behind the crystal 52 within the camera head 50 is a glass window and an arrangement of 55 PMTs. In operation, the camera head 50 is rotated about a patient such that the midpoint of planar face 52 defines a generally circular path. In this manner, the planar detector face 52, as illustrated diagrammatically in FIG. 3, collects data, i.e., detects gamma events, at viewing angles all around the object being examined. Since there are very substantial masses involved in the rotation of the gamma camera head 50, the support structure, particularly C-arm 30, flexes by varying amounts as the carrier member 20 is rotated about the x axis. As this flexing occurs, the path traversed by the planar face 52 deviates from the purely cylindrical path represented by the phantom circles C in FIG. 3.
Using the hypothetical convention of 0° representing the twelve o'clock position, FIG. 3 shows the planar face 52 at the twelve o'clock position ideally situated. However, at the four o'clock position, or at approximately 120°, planar face 52 is shown to be offset by an increment along the direction of the longitudinal axis x. Thus, it can be seen, that when the data collected in the four o'clock position is combined with the data collected at the twelve o'clock position, a blurring error will be introduced since projections of the two sets of data will not be in registration. Similarly, FIG. 3 shows planar face 52 in the eight o'clock position, or at approximately 240°, exhibiting no deviation in the axial direction but being offset somewhat from the rotational axis or the y direction since the planar face should be located where indicated by phantom rectangle 52'.
Planar face 52 will, for any given viewing angle, have an offset in either or both the x and y directions in the frame of reference of the detector plane. Thus, for example, as shown in FIG. 4, a hypothetical frame designated 100 taken at zero degrees is properly aligned while frame 101 taken at one degree will have a deviation or offset in the x direction an amount Δx i and an offset in the y direction of Δy i . In general, for a frame i taken at angle θ i the offset will be Δx i in the x direction and Δy i in the y direction. Thus, as can be visually appreciated by the diagrammatic illustration of FIG. 4, the projection data collected from a set of viewing angles will not be in registry and, hence, errors will be introduced into the reconstructed image. Ideally, all of the projection data sets from the set of viewing angles should appear aligned, as illustrated in FIG. 5.
Thus, in order to retrace the photon path accurately during back-projection, each coordinate (x,y) of an event collected in the frame of reference of the detector should be converted to an (x',y') coordinate in the frame of reference of the projection data in accordance with the following relationship:
x'=x+Δx(θ)
y'=y+Δy(θ)
wherein Δx(θ) represents the offset in the x direction for viewing angle θ and Δy(θ) represents the offset in the y direction for that same viewing angle θ.
In actual operation, a look-up table, such as illustrated in FIG. 7, is first generated for each particular machine representing its systemic path deviations. An example of the method for generating these calibration values will be given below, although the particular method should be governed by ease and convenience depending on the particular system being utilized. Once the calibration values are generated, they are stored in a storage memory area. Then, at each angle θ, prior to the data collection, the matching pair of x(θ), y(θ) offsets are retrieved from the memory and stored in two registers R 1 and R 2 .
If the number of viewing angles used turns out to be greater than the number of offset pair entries generated for the look-up table, the offset pair for each such intermediate viewing angle is interpolated from the available values in the look-up table. Then, during the data collection, each incoming event location detected on the detector face 52 by x and y coordinates is digitally converted in real time within the camera to the projection coordinate (x',y') in accordance with the following relationship:
x'=x+R.sub.1
y'=y+R.sub.2
wherein R 1 , as stated above, is the x offset for the angle θ of the detector at the time the event is detected and R 2 is the offset in the y direction for the same angle.
If the camera head rotation is intended to be circular, then the expected path of the center of the camera face 52 is defined by a fixed radius. However, to accommodate patients of different sizes the radius of rotation, in such ECT systems as the Omega 500, is operator selectable. A separate look-up table may be generated for selected radii. Also, it is often desirable for improved resolution to have the camera head traverse in a non-circular path to thereby continuously maintain a minimum distance between the camera and the photon emitting patient whose sectional periphery is generally more elliptical than circular. Each such prescribed path will have predictable errors throughout the set of data collecting viewing angles and, in general, a look-up table may be generated for each path. The number of such tables will be governed by the severity of the problem and the differences in the calculated coordinate shifts for a viewing angle from one selectable path to another.
CALIBRATION
The preferred method for generating the y offset values for each angle θ requires collecting the point spread functions, PSF, from a source located within the field of view at each viewing angle. In other words, the response of the system to a single point or impulse at each viewing angle θ. In general, the PSF or impulse response function of a system is the resultant beam of finite width produced by the system in response to seeing a point impulse. Fortuitously, the centroids of the PSF set carries the detector coordinate shift information. If we assume that (x 1 ,y 1 ) (x 2 ,y 2 ) . . . (x i ,y i ) . . . (x n ,y n ) are the centroids at angles θ 1 , θ 2 ,. . . θ i ,. . . θ n , then the axial shift in the y direction is found by calculating the y i set average (Y) and y i deviation from the average at each angle as follows: ##EQU1## The above calculation will ensure that all angle PSF centroids are located at Y such that
y.sub.i +Δy.sub.i =y.sub.i +Y-y.sub.i =Y.
The shifts in the transverse or x direction at each angle can also be found from the point source centroid data (x 1 , x 2 , . . . x n ) at each angle (θ 1 , θ 2 , . . . θ n ), based on the fact that for parallel beam imaging the expected source position variation with angle is sinusoidal with no flexing of the support structure. If the point source is located off the rotation axis the distance from the rotation axis at each angle in case of no flex is given by
x.sub.i.sup.o =S·cosθ.sub.i +u·sinθ.sub.i,
where s and u are the distances measured in a fixed orthogonal coordinate centered at the rotation axis in a transverse plane. Suppose the distances of the collected centroids measured from the profile midpoints are x i 1 . Then the x offsets are found by their deviations, Δx i .
Δx.sub.i =(s·cosθ.sub.i +u·sinθ.sub.i)-x.sub.i.sup.1
where s and u are found by taking the first harmonic components in the Fourier series of the x i 1 (θ) set, given by ##EQU2## If, s, u are in slight error from the true values, its only effect on the parallel ray reconstruction is the image shift in s,u directions by the corresponding error amounts.
The above description of the preferred embodiment represents a purely digital approach to correcting the location of each scintillation on an event by event basis. Alternatively, all events collected at an angle θ can be shifted by the amount of the centroid shift calculated for that angle θ in both the x and y directions, as, for example, by the above described calibration techniques. | A method for correcting predictable errors in the location of detected scintillation events acquired during emission computed tomography by a rotational scintillation gamma camera system. The method includes calibrating the rotational scintillation camera system and generating a look-up table comprising a set of pairs of x and y offset values, one pair for each viewing angle. The calibration reflects systemic deviations in the location of the rotating camera head detector measured in terms of x and y coordinates in the frame of reference of the detector for a plurality of view angles relative to the geometric ideal expected path. Once a look-up table is generated for a camera system, the detected location of each gamma event is altered in real time by adjusting in the camera head the x,y coordinate location of each event by the x,y offset values previously generated for the corresponding viewing angle associated with the detected event. | 6 |
FIELD OF THE INVENTION
The invention is directed to polyurethane elastomers (PU elastomers), a process for their production with special catalyst mixtures and uses thereof.
BACKGROUND OF THE INVENTION
PU elastomers have long been known and have already been customized for a wide variety of applications, see for example U.S. Pat. No. 5,952,053. In order to control their polymerization rates, a large number of diverse metal catalysts have been investigated and used. In addition to the widespread use of organotin compounds, it is also known to use organic compounds or organic salts of various other elements, such as lithium, titanium and bismuth.
The use of lithium salts of organic acids has also been described. Mixtures of a lithium carboxylate, namely lithium neodecanoate, lithium octanoate, lithium stearate or lithium naphthenate, and a zinc carboxylate are described in U.S. Pat. No. 4,256,847 as an effective catalyst combination for rigid foam applications. Lithium is known to be highly active. Other publications list lithium as the sole metal catalyst for the catalysis of PU reactions. In U.S. Pat. No. 4,107,069, lithium carboxylates are used as stable gel catalysts for rigid PU foams. U.S. Pat. No. 3,108,975 discloses their use as catalysts for rigid and flexible, as well as, cellular and non-cellular polyurethanes. The use of lithium carboxylates as a trimerization catalyst is likewise known, in fact in U.S. Pat. No. 3,634,345, moisture-insensitive, readily soluble aromatic carboxylates are used for PU resin production. in U.S. Pat. No. 3,940,517 aliphatic lithium carboxylates are used for PU foams and in U.S. Pat. Nos. 6,127,308 and 5,955,609, the controllability of the trimerization reaction is used for PU foams and prepolymer synthesis. The same procedure is used in the production of rigid foams in DE-A 59 101 001. Finally, in U.S. Pat. No. 2,894,919, lithium carboxylates, namely lithium stearate and lithium caprylate, are used as catalysts in order to produce exclusively elastic, flexible PU foams.
Organic titanium compounds have been used since the 1960's as catalysts for the synthesis of polyurethanes, such as those listed in U.S. Pat. No. 5,902,835. Known organic titanium compounds include, titanium carboxylates, as disclosed in U.S. Pat. No. 5,162,382, alkyl titanates, as disclosed in Saunders, J. H.; Frisch, K. C. Polyurethanes—Chemistry and Technology (1962) London Part I p. 168, JP 2 001/026 629, JP 5 097 952 and titanium diketonates and titanium β-keto esters, as disclosed in U.S. Pat. No. 5,902,835, DE-A 19 626 007, WO 98/15585, Chemical Abstract, Vol. 108:56652. Organic titanium compounds are commonly used as expansion and gel catalysts. Their range of applications extends from water-expanded PU foams and mechanically foamed, thermally curing PU foams to PU surface coatings to RIM systems for flexible PU foams.
Organic bismuth compounds are also known to be used as catalysts, see for example, Luo, S.-G.; Tan, H.-M.; Zhang, J.-G.; Wu, Y.-J.;
Pei, F.-K.; Meng, X.-H. J. Appl. Polym. Sci. (1997) 65(6), p. 1217-1225. Of the group of organic bismuth compounds, carboxylates are predominantly used, as disclosed in CA-A 2 049 695, DE-A 19 618 825, U.S. Pat. No. 5,792,811, and WO 2000/47642. In addition, bismuth organothiolates are used as latent catalysts, see for example, WO 95/29007 and U.S. Pat. Nos. 5,910,373, and 6,190,524. The use of bismuth compounds together with organic zinc or tin compounds is also known, see for example WO 96/20967, U.S. Pat. Nos. 5,910,373, 6,001,900, 5,859,165, 6,124,380 and 6,190,524, WO 98/14492 and WO 2000/46306. The field of application for the use of bismuth catalysts mentioned above is mainly in the area of surface coating.
In addition to the combinations of metal catalysts already mentioned, such as e.g. tin and zinc compounds, a number of catalyst combinations comprising organic compounds, of the elements, lithium, titanium or bismuth can also be found in the literature. U.S. Pat. Nos. 5,952,053, 5,952,053 and WO 2000/46306 list combinations of lithium and bismuth compounds and U.S. Pat. No. 5,902,835 discloses that organic titanium compounds can be combined with bismuth compounds, however these metal catalyst combinations display no special effects.
Shoe soles, among other things, are an important application for PU elastomers. The catalyst systems used in their production must provide for good processability of the soles. Specifically, this includes short demolding times and high demolding hardness values, as well as, long cream times, to ensure that every part of the mold is filled. The catalysts must also promote good end properties, such as high final hardness values and low puncture expansion values under repeated flexural stress. Commercial organotin catalysts do not satisfy this list of requirements.
SUMMARY OF THE INVENTION
An object of the present invention is to provide PU elastomers having high final hardness values and low puncture expansion values under repeated flexural stress, as well as a process, in which short demolding times, high demolding hardness values and long cream times are possible.
Surprisingly this object can be achieved with special catalyst combinations containing lithium and titanium compounds or organic lithium, titanium and bismuth compounds. In the case of a three-component mixture, the concentration of catalyst used can also be reduced, in comparison to the two-component mixture, with an otherwise identical effect, giving rise, in addition, to toxicological and economic advantages.
DETAILED DESCRIPTION OF THE INVENTION
The invention provides polyurethane elastomers produced by reacting
a) organic diisocyanates and/or polyisocyanates with
b) at least one polyether polyol having a number-average molecular weight of 800 g/mol to 25,000 g/mol, preferably 800 to 14,000 g/mol, more preferably 2,000 to 9,000 g/mol and having an average functionality of 1.6 to 2.4, preferably 1.8 to 2.4,
c) optionally at least a second polyether polyol differing from b) and having a number-average molecular weight of 800 g/mol to 25,000 g/mol, preferably 800 to 14,000 g/mol, more preferably 2,000 to 9,000 g/mol and having average functionalities of 2.4 to 8, more preferably 2.5 to 3.5,
d) optionally polymer polyols containing 1 to 50 wt. %, preferably 1 to 45 wt. % filler, relative to polymer polyol, and having hydroxyl values of 10 to 149 and average functionalities of 1.8 to 8, preferably 1.8 to 3.5,
e) optionally low-molecular chain extenders having average functionalities of 1.8 to 2.1, preferably 2, and having molecular weights of 750 g/mol and lower, preferably 18 g/mol to 400 g/mol, more preferably 60 g/mol to 300 g/mol, and/or crosslinking agents having average functionalities of 3 to 4, preferably 3, and having molecular weights of up to 750 g/mol, preferably 18 g/mol to 400 g/mol, particularly preferably 60 g/mol to 300 g/mol, in the presence of
f) amine catalysts and a catalyst mixture containing
i) at least one organic titanium and/or zirconium compound,
ii) and at least one organic lithium carboxylate,
iii) optionally additionally at least one organic bismuth carboxylate,
g) optionally blowing agents, and
h) optionally additives,
wherein the ratio of the amount of substance n Ti of titanium ions and/or n Zr of zirconium ions in component i) to the amount of substance n Li of lithium ions in component ii) is 0.2 to 4, preferably 0.43 to 1.5 and if component iii) is used the ratio of the amount of substance n Bi of bismuth ions in component iii) to the sum of the amounts of substance n Ti and/or n Zr and n Li is 0.0001 to 0.53, preferably 0.0001 to 0.24, more preferably 0.0001 to 0.15.
The PU elastomers are preferably produced by the prepolymer process, whereby in the first step a polyaddition adduct, having isocyanate groups, is produced from at least a portion of the polyether polyol b) or a mixture thereof, with polyol component c) and at least one diisocyanate or polyisocyanate a). In the second step solid PU elastomers can be produced from prepolymers having such isocyanate groups, by the reaction with low-molecular weight chain extenders and/or crosslinking agents d) and/or the remaining portion of the polyol components b) and optionally c). If water or another blowing agent, or mixtures thereof, are additionally used in the second step, microcellular PU elastomers can be produced.
Aliphatic, cycloaliphatic, araliphatic, aromatic and heterocyclic polyisocyanates, such as those described by W. Siefken in Justus Liebigs Annalen der Chemie, 562, pages 75 to 136, are suitable as starting component a) for the process according to the present invention, for example those having the formula:
Q(NCO) n
in which n denotes 2-4, preferably 2, and Q denotes an aliphatic hydrocarbon radical with 2 to 18, preferably 6 to 10 C atoms, a cycloaliphatic hydrocarbon radical with 4 to 15, preferably 5 to 10 C atoms, an aromatic hydrocarbon radical with 6 to 15, preferably 6 to 13 C atoms, or an araliphatic hydrocarbon radical with 8 to 15, preferably 8 to 13 C atoms. Suitable examples include ethylene diisocyanate, 1,4-tetramethylene diisocyanate, 1,6-hexamethylene diisocyanate (HDI), 1,12-dodecane. diisocyanate, cyclobutane-1,3-diisocyanate, cyclohexane-1,3- and -1,4-diisocyanate and any mixtures of these isomers, 1-isocyanato-3,3,5-trimethyl-5-isocyanatomethyl cyclohexane, 2,4- and 2,6- hexahydro-toluene diisocyanate and any mixtures of these isomers, hexahydro-1,3-and -1,4-phenylene diisocyanate, perhydro-2,4′- and 4,4′-diphenylmethane diisocyanate, 1,3- and 1,4-phenylene diisocyanate, 1,4-durene diisocyanate (DDI), 4,4′-stilbene diisocyanate, 3,3′-dimethyl4,4′-biphenylene diisocyanate (TODI), 2,4- and 2,6-toluene diisocyanate (TDI) and any mixtures of these isomers, diphenylmethane-2,4′- and/or -4,4′-diisocyanate (MDI), or naphthylene-1,5-diisocyanate (NDI).
Other examples include, triphenylmethane-4,4′,4″-triisocyanate, polyphenyl polymethylene polyisocyanates, such as those obtained by aniline-formaldehyde condensation and subsequent phosgenation and those described in GB-A 874 430 and GB-A 848 671, m- and p-isocyanatophenyl sulfonyl isocyanates according to U.S. Pat. No. 3,454,606, perchlorinated aryl polyisocyanates, such as those described in U.S. Pat. No. 3,277,138, polyisocyanates having carbodiimide groups, such as those described in U.S. Pat. No. 3,152,162 and in DE-A 25 04 400, DE-A 25 37 685 and DE-A 25 52 350, norbornane diisocyanates according to U.S. Pat. No. 3,492,301, polyisocyanates having allophanate groups, such as those described in GB-A 994 890, BE-A 761 626 and NL-A 7 102 524, polyisocyanates having isocyanurate groups, such as those described in U.S. Pat. No. 3,001,9731, in DE-A 10 22 789, DE-A 12 22 067 and DE-A 1 027 394, as well as in DE-A 1 929 034 and DE-A 2 004 048, polyisocyanates having urethane groups, such as those described in BE-A 752 261 or in U.S. Pat. No. 3,394,164 and DE-A 3 644 457, polyisocyanates having acylated urea groups according to DE-A 1 230 778, polyisocyanates having biuret groups, such as those described in U.S. Pat. Nos. 3,124,605, 3,201,372 and U.S. Pat. No. 3,124,605 and in GB-A 889 050, polyisocyanates produced by telomerization reactions, such as those described in U.S. Pat. No. 3,654,106, polyisocyanates having ester groups, such as those cited in GB-A 965 474 and GB-A 1 072 956, in U.S. Pat. No. 3,567,763 and in DE-A 12 31 688, reaction products of the above-mentioned isocyanates with acetals according to DE-A 1 072 385 and polyisocyanates containing polymeric fatty acid esters according to U.S. Pat. No. 3,455,883.
The distillation residues having isocyanate groups that are obtained during industrial isocyanate production, optionally dissolved in one or more of the aforementioned polyisocyanates, can also be used. It is also possible to use any mixture of the aforementioned polyisocyanates. Polyisocyanates that are readily accessible in industry are preferably used, for example 2,4- and 2,6-toluene diisocyanate and any mixtures of these isomers (“TDI”), 4,4′-diphenylmethane diisocyanate, 2,4′-diphenylmethane diisocyanate, 2,2′-diphenylmethane diisocyanate and polyphenyl polymethylene polyisocyanates, such as are produced by aniline-formaldehyde condensation and subsequent phosgenation (“crude MDI”), and polyisocyanates having carbodiimide groups, uretonimine groups, urethane groups, allophanate groups, isocyanurate groups, urea groups or biuret groups (“modified polyisocyanates”), in particular modified polyisocyanates that are derived from 2,4- and/or 2,6-toluene diisocyanate or from 4,4′- and/or 2,4′-diphenylmethane diisocyanate. Naphthylene-1,5-diisocyanate and mixtures of the cited polyisocyanates are also suitable.
Prepolymers having isocyanate groups that are produced by reacting at least a portion of the polyol component b) and/or c) and/or chain extenders and/or crosslinking agents e) with at least one aromatic diisocyanate from the group TDI, MDI, TODI, DIBDI, NDI, DDI, preferably with 4,4′-MDI and/or 2,4-TDI and/or 1,5-NDI, to form a polyaddition product, having urethane groups and isocyanate groups, and having an NCO content of 10 to 27 wt. %, preferably 12 to 25 wt. %, are preferably used.
As stated above, mixtures of components b), c) and e) can be used to produce the isocyanate group-containing prepolymers. Preferably, the prepolymers containing isocyanate groups are produced without chain extenders or crosslinking agents e).
Prepolymers having isocyanate groups can be produced in the presence of catalysts. It is also possible to produce the prepolymers in the absence of catalysts. However, the catalyst is incorporated into the reaction mixture for production of the PU elastomers.
Suitable polyether polyols b) or c) useful for production of the elastomers, according to the present invention, can be produced by known methods, for example by polyinsertion via DMC catalysis of alkylene oxides, by anionic polymerization of alkylene oxides in the presence of alkali hydroxides or alkali alcoholates as catalysts and with the addition of at least one initiator molecule containing 2 to 6, preferably 2 to 4 reactive hydrogen atoms in bonded form, or by cationic polymerization of alkylene oxides in the presence of Lewis acids such as antimony pentachloride or boron fluoride etherate. Suitable alkylene oxides contain 2 to 4 carbon atoms in the alkylene radical. Examples include tetrahydrofuran, 1,2-propylene oxide, 1,2- or 2,3-butylene oxide; ethylene oxide and/or 1,2-propylene oxide are preferably used. The alkylene oxides can be used individually, in succession or as a mixture. Mixtures of 1,2-propylene oxide and ethylene oxide are preferably used, whereby the ethylene oxide is used in quantities of 10 to 50% as an ethylene oxide terminal block (“EO cap”) so that the resulting polyols display over 70% primary OH terminal groups. Examples of initiator molecules include water or dihydric and trihydric alcohols, such as ethylene glycol, 1,2-propanediol and 1,3-propanediol, diethylene glycol, dipropylene glycol, ethane-1,4-diol, glycerol, trimethylol propane, etc. Suitable polyether polyols, preferably polyoxypropylene polyoxyethylene polyols, have average functionalities of 1.6 to 2.4, preferably 1.8 to 2.4, and number-average molecular weights of 800 g/mol to 25,000 g/mol, preferably 800 to 14,000 g/mol, particularly preferably 2,000 to 9,000 g/mol.
Difunctional or trifunctional polyether polyols having a number-average molecular weight of 800 to 25,000, preferably 800 to 14,000 g/mol, more preferably 2,000 to 9,000 g/mol, are used as components b) or c) in the production of the elastomers according to the present invention.
Also suitable as polymer polyols d), in addition to the above-mentioned polyether polyols, are polymer-modified polyether polyols, preferably graft polyether polyols, in particular those based on styrene and/or acrylonitrile that are produced by in-situ polymerization of acrylonitrile, styrene or preferably mixtures of styrene and acrylonitrile, in a ratio by weight of 90:10 to 10:90, preferably 70:30 to 30:70, and polyether polyol dispersions which contain as disperse phase, in quantities of 1 to 50 wt. %, preferably 1 to 45 wt. %, relative to polymer polyol, inorganic fillers, polyureas (PHD), polyhydrazides, polyurethanes containing tert.-amino groups in bonded form and/or melamine, for example.
Low-molecular difunctional chain extenders, trifunctional or tetrafunctional crosslinking agents or mixtures of chain extenders and crosslinking agents can additionally be used as component e) to produce the PU elastomers according to the present invention.
Such chain extenders and crosslinking agents e) are used to modify the mechanical properties, in particular the hardness of the PU elastomers. Suitable chain extenders include alkane diols, dialkylene glycols and polyalkylene polyols, and crosslinking agents, such as trihydric or tetrahydric alcohols and oligomeric polyalkylene polyols with a functionality of 3 to 4 and molecular weights<750 g/mol, preferably from 18 to 400 g/mol, more preferably from 60 to 300 g/mol. Alkane diols having 2 to 12, preferably 2, 4 or 6 carbon atoms, such as ethanediol, 1,6-hexanediol, 1,7-heptanediol, 1,8-octanediol, 1,9-nonanediol, 1,10-decanediol and in particular 1,4-butanediol, and dialkylene glycols having 4 to 8 carbon atoms, such as diethylene glycol and dipropylene glycol as well as polyoxyalkylene glycols, are preferably used as chain extenders. Also suitable are branched-chain and/or unsaturated alkane diols with no more than 12 carbon atoms, such as 1,2-propanediol, 2-methyl-1,3-propanediol, 2,2-dimethyl-1,3-propanediol, 2-butyl-2-ethyl-1,3-propanediol, 2-butene-1,4-diol and 2-butyne-1,4-diol, diesters of terephthalic acid with glycols having 2 to 4 carbon atoms, such as terephthalic acid-bis-ethylene glycol or terephthalic acid-bis-1,4-butanediol, hydroxyalkylene ethers of hydroquinone or resorcinol, e.g. 1,4-di(β-hydroxyethyl) hydroquinone or 1,3-(β-hydroxyethyl) resorcinol, alkanolamines with 2 to 12 carbon atoms such as ethanolamine, 2-aminopropanol and 3-amino-2,2-dimethyl propanol, N-alkyl dialkanolamines, such as N-methyl and N-ethyl diethanolamine, (cyclo)aliphatic diamines with 2 to 15 carbon atoms, such as 1,2-ethylene diamine, 1,3-propylene diamine, 1,4-butylene diamine and 1,6-hexa-methylene diamine, isophorone diamine, 1,4-cyclohexamethylene diamine and 4,4′-diaminodicyclohexyl methane, N-alkyl-substituted, N,N′-dialkyl-substituted and aromatic diamines, which can also be substituted at the aromatic radical by alkyl groups, having 1 to 20, preferably 1 to 4 carbon atoms in the N-alkyl radical, such as N,N′-diethyl, N,N′-di-sec.-pentyl, N,N′-di-sec.-hexyl, N,N′-di-sec.-decyl and N,N′-dicyclohexyl (p- or m-) phenylene diamine, N,N′-dimethyl, N,N′-diethyl, N,N′-diisopropyl, N,N′-di-sec.-butyl, N,N′-dicyclohexyl, -4,4′-diaminodiphenylmethane, N,N′-di-sec.-butyl benzidine, methylene bis(4-amino-3-methyl benzoate), 2,4-chloro-4,4′-diaminodiphenylmethane, 2,4- and 2,6-toluene diamine.
The compounds in component e) can be used in the form of mixtures or individually. Mixtures of chain extenders and crosslinking agents can also be used.
To adjust the hardness of the PU elastomers, components b), c), d) and e) can be varied in relatively broad proportions. For example, the hardness increases with the rising content of component e) in the reaction mixture.
The amounts of components b), c), d) and e) that are used to obtain the desired hardness in the PU elastomer can easily be determined by experiment. For example, 1 to 50 parts by weight, preferably 2.5 to 20 parts by weight of the chain extender and/or crosslinking agent e), relative to 100 parts by weight of the higher-molecular compounds b), c) and d) can be used.
Amine catalysts that are familiar to a person skilled in the art can be used as component f), for example tertiary amines such as triethylamine, tributylamine, N-methyl morpholine, N-ethyl morpholine, N,N,N′,N′-tetramethyl ethylene diamine, pentamethyl diethylene triamine and higher homologues, according to DE-A 26 24 527 and DE-A 26 24 528, 1,4-diazabicyclo-[2,2 ,2]-octane, N-methyl-N′-dimethylaminoethyl piperazine, bis(dimethylaminoalkyl) piperazine, N,N-dimethyl benzylamine, N,N-dimethyl cyclohexylamine, N,N-diethyl benzylamine, bis(N,N-diethylaminoethyl) adipate, N,N,N′,N′-tetramethyl-1,3-butane diamine, N,N-dimethyl-β-phenyl ethylamine, bis(dimethylaminopropyl) urea, bis(dimethylaminopropyl) amine, 1,2-dimethyl imidazole, 2-methyl imidazole, monocyclic and bicyclic amidines, bis(dialkylamino) alkyl ethers, such as e.g. bis(dimethylaminoethyl) ethers, and tertiary amines having amide groups (preferably formamide groups) according to DE-A 25 23 633 and DE-A 27 32 292. Other examples of catalysts include known Mannich bases consisting of secondary amines, such as dimethylamine, and aldehydes, preferably formaldehyde, or ketones such as acetone, methyl ethyl ketone or cyclohexanone and phenols, such as phenol, nonyl phenol or bisphenol. Catalysts in the form of tertiary amines having hydrogen atoms that are active with respect to isocyanate groups are e.g. triethanolamine, triisopropanolamine, N-methyidiethanolamine, N-ethyl diethanolamine, N,N-dimethyl ethanolamine, reaction products thereof with alkylene oxides such as propylene oxide and/or ethylene oxide and secondary-tertiary amines according to DE-A 27 32 292. Silamines with carbon-silicon bonds, such as are described in U.S. Pat. No. 3,620,984, can also be used as catalysts, for example, 2,2,4-trimethyl-2-silamorpholine and 1,3-diethyl aminomethyl tetramethyl disiloxane. Other examples include nitrogen-containing bases such as tetraalkyl ammonium hydroxides, and also hexahydrotriazines. The reaction between NCO groups and Zerewitinoff-active hydrogen atoms is also accelerated by lactams and azalactams.
At least one organic carboxylate of lithium ii) with at least one organic compound of titanium and/or zirconium i) is preferably used as catalyst. If necessary the catalyst combination can be extended with at least one bismuth compound iii) as the third component. The catalysts can be added to the polyol formulation either as a prepared mixture or separately in the corresponding ratio. Separate addition is preferred.
Saturated or unsaturated, aliphatic or alicyclic and aromatic carboxylates of lithium that are familiar to the person skilled in the art can preferably be used as component ii). They correspond to the following general formulae:
[Li(OOCR)]
[Li 2 ((OOC) 2 R)]
wherein R is a hydrocarbon radical with 1 to 25 carbon atoms. Preferred catalysts include lithium(l) versatate, tallate, oxalate, adipate and stearate. More preferred catalysts are lithium(l) naphthenate, decanoate, butyrate, isobutyrate, nonate, benzoate and caprioate. Lithium(l) neodecanoate, 2-ethyl hexanoate and octanoate are also preferred.
Component ii) can also a solution of a lithium hydroxide or carbonate or a solution of a mixture of these salts in one or more of the carboxylic acids described above.
Organic compounds of titanium and/or zirconium that are familiar to a person skilled in the art can be used as component i). They preferably correspond to the following general formulae:
[M(L 1 )(L 2 )(L 3 )(L 4 )] n
[M(L 1 )(L 2 )(L 3 )] n
[M(L 1 )(L 2 )] n
[M(L 1 )] n
wherein M denotes titanium and zirconium, n can assume values from 1 to 20 and L 1 , L 2 , L 3 and L 4 are the same or different and can be ligands of the following groups co-ordinated via O, S or N atoms:
(1) Alcoholates, phenolates, glycolates, thiolates, carboxylates or amino alcoholates containing 1 to 20 carbon atoms and optionally one or more functional groups (e.g. hydroxyl, amino, carbonylato, etc.) or having bonds containing oxygen, sulfur or nitrogen (such as, in ethers, thioethers, amines or carbonyls),
(2) Various fluorine-free, sterically unhindered chelating ligands from the group of 1-diketones, such as benzoyl acetone, dibenzoyl methane, ethyl benzoyl acetate, methyl acetoacetate, ethyl acetoacetate and 2,4-pentane dione (also known as acetylacetone) and other chelating ligands, such as N,N-dimethyl ethanolamine, triethanolamine, salicylaldehyde, salicylamide, phenyl salicylate, cyclopentanone-2-carboxylic acid, bisacetyl acetylacetone, thioacetylacetone, N,N′-bis(salicylidene) ethylene diamine, glycolic acid, ethylene glycol etc.
Preferred components i) include titanium(IV) isopropoxide, titanium(IV)-n-butoxide, titanium(IV)-2-ethyl hexoxide, titanium(IV)-n-pentoxide, titanium(IV) (triethanolaminato) isopropoxide, titanium(IV) (triethanolaminato)-n-butoxide, isopropyl triisostearyl titanate, bis(8-quinolinolato) titanium(IV) dibutoxide, bis(ethyl acetoacetato) titanium(IV) diisobutoxide, titanium(IV) bis(ethyl acetoacetato) diisopropoxide, zirconium(IV) isopropoxide, zirconium(IV)-n-butoxide, zirconium(IV)-2-ethyl hexoxide, zirconium(IV)-n-pentoxide, zirconium(IV) (triethanolaminato) isopropoxide, zirconium(IV) (triethanolaminato)-n-butoxide, isopropyl triisostearyl zirconate, bis(8-quinolinolato) zirconium(IV) dibutoxide and bis(ethyl acetoacetato) zirconium(IV) diisobutoxide.
More preferred are titanium compounds with ligands such as those listed in paragraph (2) above. Of these titanium compounds, titanium(IV) diisopropoxide-bis(2,4-pentane dionate), titanium(IV) triisopropoxide (2,4-pentane dionate), ethoxy-bis(pentane-2,4-dionato-0,0′)(propan-2-olato) titanium, titanium(IV) oxide acetylacetonate, bis(diacetylacetonato) titanium(IV) butoxide isopropoxide and bis(diacetylacetonato) titanium(IV) ethoxide isopropoxide are preferably used.
Many of the catalysts listed under i) can form agglomerates and/or higher-molecular condensation products having two or more metal sites, which are connected with one another by one or more bridging ligands. For that reason n can vary from 1 to approximately 20. Compounds having n between 1 and 10 are preferred.
Component iii) contains saturated or unsaturated, aliphatic or alicyclic and aromatic bismuth carboxylates and preferably correspond to the following general formulae:
[Bi(OOCR) 3 ]
[Bi 2 ((OOC) 2 R) 3 ]
wherein R is a hydrocarbon radical having 1 to 25 carbon atoms.
Preferred carboxylates include bismuth(III) versatate, tallate, stearate, adipate, oxalate. Bismuth(III) naphthenate, decanoate, butyrate, isobutyrate, nonate, caprioate are also preferred. Bismuth(III) neodecanoate, -2-ethyl hexanoate and octanoate are more preferred.
Components i), ii) and/or iii) are preferably used as liquid preparations with one or more solvents. Saturated or unsaturated, aliphatic or alicyclic and aromatic carboxylic acids having the general formulae:
RCOOH
HOOC—R—COOH
can be used as solvent, wherein R is a hydrocarbon radical having 1 to 25 carbon atoms. Neodecanoic acid, 2-ethyl hexanoic acid and naphthenic acid, for example, are preferred.
In place of the aforementioned carboxylic acids, the following solvents can also be used:
(1) Aliphatic and aromatic liquids, such as Stoddard solvents, naphtha, white spirit, petroleum spirits, xylene, hexane, heptane, toluene and paraffinic mineral oil,
(2) Esters, such as ethyl acetate and isopropyl acetate,
(3) Alcohols, such as ethanol, n-propanol, isopropanol, n-butanol, 2-(2-butoxyethoxy) ethanol, 2-(2-ethoxyethoxy) ethanol, diethylene glycol, triethylene glycol, diethylene glycol monoethyl ether, ethylene glycol,
(4) Ketones, such as methyl ethyl ketone, acetone and
(5) Ethers, such as diethylene glycol butyl ether
(6) and water.
The catalyst combinations of components i) and ii) or i), ii) and iii) are generally used in a quantity of between approximately 0.001 and 10 wt. %, preferably 0.01 to 0.5 wt. %, relative to the total amount of compounds from b) to h).
The catalyst combinations of components i) and ii) are mixed in a ratio of the amount of substance n Ti of titanium ions and/or n Zr of zirconium ions in component i) to the amount of substance n Li of lithium ions in component ii) such that values of 0.2 to 4, preferably 0.43 to 1.5 are established. If component iii) is additionally used, component iii) is used in an amount of substance n Bi of bismuth ions in component iii) such that the ratio of the amount of substance n Bi of bismuth ions in component i) to the sum of n Ti and/or n Zr and n Li is 0.0001 to 0.53, preferably 0.0001 to 0.24, more preferably 0.0001 to 0. 15.
In the absence of moisture and physically or chemically acting blowing agents, compact PU elastomers, for example, PU shoe outer soles can be produced.
In the production of microcellular PU elastomers, water is preferably used as blowing agent g), which reacts in situ with the organic diisocyanates and/or polyisocyanates or with the prepolymers a) having isocyanate groups to form carbon dioxide and amino groups, which in turn undergo further reaction with other isocyanate groups to form urea groups, thereby acting as chain extenders.
When water is added to the polyurethane formulation to establish the desired density, it is used in quantities from 0.001 t o 3.0 wt. %, preferably 0.01 to 2.0 wt. % and in particular 0.05 to 0.7 wt. %, relative to the weight of components a), b) and optionally c), d) and e).
As blowing agent g), gases or highly volatile inorganic or organic substances which evaporate under the influence of the exothermic polyaddition reaction and preferably have a boiling point under normal pressure ranging from −40 to 120° C., preferably −30 to 90° C., can also be used as physical blowing agents in place of water or preferably in combination with water. Examples include acetone, ethyl acetate, halogen-substituted alkanes or perhalogenated alkanes, such as (R134a, R141b, R365mfc, R245fa), also butane, pentane, cyclopentane, hexane, cyclohexane, heptane or diethyl ether as organic blowing agents, and air, CO 2 or N 2 O as inorganic blowing agents.
An expansion effect can also be achieved by adding compounds that decompose at temperatures above room temperature with release of gases such as nitrogen and/or carbon dioxide, such as azo compounds, for example, azodicarbonamide or azoisobutyric acid nitrile, or salts such as ammonium bicarbonate, ammonium carbamate or ammonium salts of organic carboxylic acids, e.g. monoammonium salts of malonic acid, boric acid, formic acid or acetic acid. Further examples of blowing agents and details of the use of blowing agents are described in R. Vieweg, A. Höchtlen (Eds.): “Kunststoff-Handbuch”, Volume VII, Carl-Hanser-Verlag, Munich, 3 rd Edition, 1993, p. 115 to 118, 710 to 715.
The amount of solid blowing agents, low-boiling liquids or gases to be used, which in each case can be used alone or in the form of mixtures, such as liquid or gas mixtures or as gas-liquid mixtures, depending on the desired density and on the amount of water used. The desired amounts can easily be determined by experiment. Satisfactory results are delivered by amounts of solids of 0.5 to 35 wt. %, preferably 2 to 15 wt. %, amounts of liquids of 0.5 to 30 wt. %, preferably 0.8 to 18 wt. % and/or amounts of gases of 0.01 to 80 wt. %, preferably 10 to 50 wt. %, relative in each case to the weight of components a), b), c) d) and e). The introduction of gas, e.g. air, carbon dioxide, nitrogen and/or helium, can be achieved both through the higher-molecular polyhydroxyl compounds b), c) and d), through the low-molecular chain extender and/or crosslinking agent e) and through the polyisocyanates a) or through a) and b) and optionally c), d) and e).
Additives h) can optionally be added to the reaction mixture for production of compact or cellular PU elastomers. Examples that can be cited include surface-active additives, such as emulsifiers, foam stabilizers, cell regulators, flame retardants, nucleating agents, oxidation retarders, stabilizers, lubricants and mold release agents, dyes, dispersing agents and pigments. Examples of emulsifiers include the sodium salts of castor oil sulfonates or salts of fatty acids with amines such as oleic acid diethylamine or stearic acid diethanolamine. Alkali or ammonium salts of sulfonic acids such as dodecyl benzene sulfonic acid or dinaphthyl methane disulfonic acid for example or of fatty acids such as ricinoleic acid or of polymeric fatty acids can also additionally be used as surface-active additives. Examples of foam stabilizers include polyether siloxanes, preferably water-soluble examples. These compounds are generally structured so that a copolymer of ethylene oxide and propylene oxide is bonded with a polydimethyl siloxane radical. Such foam stabilizers are described in U.S. Pat. Nos. 2,834,748, 2 ,917, 480 and 3,629,308. Of particular interest are polysiloxane-polyoxyalkylene copolymers according to DE-A 25 58 523 that are multiply branched by means of allophanate groups. Also suitable are other organopolysiloxanes, oxyethylated alkyl phenols, oxyethylated fatty alcohols, paraffin oils, castor oil or ricinoleic acid esters, sulfated castor oil, peanut oil and cell regulators such as paraffins, fatty alcohols and polydimethyl siloxanes. Oligomeric polyacrylates with polyoxyalkylene and fluoroalkane radicals as side groups are also suitable for improving the emulsifying effect, dispersion of the filler, cell structure and/or stabilization. The surface-active substances are conventionally used in quantities of 0.01 to 5 parts by weight, relative to 100 parts by weight of the higher-molecular polyhydroxyl compounds b) and c). Reaction retarders, also pigments or dyes and flame retardants known per se, also stabilizers against the effects of aging and weathering, plasticizers and substances having fungistatic and bacteriostatic activity can also be added.
Other examples of surface-active additives and foam stabilizers as well as cell regulators, reaction retarders, stabilizers, flame-retardant substances, plasticizers, dyes and fillers and substances having fungistatic and bacteriostatic activity that can optionally additionally be used, as well as details of the mode of use and action of these additives are described in R. Vieweg, A. Höchtlen (Eds.): “Kunststoff-Handbuch”, Volume VII, Carl-Hanser-Verlag, Munich, 3 rd Edition, 1993, p. 118 to 124.
To produce the PU elastomers according to the present invention the components are reacted in quantities so that the equivalent ratio of NCO groups in isocyanates a) to the sum of the isocyanate group-reactive hydrogens in components b), c), d) and e) and of any chemically acting blowing agents g) that may be used is 0.8:1 to 1.2:1, preferably 0.95:1 to 1.15:1 and more preferably 1.00:1 to 1.05:1.
The PU elastomers according to the present invention can be produced by the processes described in the literature, such as the one-shot or prepolymer process, with the aid of mixing devices that are known to a person skilled in the art. Preferably, the PU elastomers are produced by the prepolymer process.
In one embodiment of the production of the PU elastomers according to the invention the starting components are homogeneously mixed in the absence of blowing agents g), at a temperature of 20 to 80° C., preferably 25 to 60° C., the reaction mixture introduced into an open, optionally temperature-controlled mold and cured. In another variant of the production of the PU elastomers according to the invention the structural components are mixed in the presence of blowing agents g), preferably water, and introduced into the optionally temperature-controlled mold. After it has been filled the mold is closed and the reaction mixture is allowed to foam with packing. The degree of packing (ratio of molding density to free foam density) used is 1.05 to 8, preferably 1.1 to 6 and in particular 1.2 to 4, to form moldings. As soon as the moldings have sufficient strength they are demolded. The demolding times are dependent inter alia on the temperature and geometry of the mold and on the reactivity of the reaction mixture and are conventionally 1.5 to 15 minutes.
The PU elastomers according to the present invention have densities ranging from 180 to 1100 kg/m 3 , depending inter alia on the content and type of filler. They are used for example in molded soles or in one-component direct soling systems with densities of 400 to 650 kg/m 3 , in boot legs with densities of 500 to 700 kg/m 3 , in tightly compressed or compact outer soles of two-layer soles or direct soling systems with densities of 800 to 1100 kg/m 3 , in intermediate soles of two-layer soles or direct soling systems with densities of 400 to 500 kg/m 3 and in insoles with densities of 180 to 400 kg/m 3 .
The PU elastomers according to the invention are especially valuable raw materials for shoe soles having a single or multi-layered construction.
The invention is explained in greater detail by means of the following examples.
EXAMPLES
The polyurethane specimens were produced by mixing the A component (Table 1) at 30° C. in a low-pressure foaming plant (ND1) with the B component (Table 2) at 30° C., pouring the mixture into a folding aluminum mold heated to 50° C. (size 200×140×10 mm), closing the folding mold and demolding the elastomer after 3 minutes.
From the elastomer sheets thus produced the Shore-A hardness (DIN 53 505) was determined directly after demolding and after storage for 24 h. The puncture expansion (DIN 53 522) of a 2 mm wide puncture in the bending line of specimens (measuring 2 cm×15 cm×1 cm) after 60,000 bending cycles was also determined. The results are set out in Tables 4 to 8.
Examples 1-5
The polyurethane elastomer was obtained by reacting 100 parts of the polyol formulation (A component, see Table 1) and 61 parts of the prepolymer (B component, see Table 2). The individual examples together with their physical and chemical properties are listed in Tables 4 to 8. The chemical names corresponding to the trade names of the catalysts and other components listed in the tables are set out in Table 3. In addition to the catalyst combinations according to the invention, experiments were also performed with metal compounds and mixtures not according to the invention for comparative purposes.
TABLE 1
Polyol formulation (A component)
Wt. %
A component
Remainder
Polyether diol b) (ratio by weight PO:EO 70:30;
up to 100
molecular weight 4000 g/mol)
10
Polyether triol c)) (ratio by weight PO:EO 78:22;
molecular weight 6000 g/mol)
10
Butanediol e)
0.2
TELA e)
0.5
DABCO f)
Y
Catalysts and quantity (see Table 4)
0.10
DC-190 h)
0.35
Water g)
TABLE 2
Formulation of the prepolymer (B component)
Wt. %
B component
66
4,4′-MDI a)
5
Polymeric MDI (29.8 wt. % NCO, functionality 2.1) a)
29
Mixture of tripropylene glycol and PO polyethers; number-
average molecular weight 690 g/mol: functionality ˜2 b)
TABLE 3
Explanation of trade names/abbreviations
Trade name or
Chemical
abbreviation
name
Tyzor ® AA 95
Bis(diacetylacetonato) titanium(IV)
from DuPont
butoxide isopropoxide in butanol
Tyzor ® AA 105
Bis(diacetylacetonato) titanium(IV)
from DuPont
ethoxide isopropoxide
Li 2 Hex-Cem ®
Lithium-2-ethyl hexanoate in
from OMG
2-(2-ethoxyethoxy) ethanol
(Ontokumpu
Mooney Group)
Li Ten-Cem ®
Lithium neodecanoate in aqueous solution
water sol. from
OMG
DBTL
Dibutyl tin dilaurate
Coscat ® 83 from
Bismuth(III) neodecanoate
D. H. Erbslöh
TELA
Triethanolamine
DABCO
Diaminobicyclooctane
DC-190 ® from
Foam stabilizer
Air Products
TABLE 4
Use of tin catalysts (prior art)
Tack
Shore-A hardness determined ×
Shore-A
Tin catalyst
Cream
free
min after demolding
hardness
Puncture expansion
Amount
time in
time
after
after
after
after
24 h after
in mm after
Experiment
Name
in wt. %
[sec]
[sec]
0 min
2 min
10 min
60 min
demolding
b = 60,000 bends
1
DBTL
0.02
11
22
37
42
47
51
54
35000*/30000*
35000*/30000*
2
DBTL
0.03
10
15
34
38
44
48
52
6.7/60000*
All values marked with * indicate the number b of bends after which a test strip was broken.
TABLE 5
Use of Ti, Li and Bi catalysts with various ligands
Lithium component
Titanium component
Bismuth component
Amount
Amount
Amount
Experiment
Name
in wt. %
Name
in wt. %
Name
in wt. %
[nTi:nLi]
nBi:(nTi + nLi)
3
Tyzor AA 105
0.15
4
Li-2-Hex Cem
0.06
Tyzor AA 105
0.09
1.38
5
Li Ten Cem
0.15
6
Li Ten Cem
0.1
Tyzor AA 95
0.1
0.25
7
Octa Soligen
0.1
Tyzor AA 95
0.1
0.85
Lithium
8
Li stearate
0.03
Tyzor AA 95
0.04
Coscat 83
0.02
1.83
0.7
9
Li benzoate
0.0014
Tyzor AA 95
0.04
Coscat 83
0.02
1.83
0.7
10
Li-2-Hex Cem
0.04
Tyzor AA 95
0.04
Bis-2-ethyl
0.014
0.92
0.07
hexanoate 72%
in mineral spirit
11
Li-2-Hex Cem
0.04
Tyzor AA 95
0.04
Bis-2-ethyl
0.014
0.92
0.07
hexanoate 72%
in xylene
Shore-A hardness determined ×
min after demolding
Puncture expansion
Cream time in
Tack free time
after
after
after
after
Shore-A hardness
in mm after
Experiment
[sec]
[sec]
0 min
2 min
10 min
60 men
24 h after demolding
b = 60,000 bends
3
11
17
30
35
45
54
56
4.1/3.2
4
11
24
33
38
46
52
54
2.9/2.2
5
11
33
25
30
39
43
48
4.3/6.2
6
11
20
28
42
49
52
54
1.8/3.6
7
12
27
45
40
48
52
52
1.8/2.9
8
9
22
31
35
45
50
54
2.4/1.2
9
9
24
32
36
46
51
53
60000*/55000*
10
11
26
33
39
47
51
53
2.1/1.8
11
11
22
33
41
46
50
53
3.3/1.9
All values marked with * indicate the number b of bends after which a test strip was broken.
TABLE 6
Use of Ti and Li catalysts in various amounts
Lithium component
Titanium component
Amount
Amount
Experiment
Name
in wt. %
Name
in wt. %
n[Ti:nLi]
12
Li-2-Hex Cem
0.15
13
Li-2-Hex Cem
0.12
Tyzor AA 95
0.03
0.23
14
Li-2-Hex Cem
0.09
Tyzor AA 95
0.06
0.61
15
Li-2-Hex Cem
0.075
Tyzor AA 95
0.075
0.92
16
Li-2-Hex Cem
0.06
Tyzor AA 95
0.09
1.38
17
Li-2-Hex Cem
0.03
Tyzor AA 95
0.12
3.67
18
Tyzor AA 95
0.15
Tack
Shore-A hardness measured ×
Shore-A
Cream
free
min after demolding
hardness
Puncture expansion
time in
time
after
after
after
after
24 h after
in mm after
Experiment
[sec]
[sec]
0 min
2 min
10 min
60 min
demolding
b = 60,000 bends
12
15
44
29
34
43
51
52
45000*/4.3
13
12
32
35
39
48
53
54
2.5/7.6
14
12
23
38
41
50
55
55
2.8/4.5
15
11
23
38
42
51
55
56
4.1/4.2
16
11
21
36
41
50
54
55
3.5/4
17
10
20
35
41
50
53
55
4.1/4.5
18
11
18
34
39
49
53
56
12.6/6.7
All values marked with * indicate the number b of bends after which a test strip was broken.
TABLE 7
Use of Ti and Li catalysts in various amounts and Bi catalysts
Lithium component
Titanium component
Bismuth component
Amount
Amount
Amount
Experiment
Name
in wt. %
Name
in wt. %
Name
in wt. %
nTi:nLi]
nBi:(nTi + nLi)
19
Li-2-Hex Cem
0
Tyzor AA 95
0.1
Coscat 83
0.02
0.27
20
Li-2-Hex Cem
0.02
Tyzor AA 95
0.06
Coscat 83
0.02
2.75
0.27
21
Li-2-Hex Cem
0.04
Tyzor AA 95
0.04
Coscat 83
0.02
0.92
0.26
22
Li-2-Hex Cem
0.06
Tyzor AA 95
0.02
Coscat 83
0.02
0.31
0.26
23
LI-2-Hex Cem
0.08
Tyzor AA 95
0
Coscat 83
0.02
0.25
Shore-A hardness measured ×
min after demolding
Puncture expansion
Cream time in
Tack free time
after
after
after
after
Shore-A hardness
in mm after
Experiment
[sec]
[sec]
0 min
2 min
10 min
60 men
24 h after demolding
b = 60,000 bends
19
11
20
30
35
42
48
53
60000*/11.9
20
9
20
35
40
47
52
55
60000*/1.31
21
10
24
35
40
46
50
53
7.7/6.2
22
11
26
34
39
45
47
52
60000*/6.2
23
11
39
31
36
46
51
52
4.5/4.0
All values marked with * indicate the number b of bends after which a test strip was broken.
TABLE 8
Use of Ti and Li and Bi catalysts in various amounts
Lithium component
Titanium component
Bismuth component
Amount
Amount
Amount
Experiment
Name
in wt. %
Name
in wt. %
Name
in wt. %
[nTi:nLi]
nBi:(nTi + nLi)
24
Coscat 83
0.1
0
25
Li-2-Hex Cem
0.04
Tyzor AA 95
0.04
Coscat 83
0.02
0.92
0.07
26
Li-2-Hex Cem
0.026
Tyzor AA 95
0.026
Coscat 83
0.046
0.92
0.25
27
Li-2-Hex Cem
0.036
Tyzor AA 95
0.036
Coscat 83
0.028
0.92
0.11
28
Li-2-Hex Cem
0.042
Tyzor AA 95
0.042
Coscat 83
0.015
0.92
0.05
29
Li-2-Hex Cem
0.046
Tyzor AA 95
0.046
Coscat 83
0.008
0.92
0.03
30
Li-2-Hex Cem
0.05
Tyzor AA 95
0.05
0.92
Shore-A hardness measured ×
min after demolding
Puncture expansion
Cream time in
Tack free time
after
after
after
after
Shore-A hardness
in mm after
Experiment
[sec]
[sec]
0 min
2 min
10 min
60 men
24 h after demolding
b = 60,000 bends
24
10
35
28
35
47
50
55
1.6/1.7
25
10
24
35
40
46
50
53
7.7/6.2
26
8
23
37
43
50
53
57
3.3/4.4
27
8
22
37
42
50
54
56
4.6/3.2
28
10
28
34
39
46
50
56
9.2/4.0
29
9
25
35
40
49
51
57
60000*/13.6
30
10
22
33
38
47
50
53
3.4/3.6
All repeated flexural test results marked with * displayed fracture after b bends
All elastomer sheets in the experiments marked with # were not dimensionally stable after demolding. The sheets buckled.
Although the invention has been described in detail in the foregoing for the purpose of illustration, it is to be understood that such detail is solely for that purpose and that variations can be made therein by those skilled in the art without departing from the spirit and scope of the invention except as it may be limited by the claims. | The invention provides polyurethane elastomers (PU elastomers), a process for their production using special catalyst mixtures and their use in particular for the manufacture of shoe soles. | 2 |
Priority is claimed to French Application No. FR 08 02682, filed on May 19, 2008, the entire disclosure of which is incorporated by reference herein.
The present invention relates to a breakable coupling device, and to the associated trim actuator.
BACKGROUND
It is conventional on an aircraft, and more particularly on a helicopter, to find actuators that are arranged in parallel or in series with flight control linkages. When arranged in parallel, such actuators are commonly referred to as “trim actuators” by the person skilled in the art. Thus, a helicopter may have a trim actuator associated with its longitudinal flight controls, a trim actuator associated with its lateral flight controls, a trim actuator associated with its collective pitch flight control, and a trim actuator associated with its yaw flight controls. Each trim actuator then performs both first and second functions.
The first function improves pilot comfort by enabling the pilot to anchor a given control in a given position. For example, by blocking the collective pitch trim actuator, the pilot no longer needs to hold the collective pitch with the appropriate lever, and can therefore pay attention to other tasks.
The second function of a trim actuator consists in enabling the neutral position of a flight control to be adjusted. Furthermore, if the aircraft is fitted with an autopilot system, the trim actuator can provide information to the autopilot system. A sensor for measuring the position of a mechanical element of a trim actuator can transmit said information to the autopilot system, which can deduce therefrom the position of the associated flight control.
Under such conditions, a trim actuator generally includes a motor for driving an outlet shaft in rotation, which shaft is connected to the associated flight control by a connecting rod. For example, when the motor is actuated by the pilot, the outlet shaft of the trim actuator rotates and moves the flight control. In contrast, when the pilot acts on the flight control, it is the flight control that causes the outlet shaft to rotate and consequently rotates the rotor of the trim actuator motor relative to its stator.
That type of actuator thus satisfies requirements. Nevertheless, it is found that in the event of the motor that forms part of the trim actuator becoming jammed, that inevitably leads to a situation that is catastrophic since the flight control becomes blocked.
It is therefore essential to be able to break the connection between the trim actuator and the associated flight control, should that be necessary. For this purpose, actuator manufacturers provide a breakable pin to act as a “fuse”, e.g. between the outlet shaft and the connecting rod connecting it to a flight control. In the event of the actuator jamming, the pilot can act on the flight control and shear the pin. Although satisfactory, that solution requires the pin to be suitably dimensioned so that the force at which it breaks is neither too small nor too great. Furthermore, the pin does not necessarily break in an optimum manner. Consequently, it is possible that the flight controls continue to be impeded by a faulty trim actuator. The presently-existing solution is thus not completely satisfactory.
As a remedy, it might be envisaged to implement a suitable torque limiter in the trim actuator, the torque limiter decoupling the trim actuator motor from the flight control above a determined level of torque. In general, torque limiters comprise first and second plates that are connected together by drive means, e.g. balls. Each of the first and second plates then has a discontinuous housing provided with a plurality of orifices that are distributed equidistantly around a circle.
Below a predetermined torque, each ball is held in place, being inserted firstly in an orifice in the first plate and secondly in an orifice in the second plate. The first plate can thus drive the second plate in rotation via a connection via an obstacle, and vice versa. Above the predetermined torque, each ball leaves its orifice, thereby enabling the torque to be limited at said predetermined value, and subsequently penetrates into the next orifice. Since the balls continuously leave and enter the orifices, it will be understood that this technology is normally not suitable for being transposed into a trim actuator. That would require the pilot to fight continuously in order to work the flight controls in the event of the actuator motor jamming.
Furthermore, document U.S. Pat. No. 2,401,992 describes a device for coupling together first and second main shafts, the device being provided with blocking means, compression means, and drive means. The blocking means comprises a conical inside face provided with a first housing that is discontinuous and a second housing that is continuous.
Above a limit torque, the balls leave the first housing, slide over the conical face of the blocking means, and drop into the second housing. In order to reset that device, it then suffices to implement a simple axial action, since the device is reversible. Under such circumstances, that operation does not guarantee the operator to inspect the device as a safety precaution.
SUMMARY OF THE INVENTION
An aspect of the present invention is to provide a breakable coupling device, together with an associated trim actuator, that enables the above-mentioned limitations to be overcome by decoupling a trim actuator and the associated flight control permanently and in a manner that is certain.
The present invention provides a breakable coupling device for coupling first and second main transmission shafts that are stationary in translation along a longitudinal axis of rotation of the device with blocking means together with compression means and at least one drive means connecting the blocking means and the compression means together in rotation about the axis of rotation of the device providing said blocking means and compression means exert a torque on the drive means about said longitudinal axis of rotation of the device that lies below a predetermined level of torque. The blocking means is thus provided with a first housing that is discontinuous and that receives the drive means, e.g. a ball, below said predetermined torque.
Consequently, the drive means secures the blocking means and the compression means together in rotation about the axis of rotation of the device so long as the blocking means and the compression means exert torque on the drive means about said longitudinal axis of rotation of the device that is below a predetermined torque level.
The compression means then presses the drive means into the first housing of the blocking means, the drive means thus connecting together in rotation the compression means and the blocking means. In order to couple the first and second main transmission shafts together, it suffices to fasten the blocking means to the first main transmission shaft and the compression means to the second main transmission shaft.
Furthermore, the device of the invention is remarkable in that the blocking means include a second housing that is continuous, describing a closed loop, the device being provided with shift means suitable for shifting the drive means from the first housing to the second housing when the torque exerted on the drive means is greater than said predetermined torque level, and to do so in a manner that is not reversible, i.e. that cannot be reversed without the device being disassembled, and thus requiring human intervention.
Since the second housing is continuous, the drive means runs therealong without encountering any obstacles, thereby terminating any transmission of rotary motion from the compression means to the blocking means, and vice versa. Furthermore, decoupling is complete and final, until an approved mechanic takes action. The aircraft pilot is thus no longer confronted with the appearance of residual forces.
In addition, the device of the invention possesses one or more of the following additional characteristics. Advantageously, the first housing is provided with a succession of orifices formed along a path traveled by the drive means during its rotation about said axis of rotation in normal operation, i.e. when the blocking means are not blocked in rotation and are thus free to perform rotary motion about the longitudinal axis of rotation of the device.
This path is then made up of a succession of holes suitable for receiving the drive means, and of projections, more precisely crests. By being held in an orifice by the compression means, the drive means drive the blocking means in rotation with force being transmitted via obstacles, the drive means being set into motion by the compression means.
Conversely, when the blocking means are set into rotation, e.g. by a motor, the blocking means drive the drive means in rotation, which in turn drives the compression means in rotation. In the event of the first main transmission shaft jamming, the blocking means are no longer suitable for performing rotary motion. The drive means then leave the first housing and are shifted towards the second housing by the shift means acting via the compression means.
The second housing is optionally provided with a continuous groove that describes the entire path traveled by the drive means during its rotation about said axis of rotation in abnormal operation, i.e. when the blocking means are no longer free to perform rotary motion about the longitudinal axis of rotation of the device. It should be observed that the second housing does not have any obstacles, thereby enabling the blocking means to be decoupled from the compression means.
Furthermore, the continuous groove of annular shape, presents a first dimension that is greater than a second dimension of the drive means so that the drive means can no longer project from the continuous groove. When the drive means comprise a ball, the depth of the groove is greater than the diameter of the ball.
In abnormal operation, i.e. when the torque exerted on the drive means is greater than said predetermined torque level, the drive means then drop into the groove and no longer come into contact with the compression means, thereby guaranteeing the absence of any residual forces.
Consequently, it is not possible to reset the coupling device without human intervention, requiring the device to be disassembled and reassembled. Mere axial thrust can under no circumstances enable the drive means to be reengaged in the first housing.
In a first embodiment, the continuous groove may be in the form of a cylinder provided with first and second bases connected together by an internal peripheral wall, the external periphery of the groove facing said compression means being open so as to allow said drive means to pass therethrough.
In addition, the compression means comprise a cylindrical tube presenting at its first end one radial compression chamber per drive means, each radial compression chamber being open to the blocking means, and each drive means projecting in part from the associated compression chamber.
The compression chamber then acts as means for guiding the drive means. In order to exert a radial force on the drive means and to press them against the blocking means, the compression means are provided with at least one compression spring arranged in the compression chamber and suitable for exerting a force on the drive means.
For example, a compression spring is arranged in a cell within the cylindrical tube, the compression spring being secured to a ball of the drive means under normal conditions, i.e. when the force exerted on the drive means is less than a predetermined torque level, the compression spring exerting pressure on the ball, e.g. via a blade fastened to the turns of the spring.
Under such conditions, the base of the cylindrical tube situated at the second end of said cylindrical tube is secured to a shift spring of the shift means, the shift spring being arranged in a first direction that coincides with said axis of rotation and that is perpendicular to a second direction along which at least one compression spring of the compression means is arranged.
On expanding, the shift spring moves the compression means in translation along the axis of rotation of the device, and thus moves the drive means so that the drive means move from the first housing towards the second housing. Furthermore, in order to transmit its rotary motion to a second main transmission shaft, the compression means possess a secondary motion transmission shaft that extends the second main transmission shaft for coupling. In addition, the shift means include a shift spring and the shift spring surrounds the secondary transmission shaft in order to ensure that the device is compact.
In a second embodiment, the groove is in the form of a cylinder provided with first and second bases interconnected by an internal peripheral wall and an external peripheral wall, the first base of the groove facing said compression means being open so as to allow said drive means to pass therethrough.
Furthermore, the compression means comprises a plate having a first face presenting one radial compression chamber per drive means, the radial compression chamber being open to the blocking means and the drive means projecting in part from said compression chamber. The compression chamber then acts as guide means for guiding the drive means in contact with the blocking means.
Unlike the first embodiment, the shift means are suitable for exerting a force directly on the drive means in order to move them in translation. Furthermore, a second face of the plate of the compression means is secured to a compression spring of the compression means, the compression spring being arranged in a first direction that coincides with the axis of rotation and that is perpendicular to a second direction along which at least one shift spring of the shift means is arranged.
The compression means comprise a compression spring, which compression spring surrounds a secondary transmission shaft of the device, the secondary motion transmission shaft extending the second main transmission shaft for coupling.
Regardless of the embodiment, the secondary transmission shaft advantageously includes secondary longitudinal fluting so as to be constrained in rotation with the second main transmission shaft.
The secondary longitudinal fluting serves to constrain the secondary transmission shaft in rotation with the second main transmission shaft and also allows the secondary transmission shaft to move in translation along said axis of rotation relative to the second main transmission shaft.
The present invention also provides an aircraft trim actuator provided with first and second main transmission shafts and with a motor suitable for setting the first main transmission shaft into rotation. The trim actuator is remarkable in that it is provided with a coupling device of the invention for coupling together said first and second main transmission shafts, the blocking means being secured to the first main transmission shaft and the compression means being mechanically linked in rotation about the axis of rotation to the second main transmission shaft. Furthermore, the trim actuator optionally includes a crank provided with a wrist pin and a connecting rod for connecting the second main transmission shaft to a flight control, the wrist pin being fastened to the second main transmission shaft and to the connecting rod. The wrist pin enables the crank to avoid coming into contact with a structural element preventing the second main transmission shaft from moving in translation.
Furthermore, since the compression means are provided with a secondary transmission shaft fitted with secondary longitudinal fluting, the second main transmission shaft has primary longitudinal fluting that co-operates with the secondary longitudinal fluting in order to constrain the secondary transmission shaft in rotation with the second main transmission shaft while allowing the secondary transmission shaft to move in translation along said axis of rotation.
Furthermore, the trim actuator advantageously includes means for preventing the first and second main transmission shafts from moving in translation along said axis of rotation of the coupling device. For example, these means may comprise bearings that allow rotary motion only.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention and its advantages appear in greater detail from the following description of embodiments given by way of illustration with reference to the accompanying figures, in which:
FIG. 1 is a diagrammatic section of a trim actuator in the coupled position provided with a decoupling device constituting a first embodiment;
FIG. 2 is an isometric view of blocking means of the invention in a first embodiment of a decoupling device;
FIG. 3 is a section of compression means of the invention in a first embodiment of a decoupling device;
FIG. 4 is a diagrammatic section view of a trim actuator provided with a decoupling device in a first embodiment, when blocking occurs;
FIG. 5 is a diagrammatic section view of a trim actuator provided with a decoupling device of a first embodiment, in the decoupled position; and
FIG. 6 is a diagrammatic section view of a trim actuator in the coupled position provided with a decoupling device constituting a second embodiment.
Elements that are present in more than one of the figures are given the same references in each of them.
Three mutually orthogonal directions X, Y, and Z are shown in the figures.
DETAILED DESCRIPTION
FIG. 1 is a diagrammatic section of a trim actuator 1 in the coupled position. This trim actuator 1 comprises successively, from left to right in FIG. 1 : a motor 4 provided with a stator 4 ′ and a rotor 4 ″; a first main transmission shaft 2 ; a coupling device 10 ; and a second main transmission shaft 3 ; and then a crank 60 for connecting it to a flight control of an aircraft, for example the blade collective pitch control of a rotorcraft. It can be observed that it is perfectly possible to connect the crank 60 of the second main outlet shaft 3 to the motor of the actuator, and to connect its first main outlet shaft 2 to the flight control.
In addition, the trim actuator 1 is provided with an outer casing (not shown) that covers the above component elements. Furthermore, in order to constrain the first main transmission shaft 2 in rotation with the second main transmission shaft 3 , while allowing decoupling that is not reversible without human intervention above a certain threshold, the coupling device 10 includes blocking means 20 , compression means 30 , at least one drive means 40 , and shift means 50 for moving the drive means 40 ;
The blocking means 20 are secured to the first main transmission shaft 2 . Since this first shaft is supported by a bearing 100 of the usual type, representing means for preventing the trim actuator from moving in translation, while allowing rotary movement only about the longitudinal axis of rotation AX of the coupling device 10 , the assembly comprising the first transmission shaft 2 and the blocking means 20 is held stationary in translation along the axis of rotation AX, while being free to move in rotation about said axis of rotation AX. Similarly, the compression means 30 comprise a secondary transmission shaft 35 that co-operates with the second main transmission shaft 3 so that the secondary transmission shaft 35 is constrained in rotation about the axis of rotation AX with the second main transmission shaft 3 .
Consequently, the secondary transmission shaft 35 is fitted by way of example with external secondary longitudinal fluting 35 ′ passing through the inside of the second main transmission shaft 3 to co-operate with internal primary longitudinal fluting 3 ′ of the second main transmission shaft 3 .
Given this arrangement, it should be observed that the secondary transmission shaft 35 , and thus the compression means 30 , are capable of moving in translation along the longitudinal axis AX of rotation and symmetry of the coupling device 10 . In contrast, the second main transmission shaft 3 is stationary in translation.
In order to be connected to a flight control, the second main transmission shaft 3 is extended by a crank 60 . This crank possesses a wrist pin 61 secured to the second main transmission shaft 3 to avoid interfering with the secondary transmission shaft 35 , and then a connecting rod 62 for coupling mechanically to a flight control.
The connecting rod 62 then passes through a bearing 100 ′ of means for holding the trim actuator stationary, allowing it to move in rotation about the axis of rotation AX while preventing it from moving in translation along said axis of rotation AX.
In order to couple the first and second main transmission shafts 2 and 3 together below a certain threshold, the coupling device includes at least drive means 40 for constraining the compression means 30 in rotation with the blocking means 20 . The blocking means 20 and the compression means 30 are secured in rotation with the first and second main transmission shafts respectively, so the drive means 40 do indeed perform the intended purpose.
More precisely, independently of the embodiment, the blocking means 20 comprise a first discontinuous housing 21 ′ having a succession of orifices along the path traveled by the drive means in normal operation, i.e. when the coupling device 10 is in the coupled position. In addition, the blocking means 20 have a second continuous housing 22 provided with an annular groove 22 ′ describing the path traveled by the drive means 40 when they rotate about the blocking means 20 during abnormal operation, i.e. when the coupling device 10 is in the decoupled position.
Thus, in the coupled position, the compression means 30 compress the drive means into the first housing. For example, the coupling device has a plurality of drive means, each drive means comprising a ball 41 , with the compression means 30 urging each ball 41 into an orifice 21 ′ of the first housing. If the torque exerted on the drive means 40 by the blocking means 20 and the compression means is less than a predetermined torque, then the balls 41 constituting the drive means 40 remain in their orifices 21 .
Consequently, any rotation of the first main transmission shaft 2 , and thus of the blocking means 20 secured thereto, gives rise to rotation of the means 40 providing drive via obstacles. In turn, the drive means 40 cause the compression means 30 to rotate about the axis of rotation AX, and hence the second main transmission shaft 3 .
Conversely, any rotation of the second main transmission shaft 3 , and thus of the compression means 30 secured thereto in rotation about the axis of rotation AX, gives rise to a rotation of the drive means 40 . The drive means 40 in turn drive the blocking means 20 in rotation and thus the first main transmission shaft 2 . However, beyond the predetermined torque, the balls 41 of the drive means 40 escape from the orifices 21 of the first discontinuous housing 21 and are moved by the shift means 50 towards the second housing 22 of the blocking means. Since the second housing 22 is continuous, it does not present any obstacle, thereby enabling the blocking means 20 to be decoupled in rotation about the axis of rotation AX from the compression means 30 , and thus decoupling the first main transmission shaft 2 from the second main transmission shaft 3 . This decoupling is not reversible insofar as it is necessary for a technician to take action in order to return the coupling device to the coupled position.
In addition, independently of the embodiment selected, the continuous groove 22 ′ presents a first dimension L 1 that is greater than a second dimension L 2 of the drive means 40 so that the drive means 40 can under no circumstances project and escape from the continuous groove 22 ′ once engaged therein. FIGS. 1 to 5 show more particularly a first embodiment of the invention.
In this first embodiment, with reference to FIGS. 1 and 2 , the first and second housings 21 and 22 are arranged in succession along the axis of rotation AX. Furthermore, the groove 22 ′ of the second housing 22 is in the form of a cylinder provided with first and second bases 23 and 24 interconnected by an internal peripheral wall 25 constituting the bottom of the groove. To enable the balls of the drive means 40 to enter into the groove 22 ′, the outer periphery 26 of this groove 22 ′ facing the compression means in the decoupled position is open.
FIG. 2 shows clearly the first and second housings 21 and 22 . More particularly, it should be observed that the first and second housings 21 and 22 are respectively discontinuous and continuous.
With reference to FIGS. 1 and 3 , the compression means 30 are suitable for being constrained in rotation with each of the drive means 40 . The compression means 30 comprise a cylindrical tube 31 presenting shells 36 , each defining a respective radial compression chamber 32 that opens out solely to the blocking means 20 . The coupling device 10 has a plurality of distinct drive means, i.e. a plurality of balls, and each drive element 40 is arranged in a radial compression chamber 32 formed at the open first end 31 ′ of the cylindrical tube 31 . More precisely, all the drive means 40 are arranged in radial compression chambers 32 so as to be in contact with compression springs 33 of the compression means 30 via blades fastened to said compression springs, for example, the drive means 40 project at least in part from the associated compression chambers. The drive means project in part from the associated compression chambers in the normal condition and they project completely from the compression chambers when they drop into the continuous groove 22 ′. The base of the cylindrical tube 31 located at the second end 31 ″ of the cylindrical tube 31 is then secured to the shift means 50 , i.e. to a shift spring 51 connecting said base to the second main transmission shaft 3 . This shift spring 51 is thus disposed along a first direction D 1 that coincides with the axis of rotation AX, whereas, in contrast, the compression springs 33 of the compression means 30 are all disposed along second directions D 2 that are radial, i.e. perpendicular to said first direction. In addition, it should be observed that the shift spring 51 partially surrounds the secondary transmission shaft 35 of the compression means 30 .
With reference to FIG. 1 , in the coupled position, the various drive means are held in orifices 21 ′ of the first housing 21 of the blocking means.
With reference to FIG. 4 , beyond a predetermined torque exerted on the drive means 40 , these drive means 40 escape from their orifices 21 ′ in the direction of arrows F 1 . Since the drive means 40 are no longer blocked in the first housing 21 , the shift spring 51 of the shift means 50 can expand. Since the second main transmission shaft is stationary in translation because of the presence of means 100 ′ preventing it from moving in translation, the compression spring 51 pushes against the compression means 30 that move in translation along arrow F 2 . Since the drive means 40 are connected to the compression means 30 and are held captive in part by the associated radial compression chambers 32 , the drive means 40 move together with the compression means 30 .
With reference to FIG. 5 , the drive means 40 then reach the second housing 22 . Each compression spring 33 then pushes the associated drive means 40 into the continuous groove of the second housing 22 . Since the second housing 22 is continuous, the drive means 40 no longer encounter any obstacles suitable for pushing them or being pushed by them. Consequently, the coupling device 10 is in a decoupled position. It should be observed that regardless of its position, the secondary shaft is always arranged in part inside the second main transmission shaft 3 so as to keep the compression means 30 in place.
FIG. 6 shows a second embodiment. Unlike the first embodiment, the first and second housings within the blocking means are no longer one after another along the axis of rotation AX, but rather one above the other. The groove 22 ′ of the second housing 22 is in the form of an annular cylinder provided with first and second bases 23 and 24 and with an internal peripheral wall 25 and an external peripheral wall 26 , the first base 23 facing the compression means 30 being open so as to enable the drive means 40 to penetrate into the groove 22 ′. The second base 24 then constitutes the bottom of the groove 22 . Furthermore, it is no longer the compression spring of the compression means 30 that comes into contact with the drive means, but rather the shift means 50 .
In the second embodiment, the compression means 30 include a plate 39 . This plate 39 is provided on its first base 39 ′, facing the blocking means, with a plurality of radial compression chambers opening out solely to the blocking means 20 . The drive means 40 are then disposed inside radial compression chambers 32 , while being in contact with respective shift springs 51 of the shift means 50 , the drive means 40 projecting at least in part from the associated compression chamber. Thus, the drive means 40 are fastened to a shoulder 38 of the blocking means 20 constituting the bottoms of the radial compression chambers 32 , via a respective shift spring 51 .
The second face 39 ″ of the plate 39 is secured to the compression spring 33 connecting said second face 39 ″ to the second main transmission shaft 3 . The compression spring 33 is thus disposed along a first direction D 1 coinciding with the axis of rotation AX, whereas on the contrary the shift springs 51 of the shift means are all disposed along respective second directions D 2 that are radial, being perpendicular to said first direction.
It should also be observed that the compression spring 33 then surrounds part of the secondary transmission shaft 35 of the compression means 30 .
As in the first embodiment, above a predetermined torque, the drive means escape from their orifices in the first housing and are then pushed towards the second housing of the blocking means.
Naturally, the present invention may be subjected to numerous variants concerning its implementation. Although several embodiments are described above, it will be understood that it is not conceivable to identify exhaustively all possible embodiments. It is naturally possible to replace any of the means described by equivalent means without thereby going beyond the ambit of the present invention. | A breakable coupling device for coupling together first and second main transmission shafts stationary in translation along a longitudinal axis of rotation of the device comprises a blocking device having a discontinuous first housing and a continuous second housing forming a closed loop; a compression device; at least one drive device connecting the blocking device and the compression device together in rotation about the longitudinal axis below a predetermined torque, wherein the discontinuous first housing is configured to receive the at least one drive device below the predetermined torque; and a shifting device configured to shift the at least one drive device non-reversibly from the discontinuous first housing towards the continuous second housing when the torque exerted on the at least one drive device is greater than the predetermined torque. | 5 |
CROSS REFERENCES TO RELATED APPLICATIONS
[0001] The present invention contains subject matter related to Japanese Patent Application JP 2007-326354 filed in the Japanese Patent Office on Dec. 18, 2007, the entire contents of which being incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to a signal processor, a signal processing method suitable for applying the method to control of displaying contents of stream data on an image display apparatus, and a computer program to which the signal processing method is applied, and a recording medium on which such computer program is recorded.
[0004] 2. Description of the Related Art
[0005] Telop (the term “telop” indicates text superimposed on the screen) is often superimposed on the screen of image contents such as a television program broadcasted on the television. The contents of the images are often described using the telop. For example, in a news program, the contents of the images may be described by superimposing the telop on the lower side of the screen on television. The contents of images on a program other than the news program are also described by superimposing the telop on the screen.
[0006] In viewing such one-hour image program, a user or viewer usually consumes one hour for viewing the image program. If the user intends to consume less time than one hour for viewing such program, the user usually carries out fast-forward reproduction using a remote controller. However, some users may sometimes intend to fast-forward one content of the program to the next once having checked the content of the program with text of telop. Conversely, some other users may intend to view the program, the screen of which the telop is superimposed, without conducting fast-forward reproduction of the program. Further, time consumed to read and understand the gist of the contents of the program via the telop may largely differ between individuals when users read and understand the telop that describes contents of the program.
[0007] Japanese Unexamined Patent Application Publication No. 2007-184962 discloses technology for facilitates understanding the gist of contents of search images while reproducing the search images. In this technology, a signal indicating the presence of telop is recorded on a recording medium, so that the presence of telop in the search images is easily searched.
SUMMARY OF THE INVENTION
[0008] As described above, it seems difficult to determine how long it is to be optimal duration in displaying image contents to viewers in general. Specifically, when the images, contents of which a viewer can grasp easily, are displayed using telop, display duration of the telop may be too long for viewers. It is also difficult to determine how fast it is to be optimal duration to present audio sound of image contents to audience.
[0009] According to embodiments of the invention, viewers or audience can optimally read and hear the image contents of the program or the like and the audio sound thereof.
[0010] The embodiment of the invention includes a contents receiver receiving or storing contents of stream data, a characteristic extracting unit extracting a prescribed amount of characteristic of the contents received by the contents receiver, and a detector detecting viewing time or hearing time for the contents received by the contents receiver. The embodiments of the invention further includes a processor calculating information on a viewing status or hearing status of the contents determined based on an extraction status of the amount of characteristic extracted by the characteristic extracting unit and the viewing time or hearing time, and outputting the calculated information on the viewing status or hearing status of the contents.
[0011] With the embodiment, the information on the viewing status or hearing status of the image contents is output, and the viewing status or hearing status of the image contents can be specified by the output information on the viewing status or hearing status of the image contents.
[0012] According to the embodiments of the invention, the information on the viewing status or hearing status of the image contents is created and output, and then the viewing status or hearing status of the image contents can be specified utilizing the output information on the viewing status or hearing status of the image contents. Thus, since the reproduction of the image contents can be controlled based on the output information, a user can view or hear the image or audio sound of the contents reproduced in an optimal condition.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a block diagram illustrating an example of an overall configuration according to one embodiment of the invention.
[0014] FIG. 2 is an explanatory diagram illustrating a system configuration example according to one embodiment of the invention.
[0015] FIG. 3 is a flowchart illustrating an overall processing according to one embodiment of the invention.
[0016] FIG. 4 is a flowchart illustrating a determination processing example of whether to have identical information frames according to one embodiment of the invention.
[0017] FIG. 5 is a flowchart illustrating an image analyzing processing according to one embodiment of the invention.
[0018] FIG. 6 is a flowchart illustrating an estimating processing of required viewing time according to one embodiment of the invention.
[0019] FIG. 7 is an explanatory diagram illustrating an example of a table according to one embodiments of the invention.
[0020] FIG. 8 is an explanatory diagram illustrating an example of another table (categorical example) according to another embodiment of the invention.
[0021] FIG. 9 is an explanatory diagram illustrating a system configuration example according to still another embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] Preferred embodiments of the invention will now be described with reference to accompanying drawings.
[0023] An overall system configuration is described with reference to FIG. 1 . A system of the embodiment of the invention includes an image reproducing apparatus 10 that is connected to a display apparatus 20 such that images of image contents reproduced by the image reproducing apparatus 10 are displayed on the display apparatus 20 . The image reproducing apparatus 10 includes a remote controlling signal receiver 18 a that receives remote controlling signals transmitted by a transmitter 31 of a remote controller 30 . The remote controller 30 includes a key 32 as an operation unit, and a user M operates the key 32 of the remote controller 30 so as to carry out various kinds of operation, such as to start reproducing, fast-forward, and stop the image contents.
[0024] Next, an internal configuration of the image reproducing apparatus 10 will be described with reference to FIG. 2 . The image reproducing apparatus 10 includes a information recording unit 11 that records and reproduces the image contents received by a receiver 19 . The image contents in this embodiment imply stream data, which specifically indicates dynamic image signals and audio signals. An example of the information recording unit 11 includes a mass-storage device such as a hard-disk drive. The receiver 19 is used for receiving the image contents. For example, the receiver 19 includes a tuner for receiving broadcast signals or a receiving device for receiving image contents via the Internet.
[0025] The image contents recorded on the information recording unit 11 are read by an image reproducing unit 12 , which generates image data for reproduction and supplies the generated image data to the display apparatus 20 . The display apparatus 20 displays images of the supplied image data. In addition, although not shown, if the image data is provided with audio data, the audio data is also read from the information recording unit 11 and supplied to the display apparatus 20 by the image reproducing unit 12 , so that audio sound is output from a speaker of the display apparatus 20 .
[0026] The image reproducing unit 12 reproduces the data based on instructions given from a command receiver 18 . The command receiver 18 is supplied with the remote controlling signal received by the remote controlling signal receiver 18 a . The remote controlling signal receiver 18 a receives the remote controlling signal supplied from a separately provided remote controller. The remote controller is operated by the user M who views and hears the image and sound presented on the display apparatus 20 . The remote controlling signal is transmitted from the remote controller as an infrared signal and a radio signal. The instructions based on the remote controlling signal includes reproducing the image contents, such as starting, pausing, and stopping reproducing the image contents, or locating the image contents, such as fast-forwarding, and skipping the image contents. The remote controlling signal receiver 18 a receives and transfers the instructions to the command receiver 18 , so that the image data reproduced by the image reproducing unit 12 are appropriately displayed on the display apparatus 20 based on the received instructions. The instructions received from the command receiver 18 are also supplied to a required viewing time measuring unit 15 .
[0027] The image reproducing apparatus 10 further includes an image analyzer 13 that analyzes a reproducing status at the image reproducing unit 12 . The image reproducing unit 12 transfers the reproduced images to the image analyzer 13 , while allowing an identical image information unit detector 14 to detect consecutive identical images having identical contents. The image analyzer 13 analyzes the number of characters in telop when the telop has been superimposed on the images. The image analyzer 13 also obtains the difference between pixel areas of the image, and outputs values of the number of characters and those of the obtained pixel area differences as the outcome of the analysis. The consecutive identical images having identical contents detected by the identical image information unit detector 14 imply that the identical images having identical contents are continuously reproduced. Specifically, the identical image information unit detector 14 operates as a scene detector to detect whether the identical images having identical contents are continuously reproduced. The detecting processing to detect identical images is carried out by calculating the differences between pixels of an immediately preceding frame image and those of a current frame image. Specific processing examples of the image analyzer 13 and the identical image information unit detector 14 will be described later.
[0028] The detected outcome of the image analyzer 13 and the identical image information unit detector 14 are transferred to the required viewing time measuring unit 15 and a required viewing time estimating unit 17 , respectively. The required viewing time measuring unit 15 is also supplied with the instructions from the command receiver 18 , and calculates required viewing time based on the instructions and the results obtained by the image analyzer 13 and the identical image information unit detector 14 . Specific processing examples of calculating the required viewing time will be described later. The calculated required viewing time is stored in a table storage 16 formed of a memory.
[0029] The required viewing time estimating unit 17 estimates the required viewing time to reproduce images at the image reproducing unit 12 based on information supplied from the table storage 16 , the image analyzer 13 , and the identical image information unit detector 14 , and the estimated results are transferred to the image reproducing unit 12 . A specific processing example of calculating the required viewing time will be described later. When the estimated results are supplied to the image reproducing unit 12 , a reproducing status of the images being reproduced is controlled. When the estimated results (described later) indicate that the images have been reproduced in sufficient time for viewing the images, subsequent images are reproduced.
[0030] Next, processing operation in reproducing the image contents recorded by the information recording unit 11 of the image reproducing apparatus 10 is described with reference to flowcharts in FIG. 3 to FIG. 6 . An overall processing status is described with reference to FIG. 3 . Specifically, whether a command is input from the command receiver 18 of the image reproducing apparatus 10 is determined (STEP S 11 ), and when no input of command is detected, the image contents are analyzed during reproducing the images by the image reproducing unit 12 . Specifically, whether to have consecutive identical information frames is determined (STEP S 12 ), the contents of the images are analyzed (STEP S 13 ), table data is read from a table storage 16 (STEP S 14 ), and duration or time for presenting the images per unit is determined (Step S 15 ). Timing of reproducing image contents is controlled by the image reproducing unit 12 so as to present the information during the determined duration. When the timing of reproduction is controlled, processing of next information unit is carried out (STEP S 17 ).
[0031] When command input by a user is detected at step S 11 , the command is translated (STEP S 18 ). When the translated command is an end command that indicates stopping the reproduction of the image contents, the processing will end (STEP S 23 ). When the command is that other than the end command, whether to have consecutive identical information frames is determined (STEP S 19 ), whether the contents of the images are analyzed (STEP S 20 ), and how long to have duration of presenting the information per unit are determined (Step S 21 ). When the duration of presenting the information per unit is measured, the information on the measured duration of presentation is stored in the table storage 16 to update the information thereof.
[0032] Next, a processing example of detecting (determining) consecutive identical information frames by the identical image information unit detector 14 is described with reference to a flowchart in FIG. 4 . When processing of determining whether to have consecutive identical information frames has started, identical information frames counter is reset to “0” (STEP S 31 ), and a differential counter is also reset to “0” (STEP S 32 ). Subsequently, the difference in luminance between an original image (reference image) and a current image is calculated per pixel (STEP S 33 ), and whether the difference obtained equals or exceeds the threshold is determined (STEP S 34 ). If the difference obtained is equal to or above the threshold, the count value of the differential counter increments by one (STEP S 35 ). If the difference obtained is below the threshold, the count value of the differential counter remains unchanged. Subsequently, whether the difference in luminance has been calculated in all pixels is determined (STEP S 36 ). If the difference has not been calculated in all pixels, processing is shifted to next unevaluated pixel (STEP S 37 ) to calculate the difference in luminance again (STEP S 33 ).
[0033] If the differences have been calculated in all pixels in one frame at STEP 36 , whether the count value of the differential counter is below the threshold is determined (STEP S 38 ). If the difference obtained is below the threshold, the counter value of the identical information frame counter increments by one (STEP S 39 ), and processing of the next image frame is carried out (STEP S 40 ). The processing for the next image frame is carried out from STEP S 32 .
[0034] If the count value of the differential counter is not below the threshold; that is, the differential counter is equal to or above the threshold at STEP S 38 , the current count value of the identical information frame counter is output (STEP S 41 ), and then the current processing to determine whether to have the consecutive identical information frames will end. The processing from STEP S 31 to S 41 will be iterated while image contents are continuously reproduced. In the determination of whether to have consecutive identical information frames as shown in the flowchart of FIG. 4 , when the user carries out no operation while the image contents are reproduced, duration or time for presenting consecutive identical information frames will be detected. However, when the user operates to give instructions such as fast-forwarding reproduction of image contents, duration or time for reproducing consecutive identical information frames until such operation is given by the user is detected; that is, duration or time for consecutively displaying identical information frames on the display apparatus 20 is detected.
[0035] Next, processing at an image analyzer 13 will be described with reference to a flowchart in FIG. 5 . First, if telop is contained in one frame image to be reproduced, the number of telop characters in one frame image is counted (STEP S 51 ). The difference between the original and the current images per pixel area is also calculated (STEP S 52 ). The difference between the original and current images per pixel area is calculated in the same manner as calculating the difference in luminance between the two images per pixel at the identical image information unit detector 14 . The number of telop characters and the difference between the two images per pixel area obtained in one frame are then output (STEP S 53 ).
[0036] Next, an example of estimating processing for required time carried out by the required viewing time estimating unit 17 will be described with reference to a flowchart of FIG. 6 . In estimating processing for required time, analyzed data is received from the image analyzer 13 (STEP S 61 ). Having received the resulting data of the analysis obtained from the image analyzer 13 , data having the closest distance to the vector of the resulting analysis in the table is read (STEP S 62 ). The required viewing time indicated by the data in the table is output as an estimated result (STEP S 63 ).
[0037] The output estimated result of required viewing time is supplied to the image reproducing unit 12 to control the reproduction of the image program. For example, when duration or time of continuously viewing one static image is equal to the time indicated by the estimated result of required viewing time, reproducing position is shifted to the next unit of images.
[0038] FIG. 7 shows an example of a table stored in the table storage 16 . The example shows the number of telop characters in an image, mean difference per pixel corresponding to the number of characters, and mean duration (sec) of required viewing time for the image. As FIG. 7 shows, as the number of telop characters displayed increases in one screen, the required viewing time also increases.
[0039] With the table shown in FIG. 7 , if images having identical information (implying the status close to static images) are consecutively displayed, the required viewing time matched with the same conditions (i.e., the number of telop characters, the mean difference per pixel, and the mean duration) is read from the table. Accordingly, the required viewing time read from the table is determined as the estimated viewing time for the currently displayed image. When displaying time exceeds the time read from the table, the next unit of image will be displayed. Thus, when an image is determined to mainly contain telop characters and consecutive images having identical information are determined as being currently displayed, the display status will be changed based on the previous data of the required viewing time read from the table, so that the identical images will not be displayed for unnecessarily long time. In the processing shown in the flowchart of FIG. 3 , presenting time for images are calculated based on two amounts of the characteristic factors; that is; the number of characters in one screen, and mean duration or mean time of consecutively displaying images having identical contents (identical scenes), however, the presenting time for images are calculated with reference only to one of these characteristic factors tabulated. Other factors can also be used for calculating the presenting time of image.
[0040] In the example of FIG. 7 , a categorical factor of the image program to be reproduced is not included in calculating the time required for viewing images; however, the number of telop characters, the mean pixel difference, and the mean duration or mean time (sec) required for viewing images can be classified for each category of the image program so as to create a table to be stored as shown in FIG. 8 . When reproducing the image program, data of category matched with the category of the image program to be reproduced is read from the table, and the duration or time required for viewing the image program may be calculated based on the read data from the table. In the example of FIG. 8 , data is classified into three categories; namely, the news, information, and sports. If a category of the image contents is unknown, unknown category may be provided so that the unknown category of the table can be referred in reproducing the image contents of unknown category.
[0041] In the example of FIG. 7 , the number of operators for the image reproducing apparatus 10 of this embodiment is estimated as one, so that all the information obtained by the user's operation of the remote controller 30 is collected in one table. However, when a plurality of users or operators share to use one image reproducing apparatus 10 , information obtained by the plurality of users' operation of the remote controller 30 may be collected in separate tables corresponding to the individual users that can be identified with a certain operation or mechanism of individuals. Accordingly, the information of the table corresponding to the user viewing the image program may be used in reproducing the image program. More accurate image reproducing duration or time can be set in this manner.
[0042] In the examples described so far, the time required for the user viewing the image program is determined based on the user's operation to reproduce the image contents using the remote controller as the time corresponding to the number of telop characters in the table. However, the time required for viewing the image contents may be calculated based on any other processing. For example, as shown in FIG. 9 , a camera unit 22 may be arranged on top of a screen 21 of a display apparatus 21 ′ to image the face of a viewer M, the viewer M's sight line e can be determined based on the image captured by the camera unit 22 .
[0043] The time for the viewer M to read characters displayed as telop can be estimated based on the change in the viewer M's sight line e. When the viewer M's reading time for the telop is estimated, the estimated time and the number of telop characters are stored in the table as a required viewing time. In reproducing the image contents, the required viewing time is read from the table with reference to the number of characters so as to change reproducing duration or time complied with the next unit of images. Thus, the image reproducing duration or time can be estimated by the processing other than the viewer's input operation.
[0044] In the configuration of FIG. 2 , the image reproducing apparatus and the display apparatus are separately provided; however, the image reproducing apparatus may be incorporated in the television receiver such that a series of processing from estimating the required viewing time to displaying the image contents can be carries out by one apparatus. Alternatively, as shown in FIG. 2 , when the image reproducing apparatus and the display apparatus are separately provided, the image reproducing apparatus (image processing apparatus) can only output information on the estimated required time to supply to the display apparatus, and setting processing such as setting displaying duration can be carried out by the display apparatus.
[0045] In the embodiments described so far, the reproducing processing of the image program has been described; however, in the reproducing processing of the audio sound program, when the identical sound having identical contents are continuously reproduced, reproducing position is shifted to the next unit of sound complied with the required hearing time read from the table.
[0046] In the embodiments described so far, the embodiments are applied to the image reproducing apparatus; however, the series of processing can be programmed to cause an information processing apparatus, such as a personal computer, to execute the computer program such that the information processing apparatus can carry out the same operation as that of the image producing apparatus in FIG. 2 . In this case, the computer program for the series of processing according to this embodiment can be recorded on various recording media which may then be provided for the viewer of the image contents of stream data.
[0047] It should be understood by those skilled in the art that various modifications, combinations, sub-combinations and alterations may occur depending on design requirements and other factors insofar as they are within the scope of the appended claims or the equivalents thereof. | Disclosed is a signal processor includes a contents receiver receiving or storing contents of stream data, a characteristic extracting unit extracting a prescribed amount of characteristic of the contents received by the contents receiver, a detector detecting viewing time or hearing time for the contents received by the contents receiver, and a processor calculating information on a viewing status or hearing status of the contents determined based on an extraction status of the amount of characteristic extracted by the characteristic extracting unit and the viewing time or hearing time for the contents, and outputting the calculated information on the viewing status or hearing status of the contents. | 7 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] The present application claims domestic priority to U.S. Application Ser. No. 61/110,783, filed Nov. 3, 2008, the entire contents and disclosure of which is herein incorporated by reference.
BACKGROUND OF THE INVENTION
Field of the Invention
[0002] The present application comprises a universal closure that provides for a reduction in the number of parts necessary to form an introducer assembly of the type shown in the prior application and permits the utilization of a single seal in combination with a closing valve. The seal optionally includes a unitary seal assembly which utilizes a plurality of relief grooves on the seal. Both the closing valve and unitary seal are also provided with a chamfered front edge portion, with the seal being optionally provided with the plurality of grooves in order to assist in flexibility of the seal and to assist in the insertion therethrough of an obturator or other medical device during surgery, for example, and the subsequent withdrawal of the same there through. A preferred embodiment of the same includes relief grooves provided solely on the exterior of the seal.
[0003] Applicant has also recognized the advantage of providing for lubrication of the seal and has therefore conceived of the ability of providing a lubricant contained within a portion of the closure assembly, the lubricant being maintained in place by a removable lid having a projection extending therefrom which extends towards a tapered end portion of the seal, as explained below. Accordingly, the lubricant can be stored between the removable lid and the distal portion of the projection so as to permit removal of the lid immediately prior to insertion of the cannula or other medical device through the seal.
[0004] For example, the seal can be utilized in any structural assembly that permits passage of a member through a seal. This could include, for example, the nozzle of a filling station pump that passes through a seal mounted in the passageway of the vehicle that leads to the fuel tank of the vehicle. Other possibilities are clearly possible which would be within the knowledge of one of ordinary skill in the art of providing seals for passageways. It is therefore to be understood that within the scope of the pending claims, the invention may be practiced otherwise than as specifically described therein.
SUMMARY OF THE INVENTION
[0005] The present invention is directed to a complex universal system in which all the elements comprising the same title are formed as one single unit.
[0006] Simplicity and compactness are desirable in cannula closures along with high reliability. The system involved here is not just desirable by surgeons but also by manufacturers because its design elements are simpler in structure and are easier to fabricate and assemble.
[0007] The most common complaint of endoscopic surgeons is the loss of insufflation gas due to leakage across cannula closures or seals of a trocar. Such leakage may be caused by the design complexity of the instruments which may be difficult to introduce or manipulate during surgical procedures, thereby causing gas leakage and seal ruptures. These complaints have required extreme attention from suppliers but unfortunately have resulted in higher closure complexity and cost while in some cases compounding surgical dissatisfaction and accidents.
[0008] The design covered in the present invention comprises a geometrical combination of critical elements within a single unitary seal-valve unit. The seal includes a rather hard durometer, conical element, the orifice of which is made so as to have stiffness in the axial direction to control snagging deformations, and which is axially grooved externally to minimize hoop stresses which would cause circumferential stiffness and hard entry forces. The result is a cone that could be described as being formed by a combination of axial beams spaced by hoop-relief grooves that allow it to expand as a radially soft-hoop element while exposing a harder and low friction internal surface to contact with incoming sharp penetrating instruments. The results is a best-of-all-worlds design which does not incur the complexity of present kinematic opening systems prone to break and to either cause closure failures, or risk the release of detritus within the surgical field.
[0009] In addition to those characteristics of the novel conical orifice of the present invention is the fact that it is cast within an external conoid that completes the whole elastic closure system by ending in a bivalve, or linear slit valve, which is sufficiently stretched along the slit opening so as to insure an absolutely reliable, not just static, but forcible closure, when instruments are withdrawn.
[0010] Since this design is cast in one piece it also offers the characteristic of not allowing reversibility across the conical support base at the joint between the two cones. Such joint between the external conical-flat seal (a conoid surface) and the internal orifice cone, also known as an aperture, is not a circular joint as would appear at first sight but rather has a spatial perimeter that extends radially and axially between the two surfaces. As a result, the central orifice is supported close to the distal opening portion thereof at two sides, and at right angles it is attached to the conoid further proximally to a base thereof. The result of such configuration is to further increase the integrity of the inside orifice cone while allowing greater radial elasticity at two of its sides.
[0011] Since the two elements comprising the elastic seal are desired to have great radial elasticity, it is also logical to minimize the radial constraint imposed by the outside conoid. Therefore a set of longitudinal relief grooves is molded on the outside surface of the conoid surrounding the orifice cone. As a result, a hard durometer, low friction, seal aperture is obtained of great radial elasticity and with greater surface strength than is otherwise possible.
[0012] All of these are very desirable factors. Moreover, in the present design, an additional and very important improvement was added. Since the ease of penetration is such a critical requirement, it was decided to introduce a lubrication system into the closure described above. To do so it was necessary to guarantee that fresh fluid lubrication is available for the closure at the start of penetration and without compromising clean room essential procedures and demands on personnel.
[0013] As shown in this invention, all of those considerations have been met to full satisfaction. What was done was to use a viscous lubricant of biocompatible characteristics, such as a hydrogel like hyaluronic acid (or hyaluronan) or a comparable substance component of the human body. Hyaluronic acid is the only non-sulphated glycosaminoglycan that is found throughout the body in tissues and fluids. It is an excellent lubricant for limited periods of usage and therefore most adequate for the needs contemplated here. It is only necessary to maintain it in an enclosure to insure its use at any reasonable time after packaging.
[0014] The present invention provides the suggestion of this particular hydrogel. However, other suitable biocompatible lubricants can also be employed in this particular application. What is critical in the case of the universal cannula closure involved here is the manner in which a lubricant must be contained within a space in the closure and how it should be delivered prior to its use with the cannula.
[0015] First of all the closure should be packaged inside the cannula and not be opened until the start of a procedure. In the case of a cannula for use with a trocar the insertion of the trocar, this should be done at the time of usage. The cannula and the trocar could be packaged in separate blisters of the same package and used as indicated.
[0016] The viscous lubricant must be completely sealed within the inside of the cone at the inlet of the seal. Such a “sealed-in” space is obtained by a plugging device that will dilate and plug the orifice at the distal end of the cone and allow the lubricant to partly fill the inside portion thereof around the plug within the cone, while having a plastic cover at the proximal end which will be soft contact-bonded to the outer edges of the seal. Such a plug-and-bonded closing cover can be simply peeled off at surgery time exposing the open freshly lubricated entry space for the surgical instruments to slide in easily without forcibly pushing them.
[0017] The described seal lubricated closure becomes, in essence, a double ended closed bottle of lubricant freshly available to be doubly opened at the time of surgery. Such a design and method could be used in other areas where a double-sealed substance must be freshly delivered without encumberant risks to surgical assistants.
[0018] While the peeled-off outside of the described enclosure may not be fully protectable, the fact that the proposed system performs two simultaneous double-sealing and double opening tasks appears to be new in this field.
[0019] In addition to the described parts of this lubricated closure, the plug sealing the distal end may be hollow and be partially filled with lubricant, which in turn may be delivered through a set of wall holes when the cover center is depressed inwardly, therefore becoming a lubricant reserve if the cover is left attached at one side of the seal after partial peeling. Such an approach would be advantageous for longer term procedures requiring the passing of many instruments.
[0020] Conceivably, lubricant-filled seals of different types could be identified by color or symbols.
DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is a top, front and right side perspective view of the universal closure;
[0022] FIG. 2 is an enlarged view of an end portion of the internal cone shown in FIG. 1 ;
[0023] FIG. 3 is a cross-sectional view of the universal closure shown in FIG. 1 ;
[0024] FIG. 4 is a rear elevational view of the universal closure shown in FIG. 1 ;
[0025] FIG. 5 is a front elevational view of a casting assembly utilizing the universal closure shown in FIG. 1 ;
[0026] FIG. 6 is an exploded side view thereof showing a closing plug and housing;
[0027] FIG. 7 is a top and side perspective view of a casting assembly when assembled;
[0028] FIG. 8 is a cross-sectional view thereof;
[0029] FIG. 9 is a cross-sectional view showing the casting assembly upon removal of the closing plug;
[0030] FIG. 10 is a cross-sectional view showing an additional embodiment which includes a disk stopper and lubricant;
[0031] FIG. 11 illustrates the embodiment of FIG. 10 with the disk stopper removed;
[0032] FIG. 12 is a bottom, front and left side perspective view of a third embodiment of the invention;
[0033] FIG. 13 is a cross-sectional view thereof;
[0034] FIG. 14 is a front elevational view thereof;
[0035] FIG. 15 is a side cross-sectional view thereof; and
[0036] FIG. 16 is a bottom plan view thereof, the top plan view being a mirror image of the bottom plan view shown.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0037] With reference to FIGS. 1-4 , a conoid 1 containing an internal cone 2 as an integral part and is also formed with an attachment rim 6 to fit a cannula (not shown). FIG. 4 is a sectional view which also shows the perimeter joining the two conical elements as a line 4 , shown in dotted lines. A chamfer 5 of a 45° angle is provided on the distal end of each of the conoid 1 and cone 2 . Cone 2 is cast jointly with conoid 1 and to form a one piece assembly which includes at the outer surface thereof six longitudinal relief grooves 3 for reducing hoop stress and to facilitate dilation for entering surgical instruments and reduce insertion forces. The conoid 1 forms a closing hole for the universal closure. The cone 2 can function, moreover, without such relief grooves 3 , if desired. As a result, cone 2 comprises a strong, axially firm cone, with a radial opening softness characteristic without snagging surgical instruments inserted there through or withdrawn therefrom. These new design features make it unnecessary to resort to additional opening mechanical means to facilitate orifice dilation. In other words, cone 2 is an example of the use of stress analysis to simplify design by controlling strains in the material of the conoid 1 and cone 2 in order to obtain a desired behavior, without the need for additional kinematic complexity, as is often otherwise required. This can be accomplished by applying relief grooves 3 , 9 to the exterior of the outer conoid surface 1 surrounding the inside cone 2 , as shown in FIG. 1-4 , if desired. Conoid 1 has an elongated opening as shown in FIG. 1 while the adjacent opening of cone 2 is substantial circular in shape.
[0038] In FIGS. 5-9 , the conical integration casting 1 , 2 is shown positioned in a cylinder 7 that serves as a seal housing as shown in the left side cross section shown in FIG. 9 . In FIG. 9 , the relief grooves 9 are shown on the exterior of conoid 1 directly outside of cone 2 . The purpose of relief grooves 9 on the conoid 1 is exactly the same as the grooves 3 on cone 2 . Such grooves are intended as a novel means to facilitate radial expansion without compromising overall functional integrity. Such is a little known, but useful, novel design approach for strength and simplicity in the present invention.
[0039] In the design shown in FIGS. 7-9 , the line-vertex of the conoid 1 is shown as ending at the juncture of the two sheets of the surfaces thereof at vertex 10 . The juncture at vertex 10 between the two beveled lips of the conoid 1 have at each opposite ends a locking knob 23 insertable into a slot 24 formed in each side of the housing 7 to force a substantial stretching of the lips of 1 against each other and to assure a tight closing at all times, except when opened by a penetrating surgical instrument such as an obturator of a trocar upon insertion of the seal within the curvature of the trocar. The higher gas pressure upon insufflation in the patient must never be assumed to guarantee proper lip sealing. FIGS. 7-9 depict graphically the intended lubricant containment within the interior space of this seal.
[0040] As is well known, any water-based fluid must be maintained within air-tight containers. In the case of the self lubricated seal of the present invention, the lubricant 16 is contained within the center spaces inside the seal 2 defined between an inserted closing plug 13 between a point 11 at the distal end thereof and a cap 18 , attached to the proximal base 19 of the plug. Therefore, all the spaces between the dilated orifices at point 11 , seal 12 and the proximal cap 18 containing lubricant 16 are completely air-tight. At the moment of surgical need, the tab 22 can be stripped from position 22 to position 21 and thus be opened for insertion of surgical instruments. The tab 22 then can be either discarded or left partly attached for further use, if necessary. In the latter case additional lubricant can be ejected by reinserting the plug 13 and the pressing region 17 . Such action will release from the plug 13 some additional lubricant 16 from the space 15 through a series of openings 14 around the surface of the plug.
[0041] It is noted that a double-opening container of the described type may have extensive uses in medical applications for clinical examinations as well as surgical uses.
[0042] FIGS. 10 and 11 describe an additional preferred embodiment for fluid lubricant containment within the space inside the seal cone and illustrate a double stopper lubricated closure. This design has even better handing and effectiveness than the embodiment shown in FIGS. 5-9 .
[0043] The design in FIGS. 10 and 11 has only one double-stopper element which provides very positive sealing, assembly, and removal characteristics. The very tight fit between the seal cone inside surfaces obtained by axial compression between the small cone orifice and the slanted periphery of the flat disk 31 shown assures an air-tight internal containment for the lubricant for an indefinite period of time. In addition to that, wetting of the contacting surfaces of the stoppers 30 and 31 at assembly further improves joint sealing since the externally air-exposed edges dry out softly onto each other in a fluid-molding manner which resist shaking and thermal effects without affecting the lubrication performance.
[0044] The cost of the parts and the assembly thereof are also reduced since there is no need to bond a cover 22 to the proximal surface, and only a firm pull on handle member 33 will snap off the double-stopper while the lubricant will be partly moved toward the inside by the elastic recovery of the cone. In other words, a number of improvements serve to potentially favor this design over that shown in FIGS. 5-9 .
[0045] The proposed double-stopper container shown in FIGS. 10 and 11 include a single molded part comprising four elements including the cone 30 , element 31 , a stem 32 and a knob 33 , for being firmly inserted across the cone 2 , until the cone point 30 snaps beyond the silicone orifice and is then released, causing the traversed cone 2 to be compressed axially between the proximal flat surface of cone point 30 and the distal surface of element 31 . As a result, the narrower cone internal surfaces of the cone 2 will be pushed radially inwardly as shown by member 29 and become tightened over the end surfaces of the stem 32 while the disk stopper 31 pushes radially outwardly and distally against the proximal region of the silicone seal cone at location 35 . Such simultaneous elastic deformation results in a sealing effect for the lubricating fluid deposited into cone 2 insuring a truly air-tight space for the lubricant.
[0046] The design in FIGS. 10 and 11 also depicts a simple external region 6 ′ as compared with the one shown in FIGS. 5-9 . Region 6 ′ can be bonded at side portion 28 onto the rim of housing 7 , therefore rendering the whole seal suitable for face mounting axially against a cannula internal rim at region 6 ′.
[0047] The advantages of the universal closure for the present filed invention are that a single seal can be provided so as to reduce the number of parts necessary to form the universal seal, while maintaining sufficient flexibility and providing a tight seal around the obturator or other surgical equipment passed through the seal. Such seal also has the advantage of being a one-piece element. More particularly, a single casting molded silicone piece is preferable. The utilization of the lubricant also has the distinct and novel advantage of assisting in entry of the obturator and withdrawal of the same. Such lubricant can be a biological substance having lubrication properties such as a hydrogel such as a hyaluronic acid so as to provide a preferred smooth and reliable lubrication not presently available in conventional seals. Providing the lubricant beneath the removable lid so as to be housed between the lid, the seal and an end portion of the projection permits the lubricant to be securely housed within the seal and to maintain its lubrication properties.
[0048] An additional advantage provided by the seal shown in FIGS. 1-9 is that force reduction can be obtained by the utilization of thinner walls in the seal reinforced by longitudinal thicknesses between the grooves so as to prevent snagging and ripping of the seal opening. Such thinner walls can be made, for example, from a higher durometer (40-50, for example) material to obtain strength and a low friction coefficient while maintaining the tightness over the instrument so as to be relatively low. Such therefore requires the utilization of a higher strength durometer characteristic of the seal. A similar performance could potentially be obtained through the use of a lower strength durometer (i.e., 20-30, for example) and in making the seal walls thicker, however, such design inevitably would entail a higher friction coefficient which could be detrimental to penetration forces and enhanced snagging by sharp instruments with the walls of the seal and valve. Such snagging is a major problem and is even more of a problem than penetration force difficulties since it induces ripping which destroys the orifice of the seal if not properly designed. However, the present invention serves to prevent this type of problem.
[0049] In summary, a lower wall resistance as a result of friction can be obtained without the danger of snagging through harder wall surfaces which have a lower friction coefficient while still maintaining the strength needed by the utilization of longitudinal corrugations provided along the outside surface of the seal cone, terminating just short of the orifice thereof.
[0050] FIGS. 12-16 illustrate an additional embodiment of the invention which is similar to that described above but include ribs 232 provided on the exterior surface portion of the cone 2 . These ribs 232 are therefore positioned between the cone and the conoid 1 and have a base 233 . In addition, the conoid 1 is shown as including beveled outside edges 110 . The internal cone 2 is also provided with a cylindrically shaped channel or opening 234 having a longitudinal length of at least two times the thickness of the cone 2 . This channel or opening 234 thus provides an additional length of contact surface for an air tightly contacting an object that is inserted through the cone and thus provides an even more effective seal than that provided in the first embodiment of the present invention. The beveled outside edges 110 are acute angled (for example, at an angle of 30° with respect to the outside surface portion of the conoid 1 ), as can be understood from a review of FIG. 15 . The illustrated embodiment shows four ribs 232 provided but are greater or lesser number of ribs can be provided depending upon the composition and diameter characteristics of the material forming the cone and ribs.
[0051] As would be understandable to one of ordinary skill in the art, obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. For example, the seal can be utilized in any structural assembly that permits passage of a member through a seal. This could include, for example, the nozzle of a filling station pump or other type of insertable member that passes through the seal mounted in the passageway of the vehicle that leads to the fuel tank of the vehicle. Other possibilities are clearly possible which would be within the knowledge of one of ordinary skill in the art of providing seals for passageways. It is therefore to be understood that within the scope of the pending claims, the invention may be practiced otherwise than as specifically described therein. | A seal assembly includes a first seal and a second seal and positioned in the first end element. The second seal can include at least one longitudinal groove therein and have members connected thereto. A stopper member is coaxially positionable within the second seal and the first seal and a lubricant can be positioned between the stopper member and the second seal. The seal assembly can also be integrated with a capsule for removable insertion within a tubular member. | 0 |
BACKGROUND
The present invention relates to testing multiple data packet signal transceiver devices under test (DUTs), and in particular, to testing multiple DUTs with a shared tester to maximize tester use and thereby minimize test time.
Many of today's electronic devices use wireless technologies for both connectivity and communications purposes. Because wireless devices transmit and receive electromagnetic energy, and because two or more wireless devices have the potential of interfering with the operations of one another by virtue of their signal frequencies and power spectral densities, these devices and their wireless technologies must adhere to various wireless technology standard specifications.
When designing such wireless devices, engineers take extra care to ensure that such devices will meet or exceed each of their included wireless technology prescribed standard-based specifications. Furthermore, when these devices are later being manufactured in quantity, they are tested to ensure that manufacturing defects will not cause improper operation, including their adherence to the included wireless technology standard-based specifications.
During testing of data packet signals sent by a DUT to a tester, the packets initially transmitted, e.g., when an otherwise properly operating DUT′ transmitter first begins transmitting, its power will vary, increasing and decreasing until it “settles” to the intended nominal power, with any further power variations normally deemed to be insignificant. At that time, after settling, the tester then begins capturing data packets for analysis. Earlier data packets captured during the settling time are essentially ignored for purposes of the analysis. However, their capturing nonetheless ties up capture and analysis resources of the tester. Thus, from a tester utilization perspective, the analysis functions of the tester remain idle during the transmitter power settling interval, and thus detracts from overall tester utilization.
Current attempts to optimize tester use during testing will often predefine a test step sequence that a DUT will execute during a test, usually based on either signal transmission time or number of transmitted data packets. Consequently, the DUT will only execute a given test sequence for a predetermined time interval. When trying to test multiple DUTs contemporaneously, e.g., in parallel, one needs to design the test sequence to allow DUT performance to be analyzed in a worst case scenario where all DUTs request access to hardware at the same point in time. However, in most cases such a worst-case scenario will not occur, though all DUTs continue to execute their test sequences to satisfy the worst-case scenario. Hence, proportionally, a significant amount of test time is unproductive as the tester captures data packets unsuitable for analysis.
SUMMARY
In accordance with the presently claimed invention, methods are provided for testing multiple data packet signal transceiver devices under test (DUTs) with a shared tester. The DUTs transmit their data packet signals until predetermined numbers of data packets have been transmitted or predetermined time intervals expire, following which, each DUT awaits a synchronization request to begin transmitting data packets to the tester. Alternatively, the tester determines when its receiver is available for receiving data packets, following which, synchronization requests are sent to respective DUTs to initiate their transmissions of data packets to the tester. Further alternatively, power levels among data packets initially transmitted from the DUTs are monitored to determine when they are indicative of them having settled. As each DUT data packet signal power settles, a status signal indicating the settled nature of each DUT is provided to the tester which then begins receiving the respective DUT data packet signals, as they settle in power, for analysis.
In accordance with one embodiment of the presently claimed invention, a method for testing multiple data packet signal transceiver devices under test (DUTs) with a shared tester includes preparing each one of a plurality of DUTs for transmit signal (TX) testing by:
initiating at least partially contemporaneous transmissions of respective initial pluralities of DUT data packets from a plurality of DUTs;
terminating each one of the transmissions of respective initial pluralities of DUT data packets from the plurality of DUTs following at least one of
transmission of a respective predetermined plurality of DUT data packets, or a respective predetermined time interval; and
initiating further at least partially contemporaneous transmissions of DUT data packets by one or more of the plurality of DUTs from which the transmission of a respective initial plurality of DUT data packets has been terminated following at least one of
reception of a synchronization request signal, or another respective predetermined time interval.
In accordance with another embodiment of the presently claimed invention, a method for testing multiple data packet signal transceiver devices under test (DUTs) with a shared tester includes:
following confirmation of availability of data packet signal receiver circuitry of a tester to receive a DUT data packet signal, conveying a synchronization request signal to one of a plurality of DUTs;
waiting for at least the first to occur of
reception of a response data packet signal responsive to the synchronization request signal, or expiration of a response time interval for reception of the response data packet signal;
following a failure to receive the synchronization confirmation signal prior to the expiration of the response time interval,
conveying another synchronization request signal to another one of the plurality of DUTs, and repeating the waiting; and
following a successful reception of a response data packet signal prior to the expiration of the response time interval, receiving, with the tester, a DUT data packet signal from the one of the plurality of DUTs from which the response data packet signal was received prior to the expiration of the response time interval.
In accordance with another embodiment of the presently claimed invention, a method for testing multiple data packet signal transceiver devices under test (DUTs) with a shared tester includes:
receiving at least one status signal indicative of power variations among data packets within each one of a plurality of DUT data packet signals from a plurality of DUTs;
following confirmation of availability of data packet signal receiver circuitry of a tester to receive a DUT data packet signal, and reception of the at least one status signal being indicative of a power variation less than a first variation among data packets within a DUT data packet signal from a first one of the plurality of DUTs, performing at least one of
conveying a first synchronization request signal to the first one of the plurality of DUTs, or receiving, with the tester, the DUT data packet signal from the first one of the plurality of DUTs; and
following the reception of the DUT data packet signal from the first one of the plurality of DUTs, and reception of the at least one status signal being indicative of a power variation less than a second variation among data packets within a DUT data packet signal from a second one of the plurality of DUTs, performing at least one of
conveying a second synchronization request signal to the second one of the plurality of DUTs, or receiving, with the tester, the DUT data packet signal from the second one of the plurality of DUTs.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts a testing environment for testing multiple DUTs in accordance with exemplary embodiments of the presently claimed invention.
FIG. 2 depicts a flowchart representing a test flow in accordance with exemplary embodiments of the presently claimed invention.
FIG. 3 depicts a flowchart representing a test flow in accordance with further exemplary embodiments of the presently claimed invention.
FIG. 4 depicts synchronization signal exchanges and data packet transmissions between multiple DUTs and a shared tester in accordance with exemplary embodiments of the presently claimed invention.
FIG. 5 depicts a testing environment for testing multiple DUTs in accordance with further exemplary embodiments of the presently claimed invention.
FIG. 6 depicts synchronization signal exchanges and data packet transmissions between multiple DUTs and a shared tester in accordance with further exemplary embodiments of the presently claimed invention.
FIG. 7 depicts synchronization signal exchanges and data packet transmissions between multiple DUTs and a shared tester in accordance with further exemplary embodiments of the presently claimed invention.
DETAILED DESCRIPTION
The following detailed description is of example embodiments of the presently claimed invention with references to the accompanying drawings. Such description is intended to be illustrative and not limiting with respect to the scope of the present invention. Such embodiments are described in sufficient detail to enable one of ordinary skill in the art to practice the subject invention, and it will be understood that other embodiments may be practiced with some variations without departing from the spirit or scope of the subject invention.
Throughout the present disclosure, absent a clear indication to the contrary from the context, it will be understood that individual circuit elements as described may be singular or plural in number. For example, the terms “circuit” and “circuitry” may include either a single component or a plurality of components, which are either active and/or passive and are connected or otherwise coupled together (e.g., as one or more integrated circuit chips) to provide the described function. Additionally, the term “signal” may refer to one or more currents, one or more voltages, or a data signal. Within the drawings, like or related elements will have like or related alpha, numeric or alphanumeric designators. Further, while the present invention has been discussed in the context of implementations using discrete electronic circuitry (preferably in the form of one or more integrated circuit chips), the functions of any part of such circuitry may alternatively be implemented using one or more appropriately programmed processors, depending upon the signal frequencies or data rates to be processed. Moreover, to the extent that the figures illustrate diagrams of the functional blocks of various embodiments, the functional blocks are not necessarily indicative of the division between hardware circuitry.
As discussed in more detail below, data packet tester utilization is maximized and test time is minimized by avoiding use of tester resources, e.g., the receiver circuitry for capturing data packets for analysis, during the time that signal power levels of data packets transmitted by the DUTs (in predetermined sequences, e.g., in terms of numbers of packets or packet transmission time intervals) are settling to their intended nominal power levels. Hence, as transmitted power levels of other DUT data packets settle, data packets now being transmitted by a DUT whose output has already settled are received for capturing and analysis. Accordingly, the disclosed methods provide for separating or otherwise distinguishing between intervals during which DUT data packets are settling (in terms of transmitted signal power) before being received for capture and analysis. This ensures that the tester receiver circuitry used for capturing and analysis of data packets is used for those data packets (in sequences, as noted) for which the transmitted data packet signal power has already settled, concurrent with one or more other DUTs completing their respective transmitted signal power settling time intervals, during which their data packets are not received for capture and analysis.
Referring to FIG. 1 , in accordance with exemplary embodiments, a testing environment 100 for testing multiple DUTs includes a tester 102 , signal routing circuitry 104 (e.g., multiplexor or switch matrix circuitry) and the DUTs 106 . (For purposes of this discussion, testing is discussed in the context of three DUTs being tested contemporaneously, or in parallel, though it will be understood that the number of DUTs can be more or fewer as desired.)
Signal paths 103 , 105 between the tester 102 , routing circuitry 104 and DUTs 106 are provided, typically in the form of conductive signal paths implemented using controlled impedance radio frequency (RF) cables and connectors (e.g., co-axial,). During transmit (TX) signal testing, data packet signals from the DUTs 106 are conveyed via the signal paths 105 to the routing circuitry 104 , which routes (e.g., multiplexes or switches) the desired or selected signal via the signal path 103 to the tester 102 . Such signal routing is controlled in accordance with one or more control signals 115 , which can be provided by the tester 102 or another control signal source (not shown) external or remote from the tester 102 , such as a personal computer. The routed data packet signal is received by the tester 102 using receiver circuitry 102 a , e.g., in the form of a vector signal analyzer (VSA), where the data packets are captured for analysis.
During receive (RX) signal testing, a data packet signal is provided by a signal source 102 g within the tester 102 , e.g., in the form of a vector signal generator (VSG). This signal is conveyed via the signal path 103 to the router circuitry 104 , which routes the signal to the desired DUT 106 a , 106 b , 106 c, . . . .
Referring to FIG. 2 , in accordance with exemplary embodiments, test flow 200 for testing each one of multiple DUTs 106 can proceed as shown, with each being tested as part of a concurrent test sequence by performing each of the depicted steps. Initially, each DUT will initiate transmission of its data packets 202 . It is then determined 204 whether a prescribed number of data packets have been sent, or, alternatively, whether a prescribed time interval has elapsed or expired. If not, transmission of data packets continues 202 . However, if the prescribed number of data packets has been transmitted, or the prescribed time interval has elapsed, the DUT awaits 208 reception of a synchronization request signal from the tester. Following reception of such synchronization request signal, the DUT may respond by transmitting a synchronization confirmation signal 210 , and resumes transmitting test data packets for reception, capture and analysis by the tester.
Referring to FIG. 3 , in accordance with further exemplary embodiments, program flow 300 from the perspective of the tester 102 can proceed as shown. Initially, the tester determines 302 whether the signal reception circuitry (e.g., the VSA) is available to receive a data packet signal for capture and analysis. If not, the receiver circuitry continues to be monitored 320 for its availability. After it becomes available, the tester transmits a synchronization request signal 304 to a selected DUT. The tester then waits during a response time interval 306 for reception of a synchronization confirmation signal from the DUT to which the synchronization request signal was conveyed. Alternatively, tester waits during a predetermined response time interval 306 for reception of data packets from the DUT. If no synchronization confirmation signal is received, or if no data packets are received from the DUT within the predetermined response time interval, the routing circuitry is set 322 to select another DUT (i.e., to convey signals between the tester and selected DUT), following which another synchronization request signal is transmitted 324 to such selected DUT.
Following reception of a synchronization confirmation signal from a DUT, the tester begins receiving data packets 308 from the DUT with which synchronization has been established for capture and analysis. Following completion of such reception of data packets from the selected DUT, the routing circuitry is again set 310 to select another DUT, following which, the tester again checks for availability 302 of the receiver circuitry following its prior use for reception of data packets from the previous DUT.
Referring to FIG. 4 , in accordance with exemplary embodiments, interaction of signals between the tester and multiple DUTs (e.g., in the testing environment 100 of FIG. 1 ) begins with the DUTs 106 a , 106 b , 106 c transmitting initial data packets 411 , 412 , 413 (in sequences, as noted above) during their respective power settling time intervals. The point in time that each DUT 106 a , 106 b , 106 c begins transmitting is based upon completion of its prior transmission, and thus is at least somewhat random. Meanwhile, the tester 102 seeks to initiate test flow by transmitting multiple synchronization request signals 400 , e.g., by sending synchronization request signals 401 , 402 , 403 in a round-robin manner to the respective DUTs 106 a , 106 b , 106 c pending their completion of signal power settling.
As shown, signal power for the first DUT 106 a is the first to be considered settled (e.g., the DUT 106 a has completed transmission of a predetermined number of data packets following which power settlement is presumed). Accordingly, in response to its synchronization request signal 401 received from the tester 102 following its power settling, the first DUT 106 a responds with a synchronization confirmation signal 431 , following which, its subsequently transmitted data packets 416 are received and captured by the tester 102 .
Following completion of its capture of the data packets 416 , the tester 102 resumes transmission of synchronization request packets 402 , 403 for the second 106 b and third 106 c DUTs. By then, signal power levels for the second DUT 106 b have not yet settled. However, power levels for the third DUT 106 c have reached a state to be considered settled, so it responds to its synchronization request signal 403 from the tester 102 by transmitting, in response, synchronization confirmation signal 433 , following which its subsequently transmitted data packets 418 are received and captured by the tester 102 .
Following completion of its capture of these data packets 416 , the tester 102 resumes transmission with another synchronization request packet 404 for the first DUT 106 a . However, the first DUT 106 a has started another packet sequence 421 for which its signal power levels for have not yet settled. Meanwhile, though, signal power levels for the second DUT 106 b have reached a state to be considered settled. Accordingly, it responds to its synchronization request signal 402 from the tester 102 by transmitting, in response, a synchronization confirmation signal 432 , following which, its subsequently transmitted data packets 417 are received and captured by the tester 102 .
The synchronization request packets 401 , 402 , 403 , 404 , . . . can be transmitted at different frequencies, as desired, in accordance with their respective positions in the overall test flow for the different DUTs 106 .
Referring to FIG. 5 , a testing environment 100 a in accordance with further exemplary embodiments includes power detection, or measurement, circuits 110 disposed between the routing circuitry 104 and DUTs 106 . The respective power detectors 110 a , 110 b , 110 c detect, or measure, the power levels (e.g., by sampling individual peak data packet signal levels) of the data packet signals beings transmitted by the corresponding DUTs 106 a , 106 b , 106 c via the signal paths 105 a , 105 b , 105 c to the routing circuitry 104 . The power detectors 110 each provide one or more data signals 111 a , 111 b , 111 c indicative of the individual DUT data packet signal powers. These data signals 111 a , 111 b , 111 c are processed by control circuitry 112 to provide one or more control signals 113 to the tester 102 . These control signals 113 can be conveyed directly to the receiver circuitry 102 a or the signal generator circuitry 102 g , or both, or can be further processed by internal control circuitry 102 c within the tester 102 prior to use in controlling one or both of the receiver 102 a and generator 102 g circuitry. These detected power level signals 111 can be used, via the control signals 113 to the tester 102 , to inform the tester 102 whether and when the data packet signal power from each DUT 106 a , 106 b , 106 c has settled.
Alternatively, the power detectors 110 a , 110 b , 110 c can be used to detect the respective data packets, in which case the data signals 111 a , 111 b , 111 c can be indicative of the number of data packets that have been transmitted by the respective DUTs 106 a , 106 b , 106 c . Based upon a priori knowledge of the power settling characteristics of the DUTs 106 (e.g., empirical test data of similar DUTs known to be good), the data signals 111 a , 111 b , 111 c will then also be indicative of whether and when the power levels of the data packets transmitted by the respective DUTs 106 a , 106 b , 106 c have settled. In turn, these signals will also be indicative of the states of readiness on the part of the respective DUTs 106 a , 106 b , 106 c to be responsive to synchronization requests.
Additionally, data packet detection capabilities of the power detectors 110 a , 110 b , 110 c can be advantageously used to enable more informed planning for and uses of the tester 102 resources. For example, the data signals 111 a , 111 b , 111 c can be monitored to identify when flows of data packets from the respective DUTs 106 a , 106 b , 106 c begin and end, and thereby enable real time determinations of whether and when the tester 102 should be capturing data packets with the receiver circuitry 102 a or providing test data packets with the signal source 102 g , depending upon requirements of the test currently being performed or scheduled to be performed.
Referring to FIG. 6 , in accordance with exemplary embodiments, interactions of data packet signals between the tester 102 and DUTs 106 in the testing environment 100 a of FIG. 5 can occur as shown. The power detectors 110 a , 110 b , 110 c can determine when predetermined numbers of data packets have been transmitted by the respective DUTs 106 a , 106 b , 106 c , following which, synchronization request packets are transmitted. For example, the first power detector 110 a monitors the data packet stream transmitted by its associated DUT 106 a , and when the expected number of data packets 411 have been transmitted, the control circuitry 112 initiates scheduling of a synchronization request packet 401 for transmission by the DUT 106 a . Similarly, when the second DUT 106 b completes transmission of its expected number of data packets 412 , the control circuitry 112 initiates scheduling of a synchronization request packet 402 for transmission by the DUT 106 b . However, as depicted in the figure, the tester 102 is receiving and capturing data packets 416 from the first DUT 106 a , and is, therefore, currently unavailable for communications with the second DUT 106 b . Accordingly, transmission of the second synchronization request packet 402 is delayed until completion of the capturing of data packets 416 from the first DUT 106 a . Monitoring of data packets 413 from the third DUT 106 c , capturing of data packets 417 from the second DUT 106 b , and delaying of transmission of the synchronization request packet 403 from the third DUT 106 c are similarly performed.
Referring to FIG. 7 , in accordance with further exemplary embodiments, e.g., again when testing in the environment 100 a of FIG. 5 , alternative signal interactions can occur as shown. For example, the power levels of the data packets 411 from the first DUT 106 a may settle more quickly, e.g., as of the next-to-last data packet 411 a of the data packet sequence 411 . This is detected by the corresponding power detector 110 a , which signals 111 a to the tester 102 that data packet reception and capture can begin. Accordingly, the tester 102 begins receiving and capturing data packets 416 a prior to the exchange of the synchronization request 401 and synchronization confirmation 431 signals. Accordingly, one or more trailing packets of the initial sequence 411 of data packets may be captured, as well as the synchronization confirmation 431 packet, and one or more of the trailing data packets 416 subsequently transmitted may not be captured.
Similarly, this may happen with another DUT 106 b for which transmitted power has settled as of the next-to-last data packet 412 a , again, prior to the exchange of the synchronization request 402 and synchronization confirmation 432 signals. As before, this may result in receiving and capturing one or more trailing packets of the initially transmitted data packets 412 and failure to receive and capture one or more trailing packets of the subsequently transmitted data packets 417 .
Meanwhile, notwithstanding a similar early settling of power levels of the data packets 413 from the remaining DUT 106 c , exchange of the synchronization request 403 and synchronization confirmation 433 signals occurs later, e.g., due to the unavailability of the receiver circuitry of the tester 102 during reception and capture of data packets from the second DUT 106 b . Accordingly, reception and capture of data packets 418 a from the third DUT 106 c occurs without also receiving and capturing one or more trailing packets of the initially transmitted data packets 413 .
Alternatively, the test environment 100 a can be programmed or otherwise controlled such that, following availability of the receiver circuitry of the tester 102 , priority for reception and capture of data packets can be based on the order in which power settling has occurred. Accordingly, in this example, since the power levels of the data packets 413 from the third DUT 106 c have settled earlier than those of the data packets 412 from the second DUT 106 b , the receiver circuitry of the tester 102 will synchronize with and capture packets from the third DUT 106 c first.
Various other modifications and alterations in the structure and method of operation of this invention will be apparent to those skilled in the art without departing from the scope and the 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. It is intended that the following claims define the scope of the present invention and that structures and methods within the scope of these claims and their equivalents be covered thereby. | Methods for testing multiple data packet signal transceiver devices under test (DUTs) with a shared tester. The DUTs transmit their data packet signals until predetermined numbers of data packets have been transmitted or predetermined time intervals expire, following which, each DUT awaits a synchronization request to begin transmitting data packets to the tester. Alternatively, the tester determines when its receiver is available for receiving data packets, following which, synchronization requests are sent to respective DUTs to initiate their transmissions of data packets to the tester. Further alternatively, power levels among data packets initially transmitted from the DUTs are monitored to determine when they are indicative of them having settled. As each DUT data packet signal power settles, a status signal indicating the settled nature of each DUT is provided to the tester which then begins receiving the respective DUT data packet signals, as they settle in power, for analysis. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a method for manufacturing a screen cylinder, in which method screen wires are set at predefined intervals side by side and fastened in the axial direction of the screen cylinder to form a cylindrical screen surface in connection with ring-shaped support rods, and in which method end rings are further mounted at the ends of the screen cylinder.
The invention further relates to a method for manufacturing a screen cylinder, in which method screen wires are set at predefined intervals side by side and fastened to support rods that are bent in the shape of a ring so that the screen wires in the axial direction of the screen cylinder form a cylindrical screen surface, and in which method end rings are further mounted at the ends of the screen cylinder.
The invention yet further relates to a screen cylinder for cleaning or screening fiber pulp, the screen cylinder having screen wires in the axial direction of the screen cylinder set at predefined intervals to form a cylindrical screen surface and fastened to ring-shaped support rods, and the screen cylinder ends having end rings arranged thereto.
2. Description of Related Art
Screen cylinders are used for instance to clean and screen fiber pulp. Screen cylinders are manufactured for instance by fastening parallel screen wires that form a screen surface side by side in a cylindrical form so that a slot of a desired size remains between the wires. Generally this is done by welding or brazing the screen wires to ring-shaped support wires or rods. The screen wires can be fastened to the support rods in the radial direction of the screen cylinder either inside or outside the support rods. To strengthen the structure of the screen cylinder, separate support rings can be fastened to at least a few of the ring-shaped support rods. These support rings are fastened either to the inner circumference or outer circumference of the support rods depending on the relative order of the screen wires and support rods in the radial direction of the screen cylinder. The structure of the screen cylinder is complemented by fastening end rings at the ends of the screen cylinder. When the end rings are fastened to the ends of the screen cylinder, the ends of the screen wires are welded to the end rings.
However, fastening the end rings by welding causes a lot of work, first when opening the root of the weld and, after that, during the actual welding. For instance, in a screen cylinder with a diameter of 1200 mm, over 20 meters of weld joint is produced. Fastening the end rings to the screen cylinder by welding also causes welding stresses in the structure of the screen cylinder, whereby during use loads are generated due to the varying pressure inside the screen and mechanical loads, and the generated loads may make the structure of the screen cylinder break.
BRIEF SUMMARY OF THE INVENTION
It is an object of the present invention to provide a screen cylinder with improved strength and a method for manufacturing it.
The method of the invention is characterized by installing at least one end ring at one end of the screen cylinder in such a manner that the end ring is arranged to at least one support rod at the ends of the screen wires or closest to the ends of the screen wires, and by forming a shrink fit between the end ring and support rod, in which a substantially perpendicular force to the axis of the screen cylinder acts between the end ring and support rod, and the force, through the support rod, locks the screen surface formed by the screen wires substantially immobile in relation to the end ring.
A further characteristic of the method of the invention, in which the support rods are bent in the shape of a ring only after the screen wires are fastened to the support rods, is that at least one end ring of the screen cylinder is installed to one end of the screen cylinder in such a manner that the end ring is arranged to at least one support rod at the ends of the screen wires or closest to the ends of the screen wires, and by forming a shrink fit between the end ring and support rod, in which a substantially perpendicular force to the axis of the screen cylinder acts between the end ring and support rod, and the force, through the support rod, locks the screen surface formed by the screen wires substantially immobile in relation to the end ring.
Further, the screen cylinder of the invention is characterized in that at least one end ring is installed at one end of the screen cylinder in such a manner that the end ring is arranged to at least one support rod at the ends of the screen wires or closest to the ends of the screen wires without fastening the end ring to the screen wires, and that there is a shrink fit between the end ring and support rod, in which a substantially perpendicular force to the axis of the screen cylinder is arranged to act between the end ring and support rod, and the force, through the support rod, locks the screen surface formed by the screen wires substantially immobile in relation to the end ring.
The essential idea of the invention is that in a screen cylinder intended for cleaning or screening fiber pulp, in which screen wires are set in the axial direction of the screen cylinder at predefined intervals to form a cylindrical screen surface and fastened to support rods and in which end rings are arranged at the ends of the screen cylinder, at least one end ring is installed at one end of the screen cylinder in such a manner that the end ring is arranged to at least one support rod at the ends of the screen wires or closest to the ends of the screen wires, and a shrink fit is formed between the end ring and support rod, in which a substantially perpendicular force to the axis of the screen cylinder is arranged to act between the end ring and support rod, and the force, through the support rod, locks the screen surface formed by the screen wires substantially immobile in relation to the end ring.
The invention provides the advantage that the screen wires are not welded to the end ring, whereby stress from the welding and directed to the weld joint are avoided. The slow and expensive manufacturing stage of welding the screen wires and end ring is then also left out. By fastening the end ring and support rod to each other either by separate locking elements extending in the radial direction of the screen cylinder through the end ring to the support rod and/or one or more weld joints between the end ring and support rod, it is possible to further ensure that the screen surface of the screen cylinder does not rotate relative to the end rings and the entire body of the screen. Owing to the invention, the end rings can be re-used when replacing the screen cylinder.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
The invention will now be described in greater detail by way of preferred embodiments and with reference to the attached drawings, in which
FIG. 1 is a schematic cross-sectional view of a screen cylinder in the axial direction of the screen cylinder;
FIG. 2 is a schematic cross-sectional view of the screen cylinder of FIG. 1 as seen from the end of the screen cylinder;
FIG. 3 is a schematic cross-sectional view of a second screen cylinder in the axial direction of the screen cylinder;
FIG. 4 is a schematic cross-sectional view of a third screen cylinder in the axial direction of the screen cylinder;
FIG. 5 is a schematic cross-sectional view of a fourth screen cylinder as seen from the end of the screen cylinder; and
FIG. 6 is a schematic cross-sectional view of the screen cylinder of FIG. 5 in the axial direction of the screen cylinder.
In the figures, the invention is shown simplified for the sake of clarity. Similar parts are marked with the same reference numbers in the figures.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a schematic cross-sectional view of a screen cylinder 1 as seen from the end of the screen cylinder 1 , and FIG. 2 is a schematic cross-sectional view of the screen cylinder of FIG. 1 in the axial direction of the screen cylinder 1 . On the inner surface of the screen cylinder 1 , there are screen wires 2 placed around the entire inner circumference of the screen cylinder 1 so that they form a screen surface. Between the screen wires 2 , there are screen slots through which liquid and a desired part of the fibers is allowed to flow outside the screen cylinder 1 while slivers and too large fibers, fiber bundles and any other material to be screened remain on the inner surface of the screen cylinder 1 to be removed at its other end. The screen wires 2 are fastened to support wires 3 or rods 3 before the support rods 3 are bent in the shape of a ring in such a manner that a screen cylinder 1 having a suitable diameter is formed. The screen cylinder 1 can also be made in such a manner that the screen wires 2 are fastened to the inner circumference of the support rods 3 that are already in advance bent in the shape of a ring. There are support rods 3 at suitable intervals in the axial direction of the screen cylinder 1 so that the screen wires 2 remain sufficiently rigidly and firmly in place. The screen wires 2 can be fastened to the support rod 3 by welding, but the fastening of the screen wires 2 is also assisted by the pressure due to the bending of the support rod 3 on the inner edge of the support rod 3 . Instead of welding, the screen wires 2 can also be fastened to the support rod 3 by a crimp joint. Support rings 4 can also be installed around the support rods 3 to support the support rods 3 and receive the forces generated by the pressure difference caused by varying pressures on different sides of the screen surface of the screen cylinder 1 and, thus, to strengthen the structure of the screen cylinder 1 . FIG. 1 also shows arrow R in the radial direction of the screen cylinder 1 and pointing from the direction of the axis of the screen cylinder 1 to the direction of the outer circumference of the screen cylinder. Arrow R is also shown in FIGS. 2 to 6 to facilitate the reading of the figures.
FIG. 2 further shows schematically the fastening of the end rings 5 of the screen cylinder 1 to the screen cylinder 1 . The end ring 5 is fastened to the screen cylinder 1 by a shrink fit, in which the end ring 5 is installed around the support rod 3 at the end of the screen cylinder 1 or closest to the end of the screen cylinder 1 and surrounding the screen wires 2 , after which a shrink fit is formed between the end ring 5 and support rod 3 so that the end ring 5 presses the support rod 3 substantially perpendicularly to the axis of the screen cylinder 1 , i.e. in the radial direction of the screen cylinder 1 toward the inside of the screen cylinder 1 .
The end ring 5 can be installed on the end of the screen cylinder 1 for instance in such a manner that it is heated during the installation so that the structure of the end ring 5 expands due to the heat. When the structure of the end ring 5 is suitably expanded, the end ring 5 is installed around the end of the screen cylinder 1 in such a manner that the ends of the screen wires 2 and the support rod 3 at or close to the ends of the screen wires 2 remain inside the inner circumference 6 of the end ring 5 or a part 6 ′ thereof. The outer circumference of the end ring 5 is marked with reference number 8 . After this, the end ring 5 is allowed to cool or it is cooled, and as the end ring 5 cools, its structure is normalized and causes pressure between the support rod 3 and end ring 5 , i.e. a shrink fit is created between the support rod 3 and end ring 5 , in which the active force is directed from the direction of the end ring 5 to the direction of the support rod 3 .
The shrink fit between the support rod 3 and end ring 5 is also achieved by tightening a tightening rod around the screen cylinder close to the end of the screen cylinder 1 in such a manner that the screen cylinder 1 is pressed together in the radial direction. After this, the end ring 5 is arranged around the end of the screen cylinder 1 in such a manner that the ends of the screen wires 2 and the support rod 3 at or close to the ends of the screen wires 2 remain inside the inner circumference 6 of the end ring 5 or a part 6 ′ thereof. The tightening rod around the screen cylinder 1 is then removed and the structure of the screen cylinder 1 returns to its original form and, at the same time, pressure is generated between the end ring 5 and support rod 3 , in which the active force is directed from the direction of the support rod 3 to the direction of the end ring 5 .
The shrink fit between the end ring 5 and support rod 3 is thus generally achieved either by expanding the structure of the end ring 5 before it is installed around the support rod 3 , or by pressing the structure of the screen cylinder 1 together using a force acting in the radial direction of the screen cylinder 1 before the end ring 5 is installed around the support rod 3 , or by using both of these method together.
FIG. 2 shows schematically a possible cross-section of the end ring 5 when using a shrink fit. The shape of the outline formed by the outer dimensions of the cross-section of the end ring 5 of FIG. 2 essentially resembles a square or rectangle, the inner circumference of which lacks material at the section that will be located around the screen wires 2 and support rod 3 so that the cross-sectional shape of the end ring 5 resembles the letter L. The part 6 ′ of the inner circumference of the end ring 5 is then formed by a surface A in the axial direction of the screen cylinder 1 , which settles against the support rod 3 in the shrink fit described above. At right-angles to the surface A in the axial direction of the screen cylinder 1 and forming the part 6 ′ of the inner circumference of the end ring 5 , there is a surface B, which is thus a surface perpendicular to the axis of the screen cylinder 1 . The length of the surface A in the axial direction of the screen cylinder 1 is dimensioned in such a manner that the screen wires 2 and support rod 3 surrounding the screen wires 2 at the ends of the screen wires 2 or close thereto remain within the length of the surface A in the axial direction of the screen cylinder 1 . The length of the surface B perpendicular to the axis of the screen cylinder 1 is designed in such a manner for instance that the screen wires 2 and the support rod 3 surrounding the screen wires 2 remain within the length of the surface B perpendicular to the axis of the screen cylinder 1 . On the surface A in the end ring 5 , a small edge 7 or notch 7 can be left to support the shrink fit in the axial direction of the screen cylinder 1 so that the end ring 5 will not slide away from the support rod 3 in the axial direction of the screen cylinder 1 . Action corresponding to the mechanic locking action of the notch 7 is provided or the locking action can also be increased by making a groove on the surface A of the inner circumference part 6 ′ of the end ring 5 , the shape of the groove matching the shape of the support rod 3 and into which groove the support rod 3 is partially inserted.
Thus, a weld joint between the end ring 5 and the screen wires 2 is no longer used in fastening the end ring 5 , because it may cause welding stress in the structure of the screen cylinder 1 and, consequently, stress generated during the use of the screen may make the weld joint break. Due to the abandoning of the weld joint, the work phases related to welding, i.e. opening the weld root and the actual welding, are also left out. When using a shrink fit, the end rings 5 can, if desired, be re-used when the screen cylinders 1 are replaced, because, due to the missing weld joints, the end ring 5 is detachable from the screen cylinder 1 in its original condition with relatively little work. This re-usability of the end rings 5 thus saves material and costs when the screen cylinders 1 are replaced.
The force acting in the shrink fit between the end ring 5 and the support rod 3 at the end of the screen cylinder 1 is so strong that it prevents the rotation of the screen cylinder 1 relative to the end ring 5 and the entire body of the screen when the screen is used. This prevention of rotation can be ensured even further by fastening the end ring S with locking elements, such as locking screws 9 , to the support rod 3 , as shown in FIG. 3 , or by welding the end ring 5 with partial welds 10 to the support rod 3 , as shown in FIG. 4 . When using locking screws 9 , a hole extending from the outer circumference of the end ring 5 to the support rod 3 is drilled and a locking screw 9 is tightened to the hole to mechanically lock the end ring 5 to the support rod 3 and, thus, to the entire screen cylinder 1 . Using locking screws 9 also makes it possible to easily re-use the end rings 5 . In order to prevent the rotation of the screen cylinder 1 , the end rings 5 can, instead of the locking screws 9 or even in addition to them, be fastened with partial welds 10 to the support rod 3 , whereby short weld joints are formed between the end ring 5 and support rod 3 , preferably at several points along the length of the joint between the end ring 5 and support rod 3 .
FIGS. 1 to 4 show a screen cylinder 1 , in which the screen wires 2 are inside the support rods 3 . FIGS. 5 and 6 , in turn, show a screen cylinder 1 , in which the screen wires 2 are outside the support rods 3 . Such a screen cylinder 1 is manufactured either by fastening the screen wires 2 to the support rods 3 bent in advance into the shape of a ring or by fastening the screen wires 2 first to the support rods 3 , after which the support rods 3 are bent in the shape of a ring so that a screen cylinder 1 with a suitable diameter is formed, in which the screen surface formed by the screen wires 2 remains outside the support rods 3 . In FIG. 6 , arrow R is arranged to point into the direction of the outer surface of the screen cylinder 1 .
FIG. 6 is a schematic representation of fastening the end ring 5 to the screen cylinder 1 . In this case, too, the end ring 5 can be fastened to the screen cylinder 1 with a shrink fit. In this case, the end ring 5 is, however, mounted inside the support rod 3 at the end of the screen cylinder 1 or closest to the end of the screen cylinder 1 and inside the screen wires 2 , after which, a shrink fit is formed between the end ring 5 and support rod 3 .
In the embodiment of FIG. 6 , the end ring 5 can be mounted at the end of the screen cylinder 1 for instance by heating the screen cylinder 1 to expand its structure by the heat in the radial direction of the screen cylinder 1 . When the structure of the screen cylinder is suitably expanded, the end ring 5 is mounted inside the end of the screen cylinder 1 in such a manner that the ends of the screen wires 2 and the support rod 3 at the ends of the screen wires 2 or close to the ends of the screen wires 2 remain outside the outer circumference 8 of the end rind 5 or the part 8 ′ of the outer circumference 8 . After this, the screen cylinder 1 is allowed to cool or it is specifically cooled, whereby when the screen cylinder 1 cools, its structure returns to normal and causes pressure between the support rod 3 on the inner surface of the screen cylinder 1 and the end ring 5 , i.e. a shrink fit is formed between the support rod 3 and end ring 5 , in which the acting force is directed substantially perpendicular to the screen cylinder 1 axis from the direction of the support rod 3 to the direction of the end ring 5 . In the embodiment of FIG. 6 , the structure of the screen cylinder 1 is thus expanded in the radial direction of the screen cylinder 1 for the purpose of mounting the end ring 5 .
FIG. 6 is a schematic representation of a possible cross-section of the end ring 5 when using a shrink fit, the shape of the cross-section resembling the end ring 5 shown in FIGS. 2 to 4 . The shape of the outline formed by the outer dimensions of the cross-section of the end ring 5 shown in FIG. 6 also substantially resembles a square or rectangle, but material is missing from the outer circumference 8 of the end ring at the section surrounding the screen wires 2 and support rod 3 so that the shape of the cross-section of the end ring 5 resembles the letter L. The surface A in the axial direction of the screen cylinder 1 and settling against the support rod 3 then forms the part 8 ′ of the outer circumference 8 of the end ring 5 . The surface B, which is the surface perpendicular to the axis of the screen cylinder 1 , is at right angles to the surface A in the axial direction of the screen cylinder 1 and forming the part 8 ′ of the circumference 8 of the end ring 5 . The dimensioning of the surfaces A and B can be done as in FIGS. 2 to 4 .
The embodiment shown by FIG. 6 can also use a notch 7 or a groove made on the surface A to form a mechanical joint between the end ring 5 and support rod 3 . Further, the joint between the end ring 5 and support rod 3 can be strengthened by a locking element and/or partial welds as shown in FIGS. 3 and 4 .
The drawings and the related description are only intended to illustrate the idea of the invention. The invention may vary in detail within the scope of the claims. | A method is provided for manufacturing a screen cylinder, as well as a screen cylinder with screen wires in the axial direction of the screen cylinder set at predefined intervals into a cylindrical screen surface and fastened to support rods, with end rings are arranged at the ends of the screen cylinder. At least one end ring is mounted at one end of the screen cylinder in such a manner that the end ring is arranged to at least one support rod at the ends of the screen wires or closest to the ends of the screen wires without fastening the end ring to the screen wires. When installing the end ring, a shrink fit is formed between the end ring and support rod, wherein the end ring is arranged to press the support rod substantially perpendicular to the axis of the screen cylinder. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to, and incorporates by reference herein in its entirety, the following pending provisional applications:
[0002] Serial No. 60/346,438, (Attorney Docket No. 2001P24538), filed Jan. 7, 2002;
[0003] Serial No. 60/341,386, (Attorney Docket No. 2001P24075), filed Dec. 18, 2001;
[0004] Serial No. 60/341,539, (Attorney Docket No. 2001P23924), filed Dec. 18, 2001; and
[0005] Serial No. 60/341,384, (Attorney Docket No. 2001P24074), filed Dec. 18, 2001.
[0006] This application is related to, and incorporates by reference herein in its entirety, the following co-pending applications:
[0007] Ser. No. ______, titled “Modem Function Incorporated in Programmable Logic Controller”, (Attorney Docket No. 2001P24538US01), filed Oct. 16, 2002;
[0008] Ser. No. ______,titled “Numeric and Text Paging with an Integral PLC Modem”, (Attorney Docket No. 2001P23924US01), filed Oct. 16, 2002; and
[0009] Ser. No. ______, titled “Security Features for a PLC Modem”, (Attorney Docket No. 2001P24074US01), filed Oct. 16, 2002.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The invention and its wide variety of potential embodiments will be readily understood via the following detailed description of certain exemplary embodiments, with reference to the accompanying drawings in which:
[0011] [0011]FIG. 1 is a block diagram of an exemplary embodiment of a system 1000 of the present invention;
[0012] [0012]FIG. 2 is a block diagram of an exemplary embodiment of an information device 2000 of the present invention;
[0013] [0013]FIG. 3 is a flowchart of an exemplary embodiment of a method 3000 of the present invention;
[0014] [0014]FIG. 4 is a flowchart of an exemplary embodiment of a method 4000 of the present invention;
[0015] [0015]FIG. 5 is a flowchart of an exemplary embodiment of a method 5000 of the present invention;
[0016] [0016]FIG. 6 is a flowchart of an exemplary embodiment of a method 6000 of the present invention;
[0017] [0017]FIG. 7 is a flowchart of an exemplary embodiment of a method 7000 of the present invention;
[0018] [0018]FIG. 8 is a top view of an exemplary EM 241 modem module 8000 of the present invention;
[0019] [0019]FIG. 9 is a screen shot of exemplary graphical user interfaces 9000 of the present invention;
[0020] [0020]FIG. 10 is a screen shot of exemplary graphical user interfaces 10000 of the present invention; and
[0021] [0021]FIG. 11 is a screen shot of exemplary graphical user interfaces 11000 of the present invention.
DETAILED DESCRIPTION
[0022] At least one exemplary embodiment of the present invention includes a system comprising a modem adapted to be integrated into a programmable logic controller and adapted to facilitate communications with a main processor of the programmable logic controller via a communications medium. At least one exemplary embodiment of the present invention includes a method comprising receiving a message from a main processor of a programmable logic controller, modulating the message within the programmable logic controller, and transmitting the message via a communications network. At least one exemplary embodiment of the present invention includes a method comprising receiving a message at a programmable logic controller from a communications network, demodulating the message within the programmable logic controller, and delivering the message to a main processor of the programmable logic controller.
[0023] At least one exemplary embodiment of the present invention includes a system comprising a first modem integral to a first programmable logic controller, and a second modem integral to a second programmable logic controller, the first modem adapted to communicate with the second modem via a communications network. At least one exemplary embodiment of the present invention includes a method comprising coupling a first modem to a second modem, the first modem integral to a first programmable logic controller, the second modem connected to a second programmable logic controller, and transferring data between the first modem and the second modem.
[0024] At least one exemplary embodiment of the present invention includes a method comprising formatting a message at a first modem integral to a first programmable logic controller, and transmitting the formatted message from the first modem via a communications network. At least one exemplary embodiment of the present invention includes a system comprising a means for formatting a message at a modem integral to a programmable logic controller, and means for transmitting the formatted message from the modem via a communications network.
[0025] At least one exemplary embodiment of the present invention includes a method comprising receiving a connection request at a modem integral to a programmable logic controller, and allowing access to the programmable logic controller via the modem. At least one exemplary embodiment of the present invention includes a method comprising establishing a connection between a calling device and a modem integral to a programmable logic controller, and allowing the calling device access to the programmable logic controller via the modem.
[0026] [0026]FIG. 1 is a block diagram of an exemplary embodiment of a system 1000 of the present invention. System 1000 can include a first programmable logic controller (“PLC”) 1100 comprising a main processor 1120 coupled via a connector 1130 to a modem 1140 . In certain embodiments, modem 1140 can connect to a connector 1300 such as a system backplane and/or an expansion input/out bus, thereby freeing a communication port of processor 1200 .
[0027] Modem 1140 can be integral to PLC 1100 . That is, once installed, modem 1140 can be a component of PLC 1100 , rather than free-standing. Modem 1140 can include a communications processor 1150 having a data storage means 1160 , such as a dual port RAM, and a communications interface 1170 , such as a telephone line interface, a wireless network interface, a cellular network interface, a local area network interface, a broadband cable interface, etc. Modem 1140 can form a connection, and/or can receive, read, process, format, configure, modulate, demodulate, transmit, and/or deliver a message, which can include data. Modem 1140 can be modular in design, having its own chassis, and can draw power from connector 1130 and/or PLC 1100 .
[0028] Modem 1140 can be connected to a communications network 1200 , such as a public service telephone network (PSTN), a wireless network, a cellular network, a local area network, the Internet, etc. Also connected to network 1200 can be a second PLC 1300 , which can also have an integral modem 1320 , which can be coupled via connector 1330 to a main processor 1340 .
[0029] Connected to network 1200 also can be a first information device 1400 , such as a traditional telephone, telephonic device, cellular telephone, mobile terminal, Bluetooth device, communicator, pager, facsimile, computer terminal, personal computer, etc. Moreover, a second information device 1500 can be connected to network 1200 , and the second information device 1500 can communicate with a third information device 1600 either via network 1200 or via a second network 1520 .
[0030] [0030]FIG. 2 is a block diagram of an exemplary embodiment of an information device 2000 of the present invention. Information device 2000 can represent any information device 1400 , 1500 , or 1600 of FIG. 1. Information device 2000 can include well-known components such as one or more network interfaces 2100 , one or more processors 2200 , one or more memories 2300 containing instructions 2400 , and/or one or more input/output (I/O) devices 2500 , etc.
[0031] In one embodiment, network interface 2100 can be a telephone, a cellular phone, a cellular modem, a telephone data modem, a fax modem, a wireless transceiver, an ethernet card, a cable modem, a digital subscriber line interface, a bridge, a hub, a router, or other similar device.
[0032] Each processor 2200 can be a general purpose microprocessor, such the Pentium III series of microprocessors manufactured by the Intel Corporation of Santa Clara, Calif. In another embodiment, the processor can be an Application Specific Integrated Circuit (ASIC) or a Field Programmable Gate Array (FPGA) which has been designed to implement in its hardware and/or firmware at least a part of a method in accordance with an embodiment of the present invention.
[0033] Memory 2300 can be coupled to a processor 2200 and can store instructions 2400 adapted to be executed by processor 2200 according to one or more activities of a method of the present invention. Memory 2300 can be any device capable of storing analog or digital information, such as a hard disk, Random Access Memory (RAM), Read Only Memory (ROM), flash memory, a compact disk, a digital versatile disk (DVD), a magnetic tape, a floppy disk, and any combination thereof.
[0034] Instructions 2400 can be embodied in software, which can take any of numerous forms that are well-known in the art.
[0035] Any input/output (I/O) device 2500 can be an audio and/or visual device, including, for example, a monitor, display, keyboard, keypad, touchpad, pointing device, microphone, speaker, video camera, camera, scanner, and/or printer, including a port to which an I/O device can be attached or connected.
[0036] [0036]FIG. 3 is a flowchart of an exemplary embodiment of a method 3000 of the present invention. At activity 3100 , a message is received from the main processor of the PLC at the integral modem of the PLC. At activity 3200 , the message is processed by the modem. At activity 3300 , the processed message is modulated, and at activity 3400 , the modulated message is transmitted over a communications network, such as a telephone network. The modulated message can conform to any of numerous configurations, protocols, and/or standards. For example, the modulated message can be a 10 bit, V.34, ASCII, TAP message.
[0037] [0037]FIG. 4 is a flowchart of an exemplary embodiment of a method 4000 of the present invention. At activity 4100 , a message is received at the integral modem of the PLC via a network. At activity 4200 , the message is demodulated. At activity 4300 , the demodulated message is processed by the modem. At activity 3400 , the processed message is delivered to a main processor of the PLC.
[0038] [0038]FIG. 5 is a flowchart of an exemplary embodiment of a method 5000 of the present invention. At activity 5100 , a modem integral to a first PLC can be coupled to a modem of a second PLC. The modem of the second PLC can be integral to the second PLC or separate from the second PLC. At activity 5200 , the modem of the first PLC can modulate data, and at activity 5300 , transmit the modulated data to the modem of the second PLC. Upon receiving the modulated data, the modem of the second PLC can demodulate the data and respond accordingly, such as by processing and/or forwarding the data to a processor of the second PLC, or by replying to the modem of the first PLC. At activity 5500 , the modem of the first PLC can be de-coupled from the modem of the second PLC.
[0039] [0039]FIG. 6 is a flowchart of an exemplary embodiment of a method 6000 of the present invention. At activity 6100 , a modem integral to a PLC can receive a message specification from a processor of the PLC. In some exemplary embodiments, the message can be a paging message specification. At activity 6200 , the modem can read the message specification. At activity 6300 , the modem can determine a device to attempt to access, such as by dialing a telephone number included in the message specification. At activity 6400 , the modem can identify one or more data variables in the message specification. At activity 6500 , the modem can obtain, format, and place the data values corresponding to the specified data variables into a message. At activity 6600 , the modem can apply one or more message configuration(s) to the message as defined by the message specification and/or other configuration defining means, such as DIP switches, firmware, etc. For example, the modem can apply any of numerous pre-selected formats, modem standards, and/or protocols to the message. At activity 6700 , the modem can transmit the message via a communications network, possibly in accordance with the message specification and/or message configuration(s), to a pagable device and/or a communications device, such as a telephone, a cellular phone, a “smart” phone (such as a Handspring Treo-like device), a pager, a paging service, a messaging service (e.g., Blackberry), a computer terminal, a personal computer, a personal organizer (such as a Palm-like device), a wireless device, a mobile terminal, etc.
[0040] [0040]FIG. 7 is a flowchart of an exemplary embodiment of a method 7000 of the present invention. At activity 7100 , a connection request from a calling device can be received by a modem that is integral to a PLC. At activity 7200 , the modem can request a username and/or password from the calling device. At activity 7300 , the modem can receive a username and/or password. At activity 7400 , the modem can verify the received username and/or password, and if verified, can acknowledge the verification.
[0041] At activity 7500 , the modem can obtain a call-back telephone number from the calling device and/or from a storage device, such as a memory or a database. At activity 7600 , the modem can verify the call-back number, perhaps by comparing a call-back number received from a calling device with a call-back number obtained from storage. At activity 7700 , the modem can allow the connection, by establishing the connection, by placing a connection request, and/or by calling a pre-programmed call-back number. At activity 7800 , the modem can allow the calling device to access the PLC.
[0042] Certain exemplary embodiments of the present invention include a modem module that allows a PLC to connect directly to an analog telephone line. Certain exemplary embodiments of the modem module are sometimes referred to herein as the EM 241 Modem module, and certain exemplary embodiments of the PLC are sometimes referred to herein as the S7-200.
[0043] Certain exemplary embodiments of the present invention can support communications between the PLC and a PLC programming tool, one exemplary embodiment of which is at times referred to herein as the STEP 7-Micro/WIN. Certain exemplary embodiments of the present invention include a modem module that supports the Modbus slave RTU protocol. Communications between the EM 241 Modem module and the PLC can be made over an Expansion I/O bus of the PLC.
[0044] The PLC programming tool can provide a software wizard to help set up a remote modem or a modem module for connecting a local PLC to a remote device.
[0045] Features of the EM 241 Modem Module
[0046] [0046]FIG. 8 is a top view of an exemplary EM 241 Modem module 8000 , which can include a housing 8100 , a series of indicator lights 8200 , which can be used for displaying a status of module 8000 ; a connector 8300 , which can be used for connecting the module to a PLC interface, such as an input/output expansion bus; one or more country code switches 8400 , which can be used for configuring module 8000 for a particular country; and/or communications network interface 8500 , such as an RJ11 jack. The one or more country code switches 8400 can be manually accessible, and can be coupled to firmware that reads a country code from at least one of switches 8400 and configures modem 8000 for country specific operation.
[0047] The following description applies to certain embodiments of EM 241 Modem module 8000 , but should not be viewed as limiting.
[0048] The EM241 Modem Module can expand the functionality of the S7-200 Micro PLC into remote communications. Four Modes are supported by the Module:
[0049] (a) Mode 1 is for Micro/WIN programming and debugging. In certain embodiments, no setup is required. Instead, just Plug & Play.
[0050] (b) Mode 2 is for Modbus Master/Slave Communication.
[0051] (c) Mode 3 is for Alpha-Numeric Messaging and Numeric Paging.
[0052] (d) Mode 4 is for CPU-to-CPU Communications, such as between S7-200 Micro PLCs.
[0053] Moreover, the EM241 Modem Module can provide the following features:
[0054] (e) It can directly connect to the S7-200's Expansion I/O bus eliminating the need to tie up the CPU's communications port.
[0055] (t) Connection of an S7-200 PLC directly to an analog telephone line.
[0056] (g) Baud Rates can be self-negotiating dependent on Line Quality adjustable between 300 Baud and 33.6 kBaud (V.34bis).
[0057] (h) Provides international telephone line interface.
[0058] (i) Many country standards can be supported by the hardware rotary switches. All other settings can be stored in the PLC's variable memory.
[0059] (j) Pulse or Tone Dialing can be supported.
[0060] (k) A modem interface to STEP 7-Micro/WIN for programming and troubleshooting (teleservice).
[0061] (l) Support for the Modus RTU protocol.
[0062] (m) CPU-to-CPU or CPU-to-Modbus data transfer.
[0063] (n) Support for numeric and text paging.
[0064] (o) Support for SMS messaging.
[0065] (p) Support for Callback Function and/or Password Protection.
[0066] The EM 241 Modem module configuration can be stored in the CPU. The STEP 7-Micro/WIN Modem Expansion wizard can be used to configure the EM 241 Modem module.
[0067] International Telephone Line Interface
[0068] The EM 241 Modem module can be a standard V.34 (33.6 kBaud), 10-bit modem, and can be compatible with most internal and external PC modems.
[0069] The EM 241 Modem module can be connected to the telephone line with the six-position four-wire RJ11 connector mounted on the front of the module as shown in FIG. 8. When viewed from the front, RJ11 connector can be configured such that pin 3 provides Ring, and pin 4 provides Tip. Reverse connection can also be allowed.
[0070] In certain situations, an adapter can be used to convert the RJ11 connector for connection to the standard telephone line termination in the various countries.
[0071] The modem and telephone line interface can be powered from an external 24V DC supply. This power source can be connected to the CPU sensor supply or to an external power source. The ground terminal on the EM 241 Modem module can be connected to the system earth ground.
[0072] The EM 241 Modem module can automatically configure the telephone interface for country-specific operation when power is applied to the module. The two rotary switches on the front of the module select the country code. In some embodiments, the switches can be set to the desired country selection before the EM 241 Modem module is powered up as shown in Table 1.
TABLE 1 Countries Supported by the EM 241 Switch Setting Country 01 Austria 02 Belgium 05 Canada 08 Denmark 09 Finland 10 France 11 Germany 12 Greece 16 Ireland 18 Italy 22 Luxembourg 25 Netherlands 27 Norway 30 Portugal 34 Spain 35 Sweden 36 Switzerland 38 U.K. 39 U.S.A.
[0073] STEP 7-Micro/WIN Interface
[0074] The EM 241 Modem module can allow communication with STEP 7-Micro/WIN over a telephone line (teleservice). It is not necessary to configure or program the S7-200 CPU to use the EM 241 Modem module as the remote modem when used with STEP 7-Micro/WIN.
[0075] The following steps can be followed to use the EM 241 Modem module with STEP 7-Micro/WIN:
[0076] (q) Remove the power from the S7-200 CPU and attach the EM 241 Modem module to the I/O expansion bus. Do not attach any I/O modules while the S7-200 CPU is powered up.
[0077] (r) Connect the telephone line to the EM 241 Modem module.
[0078] (s) Connect 24 volts DC to the EM 241 Modem module terminal blocks.
[0079] (t) Connect the EM 241 Modem module terminal block ground connection to the system ground.
[0080] (u) Set the country code switches.
[0081] (v) Power up the S7-200 CPU and the EM 241 Modem module.
[0082] (w) Configure STEP 7-Micro/WIN to communicate to a 10-bit modem.
[0083] Modbus RTU Protocol
[0084] The EM 241 Modem module can be configured to respond as a Modbus RTU slave. In this situation, the EM 241 Modem module receives Modbus requests over the modem interface, interprets those requests, and transfers data to or from the CPU. The EM 241 Modem module then generates a Modbus response and transmits it out over the modem interface.
[0085] In certain embodiments, if the EM 241 Modem module is configured to respond as a Modbus RTU slave, STEP 7-Micro/WIN is not able to communicate to the EM 241 Modem module over the telephone line.
[0086] The EM 241 Modem module can support the Modbus functions shown in Table 2.
TABLE 2 Modbus Functions Supported by Modem Module Function Description Function 01 Read coil (output) status Function 02 Read input status Function 03 Read holding registers Function 04 Read input (analog input) registers Function 05 Write single coil (output) Function 06 Preset single register Function 15 Write multiple coils (outputs) Function 16 Preset multiple registers
[0087] Modbus functions 4 and 16 can allow reading or writing a maximum of 125 holding registers (250 bytes of V memory) in one request. Functions 5 and 15 can write to the output image register of the CPU. These values can be overwritten by a user program.
[0088] Modbus addresses can be written as 5 or 6 character values containing the data type and the offset. In this situation, the first one or two characters can determine the data type, and the last four characters can select the proper value within the data type. The Modbus master device can map the addresses to the correct Modbus functions.
[0089] Table 3 shows the Modbus addresses supported by the EM 241 Modem module, and the mapping of Modbus addresses to the S7-200 CPU addresses.
TABLE 3 Mapping Modbus Addresses to the S7-200 CPU Modbus Address S7-200 CPU Address 000001 Q0.0 000002 Q0.1 000003 Q0.2 . . . . . . 000127 Q15.6 000128 Q15.7 010001 I0.0 010002 I0.1 010003 I0.2 . . . . . . 010127 I15.6 010128 I15.7 030001 AIW0 030002 AIW2 030003 AIW4 . . . . . . 030032 AIW62 040001 VW0 040002 VW2 040003 VW4 . . . . . . 04xxxx VW 2*(xxxx-1)
[0090] The Modem Expansion wizard can be used to create a configuration block in the EM 241 module to support Modbus RTU protocol. The EM 241 Modem module configuration block can be downloaded to the CPU data block before use of the Modbus protocol.
[0091] Paging and SMS Messaging
[0092] The EM 241 Modem module can support sending numeric and text paging messages, and SMS (Short Message Service) messages to cellular phones (where supported by the cellular provider). The messages and telephone numbers can be stored in the EM 241 modem module configuration block which can be downloaded to the data block in the S7-200 CPU.
[0093] The Modem Expansion wizard can be used to create the messages and telephone numbers for the EM 241 Modem module configuration block. The Modem Expansion wizard also can create the program code to allow a program to initiate the sending of the messages.
[0094] Numeric Paging
[0095] Numeric paging can use the tones of a touch tone telephone to send numeric values to a pager. The EM 241 Modem module can dial the requested paging service, wait for the voice message to complete, and send the tones corresponding to the digits in the paging message. The digits 0 through 9, asterisk (*), A, B, C and D can be allowed in the paging message. The actual characters displayed by a pager for the asterisk and A, B, C, and D characters can be determined by the pager and the paging service provider.
[0096] Text Paging
[0097] Text paging can allow alphanumeric messages to be transmitted to a paging service provider, and from there to a pager. Text paging providers normally have a modem line that accepts text pages. The EM 241 Modem module can use Telelocator Alphanumeric Protocol (TAP) to transmit the text messages to the service provider. Many providers of text paging use this protocol to accept messages.
[0098] Short Message Service (SMS)
[0099] Short Message Service (SMS) messaging is supported by some cellular telephone services, including those that are GSM compatible. SMS can allow the EM 241 Modem module to send a message over an analog telephone line to an SMS provider. The SMS provider can then transmit the message to the cellular telephone, and the message can appear on the text display of the telephone. The EM 241 Modem module can use the Telelocator Alphanumeric Protocol (TAP) and/or the Universal Computer Protocol (UCP) to send messages to the SMS provider.
[0100] Embedded Variables in Text and SMS Messages
[0101] The EM 241 Modem module can embed data values from the CPU in the text messages and can format the data values based on a specification in the message. A user can specify the number of digits to the left and right of the decimal point, and whether the decimal point is a period or a comma. When the user program commands the EM 241 Modem module to transmit a text message, the EM 241 Modem module can retrieve the message from the CPU, determine what CPU values are needed within the message, retrieve those values from the CPU, and/or format and place the values within the text message before transmitting the message to the service provider.
[0102] The telephone number of the messaging provider, the message, and the variables embedded within the message can be read from the CPU over multiple CPU scan cycles. The variables embedded within a message can continue to be updated during the sending of a message. If a message contains multiple variables, those variables can be read over multiple scan cycles of the CPU.
[0103] Data Transfers
[0104] The EM 241 Modem module can allow a user program to transfer data to another CPU or to a Modbus device over the telephone line. The data transfers and telephone numbers can be configured with the Modem Expansion wizard, and can be stored in the EM 241 Modem module configuration block. The configuration block can be downloaded to the data block in the S7-200 CPU. The Modem Expansion wizard also can create program code to allow a user program to initiate the data transfers.
[0105] A data transfer can be either a request to read data from a remote device, or a request to write data to a remote device. A data transfer can read or write between 1 and 100 words of data. Data transfers can move data to or from the V memory of the attached CPU.
[0106] The Modem Expansion wizard can allow a user to create a data transfer consisting of a single read from the remote device, a single write to the remote device, or both a read from and a write to the remote device.
[0107] Data transfers can use the configured protocol of the EM 241 Modem module. If the EM 241 Modem module is configured to support PPI protocol (where it responds to STEP 7-Micro/WIN), the EM 241 Modem module can use the PPI protocol to transfer data. If the EM 241 Modem module is configured to support the Modbus RTU protocol, data transfers can be transmitted using the Modbus protocol.
[0108] The telephone number of the remote device, the data transfer request, and the data being transferred can be read from the CPU over multiple CPU scan cycles. Generally, a user program does not modify telephone numbers or messages while a message is being sent, or modify the data being transferred while a message is being sent.
[0109] If the remote device is another Modem module, the password function can be used by the data transfers by entering the password of the remote Modem module in the telephone number configuration.
[0110] Password Protection
[0111] The password security of the EM 241 Modem module can be optional and can be enabled with the Modem Expansion wizard. In certain embodiments, the password used by the EM 241 Modem module is not the same as the CPU password. Instead, the EM 241 Modem module password can be a separate password containing, for example, 8-characters, that the caller can supply to the EM 241 Modem module before being allowed access to the attached CPU. The password can be stored in the V memory of the CPU as part of the EM 241 Modem module configuration block. The EM 241 Modem module configuration block can be downloaded to the data block of the attached CPU.
[0112] If the CPU has the password security enabled in the System Data Block, the caller can supply the CPU password to gain access to password protected functions.
[0113] Security Callback
[0114] The callback function of the EM 241 Modem module can be optional and can be configured with the Modem Expansion wizard. The callback function can provide additional security for the attached CPU by allowing access to the CPU only from predefined telephone numbers. When the callback function is enabled, the EM 241 Modem module can answer any incoming calls, verify the caller, and then disconnect the line. If the caller is authorized, the EM 241 Modem module then can dial a predefined telephone number for the caller, and allow access to the CPU.
[0115] The EM 241 Modem module can support three callback modes:
[0116] (a) Callback to a single predefined telephone number
[0117] (b) Callback to multiple predefined telephone numbers
[0118] (c) Callback to any telephone number.
[0119] The callback mode can be selected by checking the appropriate option in the Modem Expansion wizard and then defining the callback telephone numbers. The callback telephone numbers can be stored in the EM 241 Modem module configuration block stored in the data block of the attached CPU.
[0120] The simplest form of callback is to a single predefined telephone number. If only one callback number is stored in the EM 241 Modem module configuration block, whenever the EM 241 Modem module answers an incoming call, it can notify the caller that callback is enabled, disconnect the caller, and dial the callback number specified in the configuration block.
[0121] The EM 241 Modem module can also support callback for multiple predefined telephone numbers. In this mode, the caller can be asked for a telephone number. If the supplied number matches one of the predefined telephone numbers in the EM 241 Modem module configuration block, the EM 241 Modem module can disconnect the caller, and call back using the matching telephone number from the configuration block. The user can configure up to 250 callback numbers.
[0122] Where there are multiple predefined callback numbers, numerous schemes are possible. In certain embodiments, the callback number supplied when connecting to the EM 241 Modem module is an exact match of the number in the configuration block of the EM 241 Modem module except for the first two digits. For example, if the configured callback is 91(123)4569999 because of a need to dial an outside line (9) and long distance (1), the number supplied for the callback could be any of the following:
[0123] (a) 91(123)4569999
[0124] (b) 1(123)4569999
[0125] (c) (123)4569999
[0126] All of the above telephone number can be considered to be a callback match. The EM 241 Modem module can use the callback telephone number from its configuration block when performing the callback, in this example 91(123)4569999. In certain embodiments, only the numeric characters in a telephone number are used when comparing callback numbers. Characters such as commas or parenthesis can be ignored when comparing callback numbers.
[0127] The callback to any telephone number can be set up in the Modem Expansion wizard by selecting the “Enable callbacks to any phone number” option during the callback configuration. If this option is selected, the EM 241 Modem module can answer an incoming call and request a callback telephone number. After the telephone number is supplied by the caller, the EM 241 Modem module can disconnect and dial that telephone number. This callback mode can provide a means to allow telephone charges to be billed to the EM 241 Modem module's telephone connection and does not necessarily provide security for the S7-200 CPU. The EM 241 Modem module password can be used for security if this callback mode is used.
[0128] The EM 241 Modem module password and callback functions can be enabled at the same time. The EM 241 Modem module can requires a caller to supply the correct password before handling the callback.
[0129] Configuration Table for the EM 241 Modem Module
[0130] All of the text messages, telephone numbers, data transfer information, callback numbers and other options can be stored in a Modem module configuration table which can be loaded into the V memory of the S7-200 CPU. The Modem Expansion wizard can guide a user through the creation of a Modem module configuration table. STEP 7-Micro/WIN then can place the EM 241 Modem module configuration table in the Data Block which can be downloaded to the S7-200 CPU.
[0131] The EM 241 Modem module can read this configuration table from the CPU on startup and within five seconds of any STOP-to-RUN transition of the CPU. The EM 241 Modem module does not necessarily read a new configuration table from the CPU as long the EM 241 Modem module is online with STEP 7-Micro/WIN. If a new configuration table is downloaded while the EM 241 Modem module is online, the EM 241 Modem module can read the new configuration table when the online session is ended.
[0132] If the EM 241 Modem module detects an error in the configuration table, the Module Good (MG) LED on the front of the module can flash on and off. A user can check the PLC Information screen in STEP 7-Micro/WIN, or read the value in SMW220 (for module slot 0) for information about the configuration error. The EM 241 Modem module configuration errors are listed in Table 4. If a user utilizes the Modem Expansion wizard to create the EM 241 Modem module configuration table, STEP 7-Micro/WIN can check the data before creating the configuration table.
TABLE 4 EM 241 Configuration Errors (Hexadecimal) Error Description 0000 No error 0001 No 24 VDC external power 0002 Modem failure 0003 No configuration block ID—The EM 241 identification at the start of the configuration table is not valid for this module. 0004 Configuration block out of range—The configuration table pointer does not point to V memory, or some part of the table is outside the range of V memory for the attached CPU. 0005 Configuration error—Callback is enabled and the number of callback telephone numbers equals 0 or it is greater than 250. The number of messages is greater than 250. The number of messaging telephone numbers is greater than 250, or if length of the messaging telephone numbers is greater than 120 bytes. 0006 Country selection error—The country selection on the two rotary switches is not a supported value. 0007 Phone number too large—Callback is enabled and the callback number length is greater than the maximum. 0008 to 00FF Reserved 01xx Error in callback number xx—There are illegal characters in callback telephone number xx. The value xx is 1 for the first callback number, 2 for the second, etc. 02xx Error in telephone number xx—One of the fields in a message telephone number xx or a data transfer telephone number xx contains an illegal value. The value xx is 1 for the first telephone number, 2 for the second, etc. 03xx Error in message xx—Message or data transfer number xx exceeds the maximum length. The value xx is 1 for the first message, 2 for the second, etc. 0400 to FFFF Reserved
[0133] Status LEDs of the EM 241 Modem Module
[0134] The EM 241 Modem module can have 8 status LEDs on the front panel. Table 5 describes the status LEDs.
TABLE 5 EM 241 Status LEDs LED Description MF Module Fail—This LED is on when the module detects a fault condition such as: H No 24 VDC external power H Timeout of the I/O watchdog H Modem failure H Communications error with the local CPU MG Module Good—This LED is on when there is no module fault condition. The Module Good LED flashes if there is a error in the configuration table, or the user has selected an illegal country setting for the telephone line interface. Check the PLC Information screen in STEP 7—Micro/WIN or read the value in SMW220 (for module slot 0) for information about the configuration error. OH Off Hook—This LED is on when the EM 241 is actively using the telephone line. NT No Dial Tone—This LED indicates an error condition and turns on when the EM 241 has been commanded to send a message and there is no dial tone on the telephone line. This is only an error condition if the EM 241 has been configured to check for a dial tone before dialing. The LED remains on for approximately 5 seconds after a failed dial attempt. RI Ring Indicator—This LED indicates that the EM 241 is receiving an incoming call. CD Carrier Detect—This LED indicates that a connection has been established with a remote modem. Rx Receive Data—This LED flashes on when the modem is receiving data. Tx Transmit Data—This LED flashes on when the modem is transmitting data.
[0135] Using the Modem Expansion Wizard to Configure the EM 241 Modem Module
[0136] A user can start the Modem Expansion wizard from the STEP 7-Micro/WIN Tools menu or from the Tools portion of the Navigation Bar.
[0137] To use this wizard, the user's project is typically compiled and set to Symbolic Addressing Mode. On first screen of the Modem Expansion wizard, a user can select Configure an EM 241 Modem module and click Next>.
[0138] The Modem Expansion wizard can acquire the EM 241 Modem module's position relative to the S7-200 CPU in order to generate the correct program code. A user can click the Read Modules button to automatically read the positions of the intelligent modules attached to the CPU. Expansion modules can be numbered sequentially starting at zero. A user can double-click the EM 241 Modem module to configure, or set the Module Position field to the position of the EM 241 Modem module.
[0139] The password protection screen allows a user to enable password protection for the EM 241 Modem module and/or to assign a 1 to 8 character password for the module. This password can be independent of the S7-200 CPU password. When the module is password-protected, anyone who attempts to connect with the S7-200 CPU through the EM 241 Modem module can be required to supply the correct password. A user can select password protection if desired, and enter a password.
[0140] The EM 241 Modem module can support two communications protocols: PPI protocol (to communicate with STEP 7-Micro/WIN), and Modbus RTU protocol. Protocol selection can be dependent on the type of device that is being used as the remote communications partner. This setting can control the communications protocol used when the EM 241 Modem module answers a call and also when the EM 241 Modem module initiates a CPU data transfer.
[0141] A user can configure the module to send numeric and text messages to pagers, or Short Message Service (SMS) messages to cellular telephones. A user can check the Enable messaging checkbox and click the Configure Messaging . . . button to define messages and the recipient's telephone numbers.
[0142] When setting up a message to be sent to a pager or cellular phone, a user can define the message and the telephone number. A user can select the Messages tab on the Configure Messaging screen and click the New Message button. A user then can enter the text for the message and specify any CPU data values to insert into the message. To insert a CPU data value into the message, a user can move the cursor to the position for the data and click the Insert Data . . . button. A user can specify the address of the CPU data value (i.e. VW100), the display format (i.e. Signed Integer) and the digits left and right of the decimal point. A user also can specify if the decimal point should be a comma or a period.
[0143] Numeric paging messages can be limited to the digits 0 to 9, the letters A, B, C and D, and the asterisk (*). The maximum allowed length of a numeric paging message can vary by service provider. Text messages can be up to 119 characters in length and contain any alphanumeric character. Text messages can contain any number of embedded variables.
[0144] Embedded variables can be from V, M, SM, I, Q, S, T, C or AI memory in the attached CPU. Hexadecimal data can be displayed with a leading ‘6#’. The number of characters in the value can be based on the size of the variable. For example, VW100 displays as 16#0123. The number of digits left of the decimal can be large enough to display the expected range of values, including the negative sign, if the data value is a signed integer or floating point value. If the data format is integer and the number of digits right of the decimal point is not zero, the integer value can be displayed as a scaled integer. For example, if VW100=1234 and there are 2 digits right of the decimal point, the data is displayed as ‘12.34’. If the data value is greater than can be displayed in the specified field size, the EM 241 Modem module can place the # character in all character positions of data value.
[0145] Telephone numbers can be configured by selecting the Phone Numbers tab on the Configure Messaging screen. A user can click the New Phone Number . . . button to add a new telephone number. Once a telephone number has been configured it can be added to the project. A user can highlight the telephone number in the Available Phone Numbers column and click the right arrow box to add the telephone number to the current project. Once a user has added the telephone number to the current project, the user can select the telephone number and add a symbolic name for this number to use in the user's program. The telephone number can consists of several fields which can vary based on the type of messaging selected by the user.
[0146] The Messaging Protocol selection can tell the EM 241 Modem module which protocol to use when sending the message to the message service provider. Numeric pagers can support only numeric protocol. Text paging services can usually require TAP (Telelocator Alphanumeric Protocol). SMS messaging providers can be supported with either TAP or UCP (Universal Computer Protocol). There are three different UCP services normally used for SMS messaging. Most providers support command 1 or 51. A user can check with the SMS provider to determine the protocol and commands required by that provider.
[0147] The Description field can allow a user to add a text description for the telephone number. The Phone Number field can be the telephone number of the messaging service provider. For text messages this can be the telephone number of the modem line the service provider uses to accept text messages. For numeric paging this can be the telephone number of the pager itself. The EM 241 Modem module can allow the telephone number field to be a maximum of 40 characters. The following characters can be allowed in telephone numbers that the EM 241 Modem module can use to dial out:
0 to 9 allowed from a telephone keypad A, B, C, D, *, # DTMF digits (tone dialing only) , pause dialing for 2 seconds ! generate a hook flash @ wait for 5 seconds of silence W wait for a dial tone before continuing ( ) ignored (can be used to format the telephone number)
[0148] The Specific Pager ID or Cell Phone Number field is where a user can enter the pager number or cellular telephone number of the message recipient. Up to 20 characters can be included. The Password field can be optional for TAP message. Some providers can require a password but normally this field can be left blank. The EM 241 Modem module can allow the password to be up to 15 characters.
[0149] The Originating Phone Number field can allow the EM 241 Modem module to be identified in the SMS message. This field can be required by some service providers which use UCP commands. Some service providers can require a minimum number of characters in this field. The EM 241 Modem module can allow up to 15 characters.
[0150] The Modem Standard field can be provided for use in cases where the EM 241 Modem module and the service provider modem cannot negotiate the modem standard. The default can be V.34 (33.6 kbaud).
[0151] The Data Format fields can allow a user to adjust the data bits and parity used by the modem when transmitting a message to a service provider. TAP can normally use 7 data bits and even parity, but some service providers can use 8 data bits and no parity. UCP can use 8 data bits with no parity. A user can check with the service provider to determine which settings to use.
[0152] A user can configure the EM 241 Modem module to transfer data to another S7-200 CPU (if PPI protocol was selected) or to transfer data to a Modbus device (if Modbus protocol was selected). A user can check the Enable CPU data transfers checkbox and click the Configure CPU-to . . . button to define the data transfers and the telephone numbers of the remote devices.
[0153] When setting up a CPU-to-CPU or a CPU-to-Modbus data transfer a user can define the data to transfer and the telephone number of the remote device. To do so, a user can select the Data Transfers tab on the Configure Data Transfers screen and click the New Transfer button. A data transfer can consists of a data read from the remote device, a data write to the remote device, or both a read from and a write to the remote device. If both a read and a write are selected, the read can be performed first and then the write.
[0154] Up to 100 words can be transferred in each read or write. Data transfers can be to or from the V Memory in the local CPU. The wizard can describe the memory locations in the remote device as if the remote device is an S7-200 CPU. If the remote device is a Modbus device, the transfer can be to or from holding registers in the Modbus device (address 04xxxx). The equivalent Modbus address (xxxx) can be determined as follows:
[0155] Modbus address=1+(V memory address/2)
[0156] V memory address=(Modbus address−1)*2
[0157] The Phone Numbers tab on the Configure CPU Data Transfers screen can allow a user to define the telephone numbers for CPU-to-CPU or a CPU-to-Modbus data transfers. A user can click the New Phone Number . . . button to add a new telephone number. Once a telephone number has been configured it can be added to the project. A user can highlight the telephone number in the Available Phone Numbers column and click the right arrow box to add the telephone number to the current project. Once a user has added the telephone number to the current project, the user can select the telephone number and add a symbolic name for this telephone number to use in the user's program.
[0158] The Description and Phone Number fields are the same as described earlier for messaging. The Password field can be required if the remote device is a Modem module and password protection has been enabled. The Password field in the local Modem module can be set to the password of the remote Modem module. The local Modem module can supply this password when it is requested by the remote Modem module.
[0159] Callback can cause the EM 241 Modem module to automatically disconnect and dial a predefined telephone number after receiving an incoming call from a remote STEP 7-Micro/WIN. A user can select the Enable callback checkbox and click the Configure Callback . . . button to configure callback telephone numbers.
[0160] The Configure Callback . . . screen can allow a user to enter the telephone numbers the EM 241 Modem module uses when it answers an incoming call. A user can check the ‘Enable callbacks to only specified phone numbers’ if the callback numbers are to be predefined. If the EM 241 Modem module is to accept any callback number supplied by the incoming caller (to reverse the connection charges), a user can check the ‘Enable callbacks to any phone number’ selection.
[0161] If only specified callback telephone numbers are allowed, a user can click the New Phone Number button to add callback telephone numbers. The Callback Properties screen allows a user to enter the predefined callback telephone numbers and a description for the callback number. The callback number entered here can be the telephone number that the EM 241 Modem module uses to dial when performing the callback. This telephone number can include all digits required to connect to an outside line, pause while waiting for an outside line, connect to long distance, etc.
[0162] After entering a new callback telephone number, it can be added to the project. A user can highlight the telephone number in the Available Callback Phone Numbers column and click the right arrow box to add the telephone number to the current project.
[0163] A user can set the number of dialing attempts that the EM 241 Modem module makes when sending a message or during a data transfer. In certain embodiments, the EM 241 Modem module can report an error to the user program only when all attempts to dial and send the message are unsuccessful.
[0164] Some telephone lines do not have a dial tone present when the telephone receiver is lifted. The EM 241 Modem module can returns an error to the user program if a dial tone is not present when the EM 241 Modem module is commanded to send a message or perform a callback. To allow dialing out on a line with no dial tone, a user can check the box, Enable Dialing Without Dial Tone Selection.
[0165] The Modem Expansion wizard can create a configuration block for the EM 241 Modem module and can require the user to enter the starting memory address where the EM 241 Modem module configuration data is stored. The EM 241 Modem module configuration block can be stored in V Memory in the CPU. STEP 7-Micro/WIN can write the configuration block to the project Data Block. The size of the configuration block can vary based on the number of messages and telephone numbers configured. A user can select the V Memory address where the configuration block is to be stored, or click the Suggest Address button if the user wants the wizard to suggest the address of an unused V Memory block of the correct size.
[0166] A final step in configuring the EM 241 Modem module can be to specify the Q memory address of the command byte for the EM 241 Modem module. A user can determine the Q memory address by counting the output bytes used by any modules with discrete outputs installed on the S7-200 before the EM 241 Modem module.
[0167] The Modem Expansion wizard can generate the project components for a user's selected configuration (program block and data block) and make that code available for use by the user's program. The final wizard screen can display the user's requested configuration project components. The user can download the EM 241 Modem module configuration block (Data Block) and the Program Block to the S7-200 CPU.
[0168] Modem Instructions and Restrictions
[0169] The Modem Expansion wizard can make controlling the EM 241 Modem module easier by creating unique instruction subroutines based on the position of the module and configuration options selected by a user. Each instruction can be prefixed with a “MODx_” where x is the module location.
[0170] Using the EM 241 Modem Module Instructions
[0171] Consider these guidelines when you use Modem module instructions:
[0172] (a) The EM 241 Modem module instructions can use three subroutines.
[0173] (b) The EM 241 Modem module instructions can increase the amount of memory required for a user's program by up to 370 bytes. If a user deletes an unused instruction subroutine, the user can rerun the Modem Expansion wizard to recreate the instruction if needed.
[0174] (c) Typically, only one instruction should be active at a time.
[0175] (d) Typically, the instructions are not used in an interrupt routine.
[0176] (e) The EM 241 Modem module can read the configuration table information when it first powers up and after a STOP-to-RUN transition. In certain embodiments, any change that the user program makes to the configuration table is not seen by the module until a mode change or the next power cycle.
[0177] Using the EM 241 Modem Module Instructions
[0178] A user can utilize the EM 241 Modem module instructions in the user's S7-200 program, by completing the following steps:
[0179] a. Use the Modem Expansion wizard to create the EM 241 Modem module configuration table.
[0180] b. Insert the MODx_CTRL instruction in the program and use the SM0.0 contact to execute it every scan.
[0181] c. Insert a MODx_MSG instruction for each message needed to be sent.
[0182] d. Insert a MODx_XFR instruction for each data transfer.
[0183] Instructions for the EM 241 Modem Module
[0184] MODx_CTRL Instruction
[0185] MODx_CTRL (Control) instruction can be used to enable and initialize the EM 241 Modem module. This instruction can be called every scan and, in certain embodiments, is used once in the project. FIG. 9 is a screen shot of graphical user interfaces 9000 that display certain MODx_CTRL instructions.
[0186] MODx_XFR Instruction
[0187] MODx_XFR (Data Transfer) instruction can be used to command the EM 241 Modem module to read and write data to another S7-200 CPU or a Modbus device. In certain embodiments, this instruction can take 20 to 30 seconds from the time the START input is triggered until the Done bit is set. FIG. 10 is a screen shot of graphical user interfaces 10000 that display certain MODx_XFR instructions.
[0188] The EN bit can be on to enable a command to the module, and can remain on until the Done bit is set, signaling completion of the process. An XFR command can be sent to the EM 241 Modem module on each scan when START input is on and the module is not currently busy. The START input can be pulsed on through an edge detection element, which only allows one command to be sent.
[0189] Phone can be the number of one of the data transfer telephone numbers. A user can utilize the symbolic name assigned to each data transfer telephone number when the number was defined with the Modem Expansion wizard.
[0190] Data can be the number of one of the defined data transfers. A user can use the symbolic name assigned to the data transfer when the request was defined using the Modem Expansion wizard.
[0191] Done can be a bit that comes on when the EM 241 Modem module completes the data transfer.
[0192] Error can be a byte that contains the result of the data transfer. Table 6 lists a number of possible error conditions that could result from executing this instruction.
TABLE 6 Parameters for the MODx_XFR Instruction Inputs/Outputs Data Type Operands START BOOL I, Q, M, S, SM, T, C, V, L, Power Flow Phone, Data BYTE VB, IB, QB, MB, SB, SMB, LB, AC, Constant, *VD, *AC, *LD Done BOOL I, Q, M, S, SM, T, C, V, L Error BYTE VB, IB, QB, MB, SB, SMB, LB, AC, *VD, *AC, *LD
[0193] MODx_MSG Instruction
[0194] The MODx_MSG (Send Message) instruction can be used to send a paging or SMS message from Modem module. In certain embodiments, this instruction can take 20 to 30 seconds from the time the START input is triggered until the Done bit is set. FIG. 11 is a screen shot of graphical user interfaces 11000 that display certain MODx_MSG instructions. Table 7 provides various parameter for the MODx-MSG instruction.
TABLE 7 Parameters for the MODx_MSG Instruction Inputs/Outputs Data Type Operands START BOOL I, Q, M, S, SM, T, C, V, L, Power Flow Phone, Msg BYTE VB, IB, QB, MB, SB, SMB, LB, AC, Constant, *VD, *AC, *LD Done BOOL I, Q, M, S, SM, T, C, V, L Error BYTE VB, IB, QB, MB, SB, SMB, LB, AC, *VD, *AC *LD
[0195] The EN bit is typically on to enable a command to the module, and can remain on until the Done bit is set, signaling completion of the process. A MSG command can be sent to the EM 241 Modem module on each scan when START input is on and the module is not currently busy. The START input can be pulsed on through an edge detection element, which only allows one command to be sent.
[0196] Phone can be the number of one of the message telephone numbers. A user can use the symbolic name assigned to each message telephone number the when the number was defined with the Modem Expansion wizard.
[0197] Msg can be the number of one of the defined messages. A user can use the symbolic name assigned to the message when the message was defined using the Modem Expansion wizard.
[0198] Done can be a bit that comes on when the EM 241 Modem module completes the sending of the message to the service provider.
[0199] Error can be a byte that contains the result of this request to the module. Table 8 defines a number of possible error conditions that could result from executing this instruction.
TABLE 8 Error Values Returned by MODx_MSG and MODx_XFR Instructions Error Description 0 No error Telephone line errors 1 No dial tone present 2 Busy line 3 Dialing error 4 No answer 5 Connect timeout (no connection within 1 minute) 6 Connection aborted or an unknown response Errors in the command 7 Numeric paging message contains illegal digits 8 Telephone number (Phone input) out of range 9 Message or data transfer (Msg or Data input) out of range 10 Error in text message or data transfer message 11 Error in messaging or data transfer telephone number 12 Operation not allowed (i.e. attempts set to zero) Service provider errors 13 No response (timeout) from messaging service 14 Message service disconnected for unknown reason 15 User aborted message (disabled command bit) TAP—Text paging and SMS message errors returned by service provider 16 Remote disconnect received (service provider aborted session) 17 Login not accepted by message service (incorrect password) 18 Block not accepted by message service (checksum or transmission error) 19 Block not accepted by message service (unknown reason) UCP—SMS message errors returned by service provider 20 Unknown error 21 Checksum error 22 Syntax error 23 Operation not supported by system (illegal command) 24 Operation not allowed at this time 25 Call barring active (blacklist) 26 Caller address invalid 27 Authentication failure 28 Legitimization code failure 29 GA not valid 30 Repetition not allowed 31 Legitimization code for repetition, failure 32 Priority call not allowed 33 Legitimization code for priority call, failure 34 Urgent message not allowed 35 Legitimization code for urgent message, failure 36 Reverse charging not allowed 37 Legitimization code for reverse charging, failure 38 Deferred delivery not allowed 39 New AC not valid 40 New legitimization code not allowed 41 Standard text not valid 42 Time period not valid 43 Message type not supported by system 44 Message too long 45 Requested standard text not valid 46 Message type not valid for pager type 47 Message not found in SMSC 48 Reserved 49 Reserved 50 Subscriber hang up 51 Fax group not supported 52 Fax message type not supported Data transfer errrors 53 Message timeout (no response from remote device) 54 Remote CPU busy with upload or download 55 Access error (memory out of range, illegal data type) 56 Communications error (unknown response) 57 Checksum or CRC error in response 58 Remote EM 241 set for callback (not allowed) 59 Remote EM 241 rejected the provided password 60 to 127 Reserved Instruction use errors 128 Cannot process this request. Either the Modem module is busy with another request, or there was no START pulse on this request. 129 Modem module error: H The location of the Modem module or the Q memory address that was configured with the Modem Expansion wizard does not match the actual location or memory address H Refer to SMB8 to SMB21 (I/O Module ID and Error Register)
[0200] Sample Program for the EM 241 Modem Module
[0201] Table 9 provides a sample program for the EM 241 Modem module.
TABLE 9 Example: Modem Module
[0202] S7-200 CPUs that Support Intelligent Modules
[0203] The EM 241 Modem module can be an intelligent expansion module designed to work with the S7-200 CPUs shown in Table 10.
TABLE 10 EM 241 Modem Module Compatibility with S7-200 CPUs CPU Description Cpu 222 Rel 1 10 or greater Cpu 222 DC/DC/DC Cpu 222 AC/DC/Relay CPU 224 Rel 1 10 or greater CPU 224 DC/DC/DC CPU 224 AC/DC/Relay CPU 226 Rel 1 00 or greater CPU 226 DC/DC/DC CPU 226 AC/DC/Relay CPU 226XM Rel 1 00 or greater CPU 226XM DC/DC/DC CPU 226XM AC/DC/Relay
[0204] Special Memory Location for the EM 241 Modem Module
[0205] Fifty bytes of special memory (SM) can be allocated to each intelligent module based on its physical position in the I/O expansion bus. When an error condition or a change in status is detected, the module can indicate this by updating the SM locations corresponding to the module's position. If it is the first module, it can update SMB200 through SMB249 as needed to report status and error information. If it is the second module, it can update SMB250 through SMB299, and so on as shown in Table 11.
TABLE 11 Special Memory Bytes SMB200 to SMB549 Intelligent Intelligent Intelligent Intelligent Intelligent Intelligent Intelligent Module in Module in Module in Module in Module in Module in Module in Slot 0 Slot 1 Slot 2 Slot 3 Slot 4 Slot 5 Slot 6 SMB200 to SMB250 to SMB300 to SMB350 to SMB400 to SMB450 to SMB500 to SMB249 SMB299 SMB349 SMB399 SMB449 SMB499 SMB549
[0206] The Special memory data area, which can be allocated for the EM 241 Modem module, is shown in Table 12. This area can be defined as if this were the intelligent module located in Slot 0 of the I/O system.
TABLE 12 SM Locations for the EM 241 Modem Module SM Address Description SMB200 to Module name (16 ASCII characters) SMB200 is the first character. SMB215 “EM241 Modem” SMB216 to S/W revision number (4 ASCII characters) 5MB216 is the first character. SMB219 5MW220 Error code 0000 - No error 0001 - No user power 0002 - Modem failure 0003 - No configuration block ID 0004 - Configuration block out of range 0005 - Configuration error 0006 - Country code selection error 0007 - Phone number too large 0008 - Message too large 0009 to 00FF - Reserved 01xx - Error in callback number xx 02xx - Error in pager number xx 03xx - Error in message number xx 0400 to FFFF - Reserved SMB222 Module status - reflects the LED status F- EM_FAULT 0- no fault 1- fault G- EM_GOOD 0- notgood 1- good H- OFF_HOOK 0- on hook, 1- off hook T- NO DIALTONE 0- dial tone 1- no dial tone R- RING 0- not ringing 1- phone ringing C- CONNECT 0- not connected 1- connected SMB223 Country code as set by switches (decimal value) SMW224 Baud rate at which the connection was established (unsigned decimal value). SMB226 Result of the user command D- Done bit; 0 - operation in progress 1 - operation complete ERROR: Error Code Description, see Table 1 8 SMB227 Telephone number selector - This byte specifies which messaging telephone number to use when sending a message. Valid values are 1 through 250. SMB22B Message selector - This byte specifies which message to send. Valid values are 1 through 250. SMB229 to Reserved SMB244 SMB245 Offset to the first Q byte used as the command interface to this module. The offset is supplied by the CPU for the convenience of the user and is not needed by the module. SMD246 Pointer to the configuration table for the Modem module in V memory. A pointer value to an area other than V memory is not accepted and the module continues to examine this location, waiting for a non-zero pointer value.
[0207] Additional Topics
[0208] Understanding the Configuration Table
[0209] The Modem Expansion wizard can be developed to automatically generate the configuration table based upon the answers given about a system. The following configuration table information is provided for advanced users who want to create their own Modem module control routines and format their own messages.
[0210] The configuration table can be located in the V memory area of the S7-200. As shown in Table 13, the Byte Offset column of the table can be the byte offset from the location pointed to by the configuration area pointer in SM memory. The configuration table information can be divided into four sections.
[0211] (a) The Configuration Block can contain information to configure the module.
[0212] (b) The Callback Telephone Number Block can contain the predefined telephone numbers allowed for callback security.
[0213] (c) The Message Telephone Number Block can contain the telephone numbers used when dialing messaging services or CPU data transfers.
[0214] (d) The Message Block can contain the predefined messages to send to the messaging services.
TABLE 13 Configuration Table for the Modem Module Byte Offset Description Configuration Block 0 to 4 Module Identification - Five ASCII characters used for association of the configuration table to an intelligent module. Release 1.00 of the EM 241 Modem module expects “M241A”. 5 The length of the Configuration Block - Currently 24. 6 Callback telephone number length - Valid values are 0 through 40. 7 Messaging telephone number length - Valid values are 0 through 120. 8 Number of callback telephone numbers - Valid values are 0 through 250. 9 Number of messaging telephone numbers - Valid values are 0 through 250. 10 Number of messages - Valid values are 0 through 250. 11 to 12 Reserved (2 bytes) 13 This byte contains the enable bits for the features supported. PD - 0 = tone dialing 1 = pulse dialing CB - 0 = callback disabled 1 = callback enabled PW - 0 = password disabled 1 = password enabled MB - 0 =PPI protocol enabled 1 = Modbus protocol enabled BD - 0 = blind dialing disabled 1 = blind dialing enabled Bits 2, 1 and 0 are ignored by the module 14 Reserved 15 Attempts - This value specifies the number of times the modem is to attempt to dial and send a message before returning an error. A value of 0 prevents the modem from dialing out. 16 to 23 Password - Eight ASCII characters Callback Telephone Number Block (optional) 24 Callback Telephone Number 1 - A string representing the first telephone number that is authorized for callback access from the EM 241 Modem module. Each callback telephone number must be allocated the same amount of space as specified in the callback telephone number length field (offset 6 in the Configuration Block). 24 + callback Callback Telephone Number 2 number . . . . . . . Callback Telephone Number n . . Messaging Telephone Number Block (optional) M Messaging Telephone Number 1 - A string representing a messaging telephone number which includes protocol and dialing options. Each telephone number must be allocated the same amount of space as specified in the messaging telephone number length field (offset 7 in the Configuration Block). The messaging telephone number format is described below M + messaging Messaging Telephone Number 2 number length . . . . . . . Messaging Telephone Number n . . Message Block (optional) N V memory offset (relative to VB0) for the first message (2 bytes) N + 2 Length of message 1 N + 3 Length of message 2 . . . . . . . Length of message n P Message 1 - A string (120 bytes max.) representing the first message. This string includes text and embedded variable specifications or it could specify a CPU data transfer. See the Text Message Format and the CPU Data Transfer Format described below. P + length of Message 2 message 1 . . . . . . . Message n . .
[0215] The EM 241 Modem module can re-read the configuration table when these events occur:
[0216] (a) Within five seconds of each STOP-to-RUN transition of the S7-200 CPU (unless the modem is currently online);
[0217] (b) Every five seconds until a valid configuration is found (unless the modem is currently online);
[0218] (c) Every time the modem transitions from an online to an offline condition.
[0219] Messaging Telephone Number Format
[0220] The Messaging Telephone Number can be a structure that contains the information needed by the EM 241 Modem module to send a message. The Messaging Telephone Number can be an ASCII string with a leading length byte followed by ASCII characters. The maximum length of a Messaging Telephone Number can be 120 bytes (which includes the length byte).
[0221] The Messaging Telephone Number can contain up to 6 fields separated by a forward slash (/) character. Back-to-back slashes indicate an empty (null) field. Null fields can be set to default values in the EM 241 Modem module.
[0222] Format: <Telephone
[0223] Number>/<ID>/<Password/<Protocol>/<Standard>/<Format>
[0224] The Telephone Number field can be the telephone number that the EM 241 Modem module dials when sending a message. If the message being sent is a text or SMS message, this can be the telephone number of the service provider. If the message is a numeric page, this field can be the pager telephone number. If the message is a CPU data transfer, this can be the telephone number of the remote device. The maximum number of characters in this field can be 40.
[0225] The ID can be the pager number or cellular telephone number. This field can consist of the digits 0 to 9 only. If the protocol is a CPU data transfer, this field can be used to supply the address of the remote device. Up to 20 characters can be allowed in this field.
[0226] The Password field can be used to supply the a password for messages sent via TAP if a password is required by the service provider. For messages sent via UCP this field can be used as the originating address or telephone number. If the message is a CPU data transfer to another Modem module, this field can be used to supply the password of the remote Modem module. The password can be up to 15 characters in length.
[0227] The Protocol field can consist of one ASCII character which tells the EM 241 Modem module how it should format and transmit the message. The following values can be allowed:
[0228] (a) Numeric paging protocol (default)
[0229] (b) TAP
[0230] (c) UCP command 1
[0231] (d) UCP command 30
[0232] (e) UCP command 51
[0233] (f) CPU data transfer
[0234] The Standard field can force the EM 241 Modem module to use a specific modem standard. The standard field can be one ASCII character. The following values can be allowed:
[0235] (a) Bell 103
[0236] (b) Bell 212
[0237] (c) V.21
[0238] (d) V.22
[0239] (e) V.22 bit
[0240] (f) V.23c
[0241] (g) V.32
[0242] (h) V.32 bit
[0243] (i) V.34 (default)
[0244] The Format field can be three ASCII characters that specify the number of data bits and parity to be used when transmitting the message. This field does not necessarily apply if the protocol is set to numeric paging. In certain embodiments, only the following two settings are allowed:
[0245] (a) 8N1-8 data bits, no parity, one stop bit (default)
[0246] (b) 7E1-7 data bits, even parity, one stop bit
[0247] Text Message Format
[0248] The Text Message Format can define the format of text paging or SMS messages. These types of messages can contain text and embedded variables. The text message can be an ASCII string with a leading length byte followed by ASCII characters. The maximum length of a text message can be 120 bytes (which includes the length byte).
[0249] (a) Format: <Text><Variable><Text><Variable> . . .
[0250] The Text field can consists of ASCII characters.
[0251] The Variable field can define an embedded data value that the EM 241 Modem module can read from the local CPU, formats, and place in the message. The percent (%) character can be used to mark the start and the end of a variable field. The address and the left fields can be separated with a colon. The delimiter between the Left and Right fields can be either a period or a comma and can be used as the decimal point in the formatted variable. The syntax for the variable field can be:
[0252] (a) %Address:Left.Right Format %
[0253] The Address field can specify the address, data type and size of the embedded data value (i.e. VD100, VW50, MB20 or T10). The following data types can be allowed: I, Q, M, S, SM, V, T, C, and AI. Byte, word and double word sizes can be allowed.
[0254] The Left field can define the number of digits to display left of the decimal point. This value can be large enough to handle the expected range of the embedded variable including a minus sign if needed. If Left is zero the value can be displayed with a leading zero. The valid range for Left can be 0 to 10.
[0255] The Right field can define the number of digits to display right of the decimal point. In certain embodiments, zeros to the right of the decimal point are always displayed. If Right is zero the number can be displayed without a decimal point. The valid range for Right can be 0 to 10.
[0256] The Format field can specify the display format of the embedded value. The following characters can be allowed for the format field:
[0257] (a) i—signed integer
[0258] (b) u—unsigned integer
[0259] (c) h—hexadecimal
[0260] (d) f—floating point/real
[0261] Example: “Temperature=%VW100:3.1i % Pressure=%VD200:4.3f%”
[0262] CPU Data Transfer Message Format
[0263] A CPU data transfer, either a CPU-to-CPU or a CPU-to-Modbus data transfer, can be specified using the CPU Data Transfer Message Format. A CPU Data Transfer Message can be an ASCII string that can specify any number of data transfers between devices, up to the number of specifications that fit in the maximum message length of, for example, 120 bytes (119 characters plus a length byte). An ASCII space can be used to separate the data transfer specifications, but is not required. All data transfer specifications can be executed within one connection. Data transfers can be executed in the order defined in the message. If an error is detected in a data transfer, the connection to the remote device can be terminated and subsequent transactions are not processed.
[0264] If the operation is specified as a read, Count number of words can be read from the remote device starting at the Remote_address, and then written to V Memory in the local CPU starting at the Local_address.
[0265] If the operation is specified as a write, Count number of words can be read from the local CPU starting at the Local_address, and then written to the remote device starting at Remote_address.
[0266] (a) Format: <Operation>=<Count>,<Local_address>,<Remote_address>
[0267] The Operation field can consist of one ASCII character and can define the type of transfer.
[0268] (a) R—Read data from the remote device
[0269] (b) W—Write data to the remote device
[0270] The Count field can specify the number of words to be transferred. The valid range for the count field can be 1 to 100 words.
[0271] The Local_address field can specify the V Memory address in the local CPU for the data transfer (i.e. VW100).
[0272] The Remote_address field can specify the address in the remote device for the data transfer (i.e. VW500). This address can be specified as a V Memory address even if the data transfer is to a Modbus device. If the remote device is a Modbus device, the conversion between V Memory address and Modbus address can be as follows:
[0273] (a) Modbus address=1+(V Memory address/2)
[0274] (b) V Memory address=(Modbus address−1)*2
[0275] Example: R=20,VW100, VW200 W=50,VW500,VW1000 R=100,VW1000,VW2000
[0276] Although the invention has been described with reference to specific embodiments thereof, it will be understood that numerous variations, modifications and additional embodiments are possible, and accordingly, all such variations, modifications, and embodiments are to be regarded as being within the spirit and scope of the invention. For example, although one specific embodiment utilized a telephone network, the utilization of other communication networks, such as the Internet, are also within the spirit and scope of the invention. Also, references specifically identified and discussed herein are incorporated by reference as if fully set forth herein. Accordingly, the drawings and descriptions are to be regarded as illustrative in nature, and not as restrictive. | At least one exemplary embodiment of the present invention includes a system comprising a first modem integral to a first programmable logic controller, and a second modem integral to a second programmable logic controller, the first modem adapted to communicate with the second modem via a communications network. At least one exemplary embodiment of the present invention includes a method comprising coupling a first modem to a second modem, the first modem integral to a first programmable logic controller, the second modem connected to a second programmable logic controller, and transferring data between the first modem and the second modem. It is emphasized that this abstract is provided to comply with the rules requiring an abstract that will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure. This abstract is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. 37 CFR 1.72(b). | 6 |
REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of U.S. Patent Application Ser. No. 025,525, filed Mar. 13, 1987 and now abandoned.
BACKGROUND OF THE INVENTION
Liposomes or lipid vesicles have been known since at least 1965. There are three general types of liposomes: multilamellar vesicles (MLV), onion-like structures having a series of substantially spherical shells formed of lipid bilayers interspersed with aqueous layers, ranging in diameter from about 0.1-4 μm; large (greater than 1 μm diameter) unilamellar vesicles (LUV) which have a lipid bilayer surrounding a large, unstructured aqueous phase; and small unilamellar vesicles (SUV) which are similar in structure to the LUV's except their diameters are less than 0.2 μm. Because of the relatively large amount of lipid in the lipid bilayers of the MLV's, MLV's are considered best for encapsulation or transportation of lipophilic materials whereas the LUV's, because of their large aqueous/lipid volume ratio, are considered best for encapsulation of hydrophilic molecules, particularly macromolecules. SUV's have the advantage of small size, which allows relatively easy access to the cells of tissue, but their small volume limits delivery of hydrophilic aqueous materials to trace amounts. However, SUV's may be useful in the transportatio of lipophilic materials.
All of the early liposome studies used phospholipids as the lipid source for the bilayers. The reason for this choice was that phospholipids are the principal structural components of natural membranes. However, there are many problems using phospholipids for liposome-type structures. First, isolated phospholipids are subject to degradation by a large variety of enzymes. Second, the most easily available phospholipids are those from natural sources, e.g., egg yolk lecithin, which contain polyunsaturted acyl chains that are subject to autocatalyzed peroxidation. When peroxidation occurs, the liposome structure breaks down, causing premature release of encapsulated materials and the formation of toxic peroxidation byproducts. This problem can be avoided by hydrogenation but hydrogenation is an expensive process, thereby raising the cost of the starting materials. Cost is a third problem associated with the use of phospholipids on a large scale. A kilogram of egg yolk lecithin pure enough for liposome production, presently costs in excess of $40,000. This is much to high a cost for a starting material for most applications.
Because of the high cost and additional problems in using phospholipids, a number of groups have attempted to use synthetic amphiphiles in making lipid vesicles. For example, Vanlerberghe and others working for L'Oreal have used a series of synthetic polymers, primarily polyglycerol derivatives, as alternatives to the phospholipids. Similarly, Kelly and a group at Sandoz, Inc. have tried aliphatic lipids.
Recently, there has been some indication, particularly from the L'Oreal group, that commercially available surfactants might be used to form the lipid bilayer in liposome-like multilamellar lipid vesicles. Both surfactants and phospholipids are amphiphiles, having at least one lipophilic acyl or alkyl group attached to a hydrophilic head group. The hydrophilic head groups in the surfactants which have been tried include polyoxyethylene or polyglycerol derivatives. The head groups are attached to one or more lipophilic chains by ester or ether linkages. Commercially available surfactants include the BRIJ family of polyoxyethylene acyl ethers, the SPAN sorbitan alkyl esters, and the TWEEN polyoxyethylene sorbitan fatty acid esters, all avauilable from ICI Americas, Inc. of Wilmington, Del.
No matter what starting material is used to form the MLV's, substantially all of the methods of vesicle production reported in the literature use either the original Bangham method, as described in Bangham et al., J. Mol. Biol., 13:238-252 (1965), or some variation thereof. The basic approach followed starts with dissolving the lipids, together with any other lipophilic substances including cholesterol, in an organic solvent. The organic solvent is removed by evaporation using heat or by passing a stream of an inert gas (e.g., nitrogen) over the dissolved lipid to remove the solvent. The residue is then slowly hydrated with an aqueous phase, generally containing electrolytes and any hydrophilic biologically active materials, to form large multilamellar lipid membrane structures. In some variations, different types of particulate matter or structures have used during the evapoartion to assist in the formation of the lipid residue. The basis for these experiments are that by changing physical structure of the lipid residue, better vesicles may form upon hydration. Two recent review publications, Szoka and Papahdjopoulos, ann. Rev. Biophys. Bioeng. 9:467-508 (1980), and Dousset and Douste-Blazy (in Les Liposomes, Puisieux and Delattre, Editors, Tecniques et Documentation Lavoisier, Paris, pp.41-73 (1985)), summarize the methods which have been used tomake MLV's.
Once the MLV's are made, it is necessary to determine the effectiveness of the process. Two measurements commonly used to determine the effectiveness of encapsulation of biological materials in liposomes or lipid vesicles are the mass of substance encapsulated per unit mass of the lipid ("encapsulated mass") and captured volume.
The captured volume is the amount of solvent trapped within the vesicles. The captured volume is defined as the concentration of the aqueous fraction inside the vesicle divided by the concentration of lipid in the vesicle, normally given in ml/gm lipid.
Multilamellar lipid vesicles made using the classic methods have a low encapsulated mass for hydrophilic materials, normally in the order of 5-15%. In addition, the captured volume of solvent is normally in the order of 2-4 ml/g lipid. However, the encapsulated mass for lipophilic materials is much better in the multilamellar liposomes. Therefore, multilamellar liposomes made using the classical procedures are considered good for encapsulating lipophilic (hydrophobic) material but not hydrophilic.
The small unilamellar liposomes, which range is diameter from 20-50 nm, have a very low captured volume (approximately 0.5 ml/g) and also a very low encapsulated mass for hydrophilic materials (0.5-1%). However, since the lipid bilayer constitutes 50-87% of the total volume, these SUV's are excellent at transporting small quantities of lipohilic material. They also can be used to transport very small quantities of hydrophilic material to tissues where the MLV's or LUV's cannot reach.
Because of the problems in encapsulating large volumes and obtaining high encapsulated mass for hydrophilic materials, LUV's have been investigated. LUV's have large captured volumes (approximately 35 ml/gm lipid) and high encapsulated mass for hydrophilic materials (40-50%) but they are very poor in encapsulating hydrophibic or lipophilic materials. Because of these characteristics, LUV's are best suited to encapsulation of hydrophilic materials, including macromolecules. However, there are problems with the use of LUV's. Since there is only a single lipid bilayer surrounding a large aqueous center, the LUV's tend to be less stable then the other liposomes and more easily subject to degradation. Further, the low lipid/aqueous volume ratio makes it difficult to use LUV's for transport of any lipophilic materials.
Although there have been some experiments reported in the literature on using synthetic surfactants rather than phospholipids as a source for making multilamellar lipid vesicles, there are no reports showing any improvement in the ability to encapsulate either small or large hydrophilic molecules using these materials. In addition, there is no report of increased stability for lipid vesicles made with these materials. Therefore, the literature has given no indication that liposomes manufactured with these synthetic materials will be useful to achieve the hydrophilic and macromolecule delivery objects sought in the liposome field.
A further problem associated with multilamellar lipid vesicles (including the small unilamellar vesicles which are normally manufactured by sonication of the multilamellar vesicles) manufactured using standard methods is that these current processes are both slow and relatively inefficient in terms of material. For example, the standard time to manufacture multilamellar lipid vesicles is in the order 2-20 hours. If SUV's are required, the sonication which breaks the multilamellar lipid structures into SUV's takes additional time. This slow processing is unwieldy and expensive for any large scale use of lipid vesicles.
Accordingly, it is an object of the invention to provide a rapid and efficient process for the formation of multilamellar vesicles.
It is a further object of the invention to develop multilamellar vesicles with high encapsulated mass for hydrophilic materials and high captured volume.
It is another object of the invention to form lipid membrane structures without the use of organic solvents or detergents.
It is still a further object of the invention to provide a method for the rapid, efficient encapsulation of biologically active macromolecules into vesicles made of relatively inexpensive, readily available surfactants.
These and other objects and features of the invention will be apparent from the detailed description and the claims.
SUMMARY OF THE INVENTION
The present invention provides a method of preparing multilamellar lipid vesicles which is rapid, efficient and produces vesicles which have high encapsulated mass for hydrophilic material and high captured volumes. The invention also provides a method of encapsulating lipophilic or hydrophilic materials in high aqueous volume multilamellar vesicles with high efficiency.
In order to prepare the vesicles, a lipophilic phase is formed by blending a surfactant with a sterol and a charge producing amphiphile while maintaining the temperature of the phase above the melting point of the surfactant. The lipophilic phase is then combined with an excess of an aqueous phase under high-shear conditions and elevated temperature in order to form the multilamellar vesicles. Whereas the temperature need not be kept constant for all the formation steps, in all cases the temperature must be above the melting point of the surfactant.
surfactants useful in the process for forming these vesicles include polyoxyethylene fatty ethers, preferably having the structure
R.sub.1 --O--(CH.sub.2 --CH.sub.2 --O--).sub.m --H
where R 1 is CH 3 -(CH 2 ) n , n ranges from 11 to 15, and m is 2 to 4. Although other polyoxyethylene ethers can be used, the most preferred materials are polyoxyethylene (2) cetyl ether and polyoxyethylene (4) lauryl ether.
An alternative group of lipids which are also useful in the invention, are the polyglycerol fatty ethers, preferably having the structure ##STR1##
where R 3 is CH 3 -(CH 2 ) y , y ranges from 11 to 15, and x ranges from 1 to 3.
The purpose of the sterol in the vesicles is to buffer the thermotropic phase transition of the membrane layer with insures optimal size and provides high stability, including stability near the transition temperature of the lipid. The most preferred sterol is cholesterol but any sterol having similar properties will provide similar results.
Vesicles made without charge producing materials lack the capacity for high volume uptake and efficient incorporation of hydrophilic molecular and macromolecules; they also have the tendency to aggregate or clump, making them unusable for most applications. Because of this, a charge producing material is used in the method of the invention to provide a net charge, either positive or negative, to the formed vesicle. The preferred negative charge producing materials are selected from a group consisting of dicetyl phosphate, cetyl sulphate, certain long chain fatty acids, retinoic acid, phosphatidic acid, phosphatidyl serine, and mixtures thereof.
In order to provide a net positive charge to the vesicles, long chain amines, long chain pyridinium compounds (e.g., cetyl pyridinium chloride), quaternary ammonium compounds or mixtures thereof can be used. A preferred material for causing a positive charge is hexadecyl trimethylammonium bromide, a potent disinfectant. The use of this disinfectant as a positive charge producing material within the vesicles provides a secondary advantage as the vesicles deteriorate; they act as a sustained release germicide carriers.
The vesicles may also include targeting molecules, either hydrophilic or amphiphilic, which can be used to direct the vesicles to particular targets in order to allow release of the material encapsulated in the vesicle at a specified biological location. If hydrophilic targeting molecules are used, they can be coupled directly or via a spacer to an OH residue of the polyoxyethylene or polyglycerol portion of the surfactant, or they can be coupled, using state of the art procedures, to molecules such as palmitic acid or phosphatidylethanolamine. If spacers are used, the targeting molecules can be interdigitating with the hydrophilic core of the bilayer membrane. Preferred hydrophilic targeting molecules include monoclonal antibodies, lectins, and peptide hormones.
In addition to hydrophilic targeting molecules, it is also possible to use amphiphilic targeting molecules. Amphiphilic targeting molecules are normally not chemically coupled to the surfactant molecules but rather interact with the lipophilic or hydrophobic portions of the molecules constituting the bilayer lamellae of the lipid vesicles. Preferred amphiphilic targeting molecules are neutral glycolipids, galactocerebrosides, (e.g., for hepatic galactosyl receptors), or charged glycolipids, such as gangliosides.
Vesicles made using the methods of the present invention can be used in diagnostic testing, e.g., agglutination testing of immunological systems. The vesicles can also be used as markers or labels for visualization, e.g., for radiography.
In another aspect, the invention provides a method of encapsulating hydrophilic or lipophilic materials. In order to encapsualte lipophilic materials within the vesicle, the lipophilic materials are blended into the lipophilic base formed of the surfactant, a sterol and a charge producing material at a temperature above the melting temperature of the surfactant. The formation of the vesicle is otherwise carried out as previously described.
In order to encapsulate a hydrophilic material, the lipophilic phase is made as previously described and the hydrophilic material to be encapsulated is added to the aqueous phase. Hydrophilic materials which can be encapsulated include macromolecules, viruses, immunological adjuvants such as muramyl dipeptide, peptide hormones such as insulin, glucagon, and pituitary hormones, growth factors such as angiogenic, epithelial and epidermal growth factors, lymphokines such as interleukin-2 and interferon, blood proteins such as hemoglobin, water-soluble plant hormones and pesticides, radionucleotides, and contrast dyes for radiological diagnosis. Examples of lipophilic materials which can be encapsulated include steroid hormones, organic pesticides, fungicides, insect repellants, and lipophilic vitamins and derivatives. A more complete listing of the types of materials that could be used in lipid vesicles is included in an article by Gregoriadis, New Engl. J. Med. 295:704-711 (1976).
The following description and examples more fully illustrate the invention.
DESCRIPTION
The present invention features a process of making a new type of multilamellar lipid vesicle with large aqueous volume using surfactants as the lipid source in a rigid production method, a method of encapsulating hydrophilic or lipophilic materials within this type of multilamellar lipid vesicle, and the high aqueous volume multilamellar lipid vesicles themselves. Based on encapsulated mass and captured volume, the multilamellar lipid vesicles of the invention appear better suited to the encapsulation and delivery of hydrophilic materials, including macromolecules, than multilamellar lipid vesicles known in the art. Further, by using the most preferred materials to form the multilamellar lipid vesicles, these vesicles appear to tolerate a broader range of pH than classic liposomes or other known multilamellar lipid vesicles and are not as susceptible to attack by oxidative systems, e.g., peroxidases and superoxide-generating systems of phagocytes. The multilamellar lipid vesicles are also much cheaper to make because of a lower cost of the starting materials.
In broad terms, the multilamellar lipid vesicles of the present invention are made by raising the temperature of the lipid structural materials, which may be polyoxyethylene fatty ethers or polyglycerol fatty ethers, to a temperature above their melting point so that they are liquid. A sterol, preferably cholesterol, together with a charge producing material and any lipophilic materials to be encapsulated is blended into the liquid surfactant to form a lipophilic phase. This lipophilic phase is then forced into an excess of an aqueous phase, also at a temperature above the melting point of the surfactant, using a high shear device. If any hydrophilic materials are to be encapsulated within the multilamellar lipid vesicles, they are included in the aqueous phase. Since the polyoxyethylene fatty ethers useful in the invention have low melting points, bioactive hydrophilic materials which are temperature-sensitive can still be encapsulated without damage. This permits the present method to be used for a broad range of materials.
Anionic or cationic amphiphiles are incorporated into the surfactant to yield a net negative or positive charge. The incorporation of a charge-bearing material into the lipid structure stabilizes the lipid structure and provides rapid dispersion. If such a charge is not used, any vesicles formed will aggregate unless they are kept at very low concentrations. The charged material is also required for a large aqueous volume to be encapsulated. The amount of charged amphiphile does not have to be large, 0.5 moles percent--5 moles percent (based on the concentration of the surfactant) is sufficient to provide proper charge to the vesicles.
Cholesterol, or another sterol with similar chemical properties, is incorporated into the lipid structure of the multilamellar vesicles in order to provide better stability and buffer the thermotropic phase transition of the membrane layer, e.g., providing stability of the membrane structure at temperature near the transition temperature of the lipid. The cholesterol also permits optimum size of the finished vesicle. The preferred surfactant/cholesterol molar ratio ranges from about 3-20, and depends to some extent on whether cholesterol competes with any lipophilic material to be encapsulated.
Although the polyoxyethylene and polyglycerol surfactants described herein are the best presently known for carrying out the method of the invention, it is possible that phospholipids or other surfactants could be used to form vesicles by this method. However, many of these phospholipids and other surfactants have such high melting temperature that it would be impractical to use these for encapsulating biologically active materials which are temperature sensitive. Further, if more unsaturated lipids are used, they are more susceptible to oxidative breakdown.
Once the lipophilic phase is formed, it is necessary to hydrate it using a high shear technique. There are a large variety of devices available on the market which can provide this high shear. Devices which could be used include a microfluidizer such as is made by Biotechnology Development Corporation, a "French"-type press, or some other device which provides a high enough shear force and the ability to handle heated, semiviscous lipids. If a very high shear device is used, it may be possible to microemulsify powdered lipids, under pressure, at a temperature below their normal melting points and still form the multilamellar lipid vesicles of the present invention.
Once the multilamellar lipid vesicles are formed, the size can be changed or the structure modified by sonication or mechanical shear. Devices for carrying this out, as well as the general procedures, are known to those skilled in the art and are commonly used in the liposome field.
If the multilamellar lipid vesicles of the present invention are used as a drug-delivery system, there is no particular limitation on how they can be used. For example, the vesicles may be dispersed directly in suspension, in aerosol form, topically, or in a gel. If used for agglutination testing or some other type of marker use, lipophilic dyes which are taken up directly into the lipid layers may be used.
In addition to use as a drug or macromolecule delivery system, the multilamellar lipid vesicles of the invention have substantial other uses. For example, the vesicles can be used as an adjuvant in order to improve the immunological response of injected material. In addition, the high aqueous volume allows the use of the multilamellar lipid vesicles of the invention as moisturizers or skin creams with advantageous results. The high captured volume/lipid ratio is such that more moisture is provided to the skin using the vesicles of the invention than is available from conventional skin care creams.
The invention will be more apparent from the following, non-limiting Examples.
EXAMPLE 1
The multilamellar lipid vesicles of this Example were made using one of the most preferred materials, polyoxyethylene (2) cetyl ether. Although syringes were used as described to provide the high shear in this and the following Examples, any high shear device could have been used.
TABLE 1______________________________________Polyoxyethylene (2) cetyl ether 0.696 gmCholesterol 0.073 gmDicetyl phosphate 0.055 gm5 mM phosphate, 150 mM NaCl, pH 7.4 10.0 ml______________________________________
Table 1 lists the materials and proportions used in preparing the multilamellar lipid vesicles for this Example. The polyoxyethylene (2) cetyl ether, cholesterol and dicetyl phosphate were placed in a 5 ml syringe and heated to 40° C., a temperature abovde the melting point of the lipid. The dicetyl phosphate provided a net negative charge to the final membrane structure. The lipophilic phase which resulted after the heating and blending of the lipophilic components was forcibly injected, via a three-way stopcock, into an aqueous phase consisting of 10 ml of 5 mM phosphate buffer containing 150 mM NaCl, pH 7.4. The phosphate buffer, which was contained in a 25 ml syringe, was also at 40° C. The process of injection of the lipophilic phase into the aqueous phase took less than five seconds. The resulting mixture was then forced into a second 25 ml syringe at a linear flow rate of 8-12 x 10 2 cm/sec through an orifice about 1 mm in diameter. The mixture was driven continously back and forth between the two 25 ml syringes for approximately 2 minutes, providing the liquid shear necessary to make the high volume lipid vesicles. A milky suspension containing the multilamellar lipid vesicles resulted. The multilamellar lipid vesicles were separated by centrifugation at 10,000 rpm for 15 minutes in a Beckman Instrumental co. J-21 centrifuge, forming a low density phase on top of the aqueous solution.
The multilamellar lipid vesicles formed would not pass through a 0.8 μm filter. Upon sonication for 6 minutes in a Branson sonicator, the lipid membrane structures attained the size of normal multilamellar vesicles, passing through a 0.45 μm filter. Upon sonification for an additional 6 minutes, the structures were reduced enough in size to pass through a 0.2 μm filter.
EXAMPLE 2
In this Example, the identical procedure was used as in Example 1 except the dicetyl phosphate, which provided a negative charge in Example 1, was replaced by cetyl trimethylammonium. The exact proportions used in this Example are shown in Table 2.
TABLE 2______________________________________Polyoxyethylene (2) cetyl ether 0.696 gmCholesterol 0.073 gmCetyl trimethylammonium 0.036 gm5 mM phosphate, 150 mM NaCl, pH 7.4 10.0 ml______________________________________
The positively charged multilamellar vesicles produced again could not pass through a 0.8 μm filter but upon sonification for 6 minutes, they passed freely through a 0.45 μm filter. Upon further sonification for an additional 6 minutes, the lipid membrane structures again passed freely through a 0.2 μm filter.
EXAMPLE 3
In this Example, a larger scale test was made using the same materials as Example 1. Three grams of lipid were employed. The molar proportions of the material used, as well as the volume of aqueous phase, are disclosed in Table 3.
TABLE 3______________________________________Polyoxyethylene (2) cetyl ether 33 mMCholesterol 11 mMDicetyl phosphate 1.5 mM5 mM phosphate, 150 mM NaCl, pH 7.4 50 ml______________________________________
The polyoxyethylene (2) cetyl ether, the cholesterol, and the dicetyl phosphate, a total of 3 gm of lipid, were placed in a 25 ml syringe and heated to 40° C. The mixture was then forcibly injected, via a three-way stopcock, into 50 ml of the phosphate buffer, also at 40° C., contained in a 60 ml syringe. This process took less than 10 seconds. The resulting mixtures were then forced into a second 60 ml syringe at a flow rate of 8-12 x 10 2 cm/sec through an orifice about 1 mm in diameter. The resulting mixture was driven continuously back and forth between the two 60 ml syringes for about two minutes, yielding a cream. Upon centrifugation at 10,000 rpm for 15 minutes, the lipid membrane structure was separated as a layer atop the nonincorporated aqueous phase. The captured aqueous volume in different experiments was 7-20.8 ml/g lipid, an amount much greater then the 2-4 ml/g lipid generally observed for multilamellar lipid membrane structures. A 1/100 dilution of the vesicles was found to be stable against aggreagation for thirty days at ambient temperature.
EXAMPLE 4
In this Example, substantially the same methods were used as in Example 3 except polyoxyethylene (4) lauryl ether was used in place of the polyoxyethylene (2) cetyl ether. Since the lauryl ether is a liquid at ambient temperature, no heating was required. Three grams of total lipid was used, with the proportions given in Table 4.
TABLE 4______________________________________Polyoxyethylene (4) lauryl ether 33 mMCholesterol 11 mMDicetyl phosphate 1.5 mM5 mM phosphate, 150 mM NaCl, pH 7.4 50 ml______________________________________
After formation of the multilamellar lipid vesicles and separation by centrifugation, the captured volume was measured and found to be 8 ml/g lipid. This is entirely surprising since the multilamellar lipid vesicles formed in this experiment passed freely through a 0.2 μm filter without sonification. Because of this small size, the lauryl vesicles may have similar access to organs that SUV's have while still allowing high captured volume and encapsulation efficiency.
EXAMPLE 5
In this Example, a macromolecule, specifically hemoglobin, was used to show encapsulation efficiency for the multilamellar lipid vesicles of the invention. The polyoxyethylene (2) cetyl ether was used to prepare the lipid membrane structures. Table 5 lists the concentrations.
TABLE 5______________________________________Polyoxyethylene (2) cetyl ether 3.1 gmCholesterol 0.7 gmDicetyl phosphate 0.13 gmRed cell hemolysate (10 mg Hb/ml) 50 ml______________________________________
The red cell hemolysate was formed by lysing fresh, washed human erythrocytes in hypotonic phosphate buffer to give a hemoglobin concentration of 10 mg/ml. This lipid, cholesterol and dicetyl phosphate were placed in a 10 ml syringe and heated to 40° C. The mixture was then forcibly ejected, via a three-way stopcock, into 50 ml of the red cell hemolysate contained in a 60 ml syringe. This injection took less than 5 seconds. The resulting mixture was then forced into a second 60 ml syringe at a flow rate of 8-12×10 2 cm/sec through an orifice of about 1 mm. The resulting mixture was driven continuously back and forth between the two syringes for approximately 2 minutes, yielding a dark pink cream.
Sevel ml of the resulting cream was mixed with 3 ml of a Ficoll-Paque density barrier (Pharmacia) and centrifugegd at 10,000 rpm for 15 minutes. Any unincorporated hemoglobin stays in the Ficoll-Paque density barrier whereas hemoglobin associated with the lipid vesicles will float with the lipophilic phase to the top of the aqueous phase. The lipophilic, vesicle-containing phase was pink colored and separated from the top of the density barrier. One ml aliquots of the two fractions (the lipid phase and the density barrier phas) were dissolved in 4 ml of soluene (0.5n quaternary ammonium hydroxide in toluene, made by Packard) and the hemoglobin content was determined by measuring the absorbance of the Soret band (420 nm). The Ficoll-Paque had a 0.42 O.D. while the lipid membrane structures had a 1.46 O.D., showing that about 22 mg of hemoglobin per gram liquid was associated with the lipid membrane structures. The corresponding aqueous volume uptake was approximately 8 ml/g.
Gassing with moist nitrogen caused the characteristic spectral change in the hemoglobin associated with the lipid membrane structures, showing a transformation from oxyhemoglobin to deoxyhemoglobin. After reexposure to ambient oxygen, the spectral change occurred, showing a transformation back to oxyhemoglobin. This illustrates that the hemoglobin is unharmed by the encapsulation process.
The hemoglobin containing structures were kept in buffer for 11 days at 40° C. then repurified on a Ficoll-Paque density barrier. Seventy percent of the hemoglobin that was encapsulated was still found to be present in the lipid phase. the hemoglobin-containing lipid membrane structures still illustrated the deosygenation-reoxygenation reaction. A similar experiment at 17 days showed that 62% of the hemoglobin initially incorporated was still retained and still exhibited normal deoxygenation-reoxygenation.
A similar experiment was fun using 30 mg hemoglobin/ml, a three-fold increase in concentration. An expected increase in hemoglobin encapsulation, 58 mg/g lipid, was observed.
EXAMPLE 6
In this Example, polyoxyethylene (10) cetyl ether was compared with polyoxyethylene (2) cetyl ether in order to determine encapsulated mass and captured volume. The proportions of the materials used were identical to those shown in Table 1. Table 6 gives the results of this experiment.
TABLE 6______________________________________ Volume Hemoglobin taken up taken upSurfactant (ml/g lipid) mg/g lipid______________________________________Polyoxyethylene (2) cetyl ether 7-9 20-60Polyoxyethylene (10) cetyl ether 2-3 <3______________________________________
For the polyoxyethylene (2) cetyl ether, 7-9 ml solvent/g lipid was taken up into the aqueous volume and the encapsulated mass for the hemoglobin was 20-60 mg/g lipid. In contrast, using the polyoxyethylene (10) cetyl ether only 2-3 ml solvent/g lipid was taken up and the encapsulated mass was less then 3 mg/g lipid. The values for the polyoxyethylene (10) cetyl ether are substantially the same as those shown in the literature using classic encapsulation methods, and phospholipids, using phospholipids and classic encapsulation methods for the formation of MLV. This shows that the method of the invention works for a variety of materials; however, the polyoxyethylene (2) cetyl ether yields a clear advantage.
EXAMPLE 7
In this Example, a lipophilic molecule, specifically retinoic acid, used to demonstrate the capacity of the multilamellar vesicles of this invention to encapsulate lipophilic molecules. The polyoxyethylene (2) cetyl ether was used as the lipid structural material of the vesicles. The retinoic acid is incorporated into the lipophilic phase of the lipid membrane structures. Two and a half grams total lipid was employed in the proportions given in Table 7 and the method used was that of Example 3.
TABLE 7______________________________________Polyoxyethylene (2) cetyl ether 33 mMCholesterol 6 mMDicetyl phosphate 1.5 mMRetinoic Acid 0.67 mM5 mM phosphate, 150 mM NaCl, pH 7.4 40 ml______________________________________
In accordance with the method of this invention, the polyoxyethylene (2) cetyl ether, cholesterol, dicetyl phosphate and retinoic acid were blended at 40° C. in a 10 ml syringe and the mixture was then forcibly injected into 40 ml 5mM phosphate, 150 mM NaCl, pH 7.4, likewise at 40° C., in a 60 mol syringe. The mixture was then subjected to high fluid shear by two minutes of mixing through a 1 mm orifice into another 60 ml syringe, yielding a yellow cream.
Upon centrifugation at 15,000 rpm for 15 minutes, the lipid vesicles separated as a yellow layer atop the nonincorporated aqueous phase. The isolated lipid vesicles could be diluted without further volume uptake to form a stable, homogeneous suspension. The measured incorporation of aqueous phase into the lipid membrane structures was 18 ml/g. This very high value under the conditions employed may be due to the added net negative charge contributed by the retinoic acid. The encapsulation of retinoic acid was 8 mg/g lipid (>99%).
EXAMPLE 8
In this Example, retinoic acid was used to replace dicetyl phosphate in providing the negative charge for lipid vesicles prepared with polyoxyethylene (2) cetyl and cholesterol. Two and a half grams of a lipid mixture with the molar proportions in Table 8 was employed. The method used was identical with that of Example 3.
TABLE 8______________________________________Polyoxyethylene (2) cetyl ether 33 mMCholesterol 6 mMRetinoic acid 1.5 mM5 mM phosphate, 150 mM NaCl, pH 7.4 40 ml______________________________________
After formation of the multilamellar vesicles and separation by centrifugation, the aqueous volume taken up was measured and found to be 12 ml/g lipid. The retinoic acid encapsulated was 17.5 mg/g/
EXAMPLE 9
This Example demonstrates the capacity of the lipid vesicles formed by the method of this invention from polyoxyethylene (2) cetyl ether were to incorproate a different lipophilic material, the insect repellent N,N-diethyl meta-toluamide. Two and a half gram of lipid was used in the proportions given in Table 9. The method used was the same as Example 7 with the N,N-diethyl meta-toluamide replacing the retinoic acid.
______________________________________Polyoxyethylene (2) cetyl ether 33 mMN,N--diethyl meta-toluamide 11 mMCholesterol 5 mMDicetyl phosphate 1.5 mM5 mM phosphate, 150 mM NaCl, pH 7.4 40 ml______________________________________
Upon centrifugation at 15,000 rpm for 15 minutes, the lipid membrane structures separated as a white layer atop the nonincorporated aqueous phase. This could readily be redispersed and diluted into a uniform suspension without separation of a low-density phase of N,N-diethyl meta-toluamide. The volume uptake was 10 ml/g lipid and >99% of the N,N-diethyl meta-toluamide was retained by the lipid membrane vesicle. Separate experiments showed that if cholesterol is eliminated from the system, the liposomes quickly lost the N,N-diethyl meta-toluamide.
EXAMPLE 10
This Example demonstrates the capacity of the lipid vesicles formed by the method of this invention to encapsulate supramacromolecular structures, specifically avian encephalitis (AE) virus, a 17 nm virion. The proportions and method used are identical to those of Example 5 except the red blood lysate was replaced by a solution of the AE virus. The results are shown in Table 10.
TABLE 10______________________________________SERUM DILUTION 1:00 1:2 1:4 1:8 1:16 1:32______________________________________SAMPLEAE VIRUS 1.47 0.75 0.48 0.24 0.21 0.17standardanD used forincorporationAQUEOUS RESIDUE 0.08 0.08 0.10 0.08 0.12 0.99CONTROL AVERAGE = 0.077STANDARD-CONTROL 1.39 0.67 0.40 0.16 0.13 0.09RESIDUE-CONTROL 0.00 0.00 0.02 0.00 0.04 0.02______________________________________
As is evident from the results of Table 10, at least 75% of AE is taken up into the multilamellar vesicles of this invention, indicating their potential usefulness in the transportation of viruses and plasmids.
EXAMPLE 11
In this Example, the percent uptake of an aqueous based solution was determined for multilamellar vesicles of the invention. The vesicles were made as disclosed in Example 1 except 2.5 grams of lipid was used to form the lipophilic phase while different amounts of a 0.25 N sorbitol solution was offered as an aqueous phase. The lipid was then separated by density gradient centrifugation and the volumes were measured. Table 11 illustrates the captured volume in ml/g of lipid.
TABLE 11______________________________________Offered Volume Volumevolume taken up taken up/g % uptake______________________________________10 ml 10 ml 4 10020 ml 20 ml 8 10030 ml 30 ml 12 10040 ml 40 ml 16 10050 ml 48 ml 19.2 9660 ml 52 ml 20.8 87______________________________________
As is evident from the results shown in Table 11, the multilamellar vesicles of the present invention have much greater captured volume than conventional multilamellar vesicles. | Disclosed is a new method of producing high aqueous volume multilamellar lipid vesicles. The method uses less expensive materials than those commonly used, is faster than classical methods, and produces vesicles with a much higher encapsulated mass and captured volume than was previously available. | 8 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention generally relates to the field of device configuration control, and more particularly relates to a system and method for controlling the configuration parameters of systems, such as server systems or networked storage systems.
[0003] 2. Description of Related Art
[0004] A problem with many storage products today relates to when and how configuration changes get updated to their associated storage system. These changes may include configuring IP addresses for ports; adding new storage disks; adding, modifying, or deleting end users; or modifying backup schedules. Most high-end NAS (Network Attached Storage) systems have only one option for configuration changes. Either the changes are activated immediately, or are queued until later, when they are manually activated by a system administrator (hereafter referred to as a user). In other systems, certain changes are activated immediately, while others are queued. This introduces some problems, such as:
[0005] Users don't easily know which changes are immediate vs. queued. Some visual indication is usually provided, but it's not a simple model for users to understand this distinction, which varies at the parameter-level throughout the application, not at the system-level. Some pages might even have a mix of immediate and queued settings.
[0006] Users are not in control of when changes get activated.
[0007] Users may, at least initially or in an emergency, prefer all changes to be activated dynamically and immediately.
[0008] Users may want to queue ALL changes if remote or during initial setups. This is essentially the same mode of operation when users manually edit a flat-file configuration and then activate all the changes at once at a later time.
[0009] Some ad ministration consoles immediately update each configuration change. This has proven to be a problem for customers as each change may take a long period of time to complete, making the system inaccessible during this time. Since these systems are clustered, all activity must be synchronized. Therefore, for example, it may take up to 30 minutes to activate the changes.
[0010] Therefore a need exists to overcome the problems with the prior art as discussed above, and particularly for an improved method of controlling the configuration parameters of networked storage systems.
SUMMARY OF THE INVENTION
[0011] According to a preferred embodiment of the present invention, a method and system presents a plurality of selections to a user for updating a system configuration from the choices of: an immediate mode, a scheduled queued mode, a queued mode, and an optimized activation mode. The immediate mode activates all changes immediately. The scheduled queued mode queues all changes and activates the changes at a predetermined time. The queued mode queues all changes and activates the changes after receiving a triggering event. The optimized activation mode analyzes the system usage to determine and optimally vary the mode among the immediate mode, the scheduled queued mode and the queued mode.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] [0012]FIG. 1 is a block diagram illustrating a network attached storage system with a user-controlled configuration in accordance with a preferred embodiment of the present invention.
[0013] [0013]FIG. 2 is a block diagram illustrating a storage area network system with a user-controlled configuration in accordance with a preferred embodiment of the present invention.
[0014] [0014]FIG. 3 is a more detailed block diagram showing a client computer system in the system of FIG. 1 according to a preferred embodiment of the present invention.
[0015] [0015]FIGS. 4, 5, 6 , 7 and 8 are operational flow diagrams illustrating exemplary operational sequences for the system of FIG. 1, according to a preferred embodiment of the present invention.
[0016] [0016]FIG. 9 is an exemplary administration interface displaying a menu for the system of FIG. 1, according to a preferred embodiment of the present invention.
[0017] [0017]FIG. 10 is an exemplary interface window displaying an implementation of activation settings for the system of FIG. 1, according to a preferred embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] The present invention, according to a preferred embodiment, overcomes problems with the prior art by providing an option to the user to enable him/her to decide the optimal time frame for updating the system configuration parameters. The ability to “flip a switch” and have configuration changes activated from within a User Interface (UI) context is a profound ease-of-use benefit.
[0019] A preferred embodiment provides a highly accessible and visible control for the user to switch between multiple activation modes. According to a preferred embodiment of the present invention, the following various activation modes may be accommodated with this visible control.
[0020] Immediate—all changes are immediately activated.
[0021] Scheduled Queued—all changes are queued until later activation, which is scheduled (e.g., for a low-impact time such as 3:00 AM)
[0022] Queued—all changes get queued until later manually activated.
[0023] Optimized Activation—the system would determine the best method of updating the system configuration, with some changes being immediate and some being queued for later.
[0024] All approaches, spanning from immediate activation of changes to queuing changes for later activation, have their benefits depending on the user and his circumstance (home, initial configuration, major configuration update, emergency, etc.). For example, if the user's NAS system has multiple nodes, and the same change is being made to each node, it will typically be most appropriate to queue up all the changes for each node and then make all the changes at once. However, for events such as a disaster recovery, the user may want to activate all changes immediately.
[0025] [0025]FIG. 1 illustrates an exemplary network attached storage system in accordance with a preferred embodiment of the present invention. The system includes at least one network attached storage system 104 , 106 , 108 , 110 that is communicatively coupled to a client computer system 102 , 124 , 126 via a local area network interface 112 . The local area network interface 112 may be a wired communication link or a wireless communication link. At least one client computer system contains a user-controlled configuration administration interface 122 for determining the method for updating configuration changes. The network attached storage system 104 , 106 , 108 , 110 may also be communicatively coupled with the world-wide-web, via a wide area network interface (not shown) via a wired, wireless, or combination of wired and wireless local area network communication links 112 . Additionally, at least one server 114 , 116 , 118 , 120 may be communicatively coupled to the network attached storage system 104 , 106 , 108 , 110 via the local area network interface 112 . The user-controlled configuration administration interface 122 may also be located on a server 114 , 116 , 118 , 120 or on a remote computer system connected via the world-wide-web.
[0026] Alternatively, FIG. 2 illustrates a storage area network system 200 in accordance with a preferred embodiment of the present invention. In this configuration, at least one network attached storage system 104 , 106 , 108 , 110 is communicatively coupled to at least one server 114 , 116 , 118 , 120 and each other via a hub 224 or another wired, wireless, or combination of wired and wireless local area network communication links. Each server 114 , 116 , 118 , 120 is, in turn, communicatively coupled to a client computer system 102 , 124 , 126 and each other, via a local area network interface 112 . At least one server 114 , 116 , 118 , 120 may also be communicatively coupled with the world-wide-web, via a wide area network interface (not shown) via a wired, wireless, or combination of wired and wireless local area network communication links 112 . In this system, at least one client computer system 102 contains the user-controlled configuration administration interface 122 for determining the method for updating configuration changes, however, the user-controlled configuration administration interface 122 may also be located on a server 114 , 116 , 118 , 120 or on a remote computer system connected via the world-wide-web.
[0027] Referring to FIG. 3, each client computer system 102 may include, inter alia, one or more computers, a display monitor 302 , and at least a computer readable medium 326 . The computers preferably include means for reading and/or writing to the computer readable medium. The computer readable medium allows a computer system to read data, instructions, messages or message packets, and other computer readable information from the computer readable medium. The computer readable medium, for example, may include non-volatile memory, such as Floppy, ROM, Flash memory, Disk drive memory, CD-ROM, and other permanent storage. It is useful, for example, for transporting information, such as data and computer instructions, between computer systems. Furthermore, the computer readable medium may comprise computer readable information in a transitory state medium such as a network link and/or a network interface 318 , including a wired network or a wireless network, that allow a computer to read such computer readable information.
[0028] [0028]FIG. 3 illustrates a client computer system 102 , according to the present example, that includes a controller/processor unit 320 , which processes instructions, performs calculations, and manages the flow of information through the computer system 102 . Additionally, the controller/processor 320 is communicatively coupled with program memory 312 . Included within program memory 312 are a configuration control administration interface 122 (which will be discussed later in greater detail), operating system platform 314 , and glue software 316 . The operating system platform 314 manages resources, such as the data stored in data memory 322 , the scheduling of tasks, and processes the operation of the configuration control administration interface 122 in the program memory 312 . The operating system platform 314 also manages a graphical and/or character-based display interface that, according to the present example, comprises the screen 304 on the display monitor 302 . Information is displayed via the screen 304 for visual output of information to a user of the computer system 102 . A user input interface comprises the keyboard 306 and the mouse 308 for receiving user input from a user of the computer system 102 . A communication network interface 318 allows for communicating with a network link 112 . Additionally, the operating system platform 314 also manages many other basic tasks of the computer system 102 in a manner well known to those of ordinary skill in the art.
[0029] Glue software 316 may include drivers, stacks, and low-level application programming interfaces (API's) and provides basic functional components for use by the operating system platform 314 and by compatible applications that run on the operating system platform 314 for managing communications with resources and processes in the computing system 102 .
[0030] The controller/processor unit 320 manages resources, such as the data stored in data memory 322 , the scheduling of tasks, and the operation of the configuration control administration interface 122 in the program memory 312 . The controller/processor unit 320 may also manage a communication network interface 318 for communicating with the network link 112 , and a computer-readable medium drive 324 . Additionally, the controller/processor unit 320 also manages many other basic tasks of the computer system 102 in a manner well known to those of ordinary skill in the art.
[0031] Although a network attached storage system 100 is described in detail, the methods described with respect to the preferred embodiments of the present invention may also be used to control the updating of configuration parameters in a variety of other network systems such as printers, scanners, personal digital assistants (PDAs), hubs, gateways, applications, servers, systems or any other device that has configuration parameters that can be controlled via a networked application. Alternatively, the instructions for performing these methods may be contained in the memory of a general-purpose computer system 102 .
[0032] [0032]FIGS. 4, 5, 6 , 7 and 8 , are operational flow diagrams illustrating exemplary operational sequences for the system of FIG. 1. The system 100 enters the sequence, at step 402 , wherein the configuration control administration interface 122 presents a number of configuration update modes to a user. At step 404 , the configuration control administration interface 122 receives an update mode selection from the user. The system, at step 406 , decides which configuration update mode to select based on the user input. If the user selects “Immediate”, then the system follows path A and enters the Immediate Mode, at step 408 . Likewise, for each of the other selections, a selection of “Queue” instructs the system to follow path B and enter the Queued Mode, at step 410 ; a selection of “Scheduled queue”, instructs the system to follow path C and enter the Scheduled Queued Mode, at step 412 ; and the selection of “Optimized Activation” causes the system to follow path D and enter the Optimized Activation Mode, at step 414 .
[0033] [0033]FIG. 5 illustrates a more detailed view of the Immediate Mode. The system 100 enters a process, at step 502 , where the configuration control administration interface 122 receives a configuration change request from a user (e.g., adds a new end user). The user in this case is the system administrator. The user may, for example, send the change request by hitting an “OK” pushbutton on the configuration control administration interface 122 . At step 504 , the change gets activated in the system immediately.
[0034] [0034]FIG. 6 shows a more detailed view of the Queued Mode. The system 100 enters the process, at step 602 , where the configuration control administration interface 122 receives a configuration change request from a user. At step 604 , the change request gets temporarily queued (does not get activated yet). These steps may be repeated over and over, at step 606 , with many changes getting queued up. The queued changes get activated in the system when one of three following things occur:
[0035] 1. The system administrator user switches to “Immediate” activation mode, which automatically activates any changes in the queue at step 608 .
[0036] 2. The system administrator user manually activates the queue at step 610 (e.g., selects “Activate queue now” menu choice).
[0037] 3. The system administrator user logs off, at step 614 . Then, the user is warned, at step 616 , that there are changes that have not yet been activated, and is prompted to activate them, at step 612 , or lose them, at step 618 , before logging off.
[0038] The Scheduled Queue Mode (shown in FIG. 7) is similar to the Queue Mode flow that is detailed above. The system enters the process at step 702 where the configuration control administration interface 122 receives a configuration change from a user. At step 704 , the change gets temporarily queued. These steps may be repeated over and over, at step 706 , with many changes getting queued up. For this mode, the queued changes get activated in the system when one of three things occur:
[0039] 1. The system administrator user switches to “Immediate” activation mode, which automatically activates any changes in the queue at step 708 .
[0040] 2. The system administrator user manually activates the queue at step 710 (e.g., selects “Activate queue now” menu choice).
[0041] 3. A predetermined activation time, if enabled, is reached at step 714 . The activation time may be absolute or relative to another event (e.g. 30 minutes after user logs off).
[0042] The changes are then activated, at step 712 .
[0043] [0043]FIG. 8 illustrates the Optimized Activation mode. This is a most complicated flow sequence, since it automates the activation type for the user. A change either gets activated in the system immediately or gets queued for a later time, depending on the optimized activation settings and automated intelligence in the system. A few of the factors that affect whether the optimized activation setting immediately activates changes or queues until later are the importance of not disrupting the general end users of the system, the importance of not disrupting administrator usage, the disruptiveness of a change to end users, and the disruptiveness of a change to administrator users. For example, if users are system developers, then it may only be “desirable” to not disrupt them, whereas if they are web users (customers), it might be “critical” to not disrupt them. In a test situation, disrupting end users might be set to “Doesn't matter”. For administrators, it could be that some admin users get very annoyed with the minutes it might take to activate most changes and want to queue them. New admin users might not trust the queuing and want each change request to get immediately activated. Some change requests might force the system to reboot, and/or users to perform some action such as remounting a drive or logging back on. Such change requests, perhaps, should be queued until an “Absolute activation time”. Some change requests might activate quickly, in a matter of a few seconds, whereas others might take a long time, such as a few minutes, as they are propagated across a clustered system with proper error checking, etc. These could be queued up until a “Relative activation time” (such as right after the admin user logs off). Other things might affect how the activation get optimized, such as:
[0044] If the system detects that a user is performing disaster recover actions in an emergency situation, then change requests should be activated either immediately, or queued and then activated when the admin user clicks the final “OK” button while doing his key task.
[0045] If system detects that a user is making similar types of change requets to each server in a clustered system, the system should wait until each server is modified until activating similar changes and synching them across the whole cluster.
[0046] The admin user can set the importance of not disrupting end users, and not disrupting his admin performance with a priority rating. For example, on a 5 point scale:
[0047] Critical=4
[0048] Very important=3
[0049] Important=2
[0050] Desirable=1
[0051] Doesn't matter=0
[0052] Each configuration change may also have an associated priority rating so that, for example, a very quick or important task may be given a very high rating, while a task that may disrupt the system for a longer period of time may be given a very low priority rating.
[0053] In a preferred embodiment, the system enters the process, at step 802 , where the configuration control administration interface 122 receives a configuration change request from a user. At step 804 , the configuration control administration interface 122 checks to see if the system is in a disaster recovery mode. If so, the system enters into the Immediate Mode and follows the procedure for that mode. If not, the priority level of the end-user, administrator, and the change itself are checked, at step 806 . If the priority of the change request is higher than the priority of the end-user or the system administrator, or the system determines that the same change request is being made to multiple devices, that change will be slated for a Queued Mode, at steps 808 , 810 , and 812 ; otherwise, the system enters into the Immediate Mode and follows the procedure for that mode. The configuration control administration interface 122 then compares the priority rating to predetermined threshold level, at step 814 . If the priority rating of the change is below the threshold, the system will enter the Scheduled Queued Mode, if not, the system enters the Queued Mode. This allows a user to set a limit for non-vital change requests to be performed at a scheduled time.
[0054] [0054]FIG. 9 is an exemplary administration interface displaying a menu for the system of FIG. 1, according to a preferred embodiment of the present invention. The menu preferably includes a selection area for the configuration update mode 902 . A menu choice for an interface window displaying an implementation of activation settings 908 (shown in FIG. 10) is also included, as well as a menu choice 907 for activating the change requests immediately. In addition to the menu, other key user interface components include a navigation area to display the type of information to configure 904 , and a content area for users to set particular configuration information to update 906 .
[0055] [0055]FIG. 10 displays an exemplary activation settings window. It may preferably contain a field 1002 for selecting a default activation mode, fields 1004 for selecting a time (relative or absolute) for activating queued changes, and fields 1006 for setting the priority rating for optimizing effects on both users and end users.
[0056] The present invention can be realized in hardware, software, or a combination of hardware and software. A system according to a preferred embodiment of the present invention can be realized in a centralized fashion in one computer system, or in a distributed fashion where different elements are spread across several interconnected computer systems. Any kind of computer system—or other apparatus adapted for carrying out the methods described herein—is suited. A typical combination of hardware and software could be a general-purpose computer system with a computer program that, when being loaded and executed, controls the computer system such that it carries out the methods described herein.
[0057] A preferred embodiment of the present invention can also be embedded in a computer program product, which comprises all the features enabling the implementation of the methods described herein, and which—when loaded in a computer system—is able to carry out these methods. Computer program means or computer program in the present context mean any expression, in any language, code or notation, of a set of instructions intended to cause a system having an information processing capability to perform a particular function either directly or after either or both of the following a) conversion to another language, code or, notation; and b) reproduction in a different material form.
[0058] A computer system may include, inter alia, one or more computers and at least a computer readable medium, allowing a computer system, to read data, instructions, messages or message packets, and other computer readable information from the computer readable medium. The computer readable medium may include non-volatile memory, such as ROM, Flash memory, Disk drive memory, CD-ROM, and other permanent storage. Additionally, a computer readable medium may include, for example, volatile storage such as RAM, buffers, cache memory, and network circuits. Furthermore, the computer readable medium may comprise computer readable information in a transitory state medium such as a network link and/or a network interface, including a wired network or a wireless network, that allow a computer system to read such computer readable information.
[0059] Although specific embodiments of the invention have been disclosed, those having ordinary skill in the art will understand that changes can be made to the specific embodiments without departing from the spirit and scope of the invention. The scope of the invention is not to be restricted, therefore, to the specific embodiments, and it is intended that the appended claims cover any and all such applications, modifications, and embodiments within the scope of the present invention. | A method and system presents a plurality of selections to a user for updating a system configuration from the choices of: an immediate mode, a scheduled queued mode, a queued mode, and an optimized activation mode. The immediate mode activates all change requests immediately. The scheduled queued mode queues all change requests and activates the change requests at a predetermined time. The queued mode queues all change requests and activates the change requests after receiving a triggering event. The optimized activation mode analyzes the system usage to determine and optimally vary the mode among the immediate mode, the scheduled queued mode, and the queued mode. | 7 |
FIELD OF THE INVENTION
This invention relates to compositions which are useful for improving the texture, feel and appearance of hair and skin. More particularly, this invention relates to conditioning compositions which are typically applied to the hair and skin subsequent to a cleansing treatment.
Hair conditioning agents assist in the control and management of hair. Conditioned hair is easily untangled and combed through after shampooing, lays orderly when dry and provides a favorable feeling to the touch. The conditioning action on hair, particularly by cationic conditioning agents, is believed to be caused by the attraction of the positively charged agent to the negatively charged sites on hair protein resulting in the deposition of the agent onto the hair fiber. After washing hair and during the subsequent management of the dry hair, the combing and brushing forces produce friction resulting in the accumulation on the hair's surface of immobile electrons or ions of the same charge. The hair is commonly referred to as containing static charge and displays the phenomenon of "fly-away". Such hair is unruly, will not lay flat and is considered generally unmanageable.
Ionic depositions including positively charged cationic conditioning agents can be used to dissipate static electricity by increasing the mobility of the electrostatic charges that accumulate on hair. Furthermore, the fatty nature of the cationic conditioning agent produces lubrication on the hair's surface that reduces friction (triboelectric friction) resulting in the overall lessening of accumulated electrostatic charges and the promotion of easy combing. The process by which cationic surfactants are applied to hair is referred to as conditioning the hair, and the treatment results in hair that no longer sustains a static charge and in hair that also feels soft, silky and is highly manageable.
Cationic surfactants have been used extensively as hair conditioning agents in creme rinses and occasionally in shampoos, generally at pH levels below pH 7 in creme rinses and through pH 7 and above in shampoos when the formula permits. In the past, best results in creme rinses have been obtained with cationic surfactants that are long chain high molecular weight quaternary ammonium compounds or long chain fatty amine salts. For example, stearalkonium chloride has been widely used as a component of creme rinse hair conditioning formulations. The positive charge of the quaternary surfactant is attracted to the negatively charged surface of the hair protein; the surfactant deposits on the surface and subsequently renders the hair manageable. The long chain constituent on the quaternary surfactant coats the hair fiber giving it lubricity during wet combing and a desirable texture after drying. The longer the chain length the more active the conditioning agent is said to be; the greater the residual film deposit on hair the easier the detangling effort and the less electrostatic charge build-up and subsequent hair fly-away.
Quaternary ammonium compounds carry and maintain positive ionic charges in media having highly alkaline to highly acidic pH. However, many industrial quaternary ammonium compounds are partially or totally unsuitable for cosmetic use because they can contain impurities which restrict use to specific pH ranges or restrict use completely. If trace quantities of deleterious quaternizing agents used in synthesis are present, the quaternary ammonium compound should not be used in cosmetics. Long chain fatty amines, which usually account as significant impurities in the quaternary ammonium compounds used for cosmetics, force the use of the quaternary ammonium compound, and the cosmetic itself, to pH's below 7. Below pH 7, the long chain amines exist as surface active salts which produce hair conditioning effects which are similar to those produced by surface active quaternary ammonium salts. Above pH 7, the amine salts revert to their free organic amine state which cause them to loose their hair conditioning properties, to produce cosmetically unaesthetic odors and appearances, and to increase irritation to the skin and eyes.
Amine oxides, which act as nonionic materials in alkaline media and weakly cationic materials in acidic media, have been reported in U.S. Pat. No. 4,714,610 to exhibit effective hair conditioning properties in compositions having a pH of about 2.4 to about 3.8 which is described as the isoelectric point of hair. As described in the aforesaid patent, the mechanism for the conditioning effect obtained from the amine oxide material is not clear in view of the neutral state of the hair protein at its isoelectric point.
This invention is related to the use of amphoteric materials, such as betaines and zwitterionic analogues thereof, in compositions useful for conditioning hair and skin.
REPORTED DEVELOPMENTS
Generic disclosures of low pH betaine and/or zwitterionic-containing compositions are included in U.S. Pat. Nos. 4,080,310; 4,107,328; 4,294,728; 4,507,280; 4,526,781; 4,534,877; and 4,663,158.
U.S. Pat. No. 4,294,728 to Vanlerberghe, assigned to L'Oreal, discloses that foaming compositions can have a pH of 2.5-10.5, and that shampoo compositions have a preferred pH of 3 to 9.5. The Vanlerberghe foaming and cleaning compositions, which are reported to exhibit good conditioning properties, comprise a variety of surfactants including amphoteric surfactants and a 1,2 alkane diol, which is disclosed to be an essential synergistic ingredient. Not a single example of a betaine-containing composition of pH less lo than 4 is disclosed.
The prior art discloses specific zwitterionic- or betaine-containing compositions having a pH less than 4 in U.S. Pat. Nos. 4,636,329 and 4,375,421, but these compositions do not include a superfatting material.
Zwitterionic- or betaine-glycinate containing compositions which include a superfatting agent are disclosed in U.S. Pat. Nos. 3,822,312; 3,928,251; 4,020,155; 4,420,410; 4,420,484; and 4,526,781 and in British Pat. No. 854,994, but none of these patents discloses even generically that the pH of the composition could be as low as 4.
The present applicant has discovered that excellent conditioning properties may be obtained with a zwitterionic- or betaine-containing composition having characteristics apparently overlooked by the prior art.
SUMMARY OF THE INVENTION
This invention relates to a composition, for conditioning the hair or skin, having a pH of about 2 to about 3.5 and including a betaine or zwitterionic compound and a superfatting material. Applicant has discovered that the incorporation of a superfatting material in a zwitterionic- or betaine-containing composition of low pH transforms it into a surprisingly effective conditioning composition.
This invention also relates to a method for conditioning the hair or skin comprising the application to the hair or skin of the aforesaid composition.
DETAILED DESCRIPTION
The following terms as used herein are defined below.
"Betaine" means an N-alkylcarboxylate-N-fatty alkyl-quaternary amine.
"Zwitterionic compound" means an N-alkylcarboxylate-N'-fatty alkyl-ammonium compound.
"Superfatting material" means a fatty alcohol, fatty acid or alkyl ester of a fatty alcohol, which are the organic carboxylic acids or derivatives thereof of a long chain alkyl or are derived from a naturally occurring oil or fat or a hydrogenated product thereof including coconut oil, castor oil, palm kernel oil, cottonseed oil, peanut oil, olive oil, palm oil, sunflower seed oil, sesame oil, corn oil, safflower oil, poppyseed oil, teaseed oil, kapok oil, rice bran oil, grain sorghum oil, rapeseed oil, linseed oil, soybean oil, perilla oil, hempseed oil, wheatgerm oil, rubberseed oil, tung oil, oiticica oil, cacahuanache oil, whale oil, pilchard oil, Japanese sardine oil, menhaden oil, herring oil, fish liver oil, tallow, milk fat or lard.
"Alkyl" means an aliphatic hydrocarbon, either straight or branched chain, and having from one to about 20 carbon atoms. Preferred alkyl groups have from one to about 8 carbons atoms. The most preferred are the "lower alkyl" groups which have from one to about six carbon atoms.
"Long Chain Alkyl" means an aliphatic hydrocarbon, either straight or branched chain, and having from about 13 to about 20 carbon atoms.
"Fatty Alkyl" means a long chain alkyl radical. Preferred fatty alkyl groups are derived from fatty alcohols obtained by purifying a fatty material derived from natural sources.
"Amido Radical" means a group of the formula ##STR1## where the R substituent group may be hydrogen, alkyl or fatty alkyl.
Examples of betaine and zwitterionic compounds are described by the formula: ##STR2## wherein: R 1 is fatty alkyl;
x is from 1 to about 3;
y is from 1 to about 6;
R 2 , R 3 , R 4 and R 5 are hydrogen, alkyl or hydroxyalkyl; R 4 , R 5 , R 6 and R 7 may also form a nitrogen-containing ring together with the carbon and nitrogen atoms to which they are attached; and
Z represents an amido radical group or a carbon-carbon single bond.
A preferred betaine compound according to Formula I is wherein Z is a single bond, R 2 and R 3 are hydrogen and R 4 and R 5 are not hydrogen.
Preferred zwitterionic compounds are according to Formula I wherein R 4 is hydrogen.
The betaine and zwitterionic compounds may be prepared by methods well known in the art, for example, by reaction of the corresponding secondary or tertiary amine with an alkylating agent, such as chloroacetic acid, or by reaction of an alkyl halide with a starting amine that includes the alkylcarboxylate group.
A special class of betaines for use in this invention include lauryl dimethyl amine glycinate, myristyl dimethyl amine glycinate, cetyl dimethyl amine glycinate, stearyl dimethyl amine glycinate, oleyl dimethyl amine glycinate, heptadecyl dimethyl amine glycinate, behenyl dimethyl amine glycinate, dimethyl cocamine glycinate, dimethyl hydrogenated tallow amine glycinate, bis (hydroxyethyl) cocamine glycinate, bis (hydroxyethyl) tallow amine glycinate, bis (hydroxypropyl) stearamine glycinate, bis (hydroxymethyl) behenamine glycinate, pentadecyl diethyl amine glycinate, tridecyl dipropyl amine glycinate, tridecyl bis (2-hydroxybutyl) amine glycinate, heptadecyl bis (2-hydroxybutyl) amine glycinate and tridecyloxypropyl bis (hydroxyethyl) amine glycinate.
Another special class of betaines include the propionate analogs of the aforementioned glycinate betaines.
Examples of betaine compounds which are specially preferred comprise one or more of hydrogenated tallow dimethyl glycinate, dihydroxyethyl tallow glycinate or stearamido ethyl ethanolamine glycinate.
Another class of betaines include, dicoco methyl amine glycinate, distearyl methyl amine glycinate, dihydrogenated tallow methyl amine glycinate, dicetyl methyl amine glycinate, cetyl isocetyl methyl amine glycinate, lauryl cetyl methyl amine glycinate, dilinoleyl methyl amine glycinate, disoya methyl amine glycinate, diisostearyl methyl amine glycinate, distearyl hydroxyethyl amine glycinate, stearyl, isostearyl hydroxymethyl amine glycinate, hexyl bis (2-hydroxyhexadecyl) amine glycinate and distearyl hydroxypropyl amine glycinate.
Another class of amido-containing betaines include cocylamido-propyl dimethyl amine glycinate, myristoylamidopropyl dimethyl amine glycinate, stearoylamidoethyl dimethyl amine glycinate, linoleoylamidopropyl dimethyl amine glycinate, hydrogenated tallow amidoethyl bis (hydroxyethyl) amine glycinate, palmitoylamidoethyl bis (hydroxypropyl) amine glycinate, stearoylamidopropyl dimethyl amine glycinate, and hydrogenated tallow amidopropyl dimethyl amine glycinate.
Still another class of betaine or zwitterionic compounds includes the imidazoline betaines and zwitterionics of the formula: ##STR3## wherein R 1 and R 2 are hydrogen, a long chain alkyl group, 2-hydroxyethyl, a derivative of 2-hydroxyethyl or a nonionic derivative of 2-aminoethyl, and R 3 is an alkylcarboxylate group.
Examples of suitable imidazoline betaines of this class include 1-hydroxyethyl-2-heptadecenyl-2-imidazoline-1-glycinate, 1-hydroxyethyl-2-heptadecanyl-2-imidazoline-1-glycinate, 1-acetylhydroxyethyl-2-tridecanyl-2-imidazoline-1-glycinate, 1-acetylaminoethyl-2-tridecanyl-2-imidazoline-1-glycinate, and 1-ethoxyethyl-2-pentadecanyl-2-imidazoline-1-glycinate
Yet another suitable class of compounds includes the morpholino compounds of the formula: ##STR4## wherein R 1 is hydrogen or a long chain alkyl group and R 3 is an alkylcarboxylate.
Examples of suitable betaines of this class include N-2-hydroxymenyl-morpholine glycinate, N-2-hydroxy-pentadecyl-morpholine glycinate, and N-2-hydroxyheptadecyl-morpholine glycinate.
Good results are obtained when the betaine or zwitterionic compounds are used at a concentration of between about 0.5% and about 15% by weight of the conditioner formulation. The preferred concentration is about 1.5% to about 8% of the compound by weight of the hair conditioning composition.
The conditioning composition includes also a superfatting material which is selected preferably from the group consisting of fatty acids, fatty alcohols or fatty acid alkyl esters. A most preferred superfatting material is cetyl alcohol.
A preferred embodiment of this invention comprises a composition which includes said betaine or amphoteric compound and said superfatting material in effective hair- and skin-conditioning amounts.
More specifically, preferred amounts of superfatting materials are about 0.5 to about 5 weight percent of said composition.
A preferred pH of the composition according to this invention is within a range of about 2.2 to about 3.2, with a most preferred pH range of about 2.5 to about 3.
In general, the composition is prepared by admixing the betaine or zwitterionic compounds, superfatting material, water and sufficient acid, for example, hydrochloric acid, to reduce the pH within the aforesaid range. Other acids that may be used include phosphoric acid and those organic acids (acetic, citric, glycolic, etc.) that offer sufficient acidity to accommodate the low pH range.
Other ingredients may be added to the conditioning composition for the purpose of performing desired functions. For example, ethoxylated cetyl alcohol which is an emulsifier, and other materials such as hydrolyzed proteins, perfumes, colorants and preservatives may be added as desired.
The following examples are illustrative of the present invention. Various of the ingredients essential to the composition may be varied in amount within the limits described herein.
EXAMPLE 1
Hydrogenated tallow dimethyl glycinate, a betaine, is used at 6.4% active concentration in an aqueous dispersion also including 1% cetyl alcohol. The "gloppy" highly pearlized creme which resulted did not display any pronounced conditioning effect when applied to hair and rinsed off.
Phosphoric acid is added to the aforementioned composition in an amount sufficient to lower the pH to 2.7. A more fluid composition is obtained. The low pH composition exhibits heightened conditioning effects after application and rinsing thereof on hair and skin of the hands.
EXAMPLE 2
The following is a formulation of a composition according to this invention.
______________________________________Dihydroxyethyl tallow glycinate (40% active) 21.0Phosphoric acid 1.0Cetyl alcohol 2.0Color, fragrance, preservative qSWater qS 100______________________________________
The glycinate, acid and alcohol are weighed into a beaker and melted. Water at 80° C. is added. The aqueous mixture is mixed and slowly cooled to 43° C. Fragrance, color and preservative are added at ambient temperatures.
During cooling, pearlescence develops and the product turns from fluid at warmer temperatures to a pituitous semi-gel at room temperature. Final pH is 2.9.
The preparation is tested as a rinse-off hair conditioner and is evaluated against a commercial hair conditioner. It produces the same order of conditioning response as the popularly sold conditioner, but differs in that the hair is left feeling cleaner with more body. When the product is massaged into the hands and rinsed away, the dried hands display unusual, highly perceptible smoothness, a smoothness not recognized with the incidental use of other hair conditioners.
EXAMPLE 3
A formula corresponding to that described in Example 2 is prepared using stearamido ethyl ethanolamine glycinate at 6% active concentration. This product shows also hair and skin conditioning effects.
The present method comprises the application of the applicant's composition to hair or skin, previously moistened with water, and distributing the composition throughout the hair or skin to permit even distribution. Application should involve rubbing or combing. The composition should be permitted to remain on the hair for a period of time sufficient to allow even distribution, for example, from 5 to 30 seconds. The composition should be rinsed from the hair or skin with water.
The conditioning properties of the present composition may be evaluated by using the following test procedures.
1. Procedure for Evaluation
A 2 gram, 10" long tress of double bleached hair is shampooed with a conventional shampoo, and reshampooed again to simulate a double shampoo typical of consumer use. The hair is rinsed thoroughly under the tap with tepid water. Five cc of a test hair conditioner is measured with a syringe and applied to the hair tress. The conditioner is worked into the hair tress for a minute and then the tress is rinsed with tepid water under the tap for one minute. The hair is touched, observed, combined, smelled and rated to a control shampooed tress without a conditioner application. Upon drying, the tress is treated again by touching, observing, combing and smelling.
Tests to determine the substantivity of the betaine or zwitterionic compound to hair protein are conducted using the "Rubine Dye Test". The dye test for determining substantivity of cationics to hair demonstrates the degree of the adhesive nature of a cationic agent to hair during rinsing with water. Hair treated with a cationic conditioner will gather a rinse-fast stain when subjected to the dye; the coloration gathered on untreated hair is readily rinsed away. The dye complexes with positively charged surfactant residues on the hair forming a stain that resists rinsing from the hair. Pyrazole Fast Bordeau 2 BL was used in these tests in place of Rubine dye. The betaines and zwitterionic compounds used in this invention produce a positive Rubine Dye Test response on tresses treated with formulations described herein.
The Rubine Dye Test employed a double bleached hair tress which is treated with the present composition. After treatment, the tress is rinsed for exactly one minute under tepid tap water. The tress is then towel-dried and immersed in a 0.2% aqueous Pyrazol Fast Bordeau 2 BL dye solution for 10 seconds. Again, the tress is rinsed under the tap to remove excess dye solution from the hair. A residual red stain left on the hair indicates a substantive deposition of betaine or zwitterionic compound. No red stain appears on a free-rinsed control hair tress that is not treated prior to treatment with dye.
The hair conditioning delivered by the compositions of this invention have properties that are variable accordingly, adjustments in formulation may be made as needed. Since conditioning effects are relative to the needs of the user, it is a convenience to have adjustable features in formula development to suit the formulator's objectives. Certain users prefer to have as their major objective in hair conditioning excellent detangling of shampooed hair. Others prefer to have less detangling effectiveness but require that their hair feel natural, not overconditioned or heavily coated. Some users like to use clear products; others opaque cremes and lotions. Most users prefer to have their hair free of static charge to allow good manageability. The wide range of physical properties that various betaines and zwitterionic compounds offer are taken advantage of at or about the isoelectric point of hair protein to produce tailor made products that have features that satisfy the user.
As a corollary, it is difficult to measure the attributes of a hair conditioning product with only one parameter describing conditioning. In the evaluation of the present compositions, three parameters may be used to assess hair conditioning effects:
(1) The Rubine Dye Test serves to demonstrate the substantivity of cationic ingredients in hair conditioners. The substantive coating that shows red with Rubine dye is composed of positive charges and/or polarized molecules which tend to conduct ions or electrons (the localized accumulation of such ions or electrons is the cause of static charges). A positive Rubine Dye Test, therefore, indicates that, because of the substantive coating on the hair which is conductive, any accumulating ions or electrons will be mobile and any electrostatic disadvantages to manageability of hair from static electricity are nullified.
(2) Touching hair serves to inform the user the state of conditioning in one's hair. The feeling is totally subjective, varying among individuals according to personal preferences. Some prefer light texture, approaching a natural or unconditioned effect; others prefer the tactile demonstration of conditioning provided by a significant coating of fatty material. In the laboratory evaluation of the "touch" parameter, using a range of 1 to 10, 10 signified a clean feeling, the absence of coating which is apparently present (Rubine Dye Test) and which can offer other advantages; 1 signified a maximum, heavily conditioned coating that can be felt with the fingers. Either effect, a clean feeling or a definitive "conditioned" coating, can be desirable depending on the users perspective.
(3) The ease rendered in combing wet hair after shampooing is perhaps the single most important benefit of creme rinse products. Immediately after shampooing, hair is usually left matted and difficult to comb through. Damage to the hair structure usually results upon combing or brushing at this stage because of the intense friction produced on the tangled hair. Furthermore, pulling and stretching the hair during wet combing result in the weakening of its tensile strength, some degree of hair breakage and in causing pain and discomfort to the individual. The application of a creme rinse balsam or other hair conditioning treatment provides a lubricant coating to the hair shaft that reduces and minimizes the combing effort. The user is thus spared the discomfort of combing tangled and snarled hair. In laboratory evaluation, the effectiveness of a conditioner application in providing easy combing after a shampoo treatment is rated on a 1 to 10 scale. A rating of 10 indicates easy wet combing comparable to the effects of a leading commercial hair conditioner based upon quaternary ammonium surfactants; a rating of 1 indicates the base state of combing hair after shampooing with a detergent cleanser and without a hair conditioner application.
The following procedure may be used to demonstrate the criticality of the pH range of the hair conditioning composition herein and the improvements in wet combing, dry combing and manageability attributable to the pH range herein compared with compositions having higher pH.
2. Procedure for Evaluation
(1) 2.5±0.5 g., 10 inch hair swatches are prepared using consistent and uniform hair types (Virgin, Bleached, Grey, etc.).
(2) The hair tresses are collectively shampooed with a 15% active sodium lauryl sulfate solution, using an excess quantity of detergent solution. The hair tresses are carefully handled to avoid excessive tangling during shampooing and are then rinsed free and rendered clean with 40° C. tap water. This process is repeated to simulate a double shampoo application. All test hair tresses are presented in an equivalent clean and "degreased" state.
(3) Individual hair tresses are separated and tagged for test application. Two cc of a test conditioner preparation (excess) is applied to a cleaned, wet tress with a syringe. The conditioner is worked through the hair for one minute with downward strokes of the fingers. The tress is rinsed thoroughly clean under 40° C. tap water for one minute. All test conditioners are treated equivalently. An untreated tress serving as a control is used as a point of reference.
A rating system of 1 to 10 is used in which 1 represents the base state of untreated, difficult-to-manage hair and 10 represents optimum conditioned hair. The rating scale may be used as follows:
10--Highest optimum rating, excellent
9--Good-Excellent
8--Good
7--Fair-Good
6--Average
5--Mediocre
4--Fair-Poor
3--Poor
2--Very Poor
1--Void of Positive Effects
A two unit spread is considered readily perceptible and significant.
The evaluation procedure is as follows:
(1) Combing--Hair is combed through, at first, in the wet state then in the dry state, using the fine teeth of a #400 "Cleopatra" comb. Prior to wet combing, excess water is squeezed from the tress in order to simulate tower-dry hair. A rating number is ascribed relative to that of a control tress.
(2) Fly-away--The degree of static charge (on dry hair only) is observed by combing a tress quickly 10 strokes with the coarse teeth of a #400 Cleopatra comb. A rating is assigned relative to a control test.
(3) Manageability is assessed relative to a control by observing its behavior pattern. A rating number is given.
Compositions of the present invention possess excellent conditioning properties as measurable by the foregoing procedures. | This invention relates to compositions which are useful for improving the texture, feel and appearance of hair and skin. More particularly, this invention relates to conditioning compositions which are typically applied to the hair and skin subsequent to a cleansing treatment. | 8 |
BACKGROUND OF THE INVENTION
[0001] Inquires have increased recently for repairing a damaged spark plug hole in an aluminum cylinder head of a vehicle engine. Most of the engines experiencing the problem have more than 80,000 miles on the vehicle. When the spark plug is removed in these high mileage engines for a tune-up the threads in the head may strip out as the plug is removed. This is due to carbon built up on the spark-plug threads.
[0002] In the past, there was no way of repairing the damaged spark plug hole. Therefore, the cylinder head had to be replaced if the spark plug hole was damaged. The cost of labor and total materials used for the head replacement can be more than two thousand dollars. It is very expensive and time consuming.
[0003] The present invention is directed to overcoming one or more of the above problems.
SUMMARY OF THE INVENTION
[0004] In accordance with the invention a new method is provided using new tools for repairing a damaged spark plug hole in a cylinder head of a vehicle engine. More specially, the repairing method uses a set of tools that would repair the damaged spark plug hole while the cylinder head having the damaged spark hole remains in the vehicle.
[0005] Additionally, a new structure of a spark plug hole is provided that is harder to damage and can be used for much longer time compared with the original spark plug hole.
[0006] An exemplary embodiment of the invention achieves the foregoing in a method including first drilling the damaged spark plug hole using a drill bit to provide a drilled hole. A stopper is used to limit the depth of the drill to prevent damaging a piston in a cylinder of the vehicle engine. Secondly, the drilled spark plug hole is tapped to provide a threaded hole with the stopper limiting the depth of the thread. Thirdly, a steel insert is threaded into the threaded hole with the stopper guiding the insert to a required depth. The insert is cylindrical having an outer threaded surface and an inner surface having a threaded portion. Finally, the insert is seated to make a spark plug seat.
[0007] In accordance with one aspect of the invention, a tapping and threading tool is used for tapping the drilled hole and threading the insert into the threaded hole.
[0008] In accordance with another aspect of the invention, a seating tool is used for seating the spark plug hole.
[0009] As a result of the foregoing repairing method, the damaged spark plug hole is repaired using much less labor hours and materials compared with the replacement of the cylinder head. The amount of money saved by this method compared with the head replacement is substantial.
[0010] The resulting repaired hole having a steel insert is stronger and more durable than the original spark plug hole in an aluminum cylinder head.
[0011] Other features and advantages will become apparent from the following specification taken in conjunction with the accompanying drawings.
DESCRIPTION OF THE DRAWINGS
[0012] [0012]FIG. 1 is a sectional view of a damage spark plug hole in a cylinder head of a vehicle engine;
[0013] [0013]FIG. 2 is a plane view of a stopper in accordance to the invention;
[0014] [0014]FIG. 3 is a plane view of a drilling adapter with a drill bit in accordance to the invention;
[0015] [0015]FIG. 4 is a plane view of a tapping and threading tool in accordance to the invention;
[0016] [0016]FIG. 5 is a plane view of an insert in accordance to the invention;
[0017] [0017]FIG. 6 is a plane view of a seating tool in accordance to the invention; and
[0018] [0018]FIG. 7 is an enlarged, exploded fragmentary view of the repaired spark plug hole in accordance to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0019] An exemplary embodiment of a set of tools for repairing a damaged spark plug hole 2 (shown in FIG. 1) in a cylinder head 4 of a vehicle engine is illustrated in FIGS. 2 - 5 .
[0020] Referring to FIG. 2, a stopper 6 is cylindrical having a bevel 8 with a small protruding ear 10 at one end and a horizontal surface 11 at another end. A cylindrical opening 12 extends through the stopper 6 . The protruding ear 10 may be used as a handle.
[0021] Referring now to FIG. 3, a drilling adapter 14 includes a shaft 16 having one end with an opening 17 receiving a drill bit 18 and another end connected to a short cylindrical block 19 . A screw 20 fastens the drill bit 18 to the shaft 16 . The short cylindrical block 20 has an opening 21 in which a rachet tool can fit. A shaft collar 22 is fixed around the shaft 16 at a selected place through screws 23 .
[0022] A tapping and threading tool 24 is shown in FIG. 4. The tapping and threading tool 24 includes a shaft 26 having one end with an opening 27 receiving a modified cutter 28 and another end connected to a short cylindrical block 30 . A screw 31 fastens the modified cutter 28 to the shaft 26 . The modified cutter 28 has a wide threaded portion 32 proximate to the shaft 26 and a narrow distal threaded portion 34 . The short cylindrical block 30 has an opening 36 in which a rachet tool can fit. There is a slip collar 38 that can slide up and down on the shaft 26 by loosening Allen screws 39 or the like. The slip collar 38 has two positions 40 , 42 that can be obtained by fastening the screws 39 . The tapping and threading tool 24 serves as a tapping tool when the slip collar 38 is secured at the first position 40 and a threading tool when the slip collar 38 is secured at the second position 42 .
[0023] Referring to FIG. 5, a seating tool 44 includes a wide shaft 46 , used as a handle, having one end with an opening 47 receiving a seating adapter 48 and another end connected to a head 49 . A screw 50 fastens the seating adapter 48 to the shaft 46 . The seating adapter 48 is generally cylindrical and has a wide near end, received in the opening 47 , connected by a wide conical portion 54 to a narrow conical portion 56 . The narrow conical portion 56 is connected at other end to a central portion 58 . The central portion 58 is connected at a shoulder to a narrow distal end 60 .
[0024] A steel insert 62 is shown in FIG. 6. The insert 62 is cylindrical having an outer threaded surface 64 and an inner surface 66 having a threaded portion 68 at one end and a smooth portion 70 at the other end.
[0025] The above described tools of FIGS. 2 - 5 can be used to simply and inexpensively repair the damaged spark plug hole of FIG. 1.
[0026] Before repairing the damaged spark hole 2 shown in FIG. 1, the battery source should be disconnected from a vehicle. With the old spark plug removed the engine is rotated from the front crankshaft pulley until the piston begins to go down to provide enough work space for repairing the hole 2 .
[0027] The repairing method first includes placing the stopper 6 on the cylinder head 4 and over the damaged spark plug hole 2 to be repaired. The bevel 8 of the stopper 6 lies facing down against the cylinder head 4 . The drill bit 18 is sprayed heavily with a compound that allows some of the aluminum shavings to adhere to the drill bit 18 as it drills. The compound can be removed later when the drill bit 18 is removed. The compound may be, for example, Napa Tack Gasket. The drilling adapter 14 having the drill bit 18 is inserted through the opening 12 of the stopper 6 into the damaged spark plug hole 2 . A rachet tool is inserted onto the opening 21 at the end of the drilling adapter 14 and turned until the drill bit 18 penetrates and completes drilling of the hole 2 and the drilling adapter 14 with its shaft collar 22 turns freely against the horizontal surface 11 of the stopper 6 . The stopper 6 will not allow the drilling adapter 14 to enter the cylinder more than required. Then, the drilling adapter 14 is removed from the drilled hole.
[0028] The repairing method second includes positioning the slip collar 38 on the tapping and threading tool 24 in the first position 40 and securing it. With the stopper 6 still positioned over the drilled spark plug hole, the tapping and threading tool 24 is inserted through the opening 12 of the stopper 6 into the hole. The stopper 6 is not only a stop for the drilling adapter 14 , but is also a depth gage for the tapping and threading tool 24 . A rachet tool is inserted onto the opening 36 at the end of the tapping and threading tool 24 and turned until the slip collar 38 is snug with the horizontal surface 11 of the stopper 6 . The wide threaded portion 32 of the modified cutter 28 completes tapping of the hole. The tapping and threading tool 24 is then removed.
[0029] During the process of drilling and tapping the hole, there may be some aluminum shavings enter the cylinder. Therefore, the cylinder may be cleaned after the hole is drilled and tapped. For example, a cloth sock is wrapped over a flexible shaft-shaped cleaner tool and secured. The cloth sock is sprayed with the compound like Napa Tack Gasket. The shaft-shaped cleaner tool having the cloth sock is inserted through the drilled and tapped hole to enter the cylinder where the shavings are located. The shaft-shaped cleaner tool is rotated. The shavings stick to the cloth sock when the shaft-shaped cleaner tool is rotated. Then, the shaft-shaped cleaner tool is pulled out from the hole. A clean cloth is used to wipe the shavings from the cloth sock. This procedure is repeated until all the shavings are removed.
[0030] Once the debris is removed from the cylinder, the repairing method thirdly includes installing the steel insert 62 onto the narrow threaded portion 34 of the modified cutter 28 of the tapping and threading tool 24 . The insert 62 is finger tightened into place. A clean solution is used to clean the outside threads of the insert 62 . Once cleaned, a locking compound, for example, Lock Tight 640, can be put on a plurality of threads to the center of the insert 62 . The slip collar 38 on the tapping and threading tool 24 is now slipped in the second position 42 and secured. The tapping and threading tool 24 with the insert 62 on the narrow threaded portion 34 of the modified cutter 28 is inserted through the opening 12 of the stopper 6 into the drilled and tapped spark plug hole. At this time the tapping and threading tool 24 is turned by hand until against the stopper 6 . A rachet tool is inserted onto the opening 36 at the end of the tapping and threading tool 24 and turned until the slip collar 38 is snug only against the horizontal surface 11 of the stopper 6 . This positions the insert 62 . With the locking compound, the insert 62 adheres to the threaded wall of the cylinder head 4 . The tapping and threading tool 24 is then unscrewed and removed by using hand pressure. The stopper 6 is also removed at this time.
[0031] Finally, the repairing method includes inserting the seating tool 44 in the hole. The seating tool 44 is allowed to position itself in the insert 62 . A small hammer is used to tap the end of the seating tool 44 until feeling secure and bottoming out. The narrow distal end 60 of the seating adapter 48 aligns itself in and with the threaded portion 68 of the inner surface 66 of the insert 62 . The central portion 58 of the seating adapter 48 aligns itself in the smooth portion 70 of the inner surface 66 of the insert 62 . When the seating tool 44 is knocked in, the narrow conical portion 56 of the seating adapter 48 forces the outer surface 64 of the insert 62 out into the threaded wall of the cylinder head 4 . This allows a lock of the insert 62 . The wide conical portion 54 of the seating adapter 48 makes a spark plug seat when the seating tool 44 is knocked inward. All these steps are done at the same time as the seating tool 44 is struck. This procedure ensures total and complete alignment when the spark plug is installed. Then the seating tool 44 is removed.
[0032] As shown in FIG. 7, the repaired spark plug hole includes a cylinder head 4 having a through cylindrical opening 72 . The opening 72 has a threaded portion 74 from a near end 76 of the opening 72 . The length of the threaded portion 76 of the opening 72 is less than that of the opening 72 itself. The metal insert 62 threaded in the threaded portion 74 of the opening 72 is cylindrical having a near end 78 and a far end 80 . The length of the threaded outer surface 64 of the insert 62 is at most equaling to that of the threaded portion 74 of the opening 72 . The inner surface 66 of the insert 62 has a threaded portion 68 proximate to the far end 80 of the insert 62 . There is a conical seat 80 in the inner surface 66 at the near end of the insert 62 formed using the tapping and threading tool of FIG. 4 as described above.
[0033] The spark plug hole is now back to standard. Then a new spark plug can be installed. | An inexpensive method for repairing a damaged spark plug hole of a cylinder engine includes drilling the damaged spark plug hole using a drill bit, tapping the drilled spark plug hole, threading a steel insert into the threaded hole and making a spark plug seat. The depth of the drilling, tapping and threading is limited by a stopper. A set of new tools are used to realize the foregoing process. All these procedures can be done while the cylinder having the damaged spark plug hole on the vehicle. The resulting hole is stronger and more durable than the original spark plug hole in the aluminum cylinder head. | 5 |
REFERENCE TO PENDING PRIOR PATENT APPLICATIONS
[0001] This patent application claims benefit of International (PCT) Patent Application No. PCT/IB2015/002005, filed 29 Oct. 2015 by Trans-Duodenal Concepts UG for BYPASS DEVICE FOR THE TRANSPYLORIC CONDUCTING OF GASTRIC CONTENT INTO OR THROUGH THE DUODENUM, AND APPLICATOR FOR PUTTING SAME IN PLACE, which claims benefit of German Patent Application No. DE 10 2014 015 919.1, filed 29 Oct. 2014, which patent applications are hereby incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The invention is directed to a bypass device which can be placed transpylorically for accepting chyme from the stomach and for the bypass-like conduction of the chyme through the pylorus in or through the duodenum of a patient, comprising a tubular, preferably radially collapsible and self-erecting transpyloric conducting element, which penetrates the pylorus, having a central conducting lumen for the chyme, and fixing elements for anchoring the transpyloric conducting element on the pylorus, consisting of an annular gastric anchor element, which is arranged on the gastric side or proximally to the pylorus, for anchoring the transpyloric conducting element proximally to the pylorus, having a gastric balloon segment, which regionally encloses a cavity of annular structure fillable with a medium, and an annular duodenal anchor element, which is located on the intestine side or distally to the pylorus in the duodenum, for anchoring the transpyloric conducting element distally to the pylorus, having a duodenal balloon segment, which regionally encloses a cavity of annular structure fillable with a medium; and an applicator for placing such a bypass device in a patient.
BACKGROUND OF THE INVENTION
[0003] In Germany, approximately 90% of all diabetics, therefore 4.5 million people, are affected by type 2 diabetes, which is usually caused or accompanied by obesity (adiposity). This restricts the quality of life of the affected persons and induces numerous related illnesses. Industrial, emerging, and developing countries are affected in this case in a similar manner. Accordingly, a significant increase of nutrition-related diabetes illnesses is expected worldwide in the coming years.
[0004] Present therapies are predominantly directed to a medicinal regulation of the metabolism, there is no causal therapy in the strict sense. In addition to the medicinal metabolic regulation, in adipose patients suffering from diabetes, various methods for adiposity surgery have become established. In these methods, a differentiation is fundamentally made between restrictive (gastric band, gastric reduction, gastric balloon) and malabsorptive methods (bypass, duodenal switch, biliopancreatic diversion), wherein the greatest and most long-lasting successes are achieved by a combination of both method principles.
[0005] More recent experiences in adiposity surgery have shown that in particular operation methods which produce a bypass to the duodenum, in addition to the weight reduction, have a direct and immediate effect on the diabetic metabolic state, so that these methods are applied with increasing relevance in the treatment of diabetics.
[0006] However, the following facts argue against a large-scale application of operative bypasses of the duodenum:
the severe and irreversible changes of the gastrointestinal tract, which are created by this operation; the fact that the long-term effects on the metabolism, bone stability, and tumor development are inadequately researched; that rare, but very severe and sometimes fatal complications can occur due to the interventions; that the patients require aftercare which is very costly in the long term, with monitoring of metabolic parameters; that substantial treatment costs arise.
[0012] Because of the complications and costs linked to operative methods, endoscopy has set the goal of developing an implant for the treatment of diabetes and obesity, which, on the basis of duodenal bypass surgery, is based on conducting chyme through the duodenum by means of a tubular prosthesis placed in the duodenum.
[0013] The secretions from the pancreas and the gallbladder, which are required for the digestion of food, normally flow to the chyme in the region of the middle duodenum. Clinical studies have been able to show that, by way of an artificially applied transduodenal bypass prosthesis, which accepts the chyme in the stomach and, without mixing with the digestion-active secretions of the duodenum, leads on a direct path into the beginning of the jejunum, the digestion and therefore the resorption of the food components can be reduced, which, in addition to a resulting reduction of the body weight, has direct influence on the blood sugar level and therefore the insulin excretion. The precise mechanism of this phenomenon has not yet been researched, but its effectiveness has been proven.
[0014] The constructive design of such bypass tubular prostheses generally provides a mechanism which anchors the device in the region of the gastric outlet or sphincter (pylorus), and which accepts the food as completely as possible in the stomach or immediately adjoining the stomach. This anchoring part is adjoined by a continuing tubular part, which conducts the chyme accepted on the gastric side through the duodenum the into the beginning jejunum. The chyme is advanced in this case by the propulsive movements (peristalsis) of the duodenum in the tube, largely analogous to the natural transportation.
[0015] A bypass technology applicable by flexible-endoscopic implantation would be distinguished by the following advantages:
minimal invasiveness; convenient reversibility, because it can also be removed again in an endoscopic manner; and cost-effective applicability.
[0019] Various endoscopically placeable duodenal bypass devices with the goal of enteral resorption reduction are presently in testing. The systems are, depending on the structural design, either anchored in a position in the upper duodenum (duodenal bulb) directly adjoining the pylorus distally or they are positioned within the sphincter or extending beyond the pylorus into the stomach.
[0020] Regardless of the respective structural type, the anchoring mechanisms have to ensure, on the one hand, that a substantially liquid-tight terminus of the anchoring head unit of the device toward the duodenal wall or the pylorus is achieved, to prevent, as efficiently as possible, food components from passing the duodenum outside the tubular prosthesis and thus restricting its effectiveness. On the other hand, the forces which act by way of the anchoring mechanism on the respective applied organ walls have to be reduced enough that degenerative changes which could result in the course of time in bleeding or perforation, can be precluded. The balance between efficient anchoring and sealing and also organ-compatible placement is not least a challenge because of the special motility of the anatomical structures in the region of the transition from the stomach to the duodenum. The anchoring and sealing component of the bypass has to follow the contractile dynamics in the most compatible possible manner.
[0021] For approximately two years, an endoscopically placed, transduodenal tubular prosthesis of approximately 60 cm length, which is anchored using a stent-like metal basket in the upper duodenum within the so-called duodenal bulb, has been the focal point of antidiabetic treatment. This anchoring of the basket is performed by spiked extensions, which dig into the mucosa of the bulb and can be the cause of severe intermittent pain in the patient. The technique requires a permanent intake of stomach-acid-inhibiting medications and can cause complications such as bleeding and perforation of the duodenal wall. In particular, the removal of the implant can be risky because of the laterally protruding metal spikes.
[0022] In addition to such stent-based techniques for anchoring the bypass devices which accept the chyme, inter alia, balloon-based and ring-based, transpylorically placed anchor systems are being tested. With these, the pylorus, which marks the anatomical transition from the stomach into the duodenum, is taken between two balloon-like or annular structures in a type of clamping seal. A corresponding transpyloric anchoring by elastically self-erecting, O-ring type elements, which press against the pylorus on the stomach and duodenal sides, is described in U.S. Pat. No. 5,820,584. The two ring elements are integrated into the conducting element and each erect themselves proximally and distally to the sphincter due to the elastic intrinsic tension thereof. The channel-type passage opening of the pylorus is lined by an annular closed membrane unfolded between the rings. A tubular formation for conducting the stomach contents through the duodenum adjoins the ring placed on the duodenal side toward the small intestine. The elastic restoring force of the self-erecting ring components, which is required for the dislocation-secure, transpyloric positioning, and which exerts a permanent small-area force effect on the tissue on both sides of the sphincter, is problematic in the case of such techniques for anchoring. This sustained force action can also result in pressure-related damage or necrosis due to the required long-term application time periods of the transduodenal bypass. In addition, the endoscopic placement of such ring elements is relatively difficult.
[0023] US 2011/0004320 A1 describes by way of example a duodenal bypass device based on two tire-like, transpylorically placed fastening elements, which are connected to one another by stranded holding lines. The ring elements each have a rim-like inner tire, on which an elastically expandable balloon tubular element is seated, which expands primarily radially upon filling and thus acts as an anchoring abutment on the gastric and duodenal sides. In this case, upon filling, the balloon-like preformed abutment elements, which press against the pylorus on both sides, enter the state of a toroidal, elastic expansion, having an approximately circular cross section, wherein the pylorus itself remains substantially unloaded, because the completely unfolded buttress elements guide the forces thereof primarily onto the portions of the stomach or the duodenum adjoining the pylorus. The resulting load of these structures can lead to corresponding degenerative damage, as with the above-described, elastically self-erecting ring elements.
[0024] To achieve optimum tissue-compatible and organ-compatible, permanent placement of a transpylorically-positioned bypass device, an anchor action would be desirable which reduces the radial force development on the structures adjacent to the pylorus and possibly also guides itself in the axial direction onto the pyloric sphincter.
[0025] Furthermore, the transpyloric anchoring should be capable of independently adapting itself as much as possible to functional changes of the sphincter. In the ideal case, the motility of the pylorus should remain unimpaired and/or the pyloric closure and a corresponding deformation of the transpyloric components of the device can take place with the least possible contraction force.
[0026] Furthermore, it should be possible in bypasses of the transpyloric type to make the force which loads the pyloric structures and the structures adjoining the pylorus adjustable from outside the body and/or to adapt it to the individual in the course of time.
[0027] For an advantageously efficient weight-reducing effect of the device, bypass devices which link the (malresorptive) bypass function with other action principles, for example, a (restrictive) reduction in size of the stomach volume, would also be significant.
SUMMARY OF THE INVENTION
[0028] The stated problem is solved for a bypass device of the type in question in that the gastric balloon segment and/or the duodenal balloon segment encloses (enclose) the transpyloric conducting element radially on the outside, is (are) not closed along a circumferential line in the toroidal direction, i.e., has (have) only twofold connectivity, and is (are) connected to the conducting element so that the latter forms a part of the enclosure of the relevant, toroidal cavity, wherein the conducting element is formed or reinforced at least in its region enclosing the gastric and/or duodenal cavity such that it has there a structural stability or self-erecting capability which is at least equal to or greater than that of the relevant balloon segment in the immediate surroundings of the conducting element.
[0029] The present invention therefore describes an endoscopically placeable, transpylorically-positioned bypass device for conducting chyme from the stomach through the duodenum, which is preferably based on very thin-walled, but dimensionally-stable, complexly formed balloon films. The embodiments of the invention described hereafter enable the radial expansion of the transpylorically-anchored balloon segments upon application of filling pressure to be adjusted with good reproducibility to a target amount which is not to be exceeded. Due to the construction-related generation of a rolling movement of the balloon segments, which is oriented in the axial action direction onto the shoulder surfaces of the pyloric sphincter, a particularly advantageous combined radially and axially acting anchoring and sealing action can be achieved.
[0030] Due to the completely or nearly completely embodied preforming of all segments of the balloon sleeves to the dimensions required for the function thereof in situ and also due to the use of less volume-expandable film materials, which are substantially dimensionally-stable upon application of filling pressure, the functionally required geometry and mechanical characteristic of the balloon components integrated in the anchoring device already develop when the internal pressure prevailing in the transition region of stomach and duodenum is slightly exceeded. The balloon bodies formed according to the invention thus do not require a force-intensive elastic expansion of the balloon wall to unfold the function thereof and can thus be placed in a substantially pressure-neutral and therefore gentle manner.
[0031] Upon increase of the filling pressure, due to the particular hardness of the film material used and/or the lesser volume expandability thereof (compliance), the radial expansion of the balloon film remains limited, while the applied force preferably passes transitions into an axially-oriented pressing action of the balloon or buttress segments, which roll against one another axially. Depending on the respective filling pressure, the axial force effect acting on the pylorus can thus be adapted by the user over an optimum broad range.
[0032] The invention furthermore describes particular embodiments of the transpyloric segment of the device, which is placed inside the pylorus channel and connects the gastric and duodenal buttress elements. In this case, maintaining the closing capability of the pylorus as much as possible and at the same time precluding axial twists of the conducting element is paramount. This is enabled in a preferred embodiment of the bypass device by a coaxial double-layered tube film arrangement, which, by way of specifically attached, punctiform or linear connections of the two concentric film layers, driven by the force currently acting on the balloon elements, causes both lumen erection of the conducting pyloric segment and also the axial untwisting thereof.
[0033] To improve the weight-normalizing effect, beyond the duodenal bypass action, the device according to the invention can optionally be equipped in its embodiment such that the balloon segment, which is placed in the stomach and primarily acts as a buttress therein, is formed in a diameter or volume amount which has a space-occupying effect in the pylorus-proximal antrum of the stomach and triggers a feeling of fullness via a moderate, but permanently acting stretching of the wall of the antrum and/or shifts the time of a feeling of fullness forward upon food intake. This restrictive effect can alternatively also be reinforced by an additional, separately fillable, for example, toroidally-formed balloon element, which adjoins the described transpyloric anchor device on the stomach side and is accordingly space-occupying.
[0034] To achieve an advantageously prompt, elastically-acting lumen erection of transpyloric conducting segments, polyurethane (PUR) is preferably used as the base material for producing the corresponding components. The shaft element extending through the pylorus, which in a preferred construction carries a balloon component on the gastric and duodenal sides, can be formed, for example, from a tubular body or also injection molded. Preferably polyurethanes of the degree of hardness range Shore 70A to 90A are used for the balloon-carrying shaft element. The elastic deformation and erection properties of the shaft element can be modified by additional sleeve-type or tubular elements made of, for example, foam, fiber, net, or gel. Such modifications can be required above all in the region of the terminal components of the conducting shaft element, which carry an annular or cylindrical balloon. The modifying structures are either inserted into the lumen of the conducting element or alternatively installed on the outer circumference thereof. The conceptually desired radial folding capability of the part of the conducting element which is placed directly at the pylorus is to be maintained as much as possible in the case of corresponding modifications.
[0035] The wall of the balloon elements integrated in the transpyloric anchoring and sealing head unit of the device also preferably consists of polyurethane. The preferred durometers range from Shore 80A to 95A, on the one hand, and Shore 55D to 70D, on the other hand. Above all, polyurethanes of the hardness Shore 95A and 55D to 65D ensure the stability required for the reliable function, even with ultrathin-walled design in the low micrometer range, even at higher filling pressures. For the permanent placement in the acid milieu of the stomach, higher durometers of aromatic TUR types are preferred. To further improve the acid resistance, the TUR-based balloon sleeves can optionally be provided with an additional outer layer made of PEBAX. The combination of the two materials can be ensured, for example, by a corresponding coextrusion of the raw tube material, which is formed by blow-molding to form the balloon.
[0036] A further advantage of the extremely thin-walled embodiment according to the invention of the anchoring and sealing balloon elements is the low overall size enabled thereby. In spite of the relatively complex structure of the device, the described film-based bypasses can be conveniently applied endoscopically. The device, which is applied to the outer surface of the endoscope shaft and is thus transported through the throat and the esophagus into the stomach of the patient, is carried on the endoscope back in the evacuated state in an optimally slim manner, which does not obstruct the passage.
[0037] The parapyloric portions of the device are preferably provided with x-ray-opaque structures, which enable the confirmation of the transpyloric location in the image converter if needed.
[0038] The fillable elements of the device are filled extracorporeally in the preferred construction via sufficiently long-dimensioned tubular supply lines. The supply lines are deposited in the stomach and can be endoscopically recovered therefrom if needed.
[0039] The transpyloric head unit adjoins the transduodenal conducting tube unit, which represents the actual bypass, toward the duodenum. The duodenal conducting tube unit is attached in a space-saving manner, preferably gathered like folded bellows, on the duodenal end of the transpyloric unit and/or directly adjoins the duodenal balloon or buttress segment, correspondingly arranged in a space-saving manner.
[0040] The bypass device can be fixed on the shaft or released therefrom by the user by way of a preferably separate carrier and coupling mechanism, which is attached to the endoscope or applicator shaft, Such a coupling can be implemented, for example, by an externally fillable, hollow-cylindrical balloon, which acts between the endoscope shaft and the bypass device and is drawn onto the shaft of the endoscope. Pressure is applied thereto for the duration of the insertion and application of the bypass and it thus holds the bypass device securely in position.
[0041] The optional construction according to the invention of the transpyloric head unit from preferably continuously formed balloon sleeves, which in the ideal case comprise both portions of the gastric, the duodenal, and also the central pyloric segment of the head unit, is furthermore advantageous because potentially critical joints can be reduced. The invention describes corresponding embodiments, which consist nearly completely of a single balloon sleeve and which reduce the number of the joints required for providing the various compartments within the head unit to a minimum by corresponding eversion or back-eversion of the balloon ends.
[0042] To generate the optionally described, axially-oriented counter-rolling movement according to the invention of the balloon or buttress components acting on the gastric and duodenal sides, a preferably cylindrically formed balloon element is applied during the mounting to a shaft element which carries the balloon, such that the shaft ends of the balloon are offset on the shaft by a certain amount, for example, 30-60% of the freely unfolded cylindrical length of the balloon, oriented toward one another. The balloon thus fixed on the shaft then rolls into a low-tension middle position upon filling via the two balloon ends, which are offset toward one another or approach one another. The balloon body can be axially deflected from this rest position, wherein an axial force acting opposite to the deflection direction has to be overcome. If the fixing points of a balloon body applied in this manner are positioned close enough to an opening to be closed, the shoulder of the balloon oriented toward the body cavity or opening detaches toward it in the manner of an axially acting rolling movement and holds the corresponding buttress element on the other side of this body cavity or opening under a corresponding tension, which is axially oriented toward the body cavity or opening to be sealed. This effect exists with balloon elements which are counter-rolling, structurally separate from one another and are both attached on one side adjacent to a body cavity or opening and also on both sides of a body cavity or opening and, and are optionally fillable in a separate or communicating manner.
[0043] Furthermore, there is a waisted embodiment of a formed balloon body, which has a central, tapered section between two terminal balloon segments having a sealing action, which is not connected to the balloon-carrying shaft and is placed within the sphincter opening, wherein the terminal balloon segments, in the event of corresponding offset of the balloon ends oriented toward one another on the shaft, are also distinguished by a rolling movement, which is oriented from the lateral toward the central waist and has a clamping and sealing action.
[0044] The present invention furthermore describes a self-erecting mechanism of coaxially applied tube film layers connected to one another by punctiform connections. In this case, a part of the filling medium can be displaced into the free space between the concentric film layers. This section then erects itself in the manner of a self-erecting, air-stabilized tubular body, which is quilted like a mattress. Upon decreasing filling pressure, this part of the device relaxes, and the conducting lumen can contract under the loading force of the closing pylorus to form a minimally space-occupying, non-dilating structure.
[0045] In one particular embodiment, the present invention combines the principle of the axially-oriented counter-rolling movement with the mode of action of the concentric film arrangement, which is self-erecting upon application of pressure.
[0046] Preferably, both the gastric and also the duodenal buttress element comprise such a fillable balloon segment. The central, transpyloric segment can have the described, concentrically arranged film construction and is preferably connected in a freely communicating manner to both buttress balloon segments, or—less preferably—only to the gastric balloon compartment.
[0047] In one particularly advantageous embodiment, all three segments are formed from a single molded blank and subsequently closed by partial or also complete back-eversion and/or inversion of the balloon ends to form a single, communicating space or also, in conjunction with stabilizing tube or ring components, compartmented to form multiple communicating partial spaces. By way of a punctiform or linear or web-like connection of the concentric film layers in the transpyloric segment exposed in the sphincter, this segment achieves its lumen-erecting and/or lumen-untwisting action.
[0048] In addition to the preferred embodiment of the transpyloric segment of the device as a self-erecting, concentric film arrangement, the transpyloric component can also be formed, for example, as a continuous tubular element, which has an elastic effect such that under contraction of the pylorus, it collapses to form a structure of smaller diameter and spontaneously erects into the opening pylorus upon decreasing tonus. The elastic self-erection of the tubular element has to withstand the pressure which acts in the balloon on the tubular element in this case and preclude a constriction of the drainage lumen. To optimize the self-erecting properties, the tube cross section can be provided with a stabilizing annular or coiled corrugation, which, with equal elastic restoring force, enables a reduction of the wall thickness of the element which is advantageous for the placement. In addition to the described corrugation of the tubular element, the tube can also consist, as a combined structure, of a continuous tube shaft, having a material layer, for example, of a netlike, fibrous, or foamed composition, which stabilizes, jackets, or also lines the shaft. The modification of the elastic active components of the individual material layers which is thus possible ensures an ideal adjustability of the closing and opening force, with which the transpyloric tubular body closes upon a contraction of the sphincter or which develops therein in the case of an opening sphincter, respectively.
[0049] At least one balloon segment should not form a completely closed torus, but rather should have at least one free edge extending circumferentially, which is closed in a ring shape and presses against the transpyloric conducting element. By means of this free edge, the relevant balloon segment can be positioned precisely on the conducting lumen and, in interaction with its preforming, its behavior during filling can be precisely influenced.
[0050] The at least one free edge of the balloon segment, which extends circumferentially and is closed in a ring shape, may be connected, in particular glued or welded, to the transpyloric conducting segment to form a seal.
[0051] At least one balloon segment can be everted (multiple times) in the region of at least one free edge which is connected to the transpyloric conducting segment to form a seal, such that it presses flatly with its inner side facing toward the relevant cavity against the transpyloric conducting element.
[0052] At least one balloon segment can be everted inwardly into the relevant balloon segment in the region of each of its two free end edges.
[0053] Preferably, a second, opposing eversion, i.e., in the direction out of the relevant balloon segment, is located between a free end edge and the eversion thereof into the relevant balloon segment.
[0054] Further advantages result in that a balloon segment is preformed such that it has different circumferential lengths in certain annular sections, in particular in that it has a smaller circumferential length in the region of each of its two free end edges than in a region of the balloon jacket located in between, which forms an outwardly everted section of the balloon segment. As a result, the shape of the unfolded balloon segment that is free of external influences may equally be determined and/or influenced as a result of a balloon segment being pre-formed, such that it has different thicknesses in certain annular sections, in particular, in that it has a greater thickness in each of its two free end edges than in a region of the balloon jacket located in between, which forms an outwardly everted section of the balloon segment.
[0055] Because a balloon segment is preformed such that, with the cavity expanded up to its preformed volume, the cross section through this cavity has a greater axial extension than in the radial direction, in relation to the longitudinal axis of the conducting element, a predominant extension of the unfolded balloon segment in the axial direction is predetermined. An optimum capability results therefrom of being able to roll back in the axial direction to provide space for the pylorus, on the one hand, but also to develop a pressing force oriented against this yielding movement, to thus anchor the conducting element. In this case, the sealing force acts in a focused manner on the shoulder surfaces of the pyloric sphincter ring, where a form fit can then be formed, which counteracts a slipping of the conducting element out of the region of the pylorus.
[0056] Accordingly, the force exposure on the structures of the stomach and the duodenum adjoining the pylorus, even at a higher filling pressure of the balloon segments, is reduced to a permanently organ-compatible amount, in particular to a pressure below the filling pressure of the balloon segments.
[0057] The fill level of the balloon segments and/or the filling level thereof, and therefore the axial sealing force acting on the pylorus should be able to be adjusted extracorporeally, optionally with the aid of a pump and/or a manometer.
[0058] As the filling pressure within one or both balloon segments, the invention provides values of 10 mbar to 100 mbar above the atmospheric pressure, in particular, values of 20 mbar to 80 mbar above the atmospheric pressure, in particular, values of 30 mbar to 60 mbar above the atmospheric pressure.
[0059] The invention may be refined in that, within at least one cavity which is regionally delimited by a balloon segment, an additional inner cushion or balloon element is arranged, which is filled or fillable using a different filling medium than that of the receiving cavity itself. Such an inner cushion or balloon element should be peripherally fixed, in particular welded or glued, to form a seal on the transpyloric conducting element, so that it cannot slip.
[0060] At least one inner cushion or balloon element preferably encloses a smaller volume and/or is preformed having a smaller volume than the external balloon segment which supports the cavity receiving it, so that within the outer balloon segment, in addition to the inner cushion or balloon element, a (remaining) cavity also remains, which is preferably fillable with a compressible medium such as air or gas and can then cling in an optimum and preferably sealing manner to the inner side of the relevant organ.
[0061] It has proven to be effective for at least one inner balloon element to be fillable with a liquid medium. A maximum structural stability thus results—in conjunction with a comparatively hard balloon material, for example, polyurethane—whereby undesired detachment of such an anchoring part from the provided anchoring point is virtually precluded. The outer balloon should therefore be filled with air, i.e., a compressible medium, in order to be able to cling optimally to the inner side of the relevant organ and be able to seal it.
[0062] The conducting element experiences a reinforcement in the region of at least one inner balloon element by a sleeve or a preferably annular or spiral spring element. Such an element is capable, without constricting the conducting lumen, of also being able to support completely unfolded anchoring elements, without collapsing.
[0063] The invention recommends that at least one inner balloon element be toroidal-shaped, i.e., with threefold connectivity. Its structural stability is thus increased and an effect which constricts the conducting lumen upon filling the relevant, inner balloon element is minimized.
[0064] At least one inner balloon element, in the region of one or both of its annular circumferential end edges, should press flatly against the transpyloric conducting element and be fixed thereon, for example, glued, with its inner side, which faces toward its filling medium.
[0065] The invention may be refined in that the gastric balloon segment and the duodenal balloon segment are united to form a single balloon, which is preformed in a dumbbell shape, having an approximately central, circumferential extending constriction to accommodate the pylorus sphincter. Therefore, the shape of the pylorus can be optimally re-created in the manner of a negative mold.
[0066] The invention is furthermore distinguished by at least one supply line or a filling tube to at least one toroidal cavity, so that one or both balloon segments are fillable after the placement of the transpyloric bypass device, in particular, the transpyloric conducting element and/or the fixing unit. In order for the oral or proximal end of such a supply line or such a filling tube to be insertable into the stomach and/or droppable therein, at least one supply line to at least one toroidal cavity, in particular, a filling tube, should be provided with a check valve.
[0067] Because the transpyloric conducting element connects the gastric anchor element to the duodenal anchor element, the arrangement experiences an optimum structural stability in any case in the axial direction.
[0068] The wall thickness of the transpyloric conducting segment should be thicker in any case in its head region, which penetrates the pylorus, than the wall thickness of the gastric balloon segment on its periphery, which bulges radially outward and/or than the wall thickness of the duodenal balloon segment on its periphery, which bulges radially outward, for example, at least twice as thick, preferably at least 5 times as thick, in particular at least 10 times as thick. The mutual location of the two anchor elements is thus predetermined.
[0069] The transpyloric conducting element can be preformed in a tube shape, so that it does not collapse upon filling of one or both balloon segments under the filling pressure therein, but rather erects itself into an approximately cylindrical shape in a state free of external forces.
[0070] Because the transpyloric conducting element is wavy or corrugated, its self-erecting properties are improved, and in addition it can be collapsed or gathered like a folded bellows.
[0071] The transpyloric conducting element can be stiffened in the region of one or both balloon segments by a sleeve or an annular or spiral spring, so that it does not collapse under the filling pressure therein upon filling of one or both balloon segments.
[0072] Furthermore, the possibility exists that the transpyloric conducting element has a coaxial double-layered tube film arrangement, or that it consists of such a coaxial double-layered tube film arrangement.
[0073] The two tube film layers of such a transpyloric conducting element constructed as double-layered should be at least regionally connected to one another, preferably by punctiform, linear, or planar connections, in particular in the section which penetrates the pylorus. The outer layer is pressed outward by a (low) inner overpressure between these two tube layers and in the process carries along the inner tube layer as a result of the connections. The conducting lumen is therefore by its nature open, but can be easily compressed if needed by the pylorus due to the low filling pressure.
[0074] Production-related advantages can result by forming the tube film layers of the transpyloric conducting elements together with one or more balloon segments from a common film tube.
[0075] At least one x-ray-opaque marking, which is placed on the transpyloric conducting element and/or in or on one or both fixing elements proximal and/or distal to the pylorus, is used to determine the correct transpyloric location of the transpyloric bypass device, in particular the transpyloric conducting element and/or the fixing element or elements.
[0076] An applicator is used to place a transduodenal bypass device according to the invention in the region of the pylorus of a patient, which is distinguished by an applicator element in the form of an endoscope or catheter, having an elongated shaft, on the outer surface of which the bypass device can be placed and/or plugged such that the applicator shaft entirely or partially penetrates the central conducting lumen of the bypass device.
[0077] The invention recommends that in this case the bypass device be held reversibly, i.e., detachably, on the applicator shaft.
[0078] The bypass device is preferably held on the applicator shaft by clamping, wherein an annular, extracorporeally fillable, gap-bridging balloon is provided for the clamping fixation of the bypass device on the outer side of the applicator shaft, which, when the bypass device is placed or plugged on, is located in the annular gap between the applicator shaft, on the one hand, and the transpyloric conducting element, on the other hand, in particular, radially inside the fixing unit and/or radially inside the front end of the transduodenal conducting tube.
[0079] A valve, preferably a check valve to be opened manually, enables the aeration and deaeration of the balloon, which clamps the bypass device on the applicator shaft.
[0080] An applicator is furthermore preferably distinguished by flushing openings, preferably distal to the gap-bridging balloon, through which liquid can be flushed extracorporeally into the duodenum via a flushing line extending along the applicator, to unfold the distal section of the conducting element.
[0081] A bypass device according to the invention may be placed in the pylorus of a patient using an applicator as follows:
a) placing or plugging the bypass device on the applicator shaft, so that it penetrates the central conducting lumen; b) fixing the bypass device by filling a gap-bridging balloon between applicator shaft and inner side of the conducting lumen; c) inserting the bypass device by means of the applicator into the stomach of a patient; d) partially or completely filling the gastric balloon segment of the gastric anchor element; e) inserting the distal section of the conducting element through the pylorus until the entirely or partially filled gastric balloon segment rests proximal to the pylorus and noticeably resists a further advance of the bypass device; f) filling the duodenal balloon segment to anchor the duodenal anchor element distal to the pylorus; g) releasing the distal section of the conducting element; h) detaching the bypass device by deaerating the gap-bridging balloon between applicator shaft and inner side of the conducting lumen.
[0090] In the process, liquid can be flushed extracorporeally into the duodenum between steps g) and h) via flushing openings arranged on the applicator shaft distal to the gap-bridging balloon, to unfold the distal section of the conducting element.
[0091] Finally, it corresponds to the teaching of the invention that after step h), the supply lines to the balloon segments are dropped into the stomach and remain therein until the bypass device is removed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0092] Further features, properties, advantages, and effects based on the invention result from the following description of preferred embodiments of the invention and on the basis of the drawing. In the figures:
[0093] FIG. 1 shows an embodiment having a back-rolling balloon component attached on one side and opposing, non-back-rolling balloon element;
[0094] FIG. 1 a shows the configuration of the back-rolling balloon element shown in FIG. 1 of the head unit which fixes the device, in the freely unfolded state outside the body;
[0095] FIG. 1 b shows the above-described head unit in situ and illustrates the axially-oriented back rolling or counter-rolling movement of the balloon component toward the pylorus;
[0096] FIG. 1 c shows an corrugated tube-like corrugated embodiment of the transpyloric conducting element placed in the pylorus;
[0097] FIG. 2 shows an embodiment having balloon components arranged on both sides, which roll axially toward the pylorus;
[0098] FIG. 2 a shows an embodiment corresponding to FIG. 2 having back-rolling balloon components on both sides, wherein the gastric balloon is enlarged in a space-occupying manner;
[0099] FIG. 3 shows an embodiment of the invention having back-rolling balloon components arranged on both sides, in conjunction with a concentric double-layered, film-based transpyloric conducting element;
[0100] FIG. 3 a shows the web-like connection of the concentric film layers in the region of the transpyloric conduction;
[0101] FIG. 3 b shows an embodiment as in FIG. 3 , wherein the lumen-stabilizing sleeve elements are arranged in the inner lumen of the conducting channel, however;
[0102] FIG. 3 c shows an embodiment in FIG. 3 , wherein the lumen-stabilizing sleeve elements are arranged in the interior of an everted balloon element;
[0103] FIG. 4 shows an embodiment having a continuously formed balloon body tapered in a dumbbell shape in the region of the transpyloric component;
[0104] FIG. 5 shows an embodiment having back-rolling balloon components attached on both sides, transduodenal extension tube, and intra-gastric space-occupying balloon element;
[0105] FIGS. 6 a, b show embodiments having a balloon-in-balloon configuration and separated filling in each case using compressible and non-compressible media;
[0106] FIGS. 7 a, b show preferred embodiments having a continuous, dumbbell-shaped, transpyloric sealing balloon and a duodenal additional fixing balloon which is partially or completely enclosed by the sealing balloon;
[0107] FIGS. 8 a, b show embodiments based on FIGS. 7 a and 7 b , wherein the additional fixing element is arranged on both sides of the pylorus;
[0108] FIG. 9 a shows a simple variant of a transport, and/or fixing or dropping device, for the application of the device to the endoscope back;
[0109] FIG. 9 b shows a variant of a unit corresponding to FIG. 9 a having a proximal stop function on the basis of a forming balloon shoulder.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0110] FIG. 1 schematically shows a bypass device 1 according to the invention and describes by way of example the required components and structural features for generating a rolling movement D, which is oriented toward the pylorus P, of a fillable balloon element.
[0111] The fixing unit 2 is shown, which is placed beyond the pylorus (transpylorically), of the bypass device, which receives the chyme from the stomach M and conducts it through the pylorus P into the duodenum Z. The unit which fixes the bypass in its transpyloric position has in the center a conducting element 4 , which carries an anchoring buttress element 5 on its gastric end 4 a and is equipped on its duodenal end 4 b with a duodenal balloon element 6 , which rolls toward the buttress element in the filled state, is formed in a specific manner, and is fixed on the conducting element. A tube element 7 , which conducts the chyme through the duodenum, adjoins the duodenal end 4 b of the conducting element.
[0112] FIG. 1 a shows the transpyloric fixing unit 2 described in FIG. 1 in the filled state outside the body. The counter-rolling duodenal balloon element 6 is shown here in a preferably cylindrical shape, wherein the balloon material used has a composition such that upon filling in a pressure range from approximately 20 to approximately 100 mbar, from the preformed state, it passes through a radial expansion of the cylindrical diameter of not greater than 10%, and particularly preferably not greater than 5%. The formed cylindrical diameter of the duodenal balloon element 6 is preferably to be dimensioned so that it does not dilate the wall of the duodenum adjoining the pylorus, and/or only puts it under moderate expansion or tension, which is limited by the described expansion properties of the balloon. The filling pressure resulting in the case of an expansion of the duodenal wall in the balloon 6 should not exceed 50 mbar.
[0113] The length of the cylindrical contact surface A should preferably be approximately 1 to 4 cm and particularly preferably 2 to 3 cm. The distance B between the balloon ends 6 a and 6 b is preferably to be 20 to 60% and particularly preferably 20 to 40% of the length of the contact surface A. The terminal edges 6 x and 6 y of the balloon ends oriented toward the balloon interior are decisive for the resulting axial rolling travel of the balloon mounted on the conducting element 4 . The distance B is accordingly defined as the distance between the terminal edges 6 x and 6 y.
[0114] The fixing of the balloon on the conducting element 4 is preferably to be performed such that the terminal edge 6 x is spaced apart by the absolute value of the section C from the pyloric shoulder 5 z of the gastric buttress element 5 , wherein C is preferably not to be greater than the absolute value which results from A/2−B/2+5 mm. This absolute value represents a state of the filled balloon 6 , in which the balloon is positioned in the central neutral state via the terminal edges 6 x and 6 y and the resulting gap between the pyloric shoulder 6 z of the duodenal balloon element 6 and the gastric shoulder 5 z of the gastric buttress element has a width of 5 mm, which approximately corresponds to the anatomical width of the pyloric sphincter. In a particularly preferred embodiment, the section C has an absolute value which is less than A/2−B/2+5 mm, can extend up to mm, or also has an absolute value which is less than A/2−B/2.
[0115] FIG. 1 b schematically shows how the duodenal shoulder 6 z of the balloon 6 presses in axially-oriented counter-rolling (arrow D) against the duodenal shoulder surface of the pylorus P. The force acting in total from the duodenal side Z and from the gastric side M on the pylorus can be adjusted by the user by way of the respective filling pressure in the balloon element 6 and adapted as needed in the individual in the course of the application. In contrast to known duodenal bypass devices, the contact pressing mechanism, which is ensured by the axially elastic rolling movement in the direction B toward the pylorus (arrow D) and in the opposite direction E away from the pylorus (arrow E), dynamically follows the respective functional state of the sphincter. Functional variations of the width of the sphincter and/or the length of the pylorus channel are thus progressively compensated for and therefore an optimum motility-compatible seal of the fixing unit in the pylorus is enabled.
[0116] In the devices described in FIGS. 1 and 1 a to 1 c , the gastric buttress element 5 can be embodied as a soft, elastically deformable, for example, gel-type structure. Alternatively, a balloon body applied in a conventional manner, i.e., without inverted fixation of the balloon ends and without corresponding counter-rolling effect, can also be used as a gastric buttress element.
[0117] The conducting element 4 can be embodied as a relatively rigid, tubular element, but preferably has the capability of elastic radial unfolding and self-erection. The lumen of the conducting element which respectively results in the sphincter is preferably to follow the physiological sphincter closure with the least possible counteracting elastic resistance. At maximum sphincter tonus, the conducting element is intended to deform to a nearly leak-tight closed residual lumen, following the complete contraction travel of the sphincter.
[0118] The described elastically acting radially folding/eversion of the conducting element passing the sphincter is preferably ensured by a tube material having primary elastic properties, for example, polyurethane (PUR). For example, PUR types of the variety Elastollan 1180A and 1185A, from BASF, have a corresponding elasticity when they are formed into a tube body having a diameter of approximately 20 mm and a tube wall thickness of approximately 200 μm.
[0119] The elastic folding capability or elastically acting erection of the tube body can be improved in its effectiveness by a corrugated tube-like profile of the conducting element. Such a profile additionally enables a reduction of the tube wall thickness. Thus, for example, as shown in FIG. 1 c , a conducting element 4 as a continuous tube body can be provided with an annular or spiral corrugated profile 4 k or also 4 kk , wherein the tube body preferably consists of Elastollan of the variety 1180A, has an inner diameter of approximately 20 mm, a wall thickness of approximately 150 to 200 μm, the corrugation has an amplitude of 1 to 2 mm (preferably 1.5 mm), and a peak-to-peak distance of 1 to 2.5 mm (preferably 1.5 to 2 mm). For further modification of its elastic properties, the corrugated profile can additionally be coated in individual segments with an additional, for example, gel-type material layer, which modifies the folding mechanism.
[0120] The structural design of the terminal segments 4 a and 4 b of the conducting element, which accept balloon or buttress bodies in a supporting manner on the outer side thereof, is of particular significance for the function of the device. The segments are preferably designed such that they elastically unfold upon a certain force action and accordingly elastically erect themselves upon decreasing force. In principle, upon the development of an elastically self-erecting effect of the terminal segments 4 a and 4 b , the same design elements which modify the deformation and erection properties, can be used as described above in the construction of the transpyloric segment.
[0121] Because the forces acting radially on the terminal segments 4 a and 4 b are generally greater than the forces acting on the transpyloric segment, the elastic, lumen-erecting effect thereof should accordingly be strengthened, for example, by a particularly tight corrugation 4 kk (peak-to-peak distance of less than 1.5 mm, for example) or by annular elements 9 which reinforce the conducting element. The elastic action of the terminal segments should be dimensioned such that they withstand an externally loading filling pressure of 20 to 100 mbar, preferably 20 to 60 mbar, without collapse of the lumen. A rigid-walled, non-collapsible embodiment of the segments 4 a and 4 b is conceivable within the scope of the invention, but is disadvantageous for the function.
[0122] FIGS. 2 and 2 a show the device according to the invention with two terminal balloon elements, which are arranged on the conducting element 4 and are each capable of back-rolling or counter-rolling, wherein the formation geometry, the balloon materials, and the specifically inverted mounting of the balloons on the conducting element correspond to the guidelines of the above figures in the case of both balloon elements. In the preferred embodiment, the two balloons positioned opposite to one another are connected by a communicated filling line, identical pressures thus result in both compartments upon the filling of the device.
[0123] The preferably cylindrical balloon bodies 6 and 8 , which are each formed with steep shoulders, are to be placed in this case on the conducting element 4 such that the respective shoulder surfaces 6 z and 8 z , upon free filling of the balloons, outside the body, in the respective neutral position thereof or without deflection from the neutral position thereof, face one another at a free distance of not greater than 5 mm, i.e., the assumed width of the pylorus. In this case, the distance J between the terminus edges 6 x and 8 x , which is decisive for the mounting of the balloon bodies, corresponds to the total of (A/2−B/2)+(G/2−H/2)+5 mm. In the filled state of the balloon bodies 6 and 8 , the shoulder surfaces 6 z and 8 z then load the pylorus in situ nearly without contact pressure. In the preferred embodiment variant of the device, the mounting-relevant distance J is less than the total of (A/2−B/2)+(G/2−H/2)+5 mm, however, and particularly preferably less than the total of (A/2−B/2)+(G/2−H/2). The “rolling paths” resulting upon filling of the balloon body from the counteracting forces correspond to the distances C<(A/2−B/2) and F<(G/2−H/2). Upon free filling of the balloon bodies, contact of the shoulder surfaces 6 z and 8 z occurs in this case, even before the neutral location of the balloon bodies is reached, the shoulder surfaces then press against one another, depending on the respective filling pressure. In the optimum case, the mounting-relevant distance J corresponds to the total of (A/2−B/2) and (G/2−H/2)−5 to −10 mm. With such a shortening of the distance J, independently of the respective contraction state of the pylorus, an elastic deflection of the balloon bodies results on both sides in the direction E, as well as a correspondingly acting, contact-pressure rolling movement D of the shoulder surfaces. If functional changes of the width of the pyloric sphincter occur, they can be compensated for by the described elasticity and counter-rolling, with substantially maintained anchoring and sealing-action tension above the pylorus.
[0124] The radial diameter of the gastric balloon body 8 can preferably be enlarged such that it fills the region of the gastric antrum, which adjoins the pylorus on the gastric side, in a space-occupying manner, and/or puts the wall thereof under a moderate tension, thereby conveying to the patient a feeling of fullness. The side of the balloon body 8 facing toward the stomach is preferably embodied as a funnel-shaped orifice T. The funnel shape of the “mouthpiece” accepting the chyme can be stabilized in its shape and action by a self-erecting, stent-like framework, which is installed in the mouthpiece region.
[0125] FIG. 3 shows an embodiment of the bypass device, in which the transpyloric section of the conducting element 14 consists of a concentric double-layered arrangement of tube films 10 and 11 , which are fixedly connected to one another by, for example, axially longitudinally-extending welding lines 12 or also by uniformly distributed punctiform spot welds. For this purpose, see the sectional plane V through the conducting element 14 , which is shown in FIG. 3 a . The concentric tube films of the conducting element thus form a cylindrical, fillable hollow tube 14 . Upon filling of or application of pressure to the hollow tube, which is “quilted” like an air mattress in the described manner, the quasi-air-stabilized tubular body erects itself radially in circular form. In addition to the radial erection, axial untwisting over the longitudinal axis additionally occurs. The hollow tube 14 is connected to one or preferably to both balloon segments 6 and 8 in a volume-communicating manner and is preferably filled via a shared filling device. It is advantageous for the particular tissue or organ compatibility that the lumen-erecting effect in the transpyloric segment of the device can be overcome relatively easily by the pyloric sphincter, i.e., the sphincter can move relatively freely. In spite of a continuous axial contact pressure of the balloon segments 6 and 8 against the shoulder surfaces of the pylorus, it is hardly impaired in its capability to contract. If a contraction of the gastric antrum occurs in the scope of reflexive gastric emptying, it is absorbed by the gastric balloon element and causes a corresponding pressure increase for the duration of the pressure decrease in the compartments connected thereto. The transient pressure increase in turn results in an intensification of the axial counter-rolling of the balloon segments, whereby the tubular hose 14 connecting the two segments is tightened over its longitudinal axis and therefore the opening and untwisting of the lumen is assisted.
[0126] The concentric tube films 10 and 11 preferably consists of PUR, for example, in the hardness range of Shore 80A to 60D, preferably in the range of 90A to 55D. The wall thickness of the films should be approximately 15 to 50 μm, preferably 20 to 30 μm. For example, PUR of the family Pellethane 2363 from Lubrizol Inc. can be used as the material type.
[0127] FIG. 3 b shows a further preferred embodiment of the device type having a pneumatically self-erecting, coaxially constructed tubular hose. All compartment-forming components of the device, i.e., both the two balloon segments 6 and 8 and also the interposed conducting segment, consist here of a single balloon film, which is a continuously formed body that is subsequently everted. It is already provided during the production with all functionally and structurally required formations and molded to its complete operating dimensions. The end 15 a of the formed balloon film is everted by the opposing balloon body end 15 b such that the various balloon segments are represented in configuration with the elements of the conducting element in the manner shown. The central openings of the terminal balloon segments 6 and 8 are each stabilized by elastically erecting sleeve elements 9 , which are inserted into the conducting lumen 16 of the head unit. The sleeve elements are used to accept and fix the terminal balloon segments, wherein preferably the instructions described in FIGS. 1 and 2 apply, and therefore an axial rolling movement of the terminal balloon segments, which is oriented toward the pylorus, is ensured. The two film layers 10 and 11 extend completely from the inverted balloon body in this embodiment. The end 15 a of the formed balloon body can additionally be lengthened in that the transduodenal bypass tube 7 protrudes therefrom without a required joint.
[0128] FIG. 3 c shows a corresponding embodiment, in which the lumen-stabilizing sleeve elements 9 are not arranged in the conducting lumen 16 , but rather are installed in the interior of the everted balloon body.
[0129] FIG. 4 shows a further embodiment of the device, in which all segments of the head unit extend from a completely formed, completely everted, dumbbell-shaped balloon body HB, wherein the terminal balloon segments HBa and HBb are applied with the balloon ends 18 a and 18 b to the supporting sleeve elements 9 or the conducting element 4 . The balloon body HB has no further connection to the balloon-supporting conducting element beyond the balloon ends 18 a and 18 b . The central section of the balloon body is provided during the molding with a constriction 19 to accept the pyloric sphincter. The distance X (distance between the shoulder faces of the constriction) is not to exceed (Y−Z)/2. The opposing shoulder faces of the balloon segments HBa and HBb move toward one another during the filling of the balloon in the illustrated embodiment and cling radially and axially to form a seal to the sphincter seated in the constriction. With increasing filling pressure of the balloon HB, the intensity of the pressing and sealing action oriented toward the pylorus increases accordingly.
[0130] The conducting element 4 consists in the present embodiment of a continuously formed tube element, which forms both the terminal elements 9 for accepting the ends of the balloon body and also the interposed element 9 a , which is exposed to the sphincter. The above-described deformability of the element 9 a during the sphincter contraction and the spontaneous elastic direction after deformation is taken into consideration in this embodiment of the device.
[0131] FIG. 5 shows the structure of a device according to the invention according to FIG. 3 a in an overview, consisting of the following functional units: transpyloric fixing device 2 (consisting of: gastric 8 and duodenal 6 balloon elements with supporting sleeve elements 9 , conducting element 4 ), and transduodenal bypass element 7 .
[0132] The duodenal bypass element 7 preferably has a wall thickness of 10 to 80 μm, preferably 15 to 30 μm, preferably consists of the same material as the functional units of the fixing device to which medium is applied, and is preferably provided with a lumen-erecting, annular or spiral corrugated profile 18 . In addition to the radial erection of the lumen, the corrugation is to assist the spontaneous axial untwisting of the tube. The length of the tube is preferably dimensioned such that the aboral end extends up into the terminal duodenum or also into the beginning jejunum. To modify the bypass effect, the element 7 can also be provided with openings 20 , which enable the partial passage of food into higher regions of the duodenum.
[0133] The dimensioning of the transpyloric fixing device is preferably implemented as follows: duodenal balloon element 6 (cylindrical diameter 25 to 35 mm; cylindrical length 15 to 50 mm, preferably 20 to 30 mm), gastric balloon segment 8 (cylindrical diameter 50 to 80 mm, cylindrical length 30 to 100 mm, preferably 40 to 60 mm), transpyloric segment 4 (diameter 15 to 30 mm, preferably 20 to 25 mm; length 5 to 15 mm, preferably 8 to 12 mm).
[0134] The compartments of the device which are fillable or to which pressure can be applied are preferably connected to one another in a communicating manner. The filling is performed, for example, by a filling tube 22 , which opens into the region of the gastric balloon segment and which is designed in its length so that it slides out orally and can be filled and/or its filling can be readjusted via its terminal closure 23 outside the body.
[0135] FIGS. 6 a and 6 b describe further embodiments of the above-described construction types, in which, in particular to improve the transpyloric anchoring, an additional anchor balloon element 24 is arranged inside a balloon element or a balloon-like expanded segment, for example, 6, 8, or also HB. This balloon element is filled by a separate supply line. For this purpose, a medium can be used which qualitatively differs from the filling medium of the region surrounding it. The anchor balloon element is completely enclosed by the surrounding balloon in a preferred embodiment. The anchor balloon element 24 can optionally be used on both sides of the pylorus. It preferably consists of material which has the characteristics of a soft film, but does not substantially exceed a predetermined shape and/or dimension upon filling and therefore precludes uncontrolled elastic expansion. If the duodenal anchoring of the device is paramount as the functional purpose, a discoid form is preferably selected. If counter-rolling oriented toward the pylorus is additionally desired, a cylindrical structural form can be used, wherein the mounting guidelines described according to the invention, which generate the counter-rolling, are applied. The element 24 is preferably filled with a non-compressible medium, for example, water or oil, while the surrounding balloon element preferably contains a gaseous medium.
[0136] Alternatively to a complete housing of the balloon 24 in a surrounding balloon, the balloon 24 can also be enclosed only in portions, as shown in FIG. 6 b , by the surrounding balloon. The contact surface 25 between the two balloon envelopes can be fixedly connected or also unconnected. In a less preferred combination of a balloon element 24 having a primarily anchoring effect with a balloon element 6 , 8 , or HB having a primarily sealing effect, a sequential arrangement of the balloon elements on the shaft element is also conceivable.
[0137] FIGS. 7 a and 7 b show a preferred embodiment of the device based on the construction types described in FIG. 4 and FIG. 6 , in which the conducting element 4 carries a dumbbell-shaped balloon HB, which is mounted on the conducting element thus resulting in the counter-rolling of the terminal balloon segments HBa and HBb, which is oriented toward the pylorus P, and which is described in FIG. 4 . The additional balloon element 24 is only installed on the duodenal side in the presented embodiment and has a discoid shape. The contour of the balloon 24 preferably corresponds to the contour of the duodenal balloon segment HBb enveloping the balloon. The balloon HBb should exceed the diameter dimensions of the inner balloon 24 , while its axial length corresponds to that of the balloon 24 in a preferred embodiment. The balloon 24 is placed directly behind the pylorus in the duodenal bulb. The counter-rolling of the gastric balloon segment HBa toward the pylorus is achieved, similarly to the construction described in FIG. 4 , by an inversion of the balloon end of the balloon segment HBa. During the transpyloric application of the described embodiment, initially the element 24 is filled with liquid and the device is thus secured in its position on the duodenal side. Subsequently, an air filling is applied to the surrounding balloon, whereby it both clings to the exposed mucosa to form a radial seal and also presses axially against the shoulder faces of the pylorus. The surrounding balloon thus assumes, in addition to the effect as a gastric buttress or as a space-occupying body in the gastric antrum, a predominantly sealing function. Its wall thickness is preferably in the range of 10 to 30 μm, less preferably in the range of 30 to 100 μm. The material hardness should be in the range of Shore 80A to 75D, but preferably 85A to 65D. The special combination of thin walls and material hardness of the surrounding dumbbell shape balloon HB enables it to absorb forces prevailing on the gastric side over a large area and to use them for efficient sealing from stomach contents in the region of the pyloric passage and in the duodenal section of the balloon body. If a contraction of the gastric antrum occurs, the contraction force is absorbed on the gastric side and filling volume, with corresponding increase of the filling pressure, is displaced into the corresponding balloon portions. The described material hardness limits the elongation of the balloon envelope in this case and therefore prevents the partial emptying of one balloon portion into an adjoining balloon portion. The particularly thin-walled nature of the balloon envelope HB enables all segments of the balloon body to be dimensioned residually, which corresponds to a formation of the respective segments beyond the anatomical dimensions which are required or to be assumed. The residually formed balloon body then presses against the mucosal surfaces as the balloon envelope unfolds, wherein a sealing closure is nonetheless ensured. With corresponding volume displacement from the gastric portion into the pyloric and duodenal portion, enabled by the residual excess, a force-absorbing elastic expansion of the envelope can thus be avoided, and the respective force acting on the gastric side can be used in its entirety for the pyloric and duodenal seal. In the design of the conducting element 4 and/or the sleeve elements 9 , the elastic self-erection action thereof has to be designed so that in the event of a transient, contraction-related pressure increase within the balloon HB, a collapse of the conducting lumen 16 can be avoided.
[0138] FIG. 7 b shows a similar embodiment, in which the counter-rolling of the gastric balloon segment HBa is nearly completely or completely omitted and only a radially acting seal of the enclosing balloon envelope acts in relation to the pylorus. The inversion of the gastric shaft ends of the balloon envelope HB described in FIG. 7 a is not applied here.
[0139] FIG. 8 shows an embodiment variant based on FIG. 7 b , in which an anchoring balloon element 24 is placed not only on the duodenal side, but also on the gastric side. The gastric element 24 a also has a discoid shape in the preferred embodiment and can be adapted in radial dimensions to the space conditions of the gastric antrum. Both elements 24 and 24 a can be fillable separately or alternatively a medium can be applied thereto via a shared supply line. Furthermore, both elements can be connected to one another by a dumbbell-shaped constriction 24 b , which is placed in the pyloric passage. A polyurethane of low compliance is preferably also used for the embodiment of the elements 24 and 24 a , to avoid volume shifting into communicating compartments upon loading of a balloon compartment and resulting in an undesired elastic elongation of the balloon envelope. The illustrated variant having flanking of the pylorus on both sides with an anchoring balloon element 24 enables an additional securing function, if the balloon envelope HB housing the balloon elements 24 is damaged and loses its filling. The transpyloric placement of the device remains ensured due to the bilateral arrangement of the elements 24 .
[0140] FIG. 9 shows an exemplary embodiment of a dropping mechanism 26 , which is required for endoscopic application and is embodied as a cylindrical coupling balloon 27 and is drawn onto the shaft 28 of an endoscope. Positioned on the distal end of the endoscope, it presses against the channel wall of the conducting segment 4 of the bypass head unit upon filling and thus establishes the coupling between bypass and endoscope. If the filling is removed from the balloon 27 , the coupling disengages and the endoscope shaft can be retracted from the channel of the head unit or also advanced in the duodenal direction. The balloon is filled from outside the body through a supply line 29 .
[0141] To ensure secure positioning of the bypass on the dropping mechanism, the coupling balloon 27 can be provided with a proximal, shoulder-type formation 30 , which serves as a mechanically active stop. A corresponding stop function can also be integrated, independently of a continuous cylindrically-embodied coupling balloon, as a separately unfolding buttress balloon in the proximal end of the coupling unit. A corresponding formation or a corresponding separate buttress balloon can additionally also be formed or arranged distal to the bypass. The coupling balloon 27 therefore assumes a dumbbell shape, which accepts the bypass device in the tapered region in a supporting manner. The envelope of the coupling balloon is preferably formed from a PUR-based material of low compliance, and a liquid medium is preferably applied thereto.
[0142] The endoscopic placement of a bypass device according to FIG. 7 a or 7 b is described hereafter by way of example.
[0143] If the bypass device seated on the endoscope tip has reached the stomach interior, firstly the outer dumbbell-shaped balloon HB is filled, preferably with 60 to 80% of its free unfolded volume. The balloon HB, which is thus filled with air in a tension-free manner, is now inserted using the endoscope into the pylorus until the pyloric shoulder of the gastric balloon segment HBa stops on the pylorus and prevents a further endoscopic advance of the bypass. The resistance resulting upon the stop of the balloon shoulder in the gastric outlet region is perceived by the user and confirms the correct transpyloric placement of the device. The internal anchor balloon 24 is then filled with a liquid medium. The outer balloon HB is subsequently filled up to its final operating dimensions.
[0144] If the head unit of the bypass device is thus secured in its transpyloric position, the bypass is released from the applicator or endoscope shaft by emptying the coupling balloon 27 and the applicator or endoscope tip is inserted further into the duodenum. In this case, the duodenal conducting portion 7 of the bypass device can be grasped using a corresponding instrument on the applicator or endoscope tip and transported into the duodenum. The device provides a suitable extension on the lower free end of the transduodenal tube 7 for this purpose. If the respective possible duodenal insertion depth of the applicator or endoscope shaft is reached, the free lower tube end of the bypass can be conveyed further into the duodenum by advancing the gripping instrument and finally dropped therein.
[0145] If the transduodenal conducting portion 7 of the device is thus partially or completely unfolded, an air insufflation into the tube or also flushing can take place for further lumen-opening unfolding of the portion 7 . This is preferably performed in such a way that the coupling balloon 27 seated on the applicator or endoscope shaft is placed in the lumen of the head unit and is blocked to form a seal therein for the duration of the insufflation or flushing, respectively. Therefore, the lumen-erecting and lumen-aligning filling of the duodenal tube portion 7 can also take place without any reflux into the stomach.
LIST OF REFERENCE SIGNS
[0000]
1 bypass device
2 fixing unit
4 conducting element
4 a gastric end
4 b duodenal end
4 kk corrugation
5 buttress element
5 z gastric shoulder
6 duodenal balloon element
6 x terminus edge
6 y terminus edge
6 z pyloric shoulder
7 tube element
8 gastric balloon element
8 z shoulder
9 element, sleeve element
10 tube film
11 tube film
11 weld line
12 conducting element
15 a end
15 b end
16 lumen
18 corrugated profile
18 a balloon end
18 b balloon end
19 constriction
20 opening
22 filling tube
23 terminal closure
24 anchor balloon element
24 a gastric element
24 b constriction
25 contact surface
26 dropping mechanism
27 coupling balloon
28 shaft
29 supply line
A cylindrical contact surface
B distance
C distance
D rolling movement, arrow
E opposite direction, arrow
HB dumbbell-shaped balloon body
HBa balloon segment
HBb balloon segment
J distance
M gastric side
P pylorus
T orifice
X distance
Z duodenal side | The invention relates to a transpyloric device for accepting chyme from the stomach and conducting said chyme on in a bypass-like manner through a patient's duodenum; said device is held in place by balloon segments which sit on a preferably radially collapsible and self-erecting transpyloric conducting element; the filling level of the balloon segments, and thus the axial sealing force acting primarily on the shoulder surfaces of the pylorus or the surrounding area thereof, can be adjusted by the user, and the force applied to the stomach and duodenum structures adjoining the pylorus is reduced to a level that is permanently bearable for the organs even when the filling pressure of the segments rolling against each other is elevated. The invention also relates to an applicator for putting a bypass device of said type in place in the region of the transition from the stomach to the duodenum. | 0 |
Subsets and Splits
No community queries yet
The top public SQL queries from the community will appear here once available.